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135MW CFBC Operation Manual 1 (20080306)
135MW CFBC Operation Manual 1 (20080306)
26-W9-YX-01
TURBINE OPERATION RULES (A)
Operation Instruction
SEPCOIII
Approved by:
No.
Time of Approval
CONTENTS
PART 1 Overview Chapter 1 Specification of Main Equipment 5 Chapter 2 Specification of Auxiliary Equipment 14 PART 2 Unit Start-up Chapter 1 Cold Start of the Unit .26 Chapter 2 Warm & Hot Start of the Unit ...38 PART 3 Unit Operation Chapter 1 Operating Parameters of Steam Turbine 42 Chapter 2 Operating Modes of the Unit ....47 Chapter 3 Regular Works and Requirements ..49 PART 4 Unit Shutdown PART 5 Treatment of Unit Accidents Chapter 1 Treating Rules of Accidents ..60 Chapter 2 Condition of Steam Turbine Tripping ... 61 Chapter 3 Condition of Unit Fault Shutdown 61 Chapter 4 Condition of Emergency Shutdown..62 Chapter 5 Procedure of Emergency Shutdown....63 Chapter 6 Procedure of Unit Fault Shutdown ..63 Chapter 7 Decreasing of Vacuum ..64 Chapter 8 Water Hammer of Steam Turbine 65 Chapter 9 Increasing of Axial Displacement ....66 Chapter 10 Steam Turbine Oil System Catching Fire ....67 Chapter 11 Abnormity of Steam Conditions .68 Chapter 12 DEH Failure .71 Chapter 13 Abnormity of Steam Turbine Lubricating Oil System 71 Chapter 14 Abnormal Vibration of the Unit .75
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Chapter 15 Generator parallels off, while turbine does not trip ...77 Chapter 16 Generator parallels off, and turbine trips 77 Chapter 17 Turbine trips, while the generator does not parallel off 78 Chapter 18 Failure of Thermodynamic Power Supply 78 Chapter 19 High Bearing Temperature of Turbine-generator Unit 79 Chapter 20 Burning out of Turbine-generator Bearing Bush .79 Chapter 21 Steam Turbine Shaft Bending 80 Chapter 22 Steam turbine Overspeed ..82 Chapter 23 Feed water pump set outlet check valve is untight and rotates reversely.83 Chapter 24 Turbine-generator unit operates at abnormal frequency 83 Chapter 25 Boiler Fire Extinction 84 Chapter 26 Treatment of Accidents & Abnormity of the Motor ..85 PART 6 Auxiliary Equipment & Common Service System Chapter 1 General Operating Rules of Auxiliary Equipment.. 89 Chapter 2 Industrial Water System.92 Chapter 3 Oil Purification System of Steam Turbine94 Chapter 4 Lubricating Oil System of Steam Turbine 98 Chapter 5 Circulating Water System ...102 Chapter 6 Shaft Sealing and Vacuum System of Steam Turbine ...108 Chapter 7 Condensate Water System ....111 Chapter 8 Feed Water Deaerating System ...117 Chapter 9 DEH System ....131 Chapter 10 Bypass System ..136 Chapter 11 Turbine Proper Water Drain System ..138 Chapter 12 Quick Cooling System of Steam Turbine ..139 Chapter 13Air Cooling System ..143
Appendix 1: Comparison Table of the Temperature & Pressure of Saturated Water & Steam .......147
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PART 1: Overview
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Rated pressure of the steam before initial steam stop valve: Rated temperature of the steam before initial steam stop valve: Rated pressure of the steam before reheat steam valve: Rated cooling water temperature: 24 Rated backpressure:5.4kpa (a) Rated speed: 3,000 rpm Feed water temperature under rated condition: 244.4
Max back pressure at which the unit is permitted to operate: 18.6kpa (a) Regeneration stages: 2 HP heaters, 4 LP heaters & 1 deaerator Length of the last blade of LP cylinder: 660mm Critical speed of shafting: 1850r/min for HP & MP rotor -5-
2116r/min for LP rotor 1290r/min for generator rotor Stages of flow path: total 39 stages: HP cylinder: 1 governing stage + 8 pressure stages MP cylinder: 10pressure stages LP cylinder: 26 pressure stages
1.3.6 The peak to peak vibration amplitude measured near the bearing journal of turbine shall be 0.075mm during normal operation, which shall not exceed 0.25mm as critical speed passing in speed rise; 1.3.7 The power load of the unit is permitted to reach 135MW when the HP heaters are cleared; 1.3.8 The unit is permitted to run continuously with low load when the exhaust pressure of turbine increases to 0.0146Mpa (a). The alarm back pressure of turbine is 16.9kPa (a) and trip back pressure is 20.3kPa (a). 1.3.9 The unit is permitted to run for long when the exhaust temperature of steam turbine is less than 79. The max temperature at which exhaust is permitted to operate is 120. 1.3.10 Permitted load variation rate of unit is: 1.3.10.1 From 100% to 50% MCR 5%/min 1.3.10.2 From 50% to 20% MCR and from 20% to 50% MCR 3%/min
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2%/min
1.3.11 The pressure after the governing stage must not exceed 10.34Mpa (a) at different working
Lower Half
MainStopValve(L) MainStopV ve(R) al
Governing Valve End The turbine unit is 14 meters long in total and arranged on the 9m operation floor, with a combination of HP initial steam stop valve and HP governing valve mounted on both sides in the
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front which is supported on the holder of main stop valve, 4 flexible HP steam inlet pipes connected with the 4 governing valves and the HP cylinders upper and lower steam inlets respectively, and governing valve controlled by oil servo-motor. The high pressure nozzle section consists of four groups of nozzle segments, The unit can reach rated power by 3 valves opening fully and the fourth group provides guarantee for the availability of rated power in summer and at low parameters. HP & MP cylinder is double-floor cylinder with 1 governing stage and 8 pressure stages in the HP part. There is a section of steam extraction led to HP heater #1 after stage 7, and steam exhausted by HP flows through lower cylinders exhaust port and HP exhaust check valve to the reheater, a portion of which is led to HP heater #2 as regenerative extraction. The reheated steam flows to MP part via MP combined valve through two rigid steam inlet pipes. There are 10 pressure stages in MP part with a third stage extraction to deaerator after stage6 and a fourth extraction led to LP heater #4 after stage 8. For MP exhaust part, the upper half is designed to exhaust steam upwards that flows into LP cylinder through 2 flexible cross over pipes with compensation capacity; the lower half has a fifth extraction led to LP heater #5. The LP cylinder is double flow and has 26 stages, there are a 6th and 7th extraction openings set in LP cylinder that lead extraction to LP heater #6 and LP heater #7 (built-in type) inside the condenser respectively and led out after the stage 3 and stage 6 respectively. This steam turbine has three bearing pedestals in all, in which 3 turbine journal bearings, 1 generator front bearing and 1 thrust bearing are mounted. All bearing pedestals are floor mounted. Besides journal bearing in bearing pedestal #1, there are also main governing set, including main oil pump and emergency governor etc. Two MP combined valves are arranged on the left and right side in the middle of the unit respectively, which may move freely on its bearing surface with expansion of the turbine, the MP governing valve only operates for regulation at below 30% load and opens fully not to take part in regulation in the case where the load is more than 30%. The rotary equipment of steam turbine rotor is mounted on the back bearing pedestal and driven by motor after speed reduction, rotor turning gear speed rotation is 7~8r/min, each bearing is equipped with HP jacking oil system in order to lower the start-up power of rotary equipment and protect all bearings from damage. LP cylinder is equipped with atomizing nozzle type low-load spray regulator inside that may operate to spray automatically in the case where the LP cylinder exhaust temperature is higher than 80 so as to ensure normal operation of the unit. 1.4.1.2 Sliding key system The sliding key system is the supporting and locating system of stator part, the steam turbine proper supporting and locating mode is: front frame, middle frame and rear frame and exhaust hood frame are fastened on the foundation by means of foundation bolts and back grouting and
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are equipped with front bearing pedestal, middle bearing pedestal, rear bearing pedestal and LP outer cylinder thereon respectively. Longitudinal keys are arranged on the front frame along the center axis, the front bearing pedestal can move on its frame along the axis. HP & MP outer cylinder upper claws are supported on the front and middle bearing pedestal, the lower claws transverse keys connect with the front and middle bearing pedestal, besides longitudinal keys, there are also transverse keys on some position of the middle frame, and the cross point of longitudinal and transverse key is the dead point of HP & MP stator part, the front bearing pedestal HP and MP cylinder and middle bearing pedestal take this as the dead point to perform axial expansion and contraction. There is a vertical key mounted on both upside and downside of both ends of HP & MP outer cylinder with key way plate fixed on the neighboring bearing pedestal for the purpose of smooth expansion and contraction and keeping cylinder center aligning. 1.4.1.3 Thrust bearing The unit adopts the Michell thrust bearing. The thrust collar integrates with steam turbine, and both its front and back sides are mounted with positive and negative thrust bearing pads with 12 pieces laid on the whole circle of each. And each pad is equipped with a RTD temperature measuring device for measuring its metal temperature. The back of thrust bearing pad rests on erection loop, and erection loop leans against the spheric seating, which gives self alignment effect. Positive or negative thrust of steam turbine bearing operates on the operating pad or nonoperating pad separately, and the bearing displacement on thrust pad shall not be more than 0.4mm. The lubricating oil enters between thrust collar and thrust pad via oil inlets on both sides for lubricating, and then flows out from thrust collar outer side, the return oil escapes from the top, and there are two return oil adjusting screws mounted on return oil outlet, which can adjust the oil return quantity to control return oil temperature. 1.4.1.4 Journal bearing This unit adopts elliptic type journal bearing, which consists of a bearing bush cast with Babbitt metal, bearing shell and spheric seating. The bearing is made into upper and lower, two halves that are fixed and positioned by screws and taper pins, the bearing case matches with spheric seating on spherical surface, which gives self alignment effect, and there are four set pieces on the spheric seating for the use of adjustment. Lubricating oil flows into bearing through a hole at lower part of bearing and then flows into bearing pedestal via the bearing end. There is a platinum resistor mounted on the bearing bush that can measure the bearing metal temperature, there is oil from return chute in the bore of locating pin in upper bearing half, which temperature can be measured as that of bearing return oil, and there is HP jacking oil hold at the bottom of bearing bush. 1.4.1.5 Shafting The steam turbine proper shafting consists of HP & MP rotor and LP rotor. Connection between HP & MP rotor and LP rotor relies on the rigid coupling integrated with main shaft forging, and the shims in between two halves of coupling are connected with screws. As configured for the
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purpose of meeting the requirement of rotor center aligning in assembly, in such a case, the center on both ends of coupling must keep correct and concordant in assembly so as to allow the rotor center line to become smooth and continuous curve in operation. The rigid coupling is very sensitive to the bearing load distribution because of high rigidity, thus its requirements for the assembly technology and shafting aligning are much higher, but it has such advantages as high strength, short rotor length, easy processing and reliable operation. Semiflexible coupling is used in between LP rotor and generator rotor, such coupling has a corrugated pipe joint on the end coupling connecting with generator rotor, which has certain flexibility, and connects with an minor axis on the other end coupling, and the minor axis covers the generator rotor to transmit the torque by means of interference and key, such semiflexible coupling may allow the unit safety operation not to be affected by slight change in the steam turbine and generator center in installation and operation. 1.4.2 Technical specifications of governing system 1.4.2.1 The governing system is able to keep idle running of steam turbine at rated steam inlet condition, rated vacuum and full open main stop valve, with speed oscillation value 6r/min. 1.4.2.2 The governing system is able to guarantee stable parallel operation of steam turbine and other units. 1.4.2.3 The governing system is able to control and guarantee the need of steam turbine incorporating into network and adaptation to changes in speed and load. 1.4.2.4 For this unit operating at rated steam conditions and rated speed, the governing system is able to control the turbine speed not to result in the trip of emergency governor as the unit rejects load. 1.4.3 Technical specifications of steam turbine control system 1.4.3.1 This unit has three sets of governors: Emergency governor handle to be tripped by operator manually for emergency; Mechanical emergency governor to trip at overspeed; Four governor solenoid valves controlled by ETS, which receive the governing signal of important parameters of steam turbine. 1.4.3.2 System function: 1.4.3.2.1 Governing function: The governor valve will trip to shut down the turbine for emergency trip as the following parameter exceeds the specified value. a. Speed rises to 110% of rated speed; b. Axial displacement exceeds 1.2mm; c. HP & MP cylinder differential expansion exceeds +8.0 or -3.0mm; d. LP cylinder differential expansion reaches +7.5mm; e. Lubricating oil pressure is lower than 0.06Mpa; f. Back pressure of the condenser is lower than 20.3kPa;
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g. Peak to peak vibration amplitude of the rotor is 0.254mm; h. Metal temperature of # bearing 1-3 reaches 112, the metal temperature of bearing #4 and #5 reaches 80 or the temperature of thrust bearing reaches 107; i. EH oil pressure decreases to 9.31Mpa; j. Power failure to DEH system; k. Exhaust temperature of LP cylinder reaches 121; l. The oil level of the main oil tank is lower than 1245mm; m. MFT of the boiler; n. Main protection of the generator operates. 1.4.3.2.2 Oil injection test function 1.4.3.2.3 Emergency governor test function 1.4.3.2.4 Steam turbine reset function
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Name No.5 extraction steam condition No.5 extraction flow No.6 extraction steam condition No.6 extraction flow No.7 extraction steam condition No.7 extraction flow
Cutting off all HP Heaters 0.264/247.5 23.568 0.0705 16.775 0.015 3.621
Note: Turbine Heat Acceptance condition (THA): means the condition in which the unit can operate safely and continuously with generators net output power of 135MW when the turbine is under rated initial steam and reheat steam conditions, back pressure is 5.4kP, make-up water percentage is 0%, and regenerative system is put into operation all normally and generators efficiency is 98.4, which heat rate is not more than the acceptance value of 8,402.9kJ/kWh. Turbine maximum continue rate (TMCR): means the condition in which the unit can operate safely and output maximum power when the turbine is under rated initial steam and reheat steam conditions, back pressure is 5.4kP, make-up water percentage is 3%, and regenerative system is put into operation all normally and generators efficiency is 98.4. Valve Wide Open condition (VWO): means the condition in which the turbines steam inlet flow is 440t/h when the turbines governing valves are wide open and the other conditions is the same with 2.1.1, which output value is 145.822MW. This condition corresponds to the Boiler Maximum Continue Rate (BMCR).
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Design pressure of shell side Design temperature of tube side Working pressure of tube side Working pressure of shell side Working temperature of tube side Working temperature of shell side Manufacturer
55
90.63
129.9
150.6
2.1.3 Specification of deaerator and deaerated water tank 2.1.3.1 Specification of deaerator Class Model Design pressure Design temperature Max working pressure Rated output Inlet water temperature Manufacturer Class I GC-514 0.88Mpa (g) 380 0.78Mpa (a) 514t/h 147 Test pressure Pressure drop of nozzle Opening pressure of safety valve Operating mode Corrosion allowance (tank /deaerator) Oxygen content of outlet water Outlet water temperature 1.374MPa 0.0588MPa 0.85MPa Sliding pressure operation 1.6/2.5mm 7PPb 169.3
2.1.3.2 Specification of dearated water tank Class Type Design pressure Design temperature Max working pressure Manufacturer 2.2 Specification of feed-water pump 2.2.1 Feed-water pump and booster pump Equipment parameter Model Number of stages Inlet water flow Outlet water flow stage m /h m /h - 14 3 3
Opening pressure of safety valve Test pressure Effective volume Total volume Corrosion allowance (tank /deaerator)
Unit
Lift Inlet water pressure Outlet water pressure Shaft power Rotating speed Working temperature Medium density Intermediate bleed-off pressure (stage 2) Intermediate bleed-off flow Guarantee efficiency Manufacturer 2.2.2 Specification of feed-water pump motor 2.2.2.1 Specification of feed-water pump motor Item Model Rated power Rated voltage Rated current Rated speed Rated frequency Connection type of stator Insulation class Power factor COS Cooling mode Temperature rise Manufacturer Class kW V A r/min Hz Unit
MPa m3/h %
80.84
Specification YKOS3700-2 3,700 6,600 370 2,982 50 Y F 0.9 Air-cooled 80 Shanghai Motor Co., Ltd.
2.2.2.2 Specification of air cooler of feed-water pump motor Item Capacity of cooler Operating water flow Circuit of cooling water Air pressure drop Working water pressure Max permitted water pressure 2.2.3 Specification of hydraulic coupling Unit kW t/h Group kPa MPa MPa Specification 160 60 2 0.32 0.2-0.4 0.5
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2.2.3.1 Parameters of hydraulic coupling Item Model Motor speed Output speed Max output power Slip Scope of speed governing Efficiency Capacity of oil tank Manufacturer r/min r/min kW % % % m3 Unit Specification R17K.2-E 2,986 4,783 3,000 3 25-100 94.7 0.85 Germany VOITH
2.2.3.2 Auxiliary equipment of coupling Item Model Oil flow Pressure Cooling surface area Cooling water flow 2.3 Circulating water system 2.3.1 Specification of circulating water pump Specification of circulating water pump (double pumps in parallel operation) Model Shaft power Lift Rotating speed Flow Efficiency Cooling water of bearing Mini submergence Manufactured by 44LBXA-23 770.3 kW 23m 595 r/min 10,728t/h 87.2% 90m /h, 0.3MPa 3m Changsha Water Pump Works Unit MPa MPa Manufactured by Shangyang Electric Machine Co., Ltd. Specification ASCS300 0.3 0.6
3
Unit
m /h MPa m2 m /h
3
7.5 0.25
Specification of circulating water pump motor Model Voltage Current Power Power factor Rotating speed YLKK900-10 6,600V 98A 900kW 0.86 595r/min
2.3.2 Automatic back washing strainer Item Model Working pressure Max pressure
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Inlet & outlet diameter Manufactured by 2.3.3 Circulating water booster pump
mm
300
Shanghai Power Equipment Research Institute Specification Model Voltage Current A Power Power factor Rotating speed Manufactured by 1,480 r/min Xian Motor Works 55 kW of circulating water
Specification of circulating water booster pump Model Shaft power Lift Rotating speed Flow Efficiency Manufactured by 10Sh-9A 40 kW 30 m 1,480r/min 420 t/h 80% Shijiazhuang Kingda Pump Co, Ltd.
