210 MW LMW TURBINE

A. GENERAL:
The turbine is condensing, tandem compound, three cylinder, horizontal, disc and diaphragm type
with nozzle governing and regenerative feed heating. The double flow LP turbine incorporate a
multi-exhaust in each flow.
The complete turbine assembly is mounted on pedestals and sole plates which are designed to
ensure that the components are free to expand whilst correct alignment is maintained under all
conditions. Live steam from Boiler enters in two Emergency Stop Valves (ESVs) of high pressure
turbine. From ESV, steam flows to four Control Valves (CVs) mounted on the casing. of High
Pressure Turbine(HPT) at the central pedestal side. Control Valves in turn feed the steam to nozzle
boxes located inside the HPT.
High pressure turbine comprises 12 stages , first stage being governing stage. The steam flow in
HPT being in reverse direction . The blades in HPT are designed for anticlockwise rotation, when
viewed in direction of steam flow.
After passing through HPT, steam flows to Boiler for reheating and reheated steam comes to the
Intermediated Pressure Turbine (IPT) through two interceptor stop valves (IVs) and four Control
Valves (CVs) mounted on the IPT itself.
The intermediated pressure turbine has 11 stages . HP & IP rotors are connected by rigid coupling
and have a common bearing.
After flowing through IPT, steam enters the middle part of low pressure turbine through two cross
over pipes. In Low Pressure Turbine (LPT) , steam flows in the opposite paths having four stages
in each path. After leaving LPT the exhaust steam condenses in surface condenser welded directly
to the exhaust. Part of the LP turbine.
Rotors of intermediate and low pressure turbine are connected by a semi-flexible coupling.
The direction of rotation of the rotors is clockwise when viewed from the front bearing end
towards the Generator. The three Rotors are supported on five bearings. The common bearing of
HP & IP rotors is a combined Journal and Radial thrust bearing.
The anchor point of the turbine is located at the middle foundation frame of the front exhaust part
of a low pressure cylinder. The turbine expands towards the front bearing nearly 32 mm and
towards generator by 3 mm in steady operation at full load with rated parameters.
Turbine is equipped with a barring gear which rotates the rotor of turbine at slow-speed of nearly
3.4 rpm for providing uniform heating during starting and uniform cooling during shutdown.
In order to heat the feed water in the regenerative cycle of the turbine , condensate from the hot
well of condenser is pumped by the Condensate Extraction Pump ( CE Pumps ) and supplied at the
Deaerator through Ejectors, Gland Steam Cooler, four number L.P. Heaters and Gland Cooler.
From Deaerator , the feed water is supplied to boiler by boiler feed pumps through three number
H.P. heaters. Extracted steam from various points of the turbine is utilized to heat the condensate in
these heat exchangers.

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TURBINE MAIN DATA:
Rated output of the Turbine : 210 MW.
Rated Speed : 3000 rpm.
Rated pressure of steam before ESV : 130 kg/cm2.
Rated live steam temperature : 535 0C
Rated live steam temperature at inlet of IV : 535 0C
Steam flow at valve wide open condition : 670 Tons/hr.
Rated CW flow through condenser : 27000 M 3 / hr.
0
i. For cooling water temp. C : 24 27 30 33
ii. Steam flow required for 210 MW Tons/hr : 638 645 652 662
iii. Rated pressure at the exhaust of LPT. mm of Hg. : 46.9 55.5 65.4 76.7

B. TURBINE BEARINGS :

Three turbine rotors are supported on five bearings. The second bearing from front pedestal side is
a combined radial thrust bearing while all other s are journal bearings. The rotors are located inside
the turbine .The HPT & IPT rotors are joined by rigid coupling and have been provided with a
common bearing. while other ends are having their own bearings.

The lubricating oil is supplied to the bearings at a pressure of about 1 kg/cm 2 and quantity of oil
going to each bearing is controlled by the orifice plate at its inlet end.

i. THRUST BEARING :
To carry the axial thrust and fix the rotor axially, the thrust bearing is provided. It is a
Michell type with bearings surface distributed over a number of self adjusting working and
surge pads to bear the axial thrust in both the directions. These pads are made of high
quality phosphor bronze faced with white metal. An oil film is formed between the thrust
collar and the pads and there is no metal to metal contact between them during operation of
the turbine.
The radial thrust bearing is supported on a spherical seating at the journal bearing centre
line. The inner surface of steel housing is machined spherical, matching with bearing
sphere. The bearing is in two halves bolted together. The whole radial thrust bearing is
housed in middle bearing pedestal. The babbit temp. of all thrust and surge pads is
monitored continuously besides babbit temp. of journal portion.

ii. JOURNAL BEARING:

The journal bearings nos. 1,3,4 & 5consists of outer shell of cast steel with an inner shell
lined with white metal. Both the shells are split at half joint and secured by the bolts. The
pads on the outer shell are machined to bore diameter of bearing pedestals. For the fine
alignment steel shims are provided under the pads. The babbit temp. of all journal bearings
is monitored continuously.

C ) BARRING GEAR :

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The barring gear is mounted on the LP rear bearing cover to mesh with spur gear on LP rotor
coupling. The primary function of barring gear to rotate the Turbine Generator rotors slowly and
continuously at 3.4 rpm during start-up or shut-down periods when changes in rotor temperature
occurs.
When a turbine is shutdown , cooling its inner elements continues for hours together. If the rotor is
allowed to remain stand still during this cooling down period , distortion of rotor begins almost
immediately. The distortion is caused by the flow of hot vapours to the upper part of the casings,
resulting in upper part of the turbine being at a higher temperature than lower half. Hence, to
eliminate the possibility of distortion during shutdown, barring gear is used to keep the rotor
revolving until the temperature change has stopped and casing have become cool. This also results
in maintenance of minimum inter stage sealing clearance with higher operating efficiency.
The same phenomenon is also observed during starting up of the turbine when steam is supplied to
the sealings to create the vacuum. If the rotor is stationary there would be non-uniform heating of
the rotor which will result in distortion of rotors. The barring gear during starting of turbine ,
would slowly rotate the turbine-generator rotor and thereby resulting in the uniform heating of
rotor. Thus any distortion in the rotor would be avoided.
During starting period , operation of barring gear eliminates the necessity of breaking away the
turbine- generator rotors from stand still and thereby provides for a more uniform smooth and
controlled starting.

SWITCHING ON THE BARRING GEAR :

Switching ON of the barring gear can be done either by remote manual control from UCP or from
local panel mounted near barring gear assembly in the turbine hall.
With the help of a selector in UCP , selection to operate the barring gear can be done either from
local panel or from remote switch in UCP.
a. For remote starting , bring the key to the ON position in UCP and start the barring gear.
b. For manual starting from local panel follow the steps given below :
i. Open the wheel cover.
ii. Turn the wheel in clockwise direction ( looking towards barring gear from wheel
side ) and at the same time pressing the hand lever to bring the driving gear in
mesh with gear on turbine rotor.
iii. Close the wheel cover.
iv. Switch on the electric motor.
Note :
a. Never allow hot rotor to stand without rolling.
b. Prior to starting of barring gear , lubricating oil system to barring gear must be on. The oil
temperature to the barring is to be maintained between 40-50 0C as long as barring gear in
operation by regulating the flow of water through oil coolers.
c. The operation of seal oil system must be ensured prior to starting of barring gear.

During a short shutdown , keep the turbine on barring gear until the turbine is again required for
rolling. If the shutdown is for a indefinite period , continue to roll the rotor until the turbine has
thoroughly cooled.

SWITCHING OFF THE BARRING GEAR :

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 a. When starting the turbine :
When the speed of turbine rotor increases, due to action of the steam, the barring gear
automatically switches off. The motor gets switched off by the release of the limit switch.

b. After stopping the turbine :

i. By moving the key in OFF position, stop the electric motor. In this case the driving
gear remains in working position ( in mesh with gear on rotor shaft ).
ii. In case it is necessary to bring the driving gear out of the mesh, then open the cover
wheel and rotate it in anticlockwise direction till the driving gear and also the external
lever comes back to its initial position ( Non-working)..

Important :
i. Supply of stem to the turbine and seals without running the rotors on barring gear
is strictly prohibited.
ii. During shutdown of turbine , engage and start the barring gear only after the
rotors have come standstill. It is strictly prohibited to engage the barring gear ,
when the rotors are still rotating.

D. INTERLOCK & PROTECTION OF TURBINE :

1. Turbine lockout relay (TLR) will trip if,

i. Unit Lockout Relay trips (ULR).

ii. Master Fuel Relay trips (MFR)
iii. Main Steam temperature is below 450 0C after a time delay relay ( For initial starting
automatic wipeout switch is provided).
iv. Oil level in damper tank is very low.
v. DM cooling Water flow to stator winding is less than 13 M3 / hr.
vi. DM cooling water specific resistivity is less than 50K. ohm/cm.
vii. Condenser vacuum is less than 540 mm of Hg.
viii. Boiler drum level is very high / low.
ix. H.P. turbine exhaust temperature is above 420 0C.
x. H.P. heater level is very high ( set point 3 this will in turn trip ULR and also te running
Boiler Feed Pumps).
xi. Lub oil pressure is low ( ).3 ata ).
xii. Shaft axial shift is high ( +1.2 , - 1.7 mm.).

- Low lub oil pr. & High axial shift will also operate the following valves as under :
a. Open Vacuum Breaker.
b. Close steam to main ejector.
c. Close steam to starting ejector.
d. Open air extraction valve of starting air ejector
Condition of (11 & 12 ) will in turn trip ULR.

xiii. Protection extraction system troubles :

a. Thyrister fans supply failure.

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 b. Regulator supply failure.
c. Rectifier transformer temperature very high.
d. Grid control unit power supply failure during auto changeover .

All the above will in turn energise turbine trip solenoid.

xiv. Emergency Turbine Trip push button will directly energise the trip solenoid.

2. The following condition will close the turbine ESVs and IVs :

i. Turbine Trip solenoid (TTS) operated.

ii. Turbine over-speed trip operated ( 11- 12 %) .
iii. Turbine over-speed trip addl. Protection operated ( 14% ).
iv. Turbine relay oil pressure is less than 10 kg/cm2.
v. Turbine Manual Trip operated.

3. Closing of ESVs and IVs will in turn operate the following :

i. Generator Lockout Relay (GLR) through Low Forward Power Relay.

ii. Close Turbine inlet M.S. valves (MS-1)
iii. Close extraction stream steam to Deaerator (ES-6 & ES-5)
iv. Close all Extraction Non-Return valves ( To open MC-53 & 54).
v. Turbine speeder gear fast reversal .
vi. Open HP-LP bypass valves after tripping of GLR.
vii. Trip the Master Fuel Relay (MFR) , provided HP, LP bypass valves are closed and load
carrying burner or coal mill is in service , through a time delay of 6 seconds.

4. COLD START UP OF TURBINE :

The turbine is considered to be cold if the temperature of lower part of HPT casing is less than 150
0
C.

ECCENTRICITY :

Before supplying steam to the turbine, when the rotors are rotating at barring speed, check the
shaft eccentricity . Increase in rotor speed , by adding steam in the turbine is PROHOBITED in
case the eccentricity of the rotor in barring speed is more than 0.07 mm. the eccentricity of the
rotors at barring speed is also checked by putting a separate dial indicator with long stem, directly
above the coupling of the rotor at the middle bearing pedestal . This mechanical dial indicator
should be removed before steam rolling the set.
The rotation of the rotors, alters the air gap between the eccentricity detector face and shaft collar.
This change in the air gap is dependent on shaft eccentricity and relative shaft vibrations.
At barring speed , the shaft vibrations are absent and therefore output from the measurement
system gives the value of shaft eccentricity only. At speed higher than the barring speed, the
variation of air gap is a combination of shaft with respect to the bearings. Thus the readings at
speeds higher than barring speed indicate the combine effect of shaft eccentricity and relative shaft
vibrations.

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During steam rolling , if the readings as indicated on eccentricity meter exceed 0.20 mm ( 200
micron) , the turbine should be shut down and put on barring gear and cause of excessive
indication be investigated.

