C 14/10/03 Jp Ch Bad Reviewed further to Client’s letter n°3407(17.09.

03) FUS
B 08/07/03 Jp Mo Bad Reviewed further to Client’s letter n°1886(21.05.03) FUS
A 24/03/03 Jp Ch Bad First issue PRE
REV DATE AUTH. CHECK. APPR. BY MODIFICATIONS STATUS
BY

TEAS
TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.
SANTRALLAR PROJE VE TESIS DAIRESI BASKANLIGI
TURKISH ELECTRICITY GENERATION - TRANSMISSION Co.

2 x 160 MW ÇAN THERMAL POWER PLANT

ALSTOM Power Centrales – ALSTOM Power Boiler GmbH. – ALSTOM Enerji-Nakil A.S. – TEKNOTES Ltd. Sti.

CONSORTIUM

PROJECT DWG. N° :

DESIGN SUBCONT.

DRAWING OVERALL OPERATING INSTRUCTIONS

TITLE
EMERGENCY SHUTDOWN

TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.

ÇAN THERMAL POWER PLANT

SCALE : - Rev. No
Drawing N° CNK 1 2 M - - - OV EO I 20 1
SIZE : C

ALSTOM Power
ALL RIGHT PERTAINING TO THE REPRODUCTION, TRANSFORMATION AND USE OF THIS DOCUMENT
IN ANY FORM OR MANNER REMAIN THE EXCLUSIVE PROPERTY OF ALSTOM POWER
abcd
Power
Plant Segment
Engineering

ÇAN THERMAL POWER PLANT

2 X 160 MW

OVERALL OPERATING INSTRUCTIONS

EMERGENCY SHUTDOWN

SUMMARY

1 PURPOSE

2 SCOPE OF THE PROCEDURE

3 INITIAL STATE

4 EMERGENCY SHUTDOWN

Reference documents :

- Plant general overview

CNK 12 M OVE --- OI 201 C October 2003

1 PURPOSE

This document is a general guidance for experienced and authorised operators. It lists the main
operations to be carried out for the emergency shutdown of the unit, with auxiliary steam not
available from the other unit.

To start the different equipment, the operator refers to the system operating instructions of the
relevant systems.

This procedure is arranged to use with DCS in an specific page preview. When will notified in the
Operating Instruction form to start or to put or to select or to adjust or to open or to close or to check
any plant or system or equipment the Operator would perform as follows :

- check the permissive before to do any action,

- display the page,
- select the group,
- select the equipment from where the action would be acted,
- follow the sequence will be performed,
- check that the results of the action have been performed,
- check that the other equipment attached are in good order and correctly arranged,
- check that the group is “ON”.

Future conditions may dictate the requirement to implement changes to this document.

All the unit load figures indicated in the loading up phase are for guidance only. Specific figures will
be determined under actual operating conditions.

2 SCOPE OF THE PROCEDURE

The emergency shutdown may be caused by various problems from which we explain in after two
majors of them :

1) major turbine oil leak,

2) major fire situation.

3 INITIAL STATE

The unit is in operation.

