KNOWLEDGE IS POWER

Jumat, 22 November 2013

BASIC OPERATION OF POWER PLANT (WHRB)

POWER PLANT OPERATION

BY MUJIYONO

BOILER
Definition
As per Indian Boiler Act 1923, Boiler is defined as any closed vessel exceeding
22.75 liters in capacity which is used exclusively for generating steam under
pressure and includes any mounting or accessories attached to such vessel, which
is wholly or partially under pressure, when steam is shut off.
A good Boiler should have some essential qualities.
1. Capable to meet large load fluctuations.
2. Fuel efficient i.e. to generate maximum steam with minimum fuel consumption.
3. Ability to start-up quickly.
4. Easy in maintenance and inspection.
5. Occupy less floor space.
6. Lower friction loss in water and flue gas circuit
7. Little attention for operation and maintenance.
Systems in a Boiler
A Boiler mainly contains following systems :
1. Feed water system.
2. Steam system.
3. Air system.
4. Flue gas system.
5. Fuel handling system.
6. Ash handling system.
Boiler Mountings
Fittings on a Boiler which are required for its safe and efficient operationare called
mountings. These are as follows :
1. Safety valve
2. Water level sight glass (gauge glass)
3. Pressure gauge
4. Blow down valve
5. Main steam stop valve
6. Feed water check valve (NRV)
7. Air Vent
8. Start-up vent
9. Manhole
Boiler Accessories
The devices which are used in a Boiler as an integral part and help to run the Boiler
efficiently are called Boiler Accessories. These are :
1. Super heater
2. De-super heater
3. Economizer
4. Air Pre-heater
5. Soot Blower
6. Feed Pump
7. ID and FD fans
8. Ash Removal system
9. Fuel supply system
10. Dosing system
11. Deaerator

Steam Generation In A Boiler..contd

In a Boiler fuel is burnt to get heat energy which is converted from chemical
energy stored in a fuel. This heat energy is utilized to produce steam from feed
water.
Fuel is fired in the furnace of the Boiler. Different fuel is used in different Boilers.
Accordingly furnace is designed. Water tubes are arranged around the furnace and
flue gas path. Water tube arrangement made around the furnace is called as water
wall. Feed water is circulated in these tubes. Water comes to water wall from
Boiler drum, and circulated back to drum after absorbing heat. Due to difference in
density which is created due to difference in temperature, water circulates in these
tubes naturally. Therefore, it is called Natural Circulation.

During circulation of water in tubes, steam is generated and collected at the upper
part of the Drum. This is called Saturated Steam corresponding to Boiler drum
pressure. This steam is further heated in Superheaters and becomes superheated
steam.
Boiler Drum is filled with fresh feed water. The feed water, before entering into
drum is heated at Economizer. Economizer is placed at the flue gas path. Most of
the heat of the flue gas is utilized inside the Boiler. Still considerable amount of
heat energy is available in it. This heat is utilized in Economizer to heat up the feed
water.
 For burning of fuel, required Oxygen is obtained from atmospheric air. Air is
required in Boiler furnace for combustion. This is supplied by Forced Draught
(FD) fan. This air is heated at air pre-heater (APH) before being sent into furnace.
If cold air is used then there will be loss in energy. Air pre-heater is placed at the
flue gas path after Economizer. Air pre-heater is a heat exchanger which exchanges
the heat of flue gas to the cold air, which is to be used in furnace. By heating the
air, burning of fuel is easier and loss of energy is minimized. If hot flue gas would
not be used to heat up feed water at Economizer and air at Air Pre-heater then it
would escape into atmosphere.
Finally the flue gas passes through Electrostatic Precipitator (ESP) and exhausted
to atmosphere through chimney. At ESP the dust particle in the flue gas is trapped
and clean gas escapes to atmosphere.
Ash which is produced in the Boiler due to combustion of solid fuel is collected at
Boiler bottom and also in Economizer, Air Pre-heater and ESP. This ash is
disposed off with the help of suitable ash handling system.
Preparations for Cold Start-up
1. All the manhole doors should be in close condition. Tightness of the Nuts and
Bolts of the man hole doors to be checked properly.
2. All the water wall drain lines should be in close condition.
3. All the steam drain lines should be in open condition.
4. Start-up vent Root Manual isolation valve should be in open condition.
5. Drum level should be at Normal Water Level (NWL).
6. Continuous Blow Down (CBD) and Intermittent Blow Down (IBD) drains should
be in close condition.
7. All the super heater vents including Drum vent and Puppy Header vent should be in
open condition.
8. Before and After Isolation valves at Feed Control Station (FCS) should be in open
condition.
9. Attemperation Control valve before and after isolation valve should be in open
condition .
10. Hydra step should be in healthy condition.
11. Safety valves should be in healthy condition.
12. Main Steam stop valve and by- pass valve should be in close condition.
13. Soot blower manual isolation valve and control valve should be in close condition.
14.Boiler Drum Gauge glass steam side and water side isolation cocks should be in
open condition.
15. HP Dosing Pumps should be in Healthy condition and open suction and discharge
valves of the pump.
16. Solution in HP Dosing agitator tank should be at normal level.
17. Boiler Feed Pumps should be in healthy condition.
18.Deaerator water level should be maintained at 60% by taking DM Transfer pump
in service.
19. Air compressors should be in healthy condition.
20. Ash handling systems should be in healthy condition.
21. ESP should be in healthy condition.
22. ID fan damper should be in Zero position.
23. All the interlocks and protection should be checked properly viz. Drum level low,
Deaerator level low, Boiler Feed Pump (BFP) discharge pressure low, Flue gas
temperature at Post Combustion Chamber (PCC) outlet high, silo level.

Cold Start-up process

1. After Kiln light-up, when flue gas temperature at PCC outlet increases to more
than 450 deg.C, open ID fan damper 5%. Due to natural draught created by
chimney, flue gas passes through Boiler and slow heating and expansion takes
place.
2. After opening of ID fan damper, Boiler furnace temperature rises slowly. When
the furnace temperature rises to 250 deg C, Open ID fan damper 10%.
3. When Flue gas temperature at PCC outlet rises more than 600 deg C., close the
ID fan damper and start ID fan.
4. When Drum pressure reaches 5 Kg/cm2, close the Drum vent and Puppy header
vent.
5. When Boiler Drum pressure reaches 20 Kg/cm2, give blow down of the water wall
to remove the deposition or sludge.
6. By adjusting damper opening raise the Boiler pressure upto 45 kg/cm2 and 485 deg
C.
7. Start-up vent should be in open condition since the admittance of hot flue gas in
boiler.
8. Open the Main steam line drains in between Boiler Main Steam Stop Valve
(MSSV) and TG MSSV.
9. Open the MSSV by pass valve to remove all the condensate in main steam line and
ensure that TG MSSV is in close condition.
10. After removal of all the condensates in Main steam line and proper line heating,
open Main Steam stop valve of Boiler.
11. Close Super heater drains.
12. Put Drum level controller in Auto mode.
13. Put Attemperator controller in Auto mode.
14. Close Start up vent as per the steam demand of TG set.
15. Charge ESP when Flue gas temperature after Economizer reaches 160deg. C
Finally the flue gas passes through Electrostatic Precipitator (ESP) and exhausted
to atmosphere through chimney. At ESP the dust particle in the flue gas is trapped
and clean gas escapes to atmosphere.
Ash which is produced in the Boiler due to combustion of solid fuel is collected at
Boiler bottom and also in Economizer, Air Pre-heater andESP. This ash is disposed
off with the help of suitable ash handling system.
 Start-up of Waste Heat Recovery Boiler (WHRB)
Hot Start-up