BEARING VIBRATION:

a. For healthy turbine, normally the vibrations are less than 40 microns. However, it is
important to asses the trend of increase rate, than the absolute level of vibrations. If during
speeding up of turbine , the vibrations gradually rise and exceed 40 microns, withhold
further speeding up of the set ( increase not in critical speed zone), investigate and remove
the cause of excessive vibrations.
b. While increasing the rotor speed, the critical speed should be passed as fast as possible to
avoid the appearance of rotor vibration. Critical speed of the shaft system are given below :

I II III IV V

1585 1881 2017 2489 4500

c. In case there is a sudden increase in vibration while increasing speed, trip the turbine
through ESV and break vacuum to decrease speed quickly. If vibrations increase during
load or while increasing load, trip the set. If necessary, break vacuum to decrease speed
quickly.

METAL TEMPERATURE :

a. While heating the casing of ESV, HPT & IPT and also while increasing speed and loading
turbine, metal temperature should be raised gradually, avoiding sudden sharp rises. The rate
of of rise of metal temperature should not exceed the limits given below :

Temperature Rate

From 100 to 2000C 20 0C per minute

From 200 to 3000C 15 0C per 5 minute
From 300 to 4000C 10 0C per 5 minute
From 400 to 5000C 10 0C per 10 minute
From 500 to 5350C 6 0C per 10 minute

The rate of heating of steam pipes should not exceed 25-30 0C per five minutes.
b. While heating the main steam and reheat steam pipes, the difference in temperature of
pipes should not exceed 150C. But when the turbine is on load , this difference should not
be more than 100C. While raising the speed of set up to 3000 rpm the difference of metal
temperature between the left hand and right hand ESV should not exceed 30 0 C.

c. The temperature difference between the upper and lower halves of HPT & IPT casing
should not exceed 50 0C near the regulation stage in case of HPT and near the zone of
steam admission in case of IPT.

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 d. While heating of Flange & Studs, the entry of heating steam should be controlled so that
the difference of temperature along the width of flange is not more than 50 0C. The
temperature of outer surface of flanges should be always lower than that of inner most
surface of flanges. Pressure of steam in the header supplying steam for heating of flange
and studs should not exceed 2 kg/cm2.

e. During the trial runs for the heating of the flanges and studs , their heating is to be adjusted
such that :

i. Temperature difference between upper and lower flanges does not exceed 10 0C .
ii. Temperature difference between left hand and right hand flanges does not exceed
10 0C .
iii. Temperature difference between flanges and studs does not exceed 20 0C and is
not negative i.e. temperature of studs must be lower than that of flanges.

f. While starting the turbine in any condition, the temperature difference between inner and
outer surfaces of the wall of HPT casing should not exceed 35 0C.

CYLINDER EXPANSION :

Longitudinal thermal expansion of turbine is measured at middle and front bearing pedestals.

Thermal expansion of the casing should be symmetrical in transverse direction. While increasing
the speed and loading the turbine , it is recommended to measure the clearances between pins
mounted on the bearings and casing supports, so as to check the expansion of turbine in transverse
direction is symmetrical.

DIFFERENTIAL EXPANSION :

It is prohibited to raise the speed of turbine rotor or the load if the relative expansion (+) or
contraction (-) of the rotor reaches the maximum permissible values given below :

For Rotor of HPT : (+) 4.0 mm or (-) 1.2 mm

For Rotor of IPT : (+) 3.0 mm or (-) 2.5 mm
For Rotor of LPT : (+) 4.5 mm or (-) 2.5 mm

(+) sign indicates that Rotor is longer than cylinder and vice versa for (-) sign.

a. If HP rotor expands quicker than the HPT casing, steam supply for heating flanges and
studs should be increased, but pressure in header supplying steam for heating should not
exceed 2 kg/cm2.

In case of further increase in the differential expansion of rotor, stop further increase in live
steam temperature and suspend further loading. If measures mentioned above are not
sufficient, decrease the live steam temperature.

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 b. If HP rotor contracts quicker than the HP casing , stop supply of heating steam to flanges
and studs, increase temperature of live steam and increase load or supply fresh steam to the
front sealings of HPT and the entry of leak-off steam into heater no. 4.

c. If IP rotor expands quicker than the IP cylinder, stop the increase the temperature of steam
after reheat or lower its temperature. If these measures are not sufficient, stop the increase
in load too.

d. If IP rotor contracts quicker than the IP casing , increase temperature of steam after reheater
and increase load or supply fresh steam to the front sealings of IPT and the entry of leak-off
steam into heater no. 4.

e. If LP rotor expands quicker than the LPT cylinder, worsen the vacuum and stop
recirculation of condensate in the condenser.

f. If LP rotor contracts quicker than the LP casing, improve vacuum in the condenser.

PARAMETERS TO BE NOTED :

a. Temperature of live steam and steam after reheat should not have sharp fluctuations.
Variation of steam temperature in the starting regimes and during operation of turbine
should not exceed ( + 5 0C ) & ( - 10 0C ).

b. Sharp increase of speed or of load, because of deterioration of boiler regime is not

permitted.

c. Starting of turbine with cold oil in lubricating and governing system is prohibited. The
temperature of oil should not be less than 40 0C.

d. Temperature of lubrication oil entering the bearings after oil coolers, should be within 45
5 0C. and in no case be less than 40 0C. The temperature of at the exit of bearings should
not exceed 65 0C... If there is sharp rise in oil temperature up to 75 0C in any of the
bearings, the turbine should be stopped.

e. The barring gear gets automatically disengaged when the rotor speed exceeds 3.4 rpm.
Electric motor of barring gear also trips automatically with the help of limit switch.

f. During heating , speeding and loading of turbine, carefully watch the readings of the
instruments indicating :

i. Vibration of bearings.
ii. Axial shift of rotors.
iii.Differential expansion of all the three rotors.
iv. Metal temperature of upper and lower halves of HPT flanges and studs and upper half
of IPT flanges.
v. Oil temperature at the inlet and outlet of the bearings.
vi. Babbit temperature of thrust bearings.

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 vii. Pressure and temperature of steam at the control panel.
viii. Vacuum.

PROCEDURE OF START UP:

a. Pre-start checks:

1. C.W. pumps are running and condenser inlet and outlet valves are fully opens.
2. All CT Fans are running.
3. Condensate Pump is running on recirculation and condensate line up to LP Heater
No. 4 is charged.
4. Turbine oil tank level is normal and machine is on barring gear with AC lubricating
oil pump running. DC lubricating oil pump is on Auto.
5. Generating casing H2 pressure is 3.5 kg/cm2 and AC Seal oil pump running with DC
Seal oil pump on Auto.
6. Boiler is on oil firing.
7. Boiler Feed Pump is running.
8. Turbine interlocks checked and found O.K.

b. Line up of turbine , MS, CR and HR lines :

The following valves are to be opened:

1. Impulse line to all pressure gauges for steam, condensate, oil and cooling water.
2. MS, HP- bypass drain valves.
3. HR, CR, LP bypass drain valves to flash box / aux. flash box and to atmosphere.
4. Aux. PRDS, Gland seal steam supply line and ejector line drains.
5. HP and LP cylinder steam admission pipe drains to flash box.
6. HP and IP cylinder drains.
7. Before seat drain of extraction NRV of extraction line to HP heater no. 7 and 5 to
flash box.
8. Before seat drain of extraction NRV of extraction line to LP heater no. 2, 3 and 4 to
flash box.
9. After seat drains of Nerves of all the extraction lines to flash box.

c. The following valves are to be kept closed :

1. Main steam stop valve (turbine side).

2. Main steam stop valve bypass isolating and regulating valves.
3. ESV, IV and control valves of HPT and IPT.
4. Aux. PRDS to Deaerator.
5. Before isolating valve of Aux. PRDS.
6. Before isolating valve of gland steam controller.
7. Before isolating steam valve of GC-1 ejector.
8. First isolating steam valve of starting and main steam ejectors.

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After ensuring the closing and opening of all the above the following procedure are to be
followed:

1. Open Main steam stop valve (Boiler end) equiliser both side when M.S. pressure is 10
kg/cm2. and temperature is around 200 0C.
2. After warming up for 30 minutes open main steam stop valve.
3. after opening drains of TAS line, slowly charge the turbine auxiliary steam line by
opening APRDS-1 controller (5-10%) and after sometime increase the pressure. Check
that operation of APRDS is alright and spray water valves are operating.
4. Charge the steam supply header to turbine gland sealing and air ejector from TAS
header by opening TAS-3, TAS-4A, and TAS-4B for heating the lines. Check that line
drains are operating.
5. Maintain TAS header pressure at 14 kg/cm 2 and temperature at 220 0C by raising MS
pressure at 35 kg/cm2 and temperature at 280 0C.
6. Start starting Oil pump and maintain oil temperature at around 42 0C.
d. VACUUM PULLING :

1. Close Reheater vents of Boiler and atmospheric drain of HR and Cr drains.

2. Open CA valves gland sealing water line header isolating valve and maintain the header
pressure at 1.5 kg/cm2, then charge gland seal water to all the CA valves.
3. Close vacuum breaker (CA-6).
4. Open first isolating valve to ejectors (AS-51).
5. Open steam valve to starting ejector (AS-54) and maintain steam pressure at 7.0 kg/cm 2
and open air off-take valves CA-2 and CA-3.
6. When condenser vacuum reaches to 150 mm of Hg, charge the turbine gland steam and
maintain the gland the gland steam header pressure at 0.15 to 0.20 kg/cm2.
Charge GC-1 steam side to maintain the GC-1 vacuum 60-80 mm hg by maintaining steam
pressure 1.5 to 3.0 kg/cm2. Before charging the GC-1, fill up the drain expander loop with
water.
7. When vacuum reaches to 450 mm Hg open MC-39 and MC-57 ( Condensate line to
condenser steam throwing device (STD),
8. Line up spray water line of HP bypass from Boiler Feed discharge line and LP bypass
valves from condensate pump discharge header.
9. When the condenser vacuum reaches about 600 mm of Hg. Put both the main ejectors in
service and maintain the steam pressure 5.5 kg / cm2 to 6.0 kg/cm2. Before putting the main
ejectors into service fill up the ejectors drain loops.
10. Check that the HPT evacuating valves CA-21, 22 and bypass valves across CR line NRVs
(Ex-20, 21) are closed.
11. Set HP & LP bypass downstream temperatures at 320 0C and 150 0C respectively.
12. Open LP bypass and HP bypass valves manually about 5% and allow the steam to flow in
HP / LP bypass line.

Note:

Open Reheater temp. control gas dampers positively when HP/LP bypass valves are charged
(If ABL make boiler ).

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13. Open HP and LP bypass valves gradually and increase the firing rate, if necessary, if
pressure drops.
14. Set HP bypass up stream pressure at 25 kg/cm2 and LP bypass upstream pressure at 0.5
kg/cm2 and put on Auto. Temperature of MS should be maintained around 300 0C.

Note:
While heating the main steam and reheat steam lines, difference in temperature of the pipes
should not exceed 15 0C.
15. when MS line metal temperature before ESV have reached to 270 0C and superheater outlet
temperature of steam is above 50 0C superheat , open bypass valves of MSV for heating the
pipe line up to turbine.
16. Close ESV and IV manually by operating the speeder gear hand wheel.
17. Open Speeder Gear up to 7 mm.
18. Open bypass valves across NRVs in CRH (ES-20,21) and heat HP turbine up to a
temperature of 120 0C. Then close ES-20 and ES-21.
19. Open both the ESVs by 10-20 mm as per scale by operating the hand wheel and heat ESV
body steam admission pipe up to HPT control valves to 150 0C. While opening ESVs, care
should be taken so that the HPT control valves remain tightly closed and steam admission
pipe drains to flash box are open.
20. Check the steam pressure in HR line, which should be less than 1 kg/cm 2 before starting the
heating of steam admission pipe up to control valves (CVs) at IPT. If the pressure in the
line is more than 1 kg/cm2, adjust and reduce the pressure by opening the LP bypass valve
manually.
21. Open both side IV about 10-15 mm as per scale by opening the hand wheel and heat the
steam admission pipes up to CVs up to 80 0C. Care should be taken so that during this
operation IPT CVs remain closed and the steam admission pipe drains to flash box are
open.

