MAY

26

TURBINE OPERATION
Chapter-13: Turbine Operation 247
Chapter 13
TURBINE OPERATION
13.1 General Operation Philosophy
The objective of starting-up 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. The proper procedure gives a logical sequence of start-up,
ensuring that no part of the system is overlooked and gives the confidence to the operating personnel that each step is
completed as specified. For this purpose, the essential requirement of any pre-start check sheet is that it is complete in itself
and includes very simple to most serious checkpoints in the logical sequence. The parameter values, or the sequence of
operation may change from one type of design to other but the operation philosophy remains same in the broad sense.
The unit operation is an integrated exercise of boiler, turbine and generator operation with proper coordination so that
operating parameters are maintained as recommended by manufacturer. Frequent crossing of high or low limits of critical
parameters may lead to serious damage to the equipment. Hence operating personnel should observe following points during
normal operation
Achieving and maintaining the required output of the unit
Maintaining plant conditions at their optimum efficiency
Inspection for plant deterioration by studying the operation trends of main equipments and their auxiliaries (condition
monitoring). The maintenance logs can be generated from this information.
Testing of stand-by plant auxiliaries, protective devices, alarms and automatic cut-in feature.
Changing over of auxiliaries depending on their running hours.
Generation of shift logs, event logs, post trip logs etc.
Readiness to respond to abnormal conditions.
In short by observing proper procedure number of trippings / outages can be brought to minimum. The long shut-downs lead
to cold start-ups which cause plant equipments, particularly working at high temperatures, to undergo stress cycle. This
deteriorates the plant life besides huge power generation loss coupled with shut-down and start-up losses.
Efforts should be made during shutdown to keep the equipments hot and reduction of shutdown period so that hot start-up
can be performed saving time, power generation loss and reducing the stress level in the components.
13.2 Turbine Start-up Requirements
13.2.1 Types of Start-ups
Turbine start-ups are classified as cold start-up, warm start-up and hot start-up depending on the HP turbine metal
temperature as follows:
If HPT metal temperature >350oC - Hot start-up
If HPT metal temperature between 150 - 350oC - Warm start-up
If HPT metal temperature < 150oC - Cold start-up
The start-up procedure decides following aspects:
i) Steam parameters suitability viz. pressure and temperature & its raising rates.
ii) Soaking time for turbine and main valves
iii) Turbine speed raising, loading rates
iv) Total time required reaching the full load.
248 Steam Turbines for Power Generation
Generally absolute cold start-up of turbine takes 6 hours to reach the full load. The turbine after two hours shutdown may
require only half an hour to one hour to reach the full load (depending on boiler load). The rate of rise of steam parameters
and turbine parameters, (speed, load) are specified by start-up curves for the regime. Operators should provide necessary
time for proper soaking of turbine at specified speeds (600 and 3000 rpm), as shown by the curves, for permitting expansions
at normal rate. This will give good temperature & load margins after synchronization.
13.2.2 Cold Start-up Steps
Turbine start-up involves following steps:
1. Pre-start checks and testing of supplies
2. Establishing lube oil and jacking oil system
3. Putting turbine on barring gear
4. Warming of main steam pipe lines (steam line drains and turbine SLC drains must be kept open)
5. Pulling-up vacuum in condenser by starting ejector
6. Establishing turbine gland sealing (at about 0.2 kg/cm2 vacuum)
7. Putting main ejector into service (at about 0.7 0.8 kg/cm2 vacuum) and withdrawing starting ejector. Normal vacuum of
0.91 kg/cm2 is obtained.
8. Charging of reheater through HP-LP Bypass system
9. Building of steam parameters suitable to turbine condition, viz. for cold start-up parameters are as follows:
M.S. H.R.H.
Pressure 30- 35 kg/cm2 10-12 kc/cm2
Temperature 320o 350oC 320o 350oC
Flow 95 100 t/hr.
10. Warm-up of turbine stop valves (ESV & IV) to get the TSE margins >30oK & fulfillment of steam pressure and
temperature criteria (X1, X2,X3)
11. Turbine trip resetting by bringing S.L.L.D. to zero position.
12. Opening of stop valves (ESV & IV) by raising the SLLD (starting device) to 42% and 56% respectively.
13. Warming of HP control valves by opening warm-up control drains valves through warm-up controller.
14. Fulfillment of steam temperature criteria with respect to mid wall temperature of turbine metal to ensure that main steam
temperature is greater than turbine metal temperature & degree of superheat is > 50oC as recommended by criteria curves
X4 and X5 respectively. TSE margins are ensured greater than 35oK.
15. Preparing the electro-hydraulic governing system ready for operation by setting the speed & load controller reference
values & keeping hydraulic governor as back-up by raising speeder gear position to 100%.
16. Turbine rolling to 600 rpm through speed controller.
17. Soaking of turbine at 600 rpm to fulfilled X6 criterion (approx. 1 hr), which ensures the proper warming of HP turbine
with respect to main steam temperature. Turbine parameters monitoring.
18. Speed raising to 3000 rpm by setting speed reference value at 3000 rpm without stopping in between.
19. Soaking of turbine at 3000 rpm to fulfilled X7 criterion (approx. 45 min.), which ensures proper warming of IP turbine
with respect to HRH temperature. Monitoring turbine expansion and shaft/bearing vibration trend.
20. Ensuring TSE upper temperature margin of turbine greater than 35oK.
21. Synchronization of generator to grid.
22. Load raising to 10% (20MW) through speed reference setter.
23. Closing of all manual operated drains
24. Ensuring closure of HP-LP bypass valves by increasing pressure set point above M.S. pressure.
25. Check that load controller becomes active at about 20 MW.
26. Raising the M.S. pr. to 50 kg/cm2 by taking coal mill into service and load is raised to 40 MW.
27. Charging of LP heaters from steam side and putting the level controllers of LPH 2 & 3 on auto.
Chapter-13: Turbine Operation 249
28. Changing over the 6.6 KV supply from station transformer to unit auxiliary transformer.
29. Taking second coal mill into service and raising steam pressure. Ensure that HP bypass set point is kept at higher value
than actual pressure.
30. Raise the turbogenerator load to 100 MW. Take HP heaters into service.
31. Establish second air cycle, second BFP, third coal mill and raise the steam parameters.
32. Changing over the deaerator pegging steam supply from CRH to extraction-4 at about 55% load (when the NRVs release
is obtained).
33. Raising the load to 150 MW
34. Taking the fourth coal mill into service. Put at least two mills on Auto. Stabilize the M.S. pressure at about 140 kg/cm2.
35. Putting CMC in to service after adjusting the M.S. Pressure set point to match with actual pressure.
36. Raising the turbogenerator load to 210 MW through unit target load set point at CMC.
37. Monitoring of turbovisory parameters, viz. absolute expansion, differential expansions, axial shift, bearing & shaft
vibrations, casing temperatures at admission and exhaust locations, bearing temperatures.
13.3 System Checks & Operation
13.3.1 General Preparation for Start-up
It should be ensured that all the repair works on turbine system have been completed and all the permits are cancelled
ensuring that equipments are healthy and in operative condition
First of all bring all the electrical equipments to a state of readiness i.e., switch-on the necessary switchgear for motors,
valve actuators, controls protections and monitoring system.
