系统概述en

Document NO. 78.
K156-2E
N300-16.7/538/538 TYPE 300MW CONDENSING REHEAT STEAM TURBINE

GENERAL DESCRIPTION AND OPERATION MANUAL
SHANGHAI ELECTRIC EQUIPMENT CO., LTD SHANGHAI TURBINE WORKS

The reproduction, transmission or use of this document or its content is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent, grant or registration of a utility, model or design are reserved. Copyrights STW all rights reserved.
Document NO. 78. K156-2E
PROLEGOMENON
1 STW means Shanghai electric equipment co., ltd Shanghai turbine works. 2This information must be read prior to the performance of any activity related to modification, operation, maintenance or repair. If the contents should appear unclear or incomplete to the reader, STW must be contacted prior to the performance of any such activity, and clarification must be obtained in writing. Revisions to the documentation only can be made in writing by personnel duty authorized by the STW. These documents do not claim to constitute a complete description of all system or component details or to cover all conceivable operating conditions in connection with modifications, operation, maintenance or repair. Such activities must therefore only be planned or performed in strict compliance with these documents. Nonobservance of this requirement can result in damage to property or in personal injury. Use of a system or component together with products supplied by other companies that do not comprise part of the system or component requires the express prior approval of the STW. 3This manual is provided for the introduced 300MW condensing reheat wet condensation steam turbine (N30016.7/538/538 or N300 16.7/537/537), which will be used for customers and other units concerned .
4This is an all-purpose manual, which can be applied to typical steam turbines made by STW, if some of the contents and data may
conflict with transmitted drawings, the drawings shall be taken as authentic, and should be reported to STW . 5The transmitted drawings are not included in the manual due to their print limitation, therefore, readers should refer to some transmitted drawings which supplied by STW when they read the manual. 6 The original manual is made of a leaflet book and bound up, each of which is unattached, but the contents connected each other. The speciality is still kept in the compiled manual. 7 While reading the manual, if readers find inconsistencies, please contact with STW in order to revise and clarify them. 8This manual will be made up as following parts: General Description and Operation Manual Control and Protect Manual Install and Assembly Manual Construct and Turbine System Manual
Table of Units Conversion
Units Used by STW Length

millimeter (mm)
Factor of Transformation
25.4 1.00E-01 1.00E-03
Units Available
inch(in) decimillimeter(dmn) litre(L) gallon(UKgal) gallon(USgal) cubic millimeter(mL) tonne(t) pound(LB) bar(bar) kilopascal(kPa) millimeter of water
Volume
cubic meter ( m 3 )
4.55E-03 3.79E-03 1.00E-09 1.00E+03
Weight
kilogram(kg) 0.45359 1.00E-01 1.00E-03 9.80E-06
( mmH 2 O ) millimeter of mercury (mmHg) pound per square inch (psi) standard atmosphere (atm) engineering atmosphere (at) kilocalorie (kcal) horsepower pound force(lbf)
Pressure
Mega Pascal(Mpa) 1.30E-04 6.90E-03 0.101325 0.0981
Energy Power Force
joule (J) watt (W) Newton(N)

2
4170 746 4.45
Note: G (Acceleration of gravity) = 9.8 m / s
(Units Used by STW) (Factor of Transformation) (Units Available)
Page 1 of 3
CONTENTS
General Description Turbine Control Settings Turbine Cooling Steam System Checks Turbine Operation Supervisory Instruments Turbine Steam and Metal Thermocouples Allowable Variations in Steam Conditions Turbine Steam Purity Operating Limits and Precautions Water in the Turbine OP.1.05.01E-00 OP.1.06.01E-00 OP.2.08.01E-00 OP.2.02.01E-00 OP.2.09.01E-00 OP.1.10.01E-00 OP.2.01.01E-00 OP.2.03.01E-00 OP.1.04.01E-00
Starting and Load Changing Recommendations OP.2.11.02E-00 Governor Valve Management (Single Valve-Sequential Valve) OP.2.12.02E-00 Operation Modes Preliminary Checks and Operations Starting Procedure before Admitting Steam Start Up With Bypass Off Start Up With Bypass in Service OP.2.13.01E-00 OP.6.14.01E-00 OP.2.15.01E-00 OP.2.16.01E-00
Page 2 of 3
Load Changing Shut Down Procedure Turning Gear Operation during Shutdown Feedwater Heater Operation Periodic Functional Test Caution for ATC Operation Remote Automatic Modes of Operation Turbine Manual Mode of Operation Limits, Precautions and Tests Curve and Table of Turbine Operation Turbine Speed Hold Recommendations Cold Start Rotor-Warming Procedure
OP.2.17.01E-00 OP.2.18.01E-00 OP.1.19.01E-00 OP.2.20.01E-00 OP.2.21.01E-00 OP.6.22.01E-00 OP.6.23.01E-00 OP.6.24.01E-00 OP.2.25.01E-00
OP.2.51.01E-00 OP.2.52.01E-00
Start Recommendations for Rolling and Minimum Load OP.2.53.01E-00 Startup Steam Conditions OP.2.54.01E-00
No-Load and Light Load Operation Guide for Reheat Turbines OP.2.55.01E-00 Load Changing Recommendations OP.2.56.01E-00
Cyclic Index for Loading and Unloading At Different Rates OP.2.57.01E-00 Gland Sealing Steam Temperature Recommendations
Page 3 of 3
OP.2.58.01E-00 Cooldown Time for A Typical Fossil Hp Turbine OP.2.59.01E-00 Off-Frequency Turbine Operation Turbine System Description LP Exhaust Spray SYS Turbine Drain System Lubrication Oil System Gland Seal Steam SYS AS.4. MAC01.P001E-00 AS.4. MAL10.P001E-00 AS.4. MAV10.P001E-00 AS.4. MAW10.P001E-00 OP.2.60.01E-00
Page 1 of 1 CompiledYu Yan 2008.09
General Description
OP.2.01.01E-00
Checked Zhang Xiaoxia 2008.09 Countersign Countersign ApprovedPeng Zeying 2008.09
General Description
These operating instructions are recommended for starting and putting the turbine in operation; they do not apply to the initial start after erection. Any such instructions can cover only the normal case and it will be recognized that under unusual circumstances, variations from this program will have to be adopted and the procedure to be followed will necessarily be determined by the best judgment of the operating engineers. The turbine-generator unit has been designed to meet the contract rating or capability requirements for continuous service during the design life of the unit. In order to meet such contract requirements, design margin and manufacturing tolerances have been provided which may make it possible to operate the unit at loads higher than the contract capability requirements. The unit is designed for continuous operation at the conditions listed on the maximum calculated heat balance diagram. If the unit is operated at other than normal cycle conditions: by such actions as removing feed water heaters from service, using reheat attemperating sprays, changing the amount of steam shown on the contract heat balance to be extracted for air heating, etc.; it could result in greater than design flows passing through the turbine down-stream of where the cycle changes occur. Turbine damage could eventually result if load is not sufficiently reduced to prevent exceeding the design conditions. Operation of the turbine-generator beyond the conditions specified above may result in equipment malfunction, will eventually affect the unit's reliability by increasing maintenance and reducing the design life, is not sanctioned by Turbine Manufacturer, and is at the purchaser's risk.
Turbine Control Settings

OP.2.03.01E-00
CompiledYu Yan CheckedZhang Xiaoxia Countersign Sheng Chaojun,
2008.09 2008.09 2008.09
Tang Jun, Zhang D.M ApprovedPeng Zeying 2008.09
Contents
Turbine Control Settings ...................................................................................................1 1 OIL PRESSURE INFORMATION ........................................................................1 2 E.H. FLUID INFORMATION ................................................................................1 3 TRANSDUCER INFORMATION..........................................................................2 4 GOVERNOR VALVE ..............................................................................................2 5 THE GOVERNOR VALVE OPENING SEQUENCE AND ARRANGEMENT 3 6 ROTOR POSITONTHRUST BEARING TRIP ............................................4 7 DEFERENTIAL EXPANSION ...............................................................................4 8 SUPERVISORY INSTRUMENT INFORMATION .............................................4 9 PRESSURE SWITCH INFORMATION ...............................................................5 10 TEMPERATURE SWITCH INFORMATION ...................................................6 11 DIAPHRAGM.........................................................................................................7 12 DEH CONTROLLER SETTING .........................................................................7 13 GAP SETTING.......................................................................................................7 14 LUB OIL TANK LEVEL SWITCH......................................................................8 15 EH FLUID RESERVOIR LEVEL SWITCH ......................................................9
Page 1 of 10
Turbine Control Settings 1 OIL PRESSURE INFORMATION

SYM DISCHARGEAT RATED SPEED MAIN OIL PUMP SUCTIONON A.C. D.C. EMERG OIL PUMP SUCITONAT SPEED H.P. SEAL OIL BACKUP PUMP DISH AUXILIARY PUMPS A.C. BEARING OIL PUMP D.C. EMERGENCY OIL PUMP A.C. BEARING LIFT PUMP RELIEF VALVES BEARING OIL PRESS SET AT SPEED MECH OSPD MAN RELIEF VLV NO.1 MECH OSPD MAN RELIEF VLV NO.2 TRIP HDR TRIP HDR A A A A A A A A SETTING MPa(g) 1.4421.8* 0.0690.1373* 0.0690.31* 0.8380.896 0.0960.124 0.0960.124 812 0.0960.124 0.690.76 0.860.93 3330r/min
OVERSPEED PROTECTION TRIP SETTING
SYM AALL PRSSURES ARE READ AT TURBINE CENTERLINE BEFORE MAKING PRESSURE SETTINGS OIL TEMPERATURE MUST BE 32C OR ABOVE. *IT IS NOT LIMITTED IF THE OIL SYSTEM PRESSURE CAN ENSURE THE DESIGN OIL PRESSURE.
2 E.H. FLUID INFORMATION

MIN. EH FLUID SUPPLY HEADER PRESS RELIEF VALVE ACCUMULATOR CHARGINGNITROGEN GAS PRESS CHARGE H.P. ACCUMULATORS TO RECHARGE ON DECREASE TO CHARGE DRAIN ACCUMULATORS TO 9.3 MPa(g) 8.27MPa(g) 0.21MPa(g) 14MPa(g) 16.2MPa(g)
Page 2 of 10 RECHARGE ON DECREASE TO FLUID OPERATION TEMP RANGE AT RESERVOIR 0.165MPa(g) 3760
3 TRANSDUCER INFORMATION
SYN XD TP IP OPC CP HPE GS TITLE THROTTLE PRESSURE FIRST STAGE PRESSURE CROSSOVER PRESSURE(ABSOLUTE) CONDENSER PRESSURE ABSOLUTE HP TURBINE EXHAUST PRESSURE GLAND STEAM SEAL HEADER PRESSURE CALIBRATED RANGE 019.6MPa 014.7MPa 01.47MPa 0101.3kPa 04.9MPa 00.15MPa OUTPUT/SCALE DC 420 420 420 420 420 420 M.A.
LP exhaust spray controllers setting is 0.186MPa(g) plus .0093MPa/m multiply elevation difference. The elevation difference means the difference between the condenser neck tube and spray controller when the controller lower than condenser neck interface.
4 GOVERNOR VALVE
No. 1 2 3 4 GV.NO. 31 30 30 31
VALVE TRAVLE
100%
SERVO AMPLIFIER ADJUST
0% 0V 10V SERVO AMPLIFIER INPUT
The Data in Governor Valve Management * Variable name in DEH

total flowFDCF*% 0.000 coordinate value for coefficient of flow COEF* 1.000
Page 3 of 10
50.00 75.00 80.02 84.94 90.06 95.38 100.00 1.000 0.991 0.961 0.923 0.864 0.790 0.707
5 THE GOVERNOR VALVE OPENING SEQUENCE AND ARRANGEMENT
Page 4 of 10
6 ROTOR POSITONTHRUST BEARING TRIP

INSTRUMENT SCALE 1.25 0 -1.25mm
COIL GAP (MW)PU/ SET POINTS RP1A and RP1B 1.5 1.6 2.5 3.4 3.5 1.5 1.6 2.5 3.4 3.5 ALM LIM 5 TRIP LIM 5 RP2A and RP2B ATC FLOW CHART (P-11) DESIGNATI ON TRIP LIM 6 ALM LIM 6 INPUT MA INSTRUMENT READING (mm) 5.6 6.4 12 17.6 18.4 5.6 6.4 12 17.6 18.4 1.0 0.9 0 0.9 1.0 -
CHAN NO.1
GOV TRIP(TB) GOV ALARM ZERO SET* GEN ALARM GEN TRIP(TB) GOV TRIP(TB) GOV ALARM ZERO SET* GEN ALARM GEM TRIP(TB)
* THRUST ROTOR DISC CENTERED BETWEEN GOV AND GEN END THRUST BRG SERFACES.
7 DEFERENTIAL EXPANSION
DEFERENTIAL EXPANSIONLP CYL END INSTRUMENT SCALE 020mm.
SET POINT ROTOR LONG COLD ROTOR SHORT TRIP ALARM TRIP ALARM INPUT mA 16.74 16.14 6.02 5.5 4.9 INSTRUMENT READING mm 15.92 15.17 2.52 1.88 1.12
8 SUPERVISORY INSTRUMENT INFORMATION

ECCENTRICITY ALERT (ALARM) 0.076mm
CHAN NO.2
Page 5 of 10 VIBRATION ALERT(ALARM) TRIP CASING EXPANSION SPEED RELAY SETTINGS 14-1/SD SPEED1r/minTSI TO TURNING GEAR 14-2/SD SPEED200 r/minTSI TO TURNING GEAR 0.127mm 0.254mm 050mm 05000r/min
9 PRESSURE SWITCH INFORMATION

SYM 63 -1 3/LB O -2 4/LB O -1/LV -2/LV -3 4/LV -1/LP SW NO. 1 2 1 2 1 2 1 2 1 2 1 2 1 2 CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE OPEN OPEN OPEN OPEN N.O.CONT* INCR PRESS DECR PRESS OPEN OPEN OPEN OPEN DESIGN MPa(g) 0.0350.048 0.0350.048 0.0350.048 0.0450.062 0.0203(ABS) 0.0169(ABS) 0.0203(ABS) 0.0186(ABS) 0.0203(ABS) 0.0203(ABS) 9.31 10 9.31 9.31 /OPC 1 2 1 2 CLOSE CLOSE CLOSE CLOSE 6.89 6.89 0.0690.075 0.0690.075 -1 2/AST SYM 63 -1 2/EOP -1/AS P -2/AS P SW NO. 1 2 1 2 1 2 1 2 3 CLOSE CLOSE OPEN OPEN OPEN OPEN OPEN N.O.CONT* INCR PRESS DECR PRESS OPEN OPEN DESIGN MPa(g) 0.0690.075 0.0690.075 9.30 9.30 4.14 4.14 6.89 6.89 6.89
-2 4/LP
/BOR
Page 6 of 10
-1 2/BOP /EHS /BLS /BLD 1 BLD2 /MPF 1 /MPF 2 /MPF 3 1 2 1 2 1 2 1 2 CLOSE CLOSE CLOSE CLOSE CLOSE CLOSE OPEN OPEN OPEN OPEN 0.075 0.082 MAX 0.14 0.021 0.048 4.2 /TG 6.5 0.69(VAC) 0.69(VAC) 0.69(VAC) /PR /XO 2 1 2 3 1 2 CLOSE CLOSE CLOSE CLOSE CLOSE 0.031 0.0395 0.0492 MAX 0.21 0.21 /EPR 1 2 1 1 2 1 CLOSE CLOSE CLOSE CLOSE OPEN OPEN 0.0690.075 0.0690.075 0.14 MAX 11.03 11.03 0.031
/TGI /MP
ABSOLUTE PRESSURE Absolute pressure switch at 0mm HG abs. (0MPa absolute pressure). A N.O. contact is open (N.C. contact closed.When the absolute pressure is increased to the pressure switch set point, A N.O. contact will closedN.C. contact opens. *All pressure switch setting instructions are referred to the normally open (N.O.) contact of each switch without regard to whether the N.O. or N.C. contact is used in a specific application. When MAX appears in column, it means to adjust switch out of operating range in order to provide a minimum ON-OFF differential to other operating switches in the same housing.
10 TEMPERATURE SWITCH INFORMATION

SYM 23 SW NO. TEMP INCR 1 /ORR 2 OPEN N.O.CONT* TEMP DECR MAX 21 DESIGN
Page 7 of 10
1 /EHR 2 CLOSE OPEN 65 21
1 /TCD 2
CLOSE OPEN
55 23
11 DIAPHRAGM
Opens on decrease auto stop oil pressure 0.36MPa(g) at 14MPa(g) HP fluid auto stop emergency trip(AST) header press. Closes on increase auto stop oil pressure 0.12MPa(g) at 0MPa(g) HP fluid auto stop emergency trip(AST) header press.
12 DEH CONTROLLER SETTING

a SPD<600 SPEED600r/min ACTIONDEH to jacking oil circuit
SPD>2600 SPEED2600r/min ACTIONDEH to water spray circuit b c Overspeed trip setpoint is 3330r/min. OPC speed setpoint is 103% of rated speed (3090r/min). Mechanical overspeed trip setpoint is 3300r/min ETS overspeed trip setpoint is 3300r/min
13 GAP SETTING
SYMBOL PU/RX PU/MPW PU/VB1 TO VB7 PU-1 TO 4/SD PU/ZS1 2 PICKUP ROTOR ECCENTRICITY TSIMARKERK ROTOR VIBRATION SPEED ZERO SPEED FIG. NO. 3* 3 3 3 3
Page 8 of 10
PU/DE PU/RP1A AND B PU/RP2A AND B PU/OS1 AND 2 DIFFERENTIAL EXPANSION ROTOR POSITION NO.1 ROTOR POSITION NO.2 OVERSPEED 1,4** 2 2 3
* Check the output voltage of froximeter, after installing. It should be in range of -11~-12V, if not, change probe clearance to meet. **There are two types of fig 1and fig 4 according to different configuration of rotor.
PU/DEA 4 PU/DEB 19 ROTOR ROTOR TURBINE END GEN END PICKUP FIG. NO.1 PICKUP TURBINE END ROTOR ROTOR FIG. NO.3 PU/DEB PICKUP DEVIATION (MM) FIG. NO.4 PU/DEA GEN. END FIG.NO.2
14 LUB OIL TANK LEVEL SWITCH

Level switch to actuate when oil reached oil level of dimensions shown.
CAPACITY m3 24 A 1333 B 152.4 OIL LEVEL mm C 152.4 D 563
Page 9 of 10
LEVEL
SWITCH
HOUSING COUPLING TOP OF
RESERVOIR DISPLACER A (TYP) HIGH B C LOW LOW LOW D OPERATING LEVEL SHELL
15 EH FLUID RESERVOIR LEVEL SWITCH

Level switch to actuate when fluid reaches level of dimensions shown.
Page 10 of 10
Page 1 of 1
Turbine Cooling Steam System Inspection

OP.1.04.01E-00
CompiledZhang D.M CheckedHuang Q.H CountersignYu Yan Countersign
2008.09 2008.09 2008.09
ApprovedPeng Zeying 2008.09
Turbine Cooling Steam System Inspection

A steam cooling system reduce the temperature of the reheat steam which bathes the blade roots and rotor at the inlet to the intermediate pressure turbine (IP). This cooling steam is required to improve the creep strength of the blade roots and rotor in the affected area and to reduce the likelihood of rotor bowing. Considering the serious consequences of having insufficient cooling steam, it is essential that an adequate supply be provided whenever the unit is in operation and reheat temperature is above 482. The cooling steam flow paths of combined high pressure-intermediate pressure turbine elements are internal and cannot inadvertently be blocked (unless altered during a shutdown for repairs). Separate IP turbine elements have a combination of internal and external flow passages for cooling steam which can be blocked by closed valves, by flanges containing blanks for blowdown, or foreign material in the passages. For this reason manufacturer recommends that: 1. 2. There are no valves in cooling steam pipes. There are no flow restrictions in cooling steam pipes except the flow measuring
device provided by manufacturer. 3. There be a complete check of the cooling steam system before initial startup of the
unit, before any restart following disassembly of the IP element, and before restart after maintenance which otherwise disturbs the cooling steam flow passages. This check is to ensure that the cooling system does not contain closed valves, solid spacers in flanges or other foreign material that blocks or restricts flow. The portion of the system inside the IP cylinders must be inspected after the IP is assembled and before the cooling steam pipes are connected to the cylinder. If a preheating system is used on a unit which requires a valve in the cooling steam pipe, it is imperative that the purchaser consult manufacturer about essential protective provisions.
Page 1 of 4
Supervisory Instruments
OP.1.05.01E-00
CompiledZhang D.M CheckedHuang Q.H CountersignYang H.Y CountersignYan W.Ch ApprovedPeng Zeying
2008.09 2008.09 2008.09 2008.09 2008.09
Supervisory Instruments
The following supervisory instruments are furnished with this unit and are to be observed during start-up, operation, and shut down when applicable. The outputs of these instruments are displayed on chart recorders. Refer to Operating Limits and Precautions section and Control Setting Instructions for supervisory instrument alarm and trip limits. A complete description of each instrument will be found under a separate tab in the instruction book.
1) CASING EXPANSION As a unit is taken from its cold condition to its hot and loaded state, the thermal changes in the casings will cause it to expand. The casing expansion instrument measures axial expansion from the anchor point in middle pedestal towards the governor pedestal. The governor pedestal is designed to move freely along lubricated longitudinal keys. If the free end of the unit is hampered from sliding smoothly along the guide keys as the casings expand, serious damage to the unit may result. The casing expansion meter measures the movement of the governor pedestal relative to a fixed point (the foundation). It indicates expansion and contraction of the casings during starting and stopping periods, and for changes in load, steam temperatures, etc. Should it fail to so indicate during these transient conditions, the situation should be investigated. The relative position of the governor pedestal, as indicated by this instrument, should be essentially the same for similar conditions of load, steam conditions, vacuum, etc.
2) ROTOR POSITION Two rotor position instruments (two dual voting Thrust Position Monitors) measure the
Page 2 of 4 relative axial position of the turbine rotor thrust collar with respect to the thrust bearing support. The thrust collar exerts a pressure against the thrust shoes, which are located on both sides of the thrust collar. Wear on the thrust shoes results in an axial movement of the rotor and is indicated on these instruments. Each instrument is equipped with an alarm which is activated if the rotor moves beyond a predetermined distance. Continued movement beyond a second predetermined distance activates rotor position trip relays which trip the turbine via the Emergency Trip System. Two rotor position pickups are provided for each instrument. Each instrument provides a two out of two (2/2) detection logic to prohibit false trips.
3) DIFFERENTIAL EXPANSION When steam is admitted to a turbine, both the rotating parts and the casings will expand. Because of its smaller mass, the rotor will heat faster and therefore expand faster than the casings. Axial clearances between the rotating and the stationary parts are provided to allow for differential expansion in the turbine, but contact between the rotating and stationary parts may occur if the allowable differential expansion limits are exceeded. The purpose of the differential expansion meter is to chart the relative motion of the rotating and stationary parts. It gives a continuous indication of the axial clearance while the turbine is in operation. The instrument is equipped with alarm and trip alarm relays which are activated if the limits of axial clearances are approached. As the rotating and stationary parts become equally heated after a transient condition, the differential expansion will decrease, resulting in larger axial clearances. The steam flow and the temperature to the turbine can then again be changed.
4) ROTOR ECCENTRICITY When a turbine has been shut down, the rotor will tend to bow due to uneven cooling if the upper half of the casing enclosing the rotor is at a higher temperature than the lower half. By rotating the rotor slowly on turning gear, the rotor will be subjected to more uniform temperatures, thereby minimizing bowing. This bowing of the rotor is recorded continuously as eccentricity from turning gear speed to approximately 600 r/min and as vibration at higher speeds (see vibration instrument description).
Page 3 of 4 The eccentricity instrument is equipped with an alarm signal which is activated when the eccentricity limit is reached. Another output signal of the eccentricity instrument is the instantaneous eccentricity. This signal is displayed on a vertical meter located on the turning gear console. When the turbine is on turning gear, the meter displays the periodic variation of the instantaneous rotor-to-pickup gap. If it becomes necessary to remove the unit from turning gear operation, it is desirable to stop the rotor with the rotor bow in the down position in order to reduce the thermal gradient between the upper and lower portions of the rotor. The optimum rotor position can be achieved by stopping the rotor when the instantaneous eccentricity meter reads a minimum value. NOTE The eccentricity pickup is located at the top vertical centerline of the turbine governor pedestal. The minimum meter reading indicates minimum rotor-to-pickup gap. In this position, the upper half of the rotor (cooler portion) is exposed to the warmer ambient temperature, thus tending to reduce the bow.
5) VIBRATION The vibration instrument is used of measure and record vibration of a turbine rotor at speeds above 600 r/min; below this speed, rotor bowing is recorded as eccentricity (see Item 4). The vibrations are measured on the rotor near the main bearings. Excessive vibrations serve as a warning for abnormal and possible hazardous conditions in the turbine. Each vibration instrument is equipped with alarm and trip relays which are activated when excessive vibrations are measured at any one of the bearings.
6) PHASE ANGLE A phase angle instrument is provided which displays the angular relationship between the "hing spot" on a particular bearing and the turbine rotor reference, namely the No. 1 balance-hole. A selector scotch located on the front face of the phase angle instrument permits selecting the readout of phase angle for any one pickup at a time.
7) VALVE POSITION
Page 4 of 4 The valve position signal is provided by the DEH Controller and is wired to record this signal continuously.
8) ZERO SPEED The zero speed instrument provides relays which are activated when the unit speed below 1r/min. The instrument utilizes two zero speed pickups which read the rotation of a rotor mounted notched wheel in the governor pedestal. The instrument includes two separate detection channels. The relay outputs are used for turning gear engage functions and are available for annunciation purposes.
9) SPEED The speed instrument utilizes one of the zero speed pickups (see Item 8) as an input device. An analog output signal of speed is wired to the recorder for continuous recording of this speed. Additional outputs are in the form of relays which are activated above a predetermined setpoint speed. There are two independent setpoints and one relay per setpoint. The relays are used for turning gear control, exhaust hood spray control, and bearing lift pump control.
Page 1 of 3
Turbine Steam and Metal Thermocouples

OP.1.06.01E-00
CompiledZhang D.M CheckedHuang Q.H CountersignTang Jun Countersign
2008.09 2008.09 2008.09
TURBINE STEAM AND METAL THERMOCOUPLES

Locations of the thermocouples listed below are shown on the drawing "Thermocouple Locations"
Item 015 016 017 TC No. TC 3010 TC 3020 TC 3030 Thermocouple Location Steam Chest-Deep-LH Steam Chest-Deep-Rh Steam Chest-Shallow-LH Metal Measures Temp. of: Comments Use with chart" Startup Steam Conditions " for adequate warming of steam chest before transferring speed control from TV to GV (see section " Operating Limits and Precautions") Use to insure that temperature difference between deep and shallow thermocouples does not exceed 83
018
TC 3040
Steam Chest-Shallow-RH
049 051 050 052
TC 3241 TC 3251 TC 3242 TC 3252
Reheat valve -Deep -LH Reheat valve -Deep-Rh Reheat valve -Shallow-LH Reheat valve -Shallow-RH
casing casing casing casing Compare with temperature of Item 041 to determine : a) Whether COLD or HOT start b) Rotor-warming time if COLD start. Colder temperature takes precedence (see chart" Cold Start Rotor-Warming Procedure" ) c) Total roll time to rated speed if HOT start (see chart "Start Recommendations"). Metal
Use to insure that temperature difference between deep and shallow thermocouples does not exceed 83
039
TC 3051 HP inner casing Metal
038
TC 3052
Page 2 of 3
Item TC No. Thermocouple Location Measures Temp. of: Comments Refer to section "Starting and Load Changing Recommendations."
041
TC 3091
IP #1 Ring
Metal
Compare with temperature of Item 038,039 to determine : a) Whether COLD or HOT start b) Rotor-warming time if COLD start. Colder temperature takes precedence (see chart" Cold Start Rotor-Warming Procedure" ) Use with Item 038,039 to compare actual with predicted temperatures based on these operating instructions. Used by the ATC Program for IP rotor stress calculations. Use with Item 023 to monitor temperature difference between gland steam and rotor metal in the gland areas (see chart "Gland Sealing Steam Temperature Recommendations"). Indicates sealing steam temperature in glands. Use with Items 021 and 022. Start counting rotor-warming time after this temperature reaches a minimum of 260(see chart "Cold Start rotorWarming Procedure"). Max. temperature difference between RSV inlets is 14 (see section "Allowable Variations in Steam Conditions). Water Detection Thermocouples. Used in pairs in temperature zones indicated. Alarm when base in 42 colder than cover. Trip if base reaches 56 colder than cover or take other suitable action as recommended in section "Water in the
037
TC 3070
First Stage
Steam
028 021
TC3331 TC 3210
IP Exhaust
Steam
022
TC 3220
HP-IP End
End
Wall-Gov.
Metal
023
TC 3230
HP Gland Steam Header (Common line to the HP and IP Glands) IP Inlet-RSV-LH
Steam
024
TC 3240
Steam 025 TC 3250 IP Inlet-RSV-RH
033 034 026 027 031 032
TC 3261 TC 3271 TC 3320 TC 3330 TC 3333 TC 3334
HP Exhaust Zone-Base HP Exhaust Zone-Cover IP Exhaust Zone-Base IP Exhaust Zone-Cover IP #1 Extraction ZoneBase IP #1 Extraction Zone-
Metal
Page 3 of 3
Item TC No. Thermocouple Location Cover 064 040 029 TC 3337 TC 3338 TC 3760 IP Inlet Zone-Base IP Inlet Zone- Cover Throttle Valve Inlet-LH Steam 030 TC 3770 Throttle Valve Inlet-RH Indicates steam temperature at each throttle valve inlet. Max. temperature difference between TV inlets is 14 (See section" Allowable Variations In Steam Conditions"). Record LP exhaust steam temperature, alarm in 79, Max. 121, 15min duration. Trip if the temperature exceed 121.(See section " Operating Limits and Precautions") Record LP gland steam temperature, alarm over 177 or under 121 Record HP Exhaust steam temperature, alarm over 400 and trip over 427 Measures Temp. of: Comments Turbine. "
019
TC3110
LP Exhaust -Gov. End Steam
020 043 042 035 036
TC3120 TC3500 TC3580 TC3335 TC3336
LP Exhaust-Gen. End LP Gland Steam HP Extraction HP Exhaust Zone-CoverLH HP Exhaust Zone-CoverRH Steam Metal Steam Steam
Page 1 of 3
Allowable Variations in Steam Conditions

OP.2.08.01E-00
CompiledYu Yan
2008.09
Allowable Variations in Steam Conditions

The turbine rating, capability, steam flow, speed regulation and pressure control are based on operation at rated steam conditions. The turbine-generator unit is capable of operation under the following variations in steam pressure and temperature. These allowable variations are intended to provide for operating exigencies and it is expected that such abnormal operation will be kept to a minimum, especially the occurrence of simultaneous variations in pressures and temperatures. 1. Initial Pressure The average initial pressure at the turbine inlet over any 12 months of operation shall not exceed the rated pressure. In maintaining this average, the pressure shall not exceed 105% of the rated pressure. Further accidental swings not exceeding 120% of the rated pressure are permitted, provided that the aggregate duration of such exceed 105% of the rated pressure swings over any 12 months of operation does not exceed 12 hours. An increase in initial pressure will normally permit the turbine to generate power in excess of its normal rating, unless action is taken through the control system to restrict the steam flow rate. The generator and associated electrical equipment may be unable to accept such additional output, and undesirable stresses may also be imposed on the turbine; the purchaser shall accordingly provide load-responsive protective means to limit the turbine output under such circumstances. 2. Reheat Pressure The pressure at the exhaust connection of the high pressure turbine shall not be greater than 25% above the highest pressure existing when the high pressure section of the turbine is passing the maximum calculated flow with rated pressure and normal operating conditions. Suitable relief valves must be provided by the Purchaser.
Page 2 of 3 3. Initial Temperature The steam temperature at the turbine throttle valve inlet connection shall average not more than rated temperature over any 12 month operating period. In maintaining this average the temperature shall not exceed rated temperature by more than 8. During abnormal operating conditions, the temperature at the turbine throttle valve inlet connection shall not exceed rated temperature by more than 14 for operating periods not more than 400 hours per 12 month operating period, nor rated temperature by more than 28 for swings of 15 minutes duration or less aggregating not more than 80 hours per 12 month operating period. In maintaining the temperatures specified in the preceding paragraphs, the steam delivered through any turbine main inlet valve must be within 14 of the steam delivered simultaneously through any other main inlet valve. During abnormal conditions, this difference may be as high as 42 for periods of 15 minutes maximum duration providing such occurrences are at least 4 hours apart. 4. Reheat Temperature The steam temperature at the turbine reheat admission shall average not more than rated reheat temperature over any 12 month operating period. In maintaining this average the reheat temperature shall not exceed rated reheat temperature by more than 8. During abnormal conditions reheat temperature shall not exceed rated reheat temperature by more than 14 for operating periods totaling not more than 400 hours per 12 month operating period, nor rated reheat temperature by more than 28 for swings of 15 minutes duration or less aggregating not more than 80 hours per 12 month operating period. In maintaining the above reheat temperature averages, the steam delivered through any hot reheat inlet zones in the turbine must be within 14 of the steam delivered simultaneously through any other hot reheat zone. During abnormal conditions this difference can be as high as 42 for periods of 15 minutes maximum duration providing the occurrences are at least 4 hours apart. 5. HP-IP Combined Turbine Where the main steam inlet and hot reheat inlet connections are arranged in the same turbine casing, temperature differences between the main steam and reheat steam inlets
Page 3 of 3 must be controlled to optimize the design life of the apparatus. The difference between the main steam and hot reheat temperatures should not deviate from the difference at rated conditions by more than 28. During abnormal conditions, deviations as large as 42 are acceptable provided the differences are limited to a reduction of the hot reheat temperature with respect to the main steam inlet temperature. These limits, in general, are assumed to apply at operating conditions near full load. As the load reduces, it is assumed that the hot reheat temperature will be below the main steam inlet temperature, in which case, the difference may approach 83 as the load approaches zone. Short time cyclic temperature fluctuations are to be avoided.
Page 1 of 7 CompiledYu Yan 2008.09
Turbine Steam Purity

OP.2.02.01E-00
Turbine Steam Purity NOTE: This recommendation is based upon current STW experience and engineering
judgment with respect to turbine steam purity. The information provided should not be considered to be all inclusive or to supplant any specification for other parts of the steam and water cycle. The Purchaser, being solely responsible for the control of turbine steam purity, assumes all risk and liability for use of this information or the results obtained therefrom, and STW NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY RESPONSIBILITY OR LIABILITY WHATSOEVER FOR SUCH USE WHETHER THE CLAIMS OF THE PURCHASER ARE BASED IN CONTRACT, IN TORT (INCLUDING NEGLIGENCE) OR OTHERWISE.
1. General The presence of corrosive impurities in steam can cause damage to turbine components by corrosion, stress corrosion, corrosion fatigue and erosion-corrosion. Caustic, salts, and acids (including organic acids and carbon dioxide) must be strictly controlled. Deposition of impurities can also cause thermodynamic losses and distress by lowering the efficiency of blades, upsetting pressure distributions and clogging seals and clearances in valves. If the extensive damage, lengthy outages and costly repairs caused by these occurrences are to be avoided, the purity of the steam throughout the turbine must be rigorously controlled. In addition, positive steps must be taken to assure that impurities from chemical cleaning procedures for plant piping and equipment do not get into the turbine. For the best control of steam purity, continuously or routinely analyze the parameters in Table 1. Samples should be collected from the high pressure turbine inlet steam for most units. The location of the sampling (tap) point should ensure that all influences on steam quality will be included (e.g. downstream spray water injection). Water injections should
Page 2 of 7 utilize condensate quality water. Therefore, hot reheat inlet steam is additionally recommended as a control point for reheat units. When steam enters the turbine at multiple pressures from separate steam sources, as in combined cycle units, each source should be individually monitored, and the steam at any location in the turbine must conform to these recommendations. Since multiple sources will rarely have the same value for any steam purity parameter, mass weighted averaging is permitted. (See Mass Weighted Averaging) However, it is simpler and better if all individual steam sources conform to this recommendation. When a steam source is operating outside the steam purity recommendations the reason should be determined since it may indicate a need for corrective action.
2. Normal Operation Recommended limits for impurities commonly found in turbine steam are given in Table 1. The normal limit values represent Turbine Manufacturer recommendations for reliable turbine operation. These values are limits where experience has shown minimal deposition of salts in the dry regions of the turbine. The reasonably achievable values provide extra assurance that corrosive impurities will not deposit and every reasonable effort should be made to operate at these values. The recommendations apply whenever steam is admitted to the turbine. Low load does not protect the turbine from deposition. The parameters given in Table 1 are for the impurities commonly found in steam power systems. If other impurities (not including the PH control agent and oxygen during oxygenated water treatment) are known to be present above 5g/kg (ppb), please consult Turbine Manufacturer for guidance on setting limits for those impurities. Table 1 Normal limit values and reasonably achievable values in normal operation for condensed steam sample
Parameter Conductivity at 25C downstream of strongly acidic sampling cation exchanger, continuous measurement at sampling point Sodium 3) (Na) Silica (SiO2) Total iron (Fe) Units S/cm g/kg * g/kg g/kg Normal limit1) <0.2 <5 <10 <20 Reasonably Achievable Value 2) (for condensing power plants) 0.1 2 5 5
Page 3 of 7
Total copper4) (Cu) g/kg <2 1 1) To avoid any corrosion or loss of efficiency, it is advisable to keep the actual values below the Normal Limit values, preferably within the range of the Reasonably Achievable Values for normal operation. 2) The values in Reasonably Achievable Values are only achievable in continuous operation. In all other cases, the respective normal limit value is regarded as a maximum value for normal operation. 3) If solid alkalizing agents (NaOH, Na3PO4) are used only in case of abnormal operating conditions, continuous monitoring of sodium is not imperative. (See discussion of sodium). 4) No copper monitoring is necessary if the steam-water cycle is free of copper alloys (see discussion of Total Copper). * 1 g/kg = 1 part per billion (ppb)
3. Action Levels It is not always possible to meet the normal values at justifiable expense, particularly during start-up of a plant. Therefore, action levels have been set up to rate the urgency of action to correct deviations from normal operating conditions. The action levels represent undesirable conditions that should be corrected to normal within the time periods indicated. During start-up and chemical upset, the values and time limits listed in Table 2 apply. Operating longer than the time limits associated with the action levels will degrade the turbine and shorten its life. It is not always required to shut the turbine down when the time is expended. It must simply be realized that life has been expended or that efficiency might be lost. Excessive operation of the turbine in the action level ranges represents the economic trade-off between immediate revenue and future repair costs. It is advisable to target the values listed in Action Level 2 or below during start-up to avoid any loss of efficiency or impairment of service life. If the values are above normal values, the values must show a noticeable downward trend. The time limits in the Action Levels still apply. Commissioning shall be limited to one annual allowance as noted in Table 2 for initial start-up of the plant. The annual clock resets to zero at commercial acceptance. Table 2 Limit values exclusively for start-up operation1) and cases of deviation from the values recommended for continuous operation
Parameter Conductivity at 25 C downstream of strongly acidic sampling cation exchanger, continuous measurement at sampling point Units Action level 1 Action level 2 Action level 3 Action level 4 = immediate shutdown
S/cm
0.2 < 0.35
0.35 < 0.5
0.5 < 1.0
1.0
Page 4 of 7
Sodium3) (Na) Silica (SiO2) Total iron (Fe) Total copper4) (Cu) Period of time per event, during which the turbine may remain in operation with the respective values Cumulative time per year g/kg g/kg g/kg g/kg h h/a 5<10 10 < 20 20 < 30 2< 5 100 2000 10 < 15 20 < 40 30 < 40 5< 8 24 500 15 < 20 40 < 50 40 < 50 8<10 4 80 20 50 50 10 02) 02)
1) In order to avoid any drop in efficiency or impairment of service life, it is advisable to operate below the action level 2 values during start-up of the turbine. The values must show a noticeable downward trend. 2) Action Level 4: The values indicate that the steam quality is substantially impaired and could quickly result in damage to the turbine (corrosion and/or deposits). Turbine shutdown is urgently recommended. 3) If solid alkalizing agents (NaOH, Na3PO4) are used only in case of abnormal operating conditions, continuous monitoring of sodium is not imperative. (See discussion of sodium). 4) No copper monitoring is necessary if the steam-water cycle is free of copper alloys (see discussion of Total Copper). In general: Once any parameter has reached or proceeded beyond a given action level, the next-higher action level shall apply.
4. Auxiliary Boiler Steam Steam from auxiliary boilers may be used for brief periods at startup or to maintain vacuum during longer outages. Its purity has usually not been a problem. Table 3 gives relaxed limits for auxiliary boiler steam during this time. Steam conforming to Table 3 minimizes deposits and corrosion on turbine parts, but it should be understood that contaminants in the auxiliary steam are ultimately sent to the main steam condenser and may make cleanup of the main cycle more difficult. Whenever possible, the auxiliary boiler steam should conform to the normal limits found in Table 1. Steam from a main boiler where pressure is reduced to provide gland and other auxiliary steam during startup will be of adequate purity for those uses. Table 3 Target values for condensed auxiliary boiler steam sample for seal steam supply with main steam valves closed.
Parameter Units Normal limit Auxiliary Steam Action Level 1 Auxiliary Steam Action Level 2 Auxiliary Steam Action Level 3 Auxiliary Steam Action Level 4 = immediate shutdown
Page 5 of 7
Conductivity at 25C downstream of strongly acidic sampling cation exchanger, continuous measurement at sampling point Period of time per event, during which the turbine may remain in operation with the respective values Cumulative time per year
S/cm
< 0.5
0.5 < 1.0
1.0 < 2.0
2.0 < 5.0
5.0
h h/a
24 500
4 80
1 20
01) 01)
1) Auxiliary Steam Level 4: Theses values indicate that the steam quality is substantially impaired and could quickly result in damage to the turbine (corrosion and/or deposits). Immediate shutdown of the seal steam supply is recommended.
5. Monitors, analyses and data storage Data from continuous monitors should be recorded, either on chart recorders or in a data acquisition system. Grab sample data should be recorded with time of sampling. Data should be saved for a minimum of two turbine inspection cycles and preferably for the life of the unit. * Conductivity downstream of strongly acidic cation exchanger (hydrogen cation exchanged conductivity): Electrical conductivity is the most important parameter for monitoring the purity of steam. Due to the use of a strongly acidic cation exchanger in the hydrogen form (connected upstream of the instrumentation unit), any alkalizing agents present in the steam-water cycle are extracted from the sample, and their conductivity is suppressed. At the same time, any impurities, e.g., salts, which may be present are converted into their corresponding acids. The higher specific conductivity of the latter increases the sensitivity of the measurement. The electrical conductivity is not substance-specific, i.e., the further identification of any impurity requires application of suitable analytical methods. Degassed cation conductivity is a different parameter and requires different values than those included in the tables in this document. On-line conductivity is recommended. * Silica (SiO2): Silica is volatile in steam. The actual concentration of silica in steam depends on such factors as the boiler pressure and the alkalinity and the silica concentration of the boiler water. Silica and silicates form very adherent deposits on turbine blades. Silica can not be
Page 6 of 7 monitored via conductivity measurement, because it is very weakly dissociated. Consequently, individual analysis (laboratory testing or on-line monitoring) is necessary. * Sodium (Na): Sodium hydroxide and sodium salts promote stress corrosion cracking within the turbine. Whenever solid alkalizing agents (NaOH, Na3PO4) are fed, the steam must be monitored for sodium. On-line sodium monitoring is recommended. When AVT (All Volatile Treatment) is used, there is less necessity for monitoring steam sodium. However, sodium may also enter the steam-water cycle as an impurity due to cooling water leakage or leaching from faulty ion exchange systems (e.g. condensate polishers). The sodium salts associated with condenser leaks may be detected as the anions with the conductivity measurements downstream of a strongly acidic cation exchanger. Sodium hydroxide is not detected by conductivity downstream of a strongly acidic cation exchanger nor can it be detected by pH or specific conductivity in the presence of ammonia or amines. Therefore, if sodium is not monitored in the steam, other means to detect sodium hydroxide ingress into the steam-water cycle must be present. * Total Iron (Fe): The total iron concentration is an indicator for corrosion processes. As such, it provides information on corrosion-product transport rates. Normally, the iron content of the steam remains well below 2g/kg where conditions for continuous operation are constant. An elevated iron content is mostly likely to occur during start-up, especially in the case of cold starts. In order to avoid the deposition of iron oxides on the blades and/or related erosion processes, the total iron concentration prior to start-up of the turbine should not exceed 50g/kg. Iron is usually a laboratory analysis. * Total Copper (Cu): The total copper concentration, like the total iron concentration, is an indicator for corrosion process. Deposits containing copper can stimulate other corrosion processes. Copper will also deposit on the inlet blading of the turbine and reduce capacity and efficiency. If the feedwater heater and condenser turbine were originally of Cu-free material (stainless steel, titanium, carbon steel, etc.) there is no need to monitor the copper concentration. After conversion from a copper alloy to all-ferrous system, copper should be monitored until it is shown that all copper has been removed from the system. Copper is usually a laboratory analysis.
Page 7 of 7 6. Mass Weighted Averaging Mass weighted averaging of steam purity parameters is permitted to allow for multiple steam sources. For example, when a second boiler is being brought into service, its steam purity may be mass averaged with the steam purity of the boiler already in service to determine whether the steam meets the purity required. Similarly, when the higher pressure steam is purer than required, lower pressure steam that does not conform may be added to the stream, provided the mass weighted average meets the recommendations in this document. In general, a parameter a may be calculated as
m a a= m
i i i
i i
Where i runs over all streams, mi is the mass of the stream (flow rate) and a ai is the value of parameter a for that stream. Remember that extracted steam must be removed at its average purity. Thus a calculation may be required upstream of an extraction to provide the averaged purity of the extracted steam. Lower pressure steam may then be blended using the remaining mass and purity. Mass weighted averaging is a complex procedure and must be carefully documented. Operating each source within the steam purity recommendations is preferable.
7. Other Suggestions For the water PH value is mainly affected by Steam Generator Feedwater System, the ideal PH value should be more than 9.6 in order to decrease the erosion of whole cycle system.
Operating Limits and Precautions

OP.2.09.01E-00
CompiledYu Yan CheckedZhang Xiaoxia Countersign Yan Weichun,
2008.09 2008.09 2008.09
Contents
OPERATING LIMITS AND PRECAUTIONS ...........................................1 1 GENERAL PRECAUTIONS ...............................................................1 2 ABNORMAL OPERATING CONDITION ........................................4 3 OFF-FREQUENCY TURBINE OPERATION ..................................5 4 GLAND SEALING STEAM ................................................................5 5 LP EXHAUST AND LP EXHAUST HOOD SPRAYS ......................6 6 WATER INDUCTION ..........................................................................9 7 DRAIN VALVES..................................................................................10 8 SUPERVISORY INSTRUMENTS ....................................................11 9 TURBINE BEARINGS AND OIL SYSTEM....................................11 10 EMERGENCY POWER ..................................................................13 11 BYPASS OPERATION .....................................................................14 12 MISCELLANEOUS..........................................................................14
Page 1 of 15
OPERATING LIMITS AND PRECAUTIONS 1 GENERAL PRECAUTIONS