Note:
a. The said CVs of IPT have been provided within built relief holes through which
steam leaks into IPT which may cause disengagement of rotor from barring gear, if
the pressure in hot reheat line exceeds 1 kg/cm2.
b. During the process of steam admission pipe heating and HPT heating, ensure that
the drain valves are open and the drain system is working normal. Check locally
that there is not clogging in the drain line.
22. Check bypass valve of MSVs and NRVs in the CR lines when ESV, HPT and Steam
Admission pipes of HPT are heated up to 120 0C. The steam parameters at MSV by this
time shall be 25 kg/cm2 and temperature of 300 0C,
23. Check that the interceptor and steam admission pipes of IPT have attained a temperature of
100 0C.
24. Close ESV and IV by operating the hand wheel.
25. Close Speeder Gear to Zero position.
26. Manually close the HP bypass valves keeping LP bypass valves on MAN mode. When
pressure in the RH line comes to condenser pressure, manually close the LP bypass valves.
Thus bypass stations are manually closed before admitting steam in the turbine for rolling
the set.

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 27. Having accomplished the heating , check and note down the following readings in the log
sheet before rolling the turbine:
a. Metal temperature of pipes before MSV.
b. Metal temperature of ESV.
c. Metal temperature of steam admission lines of HPT & IPT.
d. Metal temperature of HR lines.
e. Metal temperature in the zone of regulating stage.
f. Metal temperature of IV.
g. Steam pressure and temperature before MSV,
h. Differential expansion of HP, IP & LP rotors.
i. Axial shift.
j. HPT and IPT overall expansion.

28. Before rolling turbine, ensure that condensate level, Deaerator level and drum level are
within allowable limits.
29. Check that the eccentricity of the rotor is within limit (less than 70 microns).
30. Open CVs of HPT and IPT completely, with the help of control gear.

TURBINE IS READY FOR ROLLING:

31. Open the MSV bypass isolating valves of both sides.

32. Open the bypass regulating valve slowly thereby allowing steam to roll the turbine.

Note:
As soon as the speed of the rotor rises above 3.4 rpm check that the barring gear gets disengaged
and its motor gets switched off automatically.

33. For good listening of the turbine against rubbing etc. at 500 rpm, close the MSV bypass
regulating valve and listen the turbine carefully. In this process ensure that the rotor does
not come at rest.
34. Being certain the turbine is in healthy condition, again raise the speed to 500 rpm by
opening the regulating valve and soak the set for 10 minutes at this speed.
35. Smoothly raise the speed to 1200 rpm at the rate of about 50 rpm/ min by slow opening of
the MSV bypass regulating valve. Soak the set for 20 minutes at this speed.
36. Raise the speed smoothly to 3000 rpm without pause. It is dangerous to run the set near the
critical speeds and hence it is prohibited to hold the set in the critical speed zone.

Note:
The control valves of HPT tend to close with the rise in sped. To keep them completely open,
the speeder gear should be turned in the direction Increase.

37. Hold turbine speed at 3000 rpm for about 20 minutes for carrying out inspection, listening
and soaking of turbine.
38. When turbine main oil pump develops pressure of 18 k/cm2 before NRV at about 2800
rpm, slowly close the discharge valve of Starting Oil Pump (SOP). See that the oil pressure

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 in the governing system remains constant. Stop SOP and again open the discharge valve for
operation during stopping of turbine.
39. While raising the speed, control the temperature of oil entering the bearings. Maintain oil
cooler outlet temp. around 45 0C.
40. During speeding up of the turbine increase the boiler firing rate so that the steam
parameters before synchronization are as follows :

M.S. steam pressure : 30-35 k/cm2.

M.S. Temperature : 330 350 0C.
R.H Temperature : 300 330 0C.

41. Proceed for synchronization as follows :

a. With the help of control gear close control valves to such an extent that the speed
just begins to fall.
b. Completely open both the MSVs and close the by-pass and regulating vlv.
42. Synchronise the machine and load the machine at 10 MW.
Loading of the set:

1. After synchronizing the set hold the turbine at 10 MW load for about 30 min. to carryout
soaking.
2. The steam parameters by this time are expected to be as follows :
MS pressure : 35 kg/cm2
MS temperature : 350 0C
HR temperature : 330 0C.
3. After soaking the turbine for about 10 minutes at a load of 10 MW, close all the drain
valves of steam lines, steam admission pipes, HR drain collector and IP drain collector.
4. During heating of turbine under load, constantly monitor the differential expansion of HPT,
IPT and LPT and the overall expansion of HPT & IPT.

Note:

It is seen that during cold startup although cylinder heating is done prior to rolling of turbine HPT
differential expansion tends to increase in positive side. If the HPT differential expansion tends to
increase beyond +2.50 mm and the rate of increase is steep one, flange and stud heating should be
applied. It is not permitted to operate the flange heating device if
i. The differential expansion of rotor is less than 1 mm.
ii. The differential expansion indicating and recording instruments are either out of order
or disconnected.

Important

Check that the temperature difference across the width of the casing flange is within 50 0C.
During flange and stud heating the temperature difference between the flange and stud should not
exceed 20 0C and the temperature should never be more than that of the flange.

13
In order to maintain proper tightening of the flange joints, it is necessary to first supply steam for
heating flanges and then after sometime to studs. Separate control of steam supply for heating of
each flange or studs on the left or right side after initial adjustment is not permitted.

e. PROCEEDURE FOR HEATING OF FLANGES AND STUDS OF HP OR IP

CYLINDER ( WHICHEVER IS REQUIRED)

a. Check that AS-21, AS-22, AS-23, AS- 24, AS-25, AS-26, AS-27, AS-28, AS-29 &
AS-30 valves are open.
b. Blow-down the drains of the steam collector for flange and stud heating by opening
AS-33 (HPT) and AS-41 (IPT).
c. Open the valves AS-31 (HPT) and AS-32 (IPT) and drain vacuum of approx 300
mm of Hg in the system. Then close the drain valves AS-33 and AS-41.
d. Open the valves AS-7 or AS-8 and heat the flange and studs of the required
cylinder. The pressure in the header should be maintained at 1.5 kg/cm2 by
adjusting the valves AS-9 and AS-10 (for HPT) or AS-11 and AS-12 (for IPT).

5. Starting of the turbine should be so regulated that the metal temperature difference between
outer and inner surface of the wall of HPT casing at regulating stage does not exceed 35 0C.
6. While loading the turbine , steam temperature should be raised smoothly. The rate of
increase of steam temperature should not exceed more than 3 0C per min. in the temperature
zone of 400 0C to 535 0C.
7. After ensuring the satisfactory and healthy operation of the turbine at the load of 10 MW,
increase the load to 30 MW in a period of 70 minutes. Hold the set at this load for 20
minutes for soaking of turbine. Steam parameters should be continuously raised to attain
following values at the end of the soaking :
MS pressure before ESV : 65 kg/cm2
MS temperature : 4300C
HR temperature : 4200C

8. At this load , cut in all L.P. heaters.

9. Increase the load to 70 MW in a period of 50 minutes and hold the set at this load for 30
minutes for soaking of the turbine.
10. At 70 MW load cut in all HP heaters.
11. Put drip pump in service at around 70 MW load.
12. After soaking the turbine at the load of 70 MW , the parameters of the steam should be :
MS pressure before ESV : 100 kg/cm2
MS temperature : 4800C
HR temperature : 4700C

13. Smoothly and gradually increase the load to 210 MW in a period of 70 minutes and
simultaneously raise the steam parameters to the rated value.
14. after the turbine has been fully heated up the overall thermal expansion of the turbine at front
bearing pedestal would be around 32 mm.
14
 15. Set the point of HP bypass valves up stream pressure at 140 kg/cm2 and downstream
temperature at 380 0C and these controllers must be put on Auto
.
16. Also LP bypass valves are to be kept on Auto. Up stream pressure at 6 kg/cm 2 and
downstream temperature at 200 0C

g. WARM AND HOT START UP OF TURBINE :

Type of restart of turbine depends on the degree of cooling of ESV body, HPT and IPT casings
during the preceding shut down.
Depending upon the metal temperature of HPT casing in the regulating stage the type of start can
be shown:
i. Above 350 0C : Hot start.
0 0
ii. Between 150 C and 350 C : Warm start.
iii. Below 150 0C : Cold start.

Before warm / hot start, the auxiliary equipments should be started in the same manner and order
as in the case of cold start. In case of warm/hot start, limit of eccentricity, bearing vibration and
metal temperatures will be same as stated in the cold start up of the turbine.

GENERAL

1. Boiler is on fire and the aux. equipments e.g. B.F. Pump, CE Pp, and CW Pp are running.
2. Starting Oil Pump (SOP) is running and machine is on barring gear, check oil pressure in
lubricating and governing system and proper draining of oil from bearings.
3. Check all control and measuring instruments have been switched ON and they are
working satisfactorily.
4. Check that HPT differential expansion & IPT differential expansion are within limit i.e.
above 0.0 mm and (-) 1.0 mm respectively. If these parameters are above these values on
contraction side, rotor heating should be given at the time of vacuum pulling, otherwise
differential expansion would go further contraction side during vacuum pulling.
5. Charge the MS line and TAS header by opening the line drains.
6. Start vacuum pulling by starting ejectors. Rotor heating may be given provided IPT
differential expansion starts increasing in the negative side (below 1.2 mm.).
7. Put HP and LP bypass lines in service when condenser vacuum is above 450 mm Hg
column. Check that MSV, ESV, CVs of HPT and IPT are tightly closed.
8. Heating of body of ESV, IV and HPT & IPT steam admission pipes may be done in case
the temperature of these elements is 80 0C & 100 0C less than the lower half of HPT casing
in the regulating stage and in the zone of steam admission in case of IPT respectively. All
the drains to flash box should be opened before starting the steam admission pipe heating.

15
 9. In case of shutdown for less than 6 hours steam admission pipes of HPT and IPT and
bodies of ESV & IV do not get cooled significantly and therefore prior heating of these
elements is not required. Just before rolling these elements may be blown for 5 min.
through drains.
10. Record the metal temperature of the following :
i. HPT in the zone of regulating stage.
ii. IPT steam admission chamber.
iii. Body of ESV & IV.
iv. Steam admission pipes of HPT & IPT.
v. Overall expansion and differential expansion of all the three rotors.
11. Before admitting steam to turbine, check shaft eccentricity and see that it is less than 70
microns.
12. Check the temperature of upper and lower halves of HPT. The difference between
respective upper & lower halves should not be more than 50 0C.
13. Differential expansion of HPT, IPT & LPT should be more than 0.0 mm, -1.2 mm and + 1.0
mm respectively before rolling of turbine.
14. Before rolling, check that condenser vacuum is above 700 mm of Hg and only main ejector
is in service.

INSTRUCTIONS TO USE THE CHART :

1. The curves drawn are for various main steam pressure available before MSV at the time of
rolling the unit.
2. The diagonal lines drawn at the lower part of the chart now directly indicates the various
HPC metal temperature at the regulating stage at the time of rolling the unit.
3. For exact matching ( Which is always preferred ) use the abscissa at no.2 . For maximum
allowable positive mismatch use the abscissa at no. 1 and for maximum allowable negative
mismatch use the abscissa at no. 3. Positive mismatch means steam hotter than metal while
negative mismatch steam cooler than metal.
4. The required main steam temperature for the matching for various steam pressure can be
obtained from the ordinate of the graph.

For example, say at the time of rolling the unit, the metal temperature at regulating stage is
380 0C and main steam pressure is 70 ata.

Then, as shown by dashed lines on the chart, the main steam temperature before ESV,
required for rolling are:

For + Mismatch : 513 0C.

For + Exact Match : 468 0C.
For - Mismatch : 423 0C.