Start-up of Boiler within 2 Hrs of Tripping of Boiler is known as the Hot Start-up
of Boiler.
1. Ensure the Drum level of Boiler. It should be at Normal water level.
2. Start Air Compressors.
3. Start Boiler Feed water Pump.
4. Start ID fan with ID damper in Zero position.
5. Open Start-up vent.
6. Slowly open damper of ID fan. Watch Drum level.
7. Regulate Boiler pressure by opening start-up vent.
8. Super heater temperature has to be maintained with the help of attemperator
control valve.
9. Raise the Boiler pressure upto 45 Kg/cm2 and temperature to 485 deg C.
10. Open the drains of Main steam line in between Main Steam Stop Valve (MSSV) of
Boiler and Turbine.
11. Open By-pass valve of MSSV.
12. Condensate, if any, will be drained out and main steam line heating will be carried
out by opening of by-pass valve.
13. After ensuring proper Main steam line heating, open Main
14. steam stop valve.
15. Close all drains in main steam line.
16. Charge ESP when flue gas temperature at Economizer outlet reaches 160 deg C
17. Put drum level controller and attemperator controller in Auto mode.
18. Regulate the pressure of Boiler with the help of start-up vent.
19. Close Start-up vent as per the steam demand of TG set.
20. Normalize ID fan damper by gradual opening and loading of Boiler.
Charging of De-areator
It removes the dissolved gases from the condensate mechanically by following two
laws
1. Henry’s Law
2. Dalton’s Law of Partial Pressure.
 According to Henry’s Law, Solubility of dissolved gases decreases by increasing
water temperature. So by charging steam in Deaerator water temperature increases
and soluble gases in condensate departs.
 According to Dalton’s Law of Partial Pressure Pm= Ps+Pa
Where Pm= Partial pressure of Mixture
Ps= Partial pressure of Steam
Pa= Partial pressure of Air
 The partial pressure of air present inside the Deaerator comes out
 through Deaerator vent for equilibrium state.
Procedure Of Charging
1. Ensure DM Storage Tank level is more than 60%.
2. Start DM Transfer Pump by opening Recirculation valve.
3. Ensure Deaerator level is 60%. If the level is less then take the make up water .
4. Open all drain lines of Pegging PRDS line and observe that condensate is
completely drained out.
5. Slowly open Pegging PRDS pressure Control Valve and ensure that condensate is
drained out completely. Then close the drains.
6. Gradually increase the pressure to 2.8 Kg/cm2 by increasing pegging PRDS
pressure control valve.
7. Slowly heat the Deaerator by opening the heating line isolation valve and raise the
Deaerator temperature to 90 deg C.
8. Open the before and after isolation valve of Deaerator Pressure Control valve.
Then open the pressure control valve gradually. Slowly increase the Deaerator
pressure upto 2 kg/cm2 .After that put the Deaerator Pressure control valve in Auto
mode.
9. Start LP Dosing pump.
10. In LP Dosing Hydrazine is used. Hydrazine removes oxygen by chemical
reaction.
11. EQUATION- N2H4+O2=2H2O+N2
12. By adding Hydrazine dissolved oxygen becomes water and Nitrogen gas releases.

WHRB Interlocks
1. If Drum level becomes very low i.e. 25% then ID fan Trips and Emergency cap
opens
2. This is to protect the Boiler tubes. At low Drum level, heat flux input has to be cut
off, to protect the Boiler tubes, otherwise starvation takes place.
3. If PCC out let temperature rises to 1050 deg C then ID fan damper becomes Zero
and Emergency Cap opens.
4. This protection is incorporatedto protect the Boiler tubes from overheating.
5. If all BFPs trip then ID fan damper becomes Zero and Emergency cap opens.
6. When all running BFPs Trip, then Drum level falls drastically. To protect the
Boiler from starvation heat flux input should be cut off.
7. If Deaerator level becomes very low i.e.25% then All BFPs Trip.
8. Running of BFPs at Low Deaerator Level is harmful for the Pump.
9. If Ash Silo level is high, all ash handling systems stop.
10. When ash Silo is at high level then conveying more ash from ash handling systems
results line blockage of ash conveying line. To prevent this, it is better to stop the
systems and unload ash from Ash Silo.
11. Boiler Main steam stop valve will not open if by-pass MOV of MSSV is in close
condition.
12. This protection is to avoid line hammering due to presence of condensate in main
steam line and to prevent carry over of condensate towards Turbine side.
13. Boiler Feed Water MOV will not open if by-pass MOV of Feed water MOV is in
close condition.
14. If feed water is empty in Economizer and in the pipe line after Feed water MOV,
then by opening Feed water MOV directly without opening FW by-pass, MOV
will lead to overloading of BFP, resulting BFP Trip.
15. ESP trips, if Ash Hopper level is high.
16. ESP has high voltage. Ash has presence of combustibles.
17. This protection is to safeguard ESP at Ash Hopper level high.
18. ESP can not be charged without starting of Purge Air Blower.
20. This is to Seal the ESP by the air from Purge Air Blower before charging it.
22. ESP can not be charged till flue gas inlet temperature reaches 160 deg C.
23. This is to avoid deposition of moisture and oil content influe gas on ESP.

1. Decrease in Drum level

a. Tripping of Feed Pump
If Boiler feed Pump trips then Feed water supply to Boiler interrupts and leads to
lowering of Drum level. If this has happened then ensure that the auto stand-by
Boiler feed pump has started in Auto mode. If the auto stand-by Boiler Feed pump
has failed to start in Auto mode then start the Boiler feed pump manually otherwise
Boiler will suffer from starvation and ultimately it will lead to Boiler trip to protect
the Boiler.
b. Tube failure in Economizer
If Boiler Economizer tube fails then water supply to Boiler Drum will be affected.
This leads to decrease in drum level and Feed Control valve will open more to
compensate the Drum level to Normal water level, which leads to overloading of
Boiler Feed pump.
Observe the steam flow and feed water flow. If feed water demand to drum is
increasing then observe any sound from the furnace. If tube has failed inside boiler
then hissing sound comes and it can be noticed from outside. Simultaneously check
the smoke from the chimney. If it is of white colour then tube failure in side the
furnace is confirmed.
c. Unit getting into Island mode
When Unit comes to Island mode, it follows the load connected to the
Generator. Suppose Unit is generating more power than the Unit load
and exporting to Grid.
At the time of Islanding, Generator will follow the load connected in this
Unit and the Governing Control Valves would close according to load and
allow the steam to pass through Turbine. The surplus amount of steam
will remain in Boiler which increases the Drum pressure. This drum
 pressure will exert a downward thrust to the drum level and it decreases
drastically.

d. Whether CBD valve, EBD valve or IBD valve opened?

If any operating personnel has opened any of these valves without proper reason or
intimation then also drum level decreases rapidly. Ensure first then close the valve
or regulate it observing the drum level.

2. INCREASE IN DRUM LEVEL

a. Whether Cold start-up in Boiler is in progress?
During Cold start-up when water temperature reaches 900 C then formation of
bubble starts. This is known as swelling phenomenon. If this is the case then blow
down has to be given to maintain the drum level at Normal water level.
b. Whether Instrument air compressor tripped and air lock unit at feed control
station failed?
If Instrument air compressor trips, then air lock unit of control valve at feed control
station keeps the control valve at a position at which it was, before supply of
instrument air. This is known as stay put condition. If air lock unit fails to keep the
feed station control valve at stay put condition, then when supply of instrument air
fails, it leads to 100% opening of control valve. If this happens, start the instrument
air compressor as early as possible and regulate the feed station control valve.

c. Whether Start-up vent has opened or safety valve popped up?

