HP/LP BYPASS OPERATION

AND TURBINE HEATING

TURBINE ROLLING AND
SYNCHRONIZATION

1
2
HIGH PRESSURE (HP) AND LOW PRESSURE (LP) BYPASS SYSTEMS
ARE USED FOR QUICK START
START--UP OF THE UNIT AS WELL AS DURING
TRIP--OUT, WHERE LOAD REJECTION AT THE TURBINE DOES NOT
TRIP
AUTOMATICALLY LEAD TO A BOILER TRIP
TRIP..
WITH A BYPASS SYSTEM, START
START--UP IS QUICKER
QUICKER.. THE SYSTEM
DIVERTS THE STEAM GENERATED BY THE BOILER TO THE RE- RE-
HEATER/CONDENSER, AT THE SAME TIME REDUCING THE PRESSURE
AND TEMPERATURE OF STEAM, THUS MAINTAINING A MINIMUM
CIRCULATION OF STEAM THROUGH THE BOILER
BOILER..
THIS ENABLES RUNNING THE BOILER WITHOUT THE TURBINE IN
SERVICE, ENSURING FLOW THROUGH RE-
RE-HEATER COILS
COILS..
PROVIDED TO INCREASE THE RATE OF STEAM TEMPERATURE RISE
AND WARM UP THE HRH, CRH, IPT & TRANSFER PIPE LINES ( AT
60
60%% MCR FULL PRESSURE & TEMP
TEMP..)

ALL THE HP & LP BYPASS VALVES ARE HYDRAULICALLY OPERATED

FOR WHICH OIL AT ABOUT 50 kg/cm2 IS SUPPLIED BY A SEPARATE
OIL SUPPLY UNIT
UNIT.. 3
4
REDUCED COMMISSIONING TIME OF THE BOILER AND TURBINE
PLANT.. THE BOILER AND ASSOCIATED EQUIPMENT (E.
PLANT (E.G. THE FUEL
SYSTEMS), CAN BE FULLY TESTED AND COMMISSIONED TOTALLY
INDEPENDENT OF THE TURBINE (100
100%% CAPACITY BYPASS SYSTEM)
SYSTEM)..
EFFICIENT MATCHING OF STEAM AND TURBINE METAL
TEMPERATURES DURING COLD, WARM AND HOT START
START--UP CYCLES
CYCLES..
PREVENTION OF EXCESSIVE BOILER PRESSURE FLUCTUATIONS IN
THE EVENT OF TURBINE TRIP OR LOAD REJECTION
REJECTION..
AVOIDANCE OF THE SPRING LOADED HP SAFETY VALVES LIFTING
WITH THE ASSOCIATED SEAT MAINTENANCE AND CONDENSATE LOSS
IN THE EVENT OF A TURBINE TRIP
TRIP..
MAINTAINED REHEATER TUBE COOLING AND CONTROLLED PRESSURE
BUILD--UP DURING TURBINE START
BUILD START--UP OR FOLLOWING A TURBINE
TRIP..
TRIP
PROTECTION OF THE CONDENSER AGAINST EXCESSIVE PRESSURE
AND TEMPERATURE.
TEMPERATURE. 5
INJECTOR WATER : BOILER FEED WATER

NOS. OF HP BYPASS VALVE : 1 FOR EACH MS LINE

TOTAL CAPACITY : 200T/hr STEAM

FLOW

CAPACITY OF EACH BYPASS VALVE : 100T/hr STEAM FLOW

MAXIMUM MS : 5400C

MAXIMUM MS PRESSURE : 140 ATA

DOWN STREAM TEMPERATURE : 3800C

6
INJECTOR WATER : CONDENSATE WATER

NOS. OF LP BYPASS VALVE : 1 FOR EACH HRH LINE

CAPACITY OF EACH LP BYPASS VALVE : 112T/hr STEAM FLOW

TOTAL CAPACITY : 224T/hr STEAM FLOW

DESIGN TEMPERATURE : 5400C

DOWN STREAM TEMPERATURE : 2000C (MAX)

STEAM PRESSURE AT UPSTREAM SIDE : 6 kg/cm2

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8
BEFORE HP/LP BYPASS STATIONS ARE BROUGHT
INTO OPERATION CHECK
CHECK::
ESV, IV ARE CLOSED
OIL SYSTEM OF THE BYPASS STATION IS PUT INTO
OPERATION BY SWITCHING ON ITS MOTOR
VACUUM IN THE CONDENSER IS AT RATED ROUGHLY 600
mm OF Hg
CONDENSATE FLOW TO STEAM THROW OFF DEVICES IN THE
CONDENSER ARE ESTABLISHED BY OPENING OF THE VALVES
ENSURE THAT THE VALVES OF THE BYPASS SYSTEM ARE
FULLY CLOSED BY READING THE RESPECTIVE POSITION
INDICATORS
SET THE TEMPERATURE SET POINT OF HP BYPASS STATION
AT RATED VALUE WITH THE HELP OF PUSH BUTTON
9
PUT THE PRESSURE CONTROLLERS AND SLAVE POSITIONS OF
EACH HP BYPASS VALVES ON MANUAL MODE WITH THE HELP
OF PUSH BUTTON