2.3.4 Indoor circulating sump pit blowdown pump Specification of indoor circulating sump pit blowdown pump Model Shaft power Lift Rotating speed Flow Efficiency Manufactured by 40PV-SP 3.1kW 15m 1,800 rpm 25t/h 34% Shijiazhuang Kingda Pump Co., Ltd. Specification of indoor circulating sump pit blowdown pump motor Model Voltage Current A Power Power factor Rotating speed Manufactured by 2900 r/min Xian Motor Works 4 kW Y112M-2 415V
2.3.5 Trash remover of circulating water pump house Specification of trash remover of circulating water pump house Model Water head in operation start Max design water head Mesh size Travelling speed of scrubbing brush Total Number of scrubbing brush Rotating speed of round brush Manufactured by 2.4 Shaft seal system 2.4.1 Shaft seal HP & MP seal ring are high & low-tooth labyrinth structure and LP seal ring is flat tooth structure; HP & MP cylinder diaphragm seal is embedded seal, the sealing strip is riveted into the diaphragm with fillet; the seal ring of LP diaphragm seal is mounted in the septalium and fixed - 17 ZSB-3500 300mm 600mm 3.553 mm 6~7 m/min 4 20.33 r/min Jiangsu Yihaun Group Co., Ltd. Voltage Current A Power Power factor Rotating speed Manufactured by 87 rpm 5.5 kW 415V Specification of trash remover motor of circulating water pump house Model BWD5-87-5.5
with spring leaf. 2.4.2 Shaft seal heater Item Model Heating surface area Design flow of main condensate flow Design pressure Working pressure Test pressure Design temperature Working temperature Net weight 2.4.3 Shaft seal fan: Specification of shaft seal fan Model Full pressure Speed Flow Manufactured by AZY-09.32-020.0-01 9.32kPa 2,900r/min 20m3/min Zhejiang Yuyao Blower Plant Specification of the motor Model Power Speed Voltage Manufactured by 132S 7.5kW 2,900r/min 415V Wannan Electric Machine Co., Ltd. m
2
Unit
Specification JQ-50-1 50 Total flow, 300 minimum Tube side 3.1, shell side 0.1 Tube side 2.00 Tube side 3.9, shell side 0.125 Tube side 100, shell side 100 Tube side 60, shell side 100 2.23
2.5 Condensate and steam extraction system 2.5.1 Specification of condenser Model Type Total active cooling surface area Design pressure of tube side Design pressure of shell side Test pressure of tube side Cooling water flow Manufactured by N-9000 Single shell, bisection, double passes and surface type 9,000 m2 0.25MPa 0.1MPa/Vac 0.375MPa 20,200m3/h Shanghai Power Equipment Co., Ltd. - 18 Cooling water temperature Number of pass Velocity in cooling water pipe Outer diameter of cooling water pipe Water resistance of condenser Total number of copper tube Net weight 32.5 2 2m/s 25mm <45kPa 12,760 211t
2.5.2 Specification of condensate pump Specification of condensate pump Model Flow Lift Npsh Shaft power Rotating speed Manufactured by 2.5.3 Vacuum pump Specification of vacuum pump Model: 2BW4 253-0EK4 Min. suction pressure (min. vacuum degree): 3.3kpa (a) Pumping capacity 44kg/h (as inlet pressure of 8.83kpa and cooling water temperature of 32.5) Rotating speed:740 r/min Shaft power: 54kw max; 42kw at 8.83kp; 46.5kw at 11.8kpa Make-up water flow of separator: 0.5m /h, temperature<50 Manufactured by: Foshang Pump Works 2.5.4 LP heater drain water pump Specification of LP heater drain water pump Model:150NW55-190000 Flow: 55 m3/h Lift:190m Rotating speed: 2,970 r/min NPSH: 1.8m Efficiency: 61 Specification of the motor Model: Y280S-2 Power: 75 kW Voltage: 415 V Current: A Rotating speed: 2,970 r/min Insulation class: F
3
Specification of the motor Model Power Voltage Current Rotating speed Insulation class Manufactured by YLKK400-4 280kW 6,600V 31A 1,487r/min F Shenyang Electric Machine Works
7LDTNB-6PJS 350m3/h 190m 2.2m 223kW 1,487r/min Shenyang Pump Co., Ltd.
Specification of vacuum pump cooler Model: M16 Heat exchange surface area: 9m2 Cooling water inlet temperature: 38 max Working water flow: 10.2m3/h Working water inlet temperature: 44.5, outlet pressure: 39.5 Cooling water flow: 20~22 m3/h Manufactured by: AF LAVAL
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2.6 Specification of steam turbine lubricating oil system 2.6.1 Main oil tank Dimension (lengthdiameter) Maximum volume Working volume Operating oil level Maximum oil level Minimum oil level Suction level of oil injector 2.6.2 Oil cooler Model Cooling surface area Working temperature Flow Test pressure Empty weight All-up weight Manufactured by 2.6.3 Main oil pump Type Capacity Outlet pressure Rotating speed 2.6.4 Oil injector Oil injector Outlet oil pressure 2.6.4 Jacking oil pump Specification of jacking oil pump Model: 25SCY14-1B Flow: 25L/min Outlet pressure: 32.0MPa Rotating speed:1,500r/min Operating value of overflow valve: 12.25 Mpa (g) Manufactured by: Shanghai HP Oil Pump Works Specification of the motor Model: Y160L Voltage: 415V Power: 15kW Rotating speed:1,500r/min Insulation class: B Manufactured by: Shanghai WUYI Electric Company I 0.098Mpa (g) II 0.197Mpa (g) Centrifugal type 4.5m3/min 1.18Mpa (g) 3,000r/min GX-64P 240m2 Above 0 80l/min 21bar 1,803kg 2,283kg SWEP PHE AB 5,8103,020 mm 40 m3 24 m3 1,808mm 2,616mm 1,245mm 1,045mm
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2.6.5 AC lubricating oil pump Specification of AC lubricating oil pump Model: YS150-50B Water head: 36m Flow: 133m3/h Rotating speed: 2950r/min NPSH: 4.5m Manufactured by: Shanghai Pump Works Specification of the motor Model: YB180M-2 Power: 22kW Voltage: 415V Current: 42.2A Insulation class: F Manufactured by Shanghai Wuyi Electric Machine Works
2.6.6 DC lubricating oil pump Specification of DC lubricating oil pump Model: YSI50-50B Lift: 36m Flow:133m /min Rotating speed: 2,950r/min NPSH: 4.5m Manufactured by: Shanghai Pump Works 2.6.7 Exhaust blower of main oil tank Specification of the exhaust blower Model: GXP-155 Air flow: 0.32m /s Total pressure: 4.5kPa Matched power: 3kW Rotating speed: 2,960 r/min Manufactured by: Mudanjiang Aidi Electric Power Technology Co., Ltd. 2.6.8 Specification of the oil purifying equipment Model: Power: Voltage: Max current: Flow: HCP100 380 50 AS-SD 3.0kW 415V 8.2A 100l/min <1.0MPa -10~60
3 3
Specification of the motor Model: Z2-62 Power: 22kW Rotating speed: 3,000r/min Current: 114.2A Insulation class: B Manufactured by Hangzhou Hengli Electric Machine Manufactory Specification of the motor Model: Y100L-2 Power: 3kW Voltage: 415V Current: 6.4A Insulation class: B Manufactured by: Hebei Chengde Electric Machine Works
Water discharge: Manufacturer: 2.6.9Turning gear Model Motor capacity Rated voltage Motor speed Turning speed horizontal 37 kW AC 415V
2.7 Specification of sponge ball cleaning pump Item Model Shaft power Pump Lift Flow Rotating speed Manufacturer Model Voltage Motor Current Power Rotating speed Manufacturer 2.8 EH oil system Specification of EH oil pump Code: 029-09941-5 Model: PV29 2R50 COO Outlet pressure: 13.7MPa Specification of the motor Model: Y200L-4 B35 Power: 30kW Voltage: 415V Specification of oil cooler Model: GL02 Working pressure: 1.6MPa Working temperature: 100 Setting value of overflow valve:16.2MPa Rotating speed: 1,470r/min Manufactured by: Shanghai Lubricating Equipment Plant Manufactured by Shanghai Wuyi Electric Machine Works Current: 56.8A Cooling surface area: 2.1m2 Sponge ball cleaning pump 125JQ-15 11 kW 15 mH2O 90 t/h 1,460 r/min Qingdao Huatai Electric Equipment Co., Ltd, Y160M-4 415 V 22.6A 11 kW 1,460 r/min Rongchen Daxing Electric Machine Works
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2.9 Specification of rapid cooling device Item Model Rated air flow Voltage Power Outlet temperature Working pressure Dimension Manufactured by 2.10 Specification of bypass system Item Rated flow Design inlet pressure Design outlet pressure Design inlet temperature Design outlet temperature Inlet working pressure Outlet working pressure Inlet working temperature Outlet working temperature Manufactured by Unit t/h MPa MPa MPa MPa
Pressure reducing valve of HP bypass Attemperating water valve of HP bypass Pressure reducing valve of LP bypass Attemperating water valve of LP bypass
Specification YQL-150 40 415 150 400 0.8 250018001900 Jiangsu Yangzhong Huangneng Electric Power Equipment Plant
The two-stage series connection bypass system is adopted, in which, the flow capacity of HP pass is considered as 70% of steam flow under VWO condition and the flow capacity of LP bypass is considered as the sum of HP bypass flow plus HP bypass attemperating water flow. 2.11 Specification of air cylinder: Design pressure: Design temperature: Working temperature: Working medium Test pressure: Volume: : 1.0 MPa 100 normal temperature air 1.25 MPa 1.0 m3
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c. Hot state: 300~400 d. Very hot state: above 400 1.1.2 The turbine is not permitted to start in any case as follows: 1) Eccentricity of rotor exceeds original value by 30m (original value is measured after installation or overhaul). 2) Emergency governor operates abnormally or overspeed protection fails in operating reliably. 3) One of HP & MP automatic main stop valve, speed governing valve, steam extraction check valve or HP exhaust check valve was choked and fails in closing tightly. 4) Emergency governor operates as a result of turbine governing system failure in maintaining idle running or controlling the rotation speed after load rejection. 5) There is clear friction sound occurred to the rotating parts of turbine and generator or the current of turning gear increases obviously and oscillates greatly. 6) The temperature difference between upper and lower part of cylinder exceeds 50. 7) The differential expansion of turbine reaches limit value. 8) The monitoring function of main parameters fails (including rotating speed, vibration, axial displacement, differential expansion, lubricating oil pressure, lubricating oil temperature, EH oil pressure, bearing metal temperature, bearing return oil temperature, thrust bearing pad temperature, pressure and temperature of initial steam and reheat steam, vacuum of condenser, pressure switch of control system, metal temperature of main cylinders and etc.). 9) Any safety protection or system fails or unit protection operating values are not in accordance with stipulation. 10) Any one of the following equipment has fault or the corresponding interlock protection test is unqualified: starting oil pump, AC (DC) lubricating oil pump, jacking oil pump, turning gear, EH oil pump. 11) The oil level of main oil tank and EH oil tank is lower than the limit value or the oil quality and cleanliness are unqualified. Lubricating oil inlet temperature is abnormal and return oil temperature is overhigh.
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12) Water seeps through the turbine. 13) Quality of water and steam are not in accordance with requirements. 14) Heat preservation of the unit is imperfect. 15) Other auxiliary equipment or system fails in operation.
8) Interlock test of condensate water pump; 9) Interlock test of EH oil pump; 10) Protection test of HP& LP heater and deaerator; 11) ON/OFF tests of all motor-operated valves, and pneumatical valves and hydraulic valves; 12) Interlock test of HP & LP bypass devices; 13) Interlock test of circulating water booster pump; 14) Interlock test of inner cooling water pump; 15) Interlock test of LP heater drain water pump; 16) Interlock test of shaft seal fan; 17) Interlock protection test of steam extraction check valves.
1.3.14 Ignite the boiler to increase temperature and pressure. 1.3.15 Put the bypass system (first the LP bypass and then HP bypass) into operation after warming up the piping. Put the bypass automatic control into operation. 1.3.16 Start the feed water pump according to the water level of steam drum. The water goes via bypass valve of the HP heaters. Adjust the water flow with feed water bypass (or conduct water filling with condensate water-filling pipe). Close the recirculation valve of economizer in water filling. 1.3.17 Timely open the water filling valve of HP heater after feed water pump start to ensure the HP heater has the condition of put-in of water side. 1.3.18 The up rate of temperature and pressure shall be as per the requirement of boiler cold start. 1.3.19 When the initial steam pressure reaches 0.1Mpa, check and confirm the drain valve before the main stop valve is in open position, check the tightness of HP & MP main stop valves and HP exhaust check valves to prevent cold water and steam from going into the turbine; 1.3.20 When the pressure rises to 0.5~1.0Mpa, advise the chemical staff to test the steam quality to decide whether to put continuous blowdown flash tank into operation according to chemical treatment requirement. 1.3.21 The turbine can be impulsed when the steam pressure rises to 1.5~1.6Mpa, initial steam temperature to 360, reheat steam temperature to 300, the temperature difference between initial steam side and reheat steam side is not more than 17, the steam quality is qualified through test grade and all parts of boiler are normal.
1.4.3.3 The turbine is in turning state, turning gear current is normal and continuous turning time is not less than 4 hours; 1.4.3.4 Water side of both HP and LP heater are into operation, HP and LP heater start along with the turbine prior to turbine impulsing. 1.4.3.5 Make sure all drain valves from turbine proper to the drain water flash tank are opened, water flows through HP and LP heater normally; heater drain water system adopts automatic flow stage by stage, and all heater motor-operated emergency drain valves are on Auto condition; 1.4.3.6 Maintain the vacuum of condenser above 80kPa; 1.4.3.7 Check if the water spraying system of LP cylinder is on Auto position and the pressure of condensate is normal; 1.4.3.8 Check if the recirculation valve of feed water pump is on Auto position. 1.4.3.9 Control of the drain valves of turbine proper and initial & reheat steam piping is on Auto; 1.4.3.10 Check if the turbine lubricating oil temperature is within 38~42; 1.4.3.11 Turbine lubricating oil pressure is 0.08~0.147Mpa, and oil pressure of EH oil system is normal; 1.4.3.12 Check if the eccentricity of shaft is 0.076mm and exceed the original value by 0.03mm; 1.4.3.13 Check if the differential expansion of turbine is normal; 1.4.3.14 Check if the temperature difference between of upper and lower cylinder of turbine is normal. 1.4.3.15 Check the Emergency governor handle on turbine head that shall have been pulled to Reset position. 1.4.4 Operation of Operator Auto Mode impulsing 1.4.4.1 Put the Operator Auto on IN in Control Mode. Click the button MODE on the upper left side of the DEN OVERVIEW picture, then the sub-picture CONTROL MODE will appear. Click the button OA and click button IN within 3 seconds to put in the Operator Auto Mode. 1.4.4.2 Reset the low pressure safety oil emergency governor on the head of turbine and check if the low pressure safety oil is normal; 1.4.4.3 Click LATCH button of hand-controlled panel on control panel DEH MAN PANNEL to reset the unit. After turbine reset, check the indicator of governor TRIPPED that shall change into LATCHED reset indicator. 1.4.4.4 Open the Limit Value picture to input valve limit value 120% and click button GO, check if the valve limit value is set normally and locally check if safety oil pressure is normal. Click the main stop valve opening button TVOPN on the control panel DEH MAN PANNEL, and locally check if HP & MP main stop valves are wide open and check if the HP & MP governing valves are - 29 -
closed after the picture displays that HP & MP main stop valve are wide open. 1.4.4.5 Set the target speed at 500rpm and speed up rate at 50rpm/min on the set value subpicture CTRL SP, press button GO, here the turbine starts to impulse and speed up, check the turbine speed that shall rise step by step. 1.4.4.6 Check the turning gear that shall trip automatically to stop turning motor when the speed is > 60r/min. 1.4.4.7 Check and open the high pressure exhaust check valves, extraction check valve 1, 2, 4 and 5, open steam extraction motor-operated valve 1, 2, 4, 5 (1 and 2 may not be opened when HP heater does not start along with the turbine) and put interlock into operation. 1.4.4.8 Press the button HOLD hold the speed when turbine speeds up to 500r/min, check the operating condition of turbine in an all round way and warm the turbine for 4 min at a low speed: a. Listen to check if the sound of rotating parts of the turbine-generator unit is normal; b. Check if all bearings temperature and return oil temperature, vibration and oil flow are normal, and pay attention to checking and governing lubricating oil temperature within the range of 38~42; c. Check if the water spray valve of LP cylinder has been opened really, the control switch is on Auto and LP cylinder exhaust temperature is < 80; d. DEH & check locally to confirm: Rotor eccentricity <0.076mm; Rotor Vibration <76m; Axial displacement within 1.0mm; Indication of absolute expansion of cylinder is normal; Temperature difference between the upper and lower HP cylinder < 50 Superheat degree of initial steam is 50. 1.4.4.9 Continue to set the target speed at 2,500 r/min and speed up rate at 40rpm/min. Jacking oil pump A and B shall stop automatically when the speed reaches 1,500r/min, otherwise stop them manually; 1.4.4.10 Time of turbine speed up and warming is distributed as follows: Rotating speed r/min Hold 300~500 From 500 to 2,500 From 2,500 to 2,960 Up to 3,000 to Time (min) Speed up 10 50 10 10 Stay 4 4 2 / Temperature of HP stator lower carrier () 60 130 Above 150 Above 150 Overall expansion of cylinder mm 1 3.5 5~6 5~6 Vacuum of condenser Mpa (a) 0.0347 0.0213 Full vacuum Full
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incorporate into network It requires about 90 min from impulsing to full speed.
vacuum
1.4.4.11 Make speed up to 2,500 r/min by the operating procedure above-mentioned and warm up the turbine for 4 min: a. Reinforce the checking and adjustment of all parts of the turbine during the whole speed-up process, press the button HOLD on the DEH picture if any control value approaches the upper limit and warming up is required during speed-up process, but it is prohibited to warm up in the resonance region. The operator shall closely monitor the vibration of the unit; b. Check if the pressure and flow of cooling water of generators air cooler are normal, if the cold air temperature of steam end is essentially the same with that of slip ring end of generator in idle running. 1.4.4.12 Continue to make speed up until 2,960r/min at a speed up rate of 50rpm/min by the operating procedure above mentioned and perform checking. Pay attention to checking the operating condition of main oil pump and confirming it is operating normally when the speed is up to 2,800 r/min. 1.4.4.13 If everything is normal thorough check, continue to make speed up until 3000rpm, after all parts of turbine are normal through an overall check, locally check the high pressure exhaust check valves that shall be opened; 1.4.4.14 Perform oil injection test, valve leak test and electric overspeed test to the turbine as required, it is required to ensure the unit is qualified through oil injection test and local & remote trip test and operates on load for more than 4 hours. 1.4.4.15 Perform local and remote trip test to the turbine. 1.4.4.16 Check the main oil pump locally if its outlet oil pressure of is 1.18Mpa, inlet oil pressure is 0.098~0.3Mpa and operation is normal. 1.4.4.17 Check if AC and DC lubricating oil pump interlock are on Auto position, after main oil pump operates normally through check, stop the starting oil pump and confirm the starting oil pump interlock is on Auto position. 1.4.4.18 Check if lubricating oil pressure, EH oil pressure and temperature are normal.
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control picture, then MODE sub-picture will appear, press the button and click button IN within 3 seconds to put AUTOSYNCHRONIZATION control mode into operation, the main picture will display enter the mode AS at the same time. 1.5.2 Checking after generator paralleling in and precautions in load on 1) After paralleling in, the generator is to have 5% active load and to a certain amount of inactive load on to maintain the generator voltage and warm up the unit. 2) After paralleling in, gradually close the high and low pressure bypass according to the pressure and temperature of steam. 1.5.3 Unit is to have initial load on for 5-10 min for warming up. 1) After paralleling in, the unit is to have initial load on 6~7MW load (5% of rated load), hold the steam conditions for 5 min to observe if the unit system is normal as having little load on. 2) Put the primary FM control circuit into operation as the case may require. 3) Checking & operation during warming up with initial load: A. The unit can operate with initial load for 5-10 min stably as the case may require; B. Warm the steam extraction # 3 to make preparation for steam supply of auxiliary header; C. Check if the temperature of generator stator core and coil are normal; D. Check if the turbine vibration, differential expansion, cylinder expansion, axial displacement, each bearing metal temperature, return oil temperature, lubricating oil pressure and differential temperature between upper and lower wall of cylinder are normal. E. Put the water level control into Auto after the water level of deaerator becomes stable. F. Check if the HP and LP heater operation are normal.