By opening start-up vent, when Boiler is in steaming condition, supply of steam to
Turbine Drum level increases rapidly due to release of pressure in drum. If the
steam demand in TG has reduced to a large extent then it results Boiler drum
pressure rise quickly and at that instant drum level falls rapidly. When start-up
vent is operated to release the surplus steam or safety valve pops up, then drum
level increases rapidly. In this case at first ensure for what reason the pressure in
Boiler has increased. If drum level is increasing drastically then give blow down to
regulate it. Because at higher side drum level, the steam quality will be affected
and carry over of water particles to super heaters and turbine will take place, which
is very much harmful.
d. Whether Start-up vent has opened or safety valve popped up?Continued….
Operation should not be carried out when Boiler is in loaded condition. Donot
close the Feed Control valve fully if drum level rises because if the control valve is
closed completely, the feed water in Economizer tubes, which was passing to
Drum, will became steam due to heat in flue gas and when feed water supply
through Economizer will be again established through Feed control valve then
hammering in Economizer tubes due to presence of steam. This may lead to
 Economizer tube failure. After ensuring the reason, close the start-up vent and
dump the surplus steam in Condenser. Ensure that the safety valve has been reset
in its position and no passing is observed.
e. Whether drum level transmitter is malfunctioning?
If drum level transmitter is malfunctioning then observe the level in hydrastep and
immediately inform shift in charge and instrument personnel about this.
f. Whether rapid heat supply to Boiler?
If heat supply to Boiler will be increased suddenly with a huge amount then it
affects the drum level and it swells. To avoid this regulate the heat input supply in
a gradual loading manner. Sudden and huge amount of heat supply will overheat
the grain structure of the tubes and it suffers from fatigue. In course of time tube
fails.
g. Whether stand-by Boiler Feed Pump has started?
When stand-by Boiler feed water pump has started with running Boiler feed water
pump, then Drum level increases because at that opening in Boiler feed Control
valve when feed water pressure increases, more feed water flows to drum due to
that opening of control valve and leads to increase in drum level. This case
normally happens during scheduled Equipment change over of Boiler feed water
pump. At first the stand-by feed water pump is started and discharge valve of the
respective feed water pump is opened. After that the previously running Boiler
feed pump is stopped. Ensure whether it is a scheduled equipment change over.
h. Whether TG has come to Island mode?
If TG has come to Island mode then Boiler pressure increases as there is a cut off
steam demand as Generator has to follow the load, connected to it in this unit. If
unit was exporting the power to Grid then the surplus power will be reduced at that
instant,
which the Governor of the TG set will follow. It closes the control valve and steam
pressure rises in Boiler accordingly. Ensure that the unit is running under Island
mode. Open the start up vent to release the pressure. Ensure that the Safety valve
has popped up or not. If popped up then it has reset properly or not. Observe the
drum level during this operation. Observe the Dump control valve is functioning
properly or not. If it is responding properly then try to supply steam to condenser
by closing start-up vent after ensuring that Boiler pressure has reduced and safety
valve has reset.
h. Whether TG tripped?
If turbine trips then steam demand in Turbine will cut off and resulting Boiler
pressure rise. Ensure Dump circuit is healthy. Open the Control valve of dump and
close the start-up vent after ensuring that the safety valve reset.
i. Whether any Cooling water pump in TG has tripped?
 When Cooling water pump in TG for Condenser condensate cooling trips then the
vacuum in condenser drops quickly and at that instant if the auto stand-by pump
fails to start then the load set point at Generator has to be reduced with immediate
effect. Otherwise the TG will trip due to low vacuum. When load set point at
Generator decreased suddenly then Boiler pressure increases. In this case
communicate with the TG operator and open start-up vent and lower the Load set
point. Try to start the Main cooling water pump manually. After restoration of
cooling water pump divert the steam from start-up vent by closing it to the dump
circuit and normalize the load of Generator.

3. Decrease in Boiler Steam Pressure

a. Whether flue gas inlet temperature has reduced?
If flue gas inlet temperature reduces then it steam generation reduces in Boiler and
pressure drops. This has to be observed very carefully and the generator Load set
point has to be lowered, otherwise the TG will trip when the Main steam pressure
becomes low.
b. Whether more steam demand at TG end?
If the unit is running at low load as steam generation in Boiler is low. If as a mal
operation Load set point at Generator is given more than steam generation then
Boiler pressure decreases. and TG is running with low load set point. Unit is
importing power from Grid. If unit came to Island mode then the Generator will
follow the load which is connected to it and load set point at Generator increases
than the steam generation in Boiler. So Boiler pressure decreases. As we can not
change the load set point of Generator by putting lower set point value, Load on
the Generator has to be lowered by cutting off the load connected to it. Choose the
less important load connected to Generator and cut off it as quickly as possible
otherwise the unit will suffer from Black out condition due to TG trip at Main
steam pressure low and Grid power is unavailable.
The same case happens when the steam generation in Boiler is low

c. Whether superheater tube failed?

If superheater tube fails then Boiler steam pressure decreases. Observe steam flow
and feed water flow. If steam flow is at lowering trend and feed water flow is at
increasing trend then it indicates that tube has failed. If the tube failure has
occurred in side the furnace then white smoke comes out from chimney. When
steam pressure decreases then reduce the Generator set point accordingly to avoid
TG trip at main steam pressure low and ensure whether tube has failed or not. If
tube has failed then Boiler shut down has to be taken to replace the failed tube with
a new tube.
d. Whether ID fan damper has closed to zero position?
 This case happens when flue gas temperature at Post Combustion Chamber reaches
10500 C. Flue gas flow to Boiler cut off when ID damper closes. It means heat
supply to Boiler has cut off. It results in less steam generation. So when ID damper
closes due to high PCC temperature, immediate load reduction has to be carried
out in Generator to avoid TG trip due to Main steam pressure low.
e. Whether hand lever of Safety valve has been operated?
If any person has operated the hand lever of safety valve without proper
communication with the operating personnel for sometime then Boiler steam
pressure decreases and drum level increases.
4. INCREASE IN MAIN STEAM TEMPERATURE
a. Whether Boiler is loaded with huge amount of heat suddenly?
Main steam temperature rises if flue gas temperature at Boiler inlet rises suddenly.
As superheaters are located at convection zone, therefore when flue gas
temperature rises, it increases the superheater temperature. If attemperator control
valve fails to control the main steam temperature then TG will trip due to main
steam temperature going high. In order to avoid such a situation, if main steam
temperature rises due to rise in flue gas temperature, then immediately
attemperator control valve has to be taken to manual mode and attemperation
should be increased. Also communicate with the kiln personnel about the sudden
rise in flue gas temperature.
b. Whether Soot Blowing is in progress?
During soot blowing, steam temperature rises because more steam is required for
soot blowing and heat input to the Boiler has been increased by opening the ID fan
damper. So during soot blowing, main steam temperature has to be observed
carefully. If attemperator control valve fails to control the rise in main steam
temperature in auto mode, then it has to be controlled taking it to manual mode.
c. Whether Attemperation control valve is in manual mode or wrong value command
input by the operator?
Normally it happens when there is a high fluctuation in main steam temperature.
The attemperation control valve fails to control the temperature in Auto mode. So
the concerned operator has to take the attemperation control valve to manual mode
to control the temperature. But if he forgets to put this control valve in Auto mode
after stabilization of main steam temperature, then it will remain in manual mode
and during more heat input from Kiln, the main steam temperature would rise.
Also sometimes operator puts wrong value command for attemperation control
valve opening from control station in manual mode, which would result
in increase in main steam temperature.
d. Whether forget to open before and after isolation valves of attemperation Control
valve?
This situation comes during cold start-up of Boiler, if the inspection and checking
was not done properly by the operation personnel. During initial period, this thing
 cannot be noticed but at the time of main steam temperature rise by opening
attemperation control valve flow of water cannot be established as before and after
isolation valves are in close condition. So care has to be taken for proper inspection
and checking before start-up.
5. DECREASE IN MAIN STEAM TEMPERATURE
a. Whether inlet flue gas temperature has dropped?
If flue gas inlet temperature drops due to problem in Kiln side then main steam
temperature decreases. So if main steam temperature is in decreasing trend then
first observe the flue gas inlet temperature to Boiler.
b. Whether Load set point is given in Generator more than the Steam generation?
If Load set point in Generator is given more than the steam generation in Boiler
then main steam pressure decreases and also the main steam temperature decreases
c. Whether valve sheet of Attemperation control valve is eroded?
This situation comes during Low Load operation of Boiler. If heat input to Boiler
is low, then steam generation reduces and also the power generation. At that time,
feed water passes due to eroded valve sheet of attemperation control valve and
decreases main steam temperature.
d. Whether ID damper has become Zero due to PCC outlet temperature High?
When Post Combustion Chamber temperature increases more than 1050 0C,
opening of ID damper becomes Zero. At that time heat supply to Boiler from Kiln
stops suddenly. So it results in rapid decrease in main steam temperature. If this
situation arrives, then attemperation control valve has to be taken to Manual mode
from Auto mode and decreasing main steam temperature has to be controlled.
6. FURNACE DRAUGHT TOWARDS POSITIVE SIDE
a. Whether tube failure has occurred in side furnace?
In furnace, the draught is maintained at negative side to carry out the hot flue gas,
ash and other suspended particles from kiln to chimney through ID fan. If Boiler
tube fails inside furnace then draught goes towards positive side. As steam density
is higher than air density. Also it adds an additional load on ID fan. So ID fan
takes more current in this situation.
b. Whether draught transmitter is showing wrong value?
This can be known if other draught transmitters in flue gas path are showing right
value and one of these is showing erratic value. This problem should be brought to
the notice to shift in charge and instrumentation personnel.
7. LONG RETRACTABLE SOOT BLOWER IS NOT AT ITS ORIGINAL
POSITION
a. Whether Long Retractable soot blower’s chain has broken during Soot Blowing
operation?
 If chain breaks at intermediate position of lancer tube during soot blowing by
LRSB, then motor will be unable to retract it to the original position i.e. home
position. Check the position of lancer tube, when soot blowing operation is in
progress and chain has broken. In this situation, donot cut off steam flow through
lancer tube. It is because it is situated in high heat zone i.e. at convection zone. As
steam acts as a coolant, it will take the heat added to the lancer tube and will
protect the lancer tube from over heating and bending. The lancer tube has to be
drawn out manually. After ensuring that it has been drawn to its home position,
steam through the lancer tube can be cut off and chain maintenance work can be
carried out.
b. Whether home position limit switch is malfunctioning?
This may happen after completion of soot blowing by Long Retractable Soot
Blower. The limit switch at home position may not give home position feed back
of the LRSB due to malfunction. If this case happens then immediately the position
of the lancer tube has to be checked. Limit switch at home position has to be
rectified by Instrumentation department.
c. HAMMERING OF MAIN STEAM LINE DURING CHARGING.
Usually main steam line hammering occurs if the condensate present in that line is
not properly drained out and pipe line is in cold condition. If huge amount of steam
is allowed to pass through that pipe line then line hammering takes place which is
very much harmful for the pipe line. So to avoid this case happening always open
the drain of the pipe line. Observe the condensate is drained properly from that
pipe line. After completion of condensate draining, warm-up the pipe line with
very less quantity of steam. Gradually increase the pipe line temperature. After
confirmation that the line is properly heated, more steam flow can be allowed.