After this, carry out the necessary interlocks and protection checks feasible under stationary condition of turbine. Certain
tests and checks require bypassing of certain interlocks. All such deliberate bypassing of interlocks must be prominently
displayed in the control room during the test. After the test, all interlocks and protections should be brought to normal state.
Various valves as per the scheme are to be kept in open or close position. It must be ensured that these valves are kept up
in the required position. The isolating valves for all measuring control and protective device should be kept in fully open
position.
Turbine oil quality should be checked for viscosity, neutralization number, sludges etc. If required, the oil should be
drained from MOT and topped up with fresh oil in order to restore the quality.
Condenser tube leakage should be checked by charging the CW system and watching the increase in hot well level. If good
amount of leakage is noticed, then action must be taken to plug the leaking tubes.
13.3.3 Turbine Oil System
Check that:
MOT level is normal ( 0+350 mm ) and basket strainers are cleaned
Fire protection shut-off valve is closed and solenoid is reset at turbine floor and in MOT room.
Readiness of Lube oil pumps and JOPs
Sub-group control of oil system "Auto-ON"
Ensure one of the lube oil coolers is in service from oil side and water side.
Operation :
 AOP and JOP can be started manually from PCR or on auto through SLC-ON or through SGC "Auto-ON"
Take the standby trial of AOP, EOP and JOP
250 Steam Turbines for Power Generation
Watch drop in MOT level after AOP is started (280 mm).
Put temperature controller SLC "ON"
Watch the oil temperature at oil cooler outlet and ensure that it is maintains between 40o 45oC by temperature
controller.
Watch following parameters :
i) Discharge pressure of AOP : 6.5 kg/cm2
ii) Oil Pressure before cooler : 5.4 kg/cm2
iii) Oil pressure after cooler : 4.8 kg/cm2
iv) MOT level : + 25 mm
v) Jacking Oil Pressure : 120 kg/cm2
When the turbine is running, check the bearing drain oil temperature and babbit temperatures :
Bearing drain oil temperature : < 60oC
Journal bearing babbit temperature : < 90oC
Thrust bearing babbit temperature : < 110oC
Permissives for starting turning gear :
i) Seal oil to H2 DP : > 1 kg/cm2
ii) Seal oil pressure TE & EE : > 4.4 kg/cm2
iii) H2 gas pressure : > 3.3 kg/cm2
iv) H2 purity : > 97%
v) Liquid in generator : Not present
Turning gear can be started by opening gate valve either manually or through SLC. Observe that turbine speed on turning
gear is as follows :
i) When no vacuum in condenser : 110 120 rpm
ii) At normal vacuum condition : 150 160 rpm
After turning gear is ON, AOP amperes will increase to 125A from 105A.
AOP, JOP and turning gear trip and pick-up speeds are as follows :
Trip Speed rpm Pick-up Speed rpm
i) Turning gear 240 210
ii) J.O.P. 540 510
iii) A.O.P. 2850 2800
When MOP takes over, the discharge oil pressure will be 8.5 9.5 kg/cm2 depending on turbine speed.
Interlocks of AOP, EOP & JOP
- The standby AOP (SLC ON) will pick-up if discharge oil pressure < 4.8 kg/cm2 OR
- The running AOP is OFF
- DC Emergency Oil Pump will pick-up when SLC is ON and if lube oil pressure is < 1.1 kg/cm2
- The standby JOP (SLC ON) will pick-up if running JOP trips.
13.3.3 Vacuum Pulling and Gland Sealing Checks
- Line-up the steam ejectors
- Ensure 220 V DC supply to the solenoid of vacuum breaker valve and it is closed
- Ensure water sealing to glands of all the valves in vacuum circuit
- CW system is established
- Condensate system is established
- Ensure gland steam cooler siphone is filled-up
- Ensure electrical supply to the motors of seal steam leak-off controller and seal steam supply controller. Their oil pumps
are working on auto to maintain oil pressure of 60 kg/cm2
- Check that valve AS301 (CRH Steam to glands) is in closed position
- The turbine is put on turning gear
Chapter-13: Turbine Operation 251
Operation :
- Charge the gland steam header by opening AS 378 valve and build up the pressure 6 6. 5 kg/cm2. Set the pressure 6.5
kg/cm2 and put the ejector steam pressure control on auto.
- Start vacuum pulling through starting ejector by first opening steam valve and then the air valve.
- Start one exhauster fan of gland steam cooler
- After building up 0.2 kg/cm2 vacuum, open the gland seal steam supply valve and charge the header at pressure 0.01
kg/cm2(g). Put the gland steam pressure control on auto.
- After opening the steam supply valve, the header drain valve MAL-81 will close on auto.
- After establishing the gland sealing, the condenser vacuum will improve at a faster rate
- When vacuum builds-up to 0.7 kg/cm2, take one main ejector in to service by opening first its steam valve (AS02 or AS03)
and then the air valve. Cut-off the starting ejector by closing air valve and then steam valve.
- Note the final value of vacuum at which it stabilizes (0.92 kg/cm2) and also note HPT/IPT & LPT differential expansions.
13.3.4 Warming of Steam Piping
Checks :
- Ensure all the drain valves M.S., CRH and HRH lines are open
- M.S. line to be charged when drum pressure is raised to 10 kg/cm2 after blow-down
Operation :
- Charge the M.S. line by opening the boiler outlet bypass valves (MS 301A/302A)
- Ensure that there is no hammering in M.S. pipeline.
- Watch the temperature rise of ESV mid wall
- Rate of heating of steam pipelines should not exceed 25o to 30oC/5 min.
- During heating of M.S. & R.H. steam pipelines; the temperature difference between LHS & RHS pipelines should not
exceed 15oC. But this difference should not exceed 10oC when the set is on load.
13.3.5 HP-LP Bypass System
Checks :
- Ensure that HP Bypass control oil pumps are running on auto and maintaining the pressure oil pressure 110 kg/cm2 and oil
tank level is normal
- All the oil supply/return/leak-off Sulzer valves are open and there is no oil leakage in the system
- ESV and IVs are closed
- Cooling water to HP BP valve gland from CEP is open
- Isolating spray valve before BD valve is open and BD valve is closed on auto. Ensure that it is not passing.
- All controls of HP bypass are on manual mode and all valves are closed.
- Ensure power supply to HP BP panel is normal
- Ensure that control oil pressure to LP bypass station is > 5.5 kg/cm2
- All manually operated & auto injection water valves (V1, V2, V3, V4) of LP bypass station are closed.
- All the drain valves of HP &LP bypass are open
- Ensure condenser vacuum is > 0.75 kg/cm2
- BFP & CEP are running and discharge header pressures are adequate
Operation :
- Set the fixed pressure set point of LPBP at 3 kg/cm2
- Put the LP Bypass controller on Auto
- Make the automatic control interface "ON"
- Ensure drain valves of CRH, HRH and Warm-up valves are open
252 Steam Turbines for Power Generation
- Open HPBP warm-up valves locally.
- Set the pressure master set point at 35 kg/cm2
- Put spray water control valves BPE1 & BPE2 of HPBP on Auto
- After warming up for 15 min. open HPBP valves BP-1 and BP-2 about 5%.