1. Follow cold start or hot start procedure as determined by initial rotor metal temperatures before admitting steam to the turbine. Turbine starting procedures are defined in the section Starting and Load Changing Recommendations. 2. When following cold start procedures, determine the length of time for rotor It is important that
warming from the chart Cold Start Rotor Warming Procedure.
this time period, as determined by initial rotor metal temperatures on the first attempt to roll, not be reduced in an emergency situation, where there may be a strong desire on the part of the operator to put the unit on the line in a shorter time. Refer to the chart Turbine Speed Hold Recommendations for the allowable rotor warming soak speed range for the warming period. 3. When following hot start procedure, control the steam conditions at the throttle
valve inlet to achieve an exact match of first stage steam and metal temperatures. At no time should the first stage steam temperature be more than 111 above or 56 below the first stage metal temperature (see chart Start Recommendations). 4. Operation of the turbine with excessive backpressure can damage blading and cause
rubbing between rotating and stationary parts. The maximum allowable backpressure is load dependent and is shown on chart entitledExhaust Pressure Limitation. 5. LP turbine blade resonant speed ranges for this turbine-generator unit are shown on
the chart Turbine Speed Hold Recommendations. If, during acceleration of the turbine, it becomes necessary to hold the speed, be sure that the speed hold is not in a resonant range. If it is, reduce the speed below the resonant range. 6. For adequate warming of the steam chest before transferring from throttle valve
control to governor valve control, the temperature of the steam chest inner surface (as measured by the inner wall deep thermocouple) should be equal to or greater than the saturation temperature corresponding to the prevailing steam pressure ahead of the throttle valves. This will prevent the formation of water when the steam chest pressure is raised as a result of transferring control to the governor valves. This heating may be more difficult to accomplish when the throttle valve pilot values. The chart Start-up Steam Conditions at Turbine Throttle shows the relationship between pressure and
Page 2 of 15 temperature that must prevail at the inlet to the throttle valves if steam chest temperature is to reach the desired value. For example, with 6.89MPa steam inlet pressure, a minimum temperature of 357 at the throttle valve is required. The use of reduced pressure steam at startup is recommended. 7. The maximum temperature difference between deep and shallow thermocouples in
the steam chests should not exceed 83. 8. Observe the limits of the steam and metal thermocouples throughout the operation of
the turbine. Refer to the section Turbine Steam and Metal Thermocouples. 9. The appropriate final governor valve opening sequence as shown on Control
Setting Instructions must be strictly followed. Operation at any other sequence may result in first stage blading problems. 10. Do not operate the turbine with the throttle valve (s) on one steam chest open and the throttle valve(s) on the opposite steam chest closed. This restriction does not apply for very short periods of time such as when the valves are being tested for stem freedom. 11. Do not operate the turbine with the reheat stop and/or interceptor valves on one side of the turbine open and those on the opposite side closed. This restriction does not apply for very short periods of time such as when the valves are being tested for stem freedom. 12. If reheat spray attemperating water is used, the following operating conditions must be observed: Using the maximum calculated heat balance as a base, the quantity of reheat spray attemperating water must be measured. The load must be reduced from the load shown on this heat balance by 0.6% for each 1% of reheat spray attemperating water measured as a percentage of the throttle flow shown on this maximum calculated heat balance. 13. Two major aims of the Operations section of the instruction book are to limit the thermal stresses in the turbine and limit interference of parts due to differential thermal expansion. It is important to limit the temperature differences within various parts to avoid thermal stresses and fatigue. Differences in thermal expansion can cause rubs. Additionally, some parts of the turbine have maximum temperature limits. It is important to adhere carefully to the temperature limits given in Starting and Load Changing Recommendations chart and the charts pertaining to these instructions. Additional important temperature limits are given in Turbine Steam and Metal Thermocouples and Water in the Turbine leaflets.
Page 3 of 15 14. During turbine operation, do not operate portable radio equipment other than sound powered telephones near or in the same room with the DEH controller if the controllers cabinet doors are open. 15. If the throttle pressure controller (or limiter) is out of service and the throttle steam pressure falls uncontrolled below 90% of rated pressure for units with a drum type boiler (95% for units with a once-through type boiler), or if throttle or reheat steam temperature falls uncontrolled more than 83, remove the load and trip the turbine. Refer to the section Shutdown Procedure for instructions if the throttle pressure controller (or limiter) is in service. 16. Do not motor the turbine-generator unit for extended periods. We recommend that inadvertent motoring operation be limited to less than one minute to prevent overheating the turbine blading due to windage and lack of ventilation. Deliberate motoring is not recommended at any time. 17. Overspeed Trip Mechanism 17.1 When starting the turbine initially, after any major overhaul, or after work is performed on the governor pedestal which may affect the overspeed trip setting, the turbine should be overspeeded to insure that the overspeed trip mechanism will operate. The overspeed test should then be made periodically every six month, unless sooner required by another such occurrence. 17.2 The overspeed trip setting is specified in the Turbine Control Settings leaflet. 17.3 The overspeed trip mechanism is described in a separate leaflet Overspeed Trip Mechanism. 18. During shutdown periods, keep the turning gear in operation, except as noted in the Turning Gear Operation During Shutdown section. 19. Do not admit steam to the turbine with the rotor at rest. 20. When conducting field hydrostatic tests of the main steam inlet piping between the steam generator outlet and the turbine during which the throttle valve is expected to function as a stop valve, the affected metal and water temperatures must be determined. This is especially important in the event of a unit shutdown to effect boiler repairs. The temperature of the throttle valve body at the inner wall, a measured by a thermocouple installed in a boss provided for that purpose, must be within 83 of the temperature of the water used for the test. This temperature differential must not be exceeded in order to
Page 4 of 15 avoid distortion of the throttle valve body and internals due to high thermal gradients. The throttle valve should be on its seat when conducting the hydrostatic test. Some leakage of water can be expected past the seated valve depending on the present condition of the contact surfaces. 21. Process extraction flow must not exceed contract specifications. The customer is responsible for monitoring extraction flow and determining that it is within this limit.
2 ABNORMAL OPERATING CONDITION

1. For operation of the turbine under other than rated steam conditions, refer to the section Allowable Variations in Steam Conditions. 2. The turbine may be continuously operated at the conditions shown on the "Turbine
Maximum Calculated LoadNot Guaranteed" heat balance (refer to Thermal Performance Data). If the unit is operated at other than normal conditions by such actions as: removing feedwater heaters from service, using reheat attemperating sprays for injecting greater quantities than shown on the heat balance, reducing the amount of steam shown on the heat balance to be extracted for air heating, etc. It could result in greater-than-design flows passing through the main turbine blading downstream of where the cycle changes occur. Turbine damage-in particular, blade damage could eventually result if load is not reduced sufficiently to prevent exceeding design conditions. The large last three blading stages of the LP elements (s), in particular, can be damaged if subjected to conditions that exceed their maximum allowable design loading limits-sometimes expressed as maximum allowable end loading. Various operating rules are located in other areas of the operation leaflet to guide the operator in reducing unit load to avoid damage due to some of the abnormal conditions listed. 3. Avoid operation at less than 5% rated load. However, when necessary, auxiliary load
may be carried indefinitely on the main generator following rejection of the main load provided: 3.1 Limitations on reheat temperature and LP exhaust pressure as specified on the chart
Page 5 of 15 No-Load and Light Load, Operation Guide are maintained. 3.2 LP turbine exhaust temperatures do not exceed the limits and conditions specified in sub-section 5, Low Pressure Exhaust and Exhaust Hood Sprays, item 4. 3.3 All supervisory instrument readings are within allowable (alarm) limits: (Pay particular attention to differential expansion readings. Rapid or continued changes in readings may require timely action to avoid exceeding allowable limits. Such action would include removal from service or application of sufficient load to reestablish safe operating conditions).
3 OFF-FREQUENCY TURBINE OPERATION

Avoid off -frequency operation in order to prevent the probable occurrence of turbine blade resonance. Prolonged periods of operation at certain off-design frequencies could cause excessive vibratory stresses which could eventually generate fatigue cracking in the blades. Off-frequency operation is permitted to the degree and time limit specified on the chart Off-Frequency Turbine operation located in the "Curve and Table of Turbine Operate" section of the Operation leaflet.
4 GLAND SEALING STEAM

1. 2. Steam supplied to the turbine glands should contain not less than 14 superheat. Do not place the gland sealing steam system in service until the unit is placed on
turning gear operation. This is to avoid bowing the rotor (s). 3. The temperature limits of steam in the low pressure turbine glands are 121
minimum and 177 maximum. It is suggested that the gland system temperature controller be set at 149 . 4. To protect against rotor damage in the gland zones resulting from thermal stresses,
keep the difference between gland sealing, steam temperature and rotor surface temperature to a minimum when starting or shutting down. The estimated number of cycles to start rotor cracking due to thermal stresses at temperature differences between gland sealing steam and rotor surface metal can be determined from the "Gland Sealing Steam Temperature Recommendations" chart. As a guide to the operator, a cycle fatigue
Page 6 of 15 capacity of 10,000 cycles is recommended. 5. Where auxiliary boilers are used to furnish gland steam for hot starts, care must be
exercised to ensure that the auxiliary boiler is furnishing steam to the glands at a temperature such that the maximum allowable difference between the gland sealing steam and the rotor metal temperature is not exceeded.
5 LP EXHAUST AND LP EXHAUST HOOD SPRAYS

1. Do not operate air ejector or vacuum pumps without sealing steam on the turbine glands. 2. LP exhaust hood sprays are provided, which when placed under automatic control,
commence operation when the rotor speed reaches 2600 r/min and continues until the unit has been loaded to 15%. The control switch should always be in the automatic position during start-up. The switch also has a manual position. 3. The operator must be certain that water is available to the exhaust hood spray control
valve whenever the turbine is rolling over 3 r/min. 4. With LP exhaust hood sprays out of service, the LP exhaust hood steam temperature
limits are 79 for continuous service (alarm at 79) or 121 for short periods (15 minutes). If 121 reached, and the temperature cannot be reduced promptly, trip the turbine and correct the trouble. If 121 is exceeded, trip the turbine and correct the trouble. NOTE: With the exhaust hood spray in service, the high exhaust temperatures will be eliminated; however, high blade path temperatures may exist and observance of the back pressure limit is required to avoid temperatures in the blading that are unacceptable. 5. We do not expect overheating of the LP exhaust hood with no-load steam flow, low absolute condenser pressure, and the LP exhaust hood sprays out of service. High absolute condenser pressure will cause overheating, as will less than no-load steam flow (at rated speed) which would result if the unit were allowed to motor. 6. If the LP exhaust hood steam temperature reaches 79 the operator must lower the
temperature gradually by increasing load or improving the vacuum.

7.
Page 7 of 15 With the LP exhaust hood sprays in service, operation at high absolute condenser
pressure can cause high blade-path steam temperature. Care must be taken to insure that operation under these conditions does not cause unacceptable differential or radial expansion problems between rotating and stationary parts of the LP turbine. 8. When operating with high exhaust temperature, pay particular attention to
differential expansion, vibration, bearing metal temperature changes, etc. With the LP exhaust hood sprays out of service, temperatures may be determined by exhaust hood thermometers and thermocouples. If the exhaust hood steam temperature alarm of 79 is reached, the operator should attempt to lower this temperature by any of the following means: 8.1 Improve vacuum. 8.2 If at low load, increase load above 15% of rating. 8.3 If not on line, reduce speed to warming speed. 8.4 If at warming speed, go back to turning gear speed. 8.5 Put exhaust hood spray system into operation. 9. The exhaust hood spray regulating valve has a bypass valve which should only be
used in the event of regulating valve failure or servicing. The bypass should only be opened enough to maintain the calculated control water pressure. See Turbine Control Settings. CAUTION To prevent possible damage to the turbine it is important that this valve is not left open when operating the turbine in the range that LP exhaust hood sprays are not required. 10. The chart "No Load and Light Load Operation Guide" specifies exhaust pressure limits at no load (full speed) and at 5% load as a function of reheat temperature. 11. Set the vacuum trip to trip the unit at the setting shown in Turbine Control Settings. 12. Vacuum Breaker Operation. 12.1 When more than on LP element is used, vacuum should be broken
simultaneously in all elements. 12.2 Vacuum should be maintained on a trip out, or normal shutdown, until the unit
coasts down to about 10% of rated speed or until the unit is placed on turning gear
Page 8 of 15 provided that no emergency is involved in the trip out, or shutdown, that requires vacuum to broken immediately after the main turbine valves close. Making a practice of opening the vacuum breaker valve immediately after tripping a unit could result in blade damage due to the braking action imposed by the suddenly created dense exhaust medium. Vacuum should be broken immediately after a unit is tripped if any condition exist where possible damage to the unit can be reduced by shortening coast down time. Examples of incidents requiring vacuum to be broken immediately after a trip include, but are not restricted to: loss of ac power, loss of dc power, low bearing oil pressure, loss of lubricating oil, loss of cooling water to turbine oil coolers, thrust bearing trip, water in the turbine, any indication of rubbing between rotating and stationary parts, and excessive vibration on coast-down. 12.3 a. b. c. d. Vacuum must not be broken at any speed until:
The turbine is tripped; The turbine throttle valves are closed; The generator is separated from the system; The turbine-generator unit is in a free coast-down condition. Vacuum must not be broken when the unit is tied to the system and
12.4
turbine-generator speed is maintained by the system even though the throttle valves are closed. This condition occurs when a unit is motoring. 12.5 Vacuum must not be broken when load is rejected on the unit, but turbine speed
is maintained by the governing system to carry auxiliary load. In this case, the throttle valves are not closed nor are the turbine-generator unit in free coastdown even though the generator is separated from the system. 12.6 If gland sealing steam is lost, trip the turbine and break vacuum as soon as the
conditions of Item 12.3 above are satisfied. 12.7 Vacuum should be dissipated before gland sealing steam is shut off to avoid
pulling cool air into turbines across heated glands and rotors. 12.8 Each LP turbine vacuum must be broken at the same time if more than one LP turbine used. 13. The maximum permissible back pressure for on-line operation is 18.6kPa at loads above 10% of rated load up to 100% load. At lower loads, and at the rated speed-no load condition, substantially lower back pressures are required. Such operation should be in
Page 9 of 15 accordance with the chart, No load and Light Load Operation Guide. Failure to observe specified back pressure limits may result in blade failures or rubbing between rotating and stationary turbine parts with serious damage to turbine components. 14. If multiple condensers or a zoned condenser is provided: 14.1 The temperature difference between multiple condensers (or condenser Zones) should not exceed 17, alarm at 11 differential and trip the unit at 17 differential. The permissible pressure difference between multiple condensers (or condenser Zones) is 8.6kPa(a); alarm at 6.9kPa(a) differential and trip the unit at 8.6kPa(a). 14.2 Temperature and pressure differences between active and inactive condenser result in uneven flow distribution to the low pressure turbine blading resulting in possible operating difficulties. We recommend that the turbine be removed from service if it is necessary to remove one full condenser from service.
6 WATER INDUCTION
1. Cool water introduced into a hot casing may cause rubs, possible vibration and loss in performance. If severe enough, it will necessitate an extended outage for repair of damaged parts. The operator must ensure that the turbine drains and also the drains from the main steam, hot reheat, cold reheat, and extraction lines are not blocked during start-up. In addition, the operator must ensure that power station systems including the feed water heaters, boiler flash tank system, and the reheat attemperation system are functioning properly. 2. Water detection thermocouples are installed in pairs in the turbine cylinders (one in
the bottom of the cylinder base and one in the cover) to monitor the temperature difference between base and cover metal in selected temperature zones. The maximum permissible temperature difference between base and cover is 56, with the base colder. An alarm is activated if the temperature difference reaches 42. If the difference exceeds 56 by any amount, trip the turbine immediately. A sudden increase in the normal temperature difference indicates the pressure of water in the bottom of the outer cylinder. All turbine drains should be checked and opened immediately. All power station systems that could be introducing water into the turbine should be checked for proper operation. These include feedwater heaters, boiler flash tank systems, reheat
Page 10 of 15 attemperation systems and the drains from the main, hot and cold reheat and extraction steam lines. NOTE The turbine can remain in service with a 56 temperature difference if there is no instrument indication or other sign of distress that would necessitate tripping. This will give the operators time to isolate and dispose of the water, allowing heat from the normal steam flow through the turbine to straighten distorted stationary parts. It is of utmost importance, however, that if the temperature difference exceeds 56 by any amount, the turbine be tripped immediately regardless of the consequences. 3. It is essential that the turbine operator be thoroughly familiar with the information contained in the section Water in the Turbine.
7 DRAIN VALVES
1. Operation of the turbine drain valves is normally automatic, but if manual operation becomes necessary, all turbine drains and other drains critical to turbine safety must: 1.1 Be open until the turbine is cold when unit shut down. 1.2 Be opened before the turbine is started and before gland steam is supplied to the glands. 1.3 Remain open on increasing load until the unit is carrying 10 percent of rated load for drains from sources upstream of the turbine reheat stop valves. 1.4 Remain open until the unit is carrying 20 percent of rated load for drains from sources downstream of the turbine interceptor valves. 1.5 Open on decreasing load at 10% of rated load and remain open below 10% of rated load for drains from sources upstream of the turbine reheat stop valves. 1.6 Open on decreasing load at 20% of rated load and remain open below 20% of rated load for drains from sources downstream of the turbine interceptor valves. 2. Avoid breaking vacuum before critical drain valves are open. This recommendation does not apply in emergencies requiring vacuum to be broken immediately nor does it apply to the purchaser's main steam pipe drains. 3. On initial start-up, read and record the pressure gauge indication on each drain
manifolds with the unit on turning gear and at each speed and load hold while the drains
Page 11 of 15 are open (usually up to 10-20% load.) If the pressure in any manifold exceeds the pressure of the lowest pressure source routed to that manifold, shut the unit down and correct the problem.
8 SUPERVISORY INSTRUMENTS
1. Before the unit is rolled from turning gear speed, the portable rotor truth dial indicator measurement at any bearing oil ring should not exceed 0.0254mm double amplitude. In addition, the rotor eccentricity should not exceed 0.076mm double movement. 2. Rotor position is based on a nominal thrust bearing clearance of 0.38mm. The alarm
limit and trip limit consult Turbine Control Settings. 3. 3.1 3.2 Vibrations Limits (double amplitude-mm). 0.076mm-satisfactory. 0.127mm-alarm (investigation is needed if vibration is continuous and of the
unbalanced type). 3.3 0.254mm-trip or other suitable action (which may be load change, speed change,
etc., according to specific conditions). 4. Differential expansion limits. Refer to the Turbine Control Settings leaflet for the
alarm and trip settings as these values vary with turbine configuration. 5. There are no Alarm or Trip features on the Casing Expansion.
9 TURBINE BEARINGS AND OIL SYSTEM

NOTE For generator and exciter bearing temperature limits, see Generator Instruction Book. 1. Bearing Metal Temperature Limits
l.1 The babbitt temperature of turbine journal bearings will normally range between 66 and 112 depending on such variables as inlet oil temperature, oil flow, bearing size, bearing load, etc. The alarm is set at 107 operation above this temperature should be carefully monitored until the reason for abnormal temperature is determined. Trip the unit if the metal temperature exceeds 113.
Page 12 of 15 CAUTION Whenever any bearing exhibits erratic temperature changes, investigate the cause immediately. Trip the turbine if necessary. Inspect the bearing and make whatever repairs are needed. Comply with the appropriate instructions in the section Turning Gear operation During Shutdown depending on the extent of the damage. 1.2 Thrust bearing babbitt temperature can range from slightly inlet oil temperature to 99 depending chiefly on thrust load. The alarm setting is 99 and the trip setting is 107. Operation between the alarm and trip temperature should be carefully monitored until the reason for the abnormal temperature is determined. 2. Oil Pressure Limits
Low bearing oil pressure alarm and trip settings for this unit are shown on the Turbine Control Settings (Control Setting Instructions) leaflet. 3. Oil Temperature Limits
3.1 Do not start the motor-operated bearing oil pump if the oil temperature at the oil reservoir is less than 10. 3.2 Do not start the turning gear until the oil temperature at the oil reservoir reaches 21 minimum. This is also the minimum oil temperature for turbine operation. 3.3 Bearing (turbine) oil discharge temperatures should not exceed 82. Alarm at 77 and trip at 82. 3.4 During turbine operation, an oil temperature of 38 to 49 is considered normal. When starting the turbine, shut off the water supply to the oil coolers until the oil temperature within this range. 3.5 During turbine operation, leave the oil cooler interchange valve open to ensure that the standby cooler will be filled with oil and ready for service at all times. 4. Oil Vapor Extractors
4.1 The oil vapor extractors for the generator loop seal tank and turbine oil reservoir must be in service when starting and operating the turbine-generator unit. 4.2 The vapor extractors vacate gases (hydrogen and air) from the lubricating and seal oil systems and prevent the discharge of oil vapor to atmosphere along the rotor by establishing and maintaining a slight negative pressure throughout the turbine-generator
Page 13 of 15 lubricating and seal oil systems. 4.3 The loop seal vapor extractor performs these functions for the generator exciter while the vapor extractor on the oil reservoir serves the turbine pedestals, bearing housings, reservoir and the remainder of the oil piping. 4.4 If either vapor extractor malfunctions or is shut off during turbine-generator operation, there is a possibility that some hydrogen, oil vapor and/or lubricating oil may escape from the oil seal rings and be discharged into turbine room. Under these conditions, the turbine-generator unit should be shut down until the vapor extractor system is restored to service.
10 EMERGENCY POWER
It is essential that a reliable source of emergency power be available whenever a turbine is in operation at any speed above turning gear speed. Manufacturer normally supplies two bearing oil supply pumps, one driven by an ac motor and the other, an emergency backup pump, driven by a dc motor. Under certain emergency conditions, such as loss of ac power, a continuous source of emergency power is required for a period of time not less than the turbine-generator coast-down time to ensure safe shutdown. It is the purchaser's responsibility to provide the continuous supply of power to these pumps and damage resulting to units from a failure to have such a continuous supply shall be the purchaser's responsibility. Where batteries are provided for the emergency power supply, they must be capable of providing rated emergency oil pump power for approximately 45 to 60 minutes with the power supply lasting for the duration of the coast-down period. The unit should not be started if sufficient emergency power is not available for safe shutdown under emergency conditions. The batteries must be continuously monitored to ensure adequate dc power supply for a safe emergency shutdown. They will most likely be discharged following a coastdown on dc power or when dc power is used to test emergency equipment or systems (such as the dc emergency oil pump), which do not turn off automatically. The dc emergency oil pump imposes a heavy drain on the battery system. Thus, following operation of this pump, the adequacy of the dc power must be checked.
Page 14 of 15 CAUTION Shut off the dc emergency oil pump following testing of this pump and associated pressure switches. The switch must then be returned to the AUTO position.
11 BYPASS OPERATION
When the turbine bypass system is in service, the following restrictions should be observed: 1. The turbine control system must be in the BYPASS ON mode whenever the plant bypass system is on. Similarly, the plant bypass system must be on whenever the turbine control system is in the BYPASS ON mode. 2. At synchronization and at low loads, a maximum cold reheat pressure of 0.828MPa(a) is recommended to prevent overheating of the HP turbine. 3. The high temperature alarm limit for HP turbine exhaust steam is 400, If the HP exhaust temperature alarm of 427 , the operator should attempt to lower the temperature by the following means: 3.1 Decrease reheat pressure 3.2 Increase load If the HP exhaust steam temperature reaches 427, the turbine will be tripped automatically.
12 MISCELLANEOUS
1. Lift major turbine parts in accordance with the Lifting Gear Instructions drawings. Use only the recommended cable sizes, turnbuckles and hooks. 2. Keep a complete record of all steam pressures and temperatures. Any deviation from
normal should be investigated and corrected immediately. This applies in particular to variations in steam pressure distribution throughout the turbine at any given load. 3. Keep the lube oil system clean and free of water. It is suggested that a small quantity
of oil be drained from the bottom of the lube oil reservoir after long shutdown periods during which water and sediment may be settled to the bottom. If preferred, the lube oil may be drained and batch-treated before returning it to the system. 4. Oil leaks are unsightly and dangerous and constitute a hazard when close to parts
Page 15 of 15 carrying hot steam. Correct all such leaks immediately. 5. Ensure that the entire area around and beneath each bearing oil seal is clean and free
of dust, chunks of thermal insulation and other foreign material or debris which could absorb oil and act as fuel or a wick to support combustion. The area that must be clean includes, but is not limited to centering beams, structural supports, walkways, platforms, top of the foundation, and piping located below the pedestal and bearing housing which tend to collect this debris. Insulated parts (piping and cylinders) in these areas should be protected by an appropriate covering to prevent absorption of oil into the insulation. 6. Slop drains are provided to drain the cavities formed by the bearing housing, LP
exhaust cone and the LP turbine base structure at each end of each LP turbine element. Customers connections to these slop drains are provided at the bottom of each LP turbine element base and these drains should be routed out of the condenser neck to a waste pit at atmospheric pressure. This pit should be protected against fires since oil may be dumped to waste through the slop drains. To reduce the hazard of fires at the turbine, cavities in bearing housing areas must be kept clean of all dirt and debris and slop drains must be kept open. Therefore, a periodic check should be made to ensure that the slop drains are not plugged so that oil or water that collects in these cavities will drain to waste promptly. To ensure that the slop drains are open, MANUFACTURER recommends that a check be made every 3 months. This check consists of pouring a gallon of clean water in each cavity containing a slop drain to ensure that the water drains out promptly and that the drain is functioning properly.
CompiledZhang D.M
2008.09 2008.09
Water in The Turbine

OP.1.10.01E-00
CheckedHuang Q.H
Countersign Yan W.CH 2008.09 CountersignYu Yan 2008.09
Contents
Water in The Turbine........................................................................................1 1 OPERATION...........................................................................................1 1.1 General .................................................................................................1 1.2 Drain System ........................................................................................3 1.3 Main Steam System..............................................................................4 1.4 Reheater Attemperating Station ...........................................................5 1.5 Unit on Turning Gear ...........................................................................5 1.6 Cold Reheat Piping System..................................................................6 1.7 Extraction and Feedwater Heaters .......................................................7 1.8 Gland System .......................................................................................8 1.9 Attemperating Sprays ...........................................................................8 1.10 Feedpump Turbine Steam Supply ......................................................9 2 MAINTENANCE....................................................................................9 2.1 Startup Periods .....................................................................................9 2.2 Once per Month....................................................................................9 2.3 Every 3 Months ..................................................................................10 2.4 Annual Inspection...............................................................................11
Page 1 of 11
Water in The Turbine 1 OPERATION

Once water enters a turbine it is extremely unlikely that all damage can be prevented. Possible damage to turbines by water includes, but is not restricted to, blading and shroud failures, thrust bearing failure, rotor cracks, blade ring cracks, permanent blowing of rotors, permanent distortion of stationary parts, and crushed (blading and gland) seal strips. The degree of damage is a function of many factors including point of water entry, quantity of water, length of induction period, turbine metal temperatures, speed and/or load on the unit, steam flow, relative position of rotating and stationary parts and action taken by the operators. So many factors are involved that no single set of operating instructions will be adequate for every incident. However, we believe that power companies can devise operating instructions for each unit and train operators to use these instructions to minimize damage in most water incidents. The following
recommendations are provided for this purpose.
1.1 General
1. 2. Train operators to handle water induction incidents. Insist that operators follow prescribed procedures whenever an alarm or instrument
indicates that water induction is in progress or imminent. 3. 4. Take action immediately when water induction is indicated. Provide alarms and use a recorder in the control room for all water detection
thermocouples in the heat power cycle. 5. When an alarm sounds do not depend solely on automatic operation of critical valves. Actuate these valves remotely and check visually to be sure they are in the correct position. 6. If there is faulty protective equipment associated with a water source, isolate the
source from the turbine and adjust operating conditions as required by loss of the equipment. 7. When a water induction incident occurs analyze the incident and make required
corrections to equipment not only in the affected zone, but in all other zones susceptible to the same type of incident. Correct operating procedures and operator training
Page 2 of 11 deficiencies if corrections are needed. 8. A water induction incident is considered to be in progress if abnormal or final high
level in a heater is indicated, if the purchaser's water detection sensors in extraction pipes indicate water or if any pair of turbine water detection thermocouples indicates a difference between cylinder base and cover metal of 42 or more with the base colder. If this temperature difference exceeds 56 by any amount the unit must be tripped immediately. If the temperature difference does not exceed 56, and there are no instrument indications or other signs of distress which indicate the unit must be tripped, the unit can be kept in service to isolate and dispose of the water. A water incident is also considered to be in progress if there is vibration or swaying of pipes which did not exist before and for which there is no acceptable explanation. Obviously there may be acceptable causes: but if these are not readily discernable, operators should assume a water incident is in progress and take necessary protective steps. Should any of these conditions develop, emergency operating procedures must be instituted immediately. 9. We generally agree with the concept of detection, isolation, and removal of water
with the turbine in service, experience to date indicates that once water is in a hot turbine, distress which exceeds allowable operating limits usually occurs and the unit must be tripped. Therefore, turbine operators must be trained to handle both contingencies. The automatic protective schemes recommended are necessary for rapid action to attempt to keep the temperature difference between turbine cylinder base and cover from exceeding 56. The operating instructions that follow are based on the premise that drain and shutoff valves are power operated and remotely or automatically actuated. These instructions can be used with manual valves, but in those cases where quick action is an absolute necessity to minimize damage; manual valves may not be operable in the time available. If valves are automatically actuated the step-by-step operating procedure should be followed as a backup for possible malfunction. To avoid numerous repetitions of the basic procedure in the specific instructions, it is presented below and referred to hereafter as the Basic Isolation Procedure for Feedwater Heaters. The procedure is based on water from feedwater heaters since most incidents involve the heaters. Rapid execution of the procedure is essential. Basic isolation procedure for feedwater heaters:
Page 3 of 11 a. Close the shutoff valve in the extraction pipe. [*] b.Open all drain valves in the extraction pipe and affected turbine zone. c. Check all shutoff and drain valves visually for correct position. d.Reduce heater level to normal elevation. e. Determine and correct the cause of the incident. f. If the cause of the incident cannot be corrected immediately, the unit may be operated providing that: 1) All water is removed from the turbine as evidenced by a difference of less than
42 between cylinder base and cover. 2) 3) All water is removed from the extraction pipe. The unit can be operated safely without the faulty equipment and that this
equipment is completely isolated so that the incident will not recur. 4) All instrument indications, especially metal temperatures, eccentricity, vibration
and differential expansion, demonstrate that conditions are satisfactory for operating the unit. 5) All extraction pipe drains remain open on the turbine and heater sides of the
shutoff valve. 6) There were or are no indications of damage or distress that preclude operation
and necessitate disassembly of one or more turbine elements for immediate repairs. Bypass condensate around feedwater heaters that do not have shut off valves in
the extraction pipes. 10. Regardless of preventive equipment furnished and precautions taken, occasional water incidents can and will occur. Attempts to restart units too quickly following a water incident may result in sufficient damage to keep the units out of service for 6 months or more. Therefore, operators must recognize that once it is established that a water incident has occurred, or that there is reason to believe that an incident occurred, it is unlikely that the unit involved can be restarted safely for at least 24 hours or more. See paragraphs 1.5 2 and 1.5 3 below.
1.2 Drain System

1. a. b. All turbine drains and other drains which critical to turbine safety should be: Be opened when the unit is out of service until the turbine is cold. Be opened before the turbine is started and before sealing steam is supplied to the
Page 4 of 11 glands. c. Remain opening on increasing load until the unit is carrying 10% of rated load FOR
DRAINS FROM SOURCES UPSTREAM OF THE TURBINE REHEAT STOP VALVES(See the Note after paragraph 1.5 below). d. Remain opening until the unit is carrying 20% of rated load FOR DRAINS FROM
SOURCES DOWNSTREAM OF THE TURBINE INTERCEPTOR VALVES. e. Opened on decreasing load at 10% of rated load and remain opening below 10
percent of rated load FOR DRAINS FROM SOURCES UPSTREAM OF THE TURBINE REHEAT STOP VALVES. f. Opened on decreasing load at 20% of rated load and remain opening below 20% of
rated load FOR DRAINS FROM SOURCES DOWNSTREAM OF THE TURBINE INTERCEPTOR VALVES. Note: On units with only one load-sensing switch for drain valves, it is acceptable for the higher pressure drain valves to be open to 20% load. However, this procedure wastes steam. If the unit is operated for any appreciable time below 20% load, it is likely that the cost of adding the second load-sensing switch and associated writing will be recovered quickly 2. Avoid breaking vacuum before critical drain valves are opened. This
recommendation does not apply in emergencies requiring vacuum to be broken immediately nor does it apply to the purchaser's main steam pipe drains.
1.3 Main Steam System

1. Trip the unit if there is an indication that water is entering or about to enter the turbine from the boiler. 2. Main steam pipe drains should remain open on startup until metal temperatures and
boiler conditions indicate that there is no chance that water is present or will form in the system and be injected into the turbine. 3. Operation with the initial pressure regulator out of service for long periods is not
recommended. With this regulator out of service there is greater hazard to the turbine from the increased possibility of water carryover should boiler pressure decrease for any reason. Normally this instrument is only out of service during startup and load ramping when main steam pressure is less than the rated value. 4. Main steam drains should either be opened immediately after the turbine trips, or if
Page 5 of 11 this practice creates a condition that is contrary to recommended operating procedures for boilers, the power plant designer should have contacted STC and a mutually acceptable procedure developed for use by the operators before initial startup. 5. DO NOT ADMIT STEAM TO THE TURBINE AFTER BOILER FIRES
HAVE GONE OUT.
1.4 Reheater Attemperating Station

1. If this system malfunctions so that the turbine is endangered by insufficient spray water, trip the turbine immediately. If excess water is the problem, follow instructions for operating with water in the cold reheat pipes. 2. Attemperating sprays are usually not required at rated speed-no load. Therefore, the
spray, bypass, and blocking valves should be closed automatically whenever the unit is not carrying load and when the turbine trips. The power plant designer must determine if this procedure can be used without endangering equipment. If the boiler manufacture permits attemperating sprays to be blocked out of service at low loads, close the spray, bypass, and block valves automatically at this low load rather than at rated speed-no load as recommended above. 3. a. b. c. If there is water in the reheater or hot reheat pipes, trip the turbine immediately and: Close the reheater attemperating spray bypass and block valves. Open all drains in the reheat pipes. Do not restart until all water is removed from the reheater and/or hot reheat
piping and the cause of the incident has been corrected.
1.5 Unit on Turning Gear

1. Do not roll the turbine with steam if a water induction incident is in progress, or if water detection thermocouples in any turbine zone indicate that the cylinder base is colder than the cover by 42 or more. a. b. Accomplish the basic isolation procedure for feedwater heaters. If the cold reheat pipes are involved, close the reheater attemperating spray, bypass
and blocking valves. 2. If a cylinder is bowed by water, do not restart the unit until rotor eccentricity is within acceptable limits and the difference between all pairs of cylinder base and cover thermocouples is less than 42. If there are no water detection thermocouples in cylinder metal in the affected zone, remain on turning gear for not less than 18 hours. If
Page 6 of 11 water detection thermocouples are used to determine if a cylinder is bowed, they must be located in the cylinder base and cover approximately diametrically opposite and properly installed in cylinder metal. CAUTION: Remain on turning gear for 18 hours before restarting a unit after a cylinder is bowed. When restarting a unit after a bowed cylinder has straightened, use a low acceleration rate and close supervision of the restart. Trip the unit at the first sign of distress remains on turning gear for 6 additional hours and restart following the same procedure. 3. If the rotor is locked, attempt to place the unit on turning gear once an hour. When
the rotor moves freely, place the unit on turning gear and proceed carefully as outlined in paragraph 1.5 2 above. CAUTION: Do not attempt to turn a locked rotor by admission of steam to the unit or by use of a crane or other auxiliary methods. Such an attempt could cause serious damage to the seals, blading, and other internal parts.
1.6 Cold Reheat Piping System

1. If water enters, or might enter, the cold reheat pipes or the high pressure turbine exhaust when the unit is below rated speed, trip immediately and: a. b. c. 2. Close the reheaters attemperating spray, by-pass, and block valves. Accomplish the basic isolation procedure for feedwater heaters. Place the unit on turning gear and follow instructions for startup from turning gear. If water enters, or might enter, the cold reheat pipes or the high pressure turbine
exhaust when the unit is at rated speed-no load, or carrying load, trip, the unit immediately if required by vibration, differential expansion, metal temperature differences exceeding 56, or other signs of distress of sufficient magnitude to warrant tripping and: a. b. c. 3. Close the reheater attemperating spray, by pass, and blocking valves. Accomplish the basis isolation procedure for feedwater heaters. Place the unit on turning gear and follow instructions for startup from turning gear. If water enters, or might enter, the cold reheat pipes or the high pressure turbine
exhaust when the unit is at rated speed-no load, or carrying load, do not trip if vibration, differential expansion are satisfactory and there are no other signs of distress of sufficient
Page 7 of 11 magnitude to warrant tripping and providing that the temperature difference between cylinder base and cover does not exceed 56, proceed as follows: a. b. c. Hold at rated speed or load. Accomplish basis isolation procedure for feedwater heaters. Close the reheater attemperating spray, bypass and blocking valves if the unit is at
rated speed or low load not requiring sprays.

WARNING: DO NOT LATCH UP A TURBINE FOR STARTUP, OR FOR ANY OTHER REASON, IF THERE IS WATER IN THE COLD OR HOT REHEAT PIPES, REHEATER, OR HIGH PRESSURE TURBINE CASINGS. WATER IN ANY OF THE ABOVE COULD
CAUSE INJURY TO PERSONNEL AND SERIOUS DAMAGE TO THE SEALS, BLADING, AND OTHER INTERNAL PARTS.
4.
When a turbine is latched, interceptor, reheat stop and governor valves go open.
When this occurs with water in any of the zones listed above, and the temperature of this water is above the saturation temperature of condenser pressure, steam will flash and follow through the intermediate and low pressure turbine elements to the condenser. Under these circumstances the turbine often accelerates to some speed, depending on the amount of steam flashed, and there may be damage to the turbine or plant equipment. In particular, water hammer may occur in the cold reheat pipes causing damage to both the turbine and cold reheat piping system including broken pipes, hangers and supports. Also, pipes, cables, equipment or station steel in the vicinity of whipping pipes may be damaged and personnel may be injured. Water hammer can occur in steam pipes that are partly full of water with steam flowing over and accelerating this water to bends and valves in the piping system. Whether the source of steam accelerating the water is from flashing, pressurized reheat sections or open inlet valves, these phenomena can damage turbines, plant equipment and piping. Therefore, before latching the turbine be sure that the cold and hot reheat pipes, reheater and turbine casings are properly drained and free of water.
1.7 Extraction and Feedwater Heaters

1. If water enters, or might enter, the turbine when the unit is below rated speed, trip immediately and:
Page 8 of 11 a. b. 2. Accomplish the basic isolation procedure for feedwater heaters. Place the unit on turning gear and follow instructions for startup from turning gear. If water enters, or might enter, the turbine when the unit is at rated speed-no load, or
carrying load, trip the unit if required by vibration, differential expansion water detection thermocouples or other signs of distress of sufficient magnitude to warrant tripping and: a. b. 3. Accomplish the basic isolation procedure for feedwater heaters. Place the unit on turning gear and follow instructions for startup from turning gear. If water enters, or might enter, the turbine when the unit is at rated speed-no load, or
carrying load, do not trip if vibration and differential expansion are satisfactory and there are no other signs of distress of sufficient magnitude to warrant tripping and providing that the difference between cylinder base and cover does not exceed 56, proceed as follows: a. b. Hold at rated speed or load. Accomplish the basic isolation procedure for feedwater heaters.
4. Whenever a heater is out of service, drain valves in the associated extraction line should be open.
1.8 Gland seal System

1. When a turbine is hot and it is necessary to transfer to an auxiliary source of gland sealing steam, be sure that: a. b. The steam is superheated. the superheate should be more than 14 . The steam temperature is within 111 of rotor metal temperature in the gland
area.(the temperature difference should be lesser). The temperature of LP gland seal will be set between 121 and 177, the setting valve is 149. c. The supply piping from the auxiliary source to the turbine gland system is warm so
that steam is not condensed and injected into the gland system in liquid form. d. The pipe upstream of the gland regulating valve is dry (drain valve open or
continuous drain in service).
1.9 Attemperating Sprays

Sprays provided to desuperheat steam to the condenser from any steam dump valve should be shut off whenever the dump valves are closed or pressure ahead of the valves reach a preset low value. This will prevent possible back flow of water into the turbine
Page 9 of 11 when condenser vacuum is broken. If the system malfunctions so that the turbine is endangered by water, trip the unit immediately.
1.10 Feedpump Turbine Steam Supply

Drain from the feedpump (FP) turbine throttle steam supply line should be opened automatically when the FP turbine trips. If the FP turbine is out of service, all steam supply valves should be closed.
2 MAINTENANCE
In order to be sure that instrumentation and equipment provided to protect the turbine against water damage are in working order when needed, we recommend the establishment of a list of critical items to be checked once every 30 days to insure proper and reliable operation. In the event that actual experience indicates the need for more frequent inspections on specific items, the 30-day period can be adjusted as required. When testing critical equipment every effort should be made to test in a manner that is as close as possible to the actual operation of the equipment providing this can be done without endangering the turbine or other station equipment and without removing the unit from service. Control loops and redundant control loops should be completely tested.
2.1 Startup Periods

1. Clean all traps, orifices, and drip pots during the initial startup period after the first thirty days of operation unless there are indications that these devices must be cleaned sooner. 2. Clean traps, orifices, and drip pots approximately two weeks after startup following
disassembly of the unit, or of a turbine element.
2.2 Once per Month

1. Check turbine supervisory instruments including differential expansion, casing expansion, eccentricity, vibration, rotor position, and metal temperature recorder. These instruments should be cleaned, checked electrically and any questionable components replaced during the inspection period. 2. Check all turbine metal temperature thermocouples. These instruments should be
inspected and maintained on an every 30-day basis; but
a.
Page 10 of 11 Replace faulty thermocouples immediately. Usually this can be done with the unit in
service. b. 3. Maintain spare thermocouples for replacement of critical water detectors. Check all extraction line valves. Check all of the controls associated with these
valves including switches, solenoid valves, air filters, air supply, air sets, etc. Most of these valves can be tested in operation; they should be tested with the same frequency as the main valves on the turbine. If possible, develop procedures to check nonreturn valves for leakage since there have been difficulties caused by leaking nonreturn valves. Where there are two valves in a pipe, it may be possible to pressurize the pipe between valves with air to check for leakage. 4. Check all heater level control and alarm systems to insure proper operation. These
instruments should be cleaned and questionable equipment replaced during the inspection period. 5. Check all heater drain valves to insure proper operation. Clean each valve assembly
externally and replace questionable components.
2.3 Every 3 Months

1. Check all drain lines (and valves) from the turbine and associated piping. This includes main steam, extraction, and hot and cold reheat piping. Drain lines and valves should be checked by the temperature method. 2. Check all orifices and traps by measuring the pipe temperature upstream and
downstream of the trap or orifice. 3. Testing of drain valves and drain lines by the temperature method refers to a
procedure utilizing a contact pyrometer or thermocouples to determine by temperature difference whether or not a drain line is open. We recognize that this method is not completely reliable but is better than no check at all. It is made in operation on normally closed valves by first measuring the temperature on the upstream side of the valve close to the line source. Next, measure the temperature downstream of the valve on the drain line. The valve is then opened and these two temperatures are again checked. If they are then close to one another, we can assume that the line is open and functioning properly. If the temperatures show the same differential relationship as with the valve closed, the line is fully plugged. For best results from the temperature test, the drain line should be
Page 11 of 11 insulated from the source (at least) to the drain valve. We cannot cover every possible case that will occur; however, station operating personnel can work out temperature check procedures for each critical valve and with proper education, reasonable checks can be made to increase safe, reliable operation of the equipment. 4. For drain valves, check that threads on manual and pneumatic valves are clean and
lubricated. Manual valves should have a hand wheel or handle which is properly attached to the valve stem. Power operated drain valves should be checked completely for proper functioning of all components. Stems should be cleaned and the valves lubricated as required. Replace all questionable components during this inspection.
2.4 Annual Inspection

1. Internal inspection, cleaning and maintenance of critical valves, traps and orifices should be made at each major inspection but not less than once a year. 2. Clean drip pots at each major inspection, but not less than once each year.
Starting and Load Changing Recommendations
CompiledJiang Jianfei CheckedYu Yan
2008.09 2008.09
Countersign Zhang Haiyan 2008.09
OP.2.11.02E-00
Countersign Xiaozhong 2008.09 He Countersign ApprovedPeng Zeying 2008.09
Contents
STARTING AND LOAD CHANGING RECOMMENDATIONS .................1 1 OBJECTIVES .........................................................................................1 2 THERMAL STRESSES IN TURBINE ROTORS .................................2 3 TURBINE STARTING PROCEDURES ................................................2 3.1 Cold Start Procedure ............................................................................3 3.2 Hot Start Procedure ..............................................................................3 4 LOAD CHANGING RECOMMENDATIONS ......................................4 4.1 Load Changing-General .......................................................................4 4.2 Changing Load Using Sequential Valve and Single Valve Modes ......5 4.3 Changing Load Using Sliding Pressure and Sequential-Valve Modes (Hybrid Mode)............................................................................................7 5 DETERMINATION OF ROTOR FATIGUE CAPACITY DEPLETION ....................................................................................................................7
Page 1 of 8
STARTING AND LOAD CHANGING RECOMMENDATIONS 1 OBJECTIVES

The general objective in formulating starting and load changing recommendations is the protection of turbine parts against thermal fatigue cracking caused by internal temperature variations. The charts Start Recommendations, Load Changing Recommendations, and Cyclic Index for Loading and Unloading provide guidance for selecting appropriate starting and load-changing rates based on thermal stresses developed in the turbine rotor. The rotor is identified as the most critical element with respect to thermal stress because of its large diameter. The stationary parts, having smaller radial thickness and so constructed as to allow unrestrained thermal expansion, are subjected to lower thermal stresses than those developed in the rotor. Operating procedures designed to protect the rotor from thermal fatigue cracking will also protect the stationary parts from this type of failure. The specific objective of these recommendations is to provide for the desired number of cycles of general turbine operation before the appearance of fatigue cracking. Operating at conditions which result in a less than desired number of cycles fatigue capacity will accelerate the accumulation of thermal fatigue and result in the earlier initiation of cracks. Rotor cracks, when developed, appear in fillets, radii, and blade-attachment grooves at the rotor surface. Once initiated, cracks generally propagate slowly. Their removal by machining in the early stages of development restores the fatigue capacity of the rotor. The purpose of adhering to the recommendations for starting and load changing is to maximize turbine availability by avoiding or minimizing corrective maintenance. The turbine-generator unit may be operated in the AUTOMATIC TURBINE CONTROL (ATC), OPERATOR AUTO or MANUAL mode of control. In the ATC mode, the unit can be automatically controlled on the DEH control system from turning gear to synchronous speed to full load. Whenever possible this mode should be used especially during startups since it continuously monitors various turbine-generator parameters and controls the turbine accordingly to maximize turbine availability. Further description of the Automatic Turbine Control mode is given in a separate chapter. In the TURBINE MANUAL and OPERATOR AUTO modes of control, the process is entirely under the control of the turbine operator. The operator is urged to study the following explanatory
Page 2 of 8 material for an understanding of the intent of the recommendations and the use of the operating charts.
2 THERMAL STRESSES IN TURBINE ROTORS

A change in blade-path steam temperature will produce thermal stresses in the rotor which persist as long as there is a difference between the surface and interior temperature of the rotor body. Such a difference exists during and immediately following a rapid change in surface temperature because of the time required for heat to flow from the surface into the interior. The stress is proportional to the temperature difference and is greatest at the rotor surface. It is called a transient stress because it ceases to exist when the surface and interior temperatures have equalized. A heating of the rotor surface followed by an equal cooling constitutes a thermal cycle and imposes on the rotor a cycle of alternating stress. The rotor material has a limited capacity for withstanding stress cycles. Cracks will ultimately develop after a number of cycles which depends on the severity of the stress. The relationship between alternating stress and cyclic capacity is a material property and it is possible to predict the number of stress cycles necessary to initiate a rotor crack. For a particular temperature change, the greatest thermal stress is developed when the change is made instantaneously. The stress can be considerably reduced by accomplishing the change over a period of time, thereby increasing the number of stress cycles available before crack initiation, For large changes, the stress can be limited to any desired level by choosing an appropriate time period to make the change.
3 TURBINE STARTING PROCEDURES

The criterion for determining starting procedure is the temperature of the HP and/or IP turbine rotor metal before admitting steam to the turbine. COLD START procedure is to be followed when the initial temperature of either the HP or IP rotor metal is less than 204. HOT START procedure is to be followed when the initial temperatures of both the HP and IP rotor metal are 204 or higher. HP rotor metal temperature is measured by the inner cylinder metal base thermocouple.
Page 3 of 8 IP rotor metal temperature is measured by the IP turbine blade ring thermocouple. See chapter Turbine Steam and Metal Thermocouples.
3.1 Cold Start Procedure

Steam is admitted to the turbine with a minimum of 56 superheat at the throttle valve inlet, but not more than 427 total temperature. Throttle valve inlet temperature and pressure conditions should be in the area shown on curve Startup Steam Conditions. These steam conditions provide uniform heating and optimum differential expansion and avoid thermal shocking of the steam chests when speed control is transferred from throttle valves to governor valves. The unit is accelerated to a speed within the rotor-warming soak speed range specified on the chart Turbine Speed Hold Recommendations. The turbine is held at that speed long enough to warm the HP-IP rotor bore(s) to at least the transition temperature (121 ) before continuing to synchronous speed. And rotor-warming is not necessary for no-bore rotor from thermal stress side. Following the rotor-warming hold period, the turbine is accelerated to synchronous speed, synchronized and initially loaded in accordance with the loading instructions.
3.2 Hot Start Procedure