1.6 Load up
1.6.1 After warming up with initial load ends, check if the turbine cylinder expansion is normal without jamming; 1.6.2 Put the governing stage pressure circuit into operation as the case may require in the process of load up; 1.6.3 Make the load up to 13.5MW (10% of rated load) by means of valve position at a load up rate of 0.6MW/min. 1.6.4 Check if the auto operation of bypass system is normal, bypass valves close gradually with rise of unit parameters. 1.6.5 When the load is up to 13.5MW (10% of rated load), steam pressure to 2.0~3.5 Mpa, initial steam temperature to 450, reheat steam temperature to 400 and the temperature of HP stator lower carrier to 390, check if the drain valve at upstream of MP combined valve closed automatically, if not, close it manually. - 32 -
1.6.6 When the load reaches 27MW (20% of rated load), check if the water spray device closed automatically according to LP cylinder exhaust temperature, if not, close it manually. It may put the unit power control circuit into operation at this time. 1.6.7 When the load reaches 27MW (20% rated load): A. Check if the initial steam pressure is 4~5 Mpa, temperature is 470 and reheat steam temperature is 430; B. Check if the drain valve at downstream of MP combined valve closed automatically, if not, close it manually; 1.6.8 When the feed water pump flow is >280t/h, confirm the recirculation motor-operated valve of feed water pump closed by interlocking; 1.6.9 Open the sub-picture controlling set value on DEH control picture to set the target load at 60MW and load up rate at 1.3MW/min, press the button GO to make load of unit continue to go up. 1.6.10 When the pressure of extraction #3 is > 0.25Mpa, open the extraction #3 to the motoroperated valve of deaerator; and close gradually the auxiliary steam header to deaerator, here the deaerator operates in sliding pressure mode; 1.6.11 When the steam side pressure of No.2 HP heater is 0.3 MPa higher than that of deaerator, change the water drain of HP heater into the deaerator; close the water drain of HP heater valve to condenser valve, slightly open the HP heater No.1 and No.2 to the air valve of deaerator. When the pressure of steam extraction #3 is > 0.3 Mpa, change the steam supply of the auxiliary header into the steam extraction #3 of this unit. 1.6.12 As the load reaches 54MW (40% rated load), initial steam pressure to 7Mpa and temperature to 470 and reheat steam temperature to 450, start one LP drain water pump according to the water level of LP heater, close water drain of LP heater to drain valve of condenser, and put the auto control of drain into operation when the water level is adjusted to be normal. 1.6.13 When the load reaches 121.5MW (90% of rated load), steam conditions shall be up to nominal parameters in which initial steam pressure is 13.24Mpa, initial and reheat steam temperature are 535: 1.6.13.1 From warming up with initial load to 90% of rated load, the time of steam conditions reaching the ratings shall be controlled at 120 min; 1.6.13.2 Put the Initial Steam Pressure Control into operation on the DEH panel as the case may require after initial steam pressure reaches the rating; 1.6.14 Change the control mode of valves from Single Valve Control to Sequence Valve Control after the unit load reaches over 50MW, and pay attention to the change in load in - 33 -
changeover. 1.6.15 Continue to make load up until 135MW, perform an overall check and report the check results to the unit supervisor.
the process of speed up, closely monitor the differential expansion, hold the speed if discovering differential expansion alarm, and shut down the turbine as up to the shutdown value. 1.7.11 Absolute expansion of cylinder: In start-up, pay attention to monitoring the absolute expansion of cylinder and compare with the same in the first start-up to prevent cylinder expansion from being obstructed, cylinder shall expands continuously with jamming, if expansion is abnormal, it is required to reinforce warming up, find out and remove the cause. 1.7.12 Differential temperature between upper and lower part of the cylinder: must not be more than 50. 1.7.13 Axial displacement: must not exceed 1mm. Shut down the turbine as up to 1.2mm. 1.7.14 LP cylinder exhaust temperature: must not exceed 80 (alarm value), shut down the turbine as up to 121. 1.7.15 Metal temperature and return oil temperature of all bearings: (1) Normally return oil temperature of all bearings shall be below 75; shut down the turbine as up to 80; (2) Outlet oil temperature of oil cooler is within 38~42; (3) Metal temperature of journal bearing 1~3 shall be below 107; shut down the turbine as up to 113; the metal temperature of journal bearing 4~5 shall be below 75, shut down the turbine as up to 80; (4) Metal temperature of thrust bearing shall not be higher than 99; shut down the turbine immediately as up to 107; (5) Lubricating oil pressure is within 0.09~0.15Mpa. 1.7.16 Before the unit impulsing, adjust the initial and reheat steam parameters to meet the startup requirements by bypass, generally these is no need to adjust the parameters in the process of unit speed up so as not to affect the rotating speed. After the unit paralleling in, check if the automatic control of bypass is normal and pay attention to that the tracking of attemperating water shall be normal; the adjustment of the opening extent of HP & LP bypass shall be based on the need of boiler to prevent too acute oscillation of MP governing valve as a result of too high steam pressure of boil side and too large opening of bypass, at the same time pay attention to the pressure difference before and after HP exhaust steam check valve to prevent it from being closed and causing chocking. 1.7.17 Strictly monitor the water level of HP & LP heater, deaerator and condenser in the process of start-up. 1.7.18 Temperature rise & decrease rate Name Temperature of initial steam Temperature rise rate <2~2.5/min Temperature decrease rate <1.5/min
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Temperature of reheat steam Outer wall of initial and reheat steam pipe Outer wall of steam valve Flange wall of cylinder
<2.5/min
1.7.19 Temperature difference Name Temperature difference between upper and lower part wall of HP & MP outer cylinder stator carrier Temperature difference between upper and lower par of HP & MP outer cylinder and flange Temperature difference between upper and lower part of HP & MP outer cylinder Temperature difference between initial steam and reheat steam Temperature difference between left and right main reheat steam pipe 40~70 <40 <50 <50 <40 <30 Unit In temperature rise In temperature decrease
<17
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2.3.2 Fix impulsing parameters as per the following table according to cylinder temperature: Item upperr half metal temperature of HP inner cylinder () At least 50 higher than Initial steam the carrier Reheat steam At least 30 higher than the lower flange metal temperature of MP cylinder lower half metal temperature () temperature of HP stator At least 50 higher than metal the lower half of temperature With 50 superheat degree corresponding pressure With 50 superheat degree corresponding pressure under under 150~300 300~400 Warm state Hot state Remarks
HP stator carrier At least 30 higher than the lower flange metal temperature of MP cylinder 10 450 100 Must not be more than 500
50
speed up (r/min)
2.3.3 Impulsing speed up of turbine: 2.3.3.1 Checking and tripping operation of DEH panel are the same with that of Cold Start; 2.3.3.2 Fix the impulsing time and speed up rate according to cylinder temperature; 2.3.3.3 Other operations and checking in the process of turbine speed up are the same with that of Cold Start. 2.3.3.4 Because HP automatic main stop valve, speed governing valve, MP combined valve and steam lead pipe, etc. parts can cool quickly after shutdown, pay attention to the temperature rise rate of them in start-up to prevent excessive heating and pay attention to the vibration of unit.
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2,950
Pressure of deaerator
MPa
Low value I Low value II Normal Low pressure High pressure Unit Normal
Interlock close the steam extraction No.3 motor-operated valve and check valve interlocking, interlock close the motoroperated overflow valve of the deaerator when the water level decreases to below 2,750mm; Alarm Feed water pump trip Operate at sliding pressure Alarm for low pressure Safety valve operate Mini Remarks Alarm at 0.08Mpa; AC lubricating oil pump puts in at 0.07Mpa;
Lubricating pressure
oil
MPa
0.078~0.147
DC lubricating oil pump put in at 0.06Mpa; Shut down at 0.06Mpa; Turning stop at 0.03MPa
Inlet oil pressure of main oil pump Outlet oil pressure of main oil pump Outlet oil temperature of oil cooler Return oil temperature of bearing #1-#5 Metal temperature of journal bearing #1-3 Metal temperature of journal bearing #4-5 Metal temperature of thrust bearing Oil level of main oil tank Inlet oil pressure of jacking oil pump oil pressure of jacking oil header EH oil pressure
MPa
MPa
1.1~1.18
Interlock 0.883Mpa
start
oil
pump
at
45 <75
38
Alarm at 35 Alarm at 65 Alarm at 107, shut down at 113 Alarm at 75, shut down at 80 Alarm at 99, shut down at 107
2,616
1,245
10~12 13.7~14.5
Block start turning gear at below 4.2MPa Overflow valve operates at 16.2 Mpa;
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Name
Unit
Normal
Max
Mini
Remarks Start standby pump at 11.03 Mpa; Shut down at 9.31 Mpa. Low value II: 295.15mm Low value III: 193.54mm Start electric heater at below 23
mm
438.15~558.8 35~45
438.15
558.8
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Name High inlet flow of feed water pump Low inlet water pump Temperature motor Temperature of all bearings inside the coupling Differential sealing water pressure of of rotor winding of feed water pump flow of feed
Normal
Max
Min
Remarks Recirculation is ON at > 280 t/h Recirculation is OFF at < 132 t/h
130
MP a
<90 >0.1
95
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of thermal storage capacity of boiler and ensures the stability of steam pressure. Cooperative control system requires both boiler main controller and turbine main controller are on Auto position, otherwise it is unavailable.
can only be stopped by order given by the shift engineer after strict procedures of examination and approval. After the auxiliary equipment become normal after start-up, the standby equipments interlocking switch shall be put into operation in time to ensure good standby function. After power equipment trips, it must first check if the electrical protection operated and then confirm thermodynamic protection. The tripped equipment must not be put into operation until trip cause is found out, clear written report by maintenance personnel and approval by shift engineer are required if it is must be put into operation again. After the equipment is interlocked in operation, the original running equipment shall be checked thoroughly, if the cause is unavailable, the original running equipment shall be shut down for a detailed check.
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Note: regular switching of power equipment can be advanced if the due time meets with weekend or holiday, but it must make records through.
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1.2.4 Table of load, steam temperature & time at normal shutdown Load MW Item Time (min) Initial steam temperature () Reheat steam temperature () HP stator lower carrier metal temperature () 535 535 496 135 110 20 500 480 455 75 51 474 452 415 54 60 472 450 410 5.4 71 466 445 400 0 72 465 444 398
1.2.5 Decrease the parameter and load according to the normal shutdown curve at the rate of initial steam temperature of 1.5/min, reheat steam temperature of 2.5/min and initial steam pressure of 0.05Mpa/min. 1.2.6 Open the sub-picture of set value control on the main control picture of DEH to set target load at 75MW and load down rate at 1.13MW/min, then press RATE and ENTER button; press
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GO button, the unit load continues to decrease. 1.2.7 When the differential pressure between HP heater #2 steam side and deaerator is < 0.3MPa, stop the HP heater steam side from high to low; close the drain motor-operated valve of deaerator, change HP heater water drain to the condenser; close HP heater #1 and #2 to the deaerator air valve and close the air inlet value of HP; open the drain valves before and after extraction check valve of No. 1 and 2. 1.2.8 When No. 3 extraction pressure decreases to 0.25MPa, check if the auxiliary steam headers steam supply valve is opened, close the No. 3 extraction to deaerator air inlet valve; make the deaerator run at constant pressure of 0.192Mpa. 1.2.9 Set the target load at 54MW, load down rate at 2.33MW/min and the unit load continues to decrease; when the load decreases to 54MW, the initial steam temperature decrease to 472, reheat temperature to 450 and HP stator lower carrier metal temperature to 410. 1.2.10 When the load decreases to 45~60MW, stop the LP heater drain pump and open LP heater #6 l to multistage water-seal inlet and outlet valve; change LP heater #6 drain water to condenser 1.2.11 Set the target load at 5.4MW, load down rate at 4.42MW/ min, and the unit load continues to decrease. 1.2.12 When feed water flow decreases to 132m3/h, check the feed-water recirculation valve that shall open automatically, otherwise open it manually. In the process of load decrease, check if the shaft seal steam supply pressure is not less than 0.08 Mpa, adjust the shaft seal attemperating water and maintain the shaft seal steam supply temperature within specified range. 1.2.13 When the load decreases to 40MW, put the auto control of HP & LP bypass according to the requirement of boiler. 1.2.14 Open the attemperating water valve of proper drain flash tank. Close the air inlet valves of LP heater #4~#6. 1.2.15 When the load decreases to 27MW (20 of rated load), the drain valves of LP part shall open automatically, otherwise open them manually. 1.2.16 When the exhaust temperature is 80, check if the LP cylinder water spray starts to operate automatically 1.2.17 When the load decrease to 13.5MW (10 of rated load), the drain valves of HP part shall open automatically, otherwise open them manually. 1.2.18 When the load decreases to 6MW, the initial steam pressure decreases to 1.57~2.06Mpa, initial steam temperature to 466, reheat temperature to 445 and HP stator lower carrier metal temperature to 400, prepare to shut down the unit. 1.2.19 Set the target load at 0 MW and load down rate at 5MW/ min, and the unit load continues - 53 -
to decrease to zero. 1.2.20 Start AC lubricating oil pump, advise electrical personnel that the generator can be paralleled off, at this time the steam turbine and boiler shall interlock trip (press the button OFF to trip them in special case). Check HP & MP main stop valve, governing valve, extraction check valve and exhaust check valves of HP cylinder A & B that shall close all; unit speed decreases. 1.2.20 Works to done during unit idle time 1.2.20.1 Check the condition of unit idling, listen to its internal sound and record the idle time; 1.2.20.2 When the rotating speed is 2,500r/min, close the air valve of condenser; when the rotating speed is 1,500r/min, check if the jacking oil pump opened automatically, if not, open it manually; 1.2.20.3 When the rotating speed is 300~400r/min, open the vacuum breaker valve to decrease vacuum degree, control the rotating speed to 0 and vacuum to 0; stop the shaft seal motor, stop the shaft seal steam supply and close isolating valve; stop the vacuum pump. 1.2.20.4 When the unit comes to rest, put the continuous turning into operation and record the shaft bending and turning gear current. 1.2.21 Operation after shutdown 1.2.21.1 Check HP & LP bypass that shall stop and exit. 1.2.21.2 Close the cooling water valve of oil cooler and air cooler, close the attemperating water valve of feed water pump and open the oxygen exhaust valve of deaerator to decrease the pressure to zero. 1.2.21.3 When boiler is filled with water, stop the feed water pump, stop the deaerator heating and close the isolating valve. 1.2.21.4 Open the recirculation of condensate pump and adjust the water level of deaerator and condenser. 1.2.21.5 When the exhaust hood temperature is <50, stop the circulating water pump with approval of unit supervisor. 1.2.21.6 When the exhaust hood temperature <50, stop the condensate pump with approval of unit supervisor. 1.2.21.7 When the HP carrier lower half metal temperature is <150, stop continuous turning. 1.2.21.8 When the rotor comes to rest; release the interlocking of oil pump and stop the jacking oil pump and AC lubricating oil pump. 1.2.22 Precautions in normal shutdown 1.2.22.1 In the process of shutdown, keep the initial and reheat temperature within normal range as much as possible that shall not be lower than 450minimally. 1.2.22.2 In the process of load down, pay attention to the change in differential expansion of HP - 54 -
& MP cylinder, when the differential expansion reaches -1mm, stop load down, if such negative value continues to increase, take measures to reduce the load quickly to zero for shutdown. 1.2.22.3 When the vibration at unit idling increases, reduce the vacuum degree to make the unit speed lower quickly. 1.2.22.4 After the unit shuts down and before the boiler, deaerator and auxiliary steam header release pressure completely, closely monitor the metal temperature of steam turbine to prevent steam & water from escaping into the steam water. 1.2.22.5 If discover exhaust cylinder temperature increases after shutdown, find out the cause and cut off steam source, or else start the condensate pump and put the LP cylinder spray into operation to reduce the exhaust cylinder temperature. After shutdown, pay attention to monitoring the water level of condenser and deaerator to prevent overfeed of water.
1.3.5.1 The main controller operator on duty shall reduce the pressure and temperature at the rate of 0.04~0.049MPa/min and 1.5/min for initial steam and 2.5 /min for reheat steam; pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.2 Reduce the initial steam temperature to 500 and pressure to 10.79MPa slowly, open wide the speed governing valve gradually and reduce the load to 100MW and keep stable operation for 20 minutes. 1.3.5.3 Reduce the initial steam pressure and temperature at the rate of 0.03~0.04MPa/min and 1.5/min, unit load continues to decrease and pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.4 When the load decreases to 40MW, keep stable operation for 40 minutes. 1.3.5.5 When the initial steam flow is 30%, put HP & LP bypass and three-stage attemperating water into operation, continue to reduce the initial steam pressure and temperature at the rate of 0.03~0.04Mpa/min and 1.5/min, unit load continues to decrease and pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.6 When the load decreases to 10MW, initial steam pressure to 1.6~2.0MPa and initial steam temperature to 370~380, the sliding pressure shutdown is over and prepare to shut down. Open the sub-picture of set value control on the main control picture of DEH to set the target load at 0MW and load down rate at 5MW/min, and the unit load continues to decrease. 1.3.5.7 Report to the shift engineer when the load decreases to zero and trip to shut down the unit. 1.3.5.8 Other operations refer to normal shutdown. 1.3.6 Precautions in the sliding pressure shutdown 1.3.6.1 Strictly follow the principle of reducing pressure first and reducing temperature second in sliding pressure shutdown, and assign special person to monitor the reduction of steam temperature and pressure and read meter once every 10 minutes, within which the pressure drop must not exceed 0.4 MPa and temperature drop must not exceed 15, if not, stop reducing pressure and temperature immediately and continue after stabilizing for a period. 1.3.6.2 Keep an identity between the initial steam and reheat steam which temperature difference must not be more than 40, and degree of superheat must be higher 50 so as to prevent water hammer accident. 1.3.6.3 If discover the negative value of differential pressure increases too fast in sliding pressure shutdown, lower the load down rate. When HP differential expansion reaches -0.1m, stop reducing load and continue after differential expansion rises again, if the measures take no effect and the differential expansion continues to increase, reduce the load to zero quickly and trip to shut down the unit. Start AC lubricating oil pump, and record the idle time and listen to the sound - 56 -
of running parts after unit trips. 1.3.6.4 Closely monitor the unit vibration and metal temperature in the process of sliding pressure shutdown, and it is strictly prohibited to release the axial-displacement protection. 1.3.6.5 Pay attention to the water level of deaerator and condenser, vacuum of condenser and exhaust temperature that shall be normal. 1.3.6.6 After shutdown, cut off all steam and water sources inside the cylinder to prevent cold steam and water from entering. 1.3.6.7 Pay attention to that the initial steam pressure shall not rise in the process of load down so as to ensure the superheat degree of initial steam not lower than 50 minimally, and the initial steam temperature shall decrease steadily to prevent much fluctuation. 1.3.6.8 The governing stage temperature must not be 20 lower than the lower cylinder temperature; When the temperature difference between upper and lower cylinder is higher than 35, control the initial steam temperature more than 50 higher than the governing stage temperature. As negative differential expansion increases, contact the boiler operator to stabilize parameters, adjust the pressure of shaft seal and temperature to normal and pay attention to steam puffing up at the shaft seal. 1.3.6.9 Stop sliding parameter and reduce the load to zero quickly to trip to shut down the unit in any case as follows: a. The unit vibrates abnormally; b. The initial and reheat temperature are out of control, and drop for more than 50 within 10 minutes, it is necessary to break vacuum and shut down the unit, open the initial steam pipe and proper drain valve. c. HP & MP differential expansion reaches -2mm.