- Increase the BP1 & BP2 position manually in a step of 5%
- Check that LPBP valves and injection water valves open on auto to maintain HRH pressure
- Close LPBP warm-up valve
- When LPBP position goes to 25% increase the oil-firing rate in boiler by taking into service CD oil elevation pairs 1-3 & 2-
4.
- When the controller demand of HP BP matches with BP1 and BP2 actual position, put BP1 and BP2 on auto to maintain
M.S. pressure as per the set point.
- Automatic control interface of LP bypass will increase the fixed pressure set point value to 12 kg/cm2 and then it will be
off.
- Check the following parameters :
HRH pressure which maintains at 10 12 kg/cm2
CRH temperature after attemperation which should rise
M.S./HRH temperature should rise
- The steam parameters suitable to turbine condition are build-up through this process to get the required steam temperature
and flow at preset pressure before rolling of turbine.
13.4 Turbine Warming-up Criteria
13.4.1 Steam Parameters Matching
Before initiating the rolling of the turbine, it is necessary to raise the parameters of the steam in the boiler to a level matching
with the thermal state of the turbine. The required steam temperature is a function of the turbine metal temperature as well as
pressure conditions. The automatic Turbine Run-up System (ATRS) takes care of the matching of the steam metal
temperature and does not permit the entry of steam into turbine until the temperature at the boiler outlet has been raised to a
value higher than the barest minimum requirements depending upon the metal temperature of the turbine.
13.4.2 Start-up Diagrams
The start-up diagrams are only representative of indicating the warm-up time and loading rates. The actual duration of warm-
up, soaking time and loading rates are dynamically determined by the turbine stress evaluator and the margins are displayed
for the benefit of the operator.
13.4.3 Start-up Considerations
During the start-up and loading, the turbine is subjected to "Non-steady-state-operation". This covers the operating
conditions of a steam turbine where speed, output, pressure and temperature change with time. Under these conditions, parts
of the turbine in contact with steam are being subjected to changes in temperature, which gives rise to thermal stresses as a
result of expansion of the various components. From turbine life point of view, it is necessary to limit the extent of these
temperature changes.
In addition to limiting temperature changes, the relative expansion of shaft and casing must also be taken into account. The
axial and radial clearances between the rotating and stationary parts are sufficient to accommodate any normal expansion,
which may occur within the permitted range of temperature change. In the event of abnormal conditions, however, factors
other than temperature, such as differential expansion, vibration, casing deformation etc. also have to be considered.
13.4.4 Significance of Turbine Stress Evaluator
The temperature changes in the high pressure and intermediate pressure turbine parts depend primarily upon following
factors:
- Changes in initial steam temperature
- Changes in turbine load/speed.
Chapter-13: Turbine Operation 253
The turbine is equipped with turbine stress evaluator, which provides adequate guidance to the operator by indicating
temperature margins and load margins. These margins have been derived on the basis of actual thermal stress and material
fatigue. Therefore, the operator should be guided by the reading of the TSE and not by the start-up diagrams. However, the
starting and loading diagrams have been based on the assumption that the materials get stressed to maximum permissible
limits only, without impairing the life of the components. Frequent and substantial departures from the rates/values indicated
on diagrams, or from the TSE indications, can result in reduction of the total life of the turbine, non-permissible deformation
and cracking of the components.
The TSE temperature margins also influences the speed or loading rate of the turbine if the margins are not adequate to
sustain loading.
13.4.5 Turbine Warming-up Criteria Curves
The raising of the steam pressure at the turbine admission and the warming-up of the initial steam lines and valve bodies can
begin when the steam temperature at the turbine inlet is
- At least 50oC above the saturation temperature applicable to the available steam pressure at the turbine inlet.
- Approximately 50oC above the maximum temperature at the mid thickness of the turbine casing as measured by TSE.
The raising of pressure at the turbine admission during cold start-ups must be done slowly, in order to prevent any
condensation of steam. The raising of the pressure in the steam line is carried out by establishing flow through HP-LP bypass
system. Warming up of pipe line upto emergency stop valve is done by steam flow through the drain before ESV. Warming
of control valves body is carried out by establishing flow through the drain between ESV and Control valve. Opening of this
drain valve is controlled by the TSE margins.
The criteria curves from X1 to X7, as described below, are to be fulfilled during the start-up of turbine to rated speed and
synchronization of generator thereafter.
a) Criteria for opening main stop valves (ESV) :
Before opening the main stop valves (ESV), the main steam parameters should meet following recommended values.
i) Minimum main steam temperature with respect to Steam Pressure: This criterion ensures that degree of superheat in the
main steam at the applicable steam pressure is greater than 50oC, as shown in Fig. 13.3.
TMS > Ts + 50oC
Where TMS = Main steam temperature at boiler outlet
Ts = Temperature of saturated steam depending upon main steam pressure.
ii) Minimum and maximum values of main steam temperature with respect to HP control valve body temperature at 50%
wall thickness (criteria X1 & X3): As shown in Fig. 13.1, these criteria ensure that the main steam temperature before HP
bypass is always more than curve A. With respect to midwall (50% depth) temperature of HPCV, but should be less than
curve B with respect to midwall HPCV temperature. So the recommended zone for main steam temperature before HP
bypass is only between curve A and Curve B (X1 & X3 criteria). This ensures the proper steam temperature for warming-up
operation.
TMS > (Tmid HPCV) for Curve A
TMS < (Tmid HPCV) for Curve B
254 Steam Turbines for Power Generation
Where TMS = Main steam temperature before HP bypass
Tmid HPCV = Temperature of HP control valve body at 50% wall thickness
iii) Maximum main steam pressure ahead of the turbine with respect to mid wall temperature of HPCV (criterion X2): This
criterion (X2) is shown in Fig. 13.2 which illustrates that if the steam pressure selected is too high (i.e. high saturation
temperature), the surface metal will be heated up to saturation steam temperature due to which the temperature difference
between surface and midwall will increase beyond permissible limit. Hence steam pressure selected for rolling should be
within the reasonable limit (below the curve).
Pmax = (Tmid HPCV)
Note : However, if the control valve temperature at 50% thickness (Tmid HPCV) exceed the temperature of the saturated
steam belonging to the main steam pressure, the pressure criterion must not be observed.
b) Criteria for opening HP control valves, i.e., raising the speed to 600 rpm (X4 & X5):
Before opening the main control valves (HPCVs), the main steam and reheat steam temperature should fulfill the following
conditions.
Recommended minimum (curve A) & maximum (curve B) main steam temperature ahead of HP turbine when opening the
main stop valves (ESVs)
Fig.13.1 Minimum & Maximum Allowable Main Steam Temperatures for Opening of Main Stop Valves
Criteria X1 & X3
Chapter-13: Turbine Operation 255
Allowable maximum main steam pressure ahead of HP turbine when opening the main steam stop valves (ESVs)
Fig.13.2 Maximum Allowable Main Steam Pressure for Opening of Main Stop Valves
Steam with superheat greater than 500C
Fig.13.3 Minimum Degree of Superheat in Main Steam Before Opening Main Control Valves
Criterion X2
Criterion X4
256 Steam Turbines for Power Generation
Recommended minimum main steam temperature ahead of turbine before opening main control valves (HPCVs)
Fig.13.4 Recommended Minimum Main Steam Temperature Before Opening Main Control Valves
Recommended minimum reheat steam temperature ahead of IP turbine before opening the reheat control valves (IPCVs)
Fig.13.5 Recommended Minimum Reheat Temperature For Opening IP Control Valves
Criterion X5
Chapter-13: Turbine Operation 257
i) Criterion X4 :
A degree of superheat in main steam should be greater than 50oC as shown in Fig. 13.3.