Steam is admitted to the turbine with 56 minimum superheat. The curve Startup Steam Conditions shows the throttle valve inlet temperature and pressure conditions that should exist prior to transferring speed control from throttle valves to governor valves. The time required for accelerating the turbine from turning gear to synchronous speed is a function of the mismatch between the initial temperature of steam and metal. The appropriate accelerating time is determined from the chart Start Recommendations. To minimize the rolling time, the throttle steam conditions should be adjusted so that the throttle temperature at 5% load throttle temperature and first stage steam temperature that is within 56 of the rotor metal temperature that existed prior to rolling. In this case, the recommended acceleration time is only ten minutes. With good matching, bringing the rotor to synchronous speed in zero time is theoretically possible from the standpoint of thermal stresses, but ten minutes is selected as a minimum for practical considerations. When synchronous speed is attained, the turbine is synchronized and initially loaded as
Page 4 of 8 determined from the chart Start Recommendations.
4 LOAD CHANGING RECOMMENDATIONS 4.1 Load Changing-General

Load changes are accompanied by changed in blade-path steam temperature. Thermal stresses are developed in the rotor which depend on both the magnitude and the rate of change of the load. There is no single rate of change that can be applied uniformly to all turbine operations if the objective is to limit stress to the level corresponding to the selected fatigue capacity. Small changes can be performed instantaneously when followed by a stabilization period without exceeding the limitation, whereas large changes must be performed less rapidly. The greatest variation of steam temperature over the load range occurs at the first stage of the HP turbine. The first stage steam temperature changes with load. The amount of temperature change is dependent upon the mode of governor valve operation. The various possible modes of changing load are: (1) sequential-valve mode where multiple governor valves are sequenced to open or close in a determined order at either constant or changing inlet throttle steam conditions: (2) single valve" of throttling mode where a group of governor valves open or close in unison to change the amount of valve flow passage area and; (3) sliding pressure mode where a group of governor valves are fully open or maintained at a constantly partially open position while inlet throttle pressure is changed to vary the flow through the turbine. The governor valves regulate the steam flow to separate nozzle chambers arranged circumferentially to admit steam in a 360 full arc to the first stage blading when all the valves are open. Thus, each governor valve feeds steam to a portion of the full 360 arc. In the sequential valve mode, the governor valves, as they open and close in sequence, feed steam through a changing circumferential admission arc to the blading. The size of the arc passing steam can be expressed as a percent of full arc admission. In the single valve mode, all the governor valves operate in unison to vary the flow by changing the amount of valve opening while feeding steam to a full 360 arc of admission. In the sliding pressure mode, the governor valves remain at a fixed opening and feed steam through a constant arc or percent of admission. Operating the turbine in the single valve mode subjects the control stage to more
Page 5 of 8 moderate loading at part load than operating in the sequential valve mode. It also subjects this blading to higher temperatures, which is beneficial in regard to achieving uniformity in the mechanical load distribution at the blade/rotor interface with time. Therefore it is recommended that the turbine be operated as a single valve unit during initial operation. If after that time the purchaser is satisfied that all station controls are set correctly and that all systems are functioning properly, he should change the unit to a proper mode of operation in accordance with the actual conditions. Sequential valve operation is thermally a more efficient mode of operation at lower loads than the single valve and sliding pressure modes. However, with the sequential valve mode, first stage steam temperature changes the greatest amount as load is varied andthereforerequires a longer time to make load changes. Operating in the sliding pressure mode, where all governor valves are maintained in the full open position and the throttle pressure are varied, results in the smallest change in the first stage temperature and thus permits faster load changing rates. However, the ability to operate with a sliding pressure mode depends upon the boiler and its boiler-turbine control system. First stage temperature change when varying load in the single valve mode is less than that experienced using the sequential valve mode, but greater than the temperature variation resulting from the above described sliding pressure operational mode. Load changing charts are provided for the operators guidance for turbine operation over the 5-100% load range for these various modes. These charts permit the operator to select load change rates corresponding to any desired number of available life cycles. All load changes are assumed to take place from initially steady-state metal temperatures at the first stage zone and to be accomplished at a uniform rate. Steady turbine metal temperatures and steady differential expansion, casing expansion and rotor position readings indicate that steady-state conditions exist. See operation sections Turbine Steam and Metal Thermocouples and Supervisory Instruments concerning the instrumentation that provides this information.
4.2 Changing Load Using Sequential Valve and Single Valve Modes
Refer to the Load Changing Recommendations charts to determine the length of time to change load and thereby determine a uniform load changing rate. Load changes at lower loads are generally accompanied by changes in inlet steam pressure and temperature both of which affect first stage temperature. Because of the variability of boiler
Page 6 of 8 characteristics at low loads, it is not possible for the turbine manufacturer to devise a uniform rule for operation in the low load range. To select load changing rates consistent with the 10,000 cycle recommendation or other selected cyclic life, the influence of inlet steam conditions on first stage temperature must be considered. Figures 1 and 2 of the chart Load Changing Recommendations provide the information necessary to determining first stage temperature changes for any combination of load and inlet steam conditions. The curves for sequential valve mode in Figure 2 are for a particular minimum admission in which the governor valves are set to open in a definite sequence to admit steam through the nozzles of first stage of blading in an arc great enough to prevent overstressing the first stage blading. The curves for single valve mode are for 100% admission where all governor valves open together. Figure 2 determines the change in first stage steam temperature when changing load. By projecting this temperature change to the selected cyclic index line in Figure 4, the operator can determine the length of time to take in making the load change. The selected time period applies to both increasing and decreasing loads. It can be noted from Figure 4, that a load change resulting in an internal temperature change of 70 or less be made instantaneously without exceeding the stress corresponding to 10,000 cycles of fatigue capacity as indicated by the intersection of the 10,000 cycle line with the zero time axis. This does not imply that a series of load changes can be made in a short period of time in increments or steps in which the first stage temperature change is 70 or less. For example, if a 40% load increase causes a 70 change in first stage temperature, load should not be increased another 40% (also causing a 70 rise) 15 minutes later. Steady-state temperature conditions would not be reached in the 15 minutes period between load changes. The operator should instead determine the time or rate to make the total load change (80% in the example) from the curves. Single valve operation allows more rapid load changes than sequential valve operation. This can be seen from Figure 2 by noting the narrower band of the first stage steam temperature change across the load range for single valve compared to sequential valve operation. If, during operation, the mode of operation is switched from sequential valve to single valve using the DEH controls, the first stage steam temperature will immediately increase by the difference in the levels of these two modes shown on Figure 2.
Page 7 of 8 Refer to the Governor Valve Management content for further information on the different modes of governor valve operation.
4.3 Changing Load Using Sliding Pressure and Sequential-Valve Modes (Hybrid Mode)
Refer to chart Load Changing Recommendations (Fig.3) to determine the length of time and load changing rate to change load by sliding or ramping throttle pressure. Finger 3, while basically for sliding pressure operation, also contains curves for the throttling and sequential valve mode of load changing, In the example shown on this chart, all three modes of governor valve operation are used in increasing load from 5 to 100%. This use of a mixture of modes is also referred to as using a hybrid mode of operation. The throttling mode is used to increase load from the 5% level; the sliding pressure mode in used to increase load while ramping throttle pressure from the minimum pressure to rated pressure at a specific governor valve opening; and the sequential-valve mode is used to further increase to 100% load at constant rated throttle pressure. Figure 3 determines the first stage steam temperature change between the highest and lowest temperatures occurring during the load changing. This temperature change is based on the throttle temperature being constant during the load change. Therefore, this temperature change between load levels must be corrected by using the temperature change for any change in throttle temperature that occurs. By projecting this temperature change in Figure 4 to the desired cycles to fatigues guideline, the operator can determine the length of time to take in making the load. Referring to Figure 3, the change in first stage temperature can be noted when operating with the various modes of governor valve operation. It can be seen that the change in first stage steam temperature is much greater than that experienced through the hybrid" mode if load was changed using the throttling mode followed by the sequential valve mode at constant rated throttle pressure. The hybrid mode permits a faster load change.
DETERMINATION
OF
ROTOR
FATIGUE
CAPACITY
DEPLETION
The various cyclic capacity lines of Figure 4 permit the assessment of fatigue accumulation. For example, a change of 139 in one hour falls almost on the 5000 cycle
Page 8 of 8 line and therefore accounts for 1/5000 or 0.02 percent of the total fatigue capacity of the rotor. One hundred cyclic repetitions of such a heating phase coupled with an equal and opposite cooling phase would result in 1000.02= 2% depletion of total fatigue capacity, leaving 98% capacity available for other operation. A cycle consists of both a heating phase and a cooling phase. Thus, the 10,000 cycle line on Figure 4 represents 10,000 times the turbine first stage is heated held at steady load until temperature equalization takes place, and then cooled at the same rate and amount as load is increased and then decreased. If the unit is operated such that the unloading phase is done at a DIFFERENT rate than the loading phase, the cyclic index can be determined by using curves Cyclic Index for Loading and Unloading at Different Rates" in conjunction with Figure 4. This index can then be used to determine the depletion of the total fatigue capacity. As an example, if the unit is started where load is increased over an 80 minute period during which the first stage steam temperature rises 144, Figure 4 indicates a 10,000 cycle index. If the unit is then shutdown at a rate where the first stage steam temperature drops 144 in 30 minutes, Figure 4 indicates a 2000 cycle index. Letting the index during the loading period = 10,000cycles and the index during the unloading period = 2000 cycles, enter the Cyclic Index for Loading and Unloading at Different Rates curves to find the equivalent full cycle index = 3820 cycles. This type operation accounts for 1/3820 or 0.026% of the total fatigue capacity of the rotor. Five such cyclic repetitions in a year for 20 years results in 50.02620=2.6% depletion of the total fatigue, leaving 97.4% capacity available for other operation cycles. The example shows that occasional departures from the selected fatigue capacity can be tolerated without serious consequence. A suggestion for planning turbine operation is to perform the more frequent small load changes at rates corresponding to a large number of available cycles. Less frequent major load changes may be made more rapidly with lower cyclic capacity. The user is urged to maintain a record of fatigue accumulation and to schedule corrective maintenance for the rotor when the total accumulation approaches 100%.
Page 1 of 5
Governor Valve Management (Single Valve-Sequential Valve) OP.2.12.02E-00
CompiledJiang Jianfei CheckedYu Yan CountersignTang Jun
2008.09 2008.09 2008.09
CountersignHe Xiaozhong 2008.09 ApprovedPeng Zeying 2008.09
GOVERNOR VALVE MANAGEMENT (Single Valve-Sequential Valve)

This is a sub-mode associated with the Governor Valve Management (VM) Program. It may be selected in OPER AUTO or TURBINE MANUAL, but if selected in TURBINE MANUAL, transfer of the valve mode will not be initiated until OPER AUTO is subsequently selected. The function of this SINGLE VALVE-SEQ VALVE is to enable the operator to select either the single valve or sequential valve mode of control for the Turbine-Generator unit governor valves. Additional description of the various control modes is given in the operation section entitled Starting and Load-Changing Recommendations. Control mode selection is predicated on the resulting first stage discharge steam temperature of the turbine since this temperature will vary according to the control mode used. The operator can shift valve modes at any time during operation of the unit. However, he should be aware that an instantaneous temperature change will occur at the moment of transfer. At low loads the first stage temperature will be approximately 4256 higher using the single valve mode than the sequential valve mode. This difference will decrease to zero degrees at the valves wide open condition where the modes are identical. By proper selection and use of valve control modes, the operator can minimize the first stage temperature change during various stages of operation. This results in minimizing thermal stresses in the HP turbine element. The following guidelines can be applied to the various stages of operation.
Page 2 of 5 1. ROLLING AND MINIMUM LOADING Generally the single-valve mode should be used during the rolling to speed, synchronization and minimum load hold periods. This mode provides steam through all the control valves and nozzle chambers resulting in steam flowing in a 360full arc of admission to the control stage blading. Thus, these parts heat up and expand more uniformly. There may be occasions when sequential valve control, depending upon existing throttle steam conditions, will provide a better match of first stage steam temperature with the metal temperature and permit faster startups. The operator may determine this by referring to the Hot Start Recommendations for Rolling and Minimum Load charts. The single valve mode should definitely be used during the initial break-in period of operation. During this period, it is not uncommon for abnormal pressure and temperature excursions to occur until all station controls are set correctly and all systems are functioning properly. In order to assure the maximum reliability of the turbine-generator unit, it is desirable to minimize the effect of such abnormal conditions on the turbine. Operating the turbine in the full arc admission mode subjects the control stage to more moderate loading at part load than operating in the partial are admission mode. It also subjects this blading to higher temperatures, which is beneficial in regard to achieving uniformity in the mechanical load distribution at the blade/rotor interface with time. Therefore, it is recommended that the turbine be operated as a full arc admission unit during initial operation If, after that time, the purchaser is satisfied that all station controls are set correctly and that all systems are functioning properly, he should choose a proper mode of operation. 2. LOAD CHANGING During the loading period, if load is to be changed quickly or load level is to be changed frequently, the single valve mode should be used to minimize temperature changes in the HP turbine and thereby minimize thermal stresses. The sequential valve mode should be used to obtain higher thermal efficiency when operating below rated load for extended period.
Page 3 of 5 2.1 Increasing Load If the unit is on single valve control and it is desired to increase load as quickly as possible and hold load at the higher level for a period of time in the more efficient sequential valve mode, the transfer from single valve to sequential valve control should be made immediately after reaching the higher load level. This procedure will keep the temperature change in the rotor interior to a minimum. This can be confirmed by observing Chart Load Changing Recommendation and following the changes in first stage steam temperature that occur. It is assumed that steady state conditions exist when the internal rotor temperature is the same as the surface temperature before increasing load. During the load increase using the single valve mode, the first stage steam temperature increases from the low load single valve level to the high load single valve level. The internal rotor temperatures will increase at a slower rate and lag behind the surface temperature. During the transfer to the sequential valve mode, the first stage steam temperature decreases to the sequential valve level corresponding to this load. The lagging internal temperature should more closely match the steam temperature at the surface at the new load level. If the transfer to the sequential valve mode was made before increasing load, the first stage steam temperature would decrease to the sequential valve level driving the internal rotor temperatures downward. The steam and rotor surface metal temperatures would then increase from the lower level to the sequential-valve level when load is increased to the higher load. Thus, the internal rotor temperature cycling would be greater if transfer to the sequential valve mode was done at the low load before increasing load. 2.2 Decreasing Load If the unit has been operating in single valve control for a period and it is desirable to reduce load quickly to a load which will be held for a long period, the transfer from single valve to sequential valve control should be made after first stage steam and metal temperatures have reached steady state conditions at the lower load. Refer to the decreasing load example in Load Changing Recommendation. Delay in switching modes will permit the internal rotor temperature to decrease to the low load surface temperature level before the surface temperature decreases further along with the rotor internal temperatures after switching. If operation at low load is to be of short duration and to be followed by a rapid
Page 4 of 5 return to high load, stay in the single valve mode to minimize HP turbine cooling. 2.3 Sliding Pressure and Hybrid Operation Load Changing If boiler operation permits varying throttle pressure to change load then the sliding pressure mode can be used to permit fast load changing. The operator may place the governor valves in the sequential valve mode and hold the governor valve opening constant while throttle pressure is ramped to change load. A hybrid sliding pressure mode can be used to permit fast loading changing and provide high thermal efficiency at below rated load. The hybrid operation involves sliding or ramping throttle pressure at a fixed governor valve setting and obtaining further load changes in the sequential valve mode by changing governor valve opening at fixed throttle pressures. In order to maintain a fixed valve position during the sliding pressure mode, the operator should reset the throttle pressure correction in the valve management program and remove the MW and impulse pressure feedback loops from service. 3. SHUTTING DOWN The governor valve mode to use in a planned shutdown is predicated on the desired quickness to remove load, the expected length of the shutdown, and the subsequent conditions to be encountered on the return to operation. The load is to be reduced according to the Load Changing Recommendations. Shutting down using the single valve mode can be done at a more rapid rate for a given HP rotor thermal stress and provides more uniform temperature reduction in the first stage zone. It will also result in higher first stage metal temperatures following tripping of the unit. This higher metal temperature may permit a faster restart and return to load conditions depending on startup steam conditions and length of shutdown. This condition could be encountered on a unit being operated with cyclic duty where the unit is shutdown for a few hours during off-peak hours and returned quickly to load levels existing prior to shutdown. The sequential valve mode can be used during a controlled shutdown in order to cool the HP turbine to a lower lever than with single valve control. This is a benefit if the shutdown is for maintenance on the HP turbine since while on turning gear cool down will begin at a lower level and be shortened.
Page 5 of 5 4. CONTROL MODE TRANSFER Assuming that the turbine is operating SINGLE VALVE, this operating mode will be indicated on LCD. Subsequently, the operator may transfer to SEQUENTIAL VALVE operation by selected on LCD. Transfer from one mode to the other requires several minutes. After completion of the transfer, the operating mode of SEQ VALVE will be indicated on LCD. The procedure for switching from SEQUENTLAL VALVE to SINGLE VALVE operation is similar.
Page 1 of 5
Preliminary Checks and Operations

OP.2.13.01E-00
CompiledYu Yan CheckedZhang Xiaoxia CountersignYan Weichun,
2008.09 2008.09 2008.09
PRELIMINARY CHECKS AND OPERATIONS

1. Energize the electronic governor at least two hours before admitting steam into the
turbine. 2. 3. Turn on supervisory instruments. Check that they are recording normally. Start oil vapor extractors (oil reservoir and generator loop seal tank). Loop seal tank
extractor should be operated continuously when hydrogen gas pressure is maintained in the generator. 4. Place generator seal oil unit and generator hydrogen supply system in normal operating
condition. (See Generator Instruction Book) 5. Check lube oil reservoir level, if too low, an alarm will indicate this condition. Restore
to normal with oil pump running. 5.1 Oil temperature 10 minimum before starting oil pumps. 5.2 Bearing oil discharge temperature 21 minimum before placing unit on turning gear. 6. Start ac auxiliary oil pumps. Establish 0.07-0.1MPa (g) bearing oil pressure. Check
bearing thermometer and thermocouple readings. This pump's starting switch is interlocked with the seal oil backup pump HP startup oil pump) which will start at the same time and establish sufficient pressure to enable the overspeed trip device to be latched.
CAUTION Before the initial starting of the Seal oil Backup pumpHP startup oil pump), ensure that the pump is filled with dean oil. Starting or running a dry pump will cause galling, seizing or destructive wear between gears, side plates and pump body. Also ensure that the shutoff valve in the vent line between this pump and the top of reservoir is locked open.
7. 8.
Page 2 of 5 Turn the dc emergency oil pump motor control switch to the AUTO position. For units so equipped start the hydraulic bearing lift system by turning the selector
switch to the AUTO position. Refer to the Hydraulic Bearing Lift System content for additional operation information. 9. Make certain that cooling water to the oil coolers is shut off.
10. Place the turning gear control switch in the AUTO position. Sufficient bearing lift oil pressure must be established before the turning gear will operate. Pressure switches prevent the turning gear motor from starting until bearing oil pressure has reached 0.021~0.0345MPa(g) and bearing lift oil pressure has reached 5.512MPa(g). 11. Observe the eccentricity indicator to assertion that the rotor is straight. Before starting the turbine the rotor-eccentricity should not exceed 0.076mm double amplitude. For the original startup and subsequent startups after major overhauls, shaft outages should be measured at each bearing by inserting a truth (dial) indicator at each bearing oil ring. The movement on these indicators should be less than 0.0254mm before the turbine is started. 12. Establish water circulation through the main condenser. 13. Start the condensate pumps and establish flow through the gland condenser. 14. Turn on air supply to the desuperheater control valves. 15. Turn on air supply to the gland steam control (regulator) valves. (Shutoff and bypass valves must be closed.) 16. After ensuring that the steam lines are free of water (see Water in the Turbine section) and that the gland steam contains not less than 14 superheat open the shutoff valves in the following sequence: a. Spillover b. Cold Reheat Supply c. Auxiliary Supply (if applicable) d. High Pressure Supply The bypass valves should remain closed. 17. Just prior to opening the auxiliary (or HP) supply shut-off valve start the gland condenser exhauster. Make sure there is a slight vacuum at each turbine gland. Also be sure turbine cylinder drains are open prior to pressurizing the gland steam header. 18. Steam pressure will be established in the gland steam header when the auxiliary (or HP)
Page 3 of 5 supply shutoff valve is opened. A check valve in the cold reheat steam supply line prevents steam from entering the turbine cylinders. 19. Maintain temperature difference between gland steam and metal to a minimum (see chart Gland Sealing Steam Temperature Recommendations). 20. Close the vacuum breaker valve, start the air removal equipment and establish as high a vacuum as possible in the main condenser. 21. Make certain all the turbine main steam, hot reheat, cold reheat, and extraction line drain valves are open as soon as vacuum has been established on the condenser. Operation of the turbine drain valves is normally done automatically, however, should it be necessary to manually control the drain valves, see Drain Valves in the section Operating Limits and Precautions. And refer to the Steam, Drain and Gland Piping Diagram for drain locations. 22. While on turning gear, check the operation of the bearing oil pumps and pressure switches by turning the ac oil pump switch from the AUTO to the stop position and holding it there. The dc oil pump should start. Visually check the pump discharge gauges mounted on the reservoir to assure that pressure has been established. The rotor may trip off the turning gear momentarily. Turn the ac pump to the AUTO position. The ac pump should not start if the dc pump is operating satisfactorily. Turn the dc pump switch to the STOP position and hold. The ac pump should now start. After the ac pump starts, release dc pump control switch and it should automatically return to the AUTO position. Make certain that all pump switches are in the AUTO position before proceeding with the startup. NOTE The switches controlling each of these pumps will start the pump on falling pressure but will not stop the pump on rising pressure. To stop the pump, after the bearing oil pressure has risen above the point at which the switch doses, it is necessary to turn the switch from the AUTO to the STOP position. The pump will stop and the switch will return to the AUTO position when released, thus leaving the pump under control of its pressure switch in case of a drop in pressure. 23. The operator should not depress the LATCH push button preparatory to opening the reheat stop and interceptor valves until arc-check is made to determine that ALL drain valves are open. 24. Observe the bearing oil pressure and insure that the pressure is within 0.07-0.1MPa (g)
Page 4 of 5 range. 25. Start the EH fluid supply system in the following steps: NOTE The specific instructions which are outlined in the content Care, Handling and Application of Control System Fluid are to be followed when adding fluid to the system as well as initial charging of the fluid system. Only fluids meeting military specification MIL-H-19457B may be used. 25.1 Check reservoir fluid level. 25.2 Check fluid temperature which should not be less than 10 before the system is placed in operation. Prolonged operating with fluid temperature below 21 is not recommended. See the DEH fluid supply system describing for additional operating instructions. 25.3 Open suction valves for both pumps and start the No. 1 fluid pump. (Positive means should be provided to insure that these valves are open at all times during operation of the turbine except when intentionally closed during maintenance periods.) The slight noise which may be experienced when starting with low fluid temperatures will disappear as the fluid approaches the normal operating temperature range. Place the No. 2 fluid pump on AUTO control. 25.4 When the fluid temperature reaches 43,adjust the cooling water flow to the heat exchangers to maintain a system fluid operating temperature of 43-54. 25.5 The bypass valve to the fuller's earth filters should be fully closed. 25.6 When the bulk fluid reaches normal operating temperature range, check operation of the low fluid pressure switch by opening the manually-operated drain test valve. After several minutes operation, shut down the No. 2 pump and place the pump switch on AUTO control. With accumulators and fluid lines fully charged, the fluid system is now ready for normal operation.
PRECAUTIONS AND RECOMMENDATIONS 1. During operation, note the pump loading and unloading cycle. An abnormal change
indicates excessive high pressure fluids leakage either in the line or through the component, or loss of gas charge in accumulators. Excessive pump wear will reflect a gradual change.
Page 5 of 5 2. Correct any fluid leaks immediately. This is of utmost importance. Fluid leaks may create loss of pressure. 3. Maintain a record of filter maintenance. Change the servo actuator filters at least once
a year. Change the pump discharge filters when the pressure drop is excessive as indicated by the differential pressure switches. Keep the filters in sealed containers until ready to install. 4. This is a closed system requiring a high degree of system cleanliness. A thorough understanding of the content covering the fluid control system and the care and handling of the system fluid will contribute much to trouble free operation.
Page 1 of 2
Starting Procedure before Admitting Steam OP.6.14.01E-00
CompiledTang Jun CheckedWang Zurong Countersign Countersign
2008.09 2008.09
Starting Procedure before Admitting Steam

OPERATOR AUTO is the turbine generator's primary control mode. Except for contingency operation, the unit should always be in this mode or in a remote automatic mode if the unit is so equipped. Before latching the unit, the turbine operator should see that the LCD is displaying normal conditions. CAUTION During turbine operation do not operate portable radio equipment (other than sound powered telephones) near the DEH controller if the controller's cabinet doors are open, a 5 watt transmitter can cause a 10 to 15% change in governor valve position unless the cabinet doors are closed. When the preliminary checks and operations have been satisfactorily completed, proceed as follows: 1. Push OPER AUTO. 2. Check VALVE POSITION LIMIT DISPLAY Read present valve position limit set point in the LCD, SHOULD BE ZERO. 3. Push LATCH and hold for two seconds. When the turbine is latched, the TURBINE TRIPPED status lamp will go off and the TURBINE LATCHED status lamp will light. 4. Check the Valve Test Page on the LCD sure that RSV open, IV open, GV closed and TV closed. 5. Push VPL RAISE and hold until the value reaches 120% and the governor valves are wide open (100% position). 6. Trip the throttle, governor, reheat stop and interceptor valves with the remote trip push button or by operating the hand trip lever on the governor pedestal to activate over-speed
Page 2 of 2 trip mechanism. Be sure that all valves close freely. 7. RELATCH the unit as described in step 3 above and then repeat steps 4 and 5. 7.1 When step 5 has been repeated, the governor, reheat stop and interceptor valves
will be fully OPEN and the throttle valves will be fully CLOSED. 8. TESTING THE OVERSPEED PROTECTION CONTROLLER (OPC). 8.1 Push OPC TEST button in the MANUAL PANEL. The GV and IV should close rapidly (within two seconds). The power-assisted non-return valves (PANRV) will also close. 8.2 8.3 Push the NORMAL button. The GV, IV and PANRV should reopen. This test should be made each time the turbine is started from turning gear.
9. TESTING THE ELECTRICAL MONITORING AND TRIPPING FUNCTIONS OF THE EMERGENCY TRIP SYSTEM. 9.1 The test procedure is fully described in the content Emergency Trip System. The
test may be conducted at the operator's convenience either on the line or off the line. 9.2 10 It is recommended that this test be made on every start-up and monthly thereafter. The turbine is now ready to be rolled with steam. Refer to the section Starting
and Load Changing Recommendations. The next section is for a Cold Start. If it has been determined that Hot Start procedure may be used, skip the next section and turn to section Start Rolling with Steam.
Start Up With Bypass Off

OP.2.15.01E-00
CompiledYu Yan CheckedZhang Xiaoxia CountersignYan Weichun, Tang Jun, Zhang D.M ApprovedPeng Zeying
2008.09 2008.09 2008.09
2008.09
Contents
START UP WITH BYPASS OFF......................................................................................1 1 COLD START-ROLLING WITH STEAM ...........................................................1 1.1 STATUS BEFORE ADMITTING STEAM.........................................................1 1.2 ROLLING WITH STEAM...................................................................................2 1.3 AVOIDING LP TURBINE BLADE RESONANT SPEEDS DURING SPEED HOLDS.........................................................................................................................2 1.4 COLD START ROTOR-WARMING (HEAT SOAK) PROCEDURE.............2 1.5 TRANSFERRING CONTROL FROM THROTTLE TO GOVERNOR VALVES........................................................................................................................3 1.6 SYNCHRONIZING AND INITIAL LOADING ................................................5 1.7 OVERSPEED TRIP TEST ...................................................................................6 2 HOT START-ROLLING WITH STEAM ..............................................................8 2.1 STATUS BEFORE ADMITTING STEAM.........................................................8 2.2 ROLLING WITH STEAM...................................................................................9 2.3 AVOIDING LP TURBINE BIADE RESONANT SPEEDS DURING SPEED HOLDS.........................................................................................................................9 2.4 TRANSFERRING CONTROL FROM THROTTLE TO GOVERNOR VALVES......................................................................................................................10 2.5 SYNCHRONIZING AND INITIAL LOADING .............................................. 11
Page 1 of 13
START UP WITH BYPASS OFF 1 COLD START-ROLLING WITH STEAM

Refer to the section Starting and Load Changing Recommendations to determine when to use cold start procedure. And determine when to use start up with bypass off procedure according to operating requirements. The instructions below assume that the operator is thoroughly familiar with the information about DEH System
1.1 STATUS BEFORE ADMITTING STEAM

1. Turbine is rolling on turning gear. 2. Throttle valves are fully closed. 3. Governor valves, reheat stop valves and interceptor valves are fully open. 4. Throttle steam conditions are in accordance with the chart Start-up Steam Conditions at Turbine Throttle. 5. Vacuum breaker valve(s) is closed. 6. All turbine drain valves are open. 7. Back pressure (absolute) is as low as possible, and not greater than the combination of reheat steam temperature and LP exhaust pressure limits given by the curve for Full Speed-No Load on chart No-Load and Light Load Operation Guide for Reheat Turbines (refer to index). The limits for reheat steam temperature and LP exhaust pressure at 5% Maximum Guaranteed Load are also shown on this chart. CAUTION The maximum allowable back pressure for on-line operation is 0.0186MPa at loads above 10% of rated load up to 100%load. At lower loads, and at the full (rated) speed-no load condition, substantially lower back pressure are required. Such operation should be in accordance with the chart, No Load and Light Load Operation Guide. Failure to observe specified back pressure limits may result in blade failures or rubbing between rotating and stationary turbine parts with serious damage to turbine components. CAUTION The operator must be certain that water is available to the exhaust hood spray control valve whenever the turbine is rolling over 3 r/min.
Page 2 of 13 8. Turbine controls and bypass system controls must both be in BYPASS OFF mode.
1.2 ROLLING WITH STEAM

1. After performing the operations described in the section Starting Procedure before Admitting Steam, accelerate the turbine at 100 r/min. to a target speed of 600 r/min. 2. When the operator pushes the GO button, the DEH controller will open the throttle valve pilot valves and, after a few seconds, the turbine speed will begin to increase until it reaches 600 r/min. The turning gear will automatically disengage as described in the content Rotor Turning Gear. WARNING To avoid injury, keep clear of turning gear operating lever which is moved to DISENGAGE position by air pressure. 3. Keep the turbine rolling at 600 r/min long enough to permit a check of all turbine
supervisory instruments to insure that conditions are satisfactory. The eccentricity monitor should show a steady value of less than 0.076mm before the turbine speed is increased to above 600 r/min. Monitor vibration at speeds above 600 r/min. A vibration reading of not more than 0.076mm is considered satisfactory (see Supervisory Instruments in the section Operating Limits and Precautions)
1.3 AVOIDING LP TURBINE BLADE RESONANT SPEEDS DURING SPEED HOLDS

1. If a speed hold is required at any time during the acceleration of the turbine, push HOLD. The acceleration will stop and the turbine will continue to roll at the held speed. CAUTION If the contingency requires a speed hold, refer to the chart Turbine Speed Hold Recommendations to be sure that the hold is not in a resonant speed range. If it is, decrease the speed below the resonant range. 2. To proceed with the acceleration routine after a hold period, push Go.
1.4 COLD START ROTOR-WARMING (HEAT SOAK) PROCEDURE

CAUTION
Page 3 of 13 On the initial start-up not utilized the ATC program (if so equipped) during the heat soak period. Use the curve Cold Start Rotor-Warming Procedure. 1. Enter a target speed on CRT within the rotor-warming soak speed range shown on the chart Turbine Speed Hold Recommendations. 2. Push Go. When the selected target speed is reached, hold the turbine at that speed for a heat soak period determined from the curve Cold start rotor-Warming Procedure. Begin the heat soak period after the reheat stop valve inlet steam temperature exceeds 260 . Rotor-Warming is not needed for no-bore rotor. CAUTION It is important that this time period not be reduced in an emergency situation when there may be a strong desire by the operator to put the unit on the line in a shorter time. 3. While the rotor heat soak is in progress, limit the throttle inlet steam temperature to 427 maximum and maintain the reheat inlet steam temperature above 260. Refer to the chart Start-up Steam Conditions at Turbine Throttle to determine the throttle steam conditions that should exist before transferring from throttle to governor valve control. 4. Maintain the turbine steam and metal thermocouple limits and the turbine supervisory instrument limits throughout the operation of the turbine.
1.5
TRANSFERRING
CONTROL
FROM
THROTTLE
TO
GOVERNOR VALVES
1. Accelerate the turbine at 100 r/min to the inlet valve transfer speed shown on the chart Turbine Speed Hold Recommendations. Before transferring control from the throttle valves to the governor valves, verify that the steam chest inner wall temperature is at least equal to saturation temperature corresponding to the throttle pressure. The chart Start-up Steam Conditions at Turbine Throttle shows the desirable relationship between throttle valve inlet pressure and temperature that should prevail if the steam chest temperature is to reach the desired value. NOTE If the temperature measured by the steam chest shallow thermocouple (T1) is lower than the temperature measured by the steam chest deep thermocouple (T2), the
Page 4 of 13 temperature at the inner surface of the steam chest (Ts,) will be higher than that indicated by the deep thermocouple. The temperature at the inner surface of the steam chest (Ts,) can then be calculated by this formula: Ts=T1 + 1.36(T2 - T1) 2. When the unit reaches transfer speed and step 1 is verified. Transfer control of the turbine from throttle valves to governor valves as follows: 2.1 Push TV-GV TRANSFER 2.2 Observe transfer from throttle to governor valve control by TV and GV position indicating on the CRT. 2.3 When the transfer is completed, the TV full open, the turbine is now under control of the governor valves. 3. Observe the SINGLE VALVE &. SEQUENTIAL VALVE status on CRT, If it is not in the desired mode of valve control. Select the desired mode on CRT. For more information about the modes of valve control refer to the sections Governor Valve Management and Starting and Load Changing Recommendations. 4. 5. Accelerate the turbine to 3000 r/min at 100 r/min. It is recommended as good practice to trip the turbine after full speed is reached to be
sure that the overspeed trip mechanism and steam valves are functioning normally. Push the trip push button in the turbine control room or operate the overspeed trip mechanism with the hand trip lever on the governor pedestal. Be sure that all main and reheat steam valves close fully. Following the trip, the values in the REFERENCE and TARGET will reset to zero. 6. If, for any reason, the control system switches to TURBINE MANUAL after the trip,
reset it to OPER AUTO. 7. To relatch the turbine on the fly, proceed as follows: 7.1 Push LATCH continuously for a few seconds. The values in REFERENCE and TARGET will increase to the actual turbine speed and a speed hold will be instituted (assuming that the control system is in OPER AUTO). 7.2 Increase the acceleration value from 100r/min to 200-250 r/min. 7.3 Enter the transfer speed value (assuming the turbine speed has decreased to below this value) into the TARGET. 7.4 Push GO. When the unit reaches transfer speed, transfer from TV to GV as previously
Page 5 of 13 described. 7.5 Accelerate the unit to 3000 r/min at 200-250r/min. 8. Before synchronizing, test the Overspeed Trip Mechanism Oil Pressure Check
Device. 9. Shut off the ac bearing oil pump and the seal oil backup pump and set on AUTO
control. Turn on the water to the oil coolers, when required, and regulate the flow of water to maintain the temperature of the oil leaving the hottest bearing at less than 71 . 10. Turn on water to the generator hydrogen coolers following the specific instructions outlined in the Generator Instruction Book. 11. Maintain the no load limits expressed by the chart No Load and Light Load Operation Guide. Refer to Low Pressure Exhaust and Exhaust Hood Sprays in the section Operating Limits and Precautions.
1.6 SYNCHRONIZING AND INITIAL LOADING

1. Synchronize and promptly load to 5% of rated capacity. The time that hold at 5% load refer to Chart Star Recommendations for Rolling & Minimum Load. NOTE When load is initially applied, the OPC MONITOR light may be lit. This is normal and cannot be avoided due to the failure detection scheme for a zero based signal. As soon as the generator in initially loaded to at least 5% load, this monitor light should go out. If the light remains lit when load has been increased above 10% of rated load, the turbine has lost one of its main overspeed protection devices. Maintenance Personnel should take the following action immediately. a. Check MW transducer. b. Check OPC pressure transducer. c. Check OPC speed pickups and speed signals. If an automatic synchronizer is to be used to place the unit in the line, the turbine must be on speed control at a speed of 3000r/min 50r/min. The control of the turbine speed may then be transferred to the automatic synchronizer by depressing the AUTO SYNC push button. This push button will light and OPER AUTO will go off. The automatic synchronizer now has access to the DEH speed reference by means of Raise/Lower contact closure inputs to bring the turbine-generator to
Page 6 of 13 synchronous speed and to synchronize the unit. After the main generator breaker is closed, the AUTO SYNC push button light will go off and control of the unit will automatically return to the OPERATOR AUTO control mode. 2. With the closing of the generator breaker the REFERENCE and TARGET windows
will display a value in megawatts which will automatically position the governor valves at a position equivalent to 5% load at the existing throttle pressure. 3. Push IMP IN to place the impulse chamber pressure feedback loop in service. (When
in the IMP OUT mode, the megawatt REFERENCE value displayed does not match the actual load displayed by the megawatt meter on the monitor panel. When in the IMP in mode the megawatt REFERENCE value displayed will be reset to a new value which will approximately match the actual megawatts generated.) 4. Push MW IN to place the megawatt feedback loop in service. (When in the MW IN
mode, the megawatt REFERENCE value displayed will be trimmed to accurately match the megawatts generated.) 4.1 Transferring between IMP IN and OUT and MW IN and MW OUT is bumpless and does not affect the load level. 4.2 Transferring from MW OUT to MW IN to MW OUT while the REFERENCE is counting towards the TARGET results in halting the REFERENCE count and makes the TARGET equal to the REFERENCE. 4.3 Similar action will result when transferring from IMP IN to IMP OUT or vice versa with the megawatt feedback loop out of service (MW OUT).
1.7 OVERSPEED TRIP TEST

When starting the turbine initially, after any major overhaul, or after work is performed on the governor pedestal which may affect the overspeed trip setting, the turbine should be overspeeded to insure that the overspeed trip mechanism will operate. The overspeed test should then be made periodically every six months, unless sooner required by another such occurrence. The test must be performed using the parameters shown on the chart No-Load and Light-Load Operation Guide for reheat steam temperature and back pressure. If the test takes longer than fifteen minutes, the operator must exercise extreme care to insure safe operating conditions are not exceeded.
Page 7 of 13 CAUTION During this test, have an operator stand by the hand lever ready to trip the unit by hand instantly. 1. After synchronizing and applying initial 5% load, increase load to 10% of rated
capacity. Hold at this load for at least four hours immediately before overspeeding the turbine in order to test the overspeed trip mechanism. CAUTION When this test is performed on a periodic basis after normal operation of the turbine at load, the load should be removed in accordance with the chart Load Changing Recommendations. Do not hold 10% load if the turbine has already been on the line and carrying at least 10% load for four hours prior to the test. 2. Proceed with overspeed trip test as follows:
2.1 Remove the load at a normal rate not exceeding that specified on the chart Load Changing Recommendations. 2.2 Open the line breakers. The values displayed in the TARGET and REFERENCE display will change from load (in megawatts) to speed (in r/min). 2.3 To enable the turbine to overspeed: a) Deactivate the overspeed protection controller by turning the OPC key switch (on the OPERATOR control panel) to the OVERSPEEED DISABLE position. b) Deactivate the electrical emergency trip system by turning the OVERSPEED TRIP key switch (on the emergency trip test panel) to the INHIBIT position. 2.4 Accelerate the unit at 50r/min to 2% below the overspeed trip setting. 2.5 Enter a speed of 2% above the overspeed trip setting and accelerate the unit toward this speed. 2.6 Observe the turbine speed meter and record the speed at which the unit trips. Be prepared to trip the unit by hand. 3. If the speed at which the unit trips is satisfactory and it is desired to continue
operation relatch the unit. If the trip speed is not satisfactory, adjust the trip weight before returning the unit to service. 4. The values displayed in the REFERENCE and TARGET will increase from 0000
until they match the speed of the turbine. The REFERENCE and TARGET displays will then stop counting and the turbine speed will be controlled by the throttle valves.
5.
Page 8 of 13 If it is desired to continue with the start-up, relatch the unit on the fly and proceed
as described above in the subsection Transferring Control from Throttle to Governor Valves, item 7.
2 HOT START-ROLLING WITH STEAM

Refer to the section" Starting and Load Changing Recommendation" to determine when to use hot start procedure. And determine when to use start up with bypass off procedure according to operating requirements. The instructions below assume that the operator is thoroughly familiar with the information in the content DEH system.
2.1 STATUS BEFORE ADMITTING STEAM

1. 2. Turbine is rolling on turning gear. Throttle valves are fully closed.
3. Governor valves, reheat stop valves are fully open and either interceptor valves are fully open for Bypass Off mode. 4. Throttle steam conditions are in accordance with the chart Start Recommendations.
5. Vacuum breaker valve(s)is closed. 6. 7. All turbine drain valves are open. Back pressure (absolute) is as low as possible, but not greater than combination of
reheat steam temperature and LP exhaust pressure limits given by the curve for Full Speed-No Load on Chart No-Load and Light Load Operation Guide for Reheat Turbines (refer to index). The limits for reheat steam temperature and LP exhaust pressure at 5% Maximum Guaranteed Load are also shown on this chart. CAUTION The maximum allowable back pressure for on-line operation is 0.0186Mpa (absolute) at loads above 10% of rated load up to 100% load. At lower loads, and at the full (rated) speed-no load condition, substantially lower back pressures are required. Such operation should be in accordance with the chart, No Load and Light Load Operation Guide. Failure to observe specified back pressure limits may result in blade failures or rubbing between rotating and stationary turbine parts with serious damage to turbine components. CAUTION
Page 9 of 13 The operator must be certain that water is available to the exhaust hood spray control valve whenever the turbine is rolling over 3 r/min.