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deaerator water level and HP & LP heater water level to prevent valves of steam, extraction and drain system from untightness and resulting in cold steam and water entering the turbine; 1.4.6 In turning, pay attention to monitoring lubricating oil inlet temperature of all bearings that shall be higher than 21, as well as indications of metal temperature of all bearings, turning gear current and turbine cylinder temperature that shall be normal and record them once every hour; 1.4.7 Keep the turning gear and oil circulating system running for not less than 48 hours after normal shutdown; 1.4.8 After turbine shutdown, it is prohibited to fill the condenser and heater to test leak when the cylinder temperature is higher than 200, If it must be conducted, work out reliable preventive measures against sharp cooling of cylinder resulting in shaft bending that shall be approved by the shift engineer; 1.4.9 After bypass system is stopped, check to make sure attemperating water valve is closed tightly; 1.4.10 If there is clear friction sound inside the cylinder during turning, stop turning, but change to 15 minutes interval and turn the rotor by180, and forced turning is not permitted; 1.4.11 When the first stage metal temperature of HP cylinder is higher than 150, the turning can only be stopped with approval of unit supervisor, get done with marking clearly, record the stop time, and turn by 180 manually every 5~15 minutes according to the state of cylinder. Turning time is required to be at least 10 times larger than the stop time prior to restart; 1.4.12 After shutdown, if the bearing or other parts require maintenance, both the turning gear and oil circulation shall operate for more than 24 hours to keep the outlet oil temperature of oil cooler at about 35, and it can stop the turning gear and cut off oil circulation after which, but it is necessary to prolong the turning time prior to unit start; 1.4.13 For the shutdown for emergency maintenance, keep the turning gear and bearing oil system circulation for at least more than 3 hours, after which it can stop turning and oil circulation for 15 minutes and do not stop the oil circulation as much as possible. 15 minutes after stop, start the turning gear to operate for 2 hours or until the eccentricity becomes stable. After which, it can stop the turning gear and oil circulation, but the offtime shall not exceed 30 minutes, among which, 15 minutes after stop, start the oil circulation to turn rotor by 180. After 30 minutes mentioned above, start the turning gear and oil circulation, and run the steam turbine over again for 2 hours or until the eccentricity becomes stable. As long as turn the rotor by 180 every 30 minutes within the following six hours, the system will be able to be off for long. Start the oil circulation to lubricate all bearings during the 180 turning. 1.4.14 If it is required to stop the turning gear for emergency due to unit fault, which may make the rotor suffer from serious bending, so it must keep oil circulation for at least over 24 hours after shutdown to prevent bearing from overheating, and keep the outlet oil temperature of oil cooler
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within 21~35 during which; 1.4.15 If the rotor bending is not very serious, it can be rotated to become straight by 1~2 hours turning.
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supervisor. 1.10 The operator shall not leave the post in the process of treatment of fault and accident, If the fault occurs during work shift, it postpone the time of shift, the staff to hand over shall go on working and eliminate the accident with assistance by the staff to take over until the unit recovers normal operation or receiving the order about shift from the unit supervisor. 1.11 People irrelevant to the accident shall not stay at the spot. 1.12 After treatment of fault and accident, the staff on duty shall report the time, phenomenon, reason, development and the treatment process to the shift engineer and keep detailed records, and the meeting it after work shift shall analyze the fault. 1.13 First make every effort to eliminate the danger to personal and equipment safety in case of accident. 1.14 Strive to keep normal running of non-faulted equipment. 1.15 Prevent wrong judgment or treatment caused by bad contact, uncertain condition and inaccurate report.
3.2 In the case where the initial and reheat steam temperature on turbine side increases to above 545 and cannot recover after running for 30 minutes; where the temperature continues to rise to 555 and cannot recover within more than 15 minutes; or where the temperature exceeds 565; 3.3 The initial steam pressure increases to above 14.71Mpa; 3.4 The back pressure of conderser reaches 20.3KPa or circulating water interrupts; 3.5 The steam turbine rejects load to 0 to run for more than 15 minutes; 3.6 The change in frequency is lower than 46HZ; 3.7 The initial and reheat steam and feed water pipe or valve breaks to endanger the equipment safety; 3.8 The MFT operates, but the major interlock of turbine-boiler refuses to operate; 3.9 The main stop valve, governing valve and MP combined valve are jammed and cannot recover; 3.10 LP cylinder exhaust temperature reaches 121; 3.11 The steam turbine motor operates for more than 1 minute; 3.12 When an important monitoring meter displays inaccurately or fails, it must stop running in the condition that there is not any effective monitoring means; 3.13 The copper tube of condenser breaks resulting a great deal of circulating water entering the steam side.
decreases to the limit value; 4.12 The oil pump pipe broke and cannot be isolated, which resulting serious leak of oil to endanger the safety of equipment; 4.13 The rotating speed of steam turbine increases to 3,300r/min, but the emergency governor refuses to operate; 4.14 The HP & MP differential expansion reaches +8 or -3mm and LP differential expansion reaches +7.5mm; 4.15 The axial displacement reaches 1.2mm, and at the same time the temperature of thrust bearing increases sharply.
hand to check if the if the HP & MP main stop valve, speed governing valve, extraction check valve and HP exhaust check valve are closed and if the rotating speed of unit decreases; 6.3 Release the starting oil pump interlocking and start the lubricating oil pump; 6.4 If boiler MFT operates, treat it according to MFT operation emergency shutdown; 6.5 Adjust the steam supply pressure of deaerator and shaft seal, and switch to the standby steam source in time; 6.6 Check thoroughly, listen to the sound of unit and record the idle time; 6.7 Other operations as per normal shutdown procedure.
7. Decreasing of Vacuum
7.1 Phenomenon 7.1.1 The condenser vacuum indication decreases, local vacuum gauge, DEH or DCS displays vacuum decreasing; 7.1.2 The exhaust temperature of steam turbine rises; 7.1.3 Conderser Vacuum Low sound & light alarms. 7.2 Cause 7.2.1 The circulating water pump works abnormally and the system valve is operated by mistake, which result in interruption or lack of circulating water; 7.2.2 The steam supply of shaft seal is not enough or shaft seal carry-over; 7.2.3 The water level of condenser is too high; 7.2.4 The vacuum pump works abnormally; 7.2.5 The vacuum system leaks or the system valve is operated by mistake; 7.2.6 The condenser piping is dirty; 7.2.7 The water temperature of vacuum pump is high; 7.2.8 No level or overfeed of water of the shaft seal heater. 7.3 Treatment 7.3.1 If discover the condenser vacuum decreasing, check the exhaust temperature immediately to ascertain vacuum down; 7.3.2 If the condenser vacuum decreases, it shall start the standby vacuum pump rapidly to observe the change in vacuum; 7.3.3 If the vacuum keeps on decreasing, it shall reduce the unit load appropriately until alarm off, find out the cause and give treatment; 7.3.4 Check the operation of circulating water pump: a. Check if the circulating water pump operates normally, otherwise switch to the standby circulating pump or start another pump, when there are two pumps operating, if one pump stops - 64 -
for fault to result in decreasing of condenser vacuum, it shall close the outlet valve of faulted pump quickly; b. Check the outlet valve of circulating water pump, and open it in time if it is closed by mistake; c. Check if the circulating water pressure is normal, if it is low, check if the circulating water system leaks or is blocked; d. Check the differential pressure between the circulating water outlet and inlet of condenser is normal, if it is high, then clean a half of condenser; e. Check if the disc valve of condenser inlet & outlet is closed by mistake; if so, open it immediately; 7.3.5 Check the shaft seal system: a. If the shaft seal header pressure is low, then check if the shaft seal steam source and overflow valve are normal to adjust the shaft seal header pressure to normal; b. If the steam pressure of LP shaft seal is low, then turn down the shaft seal attemperator spray isolating valve and adjust the LP shaft seal steam temperature at 149; c. If the shaft seal heater pressure is high, then start the standby shaft seal heater blower to check if the multi-stage water seal of shaft seal heater is broken and water level is normal. 7.3.6 Check if the water level of condenser condensation sump is high, if so, it shall find out the cause and give treatment; 7.3.7 Check if the LP extraction flange and junction plane of LP cylinder leak, if the vacuum system is tight, in the case where the vacuum system leaks, seal it off and contact with maintenance personnel to treat; 7.3.8 Check if the vacuum breaker valve is opened by mistake 7.3.9 Check if any vacuum valve and flange leaks; 7.3.10 Check if the water level of vacuum pump steam-water separator is normal and if the vacuum pump water temperature is normal; 7.3.11 When the back pressure of condenser reaches 20.3KPa, the steam turbine shall trip automatically and trip it manually, and give treatment according to the procedure of fault shutdown.
8.1.4 The initial steam and reheat steam pipe or the extraction pipe vibrate, shaft seal has water hammer sound, and there is white steam belching from the main stop valve and speed governing valve lever, as well as the flange of extraction pipe; 8.1.5 Temperature of initial and reheat steam decreases sharply; 8.1.6 Temperature of LP shaft seal header decreases sharply. 8.2 Cause 8.2.1 The boiler drum is overfed with water; 8.2.2 The steam drum pressure drops sharply, which result in the carry-over; 8.2.3 Adjustment of the boiler steam temperature is inappropriate; 8.2.4 When the unit is started, the drainage of turbine proper, shaft seal system and all relevant steam pipes are not smooth; 8.2.5 The heater leaks or drainage is not smooth and deaerator is overfed water; 8.2.6 The unit load changes abruptly; 8.2.7 Boiler water is unqualified or carry-over (priming); 8.2.8 The attemperating water valve of bypass system is not closed tightly; 8.2.9 When the superheat degree of initial steam and reheat steam is low, the speed governing valve swings severely. 8.3 Treatment 8.3.1 Open the drain valves of steam turbine proper and the relevant steam pipes to intensify proper drainage; 8.3.2 If water flowing into the steam turbine is caused by water overfeed of heater, it shall stop the overfed heater and isolate it to drain water; 8.3.3 In case of white steam belching from the main and reheat steam pipe flange, and main stop valve and governing valve lever, treat according to fault shutdown; 8.3.4 Record the idle time of turbine and listen to the sound of inside of turbine in idling carefully; 8.3.5 Put the turning gear into operation after the turbine come to rest, it shall execute the stipulations for turning gear operation in shutdown strictly, and intensify proper drainage; 8.3.6 After turbine shutdown caused by water emergency, it can only restart the turbine after the unit is normal through check, temperature difference between upper and lower cylinder is<50, and rotor eccentricity <0.076mm with approval of the chief engineer; 8.3.7 In the process of the start, it shall pay attention to monitoring the axial displacement, vibration and bearing temperature, etc. parameters and drainage of relevant stem pipes of the turbine proper, if any abnormal sound or stator-rotor friction in the process of restart, it shall break the vacuum to shut down immediately; 8.3.8 In case of water flowing into the turbine, if the axial displacement, differential expansion and - 66 -
bearing temperature reach the tripping value, idle time shortens obviously, or there is any abnormal sound inside the turbine, it shall shut down to check.
10.1 Phenomenon 10.1.1 The fire monitor control raises the alarm; 10.1.2 Flare or smoke is discovered locally; 10.1.3 When the turbine oil pipe leaks, the oil level of main oil tank decreases; 10.1.4 When the lubricating oil system leaks, lubricating oil pressure decreases, signal Lubricating Oil Pressure Low may be raised and AC & DC lubricating oil pump may interlock start. 10.2 Cause 10.2.1 Oil system leaks; 10.2.2 Oil leaks to high temperature hot body or faulted electrical equipment; 10.2.3 Oil pipe is broken due to external causes and oil leaks to the hot body. 10.3 Treatment: 10.3.1 If any abnormal change in the oil level of main oil tank and all oil pressure, it shall find out the cause, if due to oil leak of oil system, it shall ascertain the leaking point and try to isolate it from surrounding hot body pat and operating equipment to prevent the oil system from catching fire, meanwhile, contact the maintenance personnel to treat the leaking point temporarily; 10.3.2 If the equipment and pipe of unit oil system is damaged to leak, in any case where the equipment or pipe cannot be isolated from system to be treated or oil has seeped into the heat distribution pipe, it shall shut down to treat immediately; 10.3.3 After the system catches fire, it shall cut of the equipment power supply endangered by the fire, and then extinguish the fire and advise the fire fighter immediately; 10.3.4 If the fire cannot be extinguished quickly and endangers the personal and equipment safety, it shall break the vacuum to shut down for emergency immediately. Release the interlocking of starting oil pump, not start the starting oil pump to shut down the lubricating oil pump; if the lubricating oil system catches fire that cannot be extinguished, resulting in shutdown, it may reduce the lubricating oil pressure to decrease oil leak in the precondition of ensuring normal lubrication of bearing. 10.3.5 When the fire endangers the main oil tank or top platform, plant building and neighboring turbine, after tripping to shut down, it shall open the emergency oil drain valve of main oil tank, keep mini permitted oil level prior to the rotor coming to rest and drain out the remaining oil after rotor coming to rest.
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become abnormal. 11.1.1 Phenomenon a. Initial steam and reheat steam pressure gauge change; b. DEH and DCS display the initial steam and reheat steam pressure alarm; c. When the unit operating in coordinated control mode, its load changes correspondingly. 11.1.2 Cause a. Fault in control system; b. Units load changes abruptly. 11.1.3 Treatment a. If it is the fault in control system that caused abnormality of initial and reheat steam pressure, it shall adjust the charge of fuel to restore the initial and reheat steam pressure; b. If it is the too quick change of units load that caused abnormality of initial and reheat steam pressure, it shall try to stabilize the load and change it after the initial and reheat steam pressure recovering; c. If the initial and reheat steam pressure are high, it may increase the units load to make the pressure recover; d. When the initial steam pressure rises up to 14.71Mpa, it shall trip to shut down the turbine; e. When the initial and reheat steam pressure change, it shall pay attention to the units vibration, sound, differential expansion and axial displacement, as well as temperature difference between upper and lower cylinder of turbine; f. When the steam pressure drops, it shall control each monitored section pressure not exceeding the max permitted value with initial steam flow rate440t/h; g. If the steam pressure keeps on dropping to below 4Mpa and cannot recover, treat according to fault shutdown. 11.2 Steam pressure does not change, but the initial steam and reheat steam temperature become abnormal. 11.2.1 Phenomenon a. Initial steam and reheat steam temperature gauge change; b. DEH and DCS display the initial steam and reheat steam temperature alarm. 11.2.2 Cause a. Governing of attemperator to the initial steam and reheat steam fails; b. Boiler steam drum is overfed with water; c. Boiler combustion is unstable and combustion condition changes; d. Units load changes greatly; e. Coking or soot deposit of furnace; - 69 -
f. In soot blowing of boiler; g. Coal quality changes. 11.2.3 Treatment a. If Auto mode of the initial steam and reheat steam attemperator fails, it shall adjust manually to keep initial steam temperature not exceed 545; b. Check the water level of steam drum and adjust the water level to normal; c. If the boiler combustion rate is high, which caused initial and reheat steam temperature becoming high, it shall reduce the load at the same time of reducing coal; d. In the case where initial and reheat steam temperature exceed 545 and cannot recover after running for more than 30 minutes; where the temperature continues to rise to 555 and cannot recover within more than 15 minutes; or where the temperature exceeds 565, treat according to fault shutdown; e. Temperature difference between the left and right of initial steam and reheat steam temperature shall be less than 17; f. When the initial steam and reheat steam temperature change in operation, it shall pay attention to the units vibration, sound, differential expansion and axial displacement, as well as temperature difference between upper and lower cylinder of turbine; g. When the initial steam temperature decreases to 500, it shall open drain valves of the turbine proper and initial steam conduit and intensify monitoring of metal temperature, axial displacement and thrust pad temperature; h. In the case where initial steam temperature decreases by 30 within 10min, it shall open the drain valves of initial steam & reheat steam pipe and proper, report to the unit supervisor and closely monitor the units vibration, axial displacement and differential expansion; i. In the case where the steam temperature decreases by more than 50 within 10min, it shall trip to shut down the turbine immediately; j. In the case where initial steam temperature decreases suddenly and superheat degree of steam decreases to below 150, it shall trip to shut down the turbine immediately. 11.3 Steam temperature and pressure decrease at the same time. 11.3.1 If the steam temperature and pressure decrease at the same time, it shall verify the superheat degree and meanwhile restore steam conditions quickly, if fail, report to the unit supervisor, reduce load and pay attention to monitoring the change in differential expansion and axial displacement; 11.3.2 When the steam temperature decrease to the value under corresponding pressure and superheat degree is not enough, it shall shut down the turbine for fault immediately; 11.3.3 Closely monitor if there is white steam belching or water drop spilling from the main stop - 70 -
valve, shaft seal and junction plane of cylinder, if any water hammer, it shall shut down the turbine for emergency. Closely monitor the change in metal temperature and differential expansion; 11.3.4 Pay attention to the change in shaft seal pressure and water level of condenser and all heaters, switch over the steam source of deaerator in time; 11.3.5 When the initial steam temperature and pressure decrease at same time, although not to the shutdown temperature, the initial steam temperature is over 50 lower than the first stage metal temperature, it shall report to the unit supervisor and request for fault shutdown.