TMS > Ts + 50oC
Where TMS = Main steam temperature ahead of turbine
Ts = Temperature of saturated steam depending on steam pressure.
ii) Criterion X5:
Main steam temperature (TMS) ahead of the turbine should be greater than Middle wall temperature of HP casing or
simulated middle phase shaft temperature (Tmid HP shaft or casing) as shown in Fig. 13.4.
TMS > (Tmid HP Casing)
Similarly the hot reheat temperature ahead of IP turbine (THRH) should be greater than middle phase temperature of IPT
shaft (Tmid IP shaft), as shown in Fig. 13.5.
THRH > (Tmid IP shaft)
The X5 criterion ensures that inlet steam temperature is greater than turbine metal temperature so that cooling of turbine &
thereby contraction is prohibited, particularly in hot rolling.
c) Criterion for raising the speed from 600rpm to 3000rpm rated speed (X6):
This criterion, called as X6, should be fulfilled before raising the speed to rated speed, i.e. 3000 rpm. This ensures the proper
warming of HP turbine rotor and casing which is a function of time (about 1 Hr.). X6 criterion is shown in Fig. 13.6 in which
the recommended zone is below the curve. When the turbine is brought to 600 rpm, the middle phase HP shaft temperature
will be in the not recommended zone, but after soaking for about 1 hr. the mid-shaft temperature will be in the recommended
zone.
TMS < (Tmid HP Shaft)
Where, TMS = Main steam temperature ahead of the turbine
Tmid HP shaft = Simulated middle phase HP shaft temperature
d) Criterion for loading the turbine (synchronization of generator) after soaking at 3000 rpm (X7):
This criterion, called as X7, should be fulfilled before synchronization of generator and loading the turbine. As shown in Fig.
13.7, this criterion exhibits the relationship between hot reheat temperature and the simulated middle phase temperature of IP
shaft. The recommended zone is below the curve, which ensures proper warming of IP turbine components during soaking
period (approx. 45 min.) at 3000 rpm speed.
THRH > (Tmid IP Shaft)
Where, THRH = Hot reheat steam temperature ahead of IP turbine
Tmid IP Shaft = Simulated middle phase temperature of the IP turbine shaft.
258 Steam Turbines for Power Generation
Fig.13.6 Criterion for Bringing the Turbine Speed to Rated Speed
Fig.13.7 Criterion for Loading the Turbine
Criterion X6
Criterion X7
Recommended HP turbine shaft middle phase temperature before the turbine is brought to rated speed. This ensures proper
soaking of HP turbine
Recommended IP turbine shaft middle phase temperature before the turbine is loaded. This ensures proper soaking of IP
turbine
Chapter-13: Turbine Operation 259
13.5 Turbine Rolling Procedure
13.5.1 Checks Before Rolling
The following checks must be completed before imitating the rolling procedure.
- The opening/ closing of valves, fittings etc. must be in desired status.
- The lubricating oil, jacking oil and control oil pressures are normal
- The temperature of lube oil is within the specified limit (42o-45oC)
- Turning gear is in operation
- Condenser vacuum is greater than 0.85 kg/cm2 to allow the vacuum protection to release the opening of valves.
- Purity of steam must be within the recommended limit before it is admitted to the turbine.
- Unit has been cleared for start-up.
13.5.2 General
After above checks have been completed, steam can be admitted to the turbine. Typical cold-start-up curves for 210 MW
KWU steam turbine are depicted in Fig.13.8. It must be ensured that steam parameters at the turbine inlet are matching with
turbine metal temperature as discussed before. While increasing the speed to 600 rpm, first the gate valve gearing (turning
gear) is closed at 240 rpm and then JOP is tripped at 540 rpm. The turbine speed during warming-up period should be
preferably kept constant. The duration of soaking period (first soaking at 600 rpm and then at 3000 rpm) depends on casing
temperature and steam pressure and temperature, as determined by TSE.
After holding the set at warm-up speed for soaking purposes, the speed can be raised to the rated value provided the
following parameters are within permissible limit.
- Adequate temperature margin available on TSE (greater than 35oK)
- The differential expansion of the turbine are within limits
- The top and bottom temperature difference of the casing within permissible limits (less than 30oC)
- Sufficient steam generation in the boiler to meet the requirement of the turbine for loading to block load after
synchronization ( > 96 t/hr ).
The speeding-up of the turbine is carried out with the help of speed-controller. The speed should be raised quickly in the
range of critical speed. The MOP takes over the supply of oil to the oil system at about 2850 rpm and at this speed AOP is
switched-off automatically.
During speeding up, bearing temperatures should be monitored closely and also the rubbing sound in the glands.
If the turbine is to run for a long period at no load, before it is synchronized (as the case in improving the I.R. value of
generator, proper care must be taken to ensure that the exhaust-hood temperature of LPT does not increase more than the
permissible value (90oC), otherwise the exhaust-hood spray valves get opened when on auto.
Before synchronization all the turbovisory parameters are checked and ensured that they are well within the limits. After the
second soaking of turbine at rated speed in case of cold start and as per the requirements of TSE, proceed to synchronize the
generator with the grid and immediately take a block load (10% of rated load). When the frequency, voltage and phase
angles are as per the desired conditions, the generator circuit breaker is closed and the loading of the turbine begins. The
amount of load, which may be placed on the turbine after synchronization, and thereafter permissible rate of load, depends
on the margins indicated by TSE.
After the 5% load has been taken on the set, the cylinder drains are closed. The load controller takes over the speed
controller at about 10% loading (21MW) and thereafter load is raised through load reference setter.
260 Steam Turbines for Power Generation
Fig.13.8 Cold Start-up Curves for 210 MW KWU Steam Turbine
Chapter-13: Turbine Operation 261
Fig.13.9 Turbine controls
262 Steam Turbines for Power Generation
13.5.3 Turbine Resetting and Stop Valves Opening
1. Turbine Reset Operation
Ensure :
All protections of turbine are reset
Turbine trip solenoid supply normal
Control oil pressure = 6 6.5 kg/cm2
Operation :
Bring the SLLD position = 0%
Observe :
Turbine trip indication resets
Governing oil pressures as follows :
- Control oil pressure = 6 6.5 kg/cm2
- Trip oil pressure = 5.5 6 kg/cm2
- Start-up oil pressure = 5.5 6 kg/cm2
- Aux. Start-up oil pressure= 5.5 6 kg/cm2
- Aux. trip oil pressure = 5.5 6 kg/cm2
Note :
If control oil pressure is less, rotate the filters in governing and ATT oil circuit.
2. Opening of Stop Valves
Ensure :
Steam parameters for cold start-up are as follows :
- M.S. Pressure = 32 35 kg/cm2
- M.S. Temperature = 320o 350oC
- M.S. Flow = 95- 100 t/hr.