Steam Turbine
Steam turbine is a mechanical device that extracts thermal energy from steam and
converts it into mechanical work. Interiors of a turbine consists of several sets of
blades. Some set of blades are fixed at casing ( Fixed Blade) and some set of
blades are fixed on the rotor ( Moving Blade) .
Fixed blades convert potential energy of the steam into kinetic energy and direct
the flow to moving blades. Moving blades convert this kinetic energy in to force,
caused by pressure drop and result in rotation of turbine shaft. Steam is allowed to
enter into the turbine through control valve. This steam after passing through
different stages of blades is allowed to exhaust. The exhaust steam is condensed in
a condenser and condensate then reused in boiler.
1. Impulse Turbine
2. Reaction Turbine
1) IMPULSE TURBINE:
In Impulse turbine instead of set fixed blades a set of nozzles are fitted in the
casing. Pressure drop of steam takes place in these nozzles and velocity of steam
 increases. This high velocity jet of steam contains significant amount of kinetic
energy. This high velocity steam is passed through a set of moving blades, where
pressure of the steam remains constant and velocity decreases.
2) REACTION TURBINE:
In reaction turbine fixed blades are fixed in the casing. Shape of these blades is
such that the space between the blades has cross section same as shape of nozzle.
Moving blades are fixed to the rotor. Fixed blades guide the steam to moving
blades . Blade shape is so designed that steam glides over the blades. Steam while
gliding over moving blades produces reaction on the blade. This reaction force
produce the rotates the rotor.
1. Casing
2. Rotor
3. Moving Blade
4. Fixed Blade
5. Steam Sealing System
6. Bearing
 Joural Bearing
 Thrust Bearing
7. Gland
8. Exhaust Hood
9. Emergency Stop Valve
10. Governing Valve And Control Valve
11. Barring Devices.
12. Governing Systems

 CASING
Casing of turbine plays important role for the performance of a turbine. This is the
outer shell of turbine. Fixed blades and nozzles are attached to this. Casing
facilitates to accommodate moving parts and provides passage for steam. Normally
it is formed by casting. As the temperature of steam for operating turbine is high
so, normally Cr, Mo alloy steel casting is used for casing of a turbine. Metal to
metal joint sealing is done to ensure no leakage of steam.

 ROTOR
Rotor is the moving part of a turbine which extracts work from steam. This is the
heaviest part of the turbine. Normally total shaft is manufactured by forging. Rotor
consist of shaft moving blade and inter stage sealing labyrinth. Thrust collar is
provided to take care of axial thrust of rotor during various load conditions. Rotor
of the turbine is allowed to expand uniformly. Rotor of the turbine should not be
allowed to remain stand still when it is hot. Due to its self weight there is a chance
of sagging or deformation. Rotor
 Moving Blades
 Enthalpy of steam is converted into rotational energy as it passes through turbine
blade sets. In each stage of the turbine there are moving and fixed blade. As in
each step pressure of steam decreases, its volume increases. The blade has to
handle more volume of steam. Blade has to withstand high pressure and
temperature of steam. Good tensile and fatigue strength is required. Good
vibration damping property, low ductility, resistance to corrosion and erosion is
essential. Blade can be divided into three portions.
1. Tip
2. Profile
3. Root

 Fixed Blades
Fixed blades facilitate expansion of steam and guide it to flow over subsequent
moving blade row. Partition between pressure stages in a turbine casing are called
diaphragms. It holds vane shaped nozzles or fixed it

MAIN COMPONENTS OF STEAM TURBINE

1. JOURNAL BEARING
Journal bearing is a cylinder, which surrounds the shaft and is filled with some
form of fluid lubricant. It consists of a split outer shell of hard metal and soft metal
at the inner cylindrical part. In this bearing a shaft or journal rotates inside the
bearing over a layer of lubricating oil, separating the shaft and bearing through a
fluid film by dynamic principle. Inner surface of this bearing is coated with a soft
metal called as white metal or Babbitt. This is a tin or lead based alloy.
2. THRUST BEARING
Journal bearings are used to take radial load of the shaft. But it can’t take axial
load. Shaft is permitted to float to both axial direction. But the axial float is
restricted to certain limit. Excessive axial shift may damage rotating and fixed
parts. For this thrust bearing is provided.
EMERGENCY STOP VALVE
 This valve is normally hydraulically operated. The valve opens hydraulically
against a spring force. To close the valve hydraulically
 Fluid is drained and valve closes immediately due to force of spring. This valve is
normally fully open and fully close type.

Auxiliary System Of Steam Turbine

1. OIL SYSTEM
 Oil tank
 Oil Pump
 Oil Cooler
 Oil Filter
 Oil Centrifuge
 Oil Over Head Tank
 Accumulator
2. CONDENSATE SYSTEM
3. GLAND SEALING SYSTEM
4. STEAM EJECTOR AND VACCUM SYSTEM
5. CONDENSER
6. COOLING WATER SYSTEM

Turbine Cold Startup Sequence Method

Operation of steam turbine is a complex process. Before starting the rolling of a
turbine, auxiliary systems are to be properly put in service. Normally for start up of
a turbine some operations are followed in sequence.
 Charging of Steam Pipe Line
From Boiler, steam is carried to turbine main steam pipe line. In cold condition,
special care is to be taken to heat up the steam line and allow gradual thermal
expansion, before giving full load on the turbine.
Drain points are provided at the steam line to drain out condensate present in steam
pipe line, that is formed due to condensation of steam. First of all, these drains are
opened before charging steam on the pipe line. After condensate is drained out
boiler main steam stop by pass valve is opened slowly .
Some steam is allowed to flow through the pipe line and it starts gaining heat from
the steam and steam is condensed. At the beginning, condensate along with some
steam is allowed to come out through the drain. These drains are throttled slowly
and closed when no more condensate but only dry steam comes out from the drain.
Steam traps provided in the pipe line are kept in line once drains are closed. Then
Main Steam Stop Valve of the boiler is opened slowly so that the line temperature
is increased gradually. Ensure extraction is not restricted anywhere. Watch the
temperature of bypass reaching the normal level after which stop valve of boiler
can be opened fully.
To circulate cooling water in the Condenser, cooling water pumps are to be started.
Before starting pump
1. Ensure Sump level of the cooling tower basin is normal (>80%)
2. Keep suction valve of the pump in open condition & discharge in closed condition.
3. Ensure inlet & outlet cooling water valves of Condenser distributer valves of
cooling tower are in open condition .
4. Ensure vents provided at Condenser water box are in open condition to remove
trapped air.
5. Start the pump & open the discharge valve .
6. Observe whether cooling water is falling on the cooling tower or not.
7. Ensure that distribution of cooling water in all chambers is equal, otherwise adjust
the valves provided at the distribution header .
8. Observe whether all the cooling water pumps are sharing load or not.
9. Once Turbine is started and loaded, cooling tower fans can be started one by one
as per requirement.