WARM START :

16
1. Read the actual temperature of HP casing at the regulating stage, which for this type of start
up should be in between 150 0C to 350 0C.
2. By using the temperature matching chart herewith, determine the desired steam
temperature and pressure for rolling the turbine on the basis of metal temperature existing
in the regulating stage of HP turbine. However, steam temperature must be more (at least
25 0C) than the hottest metal temperature of ESV and steam admission pipes of HPT.
3. Ensure that the evacuating valves CA-21 & CA-22 and the valves across NRVs in cold
reheat lines (ES-20 & ES- 21) are closed.
4. With the help of HP-LP bypass valves, raise the steam parameters of boiler to desired
value. Simultaneously heat MS, CR & HR lines, if required.
5. Open bypass valves of MS-1 and ESV by 15-20 mm and heat the steam admission pipes up
to control valves.
6. Check the steam pressure in hot reheat line, which should be kept less than 1 kg/cm 2, before
the heating of steam admission pipes of IPT. If the pressure is more than 1 kg/cm 2 adjust
the pressure accordingly. Open IV by 10-15 mm and heat the steam admission pipe up to
control valve of IPT. Care should be taken that the control valves of IPT, during this
operation should remain tightly closed. And barring gear does not disengage.
7. After completion of heating, note down various metal temperatures. Ensure that the desired
matching steam temperature is available at ESV.
8. Check also that the differential expansion of HPT, IPT and LPT are more than 0.0 mm,
-1.2 mm and + 1.0 mm respectively. Check also that HPT and IPT casing upper and lower
temperature differential is less than 50 0C.
9. Manually close the HP by-pass valves and open the LP bypass valves. When the pressure in
the reheat line comes to vacuum, close the LP by-pass valves also. Thus HP-LP by-pass
valves are closed before rolling the turbine.
10. Bring down the speeder gear to zero position and unlock the ESVs and IVs fully and close
MS-1 bypass regulating valves.
11. With the help of speeder gear, fully open ESVs, IVs and CVs of HP & IP turbine.
12. Slowly open the by-pass regulating valves of MS-1 and roll the turbine. Raise the speed up
to 500 rpm.
13. As soon as the speed of the rotor rises above 3-4 rpm check and ensure that the barring gear
gets disengaged and its motor gets switched off automatically.
14. Listen the turbine rubbing etc. at 500 rpm. Check the vibrations of the bearings.
15. After ensuring that the turbine is in healthy state, raise the speed to 1200 rpm within 3- 4
minutes by further opening of by-pass regulating valves of MS-1. Soak the turbine at this
speed for 2 3 minutes. Note all the parameters and ensure that these are within limit.
16. Raise the speed to 3000 rpm without pause. Hold the turbine speed at 3000 rpm for 5
minutes with a view to carryout the inspection, listening and soaking of turbine.
17. Ensure that Main Oil Pump takes over at 2800 rpm, and then stop SOP.
18. Synchronise the set and load the set to 20-30 MW. All the drains must be closed after some
load has been taken on the turbine.
19. The raising of steam parameters and loading of the set is carried out as per attached curve
for warm start.
20. After loading the unit put HP-LP bypass valves on Auto.
21. The second Boiler Feed Pump, LP Htrs., HP htrs. Should be cut in depending upon load
conditions of the set.

17
HOT START :

1. Read the actual metal temperature of the regulating stage of HPC which for this type of
start up should be above 350 0C.
2. Read the actual metal temperature of the following :
i. Body of ESV & IV.
ii. Steam admission pipe of HPT & IPT.
iii. Steam admission chamber of IPT.

3. With the help of steam temperature matching chart attached herewith, determine the desired
steam temperature and pressure for rolling the turbine on the basis of metal temperature
existing in the regulating stage of HP casing. However, the steam temperature before ESV
at the time of rolling of the turbine must be more (at least 25 0C.) Than hottest metal
temperature of the elements indicated in the Para (2) above.
4. The parameters of steam are raised to get the desired matching temperature with the help of
HP-LP by-pass station.
5. After ensuring all the pre-start conditions of HP-LP bypass system, put the HP-LP by-pass
valves in service and then put HP by-pass station on Auto mode. LP by-pass station also
is set on Auto and pressure be set at 6.0 ata.
6. Put the temperature control loops of HP by-pass valves on Auto and set the temperature
set point at 50 0C higher than the Cold Reheat pipes metal temperature. The set point of
temperature would have to be slided upward to meet the boiler requirements and ensuring
the allowed heating rate of CR pipe lines and Reheater. The temperature set point should
not exceed 380 0C. The temperature set point of LP bypass station to be set at 200 0C with
Auto mode.
7. Ensure that the by-pass valves across NRVs of CRH lines ( ES-20 & ES-21) are closed.
Open the evacuating line valves (CA-21 & CA-22) to release the entrapped steam from HP
casing.
8. It may be required to put HPT & IPT rotor heating for arresting HPT * IPT differential
contraction. MS temperature should be raised at least 50 0C higher than the HPT & IPT
cylinder temperature before putting the rotor heating.
9. Raise the steam parameters of boiler . The HP by-pass valves shall be kept on open
condition and swallow the entire steam generated by the boiler, until the flow passing
capability of the HP by-pass valves corresponding to set pressure is fully utilized.
10. Raise the boiler parameters to the value required under Para (3) . As the difference of
pressure, between the actual value and set point, exceeds the limit, an alarm shall appear. At
this stage , the pressure set point should be manually slided upwards, but always ensuring
that the set point value is 2 to 3% lower than the actual pressure value indicated in the
instrument.
11. After attaining the desired steam temperature and pressure suitable for rolling of the
turbine, hold the firing rate of boiler.
12. Heat the steam admission pipes between IV and CV of IPT by opening IV by 5 to 10 mm.
The valves in the drains of these pipes should be kept full open, prior to opening IV. After
heating these pipes corresponding to steam temperature, close IV fully. Care should be
taken during this operation to lower the LP by-pass station pressure set value below 1
kg/cm2 so that the turbine does not get rolled off the barring gear.

18
 13. Check also that the differential expansion of HPT, IPT and LPT are more than 0.0 mm,
-1.2 mm and + 1.0 mm respectively. Check also that HPT and IPT casing upper and lower
temperature differential is less than 50 0C.
14. Open fully both the turbine side main steam stop valves (MS-1) and also valves in the drain
lines of the transfer pipes.
15. Before rolling check that HP-LP by-pass valves are on Auto mode. LP by-pass pressure
setting should be at 6 ata.
16. Completely open ESV & IV with the help of speeder gear. Turbine will start rolling through
IPT.
17. As soon as the speed of the rotor rise above 3.4 rpm check and ensure that the barring gear
gets disengaged and its motor gets switched off automatically.
18. Start opening of CVs of IPT and raise the speed of turbine to 3000 rpm without pause.
19. Ensure that MOP takes over at 2800 rpm and then stop the SOP.
20. Synchronise the set and take around 30 MW load on the unit. Close all the drains.
21. Continuously monitor the steam temperature of HP & LP by-pass station. Immediately after
opening of CVs of IPT, monitor the pressure in HR lines. Automatically Pressure Control
Loop of LP by-pass station will not allow dropping pressure below 6 ata in the HR line. In
case it falls below this value, LP bypass control should be taken in manual for controlling
the pressure in reheat line around 6 ata.
22. Ensure that the evacuating valves CA-21 & CA-22 in the HP casing drain lines gets closed
automatically when steam flow starts through HPT.
23. Immediately increase load of the turbine @ 5 MW per minute until HP bypass valves get
closed automatically and entire steam passes through HPT. Hold the load at this stage.
24. Further loading of the set is done as per the curves for HOT start. The steam parameters are
raised by increasing boiler firing rate. The time for loading the set during hot restart
depends on the thermal condition of HPT & IPT.
25. While loading the set, ensure that the metal temperature difference between inner and outer
surfaces of the wall of HPT casing does not exceed 35 0C. In case this requirement is not
being fulfilled stop further loading of the set until these requirements is met.
26. Stop rotor heating steam supply of HPT & IPT when differential contractions reduced and
got stabilized.
27. The second Boiler Feed Pump, LP heaters and drip pumps should be put into service
depending upon the load condition of the set.

SHUTDOWN OF TURBINE :

A planned shutdown i.e. gradual load reduction leading to subsequent shutdown is desirable as
compared to abrupt trip out, which is normally done during emergency condition only. If no proper
sequence is followed during shutdown. It may result in inducing thermal stresses, differential
expansions, distortions and misalignment of turbine flow path elements. Proper shutdown
procedure will reduce the down time for restarting of the set and also it will avoid under stressing
of turbine parts. The shorter is the shutdown required, the greater must be the coordination and
precision of the operator during shutdown.

The turbine can be stopped by pressing the knob of turbine shutdown switch on the front right side
of the front pedestal. The same action can be achieved by engaging the solenoid of the shutdown
switch by remote operation from UCR. This solenoid also gets energized and trips the turbine

19
when the Turbine Lockout Relay is operated due to any fault in the unit necessitating the tripping
of turbine.

Planned Shutdown :

For planned shut down of the set, following procedure should be followed:

1. Inform the boiler operator that turbine would soon be shutdown.

2. Check the SOP and AC & DC Lub. Oil pumps and ensure their Auto cut in.
3. Check the non-seizure of ESV & IV . Check that bypass valves of MS-1 are closed.
4. Normally, the turbine is unloaded by closing gradually the CVs through remote operation
of speeder gear. The unloading should be carried out @ 3 MW per minute at rated
parameters. The rate of unloading mainly depends differential contraction of rotors. Firing
rate of boiler is to be controlled accordingly.
5. After reducing the load to 120 MW cutout HP heaters on steam side as well as drip side.
6. Switch off one of the B.F. Pumps
7. At about 70 MW load check that drip pump gets switched off under automatic controller
action.
8. While unloading and stopping the turbine , sharp fall in metal temperature of steam
distribution elements of HPT & IPT should be avoided.
9. While unloading the turbine , constantly monitor the differential expansions of Rotors,
temperature of flanges & studs, vibration of bearings, shaft eccentricity etc.
10. In case differential expansion of rotors tends to exceed the permissible limit, take necessary
measure. For minimizing the contraction rate of HP & IP, rotor heating may be applied
( after the blowing down the pipes ). Care should be taken so that steam temperature is
higher than the metal temperature of HPT and IPT as case may be.
11. Having unloaded the turbine to about 10 MW load, start the Starting Oil Pump (SOP) .
Then trip the turbine. Check that ESVs IVs and CVs get closed. Also check that Generator
Circuit Breaker has opened through Low Forward Relay.
12. Check that MS-1 have closed on Auto otherwise close these valves manually.
13. If there is jamming in ESV or IV, immediately close MS-1 ( If these are not closed on auto)
and ensure that turbine speed starts reducing.
14. When the speed has dropped to 2800 rpm, check that oil pressure in the lubrication system
is normal.
15. If for some reason , the turbine is to be stopped quickly vacuum should be broken. For this
purpose , cut off steam supply to main ejectors and open the vacuum breaker valve CA-6.
When the vacuum falls to 100 mm of Hg. Cut off gland seal steam supply and steam supply
to GC-1 ejector.
16. When the oil temperature at the outlet of the bearings drops to 45 0C , stop cooling water
supply to oil coolers.
17. When rotor comes to stop , immediately start the barring gear and roll the rotors
continuously till temperature of lower part of HP casing at regulating stage drops to 150 0C.
18. Isolate TAS header by closing the main isolating valve. Also close MS stop valves MS-2
and MS-2A or SH-7 & 7A).
19. Keep the condensate pump running on recirculation until LP exhaust hood temperature
comes to 50 0C.

20
20. Stop the condensate supply to valves and pumps glands sealing and also cooling water in
ESV & IV servomotors.
21. After the turbine is shutdown , drains of steam admission pipes and cylinders should not be
opened till the metal temperature falls below 200 0C. If the turbine is to be started before
the metal temperature drops to 200 0C, then the drain are only opened during preparation
for restarting.
22. CW Pumps can be stopped when LPT exhaust hood temperature falls to 50 0C.
23. After the turbine is stopped and the rotor is on barring gear, check shaft eccentricity and
record it in the log book.

FORCED SHUT DOWN / TRIP OUT OF TURBINE :

During forced shutdown/trip out of turbine due to some fault, ESV, IV and control valves will get
closed immediately and the generator circuit breaker will open through low forward power relay.
In that case the following operations should be done immediately :
1. Start the starting oil pump.
2. Check that MS-1 valves have closed on auto , otherwise close these valves manually.
3. Put the turbine on barring gear when rotor s have come to rest.
4. Try to detect the fault and restart the turbine if the fault is over.
5. If the fault persists , boiler fire is to be killed and vacuum may be killed as described in
normal shutdown procedure.