- H.R.H. Pressure = 10 12 kg/cm2
- H.R.H. Temperature = 320o 350oC
The criteria X1, X2, and X3 for opening the stop valves are fulfilled
TSE is selected in admission mode and upper temperature margin > 30oK
HP/IP trim device is "ON"
Following SLCs are "ON"
- Oil pumps and turning gear
- Condensate pumps
- LP Water injection valves
- MAL drain valves
- HPCVs warm-up controller drain valves
Operation :
Raise the SLLD position to 42%
Observe :
ESV 1 & 2 are open
 HPCV warm-up controller drain valves are open and HPCV body temperature at 100% and 50% depth shows increasing
trend.
Note :
Before opening the IVs, wait till the temperature of the ESVs, HPCVs at 50% depth increase and stabilize (normally a time
period of 45 min. is required).
Operation :
Raise SLLD position to 56%
Observe :
IV & IV2 are open
Governing oil pressure as follows
- Control Oil pressure = 6.5 kg/cm2
- Trip oil pressure = 5.5 kg/cm2
- Auxiliary trip oil pressure = 5.5 kg/cm2
Chapter-13: Turbine Operation 263
- Start-up oil pressure = 0
- Auxiliary start-up pressure= 0
13.5.4 Rolling of turbine with EHC
1. Raising the speed to 600 rpm (warm-up speed)
Ensure :
Criteria X4 and X5 for opening of control valves are fulfilled.
TSE upper temperature margin > 40oK
Operation :
Make the tracking device "ON"
Set the speed reference to 600 rpm.
Observe :
Gate valve gearing (turning gear) closes at 240 rpm.
JOP trips at 540 rpm
Turbine speed stabilizes at 600 650 rpm.
All turbovisory parameters are normal.
2. Turbine Trip healthiness test
Operation:
Press the "Turbine Trip" push button
Observe :
Turbine trips and following indications appears
- Turbine trip
- Turbine manual trip
- Turbine trip gear operated
- ESVs closed
AOP starts at 2800 rpm , JOP at 510 rpm & turning gear at 210 rpm
Note :
Check that HP / IP stop valves and control valves are closed.
3. Re-rolling of turbine to 600 rpm and soaking
Observe :
Values of following parameters are within limit.
- Turbine overall and HP differential expansions (should be +ve)
- Absolute shaft (specially HP rear and front) and bearing pedestal vibrations.
- Bearing metal temperatures (< 90oC)
- Bearing drain oil temperatures (< 65oC) and drain oil flow
- HPT top/bottom (mid wall) temp. (@ 160/150oC)
- Inlet of HP casing (270oC)
- Exhaust of HP casing (200oC)
- IPT top/bottom (midwall) (90oC)
- Vacuum (0.91 kg/cm2)
- HPCVs position (@20%)
- IPCV position (just start opening)
- HP secondary oil pressure = 2.6 kg/cm2
- IP Secondary oil pressure = 1.7 kg/cm2
- CRH NRVs open
Note :
Selection the TSE in turbine mode
4. Raising the speed to rated value (3000 rpm) and soaking
Note :
Soaking at 600 rpm is completed when the above parameters stabilize and TSE upper margin (admission mode) is achieved
@ 35oK. During soaking period ensure
264 Steam Turbines for Power Generation
that none of the above parameters drop drastically. Normally, one hour soaking is required to fulfill X6 criterion.
Ensure :
X6 criterion is fulfilled.
Operation :
Raise the speed reference to 3000rpm without stopping in between.
Observe :
Watch the vibration level at critical speeds 1545 rpm and 2126 rpm.
A.O.P. trips at 2850 rpm.
M.O.P. discharge pressure 9.7 kg/cm2 and lube oil pressure @ 5.5 kg/cm2
Turbine speed stabilizes at 3000 rpm.
Turbine expansion and axial shift are normal Expansion should increase steadily.
Absolute shaft vibrations < 120 m
Bearing metal temperature < 90oC
Bearing drain oil temperature < 65oC
HPT casing T/B, Inlet end & exhaust end temperatures
IPT casing T/B, LP exhaust temperature and condenser vacuum. It may be noted that LP exhaust temperature will increase.
Check LP injection spray valves open at 90oC
Governing oil parameters as follows :
- Control oil pressure = 8.5 kg/cm2
- Trip oil pressure = 7.5 kg/cm2
- Aux. trip oil pressure = 7.5 kg/cm2
- Aux. secondary oil pressure = 3.8 kg/cm2
- Secondary oil pressure for HP = 3.0 kg/cm2
- Secondary oil pressure for IP = 2.8 kg/cm2
- Primary oil pressure = 2.3 kg/cm2
Lube oil temperature is maintained between 42o 45oC
Ensure
Soaking of turbine at 3000 rpm (about 45 min) till X7 criterion for raising IP mid shaft temperature is fulfilled.
Note
1) Control valves open in proportion to secondary oil pressure for HPCV and IPCV. Control valves starts opening at 2.5
kg/cm2 sec. oil pressure and opens 100% at 5 kg/cm2 sec. oil pressure signal.
2) The rate of rise of speed is controlled by TSE margin, i.e., 0 - 30oK of TSE margin gives 0 - 600 rpm/min speeding rate.
However, if the margin is more than 30oC, the speed increases at constant rate of 600 rpm/min. If TSE is faulted, it blocks
the further raising of speed or load. If the speeding rate is < 108 rpm/min then dn/dt protection relay operates and brings
down the speed set point to 600 rpm to safeguard the turbine in critical speed zone. To get rid of this situation, operator
should ensure that TSE margin is > 35oK before rasing the speed and the speed reference should be raised to 3000 rpm
without stopping in between.
13.5.5 Rolling of turbine with Hydraulic Governor
(After opening of stop valves as per procedure 13.5.3)
Ensure :
- Tracking device is "OFF"
- CMC "OFF"
- ESV & IV Open (SLLD 56%)
- Position of following devices is 'zero'
a) S.L.L.D.,
b) Speeder gear
Chapter-13: Turbine Operation 265
c) Speed reference
d) EHC
Operation :
Raise the speed reference to 100%(3150 rpm)
Observe :
EHC position goes to 100%
Operation :
Slowly raise SLLD above 56% so that turbine speed increases and stabilizes at 600 rpm.
Note :
Soaking of turbine at 600 rpm and monitoring of turbine parameters are to be done as per earlier procedure.
Operation :
Raise the SLLD to 100% nonstop.
Observe :
HPCV & IPCV open and turbine speed increases to about 2700 rpm
( 90% of rated speed)
Note :
1) Hydraulic governor takes over at about 90% of rated speed i.e. at 2700 rpm. Hence further raising of speed is done
through raising the speeder gear.
2) TSE influence is not provided in Hydraulic governing system. Hence operator should ensure TSE margins > 35oK before
raising the speed to 3000 rpm.
Operation :
Raise the speeder gear position so that turbine speed increases to 3000 rpm.
Observe :
Turbine speed stabilizes at 3000 rpm.
Note :
1) Turbine soaking should be performed at 3000 rpm till X7 criterion is fulfilled before synchronization and loading of
turbine.
2) Watch all the turbine parameters as mentioned in 13.5.4.
13.6 Turbine Loading
13.6.1 Generator Synchronization and Loading to block load
Ensure :
- X7 criterion is fulfilled
- TSE Influence is 'ON'
- HP/IP trim device is 'ON'
- All turbovisory parameters are normal.