1. After performing the operations described in the section Starting procedure Before Admitting Steam, determine the accelerate value required based on throttle inlet steam conditions before admitting steam to the turbine. Use the chart Hot Start Recommendations. 2. Accelerate the turbine at the selected value to a target speed of 600r/min. The DEH
system content gives step by step instructions for entering values of acceleration 3. When the operator pushes the GO button, the DEH controller will open the throttle valve pilot valves and, after few seconds, the turbine speed will begin to increase until it reaches 600 r/min. The turning gear will automatically disengage as described in the content Rotor Turning Gear. WARNING To avoid injury, keep clear of turning gear operating lever which is moved to DISENGAGED position by air pressure. 4. Keep the turbine rolling at 600 r/min long enough to permit a check of all turbine
supervisory instruments to insure that conditions are satisfactory. The eccentricity monitor should show a steady value of less than 0.076mm before the speed is increased to above 600 r/min. Monitor vibration at speeds above 600 r/min. A vibration reading of not more than 0.076mm is considered satisfactory (see Supervisory Instruments in the section Operating Limits and Precautions).
2.3 AVOIDING LP TURBINE BIADE RESONANT SPEEDS DURING SPEED HOLDS

1. If a speed hold is required at any time during the acceleration of the turbine, push HOLD. The acceleration will stop and the turbine will continue to roll at the held speed. CAUTION If the contingency requires a speed hold, refer to the chart Turbine Speed Hold Recommendations to be sure that the hold is not in a resonant speed range. If it is,
Page 10 of 13 decrease the speed below the resonant range. 2. To proceed with the acceleration routine after a hold period, push GO.
2.4
TRANSFERRING
CONTROL
FROM
THROTTLE
TO
GOVERNOR VALVES
1. Accelerate the turbine at the previously selected rate to inlet valve transfer speed shown on the chart Turbine Speed Hold Recommendations. Before transferring control from the throttle valves to the governor valves, verify that the steam chest inner wall temperature is at least equal to saturation temperature corresponding to the throttle pressure. The chart Start-up Steam Conditions at Turbine Throttle shows the desirable relationship between throttle valve inlet pressure and temperature that should prevail if the steam chest temperature is to reach the desired value. NOTE If the temperature measured by the steam chest shallow thermocouple (T1) is lower than the temperature measured by the steam chest deep thermocouple (T2), the temperature at the inner surface of the steam chest (Ts) will be higher than that indicated by the deep thermocouple. The temperature at the inner surface of the steam chest (Ts) can then be calculated by this formula: Ts = T1 + 1.36 (T2- T1) 2. When the unit reaches transfer speed and step 1 is verified, transfer control of the
turbine from throttle valves to governor valves as follows: 2.1 Push TV-GV transfer. 2.2 Observe transfer from throttle to governor valve control by TV and GV POSTION Indicating on the CRT. 2.3 When transfer is complete, TV fully open and the turbine is now under control of the governor valves. 3. Observe the SINGLE VALVE / SEQUENTIAL VALVE status on the CRT. If it is not in the desired mode of valve control, select the desired mode. For more information about the modes of valve control, refer to the sections Governor Valve Management and Starting and Load Changing Recommendations. 4. 5. Accelerate the turbine to 3000 r/min at the previously selected rate. It is recommended as good practice to trip the turbine after full speed is reached to be
Page 11 of 13 sure that the overspeed trip mechanism and steam valves are functioning normally. Push the trip push button in the turbine control room or operate the overspeed trip mechanism with the hand trip lever on the governor pedestal. Be sure that all the main and reheat steam valves closed fully. Following the trip, the values in the REFERENCE and TARGET will reset to zero. 6. If for any reason, the control system switches to TURBINE MANUAL after the trip,
reset it to OPER AUTO. 7. To relatch the turbine on the fly, proceed as follows:
7.1 Push LATCH continuously for a few seconds. The values in REFERENCE and TARGET will increase to the actual turbine speed and a speed hold will be instituted (assuming that the control system is in OPERATOR AUTO). 7.2 Set the acceleration in accordance with the chart Hot Start Recommendations. 7.3 Enter the transfer speed value (assuming the turbine speed has decreased to below this value) into the TARGET 7.4 Push GO. When the turbine reaches transfer speed, transfer from TV to GV as previously described. 7.5 Accelerate the unit to 3000 r/min as previously described. 8. Before synchronizing, test the Overspeed Trip Mechanism Oil Pressure Check
Device. Follow instructions given in corresponding content. 9. Shut off the bearing oil pump and the seal oil backup pump and set on AUTO control.
Turn on the water to the oil coolers, when required, regulate the flow of water to maintain the temperature of the oil leaving the hottest bearing at less than 71 . 10. Turn on water to the generator hydrogen coolers following the specific instructions
outlined in the Generator Instruction Book. 11. Maintain the no load limits expressed by the chart No Load and Light Load
Operation Guide. Refer to Low Pressure Exhaust and Exhaust Hood Sprays in the section Operating Limits and Precautions.
2.5 SYNCHRONIZING AND INITIAL LOADING

When starting with reduced or rated throttle pressure, synchronize and promptly load to 5% of rated capacity in the following sequence: 1. Synchronize the unit.
Page 12 of 13 If an automatic synchronizer is to be used to place the unit on the line, the turbine must be on speed control at a speed of 3000 r/min50r/min. The control of the turbine speed may then be transferred to the automatic synchronizer by depressing the AUTO SYNC push button. The automatic synchronizer now has access to the DEH speed reference by means of Raise/Lower contact closure inputs to bring the turbine generator to synchronous speed and to synchronize the unit. After the main generator breaker is closed, the control of the unit will automatically return to the OPERATOR AUTO control mode. 2. With the closing of the generator breaker, the REFERENCE and TARGET will
display a value in megawatts which will automatically position the governor valves at a position equivalent to 5% load the existing throttle pressure.
NOTE When load is initially applied, the OPC MONITOR light may be lit. This is normal and cannot be avoided due to the failure detection scheme for a Zero based signal. As soon as the generator is initially loaded to at least 5% load, this monitor light should go out. If the light remains lit when load has been increased above 10% of rated load, the turbine has lost one of its main overspeed protection device. Maintenance Personnel should take the following action immediately. a. Check MW transducer. b. Check OPC pressure transducer. c. Check OPC speed pickups and speed signals. 3. Push IMP IN to place the impulse chamber pressure feedback loop in service. (When
in the IMP OUT mode. the megawatt REFERENCE value displayed does not match the actual load displayed by the megawatt meter. When in the IMP IN mode, the megawatt REFERENCE value displayed will approximately match the actual megawatts generated.) 4. Push MW IN to place the megawatt feedback loop in service. (When in the MW IN
mode, the megawatt REFERENCE value displayed will be trimmed to accurately match the megawatts generated. 4.1 Transferring between IMP IN and IMP OUT and MW IN and MW OUT is bumpless and does not affect the load level. 4.2 Transferring from MW OUT to MW IN to MW OUT while the REFERENCE is
Page 13 of 13 counting toward the TARGET results in halting the REFERENCE count and makes the TARGET equal to the REFERFNCE. 4.3 Similar action will result when transferring from IMP IN to IMP OUT or vice versa with the megawatt feedback loop out of service (MW OUT). 5. Hold at 5% load for the period of time determined from the chart Hot Start
Recommendations. NOTE If the throttle steam conditions are controlled to produce a first stage steam and metal temperature below the EXACT MATCH LINE shown on the chart Hot Start Recommendations, a hold period is not required. By keyboard entry, apply minimum load as show on the chart. Further loading is to be in accordance with the section Load Changing.
Start Up and Operation With Bypass in Service

OP.2.16.01E-00
CompiledYu Yan CheckedZhang Xiaoxia Countersign Yan Weichun, Tang Jun, Zhang D.M ApprovedPeng Zeying
2008.09 2008.09 2008.09
2008.09
Contents
START UP AND OPERATION WITH BYPASS IN SERVICE.................. 1 1 TURBINE STARTUP WITH BYPASS IN SERVICE ......................... 1 1.1 THE STATUS OF THE TURBINE BEFORE ADMITTING STEAM........................................................................................................ 1 1.2 ROLLING WITH STEAM.................................................................. 3 1.3 SYNCHRONIZATION AND INITIAL LOADING.......................... 6 2 LOAD CHANGING................................................................................ 8 2.1 LOAD CHANGING (LOW CONSTANT MAIN STEAM PRESSURE)................................................................................................ 8 2.2 LOAD CHANGING (SLIDING PRESSURE) ................................ 10 2.3 LOAD CHANGING (RATED PRESSURE).................................... 11 3. LOAD REJECTION WITH BYPASS................................................ 11
Page 1 of 13
START UP AND OPERATION WITH BYPASS IN SERVICE 1 TURBINE STARTUP WITH BYPASS IN SERVICE 1.1 THE STATUS OF THE TURBINE BEFORE ADMITTING STEAM
The status of the turbine before admitting steam should be as follows: 1. The turbine must be rolling on turning gear. 2. The following throttle and reheat steam conditions must be present (refer to "Startup Steam Conditions at Turbine Throttle" and "Reheat Steam Conditions at Interceptor Valve Inlet" charts): a. Not less than 56 superheat. b. If the initial HP or IP turbine rotor metal temperature is less than 204, the inlet steam conditions should be in the "Cold start" region. The throttle temperature should not be higher than 427. The reheat steam temperature should be in the "Cold Start" region. c. If the initial HP turbine rotor metal temperature is 204C or higher, the throttle valve inlet steam temperature should be above the curve labeled "Minimum Throttle Valve Inlet Steam Temperature at Transfer" before transferring throttle valve to governor valve control. 3. Backpressure (absolute) must be as low as possible, but not be greater than the combination of reheat steam temperature and LP exhaust pressure limits given on the chart "No-Load Light Load Operation Guide". 4. The DEH should be in OPERATOR AUTO mode. 5. Refer to Figure 1 for bypass system description, and Table 1 for Turbine and Bypass system status.
Page 2 of 13
Figure 1- Turbine Bypass System Schematic Table 1: Turbine and Bypass System Status Before Rolling Turbine SYSTEM/VALVE Throttle Valves Governor Valves STATUS Fully Closed Run fully open by operator with Valve Position Limiter (Single Valve Mode) Fully Closed Open.
Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Open to keep HP turbine under vacuum Valve Closed due to pressure difference between Cold Reheat and HP HP Exhaust Check Valve exhaust. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Open LP Exhaust Hood Sprays Off Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits.
Page 3 of 13

After performing the operations described in the Starting Procedure-Operator Automatic Mode leaflet proceed as follows: 1. Determine the rolling time from the "Startup Recommendations" chart. Convert the rolling time to an acceleration rate in r/min. 2. Accelerate the turbine to the supervisory instrument check speed 600r/min. WARNING TO AVOID INJURY, KEEP CLEAR OF THE TURNING GEAR OPERATING LEVER, WHICH IS MOVED TO DISENGAGED BY AIR PRESSURE. WARNING WATER MUST BE AVAILABLE TO THE EXHAUST HOOD SPRAY CONTROL VALVE AND LUBE OIL COOLER WHENEVER THE TURBINE IS ROLLING OVER 3r/min. 3. Refer to Table 2 for the Turbine and Bypass system status during turbine roll up to 600r/min. Table 2: Turbine and Bypass System Status Up to Supervisory Instrument Check Speed SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve STATUS Fully Closed Fully open (Single Valve Mode) Half of the valves will be throttling in speed control (demand to valve has a small bias) Open. Open to keep HP turbine under vacuum
Closed due to pressure difference between Cold Reheat and HP exhaust HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent valves Close at 600 r/min LP Exhaust Hood Sprays Off Controlling Main Steam pressure at its setpoint (specified HP Bypass by boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified LP Bypass by boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits. 4. Hold the turbine at 600 r/min long enough to check all supervisory instruments to
Page 4 of 13 ensure that conditions are satisfactory before proceeding. The eccentricity recorder should show a steady value of less than 0.076 mm before the turbine speed is increased above 600 r/min. Monitor vibration at speeds above 600 r/min. 5. Select the IV to TV/IV transfer speed as the target speed and accelerate the turbine at the previously determined acceleration rate. 6. Refer to Table 3 for the Turbine and Bypass system status during the turbine speed ramp up to the IV to TV/IV transfer speed. Table 3: Turbine and Bypass System Status During Speed Ramp (Up to IV to TV/IV Transfer Speed) SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves STATUS Begin opening to take control of speed Fully Open (Single Valve Mode) Half of the valves will be throttling in speed control (demand to valve has a small bias) until IV to TV/IV transfer speed is reached. Once transfer is complete, IV's will throttle along with TV's to hold speed. Open.
Reheat Stop Valves HP Turbine Exhaust Vent Open Valve Closed due to pressure difference between Cold Reheat and HP HP Exhaust Check Valve exhaust. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On at 2600 r/min. Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier) Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier) Attemperator sprays keeping the exit temperature within condenser design limits.
7. At the IV to TV/IV transfer speed, the control system will automatically hold speed using the interceptor valves long enough to "memorize" its stabilized flow demand (Fl), and thereafter the turbine speed will be controlled by modulating both the throttle valve pilots and the interceptor valves. The demand to both sets of valves will be common, but with a bias put on the interceptor valve flow demand to ensure that the flow through the
Page 5 of 13 interceptor valves will always be Fl% greater than the flow through the throttle valves. 8. Select the TV/IV to TV transfer speed as the target speed and accelerate the turbine at the previously determined acceleration rate. 9. During this segment of control, if the speed reference reaches the setpoint or the operator presses HOLD, the interceptor valves will "freeze" in the position at which this occurs, and all speed control will be done using the throttle valves. High and low limits that are variable as a function of the speed reference will limit the maximum and minimum positions of the interceptor valves. 10. At the TV/IV to TV transfer speed, the control system will stop controlling speed with the TV/IV valves and will hold the IV valves position at a pressure compensated value. Speed control will then be transferred to the TV's only. Table 4: Turbine and Bypass System Status at TV/IV to TV Transfer Speed. SYSTEM/VALVE Throttle Valves Governor Valves STATUS Open and controlling speed Fully Open (Single Valve Mode) Half of the valves will be throttling in speed control to hold speed at the IV to IV/TV transfer speed (half of the valves will remain closed because of a bias in control). Once the interceptor valve position is memorized, they will be frozen at that position, moving only in response to a change in hot reheat pressure to maintain a constant total flow to the IP t bi Open. Open Closed due to pressure difference between Cold Reheat and HP exhaust. Open
Interceptor Valves
Reheat Stop Valves HP Turbine Exhaust Vent HP Exhaust Check Valve HP Drain Valves
IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On at 2600 r/min. Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits.
Page 6 of 13 11. After verifying that the throttle steam conditions and the steam chest temperature meet the requirements shown on the chart "Startup Steam Conditions at Throttle Valve Inlet", transfer control of the turbine speed from the throttle valves to the governor valves. 12. During the TV to GV valve transfer, the governor valves will begin closing until the speed drops to 30 r/min. The throttle valves will be opened fully after the speed drops 30 r/min. 13. The governor valves are now in control of speed and will maintain speed at the TV to GV transfer speed. Refer to Table 5 for the turbine and bypass system status during the TV to GV speed control transfer. Table 5: Turbine and Bypass System Status at TV/GV Transfer SYSTEM/VALVE Throttle Valves STATUS Throttling in speed control to hold turbine at the TV/GV transfer speed, then opened fully after closing of governor valves causes a drop in speed of 30 r/min. Begin closing to take control of speed Holding pressure compensated position Open.
Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Open Valve Closed due to pressure difference between Cold -Reheat and HP Exhaust Check Valve HP exhaust. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On. Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier. Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier. Attemperator sprays keeping the exit temperature within condenser design limits. 14. Accelerate the turbine to synchronous speed at the previously selected rate.
1.3 SYNCHRONIZATION AND INITIAL LOADING

1. At synchronous speed, speed control will be done solely by the governor valves. Steam passing through the HP exhaust vent valve. 2. Turbine and bypass system status at synchronous speed, but prior to synchronizing the
Page 7 of 13 generator is as follows (Table 6): Table 6: Turbine and Bypass System Status at Synchronous Speed (Before Synchronizing) SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve STATUS Fully opened Throttling to hold synchronous speed Holding pressure compensated memorized position Open. Open
Closed due to pressure difference between Cold Reheat and HP exhaust. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits. 3. Before synchronizing the unit, the cold reheat pressure downstream of the HP exhaust check valve must be as low as possible. If the pressure is above 0.828MPa(a), the HP exhaust temperature may exceed allowable limits causing a turbine trip. 4. Synchronize the unit. 5. The governor valves and interceptor valves will quickly open to a position calculated to hold 5% load. 6. The HP exhaust vent valve will close after the unit is synchronized for 60 seconds. Pressure will build up in the HP exhaust until it is sufficient to open the HP exhaust check valve. If the pressure ratio across the turbine blade path is less than 1.7 for more than 60 seconds, the control system will recommend a trip of the turbine. If the HP exhaust temperature is greater than 427, Emergency Trip System will trip the turbine. 7. The status of the turbine and bypass system valves after synchronization up to minimum load is described in Table 7. Table 7: Turbine and Bypass System Status After Synchronization Up to Minimum Load SYSTEM/VALVE STATUS
Page 8 of 13 Throttle Valves. Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve Fully opened Opened to 5% rated load position (pressure compensated) immediately on synchronization Opened to 5% rated load position (pressure compensated) immediately on synchronization Open. Closes after synchronization for 60 seconds.
Open when HP exhaust pressure exceeds cold reheat pressure after HP vent valve is closed. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On. Controlling Main Steam pressure at its setpoint (specified by HP Bypass boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified by LP Bypass boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits.
2 LOAD CHANGING 2.1 LOAD CHANGING (LOW CONSTANT MAIN STEAM
PRESSURE)
1. As the load is increased, the governor valves open to admit more steam to the turbine and increase the load. The HP Bypass valves will close to maintain the main steam pressure at the HP Bypass setpoint value. 2. The interceptor valves will open as a function of the load. As the interceptor valves are opened, the LP Bypass valves will close to maintain the reheat steam pressure at the LP Bypass setpoint value. At 30~40% rated load, the interceptor valves will be fully opened and the LP bypass valves will go closed. 3. As load is increased, the plant will operate at a fixed low main steam pressure with the pressure being controlled by the bypass system. 4. The turbine and bypass system status during load changing from minimum load up to the point where the Bypass valves are fully closed is described in Table 8. Table 8: Turbine and Bypass System Status from 5% rated load until Bypass Valves are Fully Closed
Page 9 of 13 SYSTEMIVALVE Throttle Valves. Governor Valves STATUS Fully opened Controlling load with impulse pressure (throttle flow) feedback and/or MW loop feedback, if desired. Controlling load using same demand signal as governor valve. Interceptor valve will be adjusted so that they are fully opened at the load at which the bypass valves are fully closed. Open. Closed.
Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve HP Drain Valves IP Drain Valves Inlet Loop Vent Valves LP Exhaust Hood Sprays
Open. Close at 10% rated load. Close at 20% rated load. Closed Off at 15% rated load. Controlling Main Steam pressure at its setpoint (specified HP Bypass by boiler supplier). Attemperator sprays keeping the Hot Reheat temperature within plant design limits. Controlling Hot Reheat pressure at its setpoint (specified LP Bypass by boiler supplier). Attemperator sprays keeping the exit temperature within condenser design limits. 5. Once the HP and LP Bypass valves are fully closed, the HP and LP Bypass valve controls will be automatically placed in standby mode. 6. Throttle pressure control will be done by modulating the governor valves, with the loading rate controlled by the boiler firing rate (Turbine Follow mode). From this point until the plant is put into the sliding pressure mode, the turbine and bypass system valves will be operated as described in Table 9. Table 9: Turbine and Bypass System Status During Load Changing (Constant Pressure) SYSTEM/VALVE Throttle Valves. Governor Valves Interceptor Valves STATUS Fully opened Controlling a constant low throttle pressure. Fully open at approximately the same load as bypass valves are fully closed. Open.
Reheat Stop Valves HP Turbine Exhaust Closed. Vent Valve HP Exhaust Check Valve Open. HP Drain Valves Close at rated 10% load.
Page 10 of 13 IP Drain Valves Inlet Loop Vent Valves LP Exhaust Hood Sprays HP Bypass LP Bypass Close at 20% rated load. Closed Off above 15% rated load. Closed (in standby mode). Closed (in standby mode).
2.2 LOAD CHANGING (SLIDING PRESSURE)

1. When the governor valves have reached their optimum position, the load will be controlled by varying the main steam pressure (sliding pressure operation). One of the two control schemes described below may be followed: a. The turbine is left in OPERATOR AUTO and all pressure, flow, or MW loops are out of service, with the frequency loop left in service so that the plant will respond to electrical system frequency disturbances. b. The DEH is put into REMOTE which disables all feedback loops, including frequency compensation. The boiler controls begin sliding pressure control, with the turbine valves essentially not moving. The boiler controls must include frequency compensation logic that will adjust the turbine valves quickly upon a system upset. 2. During sliding pressure operation, the turbine and bypass valve positions will be as described in Table 10. Table 10: Turbine and Bypass System Status During Load Changing (Sliding Pressure) SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve HP Drain Valves IP Drain Valves Inlet Loop Vent Valves LP Exhaust Hood Sprays HP Bypass LP Bypass STATUS Fully opened Fixed at optimum position, except in response to frequency disturbances. Fu1ly opened. Open. Closed. Open. Closed Closed Closed Off Closed (in Standby mode). Closed (in Standby mode).
Page 11 of 13
2.3 LOAD CHANGING (RATED PRESSURE)

1. As load ascension continues in the sliding pressure mode, the main steam pressure will reach rated pressure, signifying the end of sliding pressure operation. The operator may choose to continue the load ramp in the Turbine Follow mode as described previously. Alternatively the operator may choose to control the load ramp using the turbine controls to open the governor valves, with the boiler controls holding the throttle pressure at rated pressure (Boiler Follow mode). 2. If boiler follow mode is chosen, the turbine valves will be operated as described in Table 11. Table 11: Turbine and Bypass System Valve Status During Load Changing (Rated Pressure) SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve HP Exhaust Check Valve HP Drain Valves IP Drain Valves Inlet Loop Vent Valves LP Exhaust Hood Sprays HP Bypass LP Bypass STATUS Fully opened Controlling load with Impulse pressure (throttle flow) and/or MW feedback, if desired. Fully opened. Open. Closed. Open. Closed Closed Closed Off Closed (in Standby mode). Closed (in Standby mode).
3. LOAD REJECTION WITH BYPASS

1. Upon receipt of a load rejection signal from the generator breaker, the turbine control system will initiate rapid closure of the governor valves and the interceptor valves to prevent an overspeed condition, as per the normal load drop anticipator (LDA) logic. 2. The bypass valves will be opened quickly to route excess boiler steam to the main condenser, up to the capacity of the bypass system. The setpoint of the HP bypass will be set at the last throttle pressure setpoint prior to the load rejection.
Page 12 of 13 3. The OPC action ceases when the turbine speed drops below 103% of rated speed. This enables the control logic of the feedback loops in the DEH. With the BYPASS ON, when the unit drops below rated speed, the interceptor valves will quickly ramp open to control speed, up to a position that is a function of the house load left on the generator, as measured by the plant instrumentation. The interceptor valve demand will be hot reheat steam pressure compensated. 4. During this portion of the transient, the valve positions will be as described in Table 12. Table 12: Turbine and Bypass System Status Following Load Rejection (After OPC Action Ceases) SYSTEM/VALVE Throttle Valves Governor Valves STATUS Fully opened Closed Throttling in speed control to hold rated speed, up to the Interceptor Valves limiting position (corrected for hot reheat pressure) Reheat Stop Valves Open. HP Turbine Exhaust Vent Opened on generator breaker opening to allow HP exhaust Valve to vent to condenser. Assist closed during OPC action. In free swing position to close on reverse flow following OPC action. Should be HP Exhaust Check Valve closed because cold reheat pressure is higher than HP exhaust pressure. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Opened during OPC action. Closed following OPC action. LP Exhaust Hood Sprays On when breaker opens and if speed is above 2600 r/min. Fully opened to limit throttle pressure at the throttle HP Bypass pressure setpoint prior to breaker opening. Fully opened to limit hot reheat pressure at LP bypass LP Bypass setpoint. 5. The flow admitted to the IP and LP turbines through the partially open interceptor valves is enough to supply sufficient cooling steam to the IP and LP turbines or to achieve proper distribution of the house load; it will not be sufficient to hold rated speed. 6. The governor valves will open to hold rated speed. Flow through the HP turbine will be vented to the main condenser through the HP exhaust vent valve. A portion of the HP turbine flow may also exhaust through the check valve to the cold reheat, depending on the HP exhaust and cold reheat pressures. During this portion of the transient, the turbine
Page 13 of 13 and bypass valve positions will be as described in Table 13. Table 13: Turbine and Bypass System Status Following Load Rejection (House Load Operation) SYSTEM/VALVE Throttle Valves Governor Valves Interceptor Valves Reheat Stop Valves HP Turbine Exhaust Vent Valve STATUS Fully opened Throttling in speed control to hold rated speed At limiting position (corrected for hot reheat pressure) Open. Opened on generator breaker opening to allow HP exhaust to vent to condenser. In free swing position to close on reverse flow. Should be HP Exhaust Check Valve closed because cold reheat pressure is higher than HP exhaust pressure. HP Drain Valves Open IP Drain Valves Open Inlet Loop Vent Valves Closed LP Exhaust Hood Sprays On when breaker opens and if speed is above 2600 r/min. Fully opened to limit, throttle pressure at the throttle HP Bypass pressure setpoint prior to breaker opening. Fully opened to limit hot reheat pressure at LP bypass LP Bypass setpoint 7. If the pressure ratio across the turbine blade path is less than 1.7 for more than 60 seconds, the control system will recommend a trip of the turbine. If the HP exhaust temperature is greater than 427, the Emergency Trip System (ETS) will trip the turbine. 8. The function of the bypass system during and immediately following a load rejection is to allow the boiler load to be transferred from the turbine to the bypass system to avoid a boiler trip. In most cases, the operator must run back the boiler load to a lower level before normal operation can be resumed. 9. When the unit is resynchronized, the governor valves and interceptor valves will be automatically raised to a position equivalent to 5% rated load above the flow required to maintain rated speed with house load. Valve positions will be corrected for measured throttle and reheat pressures.
Page 1 of 2 CompiledYu Yan 2008.09 2008.09 2008.09
Load Changing
OP.2.17.01E-00
Checked Zhang Xiaoxia CountersignTang Jun Countersign
LOAD CHANGING
With the turbine control in the OPERATOR AUTO or TURBINE MANUAL mode, the chart, Load Changing Recommendations, should be followed at all times while changing load (increasing or decreasing). See the sections entitled Staring and Load Changing Recommendations and Governor Valve Management for additional load changing information. The Automatic Turbine Control (ATC) Program provides load control capability when the main generator breaker is closed and the unit is the ATC mode of control. All load changes are intended to be completed in the ATC mode since the load control program automatically optimizes the turbine loading rate. The ATC program continually monitors various turbine parameters, calculates rotor stresses, and selects the optimum loading rate based on the current conditions. This rate is limited to the lowest of either the optimum rate as determined by rotor stress calculations, an operator selected rate, or a loading rate received as an input from an external source. The operator controls the rotor stress limits and also the maximum load in terms of megawatts. In a combined mode of control the ATC program determines if a load hold condition is required and if the remote source attempts to change load more rapidly than the lowest available rate, the remote raise or lower inputs are blocked. For load changes in any mode of control, it is assumed that the feedwater heaters and auxiliary equipment for the particular heater arrangement used are operating normally. The steam drains are to remain open on increasing load until the unit is carrying 10 percent of rated load for drains from sources upstream of the turbine reheat stop valves and 20 percent of rated load for drains from sources downstream of the turbine interceptor valves, at which time they will close automatically. Also, on decreasing load or when the turbine is tripped,
Page 2 of 2 drains will open automatically at 20 percent of rated load for drains from sources downstream of the interceptor valves and 10 percent of rated load for drains from sources upstream of the reheat stop valves. The operator must be certain that the drain valves function automatically, otherwise he must operate them manually. CAUTION The operator must be certain that the OPC monitor light is off; otherwise the turbine has lost one of its main overspeed protection devices. The trouble should be corrected immediately. LOAD CHANGING PROCEDURE 1. When rated throttle steam pressure has been achieved, put the impulse pressure feedback loop in service by depressing IMP IN. 2. Put one of the throttle pressure controllers in service by depressing either FIXED TPC IN, OPER ADJ TPC IN, or REMOTE TPC IN. (Throttle Pressure Controller Set Point should always be at least 10% below existing throttle pressure.) 3. Obtain the recommended time to change load from the chart Load Changing Recommendations and determine the loading rate in terms of percent of guaranteed capacity per minute. 4. Enter the loading rate determined above. 5. Enter the desired load in the TARGET. 6. It is recommended that all load changes be performed in the ATC or combined mode of control. Depressing AUTO TURBINE CONTROL will put the unit in the ATC mode which will control the load change through completion. If ATC is not used, depress the Go push button. The REFERENCE will count towards the TARGET at the selected load rate and indicating that load is being changed. 7. If a hold is required during a load change, depress the HOLD push button and the load change will stop. To continue, depress the GO push button. The load change will proceed at the previously selected loading rate. 8. The load change is completed when the valve in the REFERENCE is equal to the value in the TARGET. Note: When on load control with Impulse Pressure Feedback and MW Feedback in service, the DISPLAY STATION window will display actual megawatts.
Page 1 of 7
Shut Down Procedure

OP.2.18.01E-00
2008.09 2008.09 2008.09
SHUT DOWN PROCEDURE . NORMAL SHUTDOWN

Except in an emergency, load should be removed gradually. The rate of decrease for the particular turbine operating conditions should be within the guidelines specified on the chart Load Changing Recommendations. For additional information or load changing. refer to the section Starting and Load Changing Recommendations and, if provided, Governor Valve Management. 1. To decrease load:
1.1 Obtain the recommended time to decrease the load from the chart Load Changing Recommendations (see Example 2 on the chart) and determine the load changing rate in terms of percent of guaranteed capacity per minute. 1.2 Enter the MW/min value obtained above. 1.3 Enter the desired load. 1.4 It is recommended that the load reduction be performed in the ATC mode. Depressing AUTO TURBINE CONTROL will put the unit in ATC mode which will control load reduction through completion. If ATC is not used, depress GO push button. The REFERENCE will count toward the TARGET at the selected load rate and indicating the load is being reduced. 1.5 If a hold is required during the load reduction, depress the HOLD push button and the load reduction wills stop. To continue, depress the GO push button. The load reduction will proceed at the previously selected loading rate. 1.6 The load change is completed when the value in the REFERENCE is equal to the value in the TARGET.
Page 2 of 7 1.7 When the load has decreased to 20% of rated load. Assure that the drains from sources downstream of the interceptor valves are open. When the load has decreased to 10% of rated load, assure that the drains from sources upstream of the reheat stop valves are open. The drain valves normally function automatically; however, if necessary, the operator should operate them manually. 1.8 When all load has been removed, shut the unit down by tripping the overspeed trip. This closes the throttle valves, governor valves, reheat stop valves and interceptor valves. 2. The vacuum breaker valves should not be opened until the turbine unit has coasted down to about 400 r/min, or until the unit is placed on turning gear, depending on operating preference. Vacuum breaker valves should not be opened immediately following tripping of the unit except for emergency requirements to reduce rolling time. Opening the vacuum breaker valve immediately after tripping a unit could result in blade damage due to the braking action imposed by the suddenly created dense exhaust medium. Vacuum should be dissipated before gland sealing steam is shut off. 3. Be sure that the bearing oil pump starts when the bearing oil pressure drops to the
value shown in the Turbine Control Settings. 4. For units so equipped, be sure that the bearing lift oil pump selector switch is turned to
the AUTO position. Refer to the Bearing Lift System for operation information. 5. 6. Shut down the air removal equipment. Shut off the cooling water supply to the generator hydrogen coolers, following the
specific instructions given in the Generator Instruction book. 7. When the vacuum reaches zero, shut off the sealing steam to the gland steam control
valves. Shut down the gland steam condenser exhauster. Shut down condensate pump. 8. In order that the turning gear will be automatically engaged, be sure the control switch
is turned to the AUTO position. 9. Shut down circulating water pumps.
10. Regulate the water to the oil coolers to maintain the oil temperature leaving the coolers between 35 and 38. . EMERCENCY SHUTDOWN A. Loss of Electrical Tie to the System In the event of the complete or partial loss of electrical load, energy in the entrapped
Page 3 of 7 steam will cause the rotor to accelerate. The amount of acceleration is a function of the load level at the time of the load separation. 1. An Overspeed Protection Controller (OPC) is incorporated in the DEH Control System. This device performs the following functions: 1.1 The load drop anticipator function of the OPC senses complete loss of load and rapidly closes all governor valves and interceptor valves to limit the overspeed of the turbine. This function is normally activated only if load is greater than 30% of rated load and the main breaker is open. With the opening of the main generator breaker the DEH speed reference is automatically reset to rated speed and the turbine controlled in OPERATOR AUTO mode. After a time interval, the speed of the unit will decrease below the setting of the governor which in turn permitting the interceptor valves to open slowly. The entrapped steam in the reheat system will cause a second speed rise causing the OPC governor to again closing the interceptor valves. This mode of control is follow until all of the entrapped steam is dissipated through the interceptor valves. The governor valves will remain closed for speed greater than rated speed due to the speed error. After the entrapped steam in the reheat system is dissipated, the interceptor valves will stay open and the speed of the unit will decrease towards rated speed. At rated speed, the governor valves will take over the control of the turbine and keep the unit at rated speed. 1.2 The auxiliary governor function of the OPC senses excess turbine speed and closes all governor and interceptor valves when the speed is greater than 103%. The auxiliary governor function causes the same type of governor and interceptor valve operation to dissipate the reheater steam and achieve synchronous speed as described for the load drop anticipator function. 1.3 The fast valving functions of the OPC: Senses partial loss of load by comparing turbine input power (IP exhaust pressure) with generator electrical output power (from the Mw transducer). When turbine power exceeds generator power by about 60% to 80% (which would typically occur during a phase fault close to the generating station) the fast valving logic rapidly closes only the interceptor valves. This will give a corresponding momentary reduction in turbine input power and consequently a momentary reduction in generator output power to enable the unit to remain synchronized with the system. Fast valving components are supplied as standard with this
Page 4 of 7 unit. The fast valving function is inhibited unless a specific request is received from the customer to enable it. 2. After a load drop anticipator or auxiliary governor action. The unit if desired may be
resynchronized and load applied as follows: 2.1 If the unit can be synchronized within 15 minutes after loss of electrical tie, load may be applied up to the load previously carried as rapidly as desired. Further increases in load should be applied in accordance with the chart Load Changing Recommendations. 2.2 If there is more than a 15 minute delay in re-synchronizing, load should be applied in accordance with the chart Load Changing Recommendations. 2.3 If it is decided not to put the unit back on the line, the normal shutdown procedure previously outlined should be followed. 3. If the cause of the load dump cannot be determined such that there is a delay in
re-synchronizing, the unit and boiler fires should be tripped automatically after a specific time delay and the operating procedures described under Loss of Pressure or Temperature should be followed.
B. Loss of Pressure or Temperature Operation of the Throttle Pressure Limiters (TPL). The DEH controller includes three throttle pressure controllers: a fixed set point TPL, a variable set point remote TPL, and an operator adjustable set point TPL. Only one of these may be placed in service at any one time. 1. Fixed Set Point TPL
1.1 This TPL set point is a fixed value stored in the DEH controller. It is set equal to either 90% or 95% of rated throttle pressure depending on the boiler construction. See the Turbine Control Settings for the exact set point. A 90% set point is assumed for the following discussion. 1.2 The TPL can be put in service or taken out of service by pushing the FIXED TPL IN /OUT on the DEH Operator manual panel. If in an automatic mode, the operator must ensure that the existing throttle pressure is above the TPL set point before placing the TPL in service. In addition the variable set point remote TPL and the adjustable set point TPL must be out of service. 1.3 If this TPL is out of service and the control system is transferred from an automatic
Page 5 of 7 mode to TURBINE MANUAL or from TURBINE MANUAL to an automatic mode, the TPL will remain out of service. Similarly, if this TPL is in service during a mode transfer, it will remain in service. 1.4 Should a loss of throttle pressure occur while the fixed set point TPL is in service, the following will occur: 1.4.1 For any throttle pressure below the TPL set point, the throttle pressure controller will operate. 1.4.2 The load will be reduced until the throttle pressure is restored to the throttle pressure control set point or a minimum governor valve opening of 20% is reached. 1.4.3 During any loss of throttle pressure such that the valves close to their 20% valve position, the operator should decide whether the operating pressure or temperature can be maintained. If not, he must trip the turbine. 1.4.4 If the boiler pressure has increased sufficiently, the operator can increase the REFERENCE setting to the load value held before the loss of pressure. If the TPL (either the fixed set point or the variable set point) was placed in service, it may be taken out of service by the operator. 2. Variable Set Point Remote TPL 2.1 This TPL set point is a variable value obtained from a remote source in the room of an analog input to the DEH controller. 2.2 The variable set point remote TPL can be put in service or taken out of service by depressing the REMOTE TPL IN/OUT. The control system must be in an automatic mode of operation, and the fixed TPL set point must be out of service. In addition, the remote TPL permissive must also be closed. The operator must also ensure that the existing throttle pressure is above the variable remote TPL set point. 2.3 If this TPL is out of service and the control system is transferred from an automatic mode to TURBINE MANUAL or from TURBINE MANUAL to an automatic mode, the remote TPL will remain out of service. If the remote TPL is in service during an automatic mode of operation and a transfer to TURBINE MANUAL is initiated, the variable set point remote TPL will be taken out of service and it will remain inoperable during operation in the manual mode. 2.4 Should a loss of throttle pressure occur while the variable set point remote TPL is in service, the following will occur:
2.4.1
Page 6 of 7 For any throttle pressure below the remote TPL set point, the throttle pressure
controller will operate. 2.4.2 The load will be reduced until the throttle pressure is restored to the remote
throttle pressure control set point or a minimum governor valve opening of 20% is reached. 2.4.3 During any loss of throttle pressure such that the valves close to the 20% valve
position, the operator should decide whether the operating pressure or temperature can be maintained. If not, he must trip the turbine. 2.4.4 If the boiler pressure has increased sufficiently, the operator can increase the
REFERENCE setting to load value held before the loss of pressure. If the TPL (either fixed set point or variable set point remote) was placed in service, it may be taken out of service by the operator. 3. Operator Adjustable Set Point TPL
3.1 This TPL set point is a variable value that the operator enters from the operator's control panel. 3.2 The operator adjustable set point TPL can be put in service or taken out of service by depressing the OPER AD TPL IN/OUT. The control system must be in an automatic mode of operation, and the fixed TPL set point must be out of service. The operator must ensure that the existing throttle pressure is above the set point value entered by the operator. 3.3 Once the set point is established, the operator adjustable set point TPL operates in the same manner as the fixed set point TPL whose operation is described in a preceding paragraph. 4. If the Fixed Set Point TPL, Operator Adjustable Set Point TPL, and Variable Set Point
TPL are out of service, the following procedure will apply when actual throttle pressure drops in an uncontrolled fashion: 4.1 The operator will begin to reduce load in an attempt to maintain pressure above 90% of rated pressure. 4.2 If the pressure falls below 90% of rated pressure, remove the load and trip the unit. Check the turbine drain valves downstream of the interceptor valves when the load has decreased to 20% of rated load. When the load has decreased to 10% of rated load, check the drain valves from sources upstream of the reheat stop valves. Check the bypass valves around traps on all drain lines from stage extraction heaters. Place unit on turning gear and listen for rubs. If everything is normal follow the applicable Hot Start or Cold Start
Page 7 of 7 procedure to bring the unit up to speed and synchronize. 4.3 For the case where the pressure can be held above 90% of rated pressure, bring the unit up in normal manner after temperature and pressure have been restored to normal. C. Emergency Trip System Function This unit is equipped with an emergency trip system (protective trip devices) which will automatically trip the turbine in the event of certain for separate content describing the various devices which comprise the system.) An inadvertent trip can occur during the oil pressure method of testing the overspeed trip mechanism if the test level is released prematurely. 1. If the turbine is tripped as not noted above, the trouble has been recognized and
corrected, and the vacuum has been maintained, relatch the unit and proceed to synchronize. 2. If the turbine is tripped and the vacuum is lost. Let the rotor come rest following
normal shutdown procedure. After the trouble has been corrected, restart the unit in accordance with the applicable hot start or cold start procedure.
Page 1 of 5
Turning Gear Operation During Shutdown OP.1.19.01E-00
CompiledZhang D.M CheckedHuang Q.H
2008.09 2008.09
Countersign Yan W.CH 2008.09 CountersignYu Yan 2008.09
TURNING GEAR OPERATION DURING SHUTDOWN

The turbine-generator rotor is driven by a single speed turning gear at a nominal speed of 3r/min for units having a rated speed of 3000 r/min. Following a shutdown, the turbine-generator unit turning gear should engage automatically as soon as the unit stops rolling. The operator should verify that the turning gear is rolling the turbine. In order to facilitate restarting the unit, it is recommended that it be rolled by the turning gear throughout the shutdown period. Continuing turning gear operation after the turbine is comparatively cool, greatly increases the likelihood that eccentricity will be within acceptable limits for start-up by preventing bowing of the rotors if steam should leak into the turbine duping the shutdown period. Normally a unit should remain on turning gear flowing a hot shutdown until the rotors have cooled to 149~204. This might require 10 to 15 days depending upon the internal temperature level prior to the shutdown. This time can be reduced considerably by steam cooling before the shutdown as described in Part 7 of this section. Maintaining turning gear operation for this duration will prevent a rotor bow and assure the availability of the unit for start-up without delay. The rate of heat conduction through the gland ends of the turbine rotors to the journals is low. The normal oil circulation around the journals is sufficient to keep the journals cool whether the unit is at rest or on turning gear. If lubricating oil is shut off, the journal temperatures will rise at a rate depending on the turbine internal temperature. When there is no oil circulation. a journal temperature in excess of 149 may cause damage to the bearing babbitt. Bearing metal temperatures should be closely monitored during this time and oil circulation restored if excessive temperatures result. If the unit is hot (average internal temperature above 204 and not in excess of 454)
Page 2 of 5 and for some reason not turning, oil may be shut down for 2 to 3 hours before the journal temperatures become excessive. If the turbine is allowed to cool to 204, the oil supply could be shut down for approximately 10 hours. When it can be arranged without delaying work schedules, the turning gear and the oil circulatior system should be kept in operation for not less than 48 hours after shutdown. If continuous rolling during shutdown is not practical, the turning gear should be restarted and remain in operation for a sufficient length of time before admitting steam to the turbine to allow rotor straightening as determined by stable eccentricity within the limits noted in the section Operating Limits and Precautions. The preceding operating recommendations for the shutdown period may not be practical to follow when repairs or adjustments are to be made to the turbine. In these cases the following recommendations apply. 1. THE TURBINE IS TO BE DISMANTLED The turning gear should be kept in operation until the dismantling program requires that it be stopped. If an emergency necessitates it, the turning gear may be shut down immediately: however, it must be recognized that this may subject the rotor to severe bowing. Bearing oil circulation must be maintained after shutdown to protect the bearings against overheating. The minimum circulation period should be 24 hours after shutdown. During this period, the oil temperature leaving the coolers should be held between 21 and 35, if possible. 2. SHUTDOWN FOR EXTENSIVE REPAIR OR ADJUSTMENT Both the turning gear and the bearing oil circulation system should be kept in operation for a minimum of 24 hours. Oil temperature from the cooler should be maintained between 21 and 35, if possible, both the turning gear and the oil circulation may then be shut down. When operation is to be resumed, the unit should be placed on turning gear prior to turning on gland steam and establishing vacuum, and can be rolled with steam upon attaining stable eccentricity conditions within acceptable limits. These recommendations also apply to the situation where rotor bearings are to be inspected or repaired and it is necessary to shut off oil circulation. Metal temperatures at all the bearings should be monitored during this period. To avoid overheating the bearings, restore oil circulation as soon as possible.
Page 3 of 5 3. SHUTDOWN FOR MINOR REPAIR OR AJUSTMENT Depending upon the nature of the work to be done. The following schedule may be adopted: a. Keep the turning gear and the bearing oil circulation system in operation for a
minimum of 3hours. Both may then be shut off for a period of not more than 15 minutes. If practical, however, oil circulation should be maintained. b. Following the 15 minute shutdown period in (a) above roll the turbine on turning gear
for 2 hours or until stavle eccentricity conditions exist, whichever occurs first. Both turning gear and oil circulation may then be stopped for not more than 30 minutes; however, 15 minutes after stopping, the rotor is to be turned 180 degrees with the turning gear. Oil circulation should be on during the 180 degree turns to lubricate the bearings. c. Following the 30 minute shutdown period in (b) above the turbine should again be
rolled on turning gear with oil circulation for 2 hours or until stavle eccentricity conditions exist, whichever occurs first. The system may be shut down indefinitely, provided that the rotor is turned 180 degrees at 30-minute intervals for the next 6 hours. Oil circulation should be on during the 180 degrees turns to lubricate the bearings. 4. EMERGENCY TURNING GEAR OPERATION If for any reason the turbine unit is tripped and the rotor comes to rest, the unit should be placed on turning gear operation immediately. If turning gear operation is impossible because of interference between rotating and stationary parts due to thermal shock and consequent distortion, try jogging the turning gear motor after a one hour interval. If unsuccessful, repeat the attempt after another one hour interval. If unsuccessful after the second attempt, the rotor (or blade ring) may be bowed and/or stationary parts distorted to the extent that one or two days soaking in the arrested condition may be necessary before making another attempt to break the rotor loose by turning gear operation. WARNING Under no circumstances should an attempt be made to free the rotor by admission of steam to the unit or by use of a crane. Such an attempt could have disastrous results such as increased blade seal strip clearances, shroud or rotor gouging, broken blades, etc. If turning gear power is not available and the rotor remains at rest, a rotor bow can be expected. Experience indicates, however, that a one to two hour period on turning gear
Page 4 of 5 prior to start-up will roll the rotors straight. By turning the rotors 180 degrees in 15 to 20 minute intervals, the severity of the bow can be reduced and thus reduce the required turning gear operating time period to start-up. In cases such as a water incident where both rotor and cylinder might be bowed, cranking must not be attempted in order to break bound parts loose. 5. TURNING GEAR OPERATION WITH ONE OR MORE BEARING LIFT ASSEMBLIES INOPERABLE As the turbine coasts to a shutdown, the hydraulic bearing lift system will begin to operate when the rotor speed decreases to a predetermined level (see lubrication oil system introduction about Lifting oil system .) The unit will go on turning gear even if one or more of the bearing lift assemblies is inoperable. If that is the case, stick-slip may occur. If stick-slip does occur, do the following until the bearing lift system can be back in operation: a. Start the dc emergency oil pump to provide additional oil flow and reduce bearing oil temperature as much as possible but not less than 21 . b. Wait one minute. If stick-slip is still occurring stop the turning gear for 15 seconds and
then restart the turning gear. c. If stick-slip continues, stop the turning gear again. Every 10 minutes rotate the rotor
180 degree to keep the rotor straight. Continue until the rotor can be placed on turning gear without stick-slip occurring. CAUTION To avoid discharging the batteries to an unacceptable level, do not operate the dc emergency oil pump for extended periods to overcome stick-slip. Test and recharge batteries as required immediately after using the dc emergency oil pump for turning gear operation. For additional information refer to the Hydraulic bearing lift System leaflet. 6. COOLDOWN TIME FOR A TYPICAL HP TURBINE Information on the cooling of the high pressure turbine while on turning gear following a trip from load operation is shown in the curve entitled Cooldown Time for A Typical Fossil HP Turbine (see index). This information is useful in pre-planning warm or hot restarts or planning maintenance during the shutdown period.
Page 5 of 5 This curve is based on cool down information accumulated from field operating data and can be used as reference information until the Purchaser in able to plot, based on operating experience, the actual temperature decay of his unit. 7. STEAM COOLING OPERATION If it is desired to expedite cooling of the turbine elements in order to perform maintenance quickly, the unit load can be reduced and held at a low level for a period of time to steam cool the metal prior to shutdown. Reducing main and reheat steam temperature during the load reduction also aids in lowering the internal temperatures. In the case of fossil turbine units with governor valve management capability, the HP element will reach a lower temperature in the sequential governor valve mode compared to the single valve mode at the lower loads (Refer to section Governor Valve Management). The Load Changing Recommendations charts and other specified temperature change limits still apply during this shutdown operation. 8. REMOVAL OF INSULATION The cylinder insulation should not be removed from the turbine elements until they have cooled for 24 hours or longer. This delay is necessary to avoid thermally stressing the cylinders, locally cooling and deforming the cylinders and exceeding the allowed differential cooling of the cylinder parts relative to the rotor.
Feedwater Heater Operation

OP.2.20.01E-00
CompiledYu Yan Checked Zhang Xiaoxia Countersign Countersign
2008.09 2008.09
Contents
FEEDWATER HEATER OPERATION ......................................................1 1 Introduction ...........................................................................................1 2 Sequence of Placing Feed Water Heaters In and Out of Service......1 3 Effects of Removing Feedwater Heaters from Service ......................2 4 Criteria of Operation with Feedwater Heaters Out of Service.........3 5 Rules for Operation with Heaters Out of Service ..............................3 6 General Notes on Heater Operation ..................................................10
Page 1 of 14
FEEDWATER HEATER OPERATION 1 Introduction

Modern-day power plant units utilize the regenerative feedwater heating cycle in which steam is extracted from the turbine at intermediate stages and is condensed in feedwater heaters. A major portion of heat content of the extracted steam (including the heat of condensation) is transferred to the feedwater passing through the feedwater heater. The final temperature of the feedwater returned to the steam generator is considerably higher than that obtained in the straight condensing cycle having no feedwater heaters, thereby reducing the energy requirements of the boiler with a resulting improvement in overall cycle efficiency. Compared with the same throttle flow in a straight condensing turbine, less work output will be developed because all the steam does not expand entirely through the turbine; however, the improvement in performance (heat rate) overbalances the effect of lower work output. Unless special contract provisions were made, the turbine design is based on the blade path steam flows, pressure and temperatures distributions, extraction flow rates and the turbine exhaust flow condition with the configuration shown on the heat balance in the Thermal Performance Data. Normally, the heat balance is calculated with all of the feedwater heaters in operation. Check the Thermal Performance Data package for other special heat balances that might have been calculated as a result of unit specific contract requirements. The configuration shown on any special heat balance is not superceded by the rules that are presented below. Unless special instructions are supplied, all load restrictions specified may be considered a percentage of that shown on the special heat balance diagram, if higher than the others.
2 Sequence of Placing Feed Water Heaters In and Out of Service

During unit start-up and shutdown, isolate the feedwater heaters from the turbine. Heaters that are located in the condenser neck normally cannot be isolated from the turbine on the steam side. These low-pressure heaters are removed from service by .diverting the flow of condensate around the heater by use of a bypass system. Heaters that have shutoff valves in the extraction pipes should not be placed in service until the pressure on the turbine side of the isolation valve is greater than the heater shell pressure. During unit
Page 2 of 14 start-up, feed water heaters should be placed in service in sequence starting with the lowest pressure heater. During unit shutdown, heaters should be removed from service in sequence starting with the highest pressure heater.
3 Effects of Removing Feedwater Heaters from Service

Removal of one or more heaters from service will cause perturbations, which may or may not be acceptable, in the turbine and in the heater cycle, depending upon which heaters are inactive:
A. If one or more heaters are isolated and no higher pressure heater is in service, the
steam which is normally extracted to these heaters flows through the downstream stages of turbine blading to the condenser. Assuming constant throttle flow, this path increases the steam flow in the turbine downstream of the inactive extraction point(s) and increases the KW output of the unit. It also distorts the normal flow, pressure, temperature and work distribution throughout the turbine. The removal of any heater from operation decreases the efficiency of the thermal cycle. In addition, when a unit is operated with-the top heater(s) out of service, the feedwater returning to the steam generator is at a lower temperature; consequently, additional energy must be supplied in the steam generator by means of higher fuel consumption to compensate for the colder feedwater.
B. If one or more heaters are out of service while a higher pressure heater remains in
service, there will be a substantial increase in extraction flow to the next higher pressure active heater. Depending upon the number of heaters removed, the total steam flow to the active heater will now be a significantly high percentage of the sum of the normal extraction flow to this heater, plus the normal extraction flows to all adjacent inoperative lower pressure heaters. The added extraction flow will tend to overload both the steam and drain sides of the active heater, increase the steam velocity and pressure drop in the extraction piping and increase the steam velocity in the turbine extraction slot. Additionally, the pressure at the turbine zone supplying extraction steam will decrease, since the flow to the downstream blading group is reduced by virtue of the greater extraction flow. These changes to the steam flow distribution in a turbine can increase the work, flow, temperature, and the pressure drop across the stages of turbine blading. These parameters are the major factors which determine blade stress.
Page 3 of 14
4 Criteria of Operation with Feedwater Heaters Out of Service

In general, unless special design considerations are made, removing one or more heaters from service requires a reduction in load when the load generated is at or near the maximum capability of the unit. Heaters should be removed from service only in emergency situations, such as equipment malfunction, maintenance or repair. HEATERS MUST NOT BE TAKEN OUT OF SERVICE FOR THE PURPOSE OF OBTAINING ADDITIONAL LOAD. Normally, operation with heaters out of service is acceptable, providing that the work, flow, temperature and the pressure drop across the individual stages of blading do not exceed the values incurred at the maximum MW load calculated on a heat balance in the
Thermal Performance Data. The contract for some units specifies that they be capable of operation with the top heater out of service for the purpose of obtaining additional load. These turbines are specifically designed for this purpose and are guaranteed to operate safely under this condition.
5 Rules for Operation with Heaters Out of Service