A typical H.P. Control Valve Characteristic in Cold Condition:

Relay oil pressure : 16 kg/cm2 .

H.P. Cylinder 1st. stage Metal Temperature : 38 0C.

LIFT OF H.P. CONTROL VALVES

HP Cam CVSM Valve-1 Valve-2 Valve-3 Valve-4
angle position ( mm ) ( mm ) ( mm ) ( mm )
position ( mm )
degree
(0)

0 0 0 0 0 0
10 140 3 4 0 0
20 155 6 8 0 0
30 170 7 10 0 0
40 178 9 13 0 0
50 205 11 16 0 0
60 220 13 18 0 0
70 240 18 23 0 0
80 256 23 29 0 0
90 272 24 (Full open) 36 3 Starts opening
100 290 24 38 (Full open) 14 5
105 300 24 38 18 (Full open) 11 (Full open)

21
H.P. Control Valves Starts open at :

Cam Angle C.V.S.M. Valve Valve Valve Valve

Position Position No.-1 No.-2 No.-3 No.-4

00 120 mm Start - - -
100 122 mm - Start - -
740 250 mm - - Start -
900 272 mm Full Open - - Start
1000 290 mm - Full Open - -
1500 300 mm - - Full Open Full Open

GAPS in between H.P. Cam and Roller Assembly:

Control Valve Gap

Valve No.-1 5.0 mm

Valve No.-2 5.0 mm
Valve No.-3 8.0 mm
Valve No.-4 8.0 mm

I.P. control Valves Starts open at :

IPCV Angle CVSM LIFT OF CONTROL VALVE

position Position Valve Valve Valve Valve
No.-1 No.-2 No.-3 No.-4
5 10 Start Start - -
45 50 - - Start -
90 95 - - - Start
290 300 (Full open) (Full open) (Full open) (Full open)
Lift-98 mm Lift-98 mm Lift-82 mm Lift-80 mm

ESV & IV starts open at :

Speeder Gear Position (mm) ESV Lift (mm) IV Lift (mm)

5.0 - Starts opening.
6.3 Starts opening -
7.5 - Full open
8.0 Full Open -

TURBINE GOVERNING SYSTEM

1. Introduction :

22
 High pressure hydro-mechanical Governing system has been provided for the steam turbine to
maintain the speed at the desired set points during start up and normal operation. It also serves
to prevent undesired over speeds following sudden loss of export load. The control action of
the proportional type with a steady state overall speed regulation (i.e. proportional band) of 4
1% . This proportional band is necessary in order to realize :

a. Stable speed control in isolated operation of the set.

b. The desired degree of load distribution between sets running in parallel.

All the operations of starting and loading the set can be performed by manually operating the
speeder gear hand wheel located at front pedestal or by operating speeder gear motor remotely
from unit control panel.

Special features :

i. In the event of generator breaker opening following a full load loss, governing system
prevents the over speeding of the set to a dangerous level and quickly stabilizes the set
on house load or on no load, This is achieved by electro hydraulic transducer (EHT)
receives signal only for two seconds.
ii. The governing system envisages anticipatory over speed control gear termed as
Differentiator. The differentiator causes anticipatory closure of the control valves
depending on the magnitude of acceleration being experienced by the turbine. This
action prevents speeding of the set to a dangerous level.
iii. Transient speed rise is anticipated to be not more than 7 to 8% over normal speed, even
in case of total loss of export load.
iv. Speed governor can control speed in the range approx. 300-3450 rpm when the set is
not synchronized.
v. Load limiter has been provided to avoid accidental overloading of the set. The set point
of load limiter can be chosen over entire range from no load to full load.
vi. Governing gear operates on constant oil pressure principle.
vii. Initial steam pressure unloading gear (ISPUG) has been provided to unload the set in
case initial steam pressure drops by more than 10% of the rated steam pressure.

A. GOVERNING SYSTEM :
The governing or regulation process is achieved by a combination of mechanical and / or
hydraulic signals causing interactions of elements mentioned below :
a. Speed Governor.
b. Follow-pilot valve.
c. Summation pilot valve.
d. Intermediate pilot valve.
e. Control valve servo motor.
f. Load / speed control pilot valve
g. Differentiator ( Anticipatory gear ).
h. Electro hydraulic Transducer (EHT).
i. Speeder Gear.
j. Initial Steam Pressure Unloading Gear (ISPUG).

23
 k. Lever.
l. Load Limiter.

B. Protection System;

Protection system functions similar to governing system by a combination of mechanical and

hydraulic signals on various elements mentioned below :

a. Emergency governor.
b. Emergency governor lever.
c. Emergency governor indicators.
d. Emergency governor testing cock.
e. Emergency governor pilot valve.
f. Emergency stop valve servomotor.
g. Interceptor valve servomotor.
h. Turbine shutdown switch.

II. DESCRIPTION OF GOVERNING SYSTEM ELEMENTS :

A. Speed Governor :

Speed Governor Pilot Block performs malfunctions during startup of turbine and during
normal service when the turbine is being run in a grid or otherwise. The speed governor pilot
block performs these functions through the following elements :

i. Follow pilot valve.

ii. Summation pilot valve.
iii. Load / speed control pilot valve.
iv. Speeder gear.
v. Lever.

Function of the above elements :

i. Follow pilot spool follows the movement of governor sleeve and actuates the
summation pilot valve through lever.

ii. Summation pilot valve receives signal from follow pilot valve and load / speed
control pilot valve through the lever and actuates differentiator and intermediate
pilot valve.

III. Load/ Speed control pilot valve is instrumental in converting mechanical signal from speeder
gear into hydraulic signals to emergency governor pilot valve, emergency stop valve
servomotor and interceptor valve servomotor. It actuates the summation pilot valve through
lever. It performs the following functions :

24
 a. To bring the main pilot spool of the emergency governor pilot valve (EGPV) in
operative position after turbine trip out. This process is called charging of the
emergency governor pilot valve.

b. To open emergency stop valve and interceptor stop valve.

c. To control speed while the set is at no load.

d. To assist in synchronization of the set.

e. For changing the load of the set while the turbine is working in parallel with other
turbines in the grid.

IV. Speeder gear essentially actuates the load / speed control pilot valve. The speeder gear
can be actuated either by operating the hand wheel at front pedestal or by remote
operation from unit control panel.
V. Lever inter-connects the load/speed control valve , follow pilot valve and summation
PILOT VALVE.

Equilibrium of various elements and process of propulsion:

i. Equilibrium of follow pilot spool.

The pilot spool remains in equilibrium as a result of 13 ata ( oil at 20 ata enters through an
orifice of dia 3.2 mm ) pressure acting on the left face of the bobbin and pressure 5 ata
acting on the right face of the bobbin. Oil flows to open drain from the chamber ( 5 ata oil
pressure ) through radial and central holes and nozzles of 5 mm dia. Oil flow is restricted
by governor sleeve which is approximate 1.3 mm away from nozzle face.

ii. Force acting on summation pilot spool.

A continuous hydraulic force due to 20 ata pressure acting on the right face of the bobbin,
keeps the spool pressed against the lever. However, this force is feeble as compared to the
force exerted by follow pilot valve and load / speed control pilot valve through lever. Thus
the position of the spool is dictated by the position of the follow pilot spool and load /
speed control pilot spool. Primary sensitive line oil enters and leaves through ports to open
drain.

iii. Force for actuation load speed control pilot spool

Pilot spool is subjected to hydraulic forces which are self balanced by 20 ata oil pressure.
The propulsion force for the pilot spool is provided by speeder gear only.

OPERATION :
a) Speed decreasing i.e. load increasing on the set :
Under the conditions the speed governor sleeve moves towards left. This restricts oil flow
from the chamber. This in turn increases the pressure in the chamber. The equilibrium of
the pilot spool gets disturbed and it moves towards left until the distance between nozzle

25
 face and governor sleeve is again restored. It can, therefore, be said that the pilot spool is
hydraulically coupled with governor sleeve and follows its motion.

The leftward movement of the pilot spool pushes the lever towards left through tie-rod.

The lever pulls pilot spool of summation pilot valve towards left hand side. It temporarily
transmits the increased oil pressure signal to the intermediate pilot valve through the
primary sensitive oil line. The increased pressure also gets transmitted to differentiator . the
pressure increase in primary sensitive oil line actuates the intermediate pilot valve in such a
manner that the pressure in the primary sensitive oil line gets restored to its normal value
7.7 ata Similarly the pressure in the line to differentiator also gets restored to its normal
value of 8.9 ata

b) Speed increasing i.e. load decreasing on the set:

The mode of operation in this case would be just reverse of the events described above.

c) Large load dump:

Under these conditions, the follow pilot spool actuates the pilot spool of summation pilot
valve to move towards right rapidly. This causes sharp drop if pressure in the primary
sensitive oil line. At the same time due to movement of the bobbin sharp drop in oil
pressure takes place in the oil connected to differentiator. The differentiator senses the rate
of drop of pressure and gives command for anticipatory closure of control valve.

d) Charging of emergency governor pilot valve :

Following a trip out by actuation of emergency governor pilot valve (EGPV), it is
essential to bring EGPV in operative position again. For achieving this , it is necessary to
bring the spool of load / speed control pilot valve to extreme left position so that oil supply
to chamber connected to charging line is blocked

e) Opening of ESV and IV servomotors :

Anticlockwise rotation of speeder gear moves pilot spool of load / speed control pilot
valve towards right which uncovers the ports and this in turn leads the supply of 20 ata Oil
in ESV and IV servomotors. IV servomotor begins to open when the pilot spool of load /
speed control valve has moved by 4.6 mm and get completely opened at 5.9 mm travel of
the spool. Similarly ESV servomotors begin to open at 5.5 mm travel and get completely
opened at 6.65 mm travel of the spool.

f) Speed control at no load :

Anti-clockwise rotation of the hand wheel of speeder gear moves pilot spool of load / speed
governor control valve towards right. Any movement of pilot spool towards right causes
movement of summation pilot spool towards left through lever because middle pin acts as
fulcrum. The speeder gear can be operated by the DC motor also. The motion is transferred
through worm and worm gear.

9.6 mm travel of spool of load / speed control pilot valve would bring the pilot spool of
summation pilot valve in such a position that the bobbin just begins to cover the pots which

26
 would cause increased pressure signal in the primary sensitive oil line resulting in opening
of control valves ( as explained afterwards).

As speed increases , follow pilot spool would move towards right and the lever would just
push the summation pilot spool towards right by about twice the travel of follow pilot
spool. Thus net movement of summation pilot spool towards left , due to anti-clockwise
rotation of speeder gear, is the difference of travel of load/ speed control pilot spool
towards right and double the travel of follow pilot spool towards right. The negative travel
of summation pilot spool due to increase in speed is counteracted by further anti-clockwise
rotation of speeder gear. Thus speed control at no load can be done by operating pilot spool
of load / speed control pilot valve by speeder gear.

Foe synchronization of the set with grid , speed of the set can be brought to match the
frequency of the grid and then set may be connected to grid.

When the set is in grid of large capacity , its speed is governed by the grid frequency only
and load / speed control pilot valve would then control the load when actuated by the
speeder gear.

B) Intermediate Pilot Valve :

The intermediate pilot valve amplifies the hydraulic signals from summation pilot valve,
differentiator, electro-hydraulic transducer and EGP valve. The amplified hydraulic signal
is in turn , transmitted to control valve servomotor.

Oil at 20 ata Enters in the chamber from bottom hole . Oil from the chamber also flows
into another chamber, through the ports and central hole in bobbin of pilot spool, which is
connected to primary sensitive oil pressure.

Another chamber at the top is connected to the secondary sensitive oil line on one side and
to the suction line of main oil pump through ports on the other side. The pressure in the
secondary sensitive oil line is maintained at 10.3 ata Under steady state.

Equilibrium:

The pilot spool remain in equilibrium due to pressure at 15.4 ata acting downwards on
differential area of bobbins I and II and pressure 7.7 ata At lower face of bobbin I acting
upwards.
The hydraulic face on the remaining faces of the bobbins are self balanced.