13.1.5 Auxiliary oil pump operates abnormally; 13.1.6 Too low oil level of the oil tank; 13.1.7 Oil system catches fire. 13.2 Fault in the main oil pump 13.2.1 Phenomenon a. Outlet oil pressure decreases; b. Sound in the units head is abnormal; c. When the case becomes serious, the starting oil pump starts to operate automatically and the alarm window raises an alarm. 13.2.2 Treatment a. The starting oil pump shall start to operate automatically when the oil pressure decreases to 0.883MPa, otherwise start it immediately and check if the inlet oil pressure of main oil pump and stage I oil injector are normal; b. Listen to the sound of main oil pump carefully, closely observe the change in system oil pressure and report to the unit supervisor; c. Ascertain the fault in main oil pump and treat according to emergency shutdown with vacuum broken. 13.3 Oil pressure decreases, but oil level does not change. 13.3.1 Cause a. Check valves of the staring oil pump and AC & DC lubricating oil pump are untight; b. Oil injector and main oil pump operate abnormally; c. The outlet strainer of the oil cooler is blocked; d. Overpressure valve is adjusted improperly or spring is broken; e. Internal leak between oil supply system and oil return system. 13.3.2 Treatment: a. When the oil pressure decrease to 0.883Mpa, the starting oil pump should start automatically, otherwise start it manually; b. Check the cause of oil pressure being low and if the speed governing system operates normally; c. Check if the indication of oil tanks oil level gauge is normal; d. Check the return oil quantity of each bearing, if the return oil quantity of bearing #1 increases, it indicates the speed governing oil pump or main oil pump seal ring in this bearing box leaks oil; e. If there is any lubricating oil pressure decreases, when the oil pressure decreases to 0.07Mpa, the AC lubricating oil pump should start to operate automatically, otherwise start it manually to increase the lubricating oil pressure;
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f. Switch the lubricating oil strainer, and operate and check if the stage oil injector is blocked. g. If the overpressure valve operates by mistake, contact the maintenance personnel to treat; h. If the lubricating oil pressure still decreases to 0.06MPa, the DC lubricating oil pump should start to operate automatically, otherwise start it manually; i. The lubricating oil pressure still decreases to 0.06MPa even if various measures, it shall break the vacuum for emergency shutdown. 13.4 The oil pressure does not change, while oil level decreases: 13.4.1 Cause: a. Oil leak in the return oil pipe of the oil cooler, oil system or oil catch of bearing; b. Emergency oil drain valve, oil drain valve of oil tank, sampling valve or water discharging valve etc. leak or opened by mistake; c. Oil gauge malfunctioned; d. If the oil pump packing set leaks oil seriously. 13.4.2 Treatment: a. Check if the indication of the oil level gauge of oil tank is right; b. Check if the emergency oil drain valve and sampling valve etc. leak or opened by mistake; c. Check the leak of the running oil cooler, if any, it shall switch over to others. d. Check if there is oil leak of oil system pipe completely, if any, try to eliminate the leak and take strict precautions against oil leaking to high temperature pipe and equipment; e. When the oil level of oil tank decreases to 1,800mm, it shall contact the maintenance personnel to service and make up oil in time; f. When oil level decreases to 1,245mm, if any means takes no effect, it shall break the vacuum for emergency shutdown. 13.5 Oil pressure does not change, which oil level rises: 13.5.1 Phenomenon & cause: a. Great steam leakage of shaft seal and too wide clearance of main bearing oil catch caused water mixed in oil; b. Oil cooler leaks, and the pressure of water side is higher than that of oil side. 13.5.2 Treatment a. Check if the indication of the oil level gauge is right; b. Discharge the water from the bottom of oil tank, if the water quantity is high, it shall advise the chemical staff to assay the oil quality and filter the oil if necessary; c. Adjust the steam inlet pressure and flow of shaft seal; d. Switch over the oil cooler to check leaks; - 73 -
e. Ascertain the cause of water flowing into oil system then eliminate it. 13.6 Oil pressure and level decrease at the same time. 13.6.1 If the oil supply system leaks seriously, it shall report to the unit supervisor to try to stop the leak and take measures against fire, change the direction of oil leakage to keep it off the hot body if necessary, meanwhile advise the maintenance personnel to make up oil of oil tank and eliminate the defect; 13.6.2 Check if the oil and water discharge valves are on closed position; 13.6.3 Check leak of the oil cooler, if any, it shall switch to the standby oil cooler in time; 13.6.4 If the bearing oil inlet pressure decreases to below 0.06Mpa or oil level decreases to 1,245mm due to a great deal of oil leak, it shall start the lubricating oil pump immediately to break the vacuum for emergency shutdown. 13.7 The return oil temperature of bearing rises 13.7.1 Cause a. The outlet oil temperature of the oil cooler rises; b. The lubricating oil pressure decreases or the oil inlet pipe of bearing is blocked; c. The bearing pas is damaged and inlet hole is blocked; d. Much vibration of the unit; e. The steam turbine is overloaded and axial thrust is excessive; f. The oil quality decreases. 13.7.2 Treatment a. When the return oil temperature of bearing rises by 2~3 suddenly, it shall find out the cause and take corresponding measures; b. When the return oil temperature of all bearings rises, it shall check if the oil outlet temperature of oil cooler and lubricating oil pressure are normal; c. When the return oil temperature of only one bearing rises, it shall check the inlet oil pressure and return oil flow of this bearing, as well as bearing vibration and axial displacement change, and report to the unit supervisor; d. When the thrust bearing pad temperature rises to 80, report to the unit supervisor and find out the cause, if the temperature keeps on rising to 90, report to the unit supervisor to lower the oil outlet temperature of oil cooler and load appropriately, meanwhile pay attention to the axial displacement and return oil temperature of thrust bearing pad. e. When any bearing oil interrupts or smokes or bearing return oil temperature rises up to 75 sharply, it shall break the vacuum for emergency shutdown.
13.8.1 In the process of unit start, it shall treat the fault in the starting oil pump as follows: a. When the rotating speed of steam turbine reaches below 2500rpm, start the lubricating oil pump immediately, trip to shut down the turbine, and it can only restart the turbine after removing the fault in the starting oil pump; b. When the rotating speed of steam turbine reaches above 2500rpm, it shall start the AC lubricating oil pump at once, if the main oil pump is able to maintain normal oil pressure, increase the speed up to 3,000rpm quickly, stop and service the starting oil pump, it can only restart after removing the fault in the starting oil pump. 13.8.2 Treatment of fault in the auxiliary oil pump in the process of unit shutdown: a. If it is the AC lubricating oil pump that gets fault, start the starting oil pump or DC lubricating oil pump immediately to make shutdown continue; b. If all three oil pumps get fault: it shall start the jacking oil pump immediately to break the vacuum for emergency shutdown.
14.2.12 The generator rotor is not heated equally. 14.2.13 The running components in the front bearing case fall off. 14.2.14 Center of the turbine-generator is abnormal, or the rotor bending is relatively large and exceeds the specified value as starting. 14.2.15 Condenser vacuum is low; 14.2.16 The generator exciter caused the vibration; 14.2.17 Anchor bolts of all bearing bushes of the turbine-generator unit become loose; 14.2.18 Oil contains foreign matters that wear the bearing bush tungsten-base alloy or water mix in oil and oil is emulsified. 14.3 Treatment 14.3.1 The unit vibrates sharply suddenly, or metal sound inside the unit can be heard clearly, it shall break the vacuum for emergency shutdown quickly. 14.3.2 Abnormal vibration occurs during operation: a. When discovering the bearing vibration increases gradually, if the rotor vibration exceeds 0.08mm or bearing vibration exceeds 0.03mm, it shall report to the unit supervisor to try to eliminate the vibration, if the rotor vibration exceeds 0.254mm, it shall shut down immediately; b. If the unit sends out impulsive sound from the inside in operation or the conductivity of condensate increases suddenly, the monitored section pressure at same load rises and vibration increases obviously, it shall immediately break the vacuum for emergency shutdown; c. When the shaft vibration changes by 0.05mm or bush vibration changes 0.03mm, it shall find out and try to eliminate the cause, when the bearing vibration change increases to 0.015mm suddenly, it shall trip and shut down the unit immediately; d. When the load changes, it shall reduce the load until vibration disappears; e. If it fails in ascertaining the vibration cause directly, it shall take measures to reduce the load, If the vibration or abnormal sound remains, report to the unit supervisor and relative leaders for settlement. 14.3.3 Abnormal vibration occurs during start-up and shutdown: a. In the case where rotor eccentricity at a speed of below 600r/min or bearing vibration exceeds 0.03mm at a speed of below 1200r/min in the process of start-up speed rise, it shall trip and shut down the unit immediately. When the unit operates at critical speed, if the bearing vibration exceeds 0.10mm or shaft vibration exceeds 0.25mm, it shall trip and shut down the unit immediately. It is prohibited to warm up with critical speed or reduction of speed forcedly. It can only restart the unit after ascertaining and removing the cause; - 76 -
b. It shall cease the start-up when there is friction at end shaft seal or through-flow parts, report to the unit supervisor and relative leaders, it can only restart the unit after finding out the cause; c. In the process of shutdown, if friction sound inside the end shaft seal or cylinder can be heard clearly, it shall break the vacuum for emergency shutdown; d. In the case of shutdown due to abnormal vibration, it shall pay attention to the idle time and listen to the inner sound of the unit carefully and increase the time of continuous turning.
start the lubricating oil pump; 16.2.2 Pay attention to adjusting the water level of condenser and HP & LP heater, put the LP cylinder spray into operation; 16.2.3 Maintain the water level of deaerator and switch into standby steam source of deaerator; 16.2.4 Check the unit completely and switch the steam supply of shaft seal to the standby; 16.2.5 Record the idle time when the speed decreases to zero, and stop the steam supply of shaft seal when the vacuum decreases to zero and put the turning gear into operation in time; 16.2.6 After shutdown, check the unit thoroughly, find out the causes of speed governing system operating abnormally and generator paralleling off, it can only restart the unit after eliminate the causes and unit being normal through test.
17. Turbine trips, while the generator does not parallel off
17.1 Phenomenon 17.1.1 Some protection operates and makes signals, power reaches zero or displayed in negative; 17.1.2 HP & MP Main stop valve, speed governing valve, extraction check valve and HP exhaust check valves closed; 17.1.3 The generator does not parallel off and speed does not change. 17.2 Treatment 17.2.1 After the protection operating, it shall cut off the outlet switch of generator-transformer unit to parallel off and shut down, and the operating time of unit without steam shall not exceed 1 minute; 17.2.2 Check and ascertain the cause steam turbine protection operating, treat according to emergency shutdown or fault shutdown; 17.2.3 If the protection of steam turbine operates by mistake, it shall advise the thermodynamic engineer to find out and remove the cause quickly. If it fails within 15 minutes, it shall shut down the unit for fault; 17.2.4 Advise the electric staff to find out and remove the non-tripping cause of generatortransformer unit quickly; 17.2.5 After removing the fault, it can only restart the unit after it is normal through test.
18. Failure of Thermodynamic Power Supply 18.1 Phenomenon 18.1.1 The heat-control power indicator lamp goes out and the alarm window lights; 18.1.2 The indication of instruments is abnormal and all indicator lamps go out; 18.1.3 Power failure of motor-operated valves and governing valves, and malfunction of all - 78 -
automatic governing; 18.1.4 Partial protections and interlocks of the unit can not operate. 18.2 Treatment 18.2.1 Immediately contact heat engineer to recover the power supply, check and monitor primary meters locally, and switch the automatic into manual governing; 18.2.2 Report to the unit supervisor and keep the unit load stably as much as possible; 18.2.3 Avoid adjusting as much as possible, monitor the operation of equipment according to the indication of local meters and ammeter of each auxiliary equipment, etc., and make necessary adjustment locally; 18.2.4 When the system or equipment becomes abnormal, and the unit loses operating and monitoring means, which affect the safety of main equipment, report to the unit lead and conduct fault shutdown; 18.2.5 If the heat control power supply can not recover within 30 minutes, make fault shutdown. 18.2.6 If the heat control power supply of turbine and boiler fail at the same time, it shall conduct fault shutdown.
19. High Bearing Temperature of Turbine-generator Unit 19.1 Phenomenon 19.1.1 DEH displays that the bearing temperature is high and raises the alarm; 19.1.2 Local thermometer of bearing return oil displays high indication. 19.2 Cause 19.2.1 Lubricating oil temperature is high or pressure is low, and the oil quality is unqualified; 19.2.2 Bearing inlet & outlet oil pipes are jammed; 19.2.3 Motion and static bearing has friction between the stationary and rotary part; 19.2.4 Shaft seal leaks steam too seriously; 19.2.5 Vibration cause damage to the oil film, and the lubrication is poor; 19.2.6 Unit is overloaded or vacuum of condenser is low vacuum. 19.3 Treatment 19.3.1 If bearing temperature high alarm is raised, it shall intensify monitoring; 19.3.2 When the temperature of all bearings rises generally, if the lubricating oil pressure is low, it shall treat according to the decreasing of lubricating oil pressure, if the lubricating oil pressure is normal, it shall check if the state of inlet and outlet valve of oil cooler is right, and adjust the lubricating oil temperature to normal; 19.3.3 if the temperature of individual bearings is high, listen to if there is metal friction sound inside the bearing and observe the condition of return oil, and lower the unit load at high - 79 -
temperature alarm; 19.3.4 If the shaft seal pressure is high and the steam leak of shaft seal is serious, it shall check the steam source governing valve of shaft seal and adjust the shaft seal pressure to normal; 19.3.5 When the temperature of journal bearing #1-3 of turbine reaches 112, the temperature of journal bearing #4-5 of generator reaches 80 and the temperature of thrust bearing reaches 107, the steam turbine should trip automatically; if bearing return oil reaches 80, it shall treat according to emergency shutdown for fault; 19.3.6 Pay attention to adjusting the unit load and vacuum of condenser.
20.3.4 If any bearing oil interrupts, smokes or metal temperature and return oil temperature of bearing reach the limit, it shall break the vacuum to trip and shut down the unit immediately.
21.3.5 If it is the fault in turning gear that caused shutdown, after shutdown, it shall monitor the change in rotor bending, when the bending is high, it shall operate the turning gear by 180 and put the continuous turning into operation after the turning becomes normal in time; 21.3.6 After shutdown, continuous turning time must not be less than 4 hours, only after the temperature difference between upper and lower cylinder, turning gear current, and rotor eccentricity meeting the starting conditions, can restart the unit after reporting to the unit supervisor, closely monitor the rotor vibration and eccentricity etc. parameters in start, if any abnormality, trip and shut down the unit immediately.
22.3.2 When the unit speed rises up to 3,300r/min, check that the mechanical and electromagnetic overspeed protection shall operate. Otherwise it shall trip and shut down the unit manually, verify that the HP & MP main stop valve and all extraction check valve shall be closed, cut off all possible steam access to turbine and immediately open the vacuum breaker valve for emergency shutdown; 22.3.3 If the overspeed is caused by HP & MP main stop valve being jammed, it shall immediately start the overheater or reheater atmospheric exhaust valve, and etc. to reduce the pressure; 22.3.4 Eliminate the cause of overspeed after the turbine is shut down for overspeed, and it can be restarted after it is qualified through calibration, it shall intensify overall check of the unit in restart, if any abnormality, it shall find out and eliminate the cause immediately.
23. Feed water pump set outlet check valve is untight and rotates reversely
23.1 Phenomenon: 23.1.1 Feed water pump reverses; 23.1.2 The pressure of the outlet header pipe decreases and the current of the parallel running pump increases; 23.1.3 Sound of the reversing pump is abnormal and accompanied by increased vibration; 23.1.4 Water level of deaerator rises; 23.1.5 Water level of steam drum decreases and feed water flow decreases; 23.1.6 The oil inlet temperature of working oil cooler rises. 23.2 Treatment 23.2.1 Once discovering pump reversing, it shall close the outlet motor-operated valve and center tap motor-operated valve of this pump immediately; 23.2.2 If the reversing feed water pump outlet motor-operated valve and center tap valve loss power or jammed and cannot be closed, it shall stop the working feed water pump, close the forced handwheel of HP heater outlet check valve, close the main feed water motor-operated valve of boiler and feed water bypass motor-operated valve, press MFT to shut down the boiler and shut down the turbine without vacuum broken; 23.2.3 In any case, the feed water pump can only be stopped after all outlet motor-operated valves have been closed. Assign person to monitor locally if the pump reverses in the process of stopping the pump; 23.2.4 When the feed water pump restores standby, it shall open the outlet motor-operated valve with hand, and verify the outlet check valve have returned prior to electric opening.
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24.3.5 In operation at high frequency, reduce the active output as required, pay attention to the vibration of unit, if the vibration rises up to the tripping value, it shall conduct emergency shutdown.
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upper, middle and lower layer raised an alarm; 25.1.4 Steams pressure and temperature decrease sharply, the water level of steam drum first decreases and then rises; 25.1.5 Boiler fire extinguishing, MFT operates, steam turbine trips, generator-transformer unit parallels off the system; 25.2 Cause 25.2.1 Conditions of the MFT operation are met; 25.2.2 Auxiliary power interrupts; 25.2.3 Boiler load is too low, operation and adjustment are improper, disproportion between air and pulverized coal, primary air speed is too high or proportioning of primary and secondary air is improper; 25.2.4 Jet burner operates with seriously unfilled corner, coal feeder gets fault, pulverized coal chute is blocked, level of pulverized coal is too low, which make combustion unstable that is not adjusted and treated in time; 25.2.5 Water-cold wall pipe, economizer, superheater and reheater burst seriously; 25.2.6 Boiler has serious fouling and coke residue fall off by a large area; 25.2.7 Coal quality is too poor, volatile content is too low or coal type changes suddenly; 25.2.8 When ash is being removed, large amount of cold air enter the furnace; 25.2.9 When the combustion is unstable, fail in put oil into supporting the combustion in time; 25.2.10 During startup, oil gun gets fault and oil quality is poor; 25.2.11 Induced and forced draft blower trip; 25.2.12 Both flame monitor and cooling fan get fault. 25.3 Treatment 25.3.1 Extinguish the boiler fire and treat the unit as emergency shutdown; 25.3.2 Report to the unit supervisor, extinguish the boiler fire, if the turbine does not trip, reduce the load to 5~20MW according to the steam pressure, keep turbine at full speed, but if the operating time at no load exceeds 15 min, it shall trip to shut down the turbine immediately; 25.3.3 Close the attemperating water valve, change the auto control of feed water to manual control and control the water supply well, prevent the boiler from being overfed with and lack of water; monitor and adjust the water level of the deaerator and condenser, as well as shaft seal pressure. 25.3.4 In the process of fire extinction, pay attention to control no cooling of cylinder, strictly prevent water hammer accident, closely monitor the differential expansion and temperature change of all metals. 25.3.5 For boiler fire extinction, if it is to maintain low power operation, it shall keep initial steam - 85 -
pressure and temperature down rate not exceed the permitted value and fulfill the operations or checks as specified in section 25.3.2~25.3.4. 25.3.6 In the process of treatment, closely monitor we various differential expansion, axial displacement, temperature, vibration and sound, etc. of thrust bearing pad.
26.3 Treatment of Abnormal Operation & Accidents of Motor 26.3.1 When there is any abnormal state occurring in operation of motor, it shall report to the unit supervisor at once to assign special person to check. 26.3.2 For the tripped important motor (the one that will affect the output and safe operation of the - 86 -
unit ), when there is no standby one or the standby one cannot be started quickly, in order to keep the unit keep on operating, once forced closing of the tripped motor is permitted. But the following cases are not included: a. In case of fatal accident that requires immediate shutdown. b. The equipment driven by the motor is broken. c. The motor with protection operating to trip (for feed water pump & water circulating pump) 26.3.3 Treatment of motor tripping a. Start the standby power. b. If there is no standby power, it shall assign person to check, if no problem, restart it, if it trips again, then prohibit starting and advise the maintaining personnel to treat. 26.3.4 Treatment of motor starting with sound but without rotating or abnormal rotating speed a. Cut off the power supply of motor immediately and check it according to the cases above; if the fuse has blown, replace with a new one, if the voltage is too low, there is the means to adjust the voltage. b. Advise the maintenance personnel to treat. 26.3.5 Treatment of motor rotor with current oscillating periodically in operation a. Start the standby motor unit and stop the equipment with fault b. It shall intensify monitoring of the equipment with fault if there is no standby one, and it shall stop the unit with fault and report to the maintenance personnel if the check and treatment fail and oscillating amplitude of ammeter increases. 26.3.6 Treatment of motor with smoking & fire and burnt odor a. Switch off the power supply of the motor at once. b. Extinguish the fire with the forceful dry powder extinguisher, 1211 extinguisher, CO 2 extinguisher or the mist-sprinkling extinguisher. It is strictly prohibited to use high flow water, sand and foam extinguisher to extinguish the fire. c. After fire extinction, cut off the power supply of the faulted motor with and isolate it for safety purpose, and advise the maintenance personnel to treat. 26.3.7 Treatment of motor with much vibration a. Start the standby equipment and stop the operation of the equipment with vibration. b. If there is no standby equipment, it shall lower the load of motor to see if the vibration can decrease or disappear. c. If the vibration continues, it shall cut off the power supply for treatment. 26.3.8 If the motor temperature in operation rises abnormally to exceed the permitted value, it shall make the following checks: a. If the voltage is lower than the specified value and the current is higher than the rated value. b. If the cooling system and fan operate normally. c. If the three-phase current (voltage) is in balance.