5.1 Sequencing Feedwater Heaters Feedwater heaters should be placed in service in sequence starting with the lowest pressure heater. Heaters should be removed from service in sequence starting with the highest pressure heater. This rule is mandatory when the unit is operating at high loads and is primarily intended for this load condition. If load is sufficiently low, the rule is not applicable.
5.2 Emergency Operation For emergency operation, heaters may be removed from service provided that the flow, pressure drop, and work across each stage of blading does not exceed that indicated on the heat balance for the maximum MW load calculated on a heat balance in the Thermal
Performance data. Since the operator cannot easily determine the values of these parameters, emergency operation with heaters out of service will be governed by the rules noted below. When the rules necessitate a load reduction, whenever possible reduce the load before removing the heater from service; if this is not possible, the load must be
Page 4 of 14 reduced promptly. (1) Nonadjacent Heaters Out of Service One or more nonadjacent heaters may be removed from service provided the unit output is adjusted so that it does not exceed a reference load which has design margin (see Figure 1). Load is to be reduced to this level for the first heater removed, regardless of size or position in the feed water heating cycle. This reduction in load is required for removing a full or partial size heater. The reference load is defined as the maximum guaranteed load of the turbine operating at rated inlet, reheat, exhaust and makeup conditions. (See maximum guaranteed rating and the heat balances in the Thermal Performance data.)
Page 5 of 14 Figure 1 EXAMPLES
Example 1:
Single Heater Out of Service Permissible Load = Maximum Guaranteed Load
Example 2:
Two or More Non-Ajacent Heaters Out of Service Permissible Load = Maximum Guaranteed Load
Example 3:
One or More Non-Ajacent Partial Heaters Out of Service Permissible Load = Maximum Guaranteed Load
Page 6 of 14 (2) Adjacent Highest Pressure Heaters Out of Service Fossil units may be operated with up to three of the highest pressure heaters out of service provided the unit output is adjusted so that it does not exceed the reference load defined above (see Figure 1). Additional adjacent heaters may be removed from service provided the output is reduced by 5 percent below the reference load output for each additional adjacent heater which is removed from service. Thus, if a fossil unit is operated with the four highest pressure heaters out of service, the unit output must be adjusted so that it does not exceed 95 percent of reference load. (3) Adjacent Lower Pressure Heaters Out of Service with Higher Pressure Heaters In Service If it becomes necessary to remove adjacent lower pressure heaters from service at rated or higher load while higher pressure heaters remain in service, the load on the unit must be reduced by adjusting the throttle flow. For the first such heater removed from service, the maximum load should be the reference load (see Figure 1). For each successive adjacent heater removed from service, the load must be further reduced by 10 percent of the reference load. For example, if two lower pressure adjacent heaters are removed while a higher pressure heater remains in service, the load must be reduced to 90 percent of the reference load. If three adjacent heaters are removed, the load must be reduced to 80 percent. The maximum reduction necessary is 50 percent of the reference load for any combination of heaters taken out of service.
5.3 Multiple Strings of Heaters With the increase in size of units, the condensate flow and the volumetric flow of extraction steam become too large to be handled by a single string of heaters. Consequently, many power plants with larger units use multiple strings of heaters. Due to physical constraints in plant piping systems, heaters operating at the same pressure zone mayor may not be manifolded. The definition of manifolding in this context must be viewed in terms of how the turbine is affected. The steam supply to partial-size heaters is defined to be manifolded if the isolation of one heater in the string results in continued, but reduced extraction steam flow from a particular turbine zone (see Figure 1). Conversely, if the isolation of one heater results in complete cessation of extraction steam flow from a particular zone in a turbine or
Page 7 of 14 from one side of a double flow turbine element, the extraction is not manifolded. An example of external manifolding is the extraction from the same pressure zone in separate LP turbine elements where the external piping is interconnected between the turbine elements and the partial-size heaters. The isolation of one partial-size heater results in continued but reduced extraction steam flow from each of the affected zones in the turbines. An example of non-manifolding of partial-size heaters can be found in the lowest pressure extraction zone from separate LP turbine elements. When the extraction steam flow from each LP element is taken to separate partial-size heaters, the extraction steam flow from one LP element would be completely stopped if one of these heaters is isolated. Therefore, the effect on that particular LP turbine element would be the same as if a full-size heater were taken out of service, and such an extraction steam supply is not considered to be manifolded.
Page 8 of 14 Figure 1(Continued). EXAMPLES
Example 4: Highest Pressure Heater Out of Service Permissible Load = Maximum Guaranteed Load
Example 5: Two Ajacent Highest Pressure Heaters Out of Service Permissible Load = Maximum Guaranteed Load
Example 6: Two Ajacent Low Pressure Heaters Out of Service with Higher Pressure Heaters in Service Permissible Load = 90% Maximum Guaranteed Load
Example 7: Four Ajacent Low Pressure Heaters Out of Service with Higher Pressure Heaters in Service Permissible Load = 70% Maximum Guaranteed Load
Page 9 of 14 Figure 1(Continued). EXAMPLES
Example 8:
Manifolded
Example 9:
Not Manifolded
Example 10: Not Manifolded
Page 10 of 14 (1) Manifolded Partial Size Heaters When multiple strings of feedwater heaters are utilized and a manifolded heater of less than full size in one string is removed from service, the rules noted in Paragraphs 5.2.(2) and 5.2.(3) apply, except that the load reduction required for a full-size heater may be multiplied by the percentage reduction in extraction flow from the affected turbine zone. The required load reduction for a partial-size heater can be determined on the basis of actual size of the heaters remaining in service at the affected turbine extraction zone. (For example: assume that 10 percent load reduction is required by Paragraph 5.2.(3) for a full-size heater. If one of three 1/3-size heaters is taken out of service, reduce load by 3.3 percent; if one of two 1/2-size heaters is taken out of service, reduce load by 5 percent; if one of two 3/4 size heaters is taken out of service, reduce load by 2.5 percent. ) (2) Non-Manifolded Partial Size Heaters When multiple strings of feedwater heaters are utilized and a non-manifolded heater of less than full size in one string is removed from service, the rules noted in Paragraphs 5.2.(2) and 5.2.(3) apply. As noted above, the effect on the turbine of isolating such a partial-size heater is the same as isolating a full-size heater.
6 General Notes on Heater Operation

6.1 Heater Pressure at Start-Up AT NO TIME SHOULD THERE BE ANY FLOW FROM A HEATER TO THE TURBINE. To avoid this condition on start-up, heaters must not be placed in service until the extraction zone in the turbine is at or above the associated heater pressure. 6.2 Heater Isolation There are two effective ways to isolate a heater from the cycle: (1) shut off the source of extraction steam, or (2) stop the flow of water through the heater. 6.3 Water Induction into The Turbine Prevent the harmful effects of water in the heater flashing into steam, and consequent potential induction of water or injection of cool vapor into the turbine at a heater extraction zone. To provide this protection, it has become industry practice to install shutoff and non-return valves in the extraction lines. The shutoff valves can be used to isolate the heater from the turbine. To protect the turbine from water induction, the shutoff and non-return valves installed
Page 11 of 14 in the extraction lines of each heater must close automatically on high level alarms. The control system responsible for sensing this condition and removing the feedwater heater from service must respond quickly enough to prevent water from entering the turbine. This recommendation applies whether a heater is rendered inoperative by closing the shutoff valve in the extraction line or by bypassing the water flow around the heater. Either method is effective in removing the heater from service, although the use of a shutoff valve is the only positive way of preventing backflow into the turbine. To protect the turbine against water induction due to backflow from the heaters following a turbine trip, the power operated shutoff valves in the extraction pipes should automatically close on a turbine trip. Circuits and controls used to close extraction line shutoff valves following a turbine trip must operate so that a malfunction of these controls will not cause all of these valves to close when the turbine-generator is at high load. Should this type of malfunction occur, damage to the turbine-generator unit may result. 6.4 Heaters in Condenser Neck Most modern power plants have the lowest pressure feedwater heaters located in the neck of the condenser. Due to the physical arrangement of the heaters in the condenser neck, it is very difficult to install shutoff or non-return valves in these extraction lines. Those heaters which are not provided with shutoff or non-return valves in the extraction piping are removed from service by diverting the flow of water around the heater through the use of a bypass system. 6.5 Heater Drains No heater should be placed in service until the shell drain system can handle the condensed extraction steam, cascading flow from higher pressure heaters, any tube leakage that may exist, and any other miscellaneous flows routed to the heater. The major indication of the adequacy of the heater drain system is its ability to maintain the proper water level in the heater. If the water in the heater causes the protective devices to generate frequent high level alarms, the effectiveness of these devices for prevention of water induction or backflow of cool vapor into the turbine will be impaired. Experience has demonstrated that false alarms from heater level controls negate the effectiveness of the level alarm system. There is a tendency to ignore alarms which frequently give false signals.1t must also be remembered that the startup can be hot or cold, and in either case the induction of cold fluid is very
Page 12 of 14 dangerous to the turbine. 6.6 Tube Leaks Although units should not be operated with heaters having tube leaks, they are often operated with this defect. Frequently, it is not easy to tell if tube leaks exist except by specific testing methods or if a high level alarm sounds. Obviously, tube leaks that occur between tests, or are small, may not be detected for some time. In any case, when tube leaks are known to exist, the heater should not be brought into service unless the normal drain system can handle the leakage plus all the various flows piped to this heater. 6.7 Heater Vents The heater vent system must be functioning properly to avoid pressurization of heaters by air binding. Any external steam supply that is used to pressurize a heater must be at a lower pressure than the turbine zone or the turbine must be isolated from the source. This includes deaerators pressurized (pegged) to heat water for deaeration. 6.8 Deaerating Heaters It may not be practice in some power plants to take deaerator type heaters out of service. Even for water induction protection, drain flow from these heaters cannot be dumped to the condenser as this is the full condensate flow. Dumping of this flow to the condenser would starve the feed pumps with possible serious damage to the pumps. If such a situation inadvertently did occur it would be expected that protective relays in the plant would cause the unit to trip. In addition, if the deaerator is removed, deaeration of the condensate may not be possible unless the condenser design includes provisions for deaeration. Failure to deaerate the condensate is undesirable since the non-condensables would go through the rest of the cycle downstream of the deaerator including the turbine. 6.9 Flash Tanks Pressurization of some or all HP heaters, especially the top or top two heaters, is common practice on once-through boiler installations utilizing a start-up cycle with or without a flash tank. Steam and water from the start-up cycle are dumped to the two top heaters to recover heat; these heaters may become pressurized to full flash tank pressure (6.68MPa(g)) while the turbine is under vacuum. From the standpoint of water or cool vapor induction into the turbine, this is an extremely dangerous situation and stringent precautions must be taken to prevent flow into the turbine through the extraction pipes by closing the shutoff valves. Fortunately, as the unit comes up in load, a transfer is made from
Page 13 of 14 the start-up cycle to the normal cycle. Flash tank pressure decreases as load increases, and a point will be reached when turbine pressure is above heater pressure and the shutoff valves can be opened. 6.10 Turbine Thrust Avoid extremely abrupt isolation of heaters. Such action causes an abrupt change in pressure throughout the turbine. Units with a combined pressure element (VHP-HP, HP-IP) and units with a split flow design use dummies to counterbalance any axial thrust on the rotor incurred from the balding. Some of these designs incorporate piping to transmit the pressure at a particular zone in the blade path to the dummy. If the rise in pressure in the blade path is too rapid to permit equalizing the pressures at the face of the dummy and in the blade path through the piping, an unbalanced thrust condition could occur. This condition would cause the rotor to "bump" the thrust bearing. On symmetrical turbine elements a similar unbalanced thrust condition could occur as a result of heater out of service operation. If heaters, operating at the same pressure zones at opposite ends of the same element, are not interconnected, a potential thrust unbalance does exist. Removal of one of these heaters from service will impart a thrust imbalance on the rotor since the flow through the blades on opposite ends of the same element will be different. Unlike the combined pressure element, operating in this mode will continuously generate a thrust imbalance. Providing an adequate cross tie in the extraction lines for these heaters will prevent this difficulty. 6.11 Other Plant Equipment The heater out of service restrictions discussed in this leaflet do not account for the limitations on steam generators, boilers, heaters, pumps, or other cycle hardware. The power plant designer is responsible for obtaining and incorporating other equipment manufacturer's limitations into the final operating rules for his plant. In fossil-fuel fired plants, the removal of feedwater heaters from service may result in thermal shocks which may exceed the operating limits of the boiler. The rules formulated for each plant must consider conditions over the entire load range and attempt to minimize overloading and shocking of all components involved, not just the turbine. Although protection of the turbine is our major consideration, protection of associated hardware in the turbine cycle must be considered. In some situations, shocks which occur to other equipment may also have a harmful
Page 14 of 14 effect on the turbine-generator. Therefore, formulate rules to protect other auxiliary equipment.
Periodic Functional Test

OP.2.21.01E-00
2008.09 2008.09 2008.09
Contents
PERIODIC FUNCTIONAL TEST ................................................................. 1 1 WEEKLY ................................................................................................. 1 1.1 1.2 1.3 1.4 1.5 Main and Reheat Steam Inlet Valves............................................... 1 Auxiliary oil Pumps and Controls ................................................... 3 Auxiliary Oil Pump Pressure Switch Setting.................................. 4 E-H Fluid System .............................................................................. 4 Extraction Non-Return Valves ......................................................... 5
2 MONTHLY .............................................................................................. 5 3 SEMIANNUALLY .................................................................................. 5 3.1 Overspeed Trip Mechanism (Overspeed Trip Test) .......................... 5 3.2 Overspeed Protection Controller........................................................ 7 3.3 Remote Trip (By Actually Tripping The Unit) .................................. 7
Page 1 of 7
PERIODIC FUNCTIONAL TEST

In addition to the tests performed during startup, functional tests of equipment at prescribed intervals are essential to insure maximum operational reliability. Test the equipment more frequently than recommended below if operating experience indicates it is advisable. Some of the leaflets in this book describe both the equipment and the test procedure. They are noted below by title and may be found in the Instruction Book Contents.
1 WEEKLY 1.1 Main and Reheat Steam Inlet Valves

A functional test of the turbine steam inlet valves can only be made while the unit is carrying load, and the BYPASS OFF mode is selected. The purpose of this test is to ensure proper operation of the main steam throttle valves, governing valves, reheat stop valves, and interceptor valves. These vital control devices might otherwise remain motionless through long periods of operation. The operation of the valves should be observed during the tests by an operator stationed at the valve locations. Movement of the valves should be smooth and free. Jerky or intermittent motion may indicate a buildup of deposits on shafts. As proper operation of these valves is vital, prompt remedial action is imperative if difficulty of any type is indicated during these tests. (1) Main steam inlet valve The throttle valve stem freedom test is to be made with the Megawatt Feedback loop in and the Impulse Pressure Feedback loop out of service. The Megawatt Feedback loop in can regulate steam valve which is not tested through the steam flow that is shutdown by the governor valve, so this will adjust the governor valves to maintain constant load during the test. Note Main steam inlet valve testing is allowed only when the controller is in single valve mode. If Main steam inlet valve testing is allowed when the controller is in sequence valve mode, the stress of control stage is too big. For safe and reliable operation of the turbine, the main steam inlet valve test can be allowed based on the turbine manufacturer's stated recommended load range. The minimum load for testing in the single valve mode is usually imposed only to eliminate
Page 2 of 7 the possibility of motoring the turbine. The test load in the sequence valve mode should be greater than the minimum load corresponding throttle pressure to prevent overstressing the control stage blading. If the valves are tested above the turbine manufacturers stated maximum recommended load, the load will drop during the test to a level that corresponds to the maximum flow that can be passed through the governor valves in one steam chest.
The stem freedom test should be made in the following steps every week: a. Press the VALVE TEST button to start test sequence of No.1 main steam valves and corresponding governor valve. VALVE TEST and VALVE STATUS display. b. Select the TV1 to (ENTER). c. Valve-Position of the main steam valves (opening percentage) will be displayed. Press (CLOSE) button. d. The left main steam valve will be closed momentarily after the left governor valve closed. e. The main steam valves will be reopened. f. Press OPEN button, to make governor valve back to its original position. g. Repeat the above test for the No.2 throttle valves and associated governor valves. h. The electrical test circuits are interlocked so that it is not possible to test both governor valves at the same time.
Page 3 of 7 If the valves test is to be made with the Megawatt Feedback loop out of service, the unit could not reach load quick feedback. Then the governor valves will not adjust automatically to maintain constant load. Therefore, if the test is made at this condition, a major load will reduce. To avoid a major load reduction, operator should comply with the recommended load range shown on above chart. (2) Reheat steam inlet valve This test can usually be conducted at any load up to maximum load with approximately 2% load reduction during the test. The test should be made in the following steps: a. Press the test button of the corresponding valve that to be tested to close RSV and IV. The actual procedure is the same as the main steam valve test. b. Press Open button. After the RSV is fully open, the IV will reopen. c. After the two valves are all fully open, repeat the test for another group of the RSV and the IV. d. The electrical test circuits are interlocked so that it is not possible to test the RSV and the IV valves in the other side at the same time.
1.2 Auxiliary oil Pumps and Controls

Auxiliary oil Pumps and Controls during normal operation of the turbine, the oil system requirements are supplied by the main oil pump. Therefore, the procedure for testing the auxiliary oil pumps with the turbine at synchronous speed differs from the procedure with the turbine on turning gear (see Preliminary Checks and Operations). During normal operation, test the pumps as described below. To remotely test the oil pumps, the bearing oil piping is provided with test solenoids which, when energized, locally reduce the pressure and activate the pressure switches. (1) AC Bearing Oil Pump Energize the solenoid valve. This reduces the pressure to a point where the pressure switch makes contact. After verifying that the bearing oil pump motor has started, deenergize the solenoid valve. (2) DC Emergency Oil Pump To test the DC emergency oil pump, follow the same instructions given above for the AC bearing oil pump.
Page 4 of 7 Once the pressure switches have operated satisfactorily, verify that the pumps are pumping oil and record the output pressures. Pump discharge pressure taps, located on the lube oil reservoir, are provided for gauges (usually supplied by the purchaser). Compare the pump output pressures with the output pressures recorded during the initial start-up of the turbine. NOTE The auxiliary oil pump output pressures measured with the turbine in normal operation are expected to be somewhat higher than the same pressures measured with the turbine on turning gear. To stop the pumps, turn each control switch to the Off or Stop position and release. The switch should return to the Auto position.
1.3 Auxiliary Oil Pump Pressure Switch Setting

The bearing oil piping is provided with bleed-off valves which are used to reduce the oil pressure locally and activate the pressure switches. (1) Open the bleed-off valve for the bearing oil pump (BOP) to locally reduce the pressure to a point where the pressure switch (63/BOP) makes contact, thereby completing the circuit to the BOP motor. Observe the setting at which the switch makes contact and the pump starts. Compare this reading to the setting given on the Turbine Control Settingsdrawing. Close bleed-off valve. (2) To check the emergency pump pressure switch setting (63/EOP), follow the same instructions given above for the BOP pressure switch. (3) To stop pumps, turn each control switch to the Off or Stop position and release. The switch should return to the Auto position.
1.4 E-H Fluid System

The items below are identified on the content describing the EH fluid system. (1) Start the EH fluid backup pump (one of the two identical pumps located near the base of the EH fluid reservoir)at least once a week. (2) Check the pressure drop across the pump discharge filters. Replace the filters when the differential pressure switch alarms. (3) Check the pressure drop across the reservoir drain return filter. Reposition the selector valve at the reservoir to the alternate filter and heat exchanger when the alarm indicates excessive pressure drop.
Page 5 of 7 (4) Check gas pressure in accumulators once a week following procedures outlined in the EH System. Additional tests and checks as well as those listed above are discussed in greater detail in other sections of the instruction book.
1.5 Extraction Non-Return Valves

It is recommended that the extraction nonreturn valves be tested weekly with the unit below 10% load. It is necessary to test at low loads to obtain low flow and low steam density for the nonreturn valve clapper shaft to rotate an amount which will be visible to the operator stationed at the valve. The valve will close only a slight amount during the test. Test trip valves are used to perform the valve tests. Complete the testing by returning the test trip valves to normal operating position and witness that the nonreturn valves return to their full open position.
2 MONTHLY
1. 2. Overspeed Trip-Electrical (see Emergency Trip System). Overspeed Trip Mechanism Oil Pressure Check Device (see separate content with
same title). 3. 4. 5. 6. 7. 8. Low Vacuum Trip (see Emergency Trip System), Low Bearing Oil Pressure Trip (see Emergency Trip System). Low EH Fluid Pressure Trip (see Emergency Trip System). Thrust Bearing Trip (see Emergency Trip System). Remote Trip (if remote trip test capability is available ). Pressure switch settings for auxiliary oil pumps. Compare oil pressures at which the
switches actually operate with the settings shown in the leaflet Turbine Control Settings. 9. Bearing Lift Oil Pumps. The test is described in the content Hydraulic Bearing Lift
System.
3 SEMIANNUALLY 3.1 Overspeed Trip Mechanism (Overspeed Trip Test)

During the life of a turbine, the set point of the overspeed weight must be verified by
Page 6 of 7 actually overspeeding the unit at least once every six months. Also verification must be made during the initial start-up period, after any major overhaul, and after work is performed on the governor pedestal which may affect the overspeed trip setting. Prior to overspeeding the turbine to check the operation of the overspeed trip mechanism, it is necessary to heat soak the unit to stabilize rotor temperatures. This procedure must be followed to avoid developing thermal stresses due to unstable temperature distributions existing in the rotor which would add to the high centrifugal stresses which occur in the rotor bores during the overspeeding. To avoid overheating the LP exhausts during the overspeed trip testing, the back pressure should be stable and not exceed the limits specified for full speed and no load. (1) Initial Start or After Overhaul
When making the initial start after installation or a major overhaul, the turbine should be overspeeded to check the overspeed trip mechanism. Using the start-up recommendations for rolling the unit to rated speed, synchronizing and applying the initial load of 5% of rated capacity, the load should be increased to 10% of rated capacity and held for a minimum period of 4 hours immediately prior to running the overspeed trip test. The 10% load level is used for soaking because this load provides enough heat, flow, and temperature to obtain the desired temperature distribution. For testing during the initial start, the 10% load is low enough to minimize damage should the unproven emergency trip system fail to close the main steam and reheat valves following a load rejection and turbine trip. Soaking at higher load levels increases the likelihood of property damage and increases the risk of injury to persons. In fact, on some units the steam supply, equivalent to 25% load, is enough to drive the unit to destructive overspeed. Thus, it is recommended that the load not exceed 10% until the overspeed trip system is checked. Maximum of 15% of rated load can be raised for the soaking load, but only if absolutely necessary. During the soaking period at load, it is important to have stable load, main steam and reheat temperature, main steam pressure, back pressure (LP exhaust),and cycle conditions. When the soaking period is completed, reduce load promptly, in 5 minutes or less, to 5% of rated load, trip the unit, and complete the overspeed test in 15 minutes to minimize chilling of the rotors. If it is necessary to shut down the unit after the soaking period at load prior to running
Page 7 of 7 the over-speed test, the overspeed trip test may be performed within two hours following the trip from 5% load. If the shutdown is longer, the load must be returned to 10% for several hours to achieve stable temperature conditions be fore running the overspeed test. (2) Semiannual Test Prior to the overspeed test, the heat soak with stable conditions is to be made a not less than 10% of rated load, and not more than the amount of load that and be removed (to 5% load)in 5 minutes without violating the "Load Changing Recommendations " curves. Trip the unit and complete the overspeed test in 15 minutes. This procedure must be followed to avoid chilling the rotors. The overspeed trip mechanism is described in a separate content Overspeed Trip Mechanism. The procedure for testing this mechanism is described in detail in the section Startup-rolling with steam bypass off and Turbine startup with bypass in service.
3.2 Overspeed Protection Controller

The OVERSPEED PROTECTION CONTROLLER should be tested when starting the turbine initially, after any shutdown or every six months whichever occurs sooner. The test can be performed in either TURBINE MANUAL or in OPER AUTO and is described in the section Starting Procedure Before Admitting Steam. The overspeed protection controller may be tested at any speed up to rated speed. The control system inhibits the test when the generator is synchronized to the line.
3.3 Remote Trip (By Actually Tripping The Unit)
Page 1 of 1
Caution for ATC Operation

OP.6.22.01E-00
2008.09 2008.09
Caution for ATC Operation

When the turbine-generator is operated in the Automatic Turbine Control (ATC) mode, the operator must assure that the recommended operating limits and precautions, load changing rates, speed hold ranges, etc., are adhered to. The operator should observe the monitored turbine variables such as the turbine steam and metal temperatures, bearing vibration, differential expansion, rotor position, etc., to assure that they are within the allowable limits. If there is any indication that the ATC program is not properly responding, such as could be caused by a malfunction in an input device, an erroneous input signal, etc., the control of the turbine-generator should be returned to the Operator Automatic Mode, and the problem should be corrected as soon as possible. On the initial start of the unit, the rotor soak period must conform to the Cold Start Rotor Warming Procedure curve. The hold period specified by the ATC is to be ignored.
Page 1 of 2
Remote Automatic Modes of Operation

OP.6.23.01E-00
2008.09 2008.09
Remote Automatic Modes of Operation

With the unit under the OPERATOR AUTOMATIC mode of operation, control of the turbine generator may be transferred to any one of the following remote control systems. 1 AUTOMATIC SYNCHRONIZER (AUTO SYNC) The automatic synchronizer is an electronic package located apart from the DEH controller. If the automatic synchronizer is to be used to place the unit on the line, the turbine speed must be within 50 r/min of synchronous speed. The control of the turbine speed may then be transferred to the automatic synchronizer by depressing the AUTO SYNC push button. The automatic synchronizer now has access to the DEH speed reference by means of Raise/Lower contact closure inputs to bring the turbine-generator to synchronous speed and to synchronize the unit. After the main generator breaker is closed, the control of the unit will automatically return to the OPER AUTO control mode. 2. REMOTE When remote control of the turbine-generator load is desired, depress the REMOTE push button. The load of the turbine-generator is now under control of the dispatching system through Raise/Lower contact closure inputs. The operator can regain control of load at any time by depressing the OPER AUTO push button.
Page 2 of 2 2. AUTOMATIC TURBINE CONTROL (ATC) The control of the turbine may be transferred to the ATC mode from any other automatic mode by depressing the AUTOMATIC TURBINE CONTROL push button. The transfer may be made at any time without any bump in speed or load. The selection of this mode enables the ATC program to accelerate the unit from turning gear operation to synchronous speed while continually monitoring the system parameters and alarms. It checks the pre-roll conditions, determines if a rotor heat soak period is required, selects the optimum acceleration rate, transfers control from the throttle valves to the governor valves, checks the pre-synchronizing conditions and engages the automatic synchronizer. It also automatically avoids speed holds in any LP blading resonant speed ranges. In addition to providing speed control capability, the ATC program also provides load control capability when the main generator breaker is closed. The load control program automatically optimizes the turbine loading rate for either an operator initiated load change or an external source initiated change. In a strictly ATC mode of control, the loading rate is the lowest of either the optimum rate as determined by rotor stress calculations, operator selected load rate, or the loading rate as an input from an external source. See the ATC content for additional information. During the operation of the turbine, whether during the acceleration period or under load, the computer will monitor the various parameters of the turbine, compare their values with limit values and print messages to inform the operator about the conditions of the machine to guide him in the operation of the unit. These messages are presented on a typewriter and on a LCD.
Page 1 of 2
Turbine Manual Mode of Operation

OP.6.24.01E-00
CompiledTang Jun CheckedWangZurong Countersign: Countersign ApprovedPeng Zeying
2008.9 2008.9
2008.9
Turbine Manual Mode of Operation

TURBINE MANUAL mode has been provided to enable power generation capability under certain contingencies. It is an open loop type of control in which the operator position the valves (by means of the Turbine Manual push buttons), observes the results, corrects the valve Position if necessary until the desired result is achieved. Therefore, the turbine speed, acceleration, load and loading rate are all directly managed by the operator, depending on how he maneuvers those valves. Since the burden on the operator is greatly increased during TURBINE MANUAL operation, the operator should not start the turbine in the manual mode unless it is unavoidable. It is assumed that the turbine operator is thoroughly familiar with the information about the control system. STARTING PROCEDURE TURBINE MANUAL operation is initiated by depressing the LATCH push button while the TURBINE MANUAL push button is lit, and holding it for two seconds. The procedure from that point on is essentially the same as for OPERATOR AUTO, keeping in mind that the digital display and data entry system is not available in the manual mode. Then proceed as follows: 1. 2. Open governor valves to wide open position by depressing the GV RAISE. The speed of the unit can now be controlled by means of the TV RAISE and TV
Page 2 of 2 LOWER push buttons and brought to a rotor-warming speed at an acceleration rate of 100 r/min. Maintain this rotor warming speed for a period indicated by the chart "Cold Start Rotor Warming Procedure. 3. Increase the turbine speed to the TV to GV transfer speed shown in the section
Cold Start Rolling with Steam at an acceleration of 100 r/min. Before transferring control from the throttle valves to the governor valves, verify that the steam chest inner wall temperature is at least equal to saturation temperature corresponding to the throttle pressure. See chart Startup Steam Conditions at Turbine Throttle. 4. a) Transfer control from throttle valves to governor valves in the following sequence: Push GV LOWER until the speed of the unit is affected by the closing of the
governor valves. b) Slowly open the throttle valves by depressing the TV RAISE push button. The TV
RAISE push button must be held in the depressed position until the TV RAISE and TV LOWER push buttons light go off. c) The throttle valves will be in the wide open position and the turbine speed is now
controlled by the governor valves. 5. 6. Increase the speed of the turbine to 3000r/min. Synchronize and load in accordance with the section Starting and Load Changing
Recommendations.
Limits, Precautions and Tests

OP.2.25.01E-00
CompiledYu Yan CheckedZhang Xiaoxia Countersign Yan Weichun,
2008.09 2008.09 2008.09
Contents
LIMITS, PRECAUTIONS AND TESTS .....................................................1 1 SUPERVISORY INSTRUMENTS ALARM AND TRIP
SETTINGS ................................................................................................1 2 BEARINGS TEMPERATURE AND PRESSURE.............................2 3 STEAM CONDITIONS TEMPERATURES PRESSURES AND MOISTURE ..............................................................................................3 4 CONDENSER VACUUM (TURBIBE BACKPRESSURE)............10 5 WATER INDUCTION ........................................................................12 6 CONTROL SYSTEM TEST ..............................................................13 7 GENERAL ...........................................................................................14
Page 1 of 21
LIMITS, PRECAUTIONS AND TESTS 1 SUPERVISORY INSTRUMENTS ALARM AND TRIP SETTINGS
1.1 ROTOR ECCENTRICITY With the rotor on turning gear, a rotor truth dial indicator reading taken at any bearing oil ring should not exceed 0.025mm total indicator reading (TIR). At shaft speeds up to 600 r/min the alarm point for shaft eccentricity at the governor pedestal is 0.076mm double amplitude. Eccentricity should be observed up to 600 r/min. Vibration is observed above 600r/min. These limits apply to 3000r/min units. 1.2 ROTOR VIBRATION The following vibration limits are recommended, measured in mm, double amplitude (peak-to-peak amplitude): 3000r/min Satisfactory Alarm
1
0.076 0.127 0.254
Trip or other Suitable action 2

1
Rebalancing is indicated if vibration is continuous and of the unbalanced type. Under
special conditions, the turbine may be run at higher vibration levels for short periods of time under close supervision.
2
Other suitable action may be load change, speed change, etc., according to specific
conditions. 1.3 ROTOR POSITION Based on a nominal thrust bearing clearance of 0.38mm and a maximum expected thrust bearing load of 4.13MPa, the alarm limit and trop limit are reached when the thrust bearing move a distance of 0.89 mm from the middle of thrust bearing tile at any directions. Trip limit value is defined of a distance of 1.0 mm. If the thrust bearing clearance is less than or greater than 0.38mm, adjust the alarm and trip limit using 1/2 of the difference between actual value and 0.38mm. 1.4 CASING EXPANSION There are no "Alarm" and "Trip" limits established for casing expansion. Turbine expansion values from this instrument should be compared to previous readings at the
Page 2 of 21 same operating conditions. Large deviations from previous values should be explained and corrected usually by greasing the sliding surface between the pedestal base and sole plate. Sometimes it is also necessary to bump the pedestal. 1.5 DIFFERENTIAL CASING AND ROTOR EXPANSION The alarm and trip settings vary with turbine configuration. Specific values will be provided in the Turbine Control Settings.
2 BEARINGS TEMPERATURE AND PRESSURE

2.1 METAL TEMPERATURE-TURBINE (1) The alarm and trip limits for bearing Babbitt temperatures depend on the type of bearing. For the Viscosity-pump journal bearing, bearing babbitt temperatures up to 91 are considered normal. The alarm should be set at 107, and the trip at 113. (2) Tilting-pad journal bearings have the same temperature limits as the viscosity-pump journal bearings above. (3) For thrust bearings, babbitt temperatures up to 85 are considered normal. The alarm setting is 99, and the trip setting is 107. The thermocouples used to measure thrust bearing temperatures are at the center of two shoes at the governor end and two at the generator end of the bearing. Each of these four shoes contains a center and a leading edge thermocouple. Temperatures from the center of the shoes should be recorded continuously on a printing recorder. The leading edge thermocouples should be monitored in case problem diagnosis is required. 2.2 OIL TEMPERATURES-TURBINE (1) Do not start the motor-operated bearing oil pump if the temperature of the oil in the oil reservoir is less than 10. For turning gear operation and during the turbine rolling period, oil temperature should be a minimum of 21. If oil temperature is between 10 and 21, the auxiliary oil pumps should operate till oil temperature more than 21. (2) For continuous operation, bearing oil drain discharge temperatures should not exceed 71. The alarm should be set at 77. Trip at 83. (3) EH Fluid Temperature a. Normal 38- 60
Page 3 of 21 b. High Temperature Alarm c. Trip Temperature 60 None
d. The pumps should not be started until fluid is 10 or higher. e. The fluid system should not be operated until fluid is 21 or higher. f. Tubing should not be routed in areas having an ambient temperature greater than 68. 2.3 OIL PRESSURE-TURBINE (1) Units using the supervisory instrument have thrust alarms and trips initiated by the rotor position instrument. Set point refers to "Turbine Control Settings". (2) Bearing oil pressure at the centerline of the turbine-generator unit should be 0.083~0.124MPa(g). Alarm at 0.048~0.062MPa(g). Trip at 0.034~0.048MPa(g). (3) EH fluid Pressures a. Normal b. Low Pressure Alarm c. Trip Pressure 12.41~15.17MPa(g) 10.68~11.38MPa(g) 9.3MPa(g)
2.4 OIL AND METAL TEMPERATURES-GENERATOR/EXCITER Type of Measurement Metal Oil Drain r/min Normal up to Alarm 3000 3000 85 71 99 77 Trip 107 --
Oil and metal temperatures-generator/exciter just for information, detail specifications refers to Generator Instruction book.
3 STEAM CONDITIONS TEMPERATURES PRESSURES AND MOISTURE

(1). Initial first stage metal temperature and/or IP blade ring metal temperature below 204 defines the condition when cold starting procedures apply. (2). When starting a warm or hot turbine unit (initial first stage metal temperature of 204 or higher), it is recommended that the steam conditions at the throttle valve inlet be controlled to produce first stage steam temperatures which are within a range of not more than 56 below or more than 111 above the initial first stage metal temperature. (3). To facilitate matching of first stage metal and steam temperatures on start up, start up steam conditions at the throttle valves should be selected on the following basis:
Page 4 of 21 a. . For cold starts use steam at the pressures and temperatures shown on Startup Steam Conditions. Starting conditions for a cold turbine should be selected so that there is at least 56 of superheat in the steam to the throttle valves. b. . For hot starts use steam in the acceptable range, but at low pressure and high temperature to minimize the temperature loss from throttling the steam through the throttle and/or governor valves. (4). The allowable temperature differences in steam chest metal, measured by deep and shallow thermocouples in the steam chest wall, are shown on Figure 1 for fossil units. Figure 1 Steam Chest Metal Temperature Allowable Difference-Deep and Shallow Thermo-couples
EXAMPLE 1. WHEN THE STEAM CHEST DEEP METAL THERMOCOUPLE INDICATES A TEMPERATURE OF 316C THE ALLOWABLE DIFFERENCE BETWEEN DEEP AND SHALLOW TEMPERATURES IS 113C.
(5). The steam delivered through any turbine throttle valve must be within 14 of the steam delivered simultaneously through any other throttle valve. During abnormal conditions, this difference may be as high as 42 for periods of 15 minutes maximum duration provided that such occurrences are at least four hours apart. (6). The steam temperature at the turbine throttle valve inlet connections shall average not more than rated temperature over any 12-month operating period. In maintaining this average the temperature during normal operating conditions shall not exceed rated
Page 5 of 21 temperature by more than 8. During abnormal operating conditions the temperature at the turbine throttle valve inlet connection shall not exceed rated temperature by more than 14C for operating periods totalling not more than 400 hours per 12 month operating period, nor exceed rated temperature by more than 28C for swings of 15 minutes duration or less aggregating not more than 80 hours per 12- month operating period. (7). The steam temperature at the turbine reheat stop valve inlet connections shall average not more than rated reheat temperature over any 12- month operating period. In maintaining this average the reheat temperature during normal operating conditions shall not exceed rated reheat temperature by more than 8C. During abnormal conditions reheat temperature shall not exceed rated reheat temperature by more than 14C for operating periods totaling not more than 400 hours per 12- month operating period, nor exceed rated reheat temperature by more than 28C for swings of 15 minutes duration or less, aggregating nor more than 80 hours per 12- month operating period. In maintaining the above reheat temperature averages the steam delivered through any hot reheat stop valve must be within 14C of the steam delivered simultaneously through any other hot reheat stop valve. During abnormal conditions the difference can be as high as 42C for periods of 15 minutes maximum duration providing the occurrences are at least four hours apart. (8). For adequate steam chest warming prior to transferring from throttle valve speed control to governor valve speed control the temperature of the inner surface of the steam chest measured by the thermocouple closest to the inner wall (deep thermocouple) should be equal to or greater than the saturation temperature corresponding to the prevailing steam pressure ahead of the throttle valves. At transfer, the temperature of steam to the throttle valves should equal or exceed values given by the curve labeled MINIMUM THROTTLE VALVE INLET STEAM TEMP. AT TRANSFER in Startup Steam Conditions. These temperatures should help prevent the formation of large quantities of water when the steam chest pressure is raised as a result of transferring speed control to the governor valves. An alternate method of arriving at the steam chest inner surface (metal) temperature to determine if the speed control transfer can be made is to solve the following equation which is also used in the DEH computer software: Ts=T1+1.36(T2-T1)
Page 6 of 21 Where Ts = Steam Chest Inner Surface Metal Temperature T1 = Shallow Thermocouple Temperature Reading T2 = Deep Thermocouple Temperature Reading (9). Where the main steam inlet and hot reheat inlet connections are arranged in the same turbine casing, temperature differences between the main steam and reheat steam inlets must be controlled to optimize the design life of the apparatus. The difference between the main steam and hot reheat temperatures should not deviate from the difference at rated conditions by more than 28. During abnormal conditions, deviations as large as 42 are acceptable provided the differences are limited to a reduction of the hot reheat temperature with respect to the main steam, inlet temperature. These limits, in general, are assumed to apply at operating conditions near full load. As the load reduces, it is assumed that the hot reheat temperature will be below the main steam inlet temperature, in which case the difference may approach 83 as the load approaches zero. Short time cyclic temperature fluctuations are to be avoided. When the unit is at full load, the 28 limit can be with either the main steam or hot reheat 28"C higher than the other. See Figure2. All other temperature limits 42C and 83C apply only with reheat temperature lower than main steam temperature. IN ADDITION, NONE OF THESE ALLOWANCES CAN BE USED TO EXCEED THE LIMITATIONS PLACED ON MAIN AND REHEAT STEAM DEVIATIONS FROM RATED CONDITIONS.
Page 7 of 21
(10). The temperature difference between the cylinder cover inner surface and the cylinder base inner surface of the HP and IP inner and outer cylinders should not exceed 56C with the base colder. Alarm at 42C; trip at 56C. Sudden increases in the normal temperature difference between a cylinder base and cover with the base colder indicates the presence of water in the base of the cylinder. Drains should be opened immediately. When an extraction connection is in the turbine cylinder cover instead of the base, consult manufacturer for the temperature difference limits between the base and cover and the thermocouples to be used for the comparison to determine if water is present. (11). Steam supplied at any turbine gland should contain at least 14 of superheat. (12). The temperature limits for steam measured in LP turbine gland cases are 121 minimum and 177 maximum. The gland system desuperheater should be set at 149. These limits cannot be applied to steam throttled to lower temperatures to seal low
Page 8 of 21 pressure turbine glands. (13). The temperature difference between sealing steam and rotor metal in glands of HP, IP or HP-IP turbines should be limited to 111. For the effects of greater differences refer to Chart Gland Sealing Steam Temperature Recommendations. (14). Manufaturer recommends that the gland system spillover steam be routed to the main condenser as insignificant heat rate loss is involved. However, the purchaser may elect to route the spillover steam to an LP heater. If the heater option is selected, it is the purchasers responsibility to limit the temperature of the spillover steam, or steam from any source, when the heater is out of service so that the temperature of steam back flowing to the turbine through the extraction pipe is not more than 56 higher than the temperature of the turbine extraction zone where the steam enters the turbine cylinder. (15). On fossil units, primary desuperheating of steam to low pressure turbine glands is accomplished by heat loss from the bare, unsinuated gland steam supply piping in the condenser space to minimize the use of spray water. The final increment of desuperheating, and the control of steam temperature in the glands, is accomplished by the use of a (water) spray desuperheater mounted in the common gland steam supply header to the low pressured turbine glands. To permit this system to function effectively, steam to the desuperheater should be about 315 to ensure that the main unit LP glands can operate in the range of 121 To 177. If boiler feed pump turbine (BFPT) and main turbine are used together, gland steam for the BFPT is taken from the low pressure turbine gland steam header upstream of the desuperheater and cooled enroute to the BFPT glands by a separate desuperheater. Should the purchaser attempt to desuperheat the gland sealing steam for this turbine by taking it from the common gland steam supply header downstream of the desuperheater for the LP turbine glands, steam at this location may range from 260-315 depending on the amount of desuperheating in the gland steam supply lines in the condenser neck. This is too hot for the glands of the BFPT. Hence, a separate desuperheater is used. When the BFPT is furnished by another manufacturer for use with a main unit, and gland steam is to be supplied to the BFPT from the main unit gland system. The purchaser should provide a separate desuperheater for the BFPT glands. (16). To avoid heating the turbine exhaust beyond allowable limits, apply gland sealing steam, start air removal equipment and maintain as high a vacuum as possible during the
Page 9 of 21 starting period. Exhaust temperature limits are as follows: a. Turbine exhaust temperature (steam) should not exceed 79 for continuous operation or 121 for periods of about 15 minutes. Should temperature above the continuous operating limit occur, reduce these temperatures to the continuous operating range in fifteen minutes or trip the unit. These limits apply with the exhaust hood sprays out of service. The LP turbine exhaust steam temperature limit with the exhaust hood sprays in service is the saturation temperature corresponding to condenser pressure. b. Turbine exhaust temperature (steam) for unusual conditions should not exceed 121. For example, if steam is bypassed to the condenser before the turbine is rolled, the maximum, allowable exhaust temperature is 121 providing no problems develop. However, experience shows that under some conditions (such as cold start) heat rising from the condenser will cause a "rotor short" differential expansion condition which results in rubs between rotating and stationary parts. In the past this has usually been detected with the unit on turning gear when the rotor locked with turbine exhaust steam temperatures less than 93. c. A separate exhaust hood spray system is provided for each low pressure cylinder. The purchaser must furnish an individual on-auto-off switch for each spray system to facilitate use of the sprays to handle certain abnormal operating conditions that may occur in individual low pressure cylinders. d. The temperature difference between multiple adjacent or nonadjacent LP outer casings should not exceed 17, alarm at 11 differential and trip the unit at 17 differential. (17). The average initial pressure at the turbine inlet over any 12 months of operation shall not exceed the rated pressure. In maintaining this average, the pressure shall not exceed 105% of the rated pressure. Further accidental swings not exceeding 20% of the rated pressure are permitted, provided that the aggregate duration of such swings over any 12 months of operation does not exceed 12 h. An increase in initial pressure will normally permit the turbine to generate power in excess of its normal rating, unless action is taken through the control system to restrict the steam flow rate. The generator and associated electrical equipment may be unable to accept such additional output, and undesirable stresses may also be imposed on the turbine; the purchaser shall accordingly provide load-responsive protective means to limit the turbine output under such circumstances.
Page 10 of 21 (18). The pressure at the exhaust connection of the high pressure turbine shall not be greater than 25% above the highest pressure existing when the high pressure section of the turbine is passing the maximum calculated flow with rated pressure and normal operating conditions. Suitable relief valves must be provided by the Purchaser. (19). If an initial steam pressure limiter [Throttle Pressure Limiter (TPL)] is used it is usually set to cut in on decreasing throttle pressure at 90% to 95% of rated pressure. With the regulator in service, load reduction is proportional to pressure reduction to a preset minimum limit of 20% to 25% load. If the throttle pressure falls below 80% of rated pressure, or if throttle or reheat temperature drops uncontrolled more than 66 (66 in less than 30 minutes) remove load and trip the unit.
4 CONDENSER VACUUM (TURBIBE BACKPRESSURE)

(1). Maximum allowable low pressure turbine exhaust pressure for continuous on-line operation above 10 percent load is 18.6kPa abs. Alarm and trip settings for units are: Description Alarm Trip Alarm Automatic Trip Unit (kPa abs) 16.9 18.6 20.3
(2). Vacuum should be maintained on a trip out or normal shutdown until the unit coasts down to about 10% of rated speed provided that no emergency is involved in the trip out or shutdown that requires vacuum to be broken immediately after the turbine throttle, governor, interceptor, and reheat stop valves close. Vacuum should be broken immediately after a unit is tripped and in free coastdown if any condition exists when possible damage to the unit can be reduced by shortening coastdown time. Examples of incidents requiring vacuum to be broken immediately after a trip include, but are not restricted to: loss of AC power, loss of DC power, low bearing oil pressure, loss of lubricating oil, loss of cooling water to turbine oil coolers, thrust bearing trip, water in the turbine, any indication of rubbing between rotating and stationary parts, or excessive vibration on coastdown. (3). Avoid breaking vacuum before critical drain valves are open. This recommendation does not apply in an emergency requiring vacuum to be broken immediately. (4). Avoid at all times leakage of steam into the turbine casings with the rotors at rest.
Page 11 of 21 (5). Avoid air being drawn through the glands with the rotors at rest. Therefore, do not operate the air ejectors or vacuum pumps without sealing steam on the turbine glands. The unit should always be put on turning gear before admitting steam to the turbine glands. (6). The Purchaser must provide an adequate supply of steam to seal the turbine glands at all times, including during coastdown following a unit trip. This is essential to insure that air does not leak into the turbine through the rotor glands causing thermal distortion (chilling) of the gland cases which may result in damage from rotor vibration induced by rubs between gland seals and the rotors. (7). On some units using seawater for circulating water, condenser circulating water channels are periodically back flushed with warm water (about 46-49) to kill some marine life. To do this, the circulating water is heated in the condenser tubes by raising low pressure turbine exhaust pressure. Before committing to such a procedure, obtain approval of the specific details from manufacturer as there are limits on turbine operation for this procedure, including load and exhaust pressure. (8). The large blading at the exhaust end of the LP turbine blade path passes through several resonant speed ranges whenever the unit is rolled to rated speed. Do not hold speed in these resonant ranges for extended periods as extensive blade damage may result. The magnitude of the condenser pressure may have a significant influence on the possible damage resulting from operating in blade resonant speed ranges. The actual resonant range for each unit will be in the instruction book. (9). Pressure differences between active and inactive condenser result in uneven flow distribution to the low pressure turbine blading resulting in possible operating difficulties. The maximum permissible pressure difference between multiple condensers (or condenser Zones) is 8.6kPa(a); alarm at 6.9kPa(a) differential and trip the unit at 8.6kPa(a). We recommend that the turbine be removed from service if it is necessary to remove one full condenser from service. (10). If detail announce received in advance, the unit which has multiple LP turbines can be operated with one full or part condenser out of service. Necessary limits should be put before operating as following: a. The area of the condenser or part condenser in and out of service should be large enough to meet all operating limits and precautions. b. Comply with the load limits. Nominal minimum load is 20% rated load, and maximum
Page 12 of 21 load is 80%. The unit precise load limit should be determined before operating at this abnormal condition. c. The LP turbine exhaust pressure must be limited in normal range. d Should comply with other operation limits, precautions of turbine and cycle systems.
5 WATER INDUCTION
(1). For detailed design recommendations see Water in The Turbine of this manual. (2). Drain Systems-Fossil-Fueled Units A. All turbine drains and other drains critical to turbine safety must: a. Be open when the unit is out of service until the turbine is cold. b. Be opened before the turbine is started and before gland steam is supplied to the glands. c. Remain open on increasing load until the unit is carrying 10% of rated load for drains from sources upstream of the turbine reheat stop valves. d. Remain open until the unit is carrying 20% of rated load for drains from sources downstream of the turbine interceptor valves. e. Open on decreasing load at 10% of rated load and remain open below 10% of rated load for drains from sources upstream of the turbine reheat stop valves. f. Open on decreasing load at 20% of rated load and remain open below 20% of rated load for drains from sources downstream of the turbine interceptor valves. B. Drain pipe thermocouples should be provided for startup by the purchaser as a permanent installation. On every startup, monitor each drain pipe thermocouple over the operating load range up to the point where drains are closed. These thermocouples should be the strap-on, spring loaded type that press against the outside of the pipe. It is not necessary to penetrate the pipe or peen the thermocouple into a small hole drilled into the pipe wall. The thermocouples should be located at least 1220 mm but not more than 1830 mm downstream of each drain valve including the two drain valves for the turbine steam inlet loops. Each (turbine) steam inlet loop drain should also have a thermocouple installed at about the mid-point between the source and the orifice block. The drain lines and valves should all be insulated from the source to a point 915 mm past the thermocouples. Insulation thickness should be that required for the maximum temperature of the drain source at any operating condition regardless of whether or not normal
Page 13 of 21 operating procedures require the drain valves to be open when these maximum condition exists. (3). On initial startup, read and record the pressure gauge indication on each drain manifold with the unit on turning gear and at each speed and load hold while the drains are open (usually up to 20% load). If the pressure in any manifold exceeds the pressure of the lowest pressure source routed to that manifold, shut the unit down and correct the problem. (4). When the boiler is tripped through loss of firing or other causes, the turbine unit should be tripped immediately. (5). Do not admit steam to the turbine after the boiler fires have gone out. (6). A number of cold reheat piping systems and turbines have been damaged by water hammer in steam (clod reheat) lines when turbines were latched-up for startup. Therefore, do not latch-up a fossil turbine if there is water in the cold reheat lines.
6 CONTROL SYSTEM TEST