Operation :

a) Speed decreasing i.e. load increasing :

Under these conditions the pressure in primary sensitive oil line would increase causing
the upward movement of pilot spool which would result in :

27
 1. Bobbin I would reduce the area of opening of ports, thus reducing the quantity
of oil entering the chamber. The pilot spool would move only to such an extent
as to restore the pressure in primary sensitive oil line to 7.7 ata

2. Bobbin II under simultaneously reduce the area of opening of ports and thus
reducing the quantity of oil drain from secondary sensitive oil line to the
suction line of main oil pump. This would cause the transient pressure increase
in secondary sensitive oil line resulting in further opening of control valves.

b) Speed increasing i.e. load decreasing :

1. For small load changes the mode of operation would be just reverse as stated
above.
2. In case the large load dump, differentiator would cause additional oil drain
from primary sensitive oil line which would result in further downward
movement of pilot spool of intermediate pilot valve causing anticipatory
closure of control valve.
3. In case of generator breaker opening , electro-hydraulic transducer would also
come additional pressure reduction signal in primary sensitive oil line for two
seconds thereby causing the closure of control valves.

c) Emergency condition :

During action of the protection system, main pilot spool of emergency governor
pilot valve moves downwards causing drain of primary sensitive oil . It would
give a sharp decrease pressure signal in primary sensitive oil line causing
downward movement of pilot spool of intermediate pilot valve , which would
actuate control valves servomotor to completely close the control valves.

C) Control Valve Servomotor :

The servomotor receives hydraulic signal from intermediate pilot valve and actuates
four control valves of HP turbine and four control valves of IP turbine through racks,
pinion, cams etc.

Equilibrium :

At steady state , the pilot spool of servomotor pilot valve remains in equilibrium
under the action of the following forces :

i. 10.3 ata Pressure acting upwards, on the lower face of bobbin I (lower).
ii. 20 ata Pressure acting downwards on the upper face of bobbin IV ( on differential
area of bobbin IV & V)
iii. 1 ata Pressure acting downward on the upper face of bobbin V (upper ),

In steady state piston of control valve servomotor is in equilibrium under the action
of following force :

28
 i. Pressure in the chamber acting upwards on lower face of bobbin I ( lower ).
ii. Pressure in the chamber acting downwards on the upper face of bobbin I ( on
differential area of bobbin I & II ).
iii. Control Valve forces acting downwards on the piston through linkage and stem.

Operation :

a) Speed decreasing i.e. load increasing :

Under these condition , oil pressure in secondary sensitive oil line increases. Due
to unbalance the pilot valve moves upwards. As a result control oil flows into the
lower chamber of control valve servomotor through ports which disturbs the
balance of piston and it moves upwards resulting in opening of control valves.
Oil above the piston flows into a chamber of servomotor pilot valve through ports
from where it flows into suction line of MOP.

Movement of piston upwards causes downward movement of pilot spool of feed

back pilot valve by feed back action lever. This movement decreases oil supply to
chamber through ports and as soon as the servomotor opens up to the desired
level, pressure in the secondary sensitive oil line gets restored to 10.3 ata This
process is known as feed back action.

When pressure 10.3 ata is restored , pilot spool of servomotor pilot valve moves
down to its middle position and stops further oil flow into the lower chamber and
also oil flow from the upper chamber of control valve servomotor. Thus oil under
and above the piston in the main servomotor is entrapped arresting the movement
of piston.

b) Speed increasing i.e. load decreasing :

i. Under the condition, oil pressure in the sensitive oil line decreases. Due to
unbalance the pilot spool of servomotor pilot valve moves downwards. As a result
control oil flows into the upper chamber of control valve servomotor through port,
which disturbs the balance of piston and it moves downwards resulting in closing
of control valves. Oil below the piston flows into a chamber of servomotor pilot
valve through ports from where it flows into the suction line of MOP.
Movement of piston downwards causes upward movement of pilot spool of feed
back pilot valve by feed back action of lever. This movement increases oil supply
to chamber through ports and as soon as servomotor closes up to the desired level,
pressure in the secondary sensitive oil line gets restored to 10.3 ata.
When pressure 10.3 ata is restored, pilot spool of servomotor pilot valve moves
up to its middle position and stop further oil flow into the upper chamber and also
the oil flow from the lower chamber of control valve servomotor. Thus oil in the
main servomotor is entrapped.

29
 ii. During large load dump , primary sensitive oil would drain from the summation
pilot valve as well as in differentiator. Additional drain of primary sensitive oil in
the differentiator would cause anticipatory closure of control valve.
iii. During opening of generator circuit breaker causing action of EHT, 2 seconds
pressure reduction signal in primary sensitive oil causes the anticipatory closing
of control valves.
iv. Main steam pressure drop causing action of initial steam pressure unloading gear
decreases secondary oil line pressure resulting closing of the control valves and
thus unloading the turbine. If main steam pressure is restored, secondary sensitive
oil line pressure would rise resulting in opening of control valves and thus loading
the machine.

c) Operation of protection system to trip the turbine :

Under these conditions, primary sensitive oil is connected to open drain through
emergency governor pilot valve resulting in downward movement of pilot spool of
intermediate pilot valve to lower stop. It causes sufficient pressure drop in
secondary sensitive oil line leading to instantaneous and complete closure of control
valves.

D) Differentiator :

The differentiator essentially causes anticipatory closure of control valves of HPT & IPT,
in case the load throw-off is more than 50% of the nominal thus preventing undue speed
rise of turbine.

Equilibrium :

Following forces keep the pilot spool in the equilibrium position :

i. Control oil pressure 20 ata acting downwards on the upper face of bobbin.
ii. Oil pressure 8.9 ata acting upwards on the lower face of bobbin.

Piston is in equilibrium due to following forces :

i. Control oil pressure 20 ata acting downwards on the upper face of bobbin.
ii. Oil pressure 4.85 ata acting upward on lower face of bobbin.

Operation :

a) Speed decreasing i.e. load increasing :

Oil pressure temporarily increases under the pilot spool which results in upward movement
of pilot spool relative to piston causing flow of control oil from one chamber to other. It
results in movement of piston upwards till ports are again covered by bobbin of pilot spool
with some time lag ( Time constant of piston is more than time constant of pilot spool) . In

30
 this process primary sensitive oil pressure is not affected by differentiator. So under these
conditions differentiator does not participate in governing process.

b) Speed increasing i.e. load decreasing :

Oil pressure temporarily decreases under the pilot spool , which results downward
movement of pilot spool relative to piston. As a result of this oil chamber is connected
to open drain. Thus due to decrease of pressure in the chamber, piston moves down till
ports are again covered by bobbin of pilot spool. Piston follows motion of pilot spool in
downward direction also.

When load fall is less than 50% of the rated load the primary sensitive oil pressure is
not affected by the differentiator.

c) Abnormal condition ( large load dump) :

When load dump is more than 50% of the rated value, resulting in pre-determined
acceleration of the set, pilot spool moves downwards much faster than the piston. As
a result of this piston lags pilot spool by a distance more than overlap of 0.5 mm and
the ports get uncovered. It causes drain of primary sensitive oil in addition to its drain
in summation pilot valve , resulting in anticipatory closure of control valves. Speed
rise is limited to 7 to 8% of the rated value under large load dump condition, by
differentiator. Thus chances of unit trip by speed increase to 11 to 12% are eliminated.

E) Electro-Hydraulic Transducer (EHT) :

It is instrumental in converting electrical signal derived from generator circuit breaker
into hydraulic signal in the primary sensitive oil line. This is achieved by two main
elements.

a. Electromagnetic transducer :
It converts electrical signal from generator circuit breaker into movement of one
plunger.
b. Hydraulic amplifier :
It converts movement of plunger of electromagnetic transducer into an amplified
hydraulic signal to primary sensitive oil line resulting in closure of control valves.

Equilibrium :

a. Electromagnetic transducer EMT) :

When energized , sliding system of EMT experiences an upward force due to
interaction of magnetic flux of permanent magnet and operating coil. The sliding
system moves upwards until the tension of the spring equalizes the magnetic forces.

b. Hydraulic amplifier :
Primary pilot spool is in equilibrium under the influence of downward forces due
to pressure 4.6 ata acting on upper face of bobbin and upward force due to pressure
13 ata In the chamber acting on the lower face of primary pilot spool.

31
 Secondary pilot spool is in equilibrium under the influence of force from right on
bobbin due to pressure 11.8 ata and force from left on bobbin due to control oil
pressure 20 ata

Operation :
a. Generator circuit breaker opens :
Under these conditions, a time bound electrical signal (current) is transmitted to the
operating coil of EMT. Because of the interaction between the magnetic forces of
operating coil and permanent magnet sliding system of EMT would move up
thereby clearance between oil guard and nozzle and face ( upper face of bobbin of
primary pilot spool ) would increase . This increased clearance would cause more
drain through nozzle end face to initial value.

As a result of action stated above clearance between nozzle and taper part of
primary pilot spool would increase. It would result in more drain through nozzle
and ultimately decrease the pressure in right hand chamber of bobbin of secondary
pilot spool. Equilibrium of secondary pilot spool gets disturbed and it moves
towards right till the clearance comes to initial value. ( Movement of secondary
pilot spool is three times the movement of primary pilot spool). Due to the
movement of secondary pilot spool towards right, it would uncover the ports
causing the drain of primary sensitive oil from the chamber. This will cause
temporary pressure drop in primary sensitive oil line resulting in closure of control
valves.

After 2 seconds as soon as the electrical signal is cut-off , sliding system of EMT
would move down to its middle position and the processes as stated above would
occur in reverse order. Thus the drain oil of primary sensitive oil will block. In this
manner, it may be noted that EHT impulse in the primary sensitive oil line is
superimposed on the other governing signal for a duration of 2 seconds only.

b. Load / Speed changes when generator circuit breaker remains closed :

Under these condition no electrical signal is transmitted to EHT and therefore
electro-hydraulic transducer does not influence the governing system.

F) Initial Steam Pressure Unloader:

Initial steam pressure unloading gear (ISPUG) essentially reduces the load on the turbine
in case initial steam pressure falls below 90% + 2% of the rated value i.e. below (117 + 2)
ata It is achieved by partial closure of control valves. Unloading gear would
proportionally unload the set to no load if the initial steam pressure drops from (117+2)
ata to 91 ata ( i.e. 90% + 2% to 70%)

Oil Circuit:
Under normal opening condition port in the liner is covered by pilot spool coupled with
actuator and the chamber fed with oil from secondary sensitive oil line is not permitted to

32
 flow through ports. There is an overlap of 150 between the edges of ports to avoid
leakage.
a) Control action when main steam pressure starts falling down :
Electrical signal from pressure transmitter is blocked till pressure falls from 130 ata to
(117 +2 ) ata. At pressure (117+2) ata, actuator receives electrical signal and rotates
the pilot spool such that pointer indicates 1 on scale. Under this condition overlap of
150 between the edges of ports reduces to zero. On further steam pressure drop , pilot
spool starts uncovering the port which will lead to drain secondary sensitive oil into
suction of MOP. This would result in temporary oil pressure drop in secondary
sensitive oil line causing closure of control valves. When initial steam pressure drops
from 90% to 70% the set is completely unloaded from full load to no load. Unloading
is proportional to the pressure drop in the range 90% to 70% i.e. if pressure drop is
5% unloading would be 25% . If pointer indicates 2 on scale unloading is 25% at3
by 50% and so on.
b) Control action when main steam pressure building-up :
Pressure rise in the range 70% to 90% of the normal would cause movement of pilot
spool in reverse direction. It would reduce the uncovered area of the ports and thus
increase pressure in secondary sensitive oil line. As a result control valve would open
to reload the set proportional to the steam pressure rise.

G) Load limiter :
Load limiter avoid the accidental overloading of the set beyond set point. The set point
can be carried over entire load range. It is mounted on the front end of the front pedestal
of turbine.

Operation :
Operation of load limiter is unidirectional. It restricts movement of pilot spool of
summation pilot valve towards left, as soon as the bolt (located at the interconnection
point of lever and summation pilot valve) presses limiter rod. But load limiter does not
affect movement of pilot spool when the later moves towards right ( load decreasing).