CNK 12 M OVE --- OI 201 C 2/5

4 EMERGENCY SHUTDOWN

STEP ACTIONS OBSERVATIONS DISPLAY

1 Trip the turbine generator from the turbine
emergency stop push-button.
2 Identify the source and severity of this major
problem and alert the fire services to the situation.
3 Organise immediate action :
- to minimise the problem,
- to contain the problem,
- to prevent any expansion of the problem.
4 Check that :
- turbine speed is falling from 3000 rpm,
- AC lubricating oil pump has started MAV22 AP001 KP01
automatically immediately following turbine trip,
- turbine HP and IP stop and governing valves
have all closed,
- the jacking oil pump starts automatically when MAV50 AP001 KP01
turbine speed has fallen below 2900 rpm and
after 20 seconds, the electric turning gear
starts, MAD40 AE001 KE01
- electric turning gear engages (turning speed
nominally 65 rpm),
- electric turning gear motor current and turbine
rotor eccentricities settle out at their normal
values for power barring.
Note : Electric turning will start, but to use the
electric turning gear may be inadvisable if the
emergency shutdown is a consequence of low
bearing oil pressure or, high shaft axial
displacement or high rotor or bearing vibration.
5 Check (from DCS indications) that turbine drain
and vent valves have opened :
- HP steam chest, loop pipe and turbine drain MAL10 AA320M
valves,
MAL 21 AA320M
MAL22 AA320M
MAL35 AA320M
- HP exhaust drain, LCM30 AA101M
- IP steam chest and loop pipe drain, MAL50 AA320M
MAL60 AA320M
- HP cylinder evacuation valve. LCM30 AA100M
6 Check (from DCS indications) that the following
valves have closed :
- bled steam to No. 7 HP feed heater isolating
valve,
- bled steam non-return valves,
- HP cylinder exhaust check valve LCB10 AA100S

CNK 12 M OVE --- OI 201 C 3/5

 STEP ACTIONS OBSERVATIONS DISPLAY
7 Initiate the DCS SGL turbine operation shutdown
sequence and monitor the sequence to completion
as for normal shutdown.
Note 1 : It is left to the discretion of the operator to
shut down the auxiliary systems or to leave them
running, as appropriate to the cause of the
emergency shutdown.
Note 2 : If the major problem is due to the boiler,
the emergency shutdown will automatically initiate
the turbine generator trip. It is assumed that all
auxiliary services and electrical supplies to the
turbine generator unit are maintained.
Note 3 : As the turbine runs down when using
emergency shutdown due to severe oil leakage,
carry out the following :
- Select SGL turning gear off and stop the
electric turning gear by DCS manual command.
Check that the jacking oil pump is still running.
If it is not, restart the pump by DCS manual
command.
- As soon as the turbine speed has fallen to
2000rpm, shut down the condenser air
extraction and open vacuum breaking valve in
order to minimise the run-down time (this will
prevent bypass steam dumping to the
condenser, and so will prevent continuing boiler
operation).
- Unlock and select jacking oil pumps supply 3-
way valve to the maintenance position 2, i.e.
directly from the main oil tank. Check that the
jacking oil pump is still running. If it is not,
restart the pump by DCS manual command.
- As soon as the turbine is reset :
. shut down the DC lubricating oil pump (if it is
running), and switch off its power supply,
. select DCS SGL AC lubricating oil pump off,
and stop the AC lubricating oil pump by DCS
manual command,
. if fire and safety considerations permit, leave
the jacking oil in service and turn the turbine
shaft-line by hand barring until turbine HP
and IP cylinder metal temperatures are all
less than 150 °C.
Note 4 : In the event of local fire, dry powder type
extinguishers should be used. Water extinguishers
must not be used except as a last resort. Specialist
advice should be obtained, and checks, tests and
remedial actions made, as appropriate.

CNK 12 M OVE --- OI 201 C 4/5

 STEP ACTIONS OBSERVATIONS DISPLAY
If it has been necessary to use water, particularly
in quantity, the possible adverse effects should be
assessed, particularly in respect of :
- quenching of components operating at high
temperature e.g. turbine casings and valve
chests, steam pipes and valves etc.,
- degradation of thermal insulation,
- contamination of lubricating oil or hydraulic
fluid,
- degradation of electrical and electronic
equipment, and instrumentation.