The frequency of the periodic functional tests listed below should be increased if operating experience indicates that more frequent testing is required. TEST OVERSPEED Mechanical Overspeed Overspeed Trip Mechainsm Oil Pressure Check Overspeed Protection Controller Solenoid Trip STEAMINAET VALVES Throttle Valves Governor Valves Reheat Stop Valves Interceptor Valves Throttle Pressure Controller PROTECTIVE TRIP SYSTEM Low EH Fluid Pressure Monthly Weekly Weekly Weekly Weekly Twice a year Twice a year Monthly Twice a year Twice a year OFF LINE ON LINE TEST FREQUENCY
Page 14 of 21 TEST Low Bearing Oil Pressure Low Vacuum Turbine Overspeed-Electrical Purchasers Remote Trip (Optional) Thrust Bearing Trip PROTECTIVE TRIP SYSTEM SETPOINTS Low EH Fluid Pressure Low Bearing Oil Pressure Low Vacuum Electrical Overspeed LUBRICATION OIL SYSTEM Bearing Oil Pump (BOP) Running Seal Oil Backup Pump (SOB) Running Emergency Oil Pump (EOP) Running Oil Pump Pressure Switch Setpoints Bearing Lift Pumps SEAL OIL SYSTEM Air Side Seal Oil Backup Pump Pressure Switch Setpoints Backup Tests EH FLUID SYSTEM EH Fluid Standby Pump ETRACTION SYSTEM VALVES Air Test Mechanical Test Weekly Monthly Weekly Weekly Monthly Monthly Weekly Weekly Weekly Monthly Twice a year Twice a year Twice a year Twice a year Twice a year OFF LINE ON LINE TEST FREQUENCY Monthly Monthly Monthly Monthly Monthly
7 GENERAL
(1). Avoid all excessive and unnecessary thermal cycling of heavy metal parts. (2). The damaging effect of transient operation on the rotor is dependent on the magnitude of change in steam temperature at the rotor, the rate of this change and the number of repetitions of heating and cooling cycles.
Page 15 of 21 (3). The overspeed trip will normally be set to trip the unit at 111% of rated speed. Some turbines may require other overspeed trip settings. (4). Immediately prior to making the initial check of the emergency overspeed rip devices, operate units at 10 percent of rated load for 4 hours. The purpose of this load hold is to stabilize rotor temperatures at the 10 percent load level to avoid adding the thermal stresses inherent in an unstable condition to the higher stress from increased centrifugal forces generated at overspeed. Ten percent load is both a minimum and maximum for the initial check of emergency trip devices and subsequent checks following maintenance that physically disturbs these devices. Values above 10 percent may lead to increased damage in the event of a malfunction which causes all or some of the main and reheat steam valves to remain open should a trip occur during the pre-overspeed rotor soaking period. Values of less than 10 percent may require substantially longer rotor soaking times to stabilize temperatures, increase the likelihood of motoring the turbine and increase the likelihood of unacceptably high blade path temperatures in the low pressure turbine. THE PURCHASER SHOULD ENSURE THAT THE START UP STEAM SUPPLY IS ADEQUATE AND CONTROLLABLE SO AS TO PERMIT OPERATION AT 10 PERCENT OF RATED LOAD FOR INITIAL START UP AND THEREAFTER FOR ALL STARTUPS in accordance with recommended rolling and loading rates. If the temperatures of high and intermediate pressure rotors are above 121, normal operating loads greater than 10 percent can be used for rotor soaking after the initial startup. However, unstable rotor temperatures may exist during the overspeed test if there is no hold at low load to allow temperatures to stabilize after reducing load from the operating value in preparation for a trip from low load to make the overspeed check. Therefore, if rotor temperatures are not above 121, reduce load to 10 percent of rated load in accordance with information in the turbine instruction book and soak at 10 percent load for the required period. Whether or not a heat soak is required, once started, the test should be made promptly to reduce the chilling effect of the steam flow during the test. (5) A flow of 2 to 3% of the maximum calculated throttle flow should be adequate to bring a unit to rated speed. However, we recommend that 5% of the maximum calculated throttle flow be used when sizing equipment or providing steam generation capacity for start up.
Page 16 of 21 (6) It is recommended that minimum load for normal on-line operation be 5% of rated load. (7) Auxiliary load may be carried on manufacturer turbine-generator units after a major load loss in which the generator separates from the system providing the purchaser is willing to accept the reduction in rotor life inherent in such operation. Most turbine-generator units are designed to withstand complete isolation from the system and remain in service at no load or at an auxiliary load level. However, it should be recognized that some of the larger plants now in operation, and under construction, have plant control interlocks which automatically trip the complete plant in the event of load separation. The transient thermal stress in the turbine rotor is a factor to be considered when suddenly dropping from full power output to auxiliary load and the subsequent rapid application of load after the connection to the system is reestablished. The immediate effect is an instantaneous drop in first stage temperature of about 139, followed by a further decrease of 111 in about 15 minutes as the superheater outlet temperature adjusts to the newly established firing rate. This drop in first stage temperature produces a peak stress in 10 to 15 minutes after initiation of the transient which decays slowly to zero in about one hour. If auxiliary load is maintained for an hour or more, the rotor is force-cooled to a new equilibrium state. The subsequent reloading should then be performed at a moderate rate in order to avoid a large thermal stress in the opposite direction. For a typical 3000 r/min rotor, the peak stress associated with dropping from full load to a auxiliary load can be expected to initiate cracking in the rotor after 100 to 400 cycles of complete stress reversals. A single cycle of this magnitude would, therefore, account for approximately 0.25% to 1% of the total fatigue capacity of the rotor for normal load changes, but this reduction is not excessive unless many such transients occur. To minimize the accumulation of rotor fatigue damage, it is recommended that auxiliary load operation following a load loss occur only when the system conditions make it absolutely necessary. If auxiliary load is carried on unit turbine-generator, instruments should be closely observed during these periods of light load operation, particularly the turbine differential expansion meter (s). If the instruments indicate that continued operation at light load will
Page 17 of 21 cause allowable operating limits to be exceeded, the unit must be removed from service or sufficient load applied to reestablish safe operating conditions. The minimum allowable load when connected to the system is 5 percent of rated load. The minimum allowable load when disconnected from the system is auxiliary load as described below. Loads of less than 5 percent are allowed when the generator is disconnected from the system because the turbine cannot be motored. Hence, while overheating of low pressure end blading is a concern at the low flows involved in either case, unacceptable overheating of low pressure end blading and other blading in the unit is much more likely when operating at very low loads connected to the system than when operating at the same low loads disconnected from the system. When carrying auxiliary load disconnected from the system, the governor valves control turbine speed. Should the governor valves close for any reason, steam flow is cut off and turbine speed decreases until steam flow is restored or the unit comes to rest. This is not the case when the generator is connected to the system. In this case, any perturbation that increases system frequency can cause the governor valves to move in the closed direction. If throttle steam flow is cut off or reduced too much, the generator will act as a motor to drive the turbine at rated speed, but overheating of blading is likely because of insufficient cooling steam flow through the turbine. When a generator acts as a synchronous motor to drive the turbine, this is called conventional motoring which should not be confused with the condition that exists when the generator is connected to the system at other than synchronous speeds. To minimize the likelihood of conventional motoring we recommend a minimum load of 5% of rated load when the generator is tied to the system. (8). Coastdown time following a turbine-generator trip differs significantly from unit to unit for a number of reasons with inertia of the rotors and condenser pressure during the coastdown having the greatest influence. Batteries for emergency DC power should be sized for coastdown time based on maintaining vacuum in the condenser. To assist our customer with sizing these batteries, we will provide DC power requirements for the turbine-generator-exciter during coastdown along with the calculated time to bring the rotors to rest both when maintaining vacuum and breaking vacuum. (9). Crossties for flow equalization may be required between the purchasers main steam pipes for fossil units and between hot reheat pipes of fossil units. These crossties may be needed for valve testing or normal operation or both. Whether or not crossties are needed
Page 18 of 21 depends on a number of factors such as steam generator design, the number of pipes and piping arrangement. (10) A turbine-generator unit should not be motored for extended periods. It is recommended that such operation be limited to not more than 1 minute of inadvertant motoring. (11). Anti-motoring schemes which emphasize overspeed protection should be designed not only to provide assurance that throttle, governor, interceptor, and reheat stop valves are closed before the generator is separated from the system, but also to provide assurance that feedwater heaters or extraction system are not supplying sufficient fluid to the turbine to cause unacceptable overspeed. Out of 14 reported overspeed incidents, 5 were caused by extraction non return valve malfunctions or failures and none were attributed to turbine main steam or reheat valves vailing to close. Therefore, manufacturer does not recommend valve limits witches in anti-motoring schemes devised primarily for overspeed protection. These switches do not protect against the feedwater heater, extraction system or any external steam supply that can bypass the turbine main steam or reheat steam valves and enter the turbine. In addition, some limit switches may not be sufficiently reliable for this application. When the experience of a specific operating company indicates that limit switches are sufficiently reliable to meet their requirements, and they elect to use them, they should be arranged with the throttle and governor valve switches paralleled and in series with paralleled interceptor and reheat stop valve switches. In addition, protection against fluid flow from the feedwater heaters and extraction system must be included in the scheme. Reverse current relays are preferred for this duty. The current trend in anti-motoring circuits is to emphasize overspeed protection at the expense of motoring protection. For years, motoring for more than 1 minute has been unacceptable. Nothing has changed. Motoring in excess of 1 minute should be avoided, but if it is done for overspeed protection, the purchaser must accept responsibility for any damage that results. (12). When an auxiliary boiler is provided in a power plant to supply miscellaneous quantities of steam for such purposes as gland sealing or deaerator pegging, the type of boiler and the pressure and temperature rating should be considered carefully. When selecting the boiler, verify that the pressures and temperatures required can be obtained over the load range. For example, an auxiliary boiler rated at 4536kg/h at 316 could
Page 19 of 21 only provide steam at 204 when steam generation was limited to 9072kg/hr for sealing turbine glands. This prevented matching steam and rotor metal in the gland areas within required temperature difference limits for hot starts. The temperature and pressure ratings of an auxiliary boiler should be carefully selected with due consideration of the requirements of Gland Sealing Steam Temperature Recommendatios and the reduction in temperature when throttling auxiliary steam to the turbine gland system. (13). If reheat attemperating spray water is used, the following conditions must be observed: Using the maximum calculated heat balance as a base, the quantity of reheat attemperating spray water must be measured. The load must then be reduced from the load shown on the base heat balance by 0.6% for each 1% of reheat attemperating spray water measured as a percentage of throttle flow shown on the base heat balance. (14). Manufacturer furnishes a dump valve on each reheat stop valve of many units. When the unit trips, these dump valve vent steam from the chamber at the internal end of the reheat stop valve dapper shaft. The clapper shaft of each reheat stop valve has one end exposed to atmosphere and one end to full reheat pressure. In operation, the net force caused by this pressure difference pushes the shaft towards the atmospheric end so that a shoulder on the shaft seats firmly against a spherical washer. This contact forms metal-to-metal seals which help prevent steam leakage along the clapper shaft to atmosphere. When the unit trips, the pres-shaft must be eliminated quickly to reduce friction between metal surfaces of the seal. This helps prevent unacceptable, frictional resistance to closure of the reheat stop valves. Each line from these valves to the condenser must be sized for a maximum pressure drop of 0.207MPa (including exit losses at the condenser) when passing 1815kg/hr of steam at the reheat enthalpy given on the maximum calculated heat balance. The maximum allowable pressure at the discharge (purchasers connections) of the dump valves is 0.234MPa. The purchaser's vent lines should be larger than the connections on the dump valves, and may be several sizes larger. No other valves, or restrictions such as orifices, are permitted in vent lines. These vent lines must be routed to separate connections at the condenser. (15). To avoid overheating HP turbine blading immediately following a high load turbine trip or load loss, manufacturer furnishes (if require) the ventilating valves for HP turbine elements requiring ventilation because following a trip from high load, windage heating may increase the temperature of steam bottled-up in the HP blade path enough to damage
Page 20 of 21 the blades and other turbine components. The temperature increase occurs rapidly and to avoid unacceptable temperatures, ventilation is required. Some HP turbine elements have sufficient internal ventilation so that separate vent valves are unnecessary. However, some HP turbine elements require supplementary ventilation. When vent valves are provided the discharge of these valves must be routed by the purchaser to individual connections on the condenser wall or to individual connections on a short manifold mounted on the condenser wall. Only the disconnected to this manifold. The flow area between the condenser wall and internal impingement baffles over the vent valve discharge openings in the condenser must be large enough to minimize restriction to vent flow into the condenser, but not less than 2.5 times each vent line or manifold cross-sectional area. There must be no other valves or restrictions, such as orifices, in the vent lines. Since the increase in the temperature of bottled-up steam in the HP blading occurs rapidly, vent valves must open quickly. To avoid restricting the discharge of air from the vent valve actuators on a trip or load loss, and thus slowing valve opening, do not use air piping sizes smaller than the 20mm recommended by manufacturer. Also, locate the 20mm solenoid dump valve connection close to the vent valve actuators in the common airline before it separates to the two valves. Design the air piping to permit the solenoid to be close to each actuator. There should be a vent connected from one main steam inlet loop from each steam chest. (16). Nonreturn valve (NRV) actuators should close in 0.5 to 1 second maximum on load loss or turbine trip involving separation of the generator from the electrical system to effectively back-up the other (two) clapper closing forces. To accomplish this rapid closure, the purchaser must furnish a three-way solenoid valve immediately adjacent to each NRV actuator to dump the air in the required time. Experience has shown repeatedly, that without adequate capacity to dump air from NRV actuators, these actuators close in 3 to 4.5 seconds. Closing times of these magnitudes are unacceptable for both the prevention of excessive overspeed and water damage to the turbine. When solenoid dump valves are used as recommended, they can also be controlled to close NRV actuators on high level in associated feedwater heaters as required by both manufacturer and the ASME recommendations to minimize water damage to turbines.
Page 21 of 21 When separate solenoids are used as recommended, the oil operated air pilot valve furnished by manufacturer is used to supply air to NRV actuators and serve as a back-up dump valve to the occasional solenoid valve that malfunctions. (17). For many years, manufacturer producted steam turbines have been equipped with a steam cooling system to reduce the temperature of the reheat steam which bathes the blade roots and rotor at the inlet to the intermediate pressure turbine(IP). This cooling steam is required to improve the creep strength of the blade roots and rotor in the affected area and to reduce the likelihood of rotor bowing. Considering the serious consequences
of having insufficient cooling steam, it is essential that an adequate supply be provided whenever the unit is in operation and reheat temperature is above 482. The cooling steam flow paths of combined high pressure-intermediate pressure turbine elements are internal and cannot inadvertently be blocked (unless altered during a shutdown for repairs). Separate IP turbine elements have a combination of internal and external folw passages for cooling steam which can be blocked by closed valves. By flanges containing blanks for blowdown, or foreign material in the pssages. For this reason manufacturer recommends that: a. There be no valves in cooling steam pipes; b.There be no flow restrictions in cooling steam pipes except the flow measuring device provided by manufacturer; c. There be a complete check of the cooling steam system before initial startup of the unit, before any restart following disassembly of the IP element, and before restart after maintenance which otherwise disturbs the cooling steam flow passages. This check is to ensure that the cooling system does not contain closed valves, solid spacers in flanges or other foreing materal that blocks or restricts flow. The portion of the system inside the IP cylinders must be inspected after the IP is assembled and before the cooling steam pipes are connected to the cylinder. If a preheating system is used on unit which requires a valve in the cooling steampipe, it is imperative that the purchaser consult manufacturer about essential protective provisions.
Page 1 of 1
Turbine Speed Hold Recommendations

OP.2.51.01E-00
2008.09 2008.09
Turbine Speed Hold Recommendations

Do not hold speed in a resonant speed range for an extended period. If a hold is necessary, reduce speed below the resonant range before holding. The LP turbine blade resonant speed range should be avoided which are shown cross hatched below. The turbine-generator shaft critical speed refers to drawing Shaft System Alignment. For a cold start, hold the speed out of blade resonant speed range and shaft critical speed, for the warming period determined from the curve cold-start rotor warming procedure.
1475 1620 1775 1950 2120 2295 2515 2820 3000 (r/min)
500 0
1000
1500
2000
2500
This curve is applicable for the turbine with L-0 blade height is 905mm and L-1 blade height is 518mm.
Page 1 of 1
Cold Start Rotor-Warming Procedure OP.2.52.01E-00
2008.09 2008.09
COLD START ROTOR-WARMING PROCEDURE

This procedure consists of accelerating the turbine to a speed specified on the chart Turbine Speed Hold Recommendations and holding at that speed for a warming period determined from the curve below. Prior to the first attempt to roll the turbine, observe the First Stage Metal and the IP Blade Ring temperatures and use the lower temperature reading to determine the rotor warming period from the curve. This rotor warming period begins after the IP inlet steam temperature reaches a minimum of 260 . And rotor-warming is not necessary for no-bore rotor from thermal stress side.
First Stage Metal or the IP Blade Ring temperatures

Page 1 of 3
Start Recommendations For Rolling & Minimum Load OP.2.53.01E-00
2008.09 2008.09
START RECOMMENDATIONS FOR ROLLING & MINIMUM LOAD

EXAMPLE Determine the time to roll to rated speed (3000r/min), synchronize and hold at minimum load with first stage metal temperature at 260 prior to rolling off turning gear, and throttle steam conditions existing at no load synchronous speed at 6.86MPa-425. During the minimum load hold, the steam inlet conditions increase to 10.3MPa-510. Single valve control is used during the synchronization and minimum load operations. PROCEDURE Enter Figure 1 at throttle conditions 6.86MPa 425 and project to the single-valve 5% minimum load line in Figure 2. The first stage steam temperature for these conditions is indicated as 360. Project the 360 steam temperature to the 260 Initial First Stage Metal temperature line in Figure 3 to determine a mismatch of steam-metal = 100. Enter Figure 4 with the 100 mismatch to the Roll Time line. Roll time to synchronous speed is determined as 22 minutes. Project the 100 mismatch line to Figure 5. It crosses the line marked 0 First Stage Steam Temperature Rise During Hold. This intersection indicates that 5% minimum load should be held for 6 minutes if there is no first stage steam temperature change during the hold. However, in the example the steam inlet conditions are expected to increase during the minimum load hold; this requires the hold to be extended. To determine the total length of time to remain at 5% minimum load, enter Figure 1 at the 10.3MPa -510 steam conditions that are expected to be reached at the end of the 5%
Page 2 of 3 load hold. Project to the single-valve line in Figure 2. The first stage steam temperature is 432. The rise in first steam temperature is 432-360=72 during the hold. In Figure 5 extend the initial 100 mismatch to a 72 First Stage Steam Temperature Rise point. A hold time of 45 minutes is indicated at minimum load. NOTES 1. If the throttle steam conditions produce a first stage steam temperature cooler than the
metal temperature as indicated by the hatched region below the exact match line in figure 3. The unit should be rolled to rated speed in 10 minutes, synchronized and minimum loaded as indicated in Figure 4. There is no minimum load hold period required. Extending the rolling and loading time will force cool the turbine metal. 2. Figure 3 can be used as a guide to select throttle conditions in Figure 1 which will better match the residual first stage metal temperature in order to minimize thermal stresses and starting time.
Page 3 of 3
Page 4 of 3
Start recommendation for rolling and minimum load
Page 1 of 2
Startup Steam Conditions

OP.2.54.01E-00
2008.09 2008.09
STARTUP STEAM CONDITIONS

In order to avoid thermal shocking the steam chest, Curve 1 shows the desirable relationship between throttle valve inlet pressure, throttle valve inlet steam temperature and Steam Chest Deep metal temperature that should exist before transferring speed control from the throttle valves to the governor valves. And Curve 2 shows desirable relationship between interceptor valve inlet pressure and interceptor valves inlet steam temperature. When Steam Chest Metal temperature is below saturation temperature corresponding to existing throttle valve inlet pressure, continue operating with throttle valve pilot control with steam temperature at or above the Minimum Throttle Valve Inlet Steam Temperature shown until the Steam Chest Metal reaches saturation temperature before transferring to governor valve control. When starting a cold turbine, the throttle valve inlet steam conditions should be in the cold start region before transferring from throttle valve to governor valve control. When starting a hot turbine, the throttle valve inlet steam temperature should be above the curve labeled Minimum Throttle Valve Inlet Steam Temperature at Transfer before transferring from throttle valve to governor valve control.
Page 2 of 2
Curve1 Startup Steam Condition at Throttle Valve
550 Throttle Valve Inlet Steam Temperature 500 450 400 350
Minimum Throttle Valve Inlet Steam Temp. at Tranfer
Cold Startup
300 250 200 1 3 5 7 9 11 13 15 17 19 21 23 Throttle Valve Inlet Steam Pressure MPa
Minimum Throttle Valve Inlet Steam Temp. at Startup (56 SPHT)
Minimum Steam Chest Metal Temp. at Transfer (Sat.Temp.)
Curve 2 Startup Steam Condition at Interceptor Valve

400 Max. Reheat Temp. 350 300 Reheat Temperature 250 200 150 100 50 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Interceptor Valve Inlet Steam Pressure MPa
Note: Max.Reheat Temp. also refer to "No Load and Light Load Operation Guide for Reheat Turbine", and select the lower temp.
Minimum Reheat Temp.(56 SPHT)
Page 1 of 1
No-Load and Light Load Operation Guide for Reheat Turbines OP.2.55.01E-00
2008.09 2008.09
NO-LOAD AND LIGHT LOAD OPERATION GUIDE FOR REHEAT TURBINES

FOR OVERSPEED TEST USE THE FULL SPEED-NO LOAD CURVE AND MAINTAIN STABLE BACK PRESSURE
550
5% Max. Guaranteed Load

500
Reheat Temp. at Turbine Inlet
450
Full Speed No Load

400
350
300
Recommendation Operating Limits For Reheat Turbines
250 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
LP Exhaust Pressure kPa
Page 1 of 4
Load Changing Recommendations

OP.2.56.01E-00
2008.09 2008.09
LOAD CHANGING RECOMMENDATIONS

1CONSTANT PRESSURE 50Hz, 16.7MPa(a)-538/538 STEAM TURBINE DESIGN FOR 50%MINIMUM ARC ADMISSION CONTROL EXAMPLE1-INCREASING LOAD Determine the time required and load changing rate to increase load using single valve mode of operation from 50% at steady state conditions at throttle steam conditions of 11MPa/425 to 100% load at rated conditions. Assume a 10,000 cycle fatigue index. PROCEDURE Enter Figure 1 at throttle steam pressure at 11MPa. Project vertically to the throttle steam temperature of 425, continue line horizontally to (Figure2)single valve line at 50% load. The first stage steam temperature for these conditions is 377. To determine the temperature for 100% load. Start at Figure 1 throttle steam pressure at 16.7MPa, project vertically to throttle steam temperature at 538, continue line horizontally to (Figure 2) 100% load. The first stage steam temperature for these conditions is 498. The difference in first stage temperature due to the load change from 50% to 100% is 121 (498-377 = 121). Enter Figure 4 at the 121 (t) first stage temperature difference. Extend line horizontally to the 10,000 cycle fatigue index and read 63 minutes (time to change load/throttle conditions). RESULTS By following the procedure above it is determined in example that load can be increased from 50% to 100% at a uniform rate over 63 minutes for a 10,000 cycles rotor fatigue index. The load changing rate is 50%/63min. = 0.794%/min.
Page 2 of 4 EXAMPLE 2. DECREASING LOAD Determine the time and rate to reduce load using sequential valve mode of operation from 100% at rated throttle conditions to 5% load at rated conditions prior to shutting down the unit. Assume a 10,000 cycle fatigue index. PROCEDURE Enter figure 1 at existing throttle steam pressure of 16.7MPa. Project vertically to the throttle steam temperature of 538, continue line horizontally to (Figure 2) sequential valve line at 5% load. The first stage steam temperature for these conditions is 382. The existing first stage steam temperature for 100% load is 498 (Refer to Example 1). The change in first stage temperature due to the load change from 100% to 5% is 116 (498-382= 116 ). Enter Figure 4 at the 116 (t) first stage temperature difference extend line horizontally to 10,000cycle fatigue index and read 57 minutes (time to change load/throttle conditions). RESULTS The load reduction from 100% to 5% can be made over 57 minutes for a 10,000 cycles rotor fatigue index. The load changing rate is 95%/57min = 1.67%/min.
2. SLIDING PRESSURE 50Hz, 16.7MPa(a), 538 /538 STEAM TURBINE DESIGN FOR 50% MINIMUM ARC ADMISSION CONTROL SLIDING PRESSURE-SEQUENTIAL VALVE MODES EXAMPLE Determine the time required and load changing rate to increase load using both sequential valve and sliding pressure modes of operation from 5% load at throttle steam conditions of 11.0 MPa/470 to 100% load at rated conditions. Assume a 10,000 cycle fatigue index. PROCEDURE Enter Figure 3 at 5% load. Project vertical to the dotted Line Labeled 11.0MPa which represents the condition with 2 governor valves partially open. To increase load follow the 11.0MPa dotted line to 53% load at 2 valves wide open. Increase load to 83% by increasing throttle pressure to 16.7MPa at 2 valves (50%admission) wide open. Increase load to 100%
Page 3 of 4 by sequentially opening 3&4 valves at 16.67MPa. Calculate the change in first stage steam temperature due to change in load by determining the difference between highest and lowest first stage steam temperature from Figure 3 (488-436 =52), add to this change the change in inlet steam temperature that occurs during this transient (538-470 = 68) (52 + 68 = 120 ). On Figure 4 plot this change in first stage steam temperature (120) against the 10,000 cycle fatigue index to determine that this change should occur in 62 minutes. RESULTS By following the procedure above, it is determined that load can be increased from 5% to 100% at a uniform rate over 62 minutes for a 10,000 cycles rotor fatigue index. The load changing rate is 95%/62 minutes = 1.53%/min
Page 4 of 4
LOAD CHANGING RECOMMENDATIONS
Page 1 of 1
Cyclic Index for Loading and Unloading at Different Rates OP.2.57.01E-00
2008.09 2008.09
CYCLIC INDEX FOR LOADING AND UNLOADING AT DIFFERENT RATES
Page 1 of 2
Gland Sealing Steam Temperature Recommendations OP.2.58.01E-00
2008.09 2008.09
GLAND SEALING STEAM TEMPERATURE RECOMMENDATIONS

To protect against rotor damage in the gland zones resulting from thermal stresses, the difference between gland sealing steam temperature and rotor surface temperature should be kept to a minimum when starting and shutting down. The estimated number of cycles to start rotor cracking due to thermal stresses at various temperature differences between gland sealing steam and rotor surface metal can be determined from the curve below as follows:
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Page 1 of 1
Cooldown Time for A Typical Fossil Hp Turbine OP.2.59.01E-00
2008.09 2008.09
COOLDOWN TIME FOR A TYPICAL FOSSIL HP TURBINE

Note: If the unit is tripped with the temperature at a different value than that given for time zero, shift the time scale so that time zero starts at the temperature when tripping occurred.
TIME AFTER UNIT TRIP (HOURS)
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Off-Frequency Turbine Operation

OP.2.60.01E-00
2008.09 2008.09
OFF-FREQUENCY TURBINE OPERATION
Operating Time (Total Life) Frequency Hz 48.5~51.5 48.0~48.5 47.5~48.0 47.0~47.5 Accumulation (Min) 300 60 10 Every Time (Sec) 300 60 20
Continuous Operating
PreparedPan Donghua
LP exhaust spray SYS

AS.4.MAC01.P001 E-00
CheckedYan Weichun Countersign Countersign ApprovedChen Lehua
Contents
1 General and function..........................................................................1 2 Control switch....................................................................................3 3 Solenoid .............................................................................................3 4 Pressure switch ..................................................................................3 5 Pneumatic regulator valve .................................................................3 6 Bypass valve ......................................................................................5
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LP EXHAUST HOOD SPRAY SYSTEM 1 General and function

The exhaust hood spray system for this unit is designed to be put in operation automatically when the rotor speed has reached 2600 rpm and continue in operation until the unit is carrying approximately 15 percent rated load.
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Page 3 of 6 2 Control switch

The switch is usually located on the control panel and has provisions for OFF-MANUAL-AUTOMATIC operation. It should be in the automatic position during startup. Manual operation provisions are included in case it is desirable to operate the exhaust hood sprays during other than the automatic mode period.
3 Solenoid
The solenoid is actuated either by a signal from the turbine control system after the unit has reached 2600 rpm when the control switch is in the automatic position or by manual operation of the switch. When the solenoid is energized it allows the pneumatically operated valve to open which in turn provides water from the condensate pump to the exhaust hood sprays.
4 Pressure switch
This is a pressure switch, which senses across-over pressure corresponding to 10-15% load and deactivates the solenoid, thereby closing the exhaust hood spray valve.
5 Pneumatic regulator valve

This is an operated valve, which controls the flow of condensate to the exhaust hood spray nozzles. It is normally closed and is opened by air from a regulator or air set when the solenoid valve is actuated either by automatic or manual operation of the control switch. The operating air to the valve is regulated by a pressure controller, which is a mechanical device, utilizes air at a constant pressure and produces a variable output in response to a pressure change applied to a sensing element, which
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is located on the outlet side of the control valve. This provides a uniform flow of condensate to the spray nozzles.
Air at a constant pressure of 0.226 MPa (g) trained to the controller by an air set which consist of strainer and reducing valve.
A high pressure reducing valve dis installed between the sensing device and the controller to limit the signal to a maximum 0.7 MPa (g). This protects the bourdbn tube in the controller from damage.
All of the above items except the control switch are shown diagrammatically on the EXHAUST HOOD SPRAY CONTROL SYSTEM. The air set reducing valve and controller are all mounted on the control valve.
Component supplier leaflets containing recommended spare parts and operating and maintenance instructions follow this leaflet.
Overheating of the exhaust is not expected with no load steam and full vacuum. Poor vacuum will cause overheating as will materially less than no load steam flow, which would result if the unit were allowed to motor. If a temperature in excess of 80 is obtained, care must be taken to lower the temperature of the exhaust casing gradually by increasing load or improving the vacuum. The limiting exhaust casing temperature is l2l. If this temperature is reached, the unit should be shutdown and the trouble corrected. This pneumatic regulator valve is made up of body, pneumatic actor, limit switch,
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filter, solenoid valve, positioner, gauge, etc.(the detail see the manufactorys manual) In order to protect turbine, the pneumatic regulator should be closed when electric or signal, or control air failure. The pneumatic regulator is whole unit, should not disconnect on site except valve manufacture.
LP exhaust spray pneumatic regulator valve outline (typical)
6 Bypass valve
The exhaust hood spray-regulating valve has a bypass valve, which should only be used in the event of regulating valve failure of servicing. The bypass valve should only be opened enough to maintain the calculated control pressure. See Control Settings instructions.
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NOTE To prevent possible damage to the turbine it is important that the BYPASS VALVE is not left open when operating the turbine in the range that exhaust hood sprays are not required.
PreparedPan Donghua 2008.07.08
Turbine Drain System

AS.4.MAL10.P001E-00
CheckedYan Weichun 2008.07.15. Countersign Countersign ApprovedChen Lehua 2008.08.08
Contents
1 Forced cooling connection ......................................................................1 2 Drain valves.............................................................................................1 3 Main steam inlet ventilating valves.........................................................3 4 HP ventilating valve ................................................................................6 4.1 Function................................................................................................6 4.2 Structure ...............................................................................................7 5 Drain piping connection ..........................................................................7
Page 1 of 8 TURBINE DRAIN SYSTEM 1 Forced cooling connection

The term Forced Cooling refers to the forced cooling of turbine components. This process is used to cool down the steam turbine as quickly as possible so that the turning gear system can be switched off at the earliest possible point. A higher availability can be achieved in this manner.
Cooling of the turbine is achieved by the use of the vacuum pumps (customer supply) which draw in outside air via the normal steam path through the blading, using the opening of the flange connection in the drain piping. NOTE 1. Forced cooling connection must be closed when steam turbine in operated. 2. Forced cooling device can cool down the steam turbine as quickly as possible but can bring steam turbine life consumption, careful used.
3. The forced cooling device will be supplied by customer.
2 Drain valves
The drain valves are alike in physical and functional operation. They consist of diaphragm actuator and valve, three-way solenoid valve, pressure regulator valve, and limit switches. The limit switches indicate drain valve to the operator. Air is supplied through a regulating valve to a solenoid air control valve at a constant pressure. When the solenoid valve is energized, air pressure is applied to the drain valve diaphragm actuator and drain valves close. Likewise, when the solenoid valve is de-energized, air pressure on the diaphragm actuator is vented to the atmosphere and the drain valve opens. The drain valves are arranged to open, to protect the turbine, on loss of supply air
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resulting from shutdown, trip, or loss of electrical signal to the solenoid valve in the supply line. A limit switch is mounted on each drain valve. Movement of the valve stem actuates the limit switches. These switches are used to indicate valve position for interlocks. Refer to the operation leaflet section "Water in the Turbine" for more information on the operation of this system. The complete turbine drain system is shown on the "Steam, Drain & Gland Piping Diagram."
Typical drain valve control diagram (air closed) NOTE 1: In normally, the drain valve is auto-operate. If operators want to achieve handle-operate function, pay attention to the following: A: The drain valve must in on-condition when turbine shutoff until totally cooling down.
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B: The drain valve must in on-condition when turbine start up until the gland seal steam totally fill in the gland zoom. C: In order to drain the condensate form reheat stop valve upsteam, when increase turbine load, the drain valve must in on-condition until 10% rated load. D: In order to drain the condensate form reheat stop valve downstream, when increase turbine load, the drain valve must in on-condition until 20% rated load. 2: When drain valves in on-condition, vacuum break is forbidden, this prescribe is inapplicable to vacuum break emergency condition and inapplicable to main steam pipe drain. 3: When turbine startup drain valves in on-condition, turning gear device go into work and turbine increase load always until 10%-20% rated load, check the pressure in every drain piping, if the pressure exceed the pressure which come from the lowest pressure fountainhead, turbine must be turnoff and eliminate malfunction. 4: If customers adopt the motor drived valves, the measure to drain the turbine and piping condensate in emergency condition must be ensure. CAUTION 1: Before air-operated drain valves, install hand-operated or motor drived stop valve is not advised. If customers install hand-operated or motor drived stop valves, make sure the stop valve is normally-open, and check the stop valve open condition at any moment. 2: Hand wheel in air-operated drain valve is not advised also, additional force moment can influence drain valve normally work.
3 Main steam inlet ventilating valves

The ventilating valves are supplied to prevent a rapid vise in HP turbine blade
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temperature when the main and reheat steam valves are closed, trapping high density steam in HP turbine and causing windage heating. The ventilating valves consist of diaphragm actuator and valve, two-way solenoid valve, strainer, pressure reducing valve, release valve, limit switches, and check valve.
The inlet sides of the ventilating valves are connected by piping to a main steam inlet pipe from each steam chest. The outlet sides of the ventilating valves are connected by piping to the main condenser. Tubing from the ventilating valve actuators is connected through a pressure-reducing valve and EH fluid operated air pilot valve to the station instrument air supply. Tubing is also connected from the ventilating valve actuators through a solenoid valve to atmosphere. A check valve is connected in parallel to the pressure-reducing valve.
The ventilating valves open when a turbine trip results in loss of EH fluid pressure in the OPC header. When EH fluid pressure is reduced, the air pilot valve opens and blocks instrument air supply. Air from the pressure-reducing valve is vented to atmosphere through the air pilot valve. Air supplied to the ventilating valve actuators is passed through the check valve and vented through the pilot valve. The ventilating valves then open and pass HP steam to the main condenser. The ventilating valve
solenoid valve also open and loss of OPC header pressure. The pressure switch monitoring the OPC header de-energizes the solenoid valve. Air from the ventilating valve actuators is vented to atmosphere through the solenoid valve causing the ventilating valves to open.
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main steam inlet ventilating valves control diagram (typical)
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Typical main steam inlet ventilating valves outline
4 HP ventilating valve 4.1 Function

HP ventilating valve will protect the HP cylinder when steam turbine startup or shutdown. When the steam turbine startup(HP-IP combine to startup), the HP ventilating valve shall be opened till rated speed, after 1 minute , the HP ventilating valve will be closed. When the steam turbine shutdown, the HP ventilating valve shall be opened to
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extract the steam of HP cylinder.
4.2 Structure
The HP ventilation valve is one pneumatic valve, stop valve or butterfly valve all can be used.
Typical HP ventilation valve outline
5 Drain piping connection

5.1 Check turbine outer cylinder and the drawing Drain and LP Cylinder Spray Piping, confirm governing stage and turbine inner cylinder drain connection position. 5.2 Locate scaffold in correspond turbine outer cylinder place. 5.3 Remove insulation layer, drain connection extend out 200300mm form HP cylinder. 5.4 Machining drain connection to form weld groove, perforate drain connection. 5.5 Distance below form drain connection 150mm saw off drain piping. 5.6 After inner cylinder installation, base on space between machining piping
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connection. 5.7 Warm-up pipingpiping connection &drain connection to 204232. 5.8 Weld piping to piping connection or drain connection. 5.9 Coated weld zone with fabric insulation until cooling down to environment temperature. 5.10 Remove fabric insulation. 5.11 Execute magnetic powder detection or penetrant examination in weld zone. 5.12 Recovery insulation layer. 5.13 Remove scaffold.
Lubrication Oil System

AS.4.MAV10.P001E -00
Contents
1 Main equipment and function .................................................................1 1.1 Oil reservoir..........................................................................................1 1.2 Main oil pump ......................................................................................1 1.3 HP startup oil pump (AC) ....................................................................1 1.4 Auxiliary pump(AC) ............................................................................2 1.5 Emergency oil pump (DC) ...................................................................3 1.6 Oil ejector .............................................................................................3 1.7 Vapor extraction system .......................................................................4 1.8 Strainer .................................................................................................5 1.9 Oil coolers ............................................................................................5 1.10 Oil heaters...........................................................................................5 1. 11 Fluid level controls............................................................................6 1.12. Terminal box "R"...............................................................................6 1.13. Terminal box "L"...............................................................................7 1.14 Pressure-switches ...............................................................................9
2 Rated revolution ....................................................................................10 3 Auxiliary pumps ....................................................................................10 4 Oil temperature and oil coolers .............................................................12 5 Turning gear ..........................................................................................13 6 Emergency trip functions ......................................................................14 7 Lubrication oil .......................................................................................15 7.1 New oil ...............................................................................................15 7.2Oil sampling during operation ............................................................17 8 Oil reservoir...........................................................................................18 9 Oil coolers .............................................................................................19 10 Three-way valve (only used for shell & tube oil cooler) ....................20 12 Strainer ................................................................................................27 13 Pressure switch ....................................................................................27 14 Temperature switch and heaters ..........................................................28 15 Level controls ......................................................................................28 16 Oil pressure value................................................................................29 17 Bearing and lubrication oil system......................................................30 18 Backup power......................................................................................31 19 Oil system flushing and installation procedure...................................32 19.1 Preface ..............................................................................................32 19.2 Introduction ......................................................................................33
20 Shipping and on-site storage ...............................................................34 21 Installation and general housekeeping procedures..............................36 22 Pre-flush planning and familiarization................................................37 22 Pre-flush operations and procedures ...................................................39 23 General design considerations.............................................................43 24 General notes.......................................................................................45 25 Flushing procedures ............................................................................50 1. Reservoir/oil cleanliness ......................................................................50 2. Main oil pump suction and discharge lines (ref. figure 1). ..................51 4. Hydrogen seal oil lines.........................................................................57 26 Procedures for determining system cleanliness ..................................57 27 Restoration of the system ....................................................................59 28 Temporary flushing materials..............................................................60
Page 1 of 77 LUBRICATION OIL SYSTEM 1 Main equipment and function 1.1 Oil reservoir
The lubrication oil reservoir is a large carbon steel tank in which the lubrication oil is stored. The reservoir is usually located below the centerline of the turbine-generator unit. The bottom of the reservoir contains a hanged drain hole which is plugged during shipment but which may be connected to the purchasers piping system at his discretion.
1.2 Main oil pump

The main oil pump is a volute, centrifugal pump type, which mounted on the turbine rotor in the governor pedestal. It has a large capacity and a stable discharge head. At or near rated turbine speed, the main oil pump supplies all the oil requirements of the steam turbine and generator lubrication system and, in addition, provides two sources of backup for the hydrogen seal oil system of the generator. The main oil pump is not self-priming and must constantly be supplied with oil under pressure. During turbine startup and shutdown periods, the auxiliary oil pumps do this. At or near rated speed, the oil ejector supplies priming oil. The main oil pump discharge is piped back into the reservoir where it is connected to the oil ejector inlet and to the HP Seal Oil Backup Header from which the Mechanical Overspeed and Manual Trip Header by orifice.
1.3 HP startup oil pump (AC)

The HP startup oil pump(sometime named seal oil backup pump) is an AC motor driven, horizontal pump mounted on top of the reservoir. It provides high pressure oil to seal oil backup header and mechanical overspeed devices during the period of turbine startup or shutdown. If anytime the main oil pump cannot satisfy the HP seal oil requirements, including the requirements of the Mechanical Overspeed and
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Manual Trip Header, the HP startup oil pump will work. During normal operation at rated speed, the HP startup oil pump does not work, and the main oil pump supplies all of the oil requirements. The HP startup oil pump is controlled by the same pressure switch that controls the auxiliary oil pump by monitoring the bearing oil pressure. If the bearing oil pressure decreases to 0.07-0.08 Mpa(g) such as occurs during a shutdown or contingency condition, the HP startup oil pump automatically starts and brings the HP Seal Oil Backup Header up to the required pressure. The pump will not stop on rising pressure, however, and must be turned off manually from the control room. During startup procedures the HP startup oil pump is put into service before the unit is started and should not be taken out of service until the main oil pump is capable of satisfying all of the oil requirements (approximately 90% of rated speed). A relief valve in the discharge piping prevents overpressures.
1.4 Auxiliary pump(AC)

The auxiliary pump is an AC motor driven, centrifugal pump mounted on top of the reservoir. It is used during startup and shutdown procedures and also serves as a backup to the main oil pump during contingency conditions. It is capable of supplying all of the LP seal oil backup and bearing oil requirements. During normal operation at rated speed, the bearing oil pump does not work and the main oil pump supplies all of the oil requirements. A pressure switch that senses the bearing oil pressure controls the bearing oil pump. If the bearing oil pressure decreases to 0.07-0.08 Mpa(g) such as occurs during a shutdown or contingency condition the bearing oil pump will turn on and bring the pressure back up to requirements. However the pump will not automatically shut off on rising pressure and must be turned off manually from the control room. During startup procedures the bearing oil pump is put into service before the unit goes on turning gear and is not taken out of service until the main oil pump is capable of satisfying all of the oil requirements of turbine and generator bearings (approximately 90 % of rated speed).
Page 3 of 74 1.5 Emergency oil pump (DC)

The emergency oil pump is identical in construction and operation to the auxiliary pump except that it is operated by a DC motor powered by station batteries, and the controlling pressure switch is set point is below the set point of the pressure switch which controls the auxiliary pump. During startup procedures the emergency oil pump is put into service after the bearing oil pump establishes sufficient bearing oil pressure. The emergency oil pump's control switch is then set on "Automatic, and the pump will turn on if the bearing oil pressure decreases to 0.06-0.07 Mpa(g). Thus, the emergency oil pump services as a backup to the auxiliary pump and is the final backup for the turbine-generator bearings oil system. The station batteries are sized to provide sufficient power to drive the pump during a normal coast down, and it is imperative that the batteries are kept sufficiently charged to maintain this capability.
1.6 Oil ejector

One oil ejector mounted in the piping below the oil level. The oil ejector consists, essentially, of a nozzle, pickup chamber, throat, and a diffuser. The nozzle inlet is connected to the main oil pump discharge, which provides motive oil. The oil passes through the nozzle, is directed through the pickup chamber into the ejector throat, and finally passes into the diffuser. As the oil passes through the nozzle, its velocity increases. When this high velocity oil passes through the pickup chamber, it creates a low-pressure zone in the pickup chamber and causes the oil from the reservoir to be drawn into the pickup chamber and be carried with the high velocity oil into the ejector throat area. The quantity of oil picked up from the reservoir is approximately equal to the quantity provided to the nozzle inlet by the main oil pump. After passing through the ejector throat area the oil enters the diffuser where the oil velocity is converted to pressure. The oil is then piped through the oil coolers to the Bearing Oil Header, to the main oil pump suction, and to the LP Seal Oil Backup Header. A swing check valve, mounted after the diffuser, prevents backflow from the system. A check
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plate mounted above the pickup chamber inlets from the reservoir prevents a backflow into the reservoir when the bearing oil pump is running. A removable perforated, steel plate (mesh) strainer mounted on the ejectors suction side prevents foreign matter from entering the ejector.
1.7 Vapor extraction system

When the lubrication oil supply system is in operation, some of the oil becomes vaporized. These vapors collect in the oil reservoir above the oil level, in the bearing pedestals, housings, and return oil piping. If the vapor pressure becomes excessive, oil vapor could be forced through the turbine shaft oil seals into the turbine room. A vapor extraction system is provided to prevent the vapor pressure from becoming excessive. The vapor extraction system includes a demister, an adjustable blast butterfly valve, a motor drive blower and a check valve. Essentially, the oil vapor extraction system is AC motor driven gas blowers whose suction side is connected to the areas above the oil in the reservoir. When operating, it creates a slightly negative pressure in the areas where vapors accumulate and thus
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draws any vapors through the blower. Any entrained oil is removed from the vapor and returned to the reservoir, and the cleaned vapor is vented to the atmosphere.
1.8 Strainer
Periodically, remove and clean the oil strainer which is mounted in the trough inside the reservoir, annunciator provided by the purchaser will indicate this condition, and the strainer should be replaced immediately. It is recommended that a clean spare strainer and gasket be readily available to minimize the amount of time that the strainer is not in place.
1.9 Oil coolers

The oil coolers regulate the temperature of the lubrication oil. Two oil coolers are normally provided. Under normal operating conditions, one is in use and the other is on a standby status; although in some special conditions, both coolers may be in service simultaneously. The coolers are connected to the discharge sides of both the bearing oil pump and the oil ejector; thus the bearing oil, no matter what the source, passes through the coolers before flowing to the bearings. Operators can check which oil cooler is on work through flow inspect hole.
1.10 Oil heaters

The temperature switch and immersion heaters were adjusted either at the factory or at installation; however, their operation and set points should be verified periodically.
Cautions
The power to the heaters should be shut off before attempting to inspect them or perform any maintenance on them.
Page 6 of 74 1. 11 Fluid level controls