When load limiter is rotated clockwise, limiter rod moves towards right and pushes pilot
spool of summation pilot valve towards right which resets in closure of control valve.

It may be noted that control valve servomotor can be completely closed by operating the
load limiter hand wheel clockwise. But the reverse is not true i.e. control valve
servomotor may not get opened by operating the load limiter hand-wheel anti-clockwise.

Equilibrium :

Load limiter is not subjected to any hydraulic forces. It consists of mechanical elements
with a micro-switch having electrical contacts.

Procedure for adjusting the set point of load limiter :

i. By actuating the speeder gear , bring the turbine load to a load slightly lower
than the value for which load limiter is required to be adjusted.

33
 ii. Load limiter hand wheel is rotated clockwise to such an extent that annunciation
load limiter operated appears in unit control room.
iii. Now the load limiter hand wheel is rotated anti-clockwise by about 2.0 mm in
the load limiter scale so that load limiter operated annunciation disappears in
unit control room.

Note :
As soon as the annunciation load limiter operated in UCP appears , immediately steps
should be taken to reduce the load in the set so that the annunciation disappears.

III ) DESCRIPTION OF PROTECTION SYSTEM :

a) Emergency Governor :
In the unlike event of speed increasing to 111-112% of value , emergency governor strikes
fly-out of the emergency governor body to trip the set through levers and other hydraulic
circuit. It is necessary that the emergency strikers should be tested periodically during
normal service of turbine. Since over-speeding of turbine is not possible when the set is
interconnected with the grid, the effect of over-speeding is simulated by injecting oil under
the strikers. These objectives are achieved by :

1. Emergency Governor.
2. Levers.
3. Testing cock.
4. Indicators.

1. Emergency Governor :
The emergency governor is mounted on the front end of HP rotor and is dynamically
balanced with it. It is coupled to shaft of MOP by a gear coupling. Two strikers have been
provided for reliability and for on-load testing. Centre of gravity of the strikers is away
from centre line of rotation. Initial compression of the spring is adjusted so that the strikers
fly out at 11 to 12% over-speed. Centrifugal force on the strikers is counteracted by the
spring force during normal speed of the turbine.

2. Emergency Governor Levers:

Levers are mounted on a bracket which is fixed with emergency governor pilot valve. A
handle is provided outside the front pedestal which can adjust position of levers relative to
strikers. Any one or both the levers can be adjusted to receive signal from emergency
governor. During normal operation each lever placed opposite to corresponding strikers to
receive signal.
3. Testing cock ;
Testing cock is provided inside the front pedestal on left hand side. It can be operated by a
knob outside the front pedestal.
4. Indicators :
Indicators are mounted on a bracket which is fixed with differentiator. Rubber wheels are
placed just opposite to respective strikers at about 1 mm.
Oil circuit of Emergency Governor :

34
 i. Control oil at 20 ata is fed to the chamber of cock. When oil injection knob is in the
middle position there is no oil supply to any nozzle.
ii. Turning of oil injection knob anti-clockwise knob anti clockwise would cause control
oil to flow from the chamber of the cock to the nozzle of striker no.1. From nozzle
oil flows into the chamber around striker no.1 through ports. When oil supply to the
nozzle is out turning the injection knob , the accumulated oil of the chamber around
striker no.1 drains through ports inside the front pedestal.
iii. Turning of oil injection knob clockwise would cause control oil flow from chamber of
the cock to the nozzle of striker no.2, where from it flows around the chamber of
striker no.2. on cutting oil supply to nozzle , accumulated oil around the striker drains
into front pedestal similar to striker no. 1.

Operation:

a) Operation at 11% to 12% over-speed :

As soon as the speed of the turbine rises to 11%-12% of the normal speed (i.e. 3330 to
3360 rpm) centrifugal force on the strikers overcome force of the springs and the strikers
fly-out. Once the strikers begin to move out , distance between the centre of gravity of the
strikers and centre line of rotation increases, thus causing further increase of centrifugal
force. Thus strikers , once dislodged from stable position, would continue to move out until
checked by the stop of the body.
When the strikers strike one end of the levers, the other end would press the impulse pilot
spool of emergency governor pilot valve and would ultimately lead the tripping of turbine
through hydraulic circuit. Apart from actuating the trip system, the strikers press
corresponding rubber wheels. The axle of the wheel would act as a fulcrum and the rod lifts
the flap up. Movement of the flap is visible at the top of front pedestal and also indicate the
operation of the corresponding striker.

Operation during testing by oil injection :

Either striker can be tested at one time. If desired , the lever opposite to the striker under
test is disengaged in such a manner that it would not trip the set but flap would opo up to
indicate that the striker moved out due to centrifugal force of the injected oil around the
striker.

b) Emergency Governor Pilot Valve :

It is an intermediate element to convert the mechanical signal , received from emergency
governor through level to a hydraulic signals from follow pilot valve and turbine shutdown
switch. Hydraulic signal is transferred to emergency stop valve servomotor, interceptor
valve servomotor and control valve servomotor.

Equilibrium :

During normal service of turbine, the spring keeps the impulse pilot spool upwards.

i. Hydraulic forces acting on main pilot spool during normal service of turbine :
when there is no impulse from protection system, the lower face of upper bobbin of main
pilot spool is exposed to an oil pressure of 20 ata. At the same time the upper face of the

35
 bobbin (upper) of the main pilot spool is also subjected to same pressure. However the
exposed area at lower face is greater than exposed area of upper face. Therefore the pilot
spool experiences an upwards thrust.

ii. During transient period when protection system actuates the EGP valve :

under these conditions the protection line oil drains and the pressure in the chamber drops.
The downward force acting on the upper face of pilot spool becomes greater than the upward
force acting on the lower face and main pilot spool moves downwards. As soon as the main
pilot spool begins to move downwards, the area of the upper face exposed to 20 ata gets
increased. This provides additional force to accelerate the downward movement of pilot
spool.

Operation :

a) Over-speed trip signal from emergency governor ( at 11% to 12% over speed):

If either or both the strikers operate, corresponding levers would press impulse pilot spool
downwards from its top position against the spring force. The lower bobbin of impulse
pilot spool would uncover the ports which would result in draining of protection oil inside
the front pedestal. As a result net force downwards on main pilot spool increases.
As soon as the main pilot spool starts downwards control oil pressure acts downwards on a
bigger area resulting in further increase of force downwards. It would result in accelerated
movement of main pilot till lower stops.

Downward movement of pilot spool would cause drain of oil from line to ESV & IV
servomotors and primary sensitive oil line resulting in complete closure of ESV & IV and
CVs. Further oil supply from load speed control valve is also blocked as the ports are
covered by the bobbin of main pilot spool.

As soon as the main pilot spool begins to move down, the force pressing the impulse pilot
spool gets reduced and consequently the impulse pilot spool moves upward relative to main
pilot spool. This would restore 20 ata pressure in protection line. However the net resultant
force on main pilot spool would still be downwards because now area of upper face of
upper bobbin of main pilot spool exposed to 20 ata pressure is larger.

b) Charging of Emergency governor pilot valve :

Once the main pilot spool has moved down , it can not be moved up until the pressure in
chamber , receives oil from load/speed control pilot valve is relieved totally. This can be
done only by turning the speeder gear clockwise, until load/ speed control pilot occupies
extreme left position. As the pressure in the chamber of EGP pilot valve mentioned above ,
gets reduced the forces acting on the lower face of the upper bobbin would push the main
spool upwards. Control oil is now supplied to the chamber by turning the speeder gear anti-
clockwise and the emergency governor pilot valve would be ready i.e. charged to receive
impulse from protective system. The process has been termed as CHARGING OF EGP
VALVE.

36
c) Overspeed trip signal from follow pilot valve (at 14% to 15%):

In the unlike event, should speed increase to 114% to115% of the normal speed, protection
oil would drain through ports of follow pilot valve which would result in sharp drop of oil
pressure in protection oil line. This would result the tripping of the turbine.

After tripping of the set speed goes down and as soon as the ports of the follow pilot valve
are covered by bobbin of follow pilot spool, pressure in protection line gets restored. But
the net force on the main pilot spool of EGP would still be downwards as described in (a)
above.

d) Trip signal from turbine shut down switch:

If turbine shut down switch is operated manually or automatically by energizing the turbine
trip solenoid, protection oil would drain through ports of pilot valve. It would result in
sharp drop of oil pressure in protection oil line. This would result in tripping of turbine.

After trip signal, the bobbin of pilot spool of shut down switch covers the ports and
protection line pressure gets restored. But the net force on the main pilot spool of EGP
would still be downwards as described in (a) above.
C. Emergency stop valve servomotor.

Two emergency stop valve servomotors have been provided to totally cut off steam supply
to H.P. turbine in case of emergency conditions. The emergency stop valves remains in
fully open position when turbine is in service. Two servomotors, one for each emergency
stop valve, have been provided. These are mounted over emergency stop valves.

EQUILIBRIUM:
In equilibrium position the lower bobbin of pilot spool remains in equilibrium under the
action of the following forces:
1. Oil pressure acting upward on lower face of pilot spool.
2. Force of springs acting downwards.

OPERATION:
a) Manual operation by hand wheel.
By turning hand wheel clockwise, the screw compresses the spring forcing the pilot
spool through rod to move downwards. Oil under the piston of ESV gets released and
the piston downwards due to spring force, thus closing the stop valve. Downward
movement of piston would reduce compression of spring of pilot spool by feed back
lever and would bring the pilot spool back to its middle position.

By turning hand wheel anticlockwise reverse action would take place i.e. piston moves
upwards, opening the stop valve. Pilot spool would come to middle position by feed
back action.

37
 b) Operation by speeder gear.
Actuating the speeder gear anticlockwise would permit the oil flow to ESV servomotor
through load/speed control pilot valve and emergency governor pilot valve. At 5.5mm
position of speeder gear oil pressure at lower face of pilot spool becomes 10 ata which
would bring the pilot spool to its middle position. Further anticlockwise rotation of
speeder gear would open the servomotor which come to its upper stop at 6.65mm
position of speeder gear. By feed back action pilot spool would again come to its
middle position.

Clockwise movement of speeder gear would restrict oil flow and reduce the pressure
under pilot spool. It would result in downward movement of pilot spool releasing oil
under the ESV piston. Thus servomotor would again come to its middle position.

c) Emergency operation of servomotor.

In emergency condition when protection system operates, the chamber under the pilot
spool is connected to open drain through emergency governor pilot valves resulting in
sudden fall of oil pressure. Under these conditions servomotor would immediately close
the stop valve cutting off complete steam supply to H.P. turbine.

D. Interceptor Valve Servomotor:

Two interceptor valve servomotors have been provided for totally cut off steam supply to
intermediate pressure turbine in case of emergency conditions. The servomotors remain
fully open when turbine is in operation.

EQUILIBRIUM:
In equilibrium position the lower bobbin of the pilot spool covers the ports. Pilot spool
remains in equilibrium under the action of oil pressure acting upwards on the lower face of
the pilot spool and force of pair of springs acting downwards.

OPERATION:
a) Manual operation by hand wheel.
By turning the hand wheel clockwise, screw moves downwards through warm wheel
and it pushes the pilot spool downwards. Oil under the piston of IV get released and the
piston moves down due to spring force, thus closing the interceptor valve. Downward
movement of the piston would reduce compression of the springs of pilot spool by feed
back lever and would bring the pilot spool back to its middle position.

By turning hand wheel anticlockwise, reverse action would take place i.e. piston moves
upward, opening the interceptor valve. Pilot spool would again come to middle position by
feed back action.

b) Operation by speeder gear.

Actuating the speeder gear anticlockwise would permit the oil flow to IV servomotor
through load/speed control pilot valve and emergency governor pilot valve. At 4.6mm
position of speeder gear oil pressure at lower face of pilot spool becomes 5 ata which
would bring the pilot spool to its middle position. Further anticlockwise rotation of speeder

38
 gear would open the servomotor, which will come to its upper stop at 5.9mm, of speeder
gear. By feed back action the pilot spool would again come to its middle position.

Clockwise movement of speeder gear would restrict the oil flow and reduce oil
pressure under the pilot spool. It would result in downward movement of pilot spool
releasing oil under the IV piston. Thus servomotor would close the interceptor valve. By
feed action pilot spool would again to its middle position.

c) Emergency operation of servomotor.