Starting Of M.O.P ( Main Oil Pump )

1. Before starting of M.O.P check the healthy condition of Main Oil Tank ( M.O.T )
low level switch from H.M.I .
2. Before starting M.O.P, check oil level in M.O.P oil cup as well as oil level in
A.O.P & E.O.P oil cups.
3. Ensure again suction & discharge valves of M.O.P, A.O.P & E.O.P are in open
condition .
4. Start M.O.P .
5. Open J.O.P suction line coming from M.O.P & A.O.P discharge header , then
open its discharge valve .
6. Put A.O.P, J.O.P & E.O.P in auto selection mode.
Taking Oil Cooler into Line
1. When M.O.P starts, oil circulates to the circuit through oil cooler
2. To ensure oil is passing through the oil cooler or not, see through the view glass
after opening the air vent of oil cooler
3. After confirming oil is passing through the vent valve to M.O.T, close the vent
valve
4. Open the oil equalizing line of standby oil cooler and wait for some time to fill it
with oil, then close the equalizing valve
5. Maintain lub oil temperature in between 420C - 450C by adjusting the outlet cooling
water valve of online cooler

Taking Oil Cooler into Line

1. When M.O.P starts, oil circulates to the circuit through oil cooler
2. To ensure oil is passing through the oil cooler or not, see through the view glass
after opening the air vent of oil cooler
3. After confirming oil is passing through the vent valve to M.O.T, close the vent
valve
4. Open the oil equalizing line of standby oil cooler and wait for some time to fill it
with oil, then close the equalizing valve
5. Maintain lub oil temperature in between 420C - 450C by adjusting the outlet cooling
water valve of online cooler
Checking Of Lub Oil Header Pressure and Individual Bearing Pressure
1. Check the lub. oil header pressure from field and H.M.I . It must be more than
3Kg/cm2.
2. Check the individual bearing oil pressure
i. TG Front Journal Bearing – 1.2 Kg/cm2
ii. TG Thrust Bearing – 1.2 Kg/cm2
iii. TG Rear Journal Bearing – 1.2 Kg/cm2
iv. Gear Box – 2 Kg/cm2
v. Alternator Front Journal Bearing – 1 Kg/cm2
vi. Alternator Rear Journal Bearing – 1 Kg/cm2
3. Check individual bearing's return oil line view glass whether oil is passing through
it or not.
4. Check overhead tank oil return line view glass , ensure oil flow through return oil
line then close quick filling valve of overhead tank .
5. Check healthiness of overhead tank oil level indicator .
Once the above systems are in service, gland steam can be charged at gland. Care
is to be taken while charging gland steam in a cold Turbine. As the gland area of
Turbine is at normal temperature during cold condition, hot gland steam may
produce thermal shock at that area. To avoid this, steam is to be charged slowly
and condensate produced is to be drained through gland steam drain.
Following steps are to be followed for gland steam charging :
1. Charging of auxiliary PRDS (Pressure Reducing & De Superheating)
2. Charging of Gland Header
3. Charging Of Aux PRDS (Pressure Reducing And De-Superheating)
4. Open all drain valves
5. Open main manual isolation valve before & after PCV (Pressure Control Valve)
6. Open PCV by 5% from operation station
7. Open PCV by 10% as soon as condensate comes out from line
8. Close all drain valves
9. Put the PCV in Auto mode with desired pressure set point
10. Open manual isolation valve of TCV ( Temperature Control Valve)
11. Observe the temperature and then put TCV in auto mode with desired temperature
set point
Charging of Gland Header
1. Open all drain valves of gland steam header
2. Open gland steam header manual isolation valve
3. Open gland steam header PCV by 5% for line heating.
4. Open gland steam header PCV by 10% to increase gland steam header pressure
5. Close all drain valve in gland steam header
6. Put gland steam header PCV in auto mode with desired pressure set point.
Exhaust steam of turbine is condensed at condenser with the help of cooling water.
The condensate produced is evacuated from the condenser by the help of
Condensate Extraction Pump (CEP). This condensate passes through gland seal
condenser and ejector condenser to gain heat of the gland steam and ejector steam
respectively. So the temperature of condensate increases there before feeding to
deaerator for further use at boiler.
This condensate is further heated at L.P. Heater (if provided) by using LP Steam
extraction of turbine.
To put the condensate system in operation, following steps are required to be
followed:
1. Ensure condenser hot well level is adequate, otherwise fill the hot well with make
up DM Water
2. Open Suction and discharge valves of the pump. Ensure differential pressure of the
strainer is normal
3. Open condensate inlet and outlet valves of gland seal condenser, ejector condenser
and LP Heater
4. Put the re-circulation control valve in auto mode
5. Open pump gland cooling valve and start the pump
The condensate will pass through gland seal condenser & ejector condenser. It
should be re circulated to condenser again through recirculation control valve.
Once steam starts entering into turbine, discharge control valve can be put in auto
mode to maintain level of the hot well.
If the condensate extraction pump is to be started and if there is vacuum inside the
condenser, then vacuum balance line valve is to be opened to avoid any air trapped
inside the pump.

Before Main steam enters into the turbine, there should be vacuum in the
condenser. First of all, starting ejector is used to evacuate air from condenser. This
is a single stage non-condensing type ejector.

Take the following steps to build up vacuum by starting ejector:

1. Ensure availability of auxiliary steam at desired pressure & temperature
2. Ensure the vacuum breaker valve of the condenser is closed.
3. Ensure cooling water is circulating in the condenser and turbine gland is charged
fully
4. Open steam valve of the starting ejector
5. Observe steam is vented to atmosphere
6. Open ejector air valve
7. Observe vacuum inside condenser is increasing slowly.
8. Main ejector is to be taken into line once turbine is loaded and starting ejector is to
be stopped then.

To put main ejector into line, following steps to be followed :

Main ejector is to be taken into line once turbine is loaded. Starting ejector is to be
stopped then. To put main ejector in line, following steps to be followed.
1. Ensure Condensate Extraction Pump (CEP) is running .
2. Ensure cooling water inlet and outlet valves of the ejector condenser are opened.
3. Vent out air from water box of the ejector condenser by opening rotametre valve.
4. Open ejector condensate trap before and after isolation valve
5. Fill up the “U” tube by water locally
6. Open flash box stand pipe isolation valve
7. Close all drain valves of ejector
8. Open the main isolation valve of the ejector steam line
9. Slowly open the air line valve of the ejector and observe vacuum is increasing.
When vacuum is stable, then the slowly ejector can be stopped by closing air
valve first then the steam valve of ejector.
Once Auxiliary systems are in operation and full vacuum is obtained inside,
condenser turbine can be started. Turbine is required to be started in two different
conditions.
1. Cold Start-Up
2. Hot Start-Up
In cold startup turbine is started from cold condition. In this case, special care is
taken for proper heating of casing and rotor for proper thermal expansion. As both
rotor and casing are in cold condition it requires time for heat up. But in case of hot
start up both casing and rotor are in hot condition. So it can be started within a
short period.
Startup Curve
To allow proper thermal explanation of casing and rotor, the turbine
manufacturer’s advise is to be followed for start up procedure.
 steam should not enter immediately to turbine as it may damage the turbine due to
uneven expansion.
 Manufacturers suggest soaking time for low idle speed and high idle speed for
proper thermal expansion between rotor and casing means to hold the turbine at
the particular speed for a particular time, then allow the turbine speed to higher
range.
Soaking time is different for cold startup and hot startup. Manufacturer’s advice
should always be followed strictly for soaking and start up curve in cold startup
and hot start up conditions.