Two top mounted displacement type fluid level controls and which activate switch mechanisms in response to oil level changes.
a. One level control (7l/OL) activates switch mechanisms in response to either high oil levels or low oil levels. This level control is wired into the purchaser is circuits and may be connected to either alarm or trip circuits at his discretion. They are normally connected to alarm circuits. b. One level control (71/LLL) (optional for indoor units) activates a low-low level pre-trip alarm and also provides an interlock between the oil level and the heaters by activating a switch mechanism to turn of f the heaters at anomaly low oil levels.
1.12. Terminal box "R"

One terminal box "R" normally mounted approximately as shown on the side of the reservoir. The terminal box completely encloses the terminal blocks and pressure switches and is equipped with a hinged door for easy access. The tubing that connects the terminal box pressure switches to the components is usually arranged at the time of erection; thus it is not shown on the illustration. The following equipment is included in the terminal box.
a. One pressure switch (63/BOR) which indicates when the bearing oil pump is running by sensing the pressure on the discharge side of the Bearing Oil Pump between the pump and the check valve. The pressure switch is connected through an isolation valve to the gauge stem on top of the reservoir and is set to close a contact when the bearing oil pump is running and producing a discharge pressure of approximately 0.07-0.08 MPa(g). The pressure switch is wired into the purchaser is circuits and is usually connected to an annunciator in the control room.
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b. One pressure switch (63/EPR) which indicates when the emergency oil pump is running by sensing the pressure on the discharge side of the Emergency Oil Pump between the pump and the check valve. The pressure switch is connected through an isolation valve to the gauge stem on top of the reservoir and is set to close a contact when the Emergency Oil Pump is running and producing a discharge pressure of approximately 0.07-0.08 MPa(g). The pressure switch is wired into the purchaser is circuits and is usually connected to an annunciator in the control room.
c. One pressure switch (63/OVR) which indicates when the oil vapor extractor is running by sensing the pressure on the suction side of the oil vapor extraction system. The pressure switch is connected to the top of the oil reservoir and is set to close a contact when a slight negative pressure exists in the oil reservoir such as is caused by the oil vapor extractor running. The switch is wired into the purchasers circuits where it is usually connected to an annunciator in the control room. If a second (standby) oil vapor extractor blower is provided, another pressure switch may be mounted on the same position. If provided, its function is to control the standby oil vapor extractor startup automatically when the vacuum in the oil reservoir is lower.
1.13. Terminal box "L"

One terminal box "L" mounted near the turning gear. The terminal box completely encloses the terminal blocks and pressure switches and is provided, with a hinged door for easy access. The following equipment is included in the terminal box:
a. One pressure switch (63/BOP) which starts both the Bearing Oil Pump and the Seal Oil Backup pump if the Bearing Oil Header pressure falls too low. The switch has two sets of normally closed contacts that are held open by sufficient bearing oil pressure. If the oil pressure drops to 0.07-0.08 MPa(g) both sets of
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contacts close simultaneously. The closing of one set causes the Sea1 Oil Backup pump (High Pressure startup pump) to start, and the closing of the other set causes the Bearing Oil Pump to start. Although the pumps will start on failing pressure they will not stop automatically on rising pressure and must be turned off from the control room after the bearing oil pressure has risen past the pressure switch's set point. The control switch should be turned to the OFF position and held until the pumps stop; when released, it will return to the AUTO position automatically, and the circuitry will be reset.
b. One pressure switch (63/EOP) which monitors the Bearing Oil Header pressure. The switch has two sets of normally closed contacts that are held open, under normal operating conditions, by the bearing oil pressure. If the oil pressure drops to 0.06-0.07 MPa(g), the contacts close simultaneously. The closing of one set causes the emergency oil pump to start, and the other set is either wired into the ATC circuitry or is a spare. Although the pumps will start on failing pressure they will not stop automatically on rising pressure and must be turned off from the control room after the bearing oil pressure has risen past the pressure switch's set point. The control switch should be turned to the OFF position and held until the pumps stop; when released, it will return to the AUTO position automatically, and the circuitry will be reset. CAUTION Shot off pump promptly after test. Pro-longed operation of pump will drain System battery power below normal voltage required to safely operate the pump during an emergency coast down.
c. One pressure switch (63/TG) which interlocks the turning gear motor to the bearing oil pressure. The switch has two sets of normally open contacts. When the turbine-generator is operating above the supervisory instrument check speed, a
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solenoid valve, 20/TGO, isolates the pressure switch from the Bearing Oil Header thus, the switch contacts are open. When the turbine-generator speed drops below the supervisory instrument check speed, the 20/TGO solenoid valve automatically opens and allows the pressure switch to sense the Bearing Oil Header pressure. The pressure switch is set to close the contacts when the bearing oil pressure is 0.0276-0.0344 MPa(g) or greater. One set of contacts is wired in series with the turning gear motor, and thus the motor cannot start until the bearing oil pressure reaches or exceeds the set point. The second set of contacts is either a spare or if a bearing lift pump is provided, it is wired in series with the bearing lift pump motor, thus preventing that motor from starting until the proper bearing oil pressure is established. Also, both the turning gear and the bearing lift pump will be shut off if bearing oil pressure decreases below the set point and causes the contacts to open.
The operation of the pressure switch can be tested on rising pressure by first establishing sufficient bearing oil pressure and then checking to assure that the bearing lift pump motor and the turning gear motor start. Its operation on falling pressure can be tested by first establishing sufficient bearing oil pressure and then opening the manual shutoff valve in the line to the pressure switch. Opening the valve creates a localized pressure drop and causes the contacts to open. Since the pressure is orificed off from the Bearing Oil Header, the Bearing Oil Header pressure does not decay during testing. Closing the shutoff valve restores the pressure switch to normal operation.
1.14 Pressure-switches
Four pressure-switches (63/LBO) which cause a turbine trip if the Bearing Oil Header pressure is excessively low. The switches are mounted in Terminal BOX "A" on the governor pedestal, they monitor the Bearing Oil Header pressure, and they are part of the emergency trip system. Their operation, testing procedures, associated
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equipment, etc. are covered in a separate leaflet describing the "Emergency Trip System" (see "Contents").
2 Rated revolution
When the turbine in rated revolution, main oil pump supplies the whole lubrication oil of the system, see lubrication oil system drawing. The lubrication oil eject out from main oil pump through an orifice flange to HP startup oil pump and emergency trip equipment. Also the main oil pump supplies the power oil to the oil ejector. The oil comes from oil ejector is then piped through the oil coolers to the Bearing Oil Header, to the main oil pump suction, and to the LP Seal Oil Backup Header. The lubrication oil system is a hermetical system. All the lubrication oil through an oil strainer and come to oil reservoir. To make sure the lubrication oil is adequate for the whole system, the oil reservoir must supplies enough oil and oil controller give an alarm when oil level is low or high. Caution 1 To make sure the lubrication oil come into oil reservoir through oil strainer, when turbine in initialize operation, oil level in the oil reservoir is inspect at any moment. 2 Condensate may be come into lubrication system from gland steam system, in order to remove the condensate from lubrication system, oil purification system is commend to work when turbine is in operate.
3 Auxiliary pumps
The bearing oil pump is an AC motor driven, vertical pump mounted on top of the reservoir. It is used during startup and shutdown procedures and also serves as a backup to the main oil pump during contingency conditions. It is capable of supplying all of the LP seal oil backup and bearing oil requirements. During normal operation at
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rated speed, the bearing oil pump is off and the main oil pump supplies all of the oil requirements. A pressure switch that senses the bearing oil pressure controls the bearing oil pump. If the bearing oil pressure decreases to 0.076-0.083 MPa(g) such as occurs during a shutdown or contingency condition the bearing oil pump will turn on and bring the pressure back up to requirements. However the pump will not automatically shut off on rising pressure and must be turned off manually from the control room. During startup procedures the bearing oil pump is put into service before the unit goes on turning gear and is not taken out of service until the main oil pump is capable of satisfying all of the oil requirements (approximately 90 % of rated speed).The emergency oil pump is identical in construction and operation to the bearing oil pump except that it is operated by a DC motor powered by station batteries, and the controlling pressure switch is set point is below the set point of the pressure switch which controls the bearing oil pump. During startup procedures the emergency oil pump is put into service after the bearing oil pump establishes sufficient bearing oil pressure. The emergency oil pump's control switch is then set on "Automatic, and the pump will turn on if the bearing oil pressure decreases to 0.06-0.07 MPa(g). Thus, the emergency oil pump serves as a backup to the bearing oil pump and is the final backup to the bearing oil system. The station batteries are sized to provide sufficient power to operate the pump during a normal coast down, and it is imperative that the batteries are kept sufficiently charged to maintain this capability. CAUTION An insufficient charge on the batteries may not allow the emergency oil pump to operate properly thereby resulting in an insufficient supply of lubricating oil to the bearings. This will result in serious damage to the bearings, journals, and associated components.
The seal oil backup pump is an AC motor driven, horizontal pump mounted on top
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of the reservoir. It provides oil to the HP Seal Oil Backup Header and is used anytime the main oil pump cannot satisfy the HP seal oil requirements, including the requirements of the Mechanical Overspeed and Manual Trip Header. During normal operation at rated speed, the seal oil backup pump is off, and the main oil pump supplies all of the oil requirements. The seal oil backup pump is controlled by the same pressure switch that controls the bearing oil pump by monitoring the bearing oil pressure. If the bearing oil pressure decreases to 0.07-0.08 Mpa(g) such as occurs during a shutdown or contingency condition, the seal oil backup pump automatically starts and brings the HP Seal Oil Backup Header up to the required pressure. The pump will not stop on rising pressure, however, and must be turned off manually from the control room. During startup procedures the seal oil backup pump is put into service before the unit is started and should not be taken out of service until the main oil pump is capable of satisfying all of the oil requirements (approximately 90% of rated speed). A relief valve in the discharge piping prevents overpressures.
4 Oil temperature and oil coolers

In normal operate, the temperature of lubrication oil come out from oil coolers is 43-49. If the temperature of the oil in reservoir is under 10, oil circulation is prohibited. So the lubrication oil supply system must out of work. Before Auxiliary pump and the seal oil backup pump startup, if the temperature of the lubrication oil is under 10, oil heaters must put into work. The oil coolers regulate the temperature of the lubrication oil. Two oil coolers are normally provided. Under normal operating conditions, one is in use and the other is on a standby status; although in some special conditions, both coolers may be in service simultaneously. The coolers are connected to the discharge sides of both the bearing oil pump and the oil ejector; thus the bearing oil, no matter what the source, passes through the coolers before flowing to the bearings. The oil coolers are the plate
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or tube oil coolers. The oil is circulated within the hot sides while the cooling water is circulated the cold sides. The oil flow to the coolers is controlled by a manually operated stop valves or a three-way valve, which directs the flow to either cooler and permits switching coolers without interrupting the flow of oil to the bearings. The oil inlets to the coolers are connected through a crossover pipe and four stop valves (used in plate oil coolers) or a three-way valve(used in tube oil coolers), which permits the inactive cooler to be filled with oil and ready for immediate operation. The flow of water to the coolers is adjustable by means of a manually operated valve in the water supply liner hence the temperature of the oil leaving the coolers is also adjustable. The valve is normally adjusted to provide an oil temperature of 43-49 measured at the oil cooler discharge.
NOTE
In three-way valve handle, any auxiliary lever and spanner is prohibited. Caution Before three-way valve operate, operators make sure the three-way valve is open up and the connected cooler is full fill with lubrication oil. After change over, make sure the oil in the oil cooler is not interrupt, lubrication system is work normally.
5 Turning gear
In order to minimize the distortion of the rotor due to the uneven cooling of the rotor due to the uneven cooling of the turbine parts, the turning gear rotates the rotor at a low speed when the turbine is shut down. It normally operates automatically by starting when the rotor reaches zero speed, controlling the speed of the rotor, and disengaging when the rotor speed increases slightly. Interlocks prevent the turning gear from starting when the turbine speed is above the supervisory instrument check speed or if the bearing oil pressure is not adequate.
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A solenoid valve, 20/TGO, interlocks the turning gear operation to the turbine speed. The solenoid valve is energized closed by a supervisory instrument contact closure when the turbine speed is above the supervisory instrument check speed. When the turbine speed is below the supervisory instrument check speed, the contact opens causing the 20/TGO solenoid valve to open and thereby allowing lubricating oil from the bearing oil header to reach the turning gear.
A pressure switch, 63/TG, interlocks the turning gear motor to the bearing oil pressure. The pressure switch connection is located in the line after the 20/TGO solenoid valve, and thus, when the solenoid valve is open, the pressure switch monitors the bearing oil pressure. As long as sufficient bearing oil pressure (above0.0276-0.0344 Mpa(g)) is established, contact closures from the pressure switch allow the turning gear motor to be started. If the pressure falls below the set point the contacts open and prevent the turning gear motor from being started, or if the motor has been started, the contacts opening will turn it off. The turning gear can also be operated manually.
6 Emergency trip functions

Lubrication oil is used as the control medium for the interface-diaphragm valve. Mounted on the governor pedestal the interface-diaphragm valve provides an interface between the mechanical overspeed and manual trip portion of the lubrication oil system and the autostop emergency trip portion of the control system. Lubrication oil from the Mechanical Overspeed and Manual Trip Header supplied to the diaphragm valve acts to overcome a spring force to hold the valve closed and thereby block a bath to drain of the fluid in the autostop emergency Trip Header. Any decay in the Mechanical Overspeed and Manual Trip Header Pressure, such as could be caused by
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either a manual trip or an overspeed trip, allows the spring to open the interface-diaphragm valve releasing the emergency trip fluid to drain and tripping the turbine. The condition of the lubrication oil systems bearing oil supply is monitored by the emergency trip system. Four pressure switches (63/LBO) monitor the condition of the Bearing Oil Header. If the header pressure decreases to the set point contact closures from the pressure switches cause the autostop trip (20/AST) solenoid valves to open and trip the turbine. The operation of the pressure switches and the solenoid valves as well as part lists are included in the leaflet covering the emergency trip system. See the content pages.
7 Lubrication oil 7.1 New oil

The oil shall be refined mineral oil of the highest quality and uniformity. It should not contain any grit, inorganic acid, a1kali, water, soap, asphaltum, pitch, resinous substances, or any other substance that will interfere with the properties of the oil, or be detrimental to the metals that are in contact with the oil. The oil shall be capable of preventing the formation of rust on steel parts. The oils ability to retard rust formation is very important, since it is impossible to exclude moisture from lubricating oil systems. The tests given in the latest issue of ASTM Specification D-665 entitled Rust Preventing Characteristics of Steam Turbine Oil in the Presence of Water, Test For and ASTM D943 Oxidation Characteristics should be performed on samples of the turbine lubricating oil to verify its acceptability. For subsequent care of oil (after initial use) refer to ASTM Standard 118 II Recommended Practices for the Purification of Steam Turbine Generator Oil. The oil purification system must be capable of removing all of the free water (water not in solution). Also, some oil purification systems using fullers earth, or similar
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filter materials, may remove the corrosion or oxidation inhibitors that were added by the supplier. Therefore, consult with him before such systems are applied. In Table l, the physical and chemical characteristics of the lubrication oil are given The values shown in this table are based on tests made in accordance With the latest approved standards of the American Society for Testing Material, except as otherwise noted. TABLE 1 Physical and Chemical Characteristics (New Oil Only) Flash Point Viscosity Viscosity Index Carbon Residue Neutralization No. Sulphur Content Corrosion Resistance Test Oxidation Resistance Test Shall Pass (l000 Hours with a Maximum Increase in Neutrality of 0.25) Sampling Flash point ASTM D270 ASTM D92 165.6,Min 30-37mm2/s at 37.8 90,Min. 0.10%,Max. 0.20, Max. ...... Shall Pass
Visc0sity ASTM D88
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Carbon Residue ASTM Dl89 Neutralization No. ASTM D664 Sulphur Content ASTM Dl29 Corrosion Resistance ASTM D665 Oxidation Resistance ASTM D943
7.2Oil sampling during operation

It is important that the lubricating oil be properly maintained in order to avoid harmful wear to the bearings ,journals ,and pumps. Periodic analysis must be made to determine if there are any property changes in the fluid, if changes do occur the cause should be established, and immediate steps taken to correct the problem. Acceptable contamination levels are given in Table 2 below. In this table, the number of allowable particles for each range of contaminate size includes soft particles as well as hard particles. Also, these numbers are only valid for lubricating oil tested during turbine operation; different values apply to lubricating oil that is tested throughout the turbine flushing procedure. For these values, see section six Determination of System Cleanliness. TABLE 2 Acceptable Contamination Levels Contaminant Size In Microns 5-10 10-25 25-50 50-100 Allowable Particles Per 100 ML Sample 32000 10700 1510 225
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100-250 Over-250 21 None
8 Oil reservoir
Oil reservoir zoom must cleanness, no overflow lubrication oil. Operators must make sure there are no duster clothdust or oil pollution in oil reservoir. The oil reservoir and the oil conditioning unit (if available) should be drained and thoroughly cleaned. Any damaged painted surfaces that come in contact with the lubricating oil must be cleaned and repainted. Turn off oil heaters before drain lubrication oil form oil reservoir. After drain the lubrication oil form oil reservoir, clean the inside shell and repaint the damage part. Inspect the flange connection and tighten the connection blot. The filter of the motor drive pump and oil ejector must be demounted and cleaned after oil drain. Remount the filter and make sure the washer placement is correct. Clean the translate pump and piping before return the oil to oil reservoir. It is recommended that return the oil to oil reservoir through the oil purification so that the oil is purificatory. After turbine long time shutdown, if oil purification is out of work, drain little lubrication oil form oil reservoir bottom, so that it can drain the deposition and water in oil reservoir bottom. Caution 1 Motor drive pumps must be inspected every week, and operate in a short time to make sure the safe standby condition.
2 DC emergency oil pump is the turbine last safety precautions, make sure there is enough voltage.
3 After large capacity flushing, oil reservoir inside piping and connection may be
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loosed. Inspect the connection and reconvert it. 4 During operation time, fire and high temperature piping are prohibited near lubrication oil system zone. 5 If the oil level is below the operate oil level or drain the oil form oil reservoir, oil heaters must be turn off. 6 Low voltages can make DC emergency oil pump out of work, it make bring bearing and journal neck damage. 7 The oil level is strictly controlled, too high can bring oil overflow and too low can bring un-normal operate of oil pumps.
9 Oil coolers
Oil coolers continuous services for two years, in the planned outage, dismount the tubes of oil coolers and clean the tubes and shell. When clean the tubes, water chambers must be dismounted. Check the tube plates and find the damaged tube plates. Before pull out the tubes, dismount the water reverse chambertube side O-rings and gland spacer. To avoid scrape gland spacer, acuminate tool for dismount is forbidden. O-rings breakaway when pull out the tubes. Use lifting nut to pull out the tubes, tube shall be moved in support or guide rail and displaced in support board. Displaced tube in tube is forbidden. Pull tubes in rough plate may damage the tube plates. Tube plates outer diameter is actually the same to the inner shell inner diameter, They must meet very close to the equipment in good working condition. NOTE: Before water chambers dismount, drain all the oil and water from oil coolers. Pulled out tubes, inspection of all O-ring, if damaged or falling, that is to be replaced. In reverse chamber side, any O-ring diameter greater than for the outer
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diameter of the reverse tube plate, that is to be replaced. When the oil coolers outage, dry coating method is proposed to protect the oil coolers. Drain the water form oil coolers and keep dry. If the dry coating method is not practical, with the water and tubes still contact, can not remain dry, it is necessary to let water flow continued and regularly replaced. So that the accumulation of harmful pollutants caused by corrosion to minimize. Water storage must not be allowed to stay fixed. If the oil coolers are received at the site had not been installed within six months, before operation of the turbine, replace at both ends of the O-ring. For the O-ring forms and materials must be the same as the original supply.
10 Three-way valve (only used for shell & tube oil cooler)
The valve should be checked at least once a year, to ensure operational flexibility. (1) Cleaning, inspection, repair and re-assembly Should use the appropriate solvent to wash all the parts, to remove oil or attachment of fouling, until the exposed metal color. Inspection, repair and / or replacement of damaged in the dismounting of all the parts (the gap, Burr, etc.). O-ring shall be replaced if damaged. Before the re-assembly, all parts should be no damage. Re-assembly is the disintegration of the inverse process. However, before blind flange plate (item No. 068) is not installed, check handle direction, and make sure the three-way valve is in work position. At the same time check valve disc opening direction. Two disc valve openings direction must in the same side and valve processing plate must face of valve seat. (May be the disc valve overturned after the assembly). When in the replacement of O-ring, smear the O-ring a thin of grease.
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After the assembly, check whether the smooth operation of the valve. The valve should be able to facilitate smooth work in two directions. Note: Unless the release of the hand wheel and raised his disc valve, or not rotating handle. (2) Break In order to the stem disintegration, we must follow the following steps: 1. Removed pin (item No. 2) from the top, unloaded the control handle (item No. 1). 2. Anti-clockwise rotation removed the hand wheel (item No. 3). 3. Removed screw (item No. 5) and remove (item No. 15) Journal bearing. 4. Remove O-ring (item No. 7). 5. Remove bolt (item No. 10) and washer (item No. 11) and unloaded set ring (item No. 9). 6. Remove sleeve (item No. 8). 7. Remove O-ring flange (item No. 24), with an O-ring (item No. 12).
8. In the valve, removed the valve disc (item No. 16), removed the key (item No. 17) on the stem. 9. Blind flange from the valve end, removed (item No. 21, 22), which can be removed blind
flange (item No. 28). The valve stem and valve disc pull together. From the stem nut on the opposite side removed the valve disc (item No. 16), not touch dynamic positioning nut. 10. Now the stem disintegration of all the components for inspection.
(3) Troubleshooting Fault The possible reasons Treatment
Sleeve and sleeve ring
O-ring wear or damage
Replacement of O-ring
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leakage (item No. 7) (with a small amount of lubricating grease) Stem and the O-ring flange leakage O-ring wear or damage Replacement of O-ring (item No. 12) (with a small amount of lubricating grease) O-ring flange and shell flange leakage O-ring flange or bolt (item No. 21) loose. special liner wear or damage Blind flange and shell flange leakage Fixed blind flange bolt (item No. 21) .blind flange gaskets wear or damage Tighten screw, replacement special liner(item No. 19) Tightening bolt, replacement (item No. 19)
Valve operation difficulties (in the conversion operation
The pressure difference between the valve disc is too high.
Do not operate the valve. reference for oil coolers leaf note
mode)
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11 Three-way valve interconnecting piping
Connected to the two oil coolers, a three-way valve is supplied. Use the three-way
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valve, an oil cooler from standby to go into operation. Three-way valve For the oil side of the two oil coolers, connected by a pipe and a switch valve. As shown. Note Before standby oil cooler is put into operation, the oil cooler must full fill with oil. At the same time completely discharge the gas, otherwise due to pressure fluctuations in the moment, bearing low pressure will cause turbine shutdown. Open the switch valve to fill the standby oil cooler with oil, when seen the oil flow indicator with the flow of oil, that is, oil has been filled with standby oil cooler. When in the operation time, switch valve remains open to ensure that the standby oil cooler is always filled with oil and ready to put into operation. Stop valve Apart from the cold cooler switch, stop valves (if the valve supplied) in all the operation time must be open. Oil coolers switch For the process of Oil coolers switch shown as follows: 1: In standby oil cooler full fill with cooling water. Note If oil cooler put into operation before the cooling water enter the oil cooler, it will cause bearings high temperature, bearings damage and shaft scratches. 2: To check switch valve is fully open, standby oil cooler filled with oil. 3: If a stop valve installed in standby oil cooler exhaust pipe, temporarily close the valve. In order to step up oil pressure of standby oil cooler close to the oil pressure of
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operation oil cooler. Note: pressure difference between the oil coolers is smaller; three-way valve will be easier to operate. 4: Appropriate rotate hand wheel, slightly rise up the sleeve. Operate three-way valve to the standby oil cooler running position. Turn hand wheel to reduce the sleeve. Tightening sufficient to ensure that the sleeve in place. 5: Open the oil piping valve (if provided), oil cooler is put into operation. 6: When the three-way valve operation, do not use valve wrenches or any other supporting leverage to operate hand wheel. Standby oil cooler for drain and maintenance When oil coolers stop operation, in order to clean or inspect oil coolers, turn off the switch valve and drain the oil form oil coolers. After cleaninginspection and / or maintenance, close standby oil coolers drain connection and fill oil. Note: Standby oil cooler to be filled with oil and ready for transport.
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12 Strainer
Periodically, remove and clean the oil strainer which is mounted in the trough inside the reservoir, annunciator provided by the purchaser will indicate this condition, and the strainer should be replaced immediately. It is recommended that a clean spare strainer and gasket be readily available to minimize the amount of time that the strainer is not in place.
13 Pressure switch
Electrical pumps start oil temperature above 10 Turning gear oil temperature above 21 Bearing back to the oil temperature below the 71 is normal Bearing back to the oil temperature 77 alarm
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Bearing back to the oil temperature 83 shutdown Radial bearing metal temperature below 90.5 is normal Radial bearing metal temperature 107 alarm Radial bearing metal temperature 113 shutdown Thrust bearing metal temperature below 90 is normal Thrust bearing metal temperature 99 alarm Thrust bearing metal temperature 107 shutdown Bearing lubricating oil pressure 0.08 ~ 0.15MPa (g) is normal Bearing lubricating oil pressure 0.07 ~ 0.08 MPa (g) auxiliary pump (AC) and the HP startup oil pump put into work Bearing lubricating oil pressure 0.06 ~ 0.07 MPa (g) the emergency oil pump put into work Bearing lubricating oil pressure 0.045 ~ 0.055 MPa (g) Alarm Bearing lubricating oil pressure 0.035 ~ 0.048 MPa (g) shutdown Lifting oil system oil pressure 8 ~ 12MPa (g) is normal Lifting oil system oil pressure > 4.2MPa (g) turning gear can put into work All the pressure switch in lubricating oil supply system must test at least once a year.
14 Temperature switch and heaters

The temperature switch and immersion heaters were adjusted either at the factory or at installation; however, their operation and set points should be verified periodically. The power to the heaters should be shut off before attempting to inspect them or perform any maintenance on them.
15 Level controls
The level controls were calibrated either at the factory or at installation; however their set points and operation should be verified periodically. The low-level alarm and
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heater trip can be checked while the reservoir is being drained. With the power to the heaters disconnected an ohmmeter should be connected across the heater lockout contacts on the level control. As the oil level falls, the heater trip set point can be verified by noting the oil level at which the ohmmeter indicates a loss of continuity. The alarm point can be verified by noting the oil level at which the alarm activates. The high level alarm and trip set points can be checked while the reservoir is being refilled; the reservoir should be filled to a level that is sufficient to activate the alarm or trip before starting the motor driven oil pumps to fill the oil supply piping. See the section of this leaflet describing the level controls for additional information.
16 Oil pressure value

name Description OutletIn rated speed symbol Design value MPa(g) A 1.4421.8
Main oil pump
Inletand emergency oil pump put into work InletIn rated speed HP startup oil pump Auxiliary pump(AC)
0.0690.1373
A A A A A
0.0690.31 0.8380.896 0.0830.124 0.0830.124 812 0.0960.124 0.03
Auxiliary pumps emergency oil pump(DC) Lifting oil pumps Pressure set value(in rated speed) Emergency Trip set value 3330r/min Lubrication oil Auto-shutdown lubrication oil
Page 30 of 74 17 Bearing and lubrication oil system

Description: Exciter the generators bearing temperature limit may be found in "generator statement." (1) Bearing metal limit temperature (3000 r / min). a: According to oil temperature, oil flow, bearing size and bearing load different, the turbine bearings metal general temperature is between 66 to 121 . 107 alarm. In more than 107 , operator must be aware and to identify the causes of abnormal temperature . Bearing metal temperature exceeds 113 , turbine should be tripping. Note: When the bearing temperature changes frequently. Operator should immediately identify the cause and trip of turbine if necessary. Inspect bearing and necessary repairs. b: thrust bearing metal temperature range, primarily on the basis of axial loading, from slightly over oil inlet temperature up to 99 . Alarm setting value is 99 , tripping setting value is 107 . If the temperature is between alarm temperature and tripping temperature, operator should pay attention to monitor and identify the causes of abnormal temperature. (2) Lubrication oil pressure limit The turbine of the bearing oil pressure alarm value and tripping value see "restrictions on the value of preventive measures and testing" in a turbine lubrication oil pressure," the relevant provisions.
(3) Lubrication oil temperature limit a: If oil temperature of the oil reservoir below 10 , shall not be initiated bearing pumps.
b: Oil temperature of the oil reservoir at least at 21 , the startup of turning gearing
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is permit ion. 21 is also the minimum turbine operation oil temperature. c: The oil temperature of turbine bearings back to oil reservoir should be below 83 , the alarm value is 77 , the tripping value is 83 . c: When the turbine at normal operation, the lubrication oil temperature inlet bearing is between 38 and 49 ., cut off oil coolers cooling water, make oil temperature rose to above range. d: When turbine in operate, make three-ways valve in open condition, to ensure that the standby oil cooler is full of cold oil inside and can be put into work at any time. (4) Vapor extraction device a: When the turbine in operate, the vapor extraction device in oil reservoir must be put into work. b: The vapor extraction device put the mist-gas (hydrogen and air) from the lubrication oil system and seal oil system out so that the whole turbine lubrication system and sealing oil system to maintain a low of negative pressure, and prevent the fuel-air along the rotor, leakage to the atmosphere. c: These task of exciter and generator oil system is done by the seal oil system vapor extraction device, and the turbine bearing boxoil reservoir and other parts of piping to the above-mentioned tasks, is completed by the vapor extraction device in oil reservoir. d: When the turbine in operate, if one of the two vapor extraction device failure or cut off. Have the possibility that some hydrogen oil gas and (or) lubrication oil may leaked to the turbine room. Under such circumstances, the turbine generator should immediately shutdown until the vapor extraction system to regain work.
18 Backup power
When the turbine in any higher speed than turning gear, with a reliable standby power is very important. Lubrication oil system designs two bearing oil pumps; one is AC pump and the other pump is DC oil pump. In some emergency situations, such as
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the AC power cut off, in order to guarantee the safety of turbine coast down, backup power supply time for the turbine should not be less than coast down time. Provide a reliable, adequate capacity of the DC power supply is the consumers responsibility. By the power failure caused the loss should be responsible for the consumer. As a storage battery to DC power, Its capacity in the coast down time, the pump must supply the necessary rating power. Maintenance of its time is about 60 minutes. In the absence of a reliable and adequate backup power supply, turbine does not allow startup. Operator must continue to monitor the DC power capacity, at any time should guarantee the safety of turbine coast down time required capacity. Note: After the DC motor-driven pumps and its subsidiary pressure switch test, the pump must be cut off, and then switch back to the "automatic" position.
19 Oil system flushing and installation procedure 19.1 Preface

It is the responsibility of the purchaser or his installation contractor to obtain a clean oil system in accordance with the acceptance criteria of this specification. There are a number of operations, which must be carefully followed beg1nning with certain factory operations and terwinating with the flushing and restoration of the oil system for operation. Each recommendation made herein must be carefully considered and implemented accordingly. Although the basic concepts are applicable to all units, including pace and integrated BFP turbines, each unit must be reviewed and modified for specific differences. Remember that the oil system is a large complex system with large piping and oil flows. Yet a small harmful particle can damage a large journal bearing resulting in a
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costly shutdown to correct the damage.
19.2 Introduction
Oil flushing is a necessary operation, which must be performed after all of the oil piping is installed and connected. This operation, however necessary, really does not add to the physical assembly of the unit. It generally is performed when the unit is nearing completion and falls directly in the critical path for startup. Therefore, considerable attention is focused on the time spent to flush and restore the unit for operation. The primary function of the oil flushing operation is to remove any harmful particle contaminants, which can damage or cause any related turbine generator component to malfunction. Past experience has shown that most of the harmful contaminants removed during the flushing operation are those which were introduced into the system during the storing and installation of the unit. These contaminants primarily enter the system through the open pedestals, open bearing housings, and/or contaminants, which collect in the guard piping during the field installation. It is of utmost importance that all contaminants be physically or mechanically removed, wherever possible, before the flushing operation. All current units are now provided with access openings to mechanically clean and inspect all components including the guard pipes, prior to the flushing operation. Any contamination, so removed l will not score or damage a bearing or a journal. The time and effort spent during this pre-flush cleaning program will unquestionably decrease the overall flushing time required to achieve a clean system. The burden imposed on the flushing operation must be limited to the contaminants, which cannot be mechanically or physically removed prior to flushing.
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To assure compliance with the specifications and procedures, all checks as identified in the check-off list must be completed and verified by the installation contractor. All pre-flush checks required by this list must be completed before flushing begins.
20 Shipping and on-site storage

Experience has shown that during shipment some of the devices provided to protect components, such as pipe caps, may be lost or damaged. Unless these protective devices are promptly restored, the unprotected areas will gather dirt and be susceptible to corrosion. Therefore, we recommend that the following on-site precautions and procedures be exercised to include the following components: A. Oil piping, both guarded and unguarded B. Seal oil systems C. Loop seal tanks D. Pedestals E. Oil reservoirs F. Bearing housings including generator brackets G. Bearings H. Oil purification systems (Generally not furnished by STC) 1. Inspect the components, upon arrival in the job site. Ascertain that all blanks and protective devices are intact. If any blanks or protective devices are found missing or damaged, the interior surfaces they were intended to protect shall be throughly inspected and restored and reprotected to drawing requirements. 2. Report any damage or abnormal condition of the components to STC.
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3. Off-ground, under roof storage is recommended for these components. 4.If under roof storage cannot be provided, the minimum storage requirements shall be off ground and completely covered with a suitable covering to preclude direct contact with sand, dirt, rain, or snow. 5. Judgement should be exercised as to the type of shelter provided dependirig on the contemplated storage time and environment. 6. If long term storage is contemplated, the integrity of the storage procedures must be periodically confirmed by inspection of the internal surfaces of the components. Inspections may be performed by sampling 1O% of the components at the end of the first 3 months and 5% of the total number of components inspected every 6 months thereafter in accordance with the following guidelines: a. Remove the component covers that will permit access to internal surfaces exposed to oil during normal operation. Any surface showing signs of corrosion must be restored and re-protected to drawing. b. If 50% or more of the surfaces inspected have some corrosion, all components must be inspected. Any surface showing signs of corrosion must be restored and re-protected to drawing. c. If less than 50% of the sample shows corrosion, identify the components in the sample so that they are not included in subsequent inspections. Any surface showing signs of corrosion must be restored and re-protected to drawing. NOTE Moisture and sand are generally introduced during the equipment storage-make certain that the storing facility will exclude both.
Page 36 of 74 21 Installation and general housekeeping procedures

During the installation of the turbine generator unit, the environmental conditions in the powerhouse are extremely dirty, dusty, and untidy. Under these conditions l all of the exposed oil bearing surfaces can become contaminated. At this time, a large amount of debris can be introduced into the guard piping and pedestal cavities, which may not be removed prior to the final flushing operation. This debris constitutes the bulk of the contaminants removed from the system during the flushing operation. To avoid the introduction of contaminants into the system during the erection cycle, it is recommended that: A. Caps or blanks remain on the pipe joints until removed for the fit up and welding of the joints. B. Covers be provided on all pedestals and bearing housings. Temporary pedestal covers can be made of plywood or similar materials. Covers must be equipped with openings for access to sampling strainers, temporary flushing piping valves, etc. without removing the cover. C. Until the permanent coupling guards are installed, each guardpipe joint must be covered at all times except when actual pipefitting and welding is being performed on the joint to the installation of the couplings. D. Upon the completion of each butt or socket weld within the guard pipe, remove all slag. Wire brush the weld and adjacent areas to the bare metal and restore and re-protect the areas to drawing. Care must be exercised not to admit contaminants into the guard pipe. E. Prior to the assembly of the guardpipe couplings. Inspect the internals of the guardpipe and vacuum to remove all contaminants.
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F. If any drilling, burning or chipping inside of bearing housings or oil reservoirs is required, special precautions (protective barriers) must be made to protect the adjacent surfaces. All contaminants must be removed immediately. G. If modifications must be made on the oil piping, all modified piping must be mechanically cleaned except in the case of new piping used in modifications, which must be mechanically or chemically cleaned before installation. H. Avoid all burning or grinding operations adjacent to the turbine generator. I. The oil reservoir is generally the first component placed on its foundation. Aside from periodic internal inspection, all reservoir openings must be sealed until access is required for field installation. J. Polyethylene used to cover pedestals, reservoirs, or pipe openings should not be made from fiber-polyethylene plastic material as the fibers come loose and contaminate the oil system.
22 Pre-flush planning and familiarization

Although the actual flushing procedure is conducted during the final stages of the turbine installation, it is essential that the installation contractor and the responsible parties plan ahead to achieve a clean system. A. Flushing drawings, where applicable, are standardized for various frame combinations and are available for early transmittal. These drawings should be carefully reviewed along with the various component assemblies to obtain a thorough knowledge of the flushing requirements, procedures and required complement of material. B. Prepare a schedule for performing the various flushing operations. C. The purchaser is responsible for furnishing and maintaining the lubricating oil. We recommend the use of lubricating oil for flushing. The use of flushing oils other
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than lubricating oil is not recommended as these oils contain additives to enhance their cleaning capability which may be harmful to oil system components. In addition, flushing oils normally cannot be used as lubricating oil as they do not contain some of the beneficial additives as lubricating oil. However, if the customer uses flushing oils, he assumes full responsibility to ensure its compatibility with the entire lubricating oil system and all turbine equipment exposed to this oil including, but not limited to the following: 1. All components of the lubrication system. 2. Final charge of lubricating oil. 3. Permanent or temporary flushing hose linings at temperatures up to 88. Including BFPT systems. 4. Rust preventive paints used in pedestal and guard piping. 5. Preservatives used in the pipes for shipping and erection that normally are not removed. If turbine oil is used for flushing, it must be reconditioned to new oil specifications if used for operating oil. D. Power requirements 1. Both AC and DC bearing oil pumps must be operated simultaneously throughout the entire flushing operation. Therefore, sufficient AC and DC power must be available for this and other auxiliary equipment. 2. If DC power is not available for continuous operation, a temporary AC motor must be provided by the purchaser or his installation contractor to operate the DC pump 3. The seal oil backup pump must be operable as required. CAUTION
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Before starting pump: Fill the pump with clean oil to seal the clearances and lubricate the internal parts. Starting or running a dry pump will came galling, seizing or destructive war between gears, side plates and pump body. 4. The bearing lift pump l where used, must also be operable as required. E. Contamination analysis equipment The following contamination analysis equipment must be supplied by the purchaser or his installation contractor. A). The following equipments: 1. Pyrex filter holder with stainless screen. 2. Filtering flask, 1-liter capacity. 3. Vacuum hose ,gum rubber. B). One vacuum pump. C). 150-mesh wire cut at site to fit item A-l. Wire should be purchased locally. D). 10X(Min.) Scaled magnifier. Refer to section X for sampling procedures and techniques for determining system cleanliness. NOTE 150, l60, or l70-mesh can be used depending on local supplier availability. This is also applicable to 15O-mesh required in all strainers throughout the procedure. The same mesh should be wed throughout the system.
22 Pre-flush operations and procedures

It is extremely important that all oil wetted surfaces be cleaned and inspected prior to charging the system with oil. A. Ascertain that the temporary flushing connections are correctly installed.
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Generators shipped assembled will have the bearing oil bypassed at the brackets to drain. Generators assembled in the field will be treated in a manner similar to the turbine bearings. B. It is necessary to modify the oil reservoir piping to obtain the desired flow configuration, as illustrated in Fig. 1. To flush the main oil pump suction (MOPS) and discharge (MOPD) piping the oil ejector is disconnected in the reservoir. It is no necessary to remove the ejector from the reservoir. Lay the ejector on the bottom of the reservoir and place all nuts, bolts f and associated hardware in a clean sealed metal container. This container can be stored in the reservoir for the duration of the flush. The temporary modifications shown in fig. 1 will permit the flushing of the MOPS and MOPD lines, seal oil backup and the bearing lines without any further internal reservoir modifications. C. Inspection and charging the reservoir initially with oil. l. Inspect inside of reservoir carefully to ascertain that all flanges and temporary connections are tight and properly supported. 2. Reservoir internal surfaces must be clean and free of all contaminants. 3. The initial charge of oil must be passed through a 15O-mesh strainer. 4. Add sufficient oil so that during operation the oil level in the reservoir is a minimum of 0.508m above the pump discharge with BOTH coolers and BOTH pumps in operation. 5. Contaminant traps and inspection covers are furnished on the guardpipe couplings on new units. Remove all contaminants through these openings manually or with vacuum cleaners. 6. Clean and cover all pedestals, bearing housings and reservoir openings. These covers must not be removed during the entire flush unless absolutely necessary.
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D. The oil level in the (reservoir) drain trough to the strainer will run near full with both pumps in operation. Provide a temporary 150-mesh strainer over all overflow openings including those at the inlet areas. These temporary overflow strainers must be removed after completion of the flush prior to turbine generator start-up. E. Guardpipe vent line cleaning A DN100 vent line is provided in the vertical run of the guardpipe. This vent connects the reservoir with the horizontal run of guardpipe. Its function is to vent the reservoir to the horizontal guardpipe since the section of guardpipe adjacent to the reservoir runs full. This arrangement permits a negative pressure to be maintained throughout the oil system. This vent pipe normally does not pass oil and generally is a straight run of pipe. To clean the vent pipe perform the following steps: 1. When cleaning the reservoir prior to adding any oil, inspect the vent pipe internally. 2. Remove any debris by washing with solvent and blow clean with high-pressure air. 3. After pipe is clean. Add a 150-mesh temporary strainer over the opening in the reservoir using a hose clamp. The pipe generally protrudes 25.4mm to 38.1mm through the top plate.
4. Remove the screen after flush and reclean if necessary.
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F. Hot oil vapors will ignite if exposed to open flame. Avoid any burning, welding, or any open flame in the turbine areas when flushing. G. Make certain that fire extinguishers are readily available at the turbine and reservoir areas. H. Establish communications with the control room for emergency shutdown of the pumps. It is recommended that the customer provide temporary emergency switches at the reservoir to operate the AC and DC bearing oil pumps. I. Oil purification system (ref: ASME standard no.118). The oil purification system is normally supplied by the purchaser who is responsible for the cleanliness of the unit and the interconnecting piping prior to the flushing operation. 1. It is recommended that all internal surfaces contiguous with the oil be clean and painted with a permanent type of oil resistant paint. (this includes all surfaces wetted by oil or exposed to oil vapor). 2. Provide a l50-mesh temporary strainer in both the suction and discharge lines to the purification unit- The strainer in the discharge line must be located adjacent to the reservoir as shown in Fig. 2. 3. Oil from the purification system returns directly to the oil reservoir. Therefore, all interconnecting piping to and especially from the purification system must be pickled and immediately preserved. Piping must be clean before installation. 4. Provisions must be made to connect a temporary suction line to the purification system from the bottom of the reservoir. See Fig. 2. 5. The permanent purification system is generally sized to bypass l0%-20% of the reservoir capacity per hour. It is recommended that additional supplementary filtering be added to accelerate the removal of fine particles below 0.l27mm.
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NOTE The purification system must be in service throughout the entire flushing operation. If the pumping operation is conducted on less than a 24-hour per day basis, the purification system should remain in service continuously. The strainer in the return line between the purchaser's oil conditioning unit and the oil reservoir is to be removed and cleaned each time the flushing operation is shutdown. At the successful conclusion of the entire flushing operation ,this strainer can be removed permanently providing the debris on the strainer meets the particle count requirements of this specification. If the debris exceeds the specification requirements, the strainer must be replaced and remain in operation until the debris is within the specification requirements. Removal of this temporary strainer, for sampling and cleaning, can be performed at any time after the successful completion of the flushing process.
23 General design considerations