Operation :
Switch 'ON' load control
Set load reference to 20MW
Set load limit to 50 MW
Switch 'ON' load gradient
Set load gradient to 20MW (dp/dt set)
Select "Limit Pressure" mode
Synchronize the generator
Increase the load on turbine to 5-7 MW by giving pulses to speed reference.
Close all the drain valves of M.S., CRH & HRH lines.
Observe :
TSE disc changes over to load side and starts showing load margins
CRH NRVs open fully
TSE load margins shows increasing trend
LP Bypass sliding set point comes into service
Operation :
After soaking the turbine at 5 7 MW for about 15 minutes, raise the load on the turbine to 20 MW by increasing speed
reference.
266 Steam Turbines for Power Generation
Observe :
Load controller becomes active and takes over speed controller at about 20 MW.
13.6.2 Loading the Turbine to Rated Load (210 MW)
Observe :
Load controller is active.
Ensure :
Adequate TSE upper load margins
Operation :
- Close HP bypass valves by raising the pressure master set point to 55 kg/cm2 (Always keep set point higher than M.S.
pressure by 6 8 kg/cm2).
- Increase the HP bypass temperature master set point as per the HPT exhaust temperature time-to-time.
- Raise the M.S. Pressure by taking into service coal mill-A.
- Increase the load on the turbine to 40 MW through load reference (after ensuring TSE upper load margins).
- Take LP heaters, 1, 2 & 3 in to service from steam side by opening respective extraction steam valves (Ensure release for
A2, A3 NRVs is available)
- Increase the load on the turbine after noting following.
Note :
The load on the turbine should be increased through load reference by ensuring following conditions:
1) Steam pressure shows rising trend and observe arbitrarily the difference between M.S. pressure & turbine load about 10
till 60% load. Then up to 80% load M.S. pr. Can be raised to 140 kg/cm2.
2) TSE upper load margins are improved adequately by soaking at intermediate loads 40 MW, 80 MW, and 100 MW etc.
3) After 80% load, rated values of M.S. Pressure can be achieved.
4) HP heaters can be taken into service after 100 MW load.
5) After about 40% load, gland seal steam supply valve closes and leak-off valve starts opening to maintain gland steam
header pressure at 0.01 0.015 kg/cm2.
6) At about 55% load A4 NRV of Extraction-4 to deaerator is released. Changeover the deaerator pegging steam supply
from CRH to Extraction-4 (by opening Ex-301 valve).
7) Put HP bypass pressure master set point on 'Auto' in order to maintain 6 8 kg/cm2 positive bias with respect to M.S.
Pressure as per load. This ensures the HP bypass valves remain closed during normal operation of turbine.
8) CMC can be taken into service after 80% load on turbine and further raising of load to rated value can be achieved by
raising the unit target load set point.
13.6.3 Rated Parameters
Steam and Water Parameters :
- M.S. Pressure before ESV : 150 kg/cm2
- M.S. Temperature before ESV : 535oC
- Main steam flow : 627 t/hr.
- Hot reheat pressure : 34.8 kg/cm2
- Hot reheat temperature : 535oC
- Condenser Vacuum : 0.91 kg/cm2
- Condensate flow : 501 t/hr.
- Feed water flow : 650 t/hr.
- Deaerator pressure : 6.5 kg/cm2
- Seal Steam pressure : 0.012 kg/cm2
Turbovisory Parameters :
Chapter-13: Turbine Operation 267
- HPT differential expansion : -2.0 to + 5 mm
- IPT differential expansion : -2.0 to + 5 mm
- LPT differential expansion : - 7 to +25 mm
- HPT overall expansion : 26 mm
- IPT overall expansion : 13 mm
- Axial shift : + 0.3 mm
- Turbine bearing vibration : < 30 microns
- Turbine shaft vibration : < 120 microns
Levels :
- Deaerator level : 2375 mm
- HPH-6 level : 250 mm
- HPH-5 level : 250 mm
- LPH-3 level : 410 mm
- LPH-2 level : 350 mm
Governing System Parameters :
- EHC Position : 70 75%
- HPCV1, 2 position : 50 55%
- IPCV1, 2 position : 100%
- Oil Pressure
Control Oil pressure : 8.5 kg/cm2
Trip oil pressure : 7.5 kg/cm2
Aux. trip oil pressure : 7.5 kg/cm2
Aux. Secondary oil pressure : 4.3 kg/cm2
HP Secondary oil pressure : 4.3 4.5 kg/cm2
IP secondary oil pressure : 6.5 kg/cm2
Primary oil pressure : 2.1 2.2 kg/cm2
13.7 Changing over of Governing Systems on Load
13.7.1 Change over from EHC to Hydraulic Governing
It is assumed that turbine is running at full load and the status of governing controls may be as follows on EHC.
Status before Changeover :
Speed gear position : 100%
EHC position : 70 75%
Load Control : ON
Tracking Device : ON
Trimming Device : ON
Changeover Procedure
1) Switch 'OFF' tracking Device
2) Reduce speeder gear till HP secondary oil pressure drops slightly thereby load drops
3) Observe that EHC position automatically goes to 100%
4) Raise the load reference set point to 100% (so that hydraulic governor can function in entire load range).
5) Raise the SLLD position to 100%.
6) The turbine load now can be changed by the operation of speeder gear.
Note : TSE influence is not incorporated in Hydraulic Governor, hence operator should follow TSE
13.7.2 Changeover from Hydraulic Governor to EHC Status before changeover
EHC position : 100%
268 Steam Turbines for Power Generation
Speeder gear position : 75%
Load Control : ON
Load reference set point : Maximum
Tracking Device : OFF
Changeover Procedure :
1) Reduce the load reference setpoint below the actual load
2) The EHC position start coming down from 100% & stabilizes at lower position with respect to speeder gear.
3) HP secondary oil pressures drops slightly and hence the load on turbine.
4) Increase the speeder gear position to 100%
5) Switch ON Tracking Device
Now the load on the turbine can be changed with load reference in full range with TSE influence included in it.
13.8 Turbine Unloading and Shutdown
The following procedure for normal shutdown (planned shutdown) are based on the assumption that the unit is operating at
full load with CMC in service and that the intention is to cool the turbine completely for undertaking some work.
1) Gradually reduce the load on the turbogenerator through lowering the unit target load set point of CMC. Operator should
observe the lower load margin of TSE so that the step change of load should not be below this margin. The rate of reduction
of steam parameters and metal temperatures should not exceed prescribed limits and there should not be sharp changes.
2) With the reduction of turbogenerator load, the firing rate of the boiler should be reduced proportionately so that HP-LP
bypass valves should not open.
3) When the load on the machine has gradually reduced to 160 MW and all the parameters are stabilized, HP heaters 5 & 6
are withdrawn from steam side and feed water side. Also CMC should be taken out of service.
4) At load about 150 MW observe that steam supply to deaerator pegging changes from extraction No.4 to CRH on interlock
or change manually if needed.