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d. If the equipment drive is jammed and caused overload. 26.3.9 Check and treatment of motor with bearing temperature rising in operation a. Check if the oil ring can rotate, if oil carriage is normal, if oil pipeline is blocked or oil interrupted. b. If oil quantity is sufficient, pressure and temperature are normal. c. If the rolling bearing is overfed with or lacks oil. d. If the cooling water of bearing is normal. e. If there is abnormal sound or worn parts of the bearing. 26.3.10 Precautions for treatment of abnormal operation & accident of motor a. When auxiliary power disappears, do not switch off the motor within 1 minute (except that with low voltage trip). b. In the case of tripping for low voltage protection operating, it is strictly prohibited to start the motor forcedly.
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there is no regulation from the manufactory. Permitted Temperature Rise of Different Insulation Grades Insulation Grade A Max
Permitted temp. Permitted temp. rise
E Max p
Permitted temp. Permitted temp. rise
B Max
Permitted temp. Permitted temp. rise Permitte d temp.
F Max
Permitted temp. rise
Stator and rotor winding Stator core Sliding ring Sliding bearing Rolling bearing 100 100 60 60 115 110 75 70 140 140 80 80 140 130 100 90 95 55 105 65 110 70 125 85
80
40
80
40
80
40
80
40
100
60
100
60
100
60
100
60
The temperature of bearing in normal operation shall be stable, generally the sliding bearing temperature shall not exceed 65 and the rolling bearing temperature shall not exceed 80. The enclosure temperature of the motor with grade A insulation must not exceed 75; The enclosure temperature of the motor with grade E insulation must not exceed 80; The enclosure temperature of the motor with grade b insulation must not exceed 85; If excess, it shall lower the output or take measures to lower the temperature. 1.3.2 Vibration shall accord with specification: Rated rotating speed (r/min) Vibration value (mm) 750 0.12 1000 0.1 1500 0.085 above 1500 0.05
1.3.3 The axial movement must not more than 2~4mm. 1.3.4 The current and temperature rise of motor shall accord with the specification. 1.3.5 The oil level of all lubricating oil tanks is normal without oil leak. 1.3.6 Good seal of the sealing parts of equipment. 1.3.7 There is no abnormal sound and friction sound of the turning equipment and motor. 1.3.8 The mechanical connection of all adjustment devices shall be in tact without dropping. 1.3.9 The pressure of the outlet and inlet, and flow of equipment conveying medium are normal. 1.3.10 There is water, gas, power and oil leak in the auxiliary equipment and the system to which - 91 -
it is subordinate.
1.5 Conditions of emergency shutdown of rotating equipment: 1.5.1 In the case where the motor or driven equipment has such accident that emergency shutdown can avoid personal injury. 1.5.2 The driven equipment by motor is damaged seriously and can not keep on running; 1.5.3 In case of fire accident that endangers the equipment and personal safety; 1.5.4 IN case of serious leak of water and oil; 1.5.5 Bearing oil interrupts, smokes or temperature exceeds the specified value; 1.5.6 After closing, the motor fails in running or running at a lower speed than normal speed and accompanied with abnormal noise; 1.5.7 After starting, the motor current does not return within specified time or there is no indication of current; 1.5.8 After closing, the motor smokes or sparkles.
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2.2 Equipment specification Equipment specification Model Water specification pump Flow Head Speed Manufactory Model Power Motor specification Voltage Current Speed Manufactory KW V A r/min YKK450-6 400 6,600 47.4 990 m /h m r/min
3
2.3 Inspection prior to start-up 2.3.1 Inspection work is finished, no foreign matters blocking operation, check if motor connection and ground connection are sound, and insulation is qualified. 2.3.2 Oil level of all bearings is normal and oil quality is good, rotor shall be normal in turning; 2.3.3 Inlet valve of water pump is opened, and outlet valve is closed (if in standby, outlet valve is opened, and water pump shall not inverse) 2.3.4 Water level of clarified water pond is normal, and the pond inlet valve is opened; 2.3.5 Various interlocks and protections of water pump are good through static test, and motor is powered on. 2.3.6 Start water chamber vacuum pump to vacuumize the industrial water pump pipe.
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3.3.3 Close inlet valve and outlet valve of oil purification device; 3.3.4 Turn the power switch to OFF position.
3.4.8 Low water level control and alarm: After opening water discharge valve, water level will decrease promptly, as decreasing to the set water level, water discharge valve will close, water level will no longer decrease thereupon. In case water level keeps on decreasing to the set ultra low level, equipment will shut down, meanwhile low level alarm lamp (LP07) will flash. 3.4.9 Alarm of water discharge time being over long: if water level is lower than the high water level as a result of water discharge valve opening, and if the discharge time is over long that exceeds 5min, the water discharge valve can not close, equipment will shut down, and meanwhile alarm lamps of low water level and high water level will flash synchronously.
recirculating filter can be used to discharge oil in filter element. 3.6 Abnormal operation of oil purification device and its treatment 3.6.1 Frequent fault of oil purification device mainly includes the following: a. Auto water discharge valve operates disorderly resulting in oil spills from discharge outlet or no water discharging. b. Oil water interface instrument is out of order; c. Blocking occurs in inlet filter element, circulating filter, and coalescing and isolating filter element; d. Oil pump operates abnormally, and has abnormal sound or vibration. 3.6.2 The above fault shall be treated after stopping oil purification device.
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metallic friction sound inside steam turbine. And stop one jacking oil pump. 4.2.10 Measure the eccentricity of shaft that shall be < 0.076mm and less than the original value by 0.03mm.
4.4.2 Oil cooler put-in 4.4.2.1 Check if the oil outlet valve of oil cooler is closed, open oil inlet valve slightly, close air exhaust valve after draining away air, then open the oil inlet valve wide (in case of put-in after overhaul, the above operation shall be performed after accumulated water being drained away); 4.4.2.2 Open water discharge valve at water side, and check if there is any oil leakage, if any, it is strictly prohibit to put in. close water discharge valve after leakage check over. 4.4.2.3 Slowly open the water inlet valve, and close air exhaust valve at water side after draining away air, then open the water outlet valve; 4.4.2.4 Open the oil outlet valve of oil cooler; 4.4.2.5 Regulate oil temperature within specified range. In oil temperature regulation in operation, it shall open the water inlet valve wide and regulate oil temperature with return water valve, thus - 100 -
prevent fullness of oil cooler water side from being little, and deposit corrosion from accelerating.
4.4.3 Oil cooler shutdown 4.4.3.1 Check if the oil outlet valve of oil cooler has been closed; 4.4.3.2 Close cooling water outlet valve of oil cooler; 4.4.3.3 If servicing is necessary, the oil inlet valve and water inlet valve of oil cooler shall be closed, and maintenance personnel shall be contacted to discharge the accumulated oil & water in this oil cooler thoroughly; 4.4.3.4 Standby mode of standby oil cooler For standby oil cooler, oil inlet valve & water inlet valve shall be opened and oil outlet valve and outlet valve shall be closed to guarantee oil cooler in oil-filled and water-filled state for standby and prevent water side from scaling, and oil side from water or air entering.
4.5 Inspection and maintenance in lubricating oil system operation 4.5.1 Check if operation of all the oil pumps and smoke exhaust fans are normal, and vibration and motor current within specified range. 4.5.2 Check if bearing lubricating oil pressure is within the range of 0.09~0.15MPa, and jacking oil pressure is normal in turning state. 4.5.3 Check outlet oil temperature of oil cooler for normal, lubricating oil temperature shall be higher than 25C in turning; as steam turbine being in normal operation, lubricating oil temperature shall be within a rang of 38~42C, and oil pressure of oil cooler shall be larger than water pressure. 4.5.4 Normally, bearing return oil temperature is below 65C, metal temperature of journal bearing #1~3 is below 107C, metal temperature of journal bearing #4~5 is below 75C, and metal temperature of thrust bearing is below 99C. 4.5.5 Monitor oil level of main oil tank for normal, if it is over high or too low, it may discharge or make up oil to oil reservoir. 4.5.6 Oil pressure of jacking oil pump inlet shall be >0.039MPa. 4.5.7 Pay attention to the lubricating oil quality, clean or filter oil if necessary, and enhance chemical supervision to steam turbine oil. 4.5.8 When turbine operates in rated speed, oil pressure of main oil pump inlet and outlet shall be normal. 4.5.9 Check if no leak in system. 4.5.10 Starting oil pump, AC &DC lubricating oil pumps, jacking oil pump and smoke exhaust fan shall be tested periodically according to requirement. - 101 -
4.5.11 Remarks 4.5.11.1 When unit starts and stop, the main oil pump operating at above 2,700r/min ( 90% rated Rev) can meet all the oil demand of speed governing and lubrication; 4.5.11.2 The capacity of single oil cooler is 100%, and only one set is enough in normal operation; 4.5.11.3 The brand of lubricating oil is 32# steam turbine oil with cleanness up to grade NAS7.
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vibration of the pump set and check if the bearing temperature is < 70; 5.1.5 Pay attention to that the operating time when the pumps outlet valve is not opened or the pump fails in draining water to the system must not exceed 60s; 5.1.6 If one circulating water pump accords with the standby condition, put it on AUTO position and put the outlet disc valve into AUTO; 5.1.7 After the cooling water flowing into the condenser becoming normal, check if the generator air cooler, outlet and bypass valves are all opened, open slowly the strainer inlet valve of circulating water to generator air cooler to fill the generator air cooler with water; - 103 -
5.1.8 Open slowly the strainer inlet valve of circulating water to the generator air cooler manually, fill the cooling water pipeline of turbine oil cooler slowly with water, and thereafter put it into operation.
5.4.1.4 Close slowly the air valve of condenser on stopped side and circulating water inlet motoroperated disc valve, pay attention to that the back pressure of condenser shall not be lower than 16.9Kpa, start another vacuum pump if necessary to intensify monitoring of the vibration, differential expansion and axial displacement; 5.4.1.5 Close the circulating water inlet and outlet motor-operateddisc valve of condenser on the stopped side, open the circulating water discharge valve on the stopped side, pay attention to the change in vacuum. If there is serious leakage in the condensers pipe, here pay attention to vacuum decreasing, it shall close the circulating water discharge valve immediately, report to the unit supervisor to restore the original running mode immediately and make decisions after reporting; 5.4.1.6 After circulating water on the stopped side drain away, the vacuum shall keep within the permitted range, power off the motor-operated inlet disc valve of condenser on the stopped side, motor-operated outlet disc valve and rubber ball pump motor, then it may permit the maintenance personnel to open the manhole to work; 5.4.1.7 In the whole process of cleaning and leak stoppage, it shall monitor strictly the change in the condenser vacuum and exhaust temperature, if any abnormality and vacuum decreases sharply, stop working immediately and load on as per vacuum.
5.4.2 Half side operation of condenser: 5.4.2.1 Work sheets of the cleaning and leak stoppage of condenser has been packed up, all the safety measures have been removed; 5.4.2.2 Check that the manhole valve is closed tightly, close water outlet of put-in side, power on the motor-operated inlet disc valve of condenser on the put-in side, motor-operated outlet disc valve and rubber ball pump motor after confirming they are qualified in insulation; 5.4.2.3 Open narrowly the outlet motor-operated disc on the stopped side of condenser manually to charge water on water side, open the outlet and inlet motor-operated disc valve of circulating water wide; and open the air valve of condenser on the put-in side. 5.4.2.4 If the other side requires cleaning or leak stoppage, then after the put-in side operating becomes normal, stop the other side according to the above methods; 5.4.2.5 After both sides of condenser become normal, stop one vacuum pump if there are two pumping operating, and the other back to standby; 5.4.2.6 Report to the unit supervisor after checking thoroughly that the exhaust temperature and vacuum of the unit are normal, the leak stoppage work is finished, the unit load returns to normal and stop the LP cylinder spray.
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5.5 Washing of condenser rubber ball 5.5.1 Hand-operated put-in: 5.5.1.1 Before putting the rubber-ball system into operation, the operator shall contact with the personnel of Centralized Control Room to make good preparation for operation; 5.5.1.2 Check that there is no need of maintenance and the equipment is in good condition, the meters are all presented and the spot is clean; 5.5.1.3 Turn the rubber ball pump shaft to run flexibly and without jamming. Confirm the motor insulation is good and power on; 5.5.1.4 Check that the inlet valve of rubber-ball pump on the washing side has closed and the water discharge valve of Loaded Ball Room has opened, and the outlet valve has closed too, and the switch valve of Loaded Ball Room has been turned to the position of collecting the balls; 5.5.1.5 Open the top cover of Loaded Ball Room, and close it and water discharge valve after putting into adequate rubber-ball (500 pieces); 5.5.1.6 Open the inlet valve of rubber-ball pump slightly and fill Loaded Ball Room with water. When there is water overflowing, close the air valve and open the inlet valve of rubber-ball pump wide; 5.5.1.7 Contact with the personnel of Centralized Control Room to put the rubber ball of Condenser into washing. Keep records of the vacuum, load, exhaust temperature, circulating water pressure and circulating water outlet and inlet temperature; 5.5.1.8 Start the rubber-ball pump. Open the outlet valve of Loaded Ball Room and switch the valve to the Wash position to put it into operation. Pay attention to observing the vacuum change of condenser. 5.5.2 Collecting ball and shutdown 5.5.2.1 The rubber-ball shall be fetched and the switch valve shall point at the position of Wash before the process of washing is completed; 5.5.2.2 Close the outlet of Loaded Ball Room to shut down the operation of rubber-ball pump and close the inlet valve of pump; 5.5.2.3 Open the air release valve and water discharge valve of Loaded Ball Room and open the top cover to pull out the rubber-balls; 5.5.2.4 Figure out the percentage of fetching rubber-ball and compare the washing effect after finishing washing (the percentage of outballs/inballs).
5.5.3 Program control 5.5.3.1 The method of check, ball filling the and air release of Loaded Ball Room is the same with - 106 -
the hand- operated process; 5.5.3.2 Check that the rubber ball washing equipment is in the state of program control, press the button Program/ON to check if all motor-operated valves and rubber-ball pumps operating normally; 5.5.3.3 The washing is to end 30 minutes later and the system automatically starts to fetch the balls ball fetching is to end after another 20 minutes with all motor-operated valves closed and rubber ball pump shut down.
5.6 Inspection & maintenance in operation 5.6.1 Reinforce the inspection and maintenance of circulating water system in operation, pay attention to the variation of steam condenser vacuum. 5.6.2 Control the circulating water inlet temperature not to exceed the specified value; 5.6.3 Check if the valves of circulating water system are sound without leak, and water outlet temperature difference between steam condenser two sides are not more than 2C; 5.6.4 Monitor the water outlet differential pressure between two sides of condenser is normal; 5.6.5 Monitor and check if the open & close positions of steam condenser inlet & outlet motoroperated disc valves are correct; 5.6.6 Monitor inlet strainer of circulating water pump that shall not be blocked; otherwise, maintenance personnel shall be informed for clearing; 5.6.7 Pay attention to checking bearing oil level, bearing temperature, and motor coil temperature that shall be within the specified range, otherwise, give treatment in time; 5.6.8 Washing time of rubber-ball is from 60 to 80 minutes every time. From March to June, the time for putting the balls is on Monday, Wednesday, and Friday every week. At the other time, the time is on Tuesday and Friday. If discovering any dirt in the copper pipeline of Condenser, it may increase the number of times of rubber ball washing. After finishing washing, it shall switch the electric push rod into the position of ON in order to avoid jamming of circulating water.
5.7.2.1 Once circulating water interruption is ascertained, unit load shall be decreased to zero immediately, inlet & outlet disc valves of steam condenser or outlet valve of circulating water pump shall be checked for mis-close, if any, it shall be opened at once. The auxiliary water pump shall be started for recovering water supply as soon as possible, if fails, shutdown shall be performed promptly; 5.7.2.2 After shutdown for fault, if water supply for steam condenser can not be recovered temporarily, condensate pump recirculation valve shall be opened in time. 5.7.2.3 In case of circulating water interruption, the interconnection valve between industrial water and circulating water shall be opened in time, and attention shall be paid to the metal temperature of all the auxiliary equipment, outlet temperature of oil cooler and air cooler that must not exceed the specified value; 5.7.2.4 In case of circulating water interruption, pay attention to if the steam condenser rupture disk operates, if any, perform shutdown immediately.
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6.2.2.1 Open the motor-operated valve of overflow valve and auxiliary steam inlet governing valve; 6.2.2.2 Regulate the pressure of seal steam supply header to that of governing valve setting point; 6.2.2.3 Start a shaft seal heater blower, and the other for standby, regulate the water level of shaft seal heater; 6.2.2.4 Close drain valves of steam seal return steam pipes of HP & MP cylinder, and close the drain pipe of steam seal return steam header. 6.2.2.5 Regulate pressure of steam seal header to 0.02~0.03MPa, LP steam seal temperature to 121C~176C, and difference between rotor metal temperature of high & MP steam turbine shaft seal and steam pressure of shaft seal to 111C; 6.2.2.6 Check if the continuous drain operation of steam seal header between steam attemperating section and LP steam seal is normal. 6.2.2.7 Close drain valve on steam seal piping after steam supply of steam seal being normal; 6.2.2.8 Precaution: In cold start-up, it shall pump vacuum first, and then supply steam to steam seal; In warm-hot start-up, it shall supply steam to steam seal first, and then pump vacuum.
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interlocking switch of auxiliary condensate pump first. Start the standby pump first in switching condensate pumps. 7.3.2 Adjust the condensate recirculation valve to maintain the pressure of condensate water within the normal range. 7.3.3 Close the outlet motor-operated valve of condensate pump, pay attention to the variation of condensate header pressure and the water level of steam condenser and deaerator. 7.3.4 Shut down the condensate pump. 7.3.5 When the condensate pump acts as standby after shutdown, put it on the auto position and open the outlet motor-operated valve. Check the motor-operated outlet valve and pay attention to the pressure change of the condensed water main pump and water level of the Condenser and deaerator;
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temperature at a rate of 2/min that shall not exceed 3/min maximally; 7.4.2.7 Close the drain valves before and after corresponding extraction check valve; 7.4.2.8 Gradually open the steam inlet valve of LP Heater in operation according to the temperature rise of LP heater in operation; 7.4.2.9 The drain water of LP Heater # 4 & 5 shall be dumped into the LP Heater #6, and it shall start the drain pump according to the water level of #6m and check the automatic control equipment in normal operation and adjusting water level normally.
7.4.3 Paralleling off of LP Heater 7.4.3.1 Close the steam inlet and the corresponding check valve of the LP heater paralleled off; 7.4.3.2 In paralleling off the LP Heater, it shall dump the drain water from last stage LP heater into condenser, close the drain governing valve and hand-operated valve of this stage LP heater to the next stage LP heater; in paralleling off the LP heater #6, it shall dump the drain water of LP heater into the condenser and stop the LP heater drain pump; 7.4.3.3 Close the extraction valve of paralleled-off LP Heater and open the water discharge valve on the steam side; 7.4.3.4 Open the condensate bypass valve of paralleled-off LP Heater and close the water outlet and inlet valve and pay attention to the change of the pressure and temperature of deaerator and the vacuum of condenser.
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7.5.2.4 When the pump shuts down for servicing, close all cooling system valves, sealing water valves, air extraction valves and the pump outlet & inlet valves.