Turbine Rolling Preparation..contd

To start rolling of turbine, some steps are followed depending upon mode of
starting (Auto or Manual) and types of governing system (Hydraulic or Electro
Hydraulic)
Before rolling of turbine check, ensure the following points :
1. Lube oil level and control oil pressure are normal
2. Lube oil temperature is between 42 to 450C
3. Ensure gland sealing system is in operation and gland sealing pressure is normal
4. Ensure starting ejector is in the line and condenser pressure is -0.9 kg/cm2
5. Ensure cooling water is circulating in condenser and auxiliary cooling water in
lub. oil cooler
6. Ensure the casing drain, TG inlet steam line drain, TG warm
7. up vent and drain are in open condition
8. Ensure Accumulator is in line
9. Ensure over head oil tank is full and return oil flow is visible in the viewing glass
10. Ensure Condensate Extraction pump (CEP) is in operation
11. Ensure Exhaust hood spray solenoid valve is in operating condition.
12. Open the bypass of Turbine Steam stop valve (TSSV)
13. Ensure complete removal of condensate from TG inlet line and ensure the
temperature of TG inlet steam is rising after throttling drain valves. Open Turbine
Steam Stop Valve (TSSV)
14. Throttle the warm up vent as per requirement and observe steam temperature is
rising. Once steam temperature reaches at desired temperature, then prepare for TG
rolling.]

TG Rolling
1. Reset the governor from wood yard SOS
2. Reset from HMI
3. Engage trip lever and ensure build up of trip oil pressure at governing console
4. Open E.S.V. (Emergency Stop Valve) from H.M.I.
5. Check physically the opening of ESV (Emergency Stop Valve)
6. Give run command from HMI
7. Observe the rise in rpm gradually. RPM goes up and after reaching 1000 rpm
(Low Idle speed) automatically, it will hold for 15 minutes in hot start up and 30
minutes in cold startup (in case of auto rolling). Otherwise hold the speed as
advised by the manufacturer.
8. Ensure oil pressure is normal. Check vibration and any abnormal sound
9. First stop barring gear then stop jack oil pump (J.O.P)
10. Get the relay reset before 2000 rpm
11. After completion of the hold time at 1000 rpm, R.P.M. goes from low idle speed
to high idle speed 2500 rpm, if it is in auto mode, otherwise increase the speed
manually
12. After reaching 2500 rpm, it holds for 15 minutes in case of hot startup and 30
minutes in case of cold startup automatically. If it is not auto rolling, hold the
speed as per advice of manufacturer.
13. Close the TG casing drain, inlet steam line drain, warm up vent, warm up drain
14.Check the lube oil pressure at different bearings and check bearing temperature and
vibration and record it.
15. After completion of high idle speed (2500 rpm) soaking time. R.P.M. will rise up
to rated speed 7500 rpm
16.Maintain lube oil pressure and temperature at different bearings as per the
manufacturer’s advice
17. Maintain TG inlet pressure and temperature as per design
18. Give clearance to synchronize to generate power.

Turbine Protection Logic

TIME
NO DESCRIPTION SET POINT DILAY
(sec)
1 Lube Oil header press lo lo 1.2 Kg/cm2 2
Lube Oil Press after filter lo
2 4 Kg/cm2 2
lo
Oil Press lo - Trip device
3
outlet 4 Kg/cm2 2
Turbine exhaust steam press
4
hi hi -0.6 Kg/cm2 2
5 Cond. Level hi hi 95% 2
6 Cond. Level lo lo 15% 2
7 Turbine overspeed 8220 2
Trip command from
8 - 2
governor
9 Rotor axial displacement hi +/- 0.45 mm 2
 hi
10 Turbine front brg vib hi hi 200 micron 2
11 Turbine rear brg vib hi hi 200 micron 2
12 GB pinion DE brg vib hi hi 200 micron 2
GB pinion NDE brg vib hi
13 200 micron 2
hi
14 GB G shaft NDE vib hi hi 160 micron 2
15 GB G shaft DE vib hi hi 180 micron 2
Alternator front brg vib hi
16 160 micron 2
hi
Alternator Rear brg vib hi
17 160 micron 2
hi
18 86T relay operated 2
19 Inlet steam temp lo lo 400/440 deg C 6
20 Inlet steam temp hi hi 525 deg C 6
Turbine exhaust steam press
21 -0.6 Kg/cm2 0
hi hi
Turbine NWS thrust brg
22 115 deg C 8
temp hi hi
Turbine WS thrust brg temp
23 115 deg C 8
hi hi
24 Turbine front brg temp hi hi 115 deg C 8
25 Turbine rear brg temp hi hi 115 deg C 4
MOP side thrust pad temp
26 115 deg C 4
hi hi
HS Working Side temp hi
27 115 deg C 4
hi
HS Non Working Side temp
28 115 deg C 4
hi hi
29 Alt. side brg temp hi hi 115 deg C 4
30 MOP side brg temp hi hi 115 deg C 4
31 HS NWS brg temp hi hi 115 deg C 4
32 Drive end brg temp hi hi 80 deg C 4
33 NDE brg temp hi hi 80 deg C 0
34 Inlet steam press lo lo 38/39 Kg/cm2 3
35 Inlet steam press hihi 48/50 Kg/cm2 8