CNK 12 M OVE --- OI 201 C 5/5

ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 1/21
OPERATION UNDER INCIDENT OR ACCIDENT
LIST OF CONTENTS

LIST OF CONTENTS

SECTION TITLE PAGE

1 ACCIDENTS 2

1. 1 SEVERE OIL LEAKAGE 2

1. 2 BEARING FAILURE 3

1. 3 TURBINE WATER INGRESS 6

2 FIRE 9

3 LOAD REJECTION TO HOUSE LOAD 10

3. 1 LOAD REJECTION 10

3. 2 RE-LOADING 11

4 LOAD RUN BACK 12

5 STEAM TURBINE TRIP 13

6 BOILER TRIP 15

7 FEEDWATER HEATERS TRIP 16

8 LOSS OF CONDENSER VACUUM 17

9 BLACKOUT 18

10 SPECIAL OPERATIONS 21

10. 1 OPERATION WITH TURBINE HP OR IP STEAM VALVES

OUT OF SERVICE 21
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 2/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

1 ACCIDENTS

1. 1 SEVERE OIL LEAKAGE

The following is general advice on minimising the potential for fire, without
unduly increasing the risk of mechanical damage to the turbine. The actions
taken must depend on an assessment of the particular circumstances by the
appropriate responsible persons. Priority must always by given to fire
precautions and to the safety of personnel.

1. 1. 1 Procedure
1) Trip the turbine generator from the Turbine Emergency Stop pushbutton.
Check that:
• Turbine speed is falling from 3000 rev/min.
• AC lubricating oil pump MAV22 AP001 KP01 has started
automatically immediately following turbine trip.
• Jacking oil pump MAV50 AP001 KP01 starts automatically when
turbine speed has fallen below 2900 rev/min.
Note: Electric turning gear MAD40 AE001 KE01 will also start.
2) Identify the source and severity of the oil leak and alert the Fire Services
to the situation.
3) Organise immediate action:
• To minimise the oil leakage.
• To contain the spread of oil from the leak.
• To prevent oil coming into contact with steam pipes.
4) As the turbine runs down:
• Select SGL Turning Gear OFF, and stop the electric turning gear by
DCS manual command.
Check that the jacking oil pump is still running. If it is not, restart the
pump by DCS manual command.
• As soon as the turbine speed has fallen to 2000 rev/min, shut down
the condenser air extraction MAJ and open vacuum breaking valve
MAG010 AA100M in order to minimise the run-own time.
Note: This will prevent bypass steam dumping to the
condenser, and so will prevent continuing boiler
operation.
• Unlock and select jacking oil pumps supply 3-way valve
MAV50 AA100 to the Maintenance Position 2, i.e. directly from the
main oil tank. Check that duty the jacking oil pump is still running. If it
is not, restart the pump by DCS manual command.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 3/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

5) As soon as the turbine is at rest:

• Shut down the DC lubricating oil pump MAV20 AP001 KP01 (if it is
running), and switch Off its power supply.
• Select DCS SGL AC lubricating oil pump OFF, and stop the AC
lubricating oil pump by DCS manual command.
• If fire and safety considerations permit, leave the jacking oil in service
and turn the turbine shaftline by hand barring until turbine HP and IP
cylinder metal temperatures are all less than 150°C.
Refer to CNK 12 G MAV--- OI 002 Section 6 and
CNK 12 G MAV--- OI 022 for hand barring criteria and procedure.

1. 2 BEARING FAILURE
This section gives instructions and/or general advice as appropriate to enable
damage to the turbine to be kept to the minimum.

Journal bearing failure

Symptoms:
• Rapid rise in bearing metal and oil drain temperature, possibly followed by
rapid reduction to value close to oil supply temperature.
• Increase in metal temperature of adjacent bearings (due to additional
loading).
• Change of turbine generator rotor and bearing vibration.
Consequences:
• Damage to rotor journal.
• Increased loading of adjacent bearings.
• Possible loss of rotor to casing clearance (depending on which bearing or
bearings have failed), and consequent damage.
• Possible oil leakage and consequent risk of fire.
Causes:
• Interruption / failure of oil supply to bearing.
• Deterioration of oil quality.
• Overloading of bearing (e.g. due to turbine generator shaft alignment
change / foundation movement).
• Electrical circulating currents in turbine generator shaft line (due to failure
of generator shaft earthing and / or bearing insulation).
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 4/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