7.6.2 Condensate pump 7.6.2.1 Sound is normal and there are no friction and vibration; 7.6.2.2 Check the outlet pressure of the condensate pump that shall be normal; 7.6.2.3 Check the leakage of condensate packing set that shall be normal; 7.6.2.4 The temperature of motor coil is normal; 7.6.2.5 Switch over condensate pump periodically. 7.6.3 LP Heater 7.6.3.1 There shall be no water hammer and vibration in the heater; 7.6.3.2 The water level of the heater is normal; 7.6.3.3 Check the temperature and pressure of the outlet and inlet on the water side of LP heater that shall be normal. 7.6.3.4 Check the pressure and temperature on the steam side of LP Heater that shall be normal. 7.6.3.5 Check if there is no leak in the system. 7.6.4 LP Heater drain pump 7.6.4.1 There shall be a little thin flow of leakage, if it is excessive or none, it shall check and adjust the tightness of filling in time; 7.6.4.2 The bearing oil level is normal. If it is low, add oil in time.
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7.7.1.4 Bearing has smoke belching; 7.7.1.5 Leak occurs in condensate pump that endangers personal and equipment safety. 7.7.2 Vaporization or air leak occurs to condensate pump 7.7.2.1 Phenomenon: a. Outlet pressure of condensate pump fluctuates, the flow is unsteady or decreases to zero; b. Motor current decreases or fluctuates; c. Abnormal sound in pump body, vibration in outlet header and the check valve makes impact sound; d. Dissolved oxygen in condensate rises. 7.7.2.2 Causes: a. Steam condenser water level is low; b. Air leak in condensate pump inlet pipe; c. Air leak in condensate pump packing, the sealing water valve is not opened or opened too little; d. Inlet strainer of condensate pump is blocked; e. Condensate flow is too low, and the recirculation valve is not opened. 7.7.2.3 Treatment a. Check if the water level of steam condenser hot well is normal, if lower, make up water to normal; b. Check the condensate packing sealing water, and adjust the sealing water quantity to normal; c. Check the air extraction valve of condensate pump that shall be on open position; d. Open the condensate recirculation valve in time; e. If adjustment fails, start the standby pump and stop the faulted pump. 7.7.3 Steam condenser water level abnormal 7.7.3.1 Phenomenon a. Alarm for steam condenser being high or low; b. Local water level gauge indicates high or low. c. Overhigh condensate level will result in vacuum degree decrease, and too low condensate level will result in abnormal sound or vaporization in condensate pump. d. As water level of steam condenser rises to high value I, the standby condensate pump starts by interlock. 7.7.3.2 Causes: a. Condensate pump gets fault; b. Leak occurs in steam condenser copper pipe; c. Leak occurs in LP heater; d. Deaerator water level control is out of order, or deaerator water level is abnormal; e. Condensate piping gets leak or discharge valve mis-opens;
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f. Auto control device of steam condenser water level operates disorderly; g. Recirculating valve of steam condenser is not closed tightly; h. Overflow valve or water discharge valve of deaerator is untight or mis-opened. 7.7.3.3 Treatment of low steam condenser water level a. Check if make-up water control valve of steam condenser operates normally, otherwise open its make-up water bypass to make up to normal; b. Check if water level control valve of deaerator is mis-opened large or jammed, if any, adjust to normal in time. c. Check if water discharge valve of LP heater #4 outlet is mis-opened, if any, close it in time; d. Check if any leak in condensate system. 7.7.3.4 Treatment of high steam condenser water level a. In case condensate pump gets fault in operation, it shall start the standby pump, stop faulted pump, and contact maintenance personnel for treatment. b. Check if make-up water control valve of steam condenser operates normally, if inlet water flow is too large, if such, turn it down. c. In case of leak in steam condenser brass pipe, check if the steam condenser half side leaks, if serious, shut it down for treatment. d. Check if condensate recirculating is mis-opened, if any, adjust recirculation in time. e. In case of steam condenser water level rise, open the water discharge valve of LP heater #4 outlet so as to discharge to normal. 7.7.4 LP Heater is overfed with water 7.7.4.1 Phenomenon: a. Alarm for high water level LP Heater; b. The water gauges indication of LP Heater is high; c. The current of LP Heater drain pump may decrease. d. The condensate flow may reduce. 7.7.4.2 Causes: a. The pipe of Heater leaks; b. Drain governing valve works abnormally; c. Drain pump of LP Heater woks abnormally; 7.7.4.3 Treatment: a. When the water level of LP Heater is higher than normal level, it shall check if the operation of drain governing valve is normal, otherwise open the emergency drain valve of LP Heater; b. Check the LP heater drain water that shall work normally, otherwise start the standby drain pump; c. When the water level of LP Heater is II, the emergency drain valve of LP heater to condenser
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shall be opened; d. When the water level of LP Heater is III, the protection operates, it shall close the extraction check valve and steam inlet valve of LP Heater, parallel off and isolate the LP Heater; e. When discovering the copper pipeline leaks, it shall be isolate and service it in time.
gauges and protections are powered on and indicates correctly; 8.2.1.4 To confirm the water level and the higher-and-lower pressure signal can alarm well. The motor-operated valves and governing valves switch can open and close flexibly and Open-Close operating direction is correct; 8.2.1.5 Contact the chemist to prepare enough dematerialized water pump and start the demineralized water pump, make up the makeup-water tank of condensate to the high level and test the water quality that is qualified; 8.2.1.6 Supply steam to the auxiliary steam header, prior to which, it shall warm up and drain water of the auxiliary steam header; 8.2.1.7 Ask the chemist to test the water level quality when the water level of the Deaerator reaches 600mm. If the water is not qualified, discharge water until it becomes qualified. The water overflow value shall be placed on the AUTO position; 8.2.1.8 When the water is qualified and the water level rises to 1,600mm, open the deaerating valve of Deaerator properly; 8.2.1.9 Open the hand-operated valve of heating & steam inlet valve at the bottom of deaerator slowly and put the bottom heating of deaerator into operation. Pay attention to controlling the pressure of deaerator 0.15Mpa prior to supplying steam to the deaerator; 8.2.1.10 Control the water temperature at about 100when the water level rises to the normal point of 2,550mm. 8.2.1.11 After the steam turbine started, recycle the condensate after it is qualified, determine whether to open the water inlet valve of condensate to deaerator according to the condensate flow, and the condensate flow of deaerator thus to guarantee deaerating effect. At the same time, put the auxiliary heating steam source into operation. Put the automatic control of deaerator water level into operation in good time; 8.2.1.12 When the extraction 3 pressure of this turbine is higher than 0.25Mpa, put the extraction 3 into operation, close the auxiliary steam valve and close the hand-operated heating & steam inlet valve at the bottom of deaerator; 8.2.1.13 The deaerator starts with the unit at sliding parameters, after the unit is in full load, check the deaerator in an all round way that shall be normal. 8.2.2 Check and maintenance of feed water pump prior to start-up 8.2.2.1 Ensure the maintenance work has finished, the work site is clean and equipment pipe is good; 8.2.2.2 Check if the position of all valves is correct; 8.2.2.3 Contact the heat engineer to supply power to all meters, protections and motor-operated valves, test heat engineering signals and accident alarm sound that are good. - 119 -
8.2.2.4 The oil level of the oil tank is on the upper-limit the oil quality is qualified, when the auxiliary oil pump operating, the oil tank temperature of hydraulic coupling is 15C, oil pressure within 0.17~025Mpa or so and 018Mpa minimally; 8.2.2.5 Drain out the gas in the oil and water pipeline of cooler and feed oil to circulate. When the filters differential pressure is > 0.06Mpa, switch it to the cleaning side. The lubricating oil shall keep on circulating until the strainer of filter is clean; 8.2.2.6 Check if the water level of the deaerator is normal, the temperature is > 50C, the feed water pump has a temperature difference between its upper and bottom pump body is lower than 20C; 8.2.2.7 The sealing water system works normally and loop is smooth; Check if the pressure after the sealing water governing valve is the ring is 0.05~0.1Mpa higher than the unloading water pressure; 8.2.2.8 Check if all transmission contacts of hydraulic coupling speed governing mechanism are firm transmitting reliably, and the handle is flexible, after it is normal through hand operation, set the scoop tube at 0 position; 8.2.2.9 Power on the feed water pump motor after it is qualified through insulation test and it is permitted to close the switch; 8.2.2.10 Close the water discharge valve of the feed water pump body; 8.2.2.11 Check if the recirculation valve is opened wide and set it on AUTO position. 8.2.3 Check and preparation prior to HP heater operation: 8.2.3.1 Ensure the check work is finished, the work site is clean the equipment pipeline heat preservation is good, meters are all complete, report to the heat engineer to power on the meters and protections; 8.2.3.2 Measure the motor insulation of all motor-operated valves that shall be good, qualified and powered on; 8.2.3.3 Check if the system valves are on correct position; 8.2.3.4 Put the HP heater protective water source into operation and the pressure is normal; 8.2.3.5 Companying with the heat engineer to conduct relevant test and interlock tests to HP heater that is good: extraction check valve 1 & 2 are normal through test, HP heater water level protection is normal through test, and the HP steam inlet motor-operated valve and emergency drain motor-operated valve are normal through opening/closing and interlock test; 8.2.3.6 Check and test that the HP heater drain auto-control valves opening and closing are flexible, direction is correct, and automatic control is normal. 8.2.3.7 Check if the HP heater four-way valve is on the bypass position.
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8.3.14.2 When the auxiliary oil pump is operating, the lubricating oil pressure is >0.17Mpa; 8.3.14.3 Open the booster pump inlet valve, feed water pump outlet valve and the recirculation valve; 8.3.14.4 The temperature difference between the pump body and feed water pump inlet is < 20C; 8.3.14.5 The differential pressure of the sealing water of feed water pump is > 0.1Mpa; 8.3.14.6 The interlocking switch of feed water pump in on AUTO position, and the scoop tubes opening is on 60% position.
8.5.1 Put the HP protective water source into operation; 8.5.2 Verify the inlet and outlet four-way value of HP heater are closed, feed water runs along the bypass, the water filler valve is closed tightly and open the steam discharge valve on the water side of HP heater; 8.5.3 Open the primary and secondary oil filler valve of HP heater to fill HP heater with water, after there is water overflowing the air valve, close the air release valve on the water side of HP heater, after the internal pressure of HP heater becomes equal to the feed water pressure, check the HP heater four-way valve that shall open automatically, close the water filler valve, check that there is no water level on the steam side of HP heater and verify no leak in HP heater; 8.5.5 Open the drain valves before and after the steam extraction section 1 and 2 check valve to warm up the pipe; 8.5.6 Open the water discharge valve at the bottom of HP heater 1 & 2 HP heater, as well as the air release valve on the top; 8.5.7 Open the check valves of steam extraction section 1 and 2; 8.5.8 Open the air inlet motor-operated valves of HP heater 1 & 2, maintain the HP heater pressure within 0.05~0.1Mpa for warming, after there is steam coming from the air valve of HP heater, close the air release valve of HP heater, and close the drain valves before and after the steam extraction section 1 and 2 check valve; 8.5.9 Close the water discharge valve at the bottom of steam side of HP heater 1 & 2; open the continuous exhaust valve of HP heater; 8.5.10 Maintain the differential pressure between HP heater 1 and 2 at 0.5Mpa, open the air inlet motor-operated valve of HP heater 2 & 1 gradually to control the average temperature rise of the outlet water of HP heater 1.83C, (sequence of extraction to be opened: 2 HP heater air inlet valve- 1 HP heater air inlet valve) until normal, pay attention to the water level of HP heater, when the steam side pressure of HP heater 5 is more than 0.3MPa higher than the deaerator pressure, it shall dump HP drain to the deaerator; 8.5.11 When the feed water temperature reaches the rating, open wide the air inlet valves of HP heater2 & 1; 8.5.12 Put the HP protection, automation of the check valves and air inlet valves of extraction stage 1 and 2, as well as Auto of emergency drain motor-operated valve into operation.
to that the feed water temperature decreasing rate must not be more than 1.83/min; 8.6.3 When the differential pressure between the steam side of HP heater and deaerator is less than 0.3MPa, switch the drain to the condenser, close the 2 HP heater drain and lead it to the hand-operated valve of deaerator; close the continuous exhaust valve of HP heater; 8.6.4 Close the air inlet motor-operated valve of HP heater 1, close the extraction 1 check valve fully, close the air inlet motor-operated valve of HP heater #2 and the extraction 2 check valve. When closing the all, verify the inlet valve is closed tightly, then stop the water side of HP heater, close the inlet & outlet four-way valve of HP heater with the feed water running along the bypass. Check if the feed water pressure is normal; 8.6.5 Open the pipe of steam extraction 1 and 2 to drain water appropriately; 8.6.6 When there is a short time maintenance work on HP heater steam side, it is permitted to operate with only the steam side stopped, but it shall verify there is no leak in the HP heater, and open the water discharge valve on the steam side to discharge water until the steam side pressure decreases to 0 prior to operation. It is forbidden strictly for HP heater to operate with only steam side.
Auto position; 8.8.5 Start the auxiliary oil pump; 8.8.6 Reduce the rotating speed to minimal, set the scoop tube at zero point, and click the button Stop of feed water pump to stop the feed water pump. Record the idle time; 8.8.7 Adjust the sealing water pressure to normal in time; 8.8.8 When the lubricating oil inlet temperature the decreases to 40, turn down the cooling water value of lubricating oil cooler. When oil temperature of the service oil cooler is 50, turn down the cooling water valve of the service oil cooler; 8.8.9 If it is to put the feed water pump into standby, open its outlet valve and check the check valve that shall be closed tight and feed water pump is on Auto position; 8.8.10 If the feed water pump requires a maintenance, it shall ensure the auxiliary oil pimp to operate for half 30min after pump stop and supply oil to cool the feed water pump.
8.10 Check and maintenance of the feed water & deaerating system
8.10.1 Check and maintenance of deaerator a. It shall monitor the changes in pressure, temperature and water level from time to time when the deaerator is normal operation. If any abnormality, adjust it/them back to the normal range; b. When the condensate pump stopped because of fault, it shall start the standby condensate pump instantly. If the inlet water of deaerator interrupts, it shall close the air inlet valve immediately in order to prevent the deaerator from overtemperature; c. It shall open the deaerating valve wider if there is not qualified oxygen content in the water of - 125 -
deaerator. It may open the heating & steam inlet at the bottom if necessary to adjust the oxygen content to qualified; d. Check the indication of the pressure gauge, thermometer and water level gauge of deaerator on schedule, if any abnormality, it shall report for treatment in time; e. If the water level decreases because of improper adjustment of water level or the condensate pumps insufficient output, it shall take some measures to make up water timely. But pay attention to that: Dont hurry, it may affect the pressure of deaerator and cause vibration. It may lower the unit load if necessary; f. If the water level still keeps on decreasing measures, it report to the unit supervisor. If emergency water level occurs to affect normal operation of feed water pump and cause fault hereof, it shall lower the load to shut down the unit; g. Check the running condition of the safety valve of deaerator in operation regularly, when deaerator is overpressed, pop the safety valve in order to ensure normal operation of deaerator. 8.10.2 Check & maintenance of feed water pump a. Check if the feed water pump set has any friction and leak, vibration is normal and no abnormal sound. b. The oil level of oil tank and bearing is normal and the auxiliary oil pump is in good and standby state; c. All the protections have been put into operation, the automatic equipment works normally; d. The sealing and cooling water system operate normally and the return water is unimpeded; the sealing water governing valve can adjust automatically to make the pressure after valve have always been 0.05~0.1MPa higher than the pressure before the booster pump inlet valve. At the same time, maintain the return water temperature of sealing water within 70-80; e. The coupling works soundly, and the speed governing mechanism is not jammed. 8.10.3 Check and maintenance of HP heater a. HP heater water level is normal, and operation of automatic drain governing device is normal; b. No water hammer and vibration; c. Inlet and outlet temperature of water side is normal; d. Temperature and pressure of steam side are normal; e. No leak in the system through check;
8.11 Abnormal operation & treatment of the feed water & deaerating system
8.11.1 Abnormal operation & treatment of HP heater 8.11.1.1 Conditions of emergency stop of HP heater a. Pipes and valves, etc. on the steam side burst, which endangered the personal and equipment - 126 -
safety; b. Water lever of HP heater rises, treatment takes no effect and water level gauge is on the utmost; c. When water level gauge burst and can not keep on working; d. The HP heater proper leaks seriously and cannot keep on working. 8.11.1.2 Treatment of t HP heater overfeed with water Phenomenon: a. Alarm for high water level of HP heater; b. Protection may operate; c. The HP heater outlet water temperature is low, and the heater vibrates. Treatment: a. When HP heater water level is high, check if the HP heater drain system operates normally, when the drain governing valve is jammed, it shall open the emergency drain valve to lower the water level, and contact with the maintenance personnel for treatment; b. The running HP heater leaks and the water level rises to 850mm/1,125mm (HP heater1/ HP heater2) sharply, the water level high value I alarm is raised; c. If the HP heater water level rises to 1,000mm /1,275mm (HP heater 1/ HP heater 2), the water level high value II alarm is raised to open emergency drain valve automatically; d. If the Hp water level keeps on rising up to 1,200mm/1,475mm (HP heater 1/ HP heater2), the water level high value III alarm is raised, HP heater protection operates to close the feed water inlet & outlet four-way valve of HP heater, as well as the extraction motor-operated valve and check valve, open the water discharge valves on the steam side and water side and the air release valve; e. If the automatic paralleling off system of HP heater protection malfunctions and refuses to operate, it shall parallel off the HP heater by hand immediately, if still no effect, it shall operate all valves by hand locally immediately to parallel off HP heater; f. When the HP protection operates to parallel off automatically, it shall pay attention to adjusting the boiler combustion to prevent the initial steam from overtemperature or unit from overload.