TIME
NO DESCRIPTION SET POINT DILAY
(sec)
1 Lube Oil Press lo 1 Kg/cm2
2 Control oil press lo 4.5 Kg/cm2 3
Trip Oil Press lo (PSLL-
3 2 Kg/cm2 10
305A)
4 Exhaust steam press hi -0.4 Kg/cm2
5 Hotwell level hi hi
6 Turb speed hi hi - WWG 7865
Trip command from
7
governor
Turb Axial shaft
8 +/- 0.7 mm
displacement hi hi
9 Turb shaft front vib hi hi 156 microns
10 Turb shaft rear vib hi hi 156 microns
11 Turb shaft front vib hi hi 156 microns
12 GB LS shaft rear vib hi hi 340 microns
13 GB HS shaft front vib hi hi 340 microns
14 GB LS shaft rear vib hi hi 340 microns
15 Gen L/O relay 86B operated
16 Inlet steam temp lo 400 deg C 2
17 Inlet steam temp hi 520 deg C 2
18 Bearing temp hi 115 deg C
19 Thrust Brg. Temp 1 115 deg C
20 Thrust Brg. Temp 2 115 deg C
21 Thrust Brg. Temp 3 115 deg C
22 Thrust Brg. Temp 4 115 deg C
23 Tur. Front brg 115 deg C
24 Tur rear brg 115 deg C
25 GB front (HSS) brg Temp 1 115 deg C
26 GB front (HSS) brg Temp 2 115 deg C
27 GB thrust brg temp 1 115 deg C
28 GB thrust brg temp 2 115 deg C
29 GB rear (LSS) brg temp 1 115 deg C
30 GB rear (LSS) brg temp 2 115 deg C
31 Gen front brg 115 deg C
32 Gen rear brg 115 deg C
33 Inlet steam press lo 40 Kg/cm2 2
34 Inlet steam press hi 50 Kg/cm2 6
35 Exhaust temp hi 120 deg C
36 Turb speed hi hi - TSI 7860
37 Emergency trip PB1
38 Emergency trip PB2
39 Turbine trip from HMI
 Turbine Auxiliary System
In Power Plant other than turbine, there are other associated systems. The systems
are required for running of a turbine. Most of the important components and
systems for auxiliary systems are :
1. Oil System
2. Condensate System
3. Gland sealing System
4. Ejector and Vacuum System
5. Cooling water System
6. Condenser
Oil System
Lubricating oil is supplied to the bearings and used for governing of turbine. Main
function of lubricating oil is to :
1. Lubricate the bearings.
2. Cooling of bearings.
3. Flush out metallic debris.
4. Control speed of the turbine. \
Principles of Lubrication
To maintain a film of lubricant between the surfaces in running condition any one
of the following principle of lubrication prevails.
1. Hydro dynamic lubrication
2. Hydrostatic lubrication
3. Elasto-hydrodynamic lubrication
If none of the above conditions exists the condition will be of :-
Boundary lubrication
Hydrodynamic Lubrication
Also called Full Flood Lubrication/Wedge film lubrication
Wedge film formation due to geometry & speed.
a. In hydrodynamic principle fluid viscosity is not sufficient to maintain a film
between the moving surfaces & higher pressure required to support the load until
the fluid film is established, the required pressure generated internally by dynamic
action.
b. The wedge film lifts the journal and allows complete separation
c. The formation of a thick fluid film that will separate two surfaces and support a
load as the two surfaces move with respect to each other.
By feeding oil from an external source under heavy pressure into the pocket
machined into the bottom of the bearings, the journal can be lifted and floated on
fluid films.
 When the journal reaches a speed sufficient to create hydrodynamic films the
external pressure can be turned off and the bearing will continue to operate in
hydrodynamic manner.
Components of Lubricating Oil System
Main components of lubricating oil system are :
1. Oil tank
2. Oil pumps
3. Oil filter
4. Oil centrifuge
5. Oil overhead tank
6. Accumulators
Oil tank
Total oil for the system is stored in the this tank. The tank has adequate capacity to
hold sufficient oil during running & stop condition. The tank base is made sloped
to one side, so that the sediment in oil can be collected in the lower area and can
be drained out by opening drain valve. The tank has level measurement facility to
give alarm for low oil level. Also a level glass is provided to find out tank level at
any instant. Suitable tapings are provided to facilitate oil suction for oil pumps,
draining of return oil from bearings and governing system, connection for oil
centrifuge, fill up of fresh oil etc.
One oil mist fan is provided on the tank to vent out any oil vapor and keep the tank
slightly below atmospheric pressure.
Oil Pump
To pump oil from the oil tank to various lubrication points and controlling
purpose, oil pumps are provided. Normally three pumps are provided. These
pumps are :
1. Main oil pump ( M.O.P )
2. Auxiliary oil pump ( A.O.P )
3. Emergency oil pump ( M.O.P )
Oil Coolers
Normally two oil coolers of 100% capacity are provided to cool down entire oil
supplied to turbine bearings,gearbox,and generator bearings for lubrication.
Governing oil is not cooled at oil cooler. This oil taken out before oil cooler. One
cooler is put on line and another one is kept as standby. Online changeover facility
is provided to take the standby cooler in to service, without interruption of oil
supply, while turbine is running.
Before changeover, it is to be ensured that the standby cooler is filled with oil and
air is vented out properly. Otherwise there will be air lock and oil supply to
bearings may interrupt.
Oil cooler is a shell and tube type heat exchanger. Cooling water flows inside the
tube bundle and oil flows at the shell side. Cooling water for oil cooler is obtained
from main cooling water system of power plant. Regulating valves are provided at
the inlet and outlet of the cooling water supply line.
To increase and decrease oil temperature, cooling water flow is decreased and
increased respectively through these regulating valves. Always the cooling water
outlet valve is regulated to vary flow of cooling water. At any case cooling water
inlet valve is not to be throttled as sufficient cooling water will not available inside
tub and tube may damage.
Drain point is provided at the cooler to drain out settled sediment at bottom of the
cooler.
Oil Filters
Oil coming out from cooler is passed through oil filter to remove any contaminated
particle or debris. Filter is normally basket type with removable filter cartridge.
Like cooler there are two filters of 100% capacity each with suitable online
changeover arrangement. The oil is filtered up to 20-25 micron level on these
filters before circulating in bearings.
Differential pressure across the filter is measured which indicates the choking
condition of filter cartridge. If differential pressure is high it indicates, filter is
choked and needs cleaning.
Before changeover of oil filter when turbine is in operation, it is to be ensured that
standby filter is completely filled and no air is trapped inside. Filter cartridge of
standby filter is always to be kept clean, so that at any moment this can be taken in
to line, if required.
Oil Centrifuge..contd.
Centrifuge is a machine which separates water and solid particles from oil. This is
achieved by centrifugal force of a high speed rotating bowl inside the separator.
Due to centrifugal force, heavier particles are displaced towards the outer
periphery of the bowl and the lighter oil is displaced towards center of the bowl,
where it is collected and sent back to main oil tank.
Steam Ejector And Vacuum System
Vacuum is maintained by continuously evacuating non condensing gases from the
condenser with the help of steam ejector. Pressure of non condensing gases
decrease condenser efficiency. For removing non condensing gas to create vacuum
in the condenser normally steam ejector is used. This is like a pump in which
venturi effect of a converging and diverging nozzle is used to convert pressure
energy of steam to velocity energy to create suction effect.
WORKING PRINCIPLE OF EJECTOR
High pressure motive steam enters to ejector chest through nozzle and then
expanded. Pressure energy of steam is converted into velocity. Increased velocity
 causes reduced pressure which socks vapour.Diffuser section then compress the
steam vapour mixture then exhausted to condenser.
Operating Procedure Of Ejector System
1. Circulate condensate through ejector condenser.
2. Open steam of ejector. So it will create vacuum in inter ejector condenser.
3. Open steam of ejector.
4. Open air valve of condenser.

Condenser
Condenser is an important Auxiliary equipment of any steam turbine.
Exhaust steam of turbine is exhausted in to condenser, where it is
condensed in vacuum. By maintaining vacuum in condenser, maximum
energy can be extracted from steam and turbine efficiency increases.
Condensate obtained is utilized again at boiler for steam formation.

There are different types of condenser. Some of the important types

of condensers are listed below.
1. Jet type condenser
2. Air condenser
3. Surface condenser
Surface Condenser
This type of condenser is widely used at power plants. Cooling water is
not mixed with condensate in this case. Condensate obtained is pure and
can be used in boiler. This is a shell type and tube type heat exchanger.
Shell of the condenser is closed. Tubes are arranged inside the shell in
which cooling water flows. Condenser neck is connected to the exhaust
hood of turbine. An expansion joint is provided in-between to facilitate
thermal expansion.
Steam from turbine flows at the shell side of condenser and cooling
water flows inside the tube. Main components of a surface condenser are
:
- Shell - Hot well
- Air outlet - Tube
- Rapture disk - Water box