5) Further bring down the turbine load to 90 MW. The M.S. pressure is brought to the level of about 100 110 kg/cm2 and
M.S. temperature about 510oC by adjusting the firing rate. Out of two, one of the BFPs can be stopped and also one air cycle
may be taken out of service. Watch should be kept on turbovisory parameters,
6) Reduce the load on the turbine further to 50 MW. At this load changeover the feed water supply line from 100% to 30%
low load line (FD 20 line). At this point only two coal mills are in service with respective oil elevation.
7) When the load on the machine is reduced to 40 MW and even below, change over the auxiliary supply from UAT to
station transformer. Withdraw L.P. Heaters 1, 2 and 3 from steam side.
8) Ensure that HP bypass pressure set point is adjusted to 8-10 kg/cm2 higher than actual M.S. pressure.
9) Reduce the load to 30 MW and stabilize the parameters. Trip the turbine manually or through the protection trial.
10) When the turbine is tripped, ensure that generator trips on Reverse Power Protection.
Chapter-13: Turbine Operation 269
11) Check the following
- ESVs, IVs and all control valves are closed
- CRH NRVs closed
- Trip oil pressure is zero
- Extraction NRVs and extraction valves are closed
- HP-LP bypass valves open
- Check the hot-well level, deaerator level and pressure (3.5 kg/cm2) are maintained.
- As the turbine speed drops down, observe;
AOP 1 or 2 picks up on Auto at about 2850 rpm. If AOP does not pick-up on Auto, start it manually otherwise EOP will
pick-up at 1.2 kg/cm2 oil pressure.
At 510 rpm JOP 1 or 2 picks-up on Auto
At 210 rpm gate valve gearing start. Turbine speed drops to this level in about 30 min. period.
Note : If due to some reasons, the turbine speed is to be dropped quickly, open the vacuum breaker to break the vacuum in
the condenser immediately.
12) If the turbine oil temperature is dropping below 40oC, isolate the oil cooler from water side.
13) Take the HP bypass valves on manual and slowly close the valves after reducing the boiler firing. Trip the boiler.
14) Charge the PRDS header from adjacent unit and close boiler outlet valves (MS 301,302).
15) After maintaining the hot well and drum level, CEP &BFP should be stopped.
16) Turning gear can be stopped when the HPT (T/B) casing and shaft temperature are below 100oC.
17) Stop A.O.P. and J.O.P.
18) Open the turbine and pipeline drains
19) Stop CW pumps
13.9 Turbine Operational Emergencies
13.9.1 General
Any deviation from specified normal operation defines the emergency operation condition for a turbine. Emergency occurs
due to abrupt change of important parameters to unacceptable values, which may lead to temporary or permanent damage to
the equipment.
In case of severe emergency, generally the turbine is tripped abruptly either through lockout relay or manually.
Following are the emergency conditions under which the set should be tripped irrespective of the protection systems to act.
13.9.2 Under Frequency
Since the turbine design is based on constant speed operation, there are some limits on low frequency that the set can be
operated without damage to some of the components. The operation of low frequency below 6% from the rated frequency
(50 Hz) for certain sustained period is not allowed as the natural frequency of LP turbine block falls within this range and
may cause high vibration level particularly in the last stage blading. This will cause higher stresses at the root of blades,
which may fail subsequently. Therefore, efforts should be made to increase the grid frequency by loading number of sets
connected in grid to improve the frequency. Generally, turbine trips through the generator protection of very low frequency
(47.5 Hz). Otherwise, turbine should be tripped manually and vacuum is broken.
270 Steam Turbines for Power Generation
13.9.3 Overspeed
The turbine governing system is designed to control the speed on loss of bulk load (through load rejection relay). However,
in case of total isolation of the machine from the grid or failure of speed governor/emergency governor may cause speed rise
to dangerous levels of 112%. The maximum speed limit is 3360 rpm. The machine should not be allowed to cross this limit
in any case. This can be achieved by manually tripping the turbine by emergency turbine trip push button.
Frequent overspeeding of turbine may lead to failure of LP turbine last stage blading.
13.9.4 Sudden Drop in Steam Temperature/Thermal Shock
Sometimes it happens that the boiler output does not match with the turbine output, which causes fall in steam temperature.
This temperature mismatch, particularly at the 1st stage of HP turbine, occurs due to too fast load change at the control
valves causing decrease in steam temperature at the greatly reduced flow. This sharp drop in steam temperature gives serious
thermal shocks. The surface stresses may surpass the yield strength, thereby reducing the life of turbine (fatigue and creep).
Measures to be taken :
i) So in case of sharp temperature drop from 535oC to 520oC, start unloading the set by 3 MW/min. and the set should be
unloaded to 100 MW corresponding to 480oC. Below this temperature turbine should be tripped immediately.
ii) To avoid thermal shocks, load or unload the set as per the recommended curves of the manufacturer.
iii) Avoid priming of superheater in boiler as it sharply drops the temperature.
iv) Avoid mismatch of temperature beyond recommended limits during rolling the turbine.
v) In case of boiler trip, turbine should be tripped immediately.
vi) Increase the excess air percentage to increase the final superheater outlet temperature.
13.9.5 Total A.C. failure
In case of total power failure of the grid or the station getting isolated from the grid, the following emergency operations
should be carried out on turbine side.
i) Start DC lube oil pump (EOP) to save the bearings if it is not started on auto.
ii) Remove main ejectors and gland steam cooler from service and kill the condenser vacuum by opening vacuum breaker
valves or air valve of starting ejector. Stop gland sealing when machine comes to rest.
iii) If the turbine emergency board is charged through the starting of DG set, start AOP and put the machine on turning gear.
If hydraulic turning gear cannot be established, rotate the rotor by manual barring.
iv) See that all the extraction NRVs have closed.
v) Monitor bearings babbit metal temperature and bearings drain oil temperature.
13.9.6 High Axial Shift
The increase in axial shift will lead to overloading of the thrust pads of the thrust bearing and eventual failure. It also
contributes to high bearing vibration and abnormal differential expansion. Protection has been incorporated to trip the
turbine and break vacuum at a limiting value of + 1 mm of axial shift.
Some of the possible causes of increase in the axial shift are :
a) Abrupt change in load
b) Sudden drop of steam temperature
c) Sudden drop of vacuum
d) Sudden closure of extraction NRVs or IVS / IPCVs.
e) Sudden closure of HP heaters
f) Lube oil failure to thrust bearing
g) Turbine overload or scaling in the blades
Chapter-13: Turbine Operation 271
13.9.7 Condenser Vacuum Low
In case of condenser vacuum going low limit 0.75 kg/cm2, hand trip the turbine if not tripped through protection, low
vacuum in condenser may be due to following reasons.
a) Partial or complete loss of cooling water
b) High condenser level
c) Leakage in vacuum system causing air ingress
d) Loss of gland seal steam
e) Malfunction of air ejectors
f) Fouled condenser tubes i.e. condenser DP high ( > 0.5 kg/cm2 )
The rapidity of fall of vacuum due to cause (a) to (e) depend on severity of cause, whereas, in case of (f) the fall of vacuum
is very gradual over a period of time. In case the vacuum drop rate is fast, reduce the load on turbine at the first instant. Then
find out the cause of vacuum deterioration and rectify the same.
13.9.8 Exhaust Hood Temperature High
If the exhaust hood temperature goes high (105oC) accomplished with low vacuum, the turbine should be tripped
immediately. Turbine may be restarted only if the exhaust part and condenser have cooled down to 55oC. At 90oC exhaust
hood spray comes into service.