In emergency conditions when protection system operates, the chamber under the pilot
spool is connected open drain through emergency governor valves, resulting in sudden fall
in oil pressure. Under these conditions servomotor would immediately close interceptor
valve cutting off completely steam supply to intermediate pressure turbine.

E. Turbine Shut Down Switch.

The turbine shut down switch is provided to facilitate turbine tripping. One chamber
of the pilot spool is connected to the additional protection oil line. When pilot spool
uncovers ports, oil in the additional protection line is connected to open drain.

OPERATION:
a) Normal operation by knob.
When the knob is pressed downwards, pilot spool is lifted up by lever, thus uncovering
the ports which would result in draining of oil in additional protection line. All the control
valve, emergency stop valves would close.

b) Operation by solenoid.
By operating the control switch of solenoid from unit control room or when tripping
circuit gets energised, due to any fault the solenoid would get energised, pulling the lever
upwards, thus draining of additional protection oil, causing tripping of set.

4. INTERFACE ACTION OF THE GOVERNING SYSTEM

ELEMENTS UNDER VARIOUS MODES OF OPERATIONS:

A. Interface action of Governing system elements for speeder gear:

a) Increasing of speed by actuating the speeder gear:

When the turbine is stand-still and the servomotors are closed, the port of the summation
pilot spool is in the totally uncovered position. To raise the speed, it is essential to turn
the speeder gear in anticlockwise direction. This would cause the summation pilot spool
to move towards left hand side. As the summation pilot spool covers the ports, the
pressure in the primary sensitive oil line increases and this actuates the intermediate pilot
valve in such a manner as to restore the pressure in the primary sensitive oil line.
However the actuation of intermediate pilot valve would increase the pressure in
secondary sensitive oil line transiently. The increase of pressure in the secondary oil
system causes the upward movement of control valve servomotor pilot spool and this
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 results in supply of oil under the piston of the servomotor. The servomotor moves up
there by opening the control valves and admitting steam to the turbine.

The upward movement of the servomotor causes the downward movement of the feed
back pilot spool and restores the pressure in the secondary sensitive oil line. As soon as
the pressure in the secondary sensitive oil line is restored, the servomotor pilot spool
returns to its mean position, thereby checking any further upward movement of the piston
of control valves servomotor.

b) Decreasing of speed by actuating the speeder gear:

The speed of the turbine can be decreased by moving the speeder gear in clockwise
direction. The sequence of operation would be just reverse of what has been described in
paragraph (a).

B. Interface action of the governing system element when turbine is in

service and it is not interconnected to grid:

Any difference between the export load and the power generated by turbine, would result
in the change of speed. The governing system would come into action and it would
suitably actuate the control valves to bring the system in equilibrium at the new speed
within the steady state overall speed regulation limits. Since it is desirable to maintain the
network frequency at 50Hz, the speed of the set can be brought to 3000 rpm by actuating
the speeder gear suitably. The speeder gear would have to be moved in clockwise
direction to reduce the speed and anticlockwise to increase the speed. In other words the
speeder gear shifts the static characteristic (speed Vs load) of the governing system above
or below the mean position. The shifting of the characteristics dose not alter the shape of
the characteristics.

C. Interface action of the governing system elements when the turbine is

operating in a grid:

When the turbine is running in an interconnected grid, its speed is controlled by the
network frequency. If it is desired to change the load on the turbine, the same can be
achieved by actuating speeder gear. Anticlockwise movement of speeder gear would
mean increasing the load on the set i.e. the characteristics would shift upwards from its
previous position. For decreasing the load on the set, speeder gear should be moved
clockwise.

5. TESTING OF TURBINE PROTECTION:

A. Testing of overspeed protection system.
The turbine overspeed protection system can be tested either by overspeeding the set or
by injecting the oil during the normal service of turbine.

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 Testing schedule:
It is recommended to observe the following schedule/events for testing overspeed protection
system.

a) After erection or maintenance of the turbine.

b) After any maintenance work connected with the elements in front standard.
c) After any adjustment or maintenance of the governing and protection system.
d) After shut down, if its period exceeds 15 days.
e) Routine testing normal service of turbine. This should be done by injecting oil under the
striker and the corresponding lever should be disengaged from the system to avoid
spurious tripping.

a) Procedure for testing the overspeed protection system by actual

overspeed.
This testing can be most conveniently carried out during a start up before synchronizing the set
to the grid in following manner:
1. Bring the set to 3000 rpm.
2. Trip the turbine by pressing the turbine shut down switch knob.
3. Quickly turn the speeder gear clockwise to charge the EGP valve.
4. Keep both the strikers in engaged position for tripping.
5. Slowly increase the speed of the set until overspeed protection system operates.
6. Observe the speed and the striker which tripped the turbine.
7. Observe the speed at which flap moves down i.e. the speed at which the striker
rests itself.
8. Recharge the EGP valves.
9. Disengage the striker which tripped the turbine.
10. Increase the speed of the set until the other striker trips the turbine.
11. Observe the speed at which the tripping occurred.
12. Observe speed at which flap moves down i.e., the speed at which the striker
rests itself.
13. Both the tripping should occur in the speed range of 3330 to 3360 rpm. If it is
not achieved, shut down the turbine and adjust the setting of strikers.
14. It is desirable to test the overspeed protection system by oil injection after every
overspeed test. This is done to check the efficacy of the oil injection.

NOTE:
IT IS NOT RECOMMENDED TO INCREASE THE SPEED OF THE TURBINE
BEYOND 3360 RPM UNDER ANY CIRCUMSTANCES DURING TESTS OR
OTHERWISE.

b) Procedure for testing the overspeed protection system by oil injection

(Turbine connected to grid)

a. The test can be done during the normal service of the turbine.

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 b. Disengage the lever from striker No. 1 by pushing in the handle from middle
position.
c. Turn the oil injection knob anti-clockwise.
d. Observe that the flap for striker No. 1 pops up.
e. Bring oil injection knob in the middle position and observe that the flap
moves down.
f. Bring the handle to middle position.
g. Disengage the lever from striker No. 2 by pulling out the handle from middle
position.
h. Turn the oil injection knob clockwise.
i. Observe that the flap for striker No. 2 pops up.
j. Bring oil injection knob in the middle position and observe that the flap
moves down.
k. Bring the handle to middle position.

c) Procedure for testing the overspeed protection system by oil injection with
turbine at no load.
The overspeed set point of the emergency strikers can be checked by oil injection
method in the following manner. This test can be most conveniently carried out
before the synchronization of the set and after the overspeed test of the set.

a. Bring the auxiliary oil pump into service.

b. Reduce the speed of the set to 2700 rpm.
c. Disengage the lever for striker No. 1 by pushing in the handle from its middle
position.
d. Turn the oil injection knob in anticlockwise direction.
e. Raise the speed of the set slowly.
f. Observe the sped at which flap pops up. If it pops up at a speed equal to or less
than 2970 rpm, it can be construed that the overspeed set point of the striker is
within 3330 and 3360 rpm.
g. Increase the speed of the set to 3150 rpm.
h. Stop oil injection by turning the oil injection knob to neutral position.
i. Maintain the speed 3150 rpm for 30 seconds.
j. Reduce the speed slowly and observe the speed at which the flap moves down. If
the flap comes down at a speed 3065+45/35 or 3065-45/35 rpm, it may be
construed that the striker No. 1 is in a healthy state.
k. Repeat the test for striker No. 2.

NOTE:
IT IS NOT RECOMMENDED TO INCREASE THE SPEED OF THE TURBINE
BEYOND 3360 RPM UNDER ANY CIRCUMSTANCES DURING TESTS.

B. Tests for checking tightness of emergency stop valves.

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 This test can be most conveniently conducted before start up. The procedure for conducting
the test is as follows:

1. Bring the set to 3000 rpm by full arc system admission in the turbine. This
essentially means that control valves and emergency stop valves are fully open and
the main steam stop valves are partially open.
2. Quickly close both the emergency stop valves actuating the hand wheel provided at
ESV servomotors.
3. Plot the coasting down curve and measure the time required for reducing the speed
from 3000 rpm to 1500 rpm. If the time taken is less than 8 minutes, it can be
construed that the emergency stop valves are sufficiently tight.

C. TESTS FOR CHECKING THE TIGHT CLOSURE OF HPT

CONTROL VALVES.

This test can be most conveniently conducted before synchronization of the set in the
following manner:

a. Bring the turbine to 3000 rpm by seeder gear. It may be noted that the main steam
stop valves should be fully open for conducting this test.
b. Move the speeder gear in clockwise direction until the HPT and IPT control valves
are totally closed but ESV and IV are fully open.
c. Observe the time taken by the set to coast down from 3000 rpm to 1500 rpm. If it
takes less than 10 minutes then it can be construed that the HTP control valves are
having tight closure.

NOTE:
WHILE CONDUCTING THIS TEST IT SHOULD BE ENSURED THAT THE
STEAM, FROM ANY SOURCE OTHER THAN TURBINE, SHOULD NOT ENTER
THE REHEAT CIRCUIT.

D. TESTS FOR CHECKING THE TIGHT CLOSURE OF

INTERCEPTOR VALVES.

The test can be most conveniently conducted during the start up when turbine is being run
at 3.4 rpm by the barring gear. Procedure for test is as follows:

1. Connect special differential manometer for measuring differential pressure between

the condenser pressure and the pressure in the chamber after the first stage of I.P.
Turbine.
2. Keep the MSV and its by-pass, ESV, IV and CV closed.

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 3. Check the steam from HTP by-pass station is not being supplied to the reheat
circuit.
4. Turn the speeder gear in anti-clockwise direction and open the ESV, IV and control
valves of IPT.
5. By turning the hand wheel of interceptor valve servomotors, close both the
interceptor valves completely.
6. Bring in service the HPT by-pass station PRDS-2 and raise the pressure in the
reheat circuit to as high a value as permitted from other turbine considerations.
7. When the pressure in the cold reheat circuit is more than 4 ata, the differential
pressure manometer is less than 40 mm of Hg, it can be construed that the
interceptor valves are having the tight closure.
8. After conducting the test remove the special differential pressure manometer.

E. TESTS FOR CHECKING THE PROPER FUNCTIONING OF

ESV AND IV SERVOMOTORS.

This test is essentially carried out to verify that the servomotors for the ESV and IV are in a
healthy state and also to verify that the stems of the stop valves are free to move and there
is no seizure. This test can be conducted either by partially closing the servomotor or by
completely closing the servomotor. Partial closure test can be conducted at least once in
every 8 hours when turbine is in service and carrying a load not than 170MW, the full
closure test should be conducted once in a fortnight when the set is carrying a load not
more than 120MW. All the four stop valves i.e. two ESV and two IV should be tested one
after the other and not simultaneously.

Procedure for test involving partial closure of stop valve is as follows:

1. Check that the set is carrying a load less than 170MW.

2. Turn the hand wheel on the servomotor by 15 to 20 mm.
3. Reopen the servomotor fully.
4. In case of ESVs the proper functioning of the damper should be checked in the
following manner:
a. When the servomotor has moved down by 5mm from its uppermost position,
the pressure under the servomotor should be recorded.
b. The oil pressure under the piston in this piston of servomotor should be 9.6+1 or
9.6-1 ata
c. After a major overhaul of the turbine or a major stoppage, the characteristic
curve for the damper should be plotted and compared with the initial
characteristics which had been drawn at the time of commissioning.

Procedure for test involving full closure of stop valve is as follows:

1. Check that the load is not more than 120MW.

2. Turn the hand wheel on the servomotor and completely close the servomotor under test.
3. Reopen the servomotor fully.

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F. SCHEDULE FOR CONDUCTING TESTS.
Following periodicity of the test should be observed during the normal service of the
turbine.
1. Tests once in a shift
a) Partial closure of ESV.
b) Partial closure of IV.

2. Test once in a fortnight.

a) Complete closure of ESV.
b) Complete closure of IV.
c) Functioning of oil pressure switch.

3. Test once in 3 months.

Overspeed protection system by oil injection.

4. The turbine overspeed protection system should be tested by actual overspeeding after
every shut down. However frequency of such test should be limited to twice a year.

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