Thrust bearing failure

Symptoms:
• Rapid rise in bearing metal and/or oil drain temperature.
• Rapid change of thrust wear and turbine differential expansion indications.
• Change of turbine rotor and bearing vibration.
Consequences:
• Loss of rotor to casing axial clearance in HP turbine and consequent
damage.
Causes:
• Interruption / loss of oil supply.
• Deterioration of oil quality.
• Electrical circulating currents in turbine generator shaft line.
• Water carryover from steam generator.

1. 2. 1 Procedure
1) Trip the turbine generator (if not already tripped automatically by low
lubricating oil pressure or high thrust bearing wear, or by operator
response to high rotor vibration).
Check that:
• Turbine speed is falling from 3000 rev/min.
• AC lubricating oil pump MAV22 AP001 KP01 has started
automatically immediately following turbine trip.
• Jacking oil pump MAV50 AP001 KP01 starts automatically when
turbine speed has fallen below 2900 rev/min.
Note: Electric turning gear MAD40 AE001 KE01 will also start.
2) Select SGL Turning Gear OFF, and stop the electric turning gear by DCS
manual command.
Check that the jacking oil pump is still running. If it is not, restart the pump
by DCS manual command.
CAUTION: The turbine should be allowed to come to rest and
the extent of the failure assessed before any attempt
is made to turn the shaftline. It is recommended that
the electric turning gear should not be used.
3) As soon as the turbine speed has fallen to 2000 rev/min, shut down the
condenser air extraction MAJ and open vacuum breaking valve
MAG01 AA100M in order to minimise the run-down time.
Note: This will prevent bypass steam dumping to the condenser, and
so will prevent continuing boiler operation.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 5/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

4) Check at the bearings / pedestals for oil leakage indicating that the
bearing housing may be flooded.
5) Hand barring of turbine shaftline.
This will probably not be possible if any of the following have failed:
• HP/IP front bearing
• HP/IP rear bearing
• LP rear bearing
• Generator drive end bearing
• Generator non drive end bearing
• Thrust bearing
Subject to the restrictions above, the turbine shaftline should be turned by
hand barring until turbine HP and IP cylinder metal temperatures are all
less than 150°C.
Refer to CNK 12 G MAV--- OI 002 Section 6 and
CNK 12 G MAV--- OI 022 for hand barring criteria and procedure.
CAUTION: Excessive effort (e.g. additional leverage) must not
be applied to turn the shaftline. This is likely to cause
more damage than leaving the shaftline at rest until
cooled.
6) An indication of bearing condition may be obtained from measurements at
each bearing jacking pressure test point.
• Abnormally low pressure indicates increased clearances (e.g. due to
running of bearing metal).
• Abnormally high pressure indicates closing of jacking oil feed (e.g. due
to deformation of bearing metal).
7) In the event of failure of any of the generator bearings and for any further
actions or precautions specific to the generator, refer to the Generator
Operating Instructions.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 6/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

1. 3 TURBINE WATER INGRESS

This section gives instructions and/or general advice as appropriate to enable
damage to the turbine to be kept to the minimum.
Causes of water ingress are:
• Water accumulation in turbine during start up due to impaired / incorrectly
set drains.
• Water carry over from the boiler via the main steam system.
• Water ingress from feed heating system via bled steam connections.
Water accumulation in HP or IP turbine
Symptoms:
• Abnormal HP or IP cylinder top to bottom temperature differentials.
• Abnormal turbine rotor vibration.
Consequences:
• Possible loss of HP or IP turbine rotor to casing clearance, and
consequent damage.
Water carryover from the boiler via main steam system
Symptoms:
• Indications of high boiler drum water level.
• Rapid fall in HP main steam temperature which should cause automatic
turbine trip.
• Abnormal change in HP turbine rotor to casing differential expansion.
• Rapid fall in HP main steam pressure,
• Abnormal change in HP turbine cylinder metal temperatures (This may not
be immediately apparent).
Consequences:
• Possible loss of turbine rotor to casing clearance, and consequent
damage.
• High thrust bearing loading and possible failure.
• High thermal stress in HP turbine components and consequent extra
expenditure of turbine life.
Water ingress from feed heating system via bled steam connections
Symptoms:
• Indication of high feed heater water level.
• Abnormal turbine rotor vibration.
• Abnormal change in turbine rotor to casing differential expansion.
• Abnormal change in turbine cylinder metal temperatures.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 7/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