The possible causes for this problem are :
- Fall of vacuum in condenser
- High steam parameters during cold start-up
- Running at 3000 rpm without synchronization of generator or at low load operation for long time.
- Steam dumping (LPBP) water injection valve failure at low loads
- High load from steam dump to condenser at low vacuum or steam dumping at high temperature
- Motoring of generator after turbine trip out.
This malfunction will lead to following responses :
LPC differential expansion may go excessive (negative side).
Prolonged high exhaust hood temperature may cause vibration, unusual sounds from LPC, seal rub, loosening of shrunk fit
rotors.
Operator should take following actions :
Increase CW flow if possible
Try to improve vacuum
Reduce steam dumping to condenser
Do not hold the turbine on low load for long time
Charge LP heaters as early as possible
Check gland steam temperature and pressure are maintain at recommended values
Steam throw spray can be maximized to bring down exhaust hood temperature
If above measures do not serve the propose, trip the turbine, break the vacuum and cool down the exhaust hood before
restarting the machine.
13.9.9 High Bearing & Shaft Vibration
During rolling and loading of turbine, shaft and bearing vibrations should be watched carefully and in case it exceeds
permissible limit, turbine should be tripped to prevent severe damage. While rolling the set, the critical speeds should be
surpassed as quickly as possible without pause. Noise or any rubbing sound should be heard very carefully from turbine
glands and bearings.
High bearing vibrations may be due to many reasons. Most probable causes are :
272 Steam Turbines for Power Generation
Sudden change in inlet steam temperature
Too high or too low lube oil temperature and pressure at the inlet of bearings and thereby deteriorating the oil film.
Moisture content in the lube oil
Gland steam temperature very low
High differential temperature between top and bottom cylinders of turbine (50oC)
High differential expansion
High eccentricity of shaft
High axial shift
Operator should control the steam parameters as per the load on the turbine and should maintain the lube oil temperature,
pressure and oil quality as specified. Also, proper and adequate soaking of turbine should be performed during start-up so as
to reduce the thermal stresses on turbine parts, normal differential expansion and top/bottom casing temperature difference
(< 30oC).
13.9.10 High Differential Expansion
In case of excessive differential expansion, metal-to-metal contact may occur between stationary and rotating parts of the
turbine because of close running clearances. Hence it is necessary to maintain the HPT, IPT and LPT differential expansions
within prescribed limits.
Increase in differential expansion may be caused due to, too fast a change in the inlet steam temperature or due to too rapid
change in the steam flow to the turbines. Hence in normal running conditions, maintaining the steam temperatures as close as
possible to the metal temperatures and controlling the rate of change of temperature to the minimum will help in maintaining
the differential expansion within the limit. Operator should load the turbine as directed by Turbine Stress Evaluator
particularly during cold start-up and should follow the start-up curves while raising the steam parameters with recommended
rates.
During cold start-up when the steam temperature is much higher than the metal temperature the expansion tends to go
towards +ve, i.e. the rotor expands more than the casing, even though provisions are made for warming up the turbine prior
to rolling in many designs. Hence, the recommended start-up procedure regarding the inlet parameters is to raise the inlet
steam parameters, turbine speed at normal rates and give adequate time for soaking at recommended speeds. Similarly,
during a hot start, when the rotor tends to contract, the steam temperature should be high enough and rate of rise of load
should be controlled to maintain the differential expansion in +ve side.
13.9.11 Water Hammering
It is a very serious phenomenon, which may lead to disastrous consequences of failure of hangers and supports, leakage of
flange joints, cracking of material due to severe vibrations and noise level and jerks. Water hammering mainly occurs during
start-up or shutdown. During initial start-up, condensate accumulation in steam pipes should be properly drained through the
drain valves and piping connected to flash tanks and to condenser. Water spray lines should be properly isolated. Turbine
casings should also be thoroughly drained. During shutdown after tripping of the set, special care should be taken from feed
heaters side that no back flow of water takes place towards the turbine. Extraction NRVs should be force closed by its
hydraulic actuators.
Further the wet steam due to priming in boiler or fall in boiler outlet pressure abruptly may cause flashing and decrease in
turbine load coupled with severe vibration and noise in the turbine. Hence boiler outlet steam parameters should be
maintained as per requirement of turbine condition.
13.9.12 Turbine Trip
A running turbine may trip due to variety of reasons such as:
- Malfunction or trouble in one or more of its auxiliaries
- Turbine parameters crossing the specified limits or abnormal condition
- Boiler trip or generator trip
Chapter-13: Turbine Operation 273
A direct turbine trip is initiated in following cases :
- Overspeed ( > 110%)
- High axial shift ( + 0.5 mm )
- Condenser vacuum very low ( < 0.7/kg/cm2 )
- Low lube oil pressure ( < 1.2 kg/cm2 )
- Main steam temperature low ( < 480oC )
- Boiler trip
- Drum level very high ( > 225 mm )
- Generator fault/trip
- Fire protection 1 or 2 operated
- Emergency trip push button pressed
Plant Response :
Turbines trip initiates closing of ESVs, IVs and all control valves through protection and governing oil circuit.
Simultaneously generator trip is initiated with some time-delay. However, if HP-LP bypass valves do not open, boiler also
trips on reheater protection.
Immediately after turbine tripping check and ensure that :
- Turbine is coasting down at normal rate (reduction of speed)
- AOP is started at 2850 rpm and maintains adequate lube oil pressure to bearings
- JOP is started at 510 rpm and turning gear at 210 rpm. If not so, manually start them.
- Check and ensure closure of all the extraction line steam isolating valves and NRVs.
- Ensure seal oil supply to generator shaft sealing
- Turning gear maintained 150 160 rpm speed.
If the cause of trip is such that unit can be brought on line shortly, it is not needed to break the vacuum. However, in some
cases (fire hazard, abnormal sound, very high vibration etc.), it is necessary to bring rotor to a quick stop, in that case open
the condenser vacuum breaker valve and starting ejector air valve. This will quickly bring down the turbine at rest.
13.10 Automatic Turbine Tester (A.T.T.)
Healthiness of the protective devices, stop & controls valves is most important for the operation reliability and availability of
turbine. Hence it is utmost necessary to keep these equipments/devices fully serviceable and thoroughly checked. Hence
ATT program is used to test the working of protective devices and stop/control valves while the turbine is running (by
simulating the condition).
The ATT is subdivided into functional groups for each device. Each group contains the device itself and all necessary signal
transmission elements for initiation of a normal trip. The automatic turbine tester has following two subgroups.
1. Protective devices testing 2. Stop and control valves testing
The complete testing of all components, which must operate when an automatic trip becomes necessary, is assumed. The
main trip valves which store the trip signal by mechanical/hydraulic means are operated together with each protective device
and the subsequent satisfactory drop in the trip oil pr. after the valves is monitored, which initiates turbine trip alarm along
with the protective device signal.
During testing of stop valve and control valves, the closing time is monitored to assure the satisfactory operation.It is
recommended to carry out the A.T.T. once in a week by bringing down the load on the machine to about 80% (during slack
hours).
-o0o-
Posted 26th May 2015 by kishorereddy kattukolu

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