A. The primary areas contiguous with the lubrication oil surfaces are: 1. Oil reservoir 2. Oil coolers 3. Oil piping ,guarded and unguarded 4. Bearing housings and pedestals 5. Oil purification system B. Oil reservoirs: On large central station units we have standardized on the following nominal reservoir sizes: 30m3. The reservoirs are cylindrical in shape and in addition to the oil contain internal piping, check valves, oil ejector, pumps f orifices and relief valves necessary to control the lubricating oil system. Provisions are also made in the
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reservoir to supply high and low oil pressure seal oil backup to the generator seals. The oil reservoir shell is fabricated and sandblasted internally then cleaned and painted with oil resistant aluminum paint. This paint affords an excellent oxidation resistant surface. Similarly, all of the exteri or surfaces of the components inside of the reservoir are painted to aluminum paint. The inside of the oil piping is pickled and coated with a rust preservative oil. C. Oil coolers: Oil coolers are fabricated in a package including the stop valves and interconnecting piping. This cooler package is hydro-tested using water. The fluid is then drained; however, all internal surfaces of the cooler are adequately coated with the rust preservative fluid. The openings are immediately blanked for shipment. D. Oil piping-guarded and unguarded The guarded oil piping interconnects the oil reservoir with the turbine pedestals. It acts as an envelope for the internal pressure piping and also as a drain line to return the oil to the reservoir. The internal surfaces of the guard pipe and the external surfaces of the internal pressure piping are painted with aluminum paint. All of the internal surfaces of the pressure supply piping are pickled or sand blasted and coated with a rust preservative oil and capped. The end of the large guard pipes are also capped, thereby double protection is provided for the internal pipe system. E. Bearing housings and pedestals The bearing housings and pedestals are designed to eliminate any crevices, which may act as a dirt retainer. All oil supply & BRG lift lines are fabricated to avoid areas, which cannot be cleaned and inspected through suitable clean-out plugs. All pedestal internal surfaces ,base and cover,are cleaned and painted with aluminum paint. All machined surfaces are coated with a preservative.
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All assembled components are properly capped or plugged to preclude the introduction of contaminants during the shipping and subsequent on-site storage period.
24 General notes
A. Pumps and motors To obtain maximum flushing velocities the AC and DC bearing oil pumps must be run simultaneously throughout the entire flushing operation. The pumps are capable of producing flows well above the normal rated flow requirements. The maximum load imposed on the motor must be periodically checked by monitoring the input current. Record the results of each check. 1. Open drip proof motors may be operated continuously at 15% above the nameplate rating. 2. Do not exceed the nameplate rating on totally enclosed fan cooled or explosion proof motors. B. The oil flushing must be conducted on a minimum of one shift per day (8 hours normal) basis. C. Vibrators: fieldwelds in exposed and accessible oil supply piping should be rapped or vibrated in the weld areas with the following considerations and precautions: 1. Use brass or lead hammers to rap the weld areas, do not use lead on nuclear units. 2. Use blunt contoured chisels with ends surfaced with soft brass.
3. Vibrating the guard piping is not recommended since it may distort the internal pipe bracing and weld joints.
CAUTION
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Do not impair the integrity of the welds or the adjacent piping in any way the rapping or vibrating operations. D. Alternate heating and cooling of the oil is required throughout the entire flushing operation. The heating and cooling produces thermal expansion and contraction of the piping, thereby, loosening the foreign particles adhering to the walls of the pipe. Heating and cooling of the oil also produces large changes in the oil viscosity thereby, providing a better scrubbing action and capability of transporting heavier particles to the strainer. To achieve the beneficial effects of contraction and expansion and changes in viscosity, we suggest a minimum oil temperature change of 38. The maximum oil temperature should not exceed 88. E. The oil coolers normally supplied with the unit may be used to heat and cool the oil. Hot water (not exceed 93)may be circulated through one cooler to heat the oil. If hot water is not available it then will be necessary for the flushing contractor to furnish a heat exchanger for this purpose. A typical heat exchanger is shown in Fig. 3. The other cooler should be connected to a cold water source for cooling the oil' Refer to note on last page of this content F. To preclude excessive pressure drop resulting from large oil flows through a single oil cooler, the cooler bundle must be removed for the flushing operation. Therefore: 1. Supplemental heating of the oil must be furnished by the flushing contractor. 2. The source for heating the oil may be steam coils or electric immersion heaters in the oil coolers or in the oil reservoir. The heating device should be sized to heat the oil to 66-82, in approximately four (4 ) hours. A considerable amount of heat is lost by radiation when circulating at low station ambient temperatures; therefore, include this factor when sizing the oil heaters. 3. If electric immersion heaters are used they must not exceed 0.028 watts per
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square mm density. CAUTION Always maintain an oil level in the reservoir to completely cover the electric heaters' Shot off heaters when oil is not being circulated. Un-submerged, energized heaters in the reservoir will ignite the oil. 4. If steam heaters are used, inlet steam temperatures do not exceed 177. Shut off steam to heaters when oil is not being circulated. G. Supplemental pump
Although the capability of the system will produce adequate flows to obtain the desired flushing velocities, the system can be readily modified to accept a supplemental pump.
Refer to Figure 4, which diagrammatically illustrates a typical system utilizing a supple mental pump. By removing the DC pump, access for the supplemental pump suction is readily available. The pump discharge is connected to the ejector discharge in the reservoir. Priming of the pump may be accomplished by using the AC bearing oil pump in the reservoir. H. Oil coolers The oil coolers are designed for 0.33 Mpa(a)shell pressures and hydro tested to 0.50 Mpa(a) CAUTION Do not under any circumstances pressurize the coolers above 0.50 Mpa(a). I. Flow philosophy It is important that the flushing contractor understands the basic flow philosophy so that he will take the necessary steps to attain the desired flushing velocities.
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Primarily the fluid velocity in a pipe is a function of the flow and area' Figure 5 illustrates a typical bearing header supply configuration where four bearings are supplied from a single header. Each bearing requires0.76m3/min at synchronous speed with a bearing oil pressure of approximately 0.11 MPa(g) at the turbine pedestals. The header-supply pipe system is sized for a normal operating velocity of approximately 1.52m per second. In order to double the flow-velocity the discharge area must be doubled. To triple the flow-velocity through the header the discharge area must be tripled. Note that in each case the flow-velocity through the system is a function of the discharge area and obtained with moderate oil header pressures. Openings are generally provided adjacent to the bearings for cleaning and visual inspection of the supply headers in the pedestals and bearing housings. These openings are also designed to provide supplementa1 discharge areas in the bearing header. Each supplemental port must be partially open during the flushing operation to obtain cleaning and additional flow. A 2mm half gasket applied to the top half of all blind flanges or application of temporary hoses and valves; to pipe plug connections as shown on Fig. 5 will provide adequate flow. Remember that the velocity is a direct function of the flow' Doubling the flow will double the velocity. Also, the header flow is contingent on the discharge openings. Therefore, always attempt to circulate oil with all discharge areas open as wide as possible without overloading the pump motors, flooding the bearing pedestals, or overflowing the reservoir manhole cover. CAUT1ON Under emergency conditions involving loss of one pump immediately check the load on the operating pump motor, as it may become overloaded. If this
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condition occurs, reduce the flow from the header he closing selected discharge valves at the bearings until the motor current is reduced to a permissible levelDiscontinue the flushing operation until both pumps are restored to service. A general rule for the application of short (approximately 4.6m long) DN50 temporary hoses is that one hose is adequate to obtain twice the normal flow-velocity for all bearing sizes including: 406 mm 406mm- 3000RPM 533.4 mm 533.4mm- 1500RPM For larger bearing sizes a single DN 80 line or two DN50 temporary hoses must be used. For the following generator bearing use a single DN100 line or a DN80 line in parallel with a DN5O hose: 533. 4mm 533. 4mm- 3000RPM 7l1. 2mm 889mm- 1500RPM All valves used in the above temporary lines must be full flow gate valves. When instal1ing temporary hoses, select hose length to allow some slack in the line. Apply two clamps on each hose connection. Check all clamps periodically during the flushing operation and anchor all hoses to eliminate whip or walk. To preclude excessive pressure drop through the cooler with two-pump, full flow flushing, place both coolers in service simultaneously by placing the three-way vavle handle or hand wheel in the mid position. This does not interfere with the heating and cooling as described under section E. NOTE Alternate controlled admission of cold and hot cater to the respective cooler with oil flowing simultaneously through both coolers will attain the desired oil temperate
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cycling with minimum oil flow restriction and pressure drop through the coolers.
25 Flushing procedures
A. The flushing procedure is subdivided into four(4) basic parts: 1. Preliminary flushing procedure to determine reservoir/oil cleanliness. 2. Main oil pump suction and discharge lines including the associated control lines in the pedestals. 3. Bearing oil supply lines and miscellaneous lubricating oil lines including bearing lift pump lines where applicable. Bearing lift lines, where provided for the central BRG lift system, oil reservoir, are to be flushed continuously with the bearing oil lines. Figure 6 outlines the necessary modifications to a typical bearing lift line. All of the internal tubing is removable and can be visually inspected and mechanically cleaned if required. For individual bearing lift system the lines are flushed with the bearing oil line in the respective bearing housing. Fig. 6A outlines the necessary modification to a typical individual bearing lift line. The bearing lift pump is supercharged from the bearing supply header. The filter at the discharge of the lift pump shall be inspected and clean before starting the lift pump' Remove the filter element and clean after completion of the bearing oil flush. 4. Sampling is not required for bearing lift lines, hydrogen seal oil lines and HP and LP back up lines. B. The following describes details of the four flushing steps:
1. Reservoir/oil cleanliness
a. Start oil flow. Clean the reservoir return strainers as required to prevent oil from overflowing the oil reservoir manhole cover during the initial period of high debris accumulation.
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b. When approximately 8 cumulative hours of full flow flushing have been completed. Shutdown flushing operation for the overnight period immediately following the 8-hour total run. Continue operation of the oil purification system. c. After approximately 16 hours of flushing, shutdown and perform the following operations: 1). Secure purification system and inspect, clean, and reassemble the temporary strainers in the lines to and from the purification system. 2). Open guard pipe access covers and inspect and clean the inside of the guardpipe in the vicinity of the access opening as required. 3). Drain, clean and reassemble all guard pipe contaminant traps. d. Commence full flow flushing with oil purification system in service. e. Repeat step b and c. 1. f. Determine c1.anliness of reservoir by examining the temporary strainer in the suction line to the oil purification system. Recommended guidelines for action are: 1). Less than 50 hard particles greater than 0.127mm continue to flush. 2). More than 50 hard particles greater than 0.127mm drain and clean reservoir. 3). Recharge with same procedure as initial fill if step (2) is required.
2. Main oil pump suction and discharge lines (ref. figure 1).
The reservoir modifications have been made per the "pre-flush operation and procedure" to accommodate the flushing of the MOPS and MOPD lines. Provisions 11ave also been included (ref. fig. 1) whereby the temporary bypass line can be capped at "A" after flushing the MOPS and MOPD lines without draining the reservoir so that full oil flow to the bearing oil header can be accomplished. The oil, which is circulated through the main oil pump lines does not pass through the oil coolers. Therefore, it is necessary to continuously bypass oil through the bearing
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header to heat and cool the oil. The shut off valve in any bearing supply line can be opened during this flushing operation to facilitate the heating and cooling of the oil. (Bypass approximately 0.75 m3 /min). Install a sampling strainer on the temporary main oil pump discharge line (see fig. 1) at the reservoir to determine when these lines meet the acceptance criteria NOTE All miscellaneous control tubing inside, of the pedestals and bearing housings must be disconnected at this time and pumped throughout the entire flushing procedure. Connections may vary depending on unit configuration. Generally the principle connections include the following components. a. Auto-stop and protective devices. b. Zero speed indicator. c. Thrust bearing trip. d. Oil supply to the turning gear and gear sprays. Remove and catalog any orifices in these lines to insure full flushing flows. Flush the MOPS and MOPD lines by closing the valves in the temporary flushing hose lines at the bearings so that the pumps are not overloaded. However, sufficient bearing lines must remain open to provide adequate flow through the oil coolers for heating and cooling the oil. Thrust bearing supply lines are to be open throughout the entire flush. No sampling is required since the common supply line is sampled adjacent to the thrust bearing. NOTE During the M0PS and M0PD flush, open additional bearing oil lines to Pump as many bearing simultaneously as possible without overloading the pumps.
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In the event the MOPS and MOPD lines do not meet the cleanliness requirements of this specification, or show a positive and continuous reduction in the number of hard particles deposited on the sampling strainer within the first 100 hours of flushing. Shutdown and locate and remove the source of contamination before continuing the flushing operation. To ascertain that there is a positive and continuous reduction in the number of particles ,a minimum of 10 samples must be taken during the 100-hour period. The trend may be determined by counting particles on the 150-mesh filters. By weighing or by examination with a magnifying glass. All samples must be identified, protected and retained until successful completion of the flushing process for the entire oil system. These samples will be used for comparative analysis and reference in the event problems develop during the flushing operation.
If a positive and continuous reduction in the number of hard particles is not demonstrated in this initial 100-hour period, analyze the debris to determine whether or not it is typical of the foreign material usually encountered in these components as a result of normal erection procedures. If it is normal, restart and flush until the system is clean. If the debris is abnormal ,locate and remove the source before continuing the flushing procedure. In either case, if the system does not clean up in the next 100 hours, shutdown and repeat the above process. Thereafter, continue the flushing operation in 100-hour increments shutting down and executing the above procedure at the end of each 100-hour increment until the oil system meets the cleanliness requirements of this specification. After the flush has been completed, reassemble the orifices as originally found. When the MOPS and MOPD lines meet the cleanliness criteria, the temporary bypass hose line is capped or blanked off. Remember that this hose remains pressurized during the remainder of the flush.
Page 54 of 74 3. Bearing 0il supply lines

All bearing lines are f1ushed to a point adjacent to the bearing, there is no oil flow through the bearing during flushing. All thrust bearing shoes must be removed prior to commencing oil flush. Determine the type of bearings provided at each location and install the temporary bypass configuration as shown on Figures 7A, 7B. If the top half of the bearing is removed, protect the exposed journal surface. When flushing, always open as many bearing oil discharge lines as possible at the turbine pedestals and bearing housings without overloading the motor or flooding the bearing pedestals or housings. Remember, maximum flow will produce maximum velocity' Typical L P bearing housings, including the temporary hoses and sampling strainers are shown on Figures 7A. Note that the section of the supply line adjacent to the bearing is removable and a temporary pipe must be connected directly to the header. Also note that the temporary hose should be directed into the bearing drain guard to avoid flooding the pedestal. Removable flanges or plugs are available for added flow area. They must be partially open as shown in Figures 5, 7A. On other pedestal configurations, check for the location of the clean out plugs and apply temporary hoses or valves connections. These must also be partially open during the flushing operation. NOTE Record the location of the partial gaskets and the removed plugs. These flanged joints and plugs must be restored after the Pump is completed. Always install and record a bearing header gauge to monitor the pressure in the line. Opening the bearing bypass lines and the supplemental bypass lines in the bearing housings will reduce the header pressure. This is normal, and indicates that additional flow is passing through the header piping. Do not attempt to maintain a high header pressure by closing the bearing bypass valves. Remember that the velocity is a
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function of the flow through the pipe and not the pressure in the pipe. Full flow flush for 24 hours and begin sampling the cleanliness of the bearing lines. Sampling strainer screens are not to be installed during the flush unless the oil is being sampled. Remove the plug and screen to permit full flow through the strainer housing. Begin sampling after this 24-hour period, all bearings may be sampled simultaneously or individually in any sequence at the discretion of the flushing contractor. Thereafter, sampling of any bearing or bearings may be repeated in two-hour intervals. In the event, the bearing supply lines do not meet the cleanliness requirements of this specification, or show a positive and continuous reduction in the number of hard particles deposited on the sampling strainer within the first 100 hours of flushing, shutdown and locate and remove the source of contamination before continuing the flushing operation. To ascertain that there is a positive and continuous reduction in the number of particles, a minimum of 5 samples on each bearing must be taken during the 100-hour period. The trend may be determined by counting particles on the l50-mesh filters, by weighing or by examination with a magnifying glass. All samples must be identified, protected and retained until successful completion of the flushing process for the entire oil system. These samples will be used for comparative analysis and reference in the event problems develop during the flushing operation. If a positive and continuous reduction in the number of hard particles is not demonstrated in this initial l00-hour period, analyze the debris to determine whether or not it is typical of the foreign material usually encountered in these components as a result of normal erection procedures. If it is normal, restart and flush until the system is clean. If the debris is abnormal, locate and remove the source before continuing the flushing procedure. In either case, if the system does not Clean up in the next 100-hours, shutdown and repeat the above process. Thereafter, continue the flushing operation in l00-hour increments shutting down and executing the above
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procedure at the end of each l00-hour increment until the oil system meets the cleanliness requirements of this specification. Each bearing supply line must meet the acceptance criteria before it is finally judged clean. When flushing has progressed to the point where two(2) bearing line samples approach the acceptance criteria ,i.e.: a. l0-15Hard particles in the 0.127 to 0.254mm range.
b. Up to 4 hard particles above 0.254mm. Shutdown the flushing operation and remove the oil cooler bundle(s).
NOTE Coolers must be drained and pulled individually with the 3-mp valve in an appropriate position to isolate the bindle being removed. The isolated cooler must be drained before pulling any tube bundle. Clean the oil cooler shell(s) with clean, lint-free rags. Steam clean the oil cooler tube bundle(s). The cooler bundle(s) must be protected during the entire time they are removed from the cooler shell(s). Re-install the cooler bundle (s) and continue the flushing operation.
Once the cleanliness criteria is satisfied for any bearing, that bearing line is judged clean and no further sampling of that line is required. When any generator or LP turbine bearing line is judged clean, immediately connect those temporary hoses to the seal oil manifold to back-flush the seal oil lines. Provide a minimum of 3 to 5 supply lines from the generator and LP bearings to each manifold. Roll each bearing after the flushing operation and carefully inspect the babbitted surfaces. Remove any embedded hard particles by lightly scrapping the bearing surface without removing any babbit. Clean and coat journals with S. T- P. oil or SAE
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90 oil and reassemble bearing caps.
4. Hydrogen seal oil lines

The hydrogen seal oil lines interconnect the seal oil unit to the generator brackets. These lines are normally flanged at each end. By disconnecting the flanges at each end and installing side outlet flanges, each pipe section can be flushed. All interconnecting hydrogen seal oil piping is backflushed from the generator to the oil reservoir. Valves manifolds are used at the generator brackets to supply and regulate the oil through each line. A similar manifold is used at the seal oil unit to return the oil to the reservoir. Oil for back flushing is supplied to the manifolds from the generator and low-pressure turbine temporary bearing bypass lines. At least three (3) or more supply lines must be connected to each manifold in produce sufficient back flush oil. There are several configurations of seal oil piping, however, the basic back flush philosophy will apply to all units. Two DN50 temporary drain lines ate adequate to return the oil to the reservoir on fossil units under 500MW. On larger fossil and all nuclear units provide a DNl00 pipe header from the seal oil unit to the reservoir. Hose or pipe (steel f aluminum, or plastic) connections are to be used from the seal oil manifolds to the header and from the header to the reservoir. Most of the seal oil pipe connections are under DN25 and are sensing lines with little or no flow. These lines are to be backflushed for a minimum of 8 hours and checked for free flow. No sampling is required on these lines. The air side and hydrogen seal oil feed lines are to be flushed and must meet the bearing acceptance criteria. See Fig. 8 for sampling strainer locations
26 Procedures for determining system cleanliness

A. Insert a clean sampling strainer into the Y housing and open valve for 30
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minutes of full flow. 1. Close valve and carefully remove the sampling strainer and place into a clean container. 2. In a clean environment l wash the sampling strainer with a clean fluid collecting all residue on a l50-mesh filter into a vacuum flask. 3. Remove the filter and, using a scaled magnifier, scan the filter to determine the size and number of particles in the 0.l27-0.254mm range. No attempt is to be made to move or rotate particles. They are to be observed as they lay on the filter with two dimensions visible. B. Based on these two dimensions, cleanliness of the specific system being checked is acceptable if particle sizes and count meet the following requirements: 1. No hard particles above 0.254mm. 2. The total number of hard particles in the 0.127-0.254mm range must be less than five (5). C. All contaminants removed from the system should be retained and carefully inspected. Experience has shown that a system where all pre-flush cleanliness operations have been followed will yield legs than 0.5kg of contaminants. If during the normal flushing procedures, a large influx of contaminants is noted, shutdown the pumps and investigate the source of these contaminants. D. Harmful particles generally removed during the flushing operation consist of: 1. Large particles of scale or rust, weld beads, and weld slag. 2. Sand, stones ,concrete, or glass. 3. Metal chips of any sort including weld rods. 4. Large particles of cloth, plastics, or other materials, which may not score the
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journals but can impede the flow of oil through the piping or restricted openings. Particles which may exceed the 0.254mm size but are soft and not considered harmful are: lint, paper, saw dust, tobacco, asbestos, and any soft materials which can be readily powdered between the fingers. NOTE The fore-mentioned procedure is a statistical approach for determining the system cleanliness. It does not require all of the flushing oil at individual bearings to pass through the sampling strainers then samples are taken. Supplemental openings or branch lines added to increase the flushing velocities are to remain open during the sampling run.
27 Restoration of the system

It is important, after the system has been judged clean, to carefully supervise the restoration of the unit for operation. Any contaminants entering the system after this time must be mechanically removed. There is no reflush prior to the operation of the unit. Several recommendations are in order:
1. Drain reservoir, restore all internal piping ,clean and carefully inspect the reservoir after restoration. It must be thoroughly clean before the final charge of operating oil is supplied.
2. Remove main oil pump casing cover. Inspect pump casing and impeller and ascertain that pump housing, seals, and vanes are clean. 3. Clean and install all bearing pedestal covers immediately after the flushing is completed. 4. If any piping modifications are made to the oil system after the flushing operation has been completed, it may be necessary to reflush. 5. Clean all contaminant traps in the guard pipe. Carefully inspect internal piping and guard-pipe through the handhole openings and reassemble promptly.
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6. Any blanks or plugs removed or lost in the bearing housings or pedestal for flushing must be properly reassembled and tightened. Tack weld plugs or two flange nuts diametrically opposite. 7. After the system has been restored, oil must be circulated for a period of 1 hour per week to maintain an oil film on all areas contiguous with oil that are not painted. (check for leaks and proper oil operating levels). For extended lay-up of the unit after the system has been flushed consult STC. 8. Any miscellaneous fittings or valves not shown on the "TEMP CLEANING B/M" required for the flushing operation will be furnished by the flushing contractor. 9. Temporary strainers over drain through overflow slots and other locations where applied, must be removed before the startup of the turbine prevent oil spill if the return strainer should become plugged.
28 Temporary flushing materials

It is the responsibility of the purchaser or his designated flushing contractor to supply all of the necessary temporary equipment to satisfy the "oil flushing specifications and procedures." The following section will outline the basic major temporary components required for the flushing operations. It is not intended to outline in detail the miscellaneous hardware such as nuts, bolts, pipe plugs, pipe reducers, etc., which is normally carried by most piping contractors. There are a number of drawings transmitted to the customer shortly after the unit is purchased. These are the basic drawings which must be reviewed in order to produce a materials list for flushing. A. General information; drawings. Drawings transmitted to the customer. 1. Piping clear & equip LOC oil
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2. Oil sys flsh instl proc
3. Piping oil flow diagram
4. Piping oil drain guard assy 5. Piping oil generator assy 6. Piping oil seal assy 7. Lub oil reservoir outline B. General information-flushing hardware: 1. Sufficient temporary material must be procured to flush the entire system. 2. All temporary flushing equipments must be free of all harmful particle and chemical contaminants. 3. The pressure rating of the flushing materials must be suitable for the maximum working pressures encountered during the flushing operation. 4. Any hose materials used for bypass or sampling connections, must be compatible with hot oil at 88 temperatures. Neoprene or buna-N has been generally used. 5. When the lube oil pumps are used to provide the flushing oil pressures, 0.84 MPa fittings are acceptable. If a supplemental pump is used, the pressure rating of the hardware at the pump, must be furnished accordingly. 6. Use gate valves where full flow is required, otherwise, globe valves are acceptable. 7. The flushing contractor should investigate the use of aluminum irrigation piping with suitable couplings for sizes above 100 mm with suitable pressure ratings. 8. If any temporary pipe is fabricated or pre assembled and stored for any period of time, all internal surfaces contiguous with oil must be protected with a rust preventative oil compatible with turbine oil.
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C. Reservoir Preparation: 1. Supply the necessary connections to the customer' s purification system from the bottom of the reservoir. If a supplemental oil filter is used, include the necessary connections to and from the filter. The 100-mesh strainer from the reservoir is a sampling strainer to monitor the cleanliness of the flushing oil. Suitable valve is necessary to periodically remove this strainer for inspection fig. 2. 2. Provide a blank off flange at the ejector discharge fig. 1. 3. Connect temporary bypass line from MOP discharge line to the strainer trough. For all sizes use a .168 bypass line. Provide bypass sampling strainer line as shown. Provisions for a blank off flange or a DN150 valve must be made at location "A".
4. Supplemental pump: If a supplemental pump is used, the pump discharge is connected into the ejector discharge. Remove blind flange (C.l-3) fig. 4.
5. Provide a suitable heat exchanger for heating the oil fig. 3. 6. Provide a temporary AC motor if DC power is not available. D. Bearing oil fIush 1. Determine the number, size and flows for the bearings. 2. Provide one sampling hose assembly for each bearing. 3. Provide sufficient hose or pipe bypass assemblies for each bearing for required size and arrangement in pedestals refer VIII. APPENEX APPROXIMATE FLOW VELOCITY FOR VARIOUS PIPE SIZES STANDARD m3/h FLOW m3/h FLOW m3/h FLOW
Page 63 of 74
PIPE SIZE mm FOR 3.05m/s VELOCITY FOR 4.57m/s VELOCITY FOR SHORT NOZZLE WITH P=0.113MPa 64 89 102 114 140 168 219 273 22.7 51 69 91 136 204 363 568 34 77 104 136 204 306 545 850 91 198 272 363 454 795 1452 1816
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Page 65 of 74
Page 66 of 74
Page 67 of 74
Page 68 of 74
Page 69 of 74
FIGUER 6 1. Remove tubing sections "A" and "B" cap openings as shown. 2. Add temporary DN20 gate or globe valve at bearing lift inlet inside of pedestal. 3. Flush all bearing lift lines simultaneously for 4 hours. 4. Beginning at the generator end of unit, flush each line for two hours. Close all other lines. 5. After all lines have been flushed individually, re-open all lines and continue to flush until the bearing flush has bee1completed. 6. Ascertain that the bearing lift passages in the bearing are clean when the bearing is rolled out after the bearing flush. 7. Set flow control valve to maximum opening and blow through with clean dry air.
Page 70 of 74
Add clean oil to valve internals. 8. Blow out tubing sections "A" and "B" and inspect thoroughly. 9. Reassemble to drawing.
1. Remove tubing section "B" cap opening at the bearing & leave the opening at lift pump discharge open. 2. Flush the lift system for 4 hours. 3.Ascertain that the bearing lift passages in the bearing are clean when the bearing is rolled out after the bearing flush. 4. Blow out tubing sections "A" & "B" and inspect thoroughly. 5. Reassemble to drawing.
Page 71 of 74
Page 72 of 74
NOTES: 1. Protect journal and oil groove from oil. 2. Adapter to be supplied by field service. 3. Bottom half of bearing to be rolled as shown. 4. Disconnect hose connections to each pad drain into pedestal during flushing operation. Remove orifices from supply manifold to insure an equate flow. CAUTION Orifice size for upper pads is smaller than for lower pads; be sure they are correctly reinstalled upon completion of Pumping. 5. Those designs of tilting pad bearings have a horizontal inlet oil supply and having the seal ring bolted direct to the bearing support, must be flushed by
Page 73 of 74
supporting the spindle with the spindle jacks, and rolling the bearing out completely.
Page 74 of 74
Gland Seal Steam SYS

AS.4.MAW10.P001E-00
Contents
1 Gland Seal Steam ....................................................................................1 2 Gland Seal Steam Regulator Valves set points .......................................4 3 Gland seal desuperheater.........................................................................5 3.1 Operation ..............................................................................................5 3.2 Maintenance .........................................................................................6 4 Cleaning of gland steam piping...............................................................6 5 Gland seal steam temperature suggestion ...............................................8 6 Gland steam system operation ..............................................................11 6.1 Startup.................................................................................................11 6.2 Controlled load reduction...................................................................14 6.3 Turbine trip .........................................................................................15 6.4 Shutdown summary............................................................................15 6.5 Shutdown sequence ............................................................................15 7 Gland steam condenser..........................................................................17 7.1 General ...............................................................................................17 7.2 Operation ............................................................................................18
7.3 Maintenance .......................................................................................18 7.3.1 Access to tubes ................................................................................18 7.3.2 Tube plugging..................................................................................18 7.4 Tube replacement ...............................................................................19
Page 1 of 21 GLAND SEAL STEAM SYSTEM 1 Gland Seal Steam

(1) Gland seal steam should be keep 14 superheat before inter rotor gland. (2) To avoid rotor distortion, before turning gear operation, Gland seal steam system should be prohibited to work. (3) The temperature of steam in the LP glands is maintained in the range of 121 to 177 to prevent possible distortion of the gland cases and damage to the turbine rotor. Gland seal steam desuperheater temperature controller set point is 149. Signal from LP cylinder GEN END rotor gland thermocouple. (4) To protect rotor gland from heat stress damage, when turbine in operated or shut down, minimize the temperature difference between gland seal steam and rotor. Difference temperature heat stress damage can make rotor flaw in period which can examine in Gland seal steam temperature suggestion flag. For operator, 10000 weeks be suggested used for allowable period endurance fatigue limit. (5) If customers adopt the motor dr0ve regulate valve, translate pressure signal to control room from pressure switch. Basis on regulate set value, feedback 4-20mA signal to the motor drove regulate valve. (6) When turbine in hot startup, if customer used Auxiliary Supply steam as gland seal steam, pay attention to the following notes: A: Gland seal steam must be superheat steam, 14 superheat at least. B: The temperature difference between gland seal steam in rotor gland and rotor must less than 110. C: Be sure the gland steam piping from Auxiliary Supply station to turbine is hot, so it can prove that there is no condensate in gland steam piping. D: Be sure the gland steam piping before gland steam regulator valve station is dry.
Page 2 of 21
( Drain valve is on work). (7) If the gland seal steam temperature is low or gland seal desuperheater have condensate, It can bring turbine vibration increase. Each valve is equipped with a pressure control pilot mounted on the valve and an air pressure reducing valve containing an integral filter The reducing valve supplies air to the control pilot at a constant pressure off 0.1379-0.1517 MPa g The control pilot turn utilizes this air to produce variable In output in response to pressure changes transmitted to the pilot through a sensing line connected to the gland steam header The controlling regulator valve is then able to maintain sealing steam to the glands at a pressure established by the set point of its control pilot under all turbine operating conditions The control pilot of each valve senses gland steam header pressureAs required by turbine steam and load Conditions steam is supplied through the regulating valve with the highest control pilot pressure setting providing steam is available at the sourceNormally the HP steam supply is used on startupfollowing trips and load rejectionsor at low loads when the cold reheat supply is not available. Therefore, the HP supply control pilot is set at the lowest pressure setting and the cold reheat supply control pilot is set 0.00345 MPaghigher If the leakage past the inner glands into chamberXexceeds the mount of steam required to seal the LP turbine glands the header pressure will increase the supply valve will completely close and the spillover valve will open dumping the excess steam to the condenser thereby controlling steam pressure In the gland steam header .Therefore the control pilot of the spillover valve is set above the set point of the cold reheat supply control pilot NOTE
Page 3 of 21
1:Gland steam supply to the three Supply valve have different parameter,
Item
Pressure MPa(g)
Temperature
Flow Kg/h
HP Supply valve Cold reheat Supply valve Auxiliary Supply valve
17.48 4.024 0.655
538 326.1 200
3325.8 2290.2 3325.8
table as follow show the refer parameter (reference): Notes: 1. the detail requirements see the P&ID, the drawing NO XXXX.98.01(Gland seal, drain & customer connects) 2. Before air pressure reducing valve , The Supply air which control pneumatic regulator valves pressure is 0.30.8MPa(g), temperature is 4060. 3. If customer adopt the motor drove boiler feed pump turbine(BFPT), the gland seal system of main turbine will be absolute. 4. The temperature is the most important parameter, mixture two supply gland seal steam to control the temperature will be allowed. 5. Difference temperature between steam and shaft not exceed 111,at any time, the gland seal steam should be superheated (14 above saturated temperature). 6. The supply pneumatic regulator should be opened when electric or signal, or control air failure. The spillover pneumatic regulator should be closed.
Page 4 of 21 2 Gland Seal Steam Regulator Valves set points

Normally, the HP steam supply is used on startupfollowing trips and load rejectionsor at low loads when the cold reheat supply is not available. Therefore, the HP supply control pilot is set at the lowest pressure setting and the cold reheat supply control pilot is set 0.00345 MPaghigher. If the leakage past the inner glands into chamber X exceeds the mount of steam required to seal the LP turbine glands, the header pressure will increase, the supply valve will completely close, and the spillover valve will open dumping the excess steam to the condenser thereby controlling steam pressure In the gland steam header .Therefore, the control pilot of the spillover valve is set above the set point of the cold reheat supply control pilot The set pointsapproximate are as follows Control Pilot HP Supply Auxiliary Cold Reheat Supply Spillover Set Point 0.0207 MPag 0.0241 MPag 0.0276 MPag 0.0310 MPag
The status of the valves at various gland header pressures is shown on Table l TABLE 1Regulating valve status(reference):
Gland Pressure
Header
HP Supply Valve
Auxiliary valve
Supply
Cold Reheat Supply Valve
Spillover Valve
0.0207MPa(g) 0.0241MPa(g)
open and controlling
open
open open
closed closed
closed
Page 5 of 21
0.0276MPa(g) 0.0310MPa(g)
closed closed
closed closed
closed
closed
3 Gland seal desuperheater 3.1 Operation

The LP gland seal desuperheater lowers the temperature of the LP gland sealing steam in the supply pipe before this pipe enters the condenser space. The temperature of steam in the LP glands is maintained in the range of 121 to 177 to prevent possible distortion of the gland cases and damage to the turbine rotor. Desuperheating of the steam is obtained by utilizing the natural desuperheating that occurs in the bare supply pipe in the condenser space supplemented and controlled by a temperature sensitive spray system. The temperature, which actuates the spray system is sensed in one LP gland. Using this system, with the temperature of steam to the desuperheater at about 260 or higher, gland temperatures in the range of 12l to 177 can be obtained. However, if the temperature of steam to the desuperheater is much below 260,and particularly if it is close to the control range of 121 to 177,the sprays will not be needed and the natural desuperheating effect in the bare supply pipe may lower the gland temperatures below the 121 limit. The desuperheater and associated piping is shown diagrammatically on the drawing "Piping-Steam, Drain and Gland Diagram." The superheated steam enters the desuperheater where steam velocity increases in the reduced section of pipe' The steam then passes the spray nozzle where cooling water is injected into the high velocity stream thus insuring positive atomization and reducing the temperature of the steam as the cooling water is evaporated. Cooling water from the condensate pump enters the desuperheater through a pipe to the spray nozzle located in the throat of the desuperheater. The flow of cooling water to the spray nozzle is controlled by a diaphragm-operated valve responsive to an air signal from a pilot sensing temperature
Page 6 of 21
at one of the low pressure glands. A drain is provided in the supply pipe at least 1500 mm downstream of the spray nozzle. Notes The set temperature come from LP cylinder gland(GNN). Drain point should be set at least 1500mm downstream of the spray nozzle.
3.2 Maintenance
(1) Check regulator valve agility one time at least one week. (2) Check spray nozzle blockage condition per minor overhaul, change the nozzle if the nozzle is block. (3) Set a filter before condensate water inter nozzle to protect nozzle block.
4 Cleaning of gland steam piping

Blowdown with Steam Blowdown with steam is the preferred and most effective method of cleaning gland steam piping in that temperature cycling helps to dislodge foreign particles (mill scale ,weld beads ,etc.) from the inside pipe wall surfaces. 1. Y" type steam strainer assemblies are provided by manufactory in the steam inlet pipe to all steam sealed rotor glands. These strainer assemblies are furnished with an extra (unperformed ) element which is installed in place of the strainer (Item 1 Figure 2) for the blowdown procedure. 2. To prepare the gland steam system for blowdown, the following steps must be taken: a. Replace all strainers (Item l) with the unperforated elements. b. Replace all plugs (Item2) with a section of pipe containing a blow-off valve (Item 3).
Page 7 of 21
Fig 2. "y" Strainer. c. Isolate all the gland regulators with valves normally used for regulator isolation. (Refer to "Piping-Steam Drain & Gland Diagram ). d. Gag the outer gland system relief valve. e. For units having a desuperheating section in the LP gland supply line, remove spray nozzle and blank off opening. f. Isolate pressure gauges, regulator sensing lines and switches in the gland system. g. Provide connection for the introduction of steam in the cold reheat supply line to regulator as close to its source as practical. 3. Gland System Blowdown Procedure: a. Prior to the operation of unit, introduce steam from the boiler into the gland piping system through the high pressure supply by-pass valve and cold reheat supply line. b. If boiler steam is not available, steam from an external source may be introduced into the gland piping through a connection as close to the supply source as practical. c. The maximum recommended steam pressure and temperature in the gland system for blowdown is 11.6bar(g) and 232. d. Blowdown the large gland pipe lines by opening all blow-off valves (Item 3)
Page 8 of 21
for a period of 2 to 3 minutes or as required to remove foreign matter. e. Repeat this process several times with sufficient time (1O to 15 minutes ) allowed between blows to insure some cooling of the pipes. Cycling the temperature in this manner will aid the steam in removing loose scale from the pipes. Hammering on the pipes in the area of welds during blowdown is also effective in removing loose scale. f. Close all blow-off valves (Item 3). g. Open each blow-off valve repeating procedure as shown in paragraph "e. h. Continue the blowdown procedure until all pipes are clean then replace all strainers (Item 1 ) and all plugs (Item 2). The plugs need not be replaced if the blow-off pipes and valves are left in place with the valves closed tightly. i. Pipes between the steam strainers and the gland cases should be cleaned before erection and the inlet holes in the gland cases for these pipes sh0uld be covered during erection. j. the arrangement will be see the drawing GLAND SEAL DRAIN AND CUSTOMER CONNECT, drawing number is xxx.98.01.
5 Gland seal steam temperature suggestion

To protect rotor form heat stress damage in gland zoom, minimize the difference temperature between rotor and gland seal steam when turbine in startup or shutoff. In difference temperature between rotor and gland seal steam, the time produce flaw because of heat stress damage can examine by the following diagram. (1) The different temperature between rotor and gland seal steam can be change in different operating condition, we can count the rotor life consumption in differential temperature T by the expressions as follow: Differential temperature T operating time Rotor life consumption percent = 100 Differential temperatureT produce flaw time
Page 9 of 21
=(N/E)100
(2) For example, give the times in different operation: N1= In differential temperatureT=166.7 startup 60 times N2= In differential temperatureT=138.9 shutoff 55 times N3= In differential temperatureT=125master switch trip 20 times Examine the diagram to check the time produce flaw: E1=2600 timesT=166.7) E2=4600 timesT=138.9) E3=6600 timesT=125) Take the value to the expressions, count the rotor life consumption in gland seal steam zoom: (N/E)100=(60/2600+55/4600+20/6600)100=3.8%
Page 10 of 21
Page 11 of 21 6 Gland steam system operation 6.1 Startup

6.1.1 Place unit on turning gear, with all turbine and inlet pipe drains open. 6.1.2 Establish water circulation through main condenser. 6.1.3 Start condensate pumps, and establish cooling water flow through gland condenser. 6.1.4 Open vents on gland condenser water chambers until all residual air is purged to atmosphere. 6.1.5 Make sure that condenser shell drain system is open to main condenser. 6.1.6 Make sure that gland condenser level alarm is in service and that instrument shutoff valves are open. 6.1.7 Turn on air supply to LP turbine gland steam desuperheater control valve. Open manual shutoff valves on either side of control valve. Control valve should stay in the closed position, since no steam is being supplied to LP turbine glands. Make sure bypass valve around control valve is closed. 6.1.8 Make sure manual shutoff valves and bypass valve at each gland system pressure regulating valve station are closed. 6.1.9 Turn on air supply to each gland pressure-regulating valve. 6.1.10 Make sure that steam drains on inlet side of HP and cold reheat supply pressure regulating valves are open and that supply pipes are free of water. 6.1.11 The operator should verify that the HP supply steam temperature is compatible with the measured rotor metal surface temperature for the HP-IP turbine. See the turbine "Operation" leaflet for information on gland sealing steam temperature limits.
Page 12 of 21
6.1.12 After making sure that the supply piping upstream of regulating valve is free of water and that steam supply temperature is within the specified range, open manual shutoff valves on both sides of regulating valve in this order: spillover, cold reheat supply and, finally, HP supply. The bypass valve around each regulating valve should stay closed. 6.1.13 Steam pressure will be established in gland supply header when the HP steam supply shutoff valves are opened. Make sure gland header pressure stabilizes at the set point pressure for the controlling regulator valve. 6.1.l4 Start gland condenser exhauster immediately after gland header supply pressure is established. 6.1.15 Make sure there is a slight vacuum at each turbine gland. 6.1.16 Make sure there is no steam leakage to atmosphere from any turbine steam gland. If steam leakage is found, increase vacuum in gland condenser, or adjust set point on regulating valves to lower steam pressure in gland header until external leakage stops. 6.1.l7 Check that steam temperature at LP turbine glands is between the limits of l21 and 177. Also check that gland header continuous drain, located between steam desuperheating section and LP glands is working right. 6.1.18 Close main condenser vacuum breakers. Start air removal equipment, and establish as high a vacuum as possible in main condenser. The amount of gland sealing steam required will increase as the vacuum in the condenser is improved until a maximum flow rate is established at each turbine gland. 6.1.19 If startup is under Automatic Turbine Control (ATC), a roll off turning gear will be prevented if: a. HP gland steam temperature is too low.
Page 13 of 21
b. Differential between gland steam supply temperature and end wall metal temperature is too high. c. LP gland steam temperature is not being properly regulated between maximum and minimum limits by gland desuperheater. ATC will turn on Gland System Error Alarm indicator if any of the above three conditions are detected and will prevent a roll off turning gear until the fault is corrected or the operator overrides the alarm. 6.1.20 As load is increased over the initial value, the quantity of external sealing steam required will begin to decrease. At about 25 percent of rated load, the cold reheat supply connection will provide all makeup steam required sealing turbine gland seal system. At higher loads, gland leakage from HP and IP turbine glands may be equal to total requirements of LP turbine glands. As high load is approached, gland header steam pressure will increase to set point of cold reheat supply valve pilot, and this regulating valve will close. If gland header pressure continues to increase, gland header spillover valve will open and allow excess gland leakoff steam to flow to main condenser. NOTE 1: Check the gland clearance when turbine in installation, be sure the clearance error is in the allowable value. Otherwise it can influence the gland seal steam regulator valves set point, and it can increase gland seal steam supply. 2: If the gland seal steam leak to atmosphere, inspect the gland clearance and gland seal steam mother pipe pressure, be sure the clearance and pressure are not exceed the allowable value. 3: In normally, one gland steam condenser exhauster is on work can satisfy the turbine operation, but in abnormal condition the two exhausters can work at one time.
Page 14 of 21
4: If the gland seal steam temperature is low or gland seal desuperheater have condensate, It can bring turbine vibration increase. In this condition, the following process can help the operator to find out the cause: A: Check the set point of LP gland desuperheater is correct. B: Check the temperature which actuates the spray system is sensed in one LP gland. C: Increase the temperature of gland seal steam. D: Be sure the superheat of the gland seal steam is above 14. E: Gland seal steam piping inside condenser must heat insulation. F: Regulate the hand-operated valve before LP gland desuperheater valve, control the pressure of condensate inter desuperheater regulator valve is between 0.5MPa (g). G: Check the LP gland desuperheater spray nozzle is installed correctly, include nozzle size and spray direction.
6.2 Controlled load reduction

On a controlled load reduction, the gland seal system make-up requirements are taken from the main cold reheat piping as long as the cold reheat pressure is high enough to maintain the gland supply header steam pressure above 0.0207 Mpa(g). If the header pressure drops below0.0207 Mpa(g), the HP supply regulating valve opens as required to keep the header pressure at the 0.0207 Mpa(g) level. The temperature of the HP supply of sealing steam should be adjusted to match the HP-IP rotor metal surface temperature as the load is reduced. Matching of the steam and metal temperatures minimizes the rotor thermal stress (in the gland areas) when the gland sealing steam makeup is taken from an external source.
Page 15 of 21
There is a check valve in the cold reheat seal supply piping upstream of the regulating valve. This check valve prevents backflow from the gland steam header to the main cold reheat piping when cold reheat pressure becomes less than gland header pressure.
6.3 Turbine trip

In case of a turbine trip, the sealing steam makeup flow is taken from the main cold reheat piping until the cold reheat pressure drops to a level that causes the gland header pressure to fall below 0.0207 Mpa(g). When header pressure drops, the steam sealing supply is taken from the HP steam supply source as described in the previous paragraphs. Temperature matching between HP supply steam and cylinder end wall metal is limited at this time because of the rapid transfer in the source of seal supply. However, if proper temperature matching was in effect before the trip, excessive rotor metal surface temperature cycling is minimized when the shift to an external steam supply takes place.
6.4 Shutdown summary

Gland steam must be supplied to the turbine glands as long as there is a vacuum to draw air through the seals into the cylinders. The flow of cool air chills the rotor surface metal and can distort the hot stationary gland cases. Do not shut off the sealing steam supply until the air removal equipment for the main condenser has been shut down and the main condenser vacuum has been completely dissipated.
6.5 Shutdown sequence

6.5.1 With the unit on turning gear and sealing steam supply from an external source, make sure main condenser vacuum has been completely dissipated. 6.5.2 Turn off gland condenser exhauster.
Page 16 of 21
6.5.3 Close manual shutoff valves on both sides of gland steam pressure regulating valves in this order: a. HP Supply Valve b. Auxiliary Supply Valve c. Cold Reheat Supply Valve d. Spillover Valve. The above valves should be closed immediately after the gland condenser exhauster is shutdown. Operation of sealing steam supply without vacuum in gland cases with result in a steam blow to atmosphere. This same steam can enter the lubricating oil leakoff area and condense. The condensed steam in the lubricating oil builds up in the oil reservoir as a contaminant. 6.5.4 Turn off air supply to each gland steam pressure-regulating valve. 6.5.5 Close manual shutoff valves on both sides of gland steam desuperheating control valve. 6.5.6 Turn off air supply to gland steam desuperheating control valve. 6.5.7 Shut off cooling water flow through gland condenser.
Page 17 of 21 7 Gland steam condenser 7.1 General
Page 18 of 21
The purpose of the gland steam condenser is to maintain in the gland leak off system a pressure slightly below atmospheric pressure, to prevent the escape of steam from the ends of the glands, and to remove and condense the vapor.
7.2 Operation
The circulating water enters the inlet chamber, and flows through the tubes in the gland condenser, and exits via the discharge chamber. The gland seal steam is admitted into the condensing section via the steam inlet and then passes among the tubes. The air and other on condensable vapors are discharged to atmosphere by an air exhauster, which is described in another leaflet. The drain of the exhauster should be left open to waste for removal of condensate. The condensate formed in the gland steam condenser shell is removed via the drain.
7.3 Maintenance 7.3.1 Access to tubes

To clean or inspect the tube ends, both water chambers must be removed. When the gland condenser is not in use dry lay up procedures are recommended. Drain and thoroughly dry the tube side of the gland condenser. If dry lay up is not practical and water must remain in contact with the tubing it must be continuously circulated and periodically replaced to minimize corrosion caused by the concentration of deleterious contaminants. At no time should water become stagnant.
7.3.2 Tube plugging

Tubes, which develop leaks, should be plugged at each until an opportune time arises for their replacement. Using light hammer blows, firmly tap the tube plugs into the tube ends. Tubes, which are leaking at the tube joints, but are otherwise in good condition, should not be plugged. The proper repair in such cases involves re-rolling
Page 19 of 21
the tube-to-tube plate joint. If leakage persists replace the tubes at the first opportunity.
7.4 Tube replacement

Removal of a tube requires the use of a tube reamer with a pilot and a pushing pin. The pilot serves as an aligning device to avoid tilting the reamer and inadvertently reaming through the diameter of the tube. Reaming is required to relieve the pressure between the tube and the tube plate, and to establish a shoulder for the use of the pushing pin. Ream to a distance of 0.80 past the rolling ridge on the I.D. of the tube at each end of the condenser. Reaming beyond this point will cause the tube to split when using the pushing pin. Insert the pushing pin at either end of the tube strike the pin with sufficient force to jar the tube and break it loose from the tube plates. Withdraw the tube. Insert a new tube, expand, and machine flush with the tube plates. LIST OF PARTS Item 0l 03 05 07 09 11 13 15 17 Name Shell Gasket Nut Coupling Coupling Nut Blower With AC Motor Cover Bolt 02 04 06 08 10 12 14 16 18 Water Chamber Bolt Washer Stop Valve Bolt Washer Plug Cover Nut
Page 20 of 21
19 21 23 25 27 29 31 33 35 37 Washer Gasket Bolt Gasket Bolt Stud Level Indicator Bolt Name Plate Glass Tube 20 22 24 26 28 30 32 34 36 38 Butterfly Valve Tube Check Valve Tube Level Controller Nut Gasket Name Plate Screw Brass Tube
Page 21 of 21
gland steam condenser(typical)


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Document NO. 78.

N300-16.7/538/538 TYPE 300MW CONDENSING REHEAT STEAM TURBINE

SHANGHAI ELECTRIC EQUIPMENT CO., LTD SHANGHAI TURBINE WORKS

Document NO. 78. K156-2E

Document NO. 78. K156-2E

Document NO. 78. K156-2E

Table of Units Conversion

Units Used by STW Length

4.55E-03 3.79E-03 1.00E-09 1.00E+03

kilogram(kg) 0.45359 1.00E-01 1.00E-03 9.80E-06

Mega Pascal(Mpa) 1.30E-04 6.90E-03 0.101325 0.0981

Energy Power Force

joule (J) watt (W) Newton(N)

4170 746 4.45

Note: G (Acceleration of gravity) = 9.8 m / s

(Units Used by STW) (Factor of Transformation) (Units Available)

Document NO. 78. K156-2E

Document NO. 78. K156-2E

OP.2.17.01E-00 OP.2.18.01E-00 OP.1.19.01E-00 OP.2.20.01E-00 OP.2.21.01E-00 OP.6.22.01E-00 OP.6.23.01E-00 OP.6.24.01E-00 OP.2.25.01E-00

Document NO. 78. K156-2E

Page 1 of 1 CompiledYu Yan 2008.09

Checked Zhang Xiaoxia 2008.09 Countersign Countersign ApprovedPeng Zeying 2008.09

Turbine Control Settings

CompiledYu Yan CheckedZhang Xiaoxia Countersign Sheng Chaojun,

2008.09 2008.09 2008.09

Tang Jun, Zhang D.M ApprovedPeng Zeying 2008.09

Turbine Control Settings 1 OIL PRESSURE INFORMATION

OVERSPEED PROTECTION TRIP SETTING

2 E.H. FLUID INFORMATION

SERVO AMPLIFIER ADJUST

0% 0V 10V SERVO AMPLIFIER INPUT

The Data in Governor Valve Management * Variable name in DEH

5 THE GOVERNOR VALVE OPENING SEQUENCE AND ARRANGEMENT

6 ROTOR POSITONTHRUST BEARING TRIP

8 SUPERVISORY INSTRUMENT INFORMATION

9 PRESSURE SWITCH INFORMATION

10 TEMPERATURE SWITCH INFORMATION

12 DEH CONTROLLER SETTING

14 LUB OIL TANK LEVEL SWITCH

HOUSING COUPLING TOP OF

15 EH FLUID RESERVOIR LEVEL SWITCH

Turbine Cooling Steam System Inspection

CompiledZhang D.M CheckedHuang Q.H CountersignYu Yan Countersign

2008.09 2008.09 2008.09

ApprovedPeng Zeying 2008.09

Turbine Cooling Steam System Inspection

2008.09 2008.09 2008.09 2008.09 2008.09

Turbine Steam and Metal Thermocouples

CompiledZhang D.M CheckedHuang Q.H CountersignTang Jun Countersign

2008.09 2008.09 2008.09

ApprovedPeng Zeying 2008.09

TURBINE STEAM AND METAL THERMOCOUPLES

049 051 050 052

TC 3241 TC 3251 TC 3242 TC 3252

TC 3051 HP inner casing Metal

HP Gland Steam Header (Common line to the HP and IP Glands) IP Inlet-RSV-LH

Steam 025 TC 3250 IP Inlet-RSV-RH

033 034 026 027 031 032

TC 3261 TC 3271 TC 3320 TC 3330 TC 3333 TC 3334

LP Exhaust -Gov. End Steam

020 043 042 035 036

TC3120 TC3500 TC3580 TC3335 TC3336

Allowable Variations in Steam Conditions