Overhead Tank
Oil accumulator is provided on the governing or control oil line of the
turbine. This accumulator maintains oil pressure in the line during
momentary fluctuation of oil pressure during oil pump change over or
sudden operation of servomotor of governing valve.
In the accumulator an inert gas filled bladder is provided. Gas pressure
inside the bladder is maintained slightly below the normal oil pressure.
During normal operation, oil pressure of the line compress the bladder
and oil is occupied in the oil space of the accumulator. When, pressure at
the line drops, the bladder is expanded, due to the inside gas pressure. So
it pushes out oil of space to the line and takes care momentary oil
pressure fluctuation.
Oil Accumulator
Oil accumulator is provided on the governing or control oil line of the
turbine. This accumulator maintains oil pressure in the line during
momentary fluctuation of oil pressure during oil pump change over or
sudden operation of servomotor of governing valve.
In the accumulator an inert gas filled bladder is provided. Gas pressure
inside the bladder is maintained slightly below the normal oil pressure.
During normal operation, oil pressure of the line compress the bladder
and oil is occupied in the oil space of the accumulator. When, pressure at
the line drops, the bladder is expanded, due to the inside gas pressure. So
it pushes out oil of space to the line and takes care momentary oil
pressure fluctuation.
Emergency Situation In Steam Turbine
Steam Turbine is a critical rotating equipment. High temperature and
pressure steam is used to rotate the turbine at high speed. Mass of the
rotating part is high. There is always chance of severe misshapen
leading to fatal accident and damage of high cost equipment. Incase of
any system goes wrong generation of power may be interrupted for a
longer period leading to heavy loss to the plant. So the power plant
engineer should be trained enough to face any emergency situation, at
any time and properly handled emergency situations.
1) Overspeed
Due to failure of governing system the turbine speed may become
dangerously high. Rotor can rotate momentarily without damage up to
110% of rated speed. At higher speed rotor stress increases. Due to high
centrifugal forces the blades which are fixed to the rotor may come out.
Failure of blade root can cause severe accident and damage to
turbine. To avoid dangerous over speed turbine is provided with
mechanical and electrical over speed trip arrangements. Tripping limits
are set in such a way that turbine speed does not exceed 110% of rated
speed. These overspeed tripping limits are to be checked regularly.
Mechanical overspeed device is to be set within set limit and checked at
suitable intervals. At any circumstance overspeed tripping limit is not to
be bypassed. If overspeed tripping does not work, immediately stop the
turbine by applying emergency trip push button. For the 18.5 MW
turbine at Tata Sponge, overspeed tripping limit is 7865 rpm.
2 ) Failure Of Lubrication Oil System :
Lubrication Oil is used to lubricate and cool down bearing metal.
Sometimes the lubrication oil supply may be interrupted due to failure of
pumps, leakage in oil line or choking of oil filter. This condition may
damage bearings and gear box. If such an incident happens for any
reason, the turbine is required to be stopped as soon as possible. Low
lube oil header pressure tripping is incorporated with turbine to trip the
turbine immediately. If lube oil header pressure becomes 1kg/cm2, oil
supply is to be restored as early as possible. After resuming oil supply, if
possible, turbine is to be rotated manually to find out any damage
(inspect bearings).
3. High Vibration
Rotor of the turbine rotates at high speed. Any deformation or unbalance
of the rotor produces high vibration. Sometimes deposits on blades and
damage of any rotating part may create heavy vibration. Damage of
journal bearing may also produce vibration. The moving and rotating
parts of the turbine are closed spaced. Due to disturbance in rotor shaft
or differential expansion, there is chance of rubbing. Rubbing creates
high vibration and abnormal sound, so at any case high vibration of
turbine is not be overlooked. Incase of high vibration the turbine should
be stopped immediately and turbine internals to be inspected to avoid
further damage. High vibration protection in logic is incorporated with
turbine to trip the turbine when turbine front and rear journal bearing
vibration goes to 156 Micron and gear box front and rear journal bearing
goes to 340 microns.
4) High Bearing Temperature
High bearing temperature occurs due to inadequate oil flow in the
bearing or metal to metal contact in between bearing and rotor. High
temperature damages Babbitt material of the bearing. In case of high
temperature of the bearing, a turbine is required to be stopped. Oil
supply to bearing is to be checked and if required bearing is to be
opened for inspection. High bearing temperature protection logic is
provided to turbine. For different bearing 1150C is a tripping limit.
5) Failure Of Barring Device
When turbine is stopped in hot condition, it is to be put on barring. In
some situation just after stopping turbine barring gear may be found not
working. It is not recommended to keep the rotor in standstill condition.
By any means rotor is to be rotated normally by hand barring
arrangements provided to change the rotor position by 180◦C
continuously.
6) High Condenser Hot Well Level
Due to problem in condensate extraction pumps, sometimes the
condensate cannot be evacuated from hot well. So hot well level
becomes high. In this situation there is possibility that water level in
condenser increases and enters into turbine through exhaust hood.
Condenser vacuum reduces drastically in this condition. If at any case
water enters into a running turbine it creates a serious situation and
damages the turbine. Load is to be reduced on turbine in this situation. If
situation is not controllable, turbine is to be stopped.
9) High Steam Parameter
Like low steam temperature and pressure, high steam temperature and
pressure is not desirable for turbine operation. High steam temperature
may damage turbine as the metrology of the turbine is designed for a
particular temperature.
10) Low Condenser Vacuum
 Due to vacuum in condenser the steam from turbine is easily exhausted
into condenser. If vacuum inside the condenser drops, it restricts exhaust
of steam of turbine. This creates back pressure inside turbine. Vacuum
may drop due to failure in cooling water system, failure of ejectors, or
leaking condenser air line. Standby ejector or starting ejector is to be
immediately taken into line. Leaking air line is to be arrested promptly
or cooling water supply to be increased. If vacuum is not improved, the
turbine is to be stopped immediately. Low vacuum protection logic is
provided to trip the turbine when condenser vacuum drops to -0.4
kg/cm2.
11) Failure Of Cooling Water Systems
Due to failure of cooling water pumps or choking in cooling water
circuit, cooling water supply may be reduced or interrupted. In this case
turbine exhaust steam cannot be condensed. This will increase the
pressure of the condenser and drop the vacuum. Rapture disks of the
condenser may rapture, heavy back pressure will be created in turbine.
In this case load is to be reduced first and care is to be taken to
normalize cooling water supply. If situation does not improve then
turbine is to stopped.
Black Out maneuver Method for WHRB Power Plant
Both the TG fails and Grid not available : (BLACK OUT
CONDITION)
1. In the above cases ( Total blackout condition ) ensure availability of DG
emergency power to all the emergency drives of both the CPP within 10
seconds (i.e. Boiler main steam stop valve, Auxiliary oil pump, Barring
gear, Emergency oil pump, Boiler feed pump discharge valve, CPP area
lighting & Jack oil pump & TG steam stop valve )
2. Ensure from field pressure gauge that lubrication continues in both the
TG by gravity method (oil flows from over head tank to all the TG
bearings and returns to main oil tank by drain header )
3. Ensure from HMI & field that Emergency oil pump is running through
DC power & oil supply continues to all the bearings.
4. Start the Jack oil pump of TG.
5. If emergency power is not available within 10 seconds, then
immediately contact the Electrical Shift In Charge about the matter and
try to resume emergency power as quickly as possible, with the help of
Shift In Charge CPP & Shift In Charge Electrical.
6. After resuming of emergency power, close main steam stop valve of all
the three Boilers and maintain the drum pressure through start-up vent.
7. In blackout condition, ensure that Kiln stack cap will remain 100% open
till the availability of boiler feed pump. If stack cap is closed or partially
closed, then contact Kiln control rooms to open the same through Shift
In Charge CPP.
8. In blackout condition, all the boilers will be in hot box-up condition.

9. Ensure emergency stop valve of TG is in closed condition

10. Close the TG inlet motorised valve .
11. Close all the boilers feed pump discharge motorised valves.
12. After resuming of emergency power, auxiliary oil pump will start in
auto mode. Ensure the same from field & HMI, then stop the
emergency oil pump from panel and put it in auto mode.
13. After resuming of 1000kva DG, power start one feed pump of CPP-1
and supply water to all three boilers and maintain the drum level upto
40% .

Diposting oleh Mujiyono Ath di 17.44

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11 komentar:

1.

Cooper Freer10 Maret 2014 03.01

such a great resource that you are providing and you give it away for free. I love
seeing websites that understand the value of providing a quality resource for free. It's
the old what goes around comes around routine.
Balas
Balasan

1.
Focus Engineerrs7 Juli 2016 04.48

Thanks for sharing latest techniques.

Metering Pump Manufacturer in India

Dosing Pump Manufacturer in India | Chemical Dosing System | water
treatment equipments
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2.

Zhu Y27 Juli 2015 02.03

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3.

Focus Engineerrs15 April 2016 03.48

Thank you so much for taking the time to share such a nice information.
reliable chemical dosing system
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4.

Jagannath jena..... Tata steel11 September 2016 08.33

why drum level low in fuel cut off???/

Balas

5.

Herry Anderson16 Desember 2016 20.56

hii, Mujiyono Ath you have shared a informational article with us. You explained
definition of boilers. its quality, system, accessories, startups etc. excellently. Please
keep sharing like this.

Building automation
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6.

Jagan Jai24 Februari 2017 02.27

This is my personal experience in following Comments and this review will be helpful
after buying Boom Lift rental machine. I am using Boom Lift machine for my Company
inner outer room work last two months and I bought Boom Lift machine from
TheSendhamarai Engineering.
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7.

Arshad Khan26 Februari 2017 05.21

sir why we keep turbine tripping limit on 3rd extraction low pressure and high
pressure?
Balas

8.

Pradeep Singh9 Juni 2017 05.10

 U look sathiyam cinemas Pantry the Modular Kitchen In Chennai is more preferred for
looking and sound effects
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9.

Unknown1 Agustus 2017 19.30

Few years I spent as a steam turbine operator summarized here.Thanks for this.
Balas

10.

Hitek Engineers3 Desember 2017 22.39

Re-refining is a profitable opportunity since lube oil can be re-refined as many times
as you like, therefore becoming a very
attractive business opportunity while safeguarding the environment.