8.11.2 Abnormal operation of deaerator 8.11.2.1 Deaerator pressure rise Cause: a. Air inlet interrupts or reduces; b. The opening of governing valve of HP heater drain to deaerator is too large; c. The unit load increases too quickly; - 127 -
d. Misoperation of system valve. Treatment: a. Increase the condensate flow, maintain normal water level to make the pressure recover; b. If the opening is too large, adjust it in time; c. Stabilize the units load and decrease it properly; d. Check if standby steam resource valve of deaerator is opened by mistake. 8.11.2.2 Deaerator pressure decrease Cause: a. Water Inlet flow increases suddenly or temperature decreases; b. The steam source pressure of deaerator is too low. Treatment: a. Check if the deaerator steam source is normal, if not, transfer to the standby steam source; b. Adjust the condensate governing valve according to the water level of deaerator. 8.11.2.3 Water level of deaerator rise Cause: a. Feed water pump trips, but the standby pump does not interlock or treatment is not timely; b. The water level auto-governing system of deaerator malfunctions or the opening of condensate governing valve is too large; c. The water quantity used by the boiler decrease suddenly; d. Mode of water filling is incorrect. Treatment: a. If the high water level I alarm of deaerator is raised, it shall turn down the governing valve of condensate to deaerator; b. When the water level of deaerator rises up to value II (2880mm), the overflow motor-operated valve opens automatically; c. Check if the feed water pump is started by mistake, if the mode of water filling is normal, if not, stop it; d. If the water level of deaerator rises up to the flood stage of 2950mm, the protection shall operate, close the steam extraction check valve and motor-operated steam inlet valve of extraction 3. 8.11.2.4 Water level of deaerator decrease Cause: a. The opening of the governing valve of condensate to deaerator is too small; b. The condensate flow interrupts or reduces; c. Feed water pump flow increases; - 128 -
d. The water discharge valve of deaerator is opened by mistake. Treatment: a. When the water level of the deaerator decreases, adjust timely the governing valve of condensate to deaerator, or open wider the makeup water to maintain normal water level; b. Pay attention to the change in condensate flow and maintain normal water level of condenser; c. Stabilize the water quantity used by the boiler and pay attention the adjustment of the scoop tube. 8.11.3 Abnormal operation & treatment of feed water pump 8.11.3.1 If any case as follows, the feed water pump protection will trip: a. The deaerator water level is the low value II (680mm); b. The differential pressure of sealing water is low; c. The oil inlet temperature of the service oil cooler of feed water pump is > 130; d. If the outlet flow of feed water pump is low (<132t/h), open the recirculation valve that does not open after 15 seconds; e. The librating oil pressure of feed water pump is the low value II (0.08MPa). 8.11.3.2 Conditions for emergency stop of feed water pump a. The main feed water system leaks and a great deal of water spraying that cannot be isolated, which endangered the personal and equipment safety; b. Water pump, booster pump and hydraulic coupling vibrate violently; c. There is metal impacting and friction sound between stationary and rotary part; d. The feed water pumps motor or bearing smokes and catches fire; e. Oil system catches fire that can not be extinguished in time, which endangered the safe operation of pump set; f. Vaporization in feed water pump, and the outlet pressure and current oscillate greatly and decrease; g. The thrust bearing temperature rises up to 95 sharply; h. Protection of feed water pump operates to trip. 8.11.3.3 Operating procedure of emergency stop of pump: a. Start the auxiliary oil pump; b. Press the emergency button of the faulted pump or open the console switch immediately; c. Check the standby feed water pump that shall start to operate automatically, if not, start it by hand. Check if the header pressure is normal, if it is the feed water pipe bursting, it shall be prohibited to start the standby pump. d. Close the outlet valve, recirculation and center tap valve of the faulted pump and open the outlet and center tap valve of the interlocked pump; - 129 -
e. Record the idle time and vibration value of the faulted pump; f. Complete other operations of pump stop, and take necessary safety measures as the fault may be; g. Report to the unit supervisor if there is no standby pump to shut down the unit for emergency. 8.11.3.4 Tripping off of feed water pump Phenomenon: a. The service pumps current reaches 0, the pump stops, emergency alarm is raised and feed water pressure swings or decreases; b. The standby pump interlock starts. Cause: a. Fault in the 6.6 KV busbar; b. Protections of feed water pump and motor operate or are operated by mistake; c. Misoperation made by man; d. The emergency button is pressed by mistake. Treatment: a. Check and close the outlet motor-operated valve and center tap valve of the tripped-off pump, check the auxiliary oil pump of the tripped-off pump that shall interlock to stop automatically; b. If the standby pump doesnt start, start it immediately, if no standby pump, or the standby pump cannot be started by hand, it may recluse the tripped-off pump once more (when it doesnt reverse); c. Adjust the interlocked pumps rotating speed, put the feed water automation into operation, and check if every part operating normally; d. Check the recirculation valve of the tripped-off pump that shall be opened, and the recirculation valve of interlocked pump shall be closed, otherwise operate by hand; e. If no standby pump is available in the system, and the faulted pump can not start either, report to the unit supervisor as soon as possible to conduct fault shutdown. 8.11.3.5 Vaporization in feed water pump Phenomenon: a. Abnormal noise occurs to the feed water pumps inlet pipe or the inner of pump body; b. Current and pressure of the inlet and outlet swing greatly; c. Feed water pressure decreases. Cause: a. Deaerator pressure and water level decrease suddenly; b. The inlet strainer is blocked; c. When the flow decreases to the opening value of the automatic recirculation valve, but it fails in - 130 -
operating, for which the operation and treatment are not timely; d. The inlet valve of booster pump is closed by mistake in operation. Treatment: a. Treat as per the requirements of emergency stop of pump; b. Find out the causes for vaporization in feed water pump, and eliminate the abnormity; c. If the vaporization is caused by inlet strainers of booster pump and feed water pump being blocked, it shall start the standby pump immediately; d. Only when the inlet pressure and deaerator pressure and water level become normal can it restart the pump or put the standby into operation. 8.11.3.6 Feed water pressure decrease Cause: a. Fault in the hydraulic coupling or the scoop tube is jammed; b. Water quantity used by the boiler increases greatly suddenly; c. Water pipe breaks or HP heater leaks seriously; d. The outlet check valve of standby pump is not closed tightly and the pump reverses; e. The system valve is operated by mistake; f. The service feed water pump is vaporized; g. When the feed water flow is 280t/h, the recirculation valve of service feed water pump is not closed. Treatment: The fead water flow exceeds 200t\h.The recirculation valve of the working feed water pump hasnt been closed. a. If the feed water pressure decreases, it shall ascertain the cause quickly and report to the unit supervisor at the same time; b. If the feed water pump gets fault, start the standby pump quickly; c. If the standby pump reverses, close the outlet motor-operated valve; d. Stabilize the water quantity used by the boiler if the cause is sudden increase of water quantity, adjust the speed of feed water pump and start the standby pump if necessary; e. If the standby pump has interlocked, it shall adjust the rotating speed timely to prevent the feed water from overpressure, after everything is normal, stop one feed water pump; f. If the recirculation valve of feed water pump operates abnormally, contact the maintenance personnel to treat. 8.11.3.7 Hydraulic coupling scoop tube being jammed Phenomenon: a. Adjustment to the scoop tube takes no effect; - 131 -
b. The feed water pump operates at a certain speed, which cant satisfy the requirement of the boiler or the rotating speed decreases. Treatment: a. Move the scoop tube locally to make it return to normal; b. If moving the scoop tube locally is useless, it shall stop the faulted pump and start the standby pump in time; c. Contact the maintenance personnel, it must not restart or put the standby into operation until eliminating the defect.
Steam turbine in the state of tripping; Starting oil pump and EH oil pump operate normally and oil pressure is normal; Manual shutdown is on the Reset position;
Then DEH will rise or decrease pulse according to the command received from electric aspect, turbine set value will change thereupon. Each pulse can rise or decrease the turbine set value by 1r/min, and with internal PID regulator, DEH can control turbine rotating speed to change thereupon, thus makes turbine rotating speed be synchronous with network. After synchronization, DEH will let turbine load on 5% initial load automatically. In the meanwhile, AS mode will disengage automatically and transfer back to OA mode. 9.5.3 Put-in and trip of power loop (MW IN, MW OUT) In on load operation, operator can select to put power loop feedback into operation: operator can click the button Feedback state on lower left of main control panel to pop up the sub picture, then click button power loop, afterwards click put-in button within 3S, then control will enter the power loop put-in mode, meanwhile the main panel displays device has entered to Power loop IN mode, After power loop feedback put-in, load signal will enter controller as feedback signal to control load to be identical with set value (undisturbed switch). Prior to power feedback put-in, DEH is in open-loop control, and there is certain difference between load set value and load, which is decided by the current main steam pressure, if main steam pressure is the rated value, load set value will be close to the load value. Generally, operator shall select the power loop clearing mode in order to ensure the initial steam pressure stable and boiler combustion adjustment stable. That is because after power feedback put-in, when main steam pressure fluctuates, valve opening will vary thereupon to guarantee developed power being identical with the load set value, and that vibration will accelerate vibration of boiler outlet pressure, but in order to guarantee load steady, power loop put-in is necessary. 9.5. 4 Remote control mode (ADS) In on load OA operation, and the set value is close to the remote control set value, operator can select to enter remote control mode: operator shall send out DEH remote control request, then press the button Control mode on top left of main control panel to pop up the sub picture, click button Remote control, afterwards click button Put-in within 3S, and then control will enter the ADS mode, meanwhile the main panel displays device has entered to ADS mode. At that time, load set value is under the control of CCS (Coordination control) system. Attention: as entering OA mode, ADS mode will disengage automatically. 9.5.5 Initial steam pressure limit (TPL) In on load OA operation, and initial steam pressure is higher than 90% rated pressure, operator can select the TPL (initial steam pressure limit) mode: operator can pressure the Limit value on lower left of main control panel to pop up the sub picture, then click button Initial steam pressure - 134 -
limit, afterwards click button Put-in within 3S, and then control will enter to TPL mode, meanwhile the main panel will display the main steam pressure limit is IN In the case of TPL mode, as initial steam pressure being lower than 90% rated pressure, load set value will decrease at a fixed rate. Shut down the control valve hydraulic servomotor can compensate the decrease of main steam, thus avoid initial steam pressure decrease being to large. TPL mode also can be cleared on limit at sub picture: click the button initial steam pressure restriction, afterwards click button Clear within 3S, and then control will disengage from TPL mode. 9.5.6 Remote control initial steam pressure limit (RTPL) In OA operation, and the initial steam pressure is larger than 90% rated pressure, operator can select the RTPL (Remote control initial steam pressure limit) mode: operator shall press the limit value on lower left of the main control panel to pop up the sub picture, then click button Remote control initial steam pressure limit, afterwards click button Put-in within 3S, and then control will enter the RTPL mode, meanwhile, the main panel will display the Remote control initial steam pressure limit being IN In RTPL mode, and the initial steam pressure is lower than 90% rated pressure, load set value will decrease at a fixed rate. Shut down the control valve hydraulic servomotor can compensate the decrease of initial steam, thus avoid initial steam pressure decrease being to large. RTPL mode also can be cleared on limit sub picture: click button Initial steam pressure restriction, afterwards click Clear button within 3S, and then control will disengage from TPL mode. 9.5.7 Load limit (HLL) mode In on-load OA operation, operator also can select high load limit mode: operator can press the button limit value on lower left of main control panel to pop up the sub picture, then input the load set value in high load limit mode area, afterwards click button High load limit, and click button Put-in within 3S, control will enter the high load limit mode thereupon, meanwhile the main panel will display IN. In case of high load limit mode, set value will not exceed the load limit value. High load limit mode also can be tripped on limit value sub picture: click button High load limit, and then click button Clear, control will disengage from the high load limit mode thereupon. 9.5.8 Valve position limit mode (VPL) In OA operation, operator also can select the valve position limit mode: operator can click the button limit value on lower left of main control panel to pop up the sub picture, click valve position limit, then input valve position limit value in valve position limit mode area, afterwards - 135 -
click button GO, here valve limit value will enter the DEH control logic. In case of valve position limit mode, valve command will not exceed the valve position limit value. 9.5.9 Single valve/ sequence valve (SIG/SEQ) mode In case of OA operation, operator also can select SIGLE (single valve) or SEQ (sequence valve) operation mode: click the button valve mode on milled lower part of main control panel to pop up he side picture, click single valve (or sequence valve) and the two switching buttons (press switching button within 3S after clicking single valve button, and it will be effective if the two buttons being red synchronously. In SIGLE mode, command of all the control valves is the same and all the control valves take part in control synchronously; in SEQ mode, four control valves will operate one after another according to a certain sequence. The switching time between two modes is about 3S so as to guarantee no disturbance of load in the whole switching process. 9.5.10 OPC mode (OPC MODE) Moreover, there is OPC (overspeed protection control) function set in DEH, in case load of steam turbine is over 30%, and main oil switch of motor trips, at that time, with the function of solenoid valve, all the hydraulic servomotors of control valve will control oil pressure to unload, thereby closing all hydraulic servomotors of governing steams. With the quick close of hydraulic servomotor, rotating speed acceleration will be restrained, and if steam turbine rotating speed is lower than 103% rated speed, and it is already 7.5S after OPC operation, then solenoid valve will lose excitation and hydraulic servomotor will start to maintain normal operation for waiting for synchronization. If steam turbine rotating speed still is larger than 103% after 7.5S, the valve will not open until steam turbine speed is lower than 103%. 9.5.11 Manual (TM) mode It also can enter the manual control mode in steam turbine operation. Pay attention that in manual operation, operator can change the set value (GVSPT/TVSPT) of control valve and main steam valve directly without the participation of DEH, and this is belonging to open loop operation, which is inappropriate to be used except rotating speed path fault, etc. special situation. The method for entering manual (TM) is as follows: press the manual button on manual control panel, if red lamp lights, that indicates device being in manual operation state, here operator can click the control mode button on top left of main panel to pop up the sub picture, and the manual state bar will display IN, meanwhile main panel will display device being in TM mode. In manual operation, operator can realize the control of steam turbine by controlling control valve set value directly with operating the GVUP GVDN buttons on manual operation panel, thereby change rotating speed and actual load. - 136 -
In TM mode, OPC function remains, once OPC operate, it still will close all steam governing valves.
10.2.5 During bypass put-in, put HP bypass in first, then the HP bypass, regulate pressure after governing valve and steam temperature to meet the requirement of start-up till outlet parameter being steady and normal; 10.2.6 In unit shutdown, the temperature and pressure releasing valve, pressure reducing valve and water spray control valve need to be open step by step according to operation parameter, after unit shutdown, the above shall be closed in time. 10.2.7 Bypass device operating time is less than 8S at constant speed; 10.2.8 The max designed through flow of bypass system is 70%B MCR Notes: six hydrodynamically-operated valves (including HP bypass pressure release valve, HP bypass attemperating water isolating valve, HP attemperating water governing valve, LP pressure release valve, LP bypass attemperating water isolating valve and LP attemperating water governing valve), shall open automatically in case of unit fault (all are on the interlocking position). 10.3 Shutdown of 70% bypass system 10.3.1 After unit loads on, bypass system shall be tripped according to the regulating requirement of boiler parameter. 10.3.2 In bypass trip, HP bypass shall be tripped first, and then the LP bypass, the attemperating water valve shall be closed first and then the pressure relief valve.
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11.3 The turbine proper part includes the following drains: 11.3.1 Drain of cold and hot section of the initial and reheat steam pipes; 11.3.2 Drain of HP air duct; 11.3.3 Drain of MP air duct; 11.3.4 Drain of HP cylinder jacket; 11.3.5 Drain of valve level steam leakage; 11.3.6 Drain before and after HP exhaust check valve and extraction check valve.
12.1.9 Verify the air compressor and service air system are put into operation and operating normally. 12.1.10 The manhole on the steam side of condenser steam side is opened. Check if the drain valve before HP exhaust check valve is opened. 12.1.11 Only when the cylinder temperature decreases to below 350, it can put the quick cooling equipment into operation. 12.2 Monitoring of parameters in quick cooling process: In order to ensure the mental temperature inside the turbine can decrease evenly in the process of quick-cooling after turbine shutdown so as to prevent overstress due to excessive cooling, rotor from bending and cylinder and welded junction from deforming, it must strictly monitor the changes in each point temperature, temperature difference between cylinder inner and outer wall, temperature difference between upper and lower cylinder, absolute expansion, differential expansion, axial deflection, rotor eccentricity, turning gear current, compressed air temperature and flow and electric heater current in the process of putting the quick cooling equipment of turbine into operation. The monitor control index of main parameters includes: 12.2.1 First stage metal temperature decreasing rate of HP cylinder is<5/h. 12.2.2 Carrier temperature decreasing rate of MP cylinder is<5/h. 12.2.3 Temperature difference between upper and lower cylinder of HP & MP cylinder is <42. 12.2.4 Indication of HP cylinder differential expansion is -2~+7.0 mm. 12.2.5 Indication of LP cylinder differential expansion is +6.5mm. 12.2.6 Rotor eccentricity is <0.076mm. 12.2.7 Turning gear current is normal. 12.2.8 Lubricating oil pressure is 0.12Mpa. 12.2.9 Cylinder expansion and contraction are smooth without sudden change 12.2.10 Control the compressed air flow within 25~80t/h. 12.2.11 After putt the quick cooling equipment of turbine into operation, , try to adopt no temperature difference and little flow mode as much as possible in the early stage of air supply, then slowly reduce the air temperature to keep the little temperature differences and increase the flow to observe the change in the cylinders temperature. Strictly control the cylinders air inlet temperature and ventilation quantity. In principle, keep stable for 30min every time of adjustment, if there is no change or great change, make readjustment. The outlet temperature of air heater shall decrease steadily without sudden change. When the air duct wall temperature of HP & MP cylinder is about 100 and the first stage metal temperature of HP cylinder decreases by less than 200 , it may increase the ventilation quantity. When the first stage metal temperature of HP cylinder and No.1 stator carrier temperature of MP cylinder reach below 140 and do not - 141 -
rise again obviously, it may end the forced ventilation. Close the air inlet valve and keep on turning for 30min to see if the temperature of all points rises again, if not, it may stop turning to start servicing. 12.3 Put-in of quick cooling equipment of turbine: 12.3.1 Put the LP cylinder spray of main machine into operation normally. 12.3.2 Slightly open the blowdown valve of oil-water separator and the drain valve of the gas collection tank. 12.3.3 Open the total valve of compressed air. 12.3.4 Put the heater into operation. 12.3.5 Open wide the primary valve and adjust the air inlet flow of secondary valve as putting the quick cooling equipment into operation. Slowly open the hand-operated air inlet valve of compressed air to HP & LP drain pipe. 12.3.6 Open gradually the air inlet valve wider and set the outlet temperature of air heater according to the decreasing of cylinders temperature, and control the temperature decreasing rate not exceed 5/h. 12.3.7 Check if the exhaust temperature that shall not exceed 80. 12.3.8 In the process of put-in, check if the temperature difference between upper and lower cylinder that shall not be more than 41. 12.3. In the process of put-in, pay attention to the change in cylinder expansion, differential expansion and deflection. 12.3.10 Pay attention to the turning gear operating that is normal. 12.3.11 Keep various records. 12.3.12 If any abnormality, it shall stop air inlet of cylinder and report to the shift engineer. 12.4 Precautions in quick cooling operation: 12.4.1 Prior to forced cooling, purge the forced cooling system first up to standard and drain out the water depositing in the system pipe. 12.4.2 In the case where turning gear of turbine is not put into operation, it is absolutely prohibited to put the quick cooling equipment into operation; if so, stop the quick cooling system immediately after the turning gear tripping. 12.4.3 Put the electric heater into adjusting the outlet steam temperature to warm up the system pipe. 12.4.4 In the process of cooling, control the air inlet flow and outlet steam temperature strictly in accordance with the specified decreasing rate, intensify monitoring, make adjustment from time to time, control various parameters within permitted range and ensure safety of the unit. 12.4.5 In the process of forced cooling, it shall monitor and ensure normal operation of lubricating - 142 -
oil system, jacking oil system, turning gear, LP cylinder spray system and circulating water system, if any system above stops, it shall stop forced cooling of turbine until the system recovers. 12.4.6 In the process of forced cooling, intensify the monitoring of the operation of service compressed air system at the same time. 12.4.7 In the process of cooling, if the decreasing rate difference between HP & MP cylinder temperature is high, it may adjust and control with each branch valve. 12.4.8 It must not interrupt the compressed air as putting the quick cooling equipment into operation so as to avoid dry heating of heater. 12.4.9 When the quick cooling equipment heater is in operation, pay attention to the operation of heater, if air compressor stops or compressed air interrupts, it shall stop inlet of compressed air and stop the quick cooling equipment. 12.4.10 When the quick cooling equipment is in operation, keep record of the turning gear current, exhaust cylinder temperature, governing stage metal temperature of turbine, MP carrier temperature, cylinder expansion, differential expansion, deflection and cylinder temperature, etc. proper parameters once every half a hour.
12.4.11 In the process of quick cooling, it shall drain the water of steam-water separator, steam bleeding box and gas container of air compressor and clean the filter periodically to prevent oil and water dirty from entering