PUT THE LP BYPASS VALVES ON ‘AUTO’ MODE AND SET THE

TEMPERATURE SET POINT OF LP BYPASS STATION AT RATED
VALUE ROUGHLY 200
200°
°C WITH THE HELP OF PUSH BUTTON BY
READING ITS VALUE ON THE INDICATOR

PUT THE CONTROL OF LP BYPASS VALVES ON 'AUTO' MODE

WITH PRESSURE LOOP IN CIRCUIT WITH THE HELP OF
SELECTOR SWITCH BY MAKING THE CONTACT IN 'R POSITION
AND SET THE PRESSURE SET POINT OF RATED VALUE
ROUGHLY AS 6.0 AT WITH THE HELP OF PUSH BUTTON

CHECK THAT THE HPT EVACUATING VALVES AND BYPASS

VALVES ACROSS NRV COLD REHEAT LINE ARE TIGHTLY
CLOSED
10
AFTER THE INTERNAL SUPERHEATER FLOW HAS BEEN ESTABLISHED
THROUGH START UP VENT, OPEN THE DRAIN VALVES BEFORE BYPASS
VALVES, OPEN THE DRAIN VALVES OF MS,
AND AFTER BYPASS DRAIN VALVES,
CR & HR LINES AND ALSO OPEN AFTER LP BYPASS DRAIN VALVES
OPEN FULLY THE HP BYPASS WITH THE HELP OF PUSH BUTTON AND
THEN OPEN THE BOILER OUTLET VALVES AND CHECK THE
TEMPERATURE CONTROL LOOP IS FUNCTIONING NORMAL

WATCH THE RISE OF METAL TEMPERATURE OF MS, CR & HR LINES

AND AFTER 50
50°
°C SUPERHEAT IS AVAILABLE AT THE SUPERHEATER
OUTLET OPEN THE BYPASS VALVES OF MSV FOR HEATING THE PIPE
LINES UPTO TURBINE

OPEN THE ESV TO CVs DRAIN VALVES AND OPEN ESV BY ABOUT 1010--
20 mm AS PER THE SCALE ACCORDING TO INSTRUCTION AND HEAT
THE STEAM ADMISSION PIPE UPTO CONTROL VALVES TO A TEMP.
TEMP. OF
150°
150 °C AS RATED AND RISE OF METAL TEMP
TEMP.. SHOULD NOT BE MORE
THAN 4°C PER MINUTE
11
12
CHECK BEFORE CHARGING HP/LP BYPASS SYSTEM
MS PRESSURE 12 Kg/cm2 , CRH AND HRH STEAM LINE DRAINS ARE
OPEN..
OPEN

HP BYPASS OIL UNIT'S OIL LEVEL NORMAL, ITS PUMP ON AND ITS
PRESSURE ADEQUATE
ADEQUATE..
LP BYPASS RACK IS LINED UP AND ALL SETTING & TRIPPING
VALUES CHECKED
CHECKED..
HP BYPASS DOWNSTREAM TEMPERATURE SET POINT IS AT 200OC
APPROX..
APPROX
HP BYPASS SPRAY PRESSURE SET POINT
POINT:: 70 Kg/cm2
Kg/cm2.
ALL ISOLATING VALVES BEFORE THE SPRAY PRESSURE
CONTROLLER ARE OPEN
OPEN..
HP BYPASS UPSTREAM PRESSURE (MAIN STEAM PRESSURE) SET
POINT IS AT 10 Kg/cm2.
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14
TRANSFER LP BYPASS CONTROL TO AUTO AND SWITCH ON THE
AUTOMATIC CONTROL INTERFACE (ACI)
(ACI)..
HRH FIXED SET POINT COMES TO 3 Kg/cm
Kg/cm22.

TRANSFER HP BP CONTROL TO AUTO

AUTO..
HP BYPASS VALVES (BP
(BP--1/BP
/BP--2) START OPENING IF MS PR.
PR. IS
MORE THAN THE SET POINT
POINT..
CRH PRESSURE STARTS INCREASING
INCREASING..

HP BYPASS TEMPERATURE CONTROLLER AND SPRAY PRESSURE

CONTROLLER TRANSFER TO AUTO AND MAINTAIN SET VALUES OF
DOWNSTREAM TEMP & SPRAY PRESSURE
PRESSURE..
ADJUST MAIN STEAM PRESSURE SET POINT TO OBTAIN DESIRED MS
PRESSURE..
PRESSURE
HP BYPASS VALVES OPEN OR CLOSE, DEPENDING ON WHETHER SET
POINT IS LESS OR MORE THAN THE MS PRESSURE RESPECTIVELY
RESPECTIVELY..
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16
CONDENSOR VACUUM IS LOW (> 0.6 BAR ABSOLUTE)

SPRAY WATER PRESSURE IS LOW (< 8.5 /9.5 BAR)

TEMPERATURE OF CONDENSER BODY IS HIGH (>90

(>90°°C)

17
OPEN THE BYPASS VALVES ACROSS THE NRVs IN THE COLD REHEAT
LINE AND THE DRAIN VALVES OF HPT AND HEAT THE HP TURBINE
UPTO 150
150°°C

CHECK THE STEAM PRESSURE IN HOT REHEAT LINE TO BE LESS

THAN 1 kg/cm2
kg/cm2 (GAUGE) BEFORE STARTING THE HEATING OF
STEAM ADMISSION PIPE UPTO CONTROL VALVES OF IPT AND IF THE
PRESSURE EXCEEDS LIMITING VALUE ADJUST THE SET VALUE AT 1
kg/cm2
kg/cm 2 (GAUGE) WITH THE HELP OF PUSH BUTTON AND INDICATOR
OF LP BYPASS STATION

OPEN THE IV TO CVs DRAIN VALVES AND OPEN THE INTERCEPTOR

VALVE SERVOMOTOR BY ABOUT 10 10--15 mm AS PER THE SCALE
INSTRUCTIONS AND HEAT THE STEAM ADMISSION PIPES UPTO
CONTROL VALVES TO A SPECIFIED TEMP, ROUGHLY 100
100°°C

18
CLOSE BYPASS VALVE OF MSV IN THE COLD REHEAT LINES WHEN
STEAM PARAMETER BEFORE MSV ARE 20
20--25 kg/cm2
kg/cm2 AND 280-
280-300°
300°C
& STEAM ADMISSION PIPE OF HPT AND IPT ARE HEATED UPTO
150°
150 °C & 100°
100°C RESPECTIVELY

CLOSE ESV & IV AND BRING THE CONTROL OF LP BYPASS VALVES

ON ‘MANUAL
‘MANUAL'' MODE WITH THE HELP OF PUSH BUTTON

MANUALLY CLOSE THE HP BYPASS VALVES WITH THE HELP OF PUSH

BUTTON AND WHEN THE PRESSURE IN THE HOT REHEAT LINE
COMES TO CONDENSER PRESSURE MANUALLY CLOSE THE LP
BYPASS WITH THE HELP OF PUSH BUTTON

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20
OBJECTIVE::
OBJECTIVE
THE OBJECTIVE OF STARTING UP OF THE
TURBOGENERATOR IS TO BRING A UNIT ON LOAD
AND RAISE IT TO THE RATED OUTPUT WITHIN THE
OPTIMUM TIME BUT WITHOUT UNDUE STRESSES ON
THE TURBINE COMPONENTS
COMPONENTS..

21
TURBINE START UP ARE CLASSIFIED AS
COLD, HOT & WARM START UP

COLD START UP : IF HPT METAL TEMP.<1500C

WARM START UP : IF HPT METAL TEMP. BETWEEN

150 to 3500C

HOT START UP : IF HPT METAL TEMP. > 3500C.

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23
AFTER HAVING ACCOMPLISHED THE HEATING, CHECK AND
NOTE DOWN THE FOLLOWING READINGS IN THE LOG SHEET
BEFORE ROLLING THE TURBINE
METAL TEMP
TEMP.. OF PIPES BEFORE MSV, AND ALSO BEFORE ESV,
NOTE:: WHILE HEATING THE MAIN STEAM AND REHEAT STEAM
NOTE
PIPES, THE DIFFERENCE IN TEMPERATURE OF PIPES SHOULD NOT
EXCEED 1515°
°C. BUT WHEN THE TURBINE IS ON LOAD, THIS
DIFFERENCE SHOULD NOT BE MORE THAN 10
10°°C

METAL TEMP
TEMP.. OF STEAM ADMISSION LINES
METAL TEMP
TEMP.. OF HOT REHEAT LINE
METAL TEMP. OF INTERCEPTOR VALVE
METAL TEMP. OF HPT AND IPT TOP/BOTTOM
STEAM PARAMETER BEFORE MSV
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DIFFERENTIAL EXPANSION OF HP ROTOR, IP ROTOR AND LP
ROTOR

AXIAL SHIFT, TOTAL EXPANSION OF HPT/IPT AND

CONDENSER VACUUM

ECCENTRICITY OF TURBINE ROTOR ON BARRING GEAR

OPEN THE DRAIN VALVES OF HPT, IPT, HP AND LP

EXTRACTION VALVES AND OPEN ESV, IV, CONTROL VALVES
OF HPT AND IPT COMPLETELY WITH THE HELP OF CONTROL
GEAR

25
SLOWLY OPEN THE BYPASS VALVES OF MAIN STEAM VALVE BEFORE
ESV
ALLOW THE STEAM TO ROLL THE TURBINE AND CHECK DURING THE
PROCESS OF RAISING THE SPEED, BEARING VIBRATION SHOULD
NOT EXCEED 40 MICRONS
CHECK THAT BARRING GEAR HAS GOT DISENGAGED AND ITS MOTOR
GETS SWITCHED OFF AUTOMATICALLY
AT A SPEED OF 500 RPM, STOP THE STEAM SUPPLY TO THE TURBINE
BY CLOSING THE BYPASS VALVES OF MSV AND LISTEN CAREFULLY
FOR ANY RUBBING SOUND, IF ANY ABNORMALITY IS FOUND STOP
THE ROLLING OF THE TURBINE
IF THE TURBINE IS IN HEALTHY STATE, AGAIN RAISE THE SPEED TO
500 RPM BY OPENING THE BYPASS VALVES OF MS VALVE AND SOAK
THE SET FOR 5-10 MTS
IT IS PROHIBITED TO RAISE THE SPEED OF TURBINE IF THE
DIFFERENTIAL EXPANSION OF THE TURBINE ROTOR REACHES TO
THE MAXIMUM PERMISSIBLE VALUES
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AT A SPEED OF 1200 RPM SOAK THE SET FOR ABOUT 20 MTS, NOTE
THAT THE CONTROL VALVES OF HPT TEND TO CLOSE WITH THE RISE
OF SPEED

RAISE THE SPEED OF TURBINE TO 3000 RPM FROM 1200 RPM IN 5

MTS.. WITHOUT ANY PAUSE, THE CRITICAL SPEED OF THE M/C
MTS
SHOULD BE PASSED AS FAST AS POSSIBLE TO AVOID THE
APPEARANCE OF ROTOR VIBRATION

AT A SPEED OF 3000 RPM, HOLD THE TURBINE AT 3000 RPM FOR

ABOUT 20
20--25 MTS, CARRY OUT INSPECTION AND SOAKING OF THE
TURBINE, PERFORM THE CHECKING OF PROTECTION AND
GOVERNING SYSTEM AND TIGHTNESS TEST OF ESV AND CONTROL
VALVES OF HPT

OBSERVE THE TEMPERATURE OF LUB OIL ENTERING THE BEARINGS

AND MAINTAIN THE LUB OIL TEMP AT 40
40°
°C BY CONTROLLING THE
COOLING WATER SUPPLY TO THE OIL COOLERS, STOP THE
STARTING OIL PUMP AND KEEP IT READY

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28
A. AT THE SPEED OF 500
500,, 1200 AND 3000 RPM NOTE DOWN
THE FOLLOWING READINGS IN THE LOG BOOK
BOOK::

1. CONDENSER VACUUM
2. AXIAL SHIFT
3. DIFFERENTIAL EXPANSION OF HPT, IPT AND LPT
4. OVERALL TOTAL EXPANSION OF HPT, IPT
5. BEARING VIBRATION
6. TURBINE LPT EXHAUST HOOD TEMP
7. STEAM PARAMETER AT MSV
8. MOP DISCHARGE PRESSURE

B. WATCH THAT DIFFERENT METAL TEMPERATURES HAVE

TENDENCY TO RISE AND NOTE DOWN THE TEMPERATURE
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SYNCHRONIZE THE MACHINE WITH THE GRID AND TAKE A LOAD OF
10 TO 15 MW, CONSTANTLY WATCH THE DIFFERENTIAL EXPANSION
AXIAL SHIFT, METAL TEMP, DIFFERENCE BETWEEN OUTER AND
INNER SURFACE OF THE WALL OF HPT CASING AND IPT
HOLD THE TURBINE AT THIS LOAD FOR 30 MINUTS TO CARRY OUT
SOAKING AND LISTEN FOR RUBBING
AFTER SOAKING, CLOSE ALL THE DRAIN VALVES ON STEAM LINES,
STEAM ADMISSION PIPES, HP, IP DRAIN COLLECTORS
CHARGE LP HEATERS FROM WATER SIDE AND STEAM SIDE
AT THE LOAD OF 30 MW
MW,, CLOSE THE DRAIN VALVES IN LP HEATER
EXTRACTION LINES, NOTE THE THERMAL EXPANSION OF THE
TURBINE AND ALL THE OTHER READINGS, CHARGE DEAERATOR BY
OPENING THE EXTRACTION STEAM VALVE IF PRESSURE IN
DEAERATOR IS LESS THAN 2 kg/cm2
kg/cm2
AT THE LOAD OF 60 TO 70 MW, PUT THE HP HEATERS IN SERVICE,
CHARGE THE HP HEATERS FROM WATER SIDE AND STEAM SIDE,
CLOSE THE HP EXTRACTION DRAIN VALVES 30
PUT THE DRIP PUMP IN SERVICE, STOP THE FLANGE AND STUD
HEATING

AT ABOUT 80 MW LOAD, START THE SECOND CONDENSATE PUMP &

BFP AND KEEP THE THIRD AS STANDBY
AT ABOUT 150 MW LOAD, CHANGE OVER STEAM SUPPLY TO
DEAERATOR FROM EXTRACTION OPENING

AT THE LOAD OF 210 MW SET THE POINT OF HP BYPASS VALVES

PRESSURE CONTROL LOOP AT 140 ATA WITH THE HELP OF PUSH
BUTTON AND CHANGE OVER THE MANUAL MODE OF PRESSURE
CONTROL LOOPS OF HP BYPASS VALVES TO 'AUTO' WITH THE HELP
OF PUSH BUTTONS

SET THE LP BYPASS VALVE PRESSURE SET POINT TO 6.0 kg/cm2

kg/cm2
(ATA) AND TEMPERATURE SET POINT TO 200
200°°C. CHANGE OVER THE
LP BYPASS OPERATION FROM MANUAL MODE TO 'AUTO' MODE
WITH PRESSURE CONTROL LOOP IN CIRCUIT

31
PURPOSE
CHAMBER HEATING IS TO BE CARRIED OUT WHENEVER THE
DIFFERENTIAL EXPANSION OF HP & IP CYLINDERS ARE TOO
MUCH ON THE NEGATIVE SIDE THAT MEANS BEYOND HP (-) 0.5
AND IP(-
IP(-) 1.5 mm (FOR THE TURBINE OF 210 MW INSTALLED
AT BTPS SUPPLIED BY BHEL)

CHAMBER HEATING IS ALSO TO BE CARRIED OUT WHENEVER

THE DIFFERENTIAL TEMPERATURE BETWEEN TURBINE TOP
AND BOTTOM EXCEEDS 50
50°
°C

32
PROCESS
CHAMBER HEATING IS REQUIRED GENERALLY DURING HOT
START UP OF TURBINE

CHAMBER HEATING ESSENTIALLY CONSISTS OF SUPPLYING

LIVE STEAM TO THE HP ROTOR AND IP ROTOR THROUGH THE
GLAND SEALS AT A LOW PRESSURE

THIS WILL HELP IN HEATING THE HP ROTOR AND IP ROTOR

THUS HELP IN REDUCING DIFFERENTIAL EXPANSION

33
STEPS TO BE TAKEN FOR CHAMBER HEATING
CHAMBER HEATING SHOULD BE STARTED ONLY WHEN HP
DIFFERENTIAL EXPANSION IS MORE THAN -0.5 mm AND IP
DIFFERENTIAL EXPANSION EXCEEDS -1.5 mm

TEMPERATURE OF LIVE STEAM SHOULD BE RAISED AS HIGH

AS POSSIBLE AND SHOULD BE HIGHER THAN THE HOTTEST
METAL TEMP OF THE TURBINE

THE PRESSURE OF STEAM FOR CHAMBER HEATING SHOULD

NOT EXCEED 4 kg/cm
kg/cm2
2

CHAMBER HEATING IS TO BE STARTED WHILE THE MACHINE

IS ON BARRING GEAR

34
DURING THE PROCESS OF CHAMBER HEATING IF THE
BARRING GEAR STOPS CHAMBER HEATING MUST BE
STOOPED IMMEDIATELY

DURING THE CHAMBER HEATING PROCESS, SHAFT

ECCENTRICITY SHOULD BE WATCHED CAREFULLY, WHICH
HAS A TENDENCY TO RISE, THE PROCESS IS TO BE
CONTROLLED IN ORDER TO MAINTAIN THE ECCENTRICITY
WITHIN 0.07 mm

THE FOLLOWING PARAMETERS TO BE NOTED

DURING THE PROCESS
PROCESS::
a. LIVE STEAM TEMPERATURE
b. DIFFERENTIAL EXPANSION OF HP, IP & LP CYLINDERS

35
THE 210 MW TURBINE HAS BEEN PROVIDED WITH A DEVICE
FOR HEATING FLANGES AND STUDS OF HP AND IP CASING

THE PURPOSE IS TO LOWER THE TEMPERATURE DIFFERENCE

OF THE METAL, AT THE WIDTH OF THE CASING FLANGES AND
BETWEEN DIFFERENT POINTS OVER THE CASING SECTION,
ALSO BETWEEN THE CASING FLANGES AND STUDS AT THEIR
CORRESPONDING POINTS

BY DOING SO THE TURBINE MAY BE ROLLED QUICKLY FROM

COLD OR WARM STATE

36
 ALARM TRIP
HPT +4.5mm +5.5mm
-2.5mm -3.5mm

IPT +5.0mm +6.0mm

-2.0mm -3.0mm

LPT +25 mm +30 mm

- 5 mm - 7mm

37
LIVE STEAM IS BLED FROM MAIN STEAM PIPE LINE BEFORE
MAIN GATE VALVES OF THE TURBINE FOR HEATING FLANGES
AND STUDS
THE DEVICE CONSISTS OF JACKETS WELDED TO SIDE WALL
OF CASING FLANGES AND SPECIAL PIPING COMPLETE WITH
FITTING AND MEASURING INSTRUMENTS FOR STEAM INLET,
OUTLET AND DRAINS.
DRAINS. SPECIAL RECESSES ARE PROVIDED IN
THE HORIZONTAL FLANGES OF THE HP & IP CASING JOINT
PLANE FOR PASSAGE OF HEATING STEAM TO THE STUDS
IN THE LOWER HALF FLANGES, RECESSES ARE PROVIDED
AND IN THE UPPER HALF OF THE CASING ALONG THE HEIGHT
OF STUDS THERE ARE BAFFLES FOR GUIDING THE STEAM
FLOW OVER THE STUDS

38
THE SPECIAL PIPE LINES EACH DELIVERING STEAM TO TWO
SEPARATE HEADERS HAVE BEEN PROVIDED, TWO HEADERS
ARE MEANT TO SUPPLY STEAM TO FLANGES AND STUDS
SEPARATELY

THE HEADER TO THE FLANGE JACKETS SUPPLIES STEAM FOR

HEATING FLANGES, AND THE HEADER TO THE RECESS IN
HORIZONTAL JOINT OF HP & IP CASING BOTTOM FLANGES
SUPPLIES STEAM FOR HEATING OF STUDS THROUGH HOLES
IN THE BOTTOM FLANGES ON THE RIGHT AND LEFT SIDE

STEAM FROM JACKETS AND RECESSES IN THE HP & IP

CASING FLANGES IS COLLECTED IN COMMON HEADER AND
THEN FLOWS THROUGH PIPING TO THE CONDENSER STEAM
SPACE

39
THE USE OF DEVICE FOR HEATING FLANGES AND STUDS OF THE
CASING IS PERMITTED ONLY IF A CAREFUL CHECK IS KEPT OVER
THE TEMPERATURE DIFFERENCE ACROSS THE METAL AT THE
AVAILABLE REFERENCES POINTS

THE MEASURING AND RECORDING OF TEMPERATURE DIFFERENCES

SHOULD BE CARRIED OUT DURING TURBINE STARTING AT LEAST
ONCE EVERY 10 MINUTES

THE TEMPERATURE DIFFERENCE ACROSS THE WIDTH OF THE

CASING FLANGE SHOULD BE WITHIN 50
50°°C

THE TEMPERATURE OF OUTSIDE FLANGE SURFACE SHOULD NEVER

EXCEED THAT MEASURED WITH A THERMOCOUPLE AT A MAXIMUM
DEPTH INSIDE THE FLANGE

THE DIFFERENCE BETWEEN THE FLANGE AND STUD TEMPERATURE

SHOULD NOT EXCEED 20 20°
°C AND STUD TEMPERATURE SHOULD
NEVER BE MORE THAN THAT OF THE FLANGE 40
WHEN STARTING THE TURBINE FROM COLD OR WARM (TEMP.
(TEMP. OF
METAL OF THE UPPER HALF OF THE HP CASING BEING UPTO 250
250°°C),
HEATING OF FLANGE AND STUDS IS PERMITTED PROVIDED
DIFFERENTIAL EXPANSION OF THE ROTOR IS POSITIVE AND NOT
LESS THAN 1 mm IT IS NOT PERMITTED TO OPERATE THE FLANGE
HEATING DEVICE
IF THE RELATIVE EXPANSION OF ROTOR COMPARED TO CASING IS
LESS THAN 1 mm
IF THE DIFFERENTIAL EXPANSION INDICATING AND RECORDING
INSTRUMENTS ARE EITHER OUT OF ORDER OR DISCONNECTED
IN ORDER TO MAINTAIN PROPER TIGHTENING OF FLANGE JOINTS, IT
IS NECESSARY TO FIRST SUPPLY STEAM FOR HEATING FLANGES AND
ONLY THEN AFTER SOME TIME TO STUDS

NOTE: DUE TO SPECIAL CONSTRUCTIONAL FEATURES OF KWU

TURBINES BOTH THE CHAMBER HEATING AND FLANGE AND STUD
HEATING SYSTEM IS NOT PROVIDED 41
42
ENSURE GENERATOR SEAL OIL & HYDROGEN COOLING
SYSTEM ARE NORMAL
ENSURE THE MAIN OIL TANK LEVEL IS NORMAL AND QUALITY OF
OIL TO BE O.K.
A.C. SEAL OIL PUMP SHOULD BE RUNNING AND CHECK THE
AVAILABILITY OF D.C. SEAL OIL PUMP
PUMP..
HYDROGEN PRESSURE IN GENERATOR CASING SHOULD BE
MAINTAINED AT RATED VALUE AND SEAL OIL SYSTEM AND H2
COOLING SYSTEM RUNNING NORMAL.
NORMAL.
A.C. STANDBY OIL PUMP SHOULD BE RUNNING
RUNNING.. LUB.
LUB. OIL PRESSURE
AT RATED VALUE AT BEARING HEADER AND ALSO CHECK THE
AVAILABILITY OF D.C. OIL PUMP
PUMP..
LUBE OIL PUMP INTERLOCK SWITCH SHOULD BE 'ON' AND OIL
TEMPERATURE AT BEARING SEAL SHOULD BE AROUND 40
40°°C.
CHECK PROTECTION AND INTERLOCK OF LUB
LUB.. OIL SYSTEM
SYSTEM..
43
PRE--SYNCHRONISING CHECKS
PRE
AFTER ATTAINING THE SPEED OF 3000 RPM.
RPM. GENERATOR IS
TO BE SYNCHRONISED TO THE GRID FOR SUPPLYING
POWER..
POWER
BEFORE STARTING, FOLLOWING SHOULD BE CHECKED AND
ENSURED::
ENSURED
SUPPLY OF OIL TO GENERATOR BEARINGS AND SHAFT SEALS IS
AVAILABLE AND FLOW OF OIL IS NORMAL
NORMAL..
H2 PRESSURE AND PURITY ARE UPTO RATED VALUE
VALUE..
H2 GAS COOLERS WATER SUPPLY SHOULD BE CHECKER) FOR
DESIRED QUALITY AND ENSURE NORMAL TEMPERATURE
PRESSURE AND FLOW.
FLOW.
STATOR WATER COOLING SYSTEM IS AVAILABLE
AVAILABLE..
44
CHECK SEAL OIL SYSTEM FOR SEAL OIL PRESSURE, FLOW AND
TEMPERATURE.. IF THE OIL PRESSURE IS NOT PROPER, ADJUST
TEMPERATURE
DIFFERENTIAL PRESSURE REGULATOR
REGULATOR.. IN CASE OF TEMPERATURE,
ADJUST COOLING WATER FLOW
FLOW..
CHECK H2 COOLING SYSTEM FOR H2 PRESSURE, PURITY AND GAS
LEAKAGE.. IF THE H2 PRESSURE AND PURITY ARE LOW, FILL MORE
LEAKAGE
H2 CYLINDERS FOR INCREASING THE PRESSURE AND PURITY.
PURITY.
CHARGE STATOR WINDING COOLERS WITH DISTILLATE AND ENSURE
QUALITY, PRESSURE, FLOW AND TEMPERATURE OF THE DISTILLATE
DISTILLATE..
CHECK THAT GENERATOR BREAKER AND GENERATOR FIELD
BREAKER ARE OPEN.
OPEN. IF NOT, OPEN GENERATOR BREAKER OR FIELD
BREAKER AS THE CASE MAY BE.
BE.
ADVICE ROLLING OF TURBINE TO RATED FULL SPEED (3000 RPM).
RPM).
ENSURE THAT THE MACHINE HAS ATTAINED THE RATED SPEED OF
3000 R.P.M. OBTAIN A GO FORWARD SIGNAL FROM BOILER AND
TURBINE OPERATOR TO SYNCHRONISE THE MACHINE
MACHINE..
45
ENQUIRE FROM THE SWITCHYARD CONTROL ROOM ABOUT
SYNCHRONISING OF MACHINE TO THE REQUIRED BUS
BUS..
CLOSE THE ISOLATOR FOR BUS
BUS..
ASK SWITCHYARD CONTROL ROOM OPERATOR TO CLOSE
TRANSFORMER SIDE ISOLATOR AND REPORT BACK TO UCB ABOUT
PROPER CLOSING OF THE ISOLATORS AFTER PHYSICALLY
VERIFYING THE SAME
SAME..
IF THE ISOLATORS ARE NOT CLOSED PROPERLY, OPEN THE
ISOLATORS..GIVE SHUT DOWN FOR CHECKING ALIGNMENT,
ISOLATORS
OPERATING MECHANISM AND LIMIT SWITCHES
SWITCHES.. TAKE CORRECTIVE
MEASURES..
MEASURES
CHECK THAT THE SYNCHROSCOPE CUT OFF SWITCH IS "OFF" AND
SYNCHRONISING CHECK RELAY "SKE" BYPASS SWITCH IS ON "IN
CIRCUIT" POSITION
POSITION.. IF NOT, PUT THESE SWITCHES IN THE SAID
POSITIONS..
POSITIONS

46
CLOSE EXCITER FIELD BREAKER
BREAKER.. GIVE CLOSING IMPULSE FOR
ABOUT 5-SEC.
SEC., AND RELEASE THE SWITCH WHEN RED LAMP GLOWS
INDICATING THE CLOSING OF BREAKER
BREAKER..
VOLTAGE WILL START BUILDING UP DUE TO RESIDUAL
MAGNETISM.. CHECK THAT THE VOLTAGE IS EQUAL IN ALL THREE
MAGNETISM
PHASES..
PHASES
PUT AUTO/MANUAL EXCITATION MODE SELECTOR SWITCH ON
"AUTO" POSITION VOLTAGE WILL START BUILDING UPUP.. CHECK
THAT THE RATE OF BUILDING UP IS NORMAL
NORMAL.. IF THE RATE OF
VOLTAGE BUILD UP IS MORE THAN THE PERMISSIBLE LIMITS,
SWITCH OVER TO "MANUAL” MODE AND BUILD UP VOLTAGE
MANUALLY..
MANUALLY

47
WHEN THE VOLTAGE HAS BUILT UP APPROX
APPROX.., UPTO 15 KV, CHECK
THAT THE VOLTAGE AND FREQUENCY OF THE INCOMING MACHINE
AND THAT OF THE SYSTEM AND APPROXIMATELY EQUAL
EQUAL..
IF THE FREQUENCY IS NOT APPROX.
APPROX., EQUAL, GIVE IMPULSE TO THE
LOAD CHANGER TO BRING THE FREQUENCY APPROX
APPROX.. EQUAL.
EQUAL.
IF THE EXCITATION MODE IS ON "AUTO" IT WILL AUTOMATICALLY
MATCH THE VOLTAGE
VOLTAGE;; OTHERWISE IN "MANUAL” MODE, GIVE
IMPULSE TO FIELD RHEOSTAT SWITCH TO MATCH THE VOLTAGE
VOLTAGE..
SWITCH ON THE SYNCHROSCOPE
SYNCHROSCOPE.. IF THE FREQUENCY OF THE
INCOMING M/C IS HIGHER THAN THE SYSTEM FREQUENCY, THE
SYNCHROSCOPE POINTER WILL MOVE IN THE CLOCKWISE
DIRECTION, AND IF THE FREQUENCY IS LOWER, IT WILL MOVE IN
ANTI--CLOCKWISE DIRECTION
ANTI DIRECTION..
SPEED OF ROTATION OF THE POINTER WILL DEPEND UPON THE
DIFFERENCE IN FREQUENCIES
FREQUENCIES.. GIVE IMPULSE BY LOAD CHANGE
SWITCH TO HAVE VERY SLOW CLOCKWISE ROTATION
ROTATION..

48
WHEN THE VOLTAGE AND FREQUENCY MATCH, THE SYNCHROSCOPE
WILL MOVE VERY SLOWLY IN THE CLOCKWISE DIRECTION
DIRECTION.. THIS
POSITION SHOWS THAT
THAT::
1. PHASE SEQUENCE OF GENERATED VOLTAGE AND SYSTEM
VOLTAGE IS SAME
SAME..
2. EFFECTIVE VALUES OF BOTH THE VOLTAGE ARE SAME.
SAME.

3. FREQUENCY OF BOTH THE SYSTEM AND THE INCOMING M/C IS

SAME..
SAME

GIVE CLOSING IMPULSE TO GEN

GEN.. BREAKER THE INSTANCE WHEN
THE SYNCHROSCOPE POINTER IS IN BETWEEN 11 AND 12 ° CLOCK
POSITION WHICH INDICATES SYNCHRONISM BY THE GLOWING OF
LAMP AT THE GEN
GEN.. ANNUNCIATION PANEL.
PANEL.

TAKE 10
10--20 MW LOAD ON THE MACHINE
MACHINE.. ASK FSSS/BOILER DESK
ENGINEER TO CARRY OUT NECESSARY OPERATIONS ON BOILER
SIDE TO RAISE THE STEAM PRESSURE AND TEMPERATURE, SO THAT
LOAD CAN BE RAISED
RAISED..
49
50
PUT SYNCHROSCOPE SWITCH TO "OFF" POSITION
POSITION.. RETURN
SYNCHRONISING SWITCH TO "OFF" POSITION AND LOCK IT.
IT. ASK
TURBINE DESK ENGINEER TO CARRY OUT NECESSARY OPERATIONS
ON TURBINE SIDE REQUIRED FOR RAISING THE LOAD
LOAD..

PUT "ANTIMOTORING" PROTECTION SWITCH ON "ON" POSITION

AFTER TAKING SOME LOAD ON THE MACHINE (SAY 20 MW).
MW).

GEN. VOLTAGE AND P.F., WILL BE MAINTAINED BY AVR IF THE

GEN.
EXCITATION MODE IS ON "AUTO", OTHERWISE, MAINTAIN GEN GEN..
VOLTAGE AND PF BY VARYING THE FIELD RHEOSTAT FROM THE
GEN.. CONTROL DESK
GEN DESK.. IF EXCITATION MODE IS ON MANUAL, THEN
CHANGE OVER TO "AUTO" MODE AFTER MATCHING THE
PARAMETERS..
PARAMETERS

SLOWLY RAISE THE LOAD ON GENERATOR UPTO 80 MW (FOLLOW

THE GUIDE LINES GIVEN FOR LOADING THE MACHINE)
MACHINE).. NOW THE
VOLTAGE AND POWER FACTOR WILL BE MAINTAINED BY THE
AUTOMATIC VOLTAGE REGULATOR (AVR)
(AVR).. HOWEVER, THE LEVEL
CAN BE CHANGED BY VARYING THE RHEOSTAT RESISTANCE
RESISTANCE..
51
CHANGEOVER 6.6 KV AUXILIARY BUS FROM STATION
SUPPLY TO UNIT AUXILIARY SUPPLY TAKING BOTH THE
UNIT AUXILIARY TRANSFORMER INTO CIRCUIT
CIRCUIT..

CHECK THAT THE UNIT AUXILIARY SUPPLY INCOMING

BREAKERS ARE RACKED IN SERVICE POSITION, SPRINGS
ARE CHARGED AND "LOCAL/REMOTE" SWITCHES ARE ON
"REMOTE" POSITION
POSITION..

52
HP/LP BYPASS CLOSED

ALL MS, HRH, CRH AND CYLINDER DRAINS ARE

CLOSED AFTER 5% LOADING HAS BEEN DONE

FURTHER LOADING TO BE DONE AS PER

MANUFACTURERS GUIDE LINES

MONITOR-AXIAL SHIFT, DIFFERENTIAL EXPANSION,

MONITOR-
METAL TEMP, VIBRATION, ELECTRICAL PARAMETERS
ETC..
ETC

53
 THANK YOU!
• +91 9650993009
• jaiswalrk1950@gmail.com
RK
JAISWAL

• +91 9810174125
• narindertuteja@gmail.com
NK
TUTEJA

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