Consequences:
• Possible loss of turbine rotor to casing clearance, and consequent
damage.
• High thrust bearing loading and possible failure.
• High thermal stress in turbine components and consequent extra
expenditure of turbine life.

1. 3. 1 Procedure
If the incident has caused turbine parameters (e.g. vibration, metal
temperature differentials) to reach limiting values, the turbine generator will
have been shut down in response to the relevant alarms and indications.
If parameters have not reached limiting values, the reliability / risks of
continued operation will have to be assessed from the degree of permanent
change of turbine dynamic behaviour. It is recommended that the turbine be
shut down as soon as possible if:
• Rotor vibration is permanently above the alarm value, or
• Indications show that partial failure of the thrust bearing has occurred.
1) Monitor the turbine rundown for the following:
• Persistence of high rotor vibration/eccentricity (i.e. above alarm value)
as speed falls below 500 rev/min.
• Abnormally short rundown time.
• HP or IP turbine casing top to bottom temperature differential outside
limits.
• Turbine rotor to casing differential expansion outside limits.
2) If any of the above are present:
• Select SGL Turning Gear OFF, and stop the electric turning gear by
DCS manual command.
Check that the jacking oil pump is still running. If it is not, restart the
pump by DCS manual command.
• When the turbine has come to rest, turn the turbine shaftline by hand
barring if possible.
Refer to CNK 12 G MAV--- OI 002 Section 6 and
CNK 12 G MAV--- OI 022 for hand barring criteria and procedure.
CAUTION: Excessive effort (e.g. additional leverage) must
not be applied to turn the shaftline. This is likely
to cause more damage than leaving the shaftline
at rest until cooled.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 8/21
OPERATION UNDER INCIDENT OR ACCIDENT
ACCIDENTS

3) Use of the electric turning gear may be resumed when the following
conditions are satisfied:
• HP and IP turbine cylinder top to bottom temperature differentials are
within limits.
• Turbine rotors to casings differential expansions are within limits.
• Turbine shaftline turns freely by hand barring.
CAUTION: Turbine rotor eccentricities should be
continuously monitored. Electric turning should
be discontinued and hand barring resumed if
rotor eccentricities increase abnormally.
4) If during turbine rundown the criteria in 1) above are not exceeded, the
electric turning gear may be put into service as normal. However, turbine
rotor eccentricities should be continuously monitored and action taken as
in 2) and 3) above.
ABCD CNK 12 G MA---- OI 002
STEAM TURBINE Issue B Page 9/21
OPERATION UNDER INCIDENT OR ACCIDENT
FIRE

2 FIRE
In the event of local fire (e.g. due to oil leakage at bearing pedestals), dry
powder type extinguishers should be used. Water extinguishers must not be
used except as a last resort.

If it has been necessary to use water, particularly in quantity (e.g. from fixed
deluge type installations), the possible adverse effects should be assessed,
particularly in respect of:
• Quenching of components operating at high temperature - e.g. turbine
casings and valve chests, steam pipes and valves etc.
• Degradation of thermal insulation
• Contamination of lubricating oil or hydraulic fluid
• Degradation of electrical and electronic equipment, and instrumentation
Specialist advice should be obtained, and checks, tests and remedial actions
made, as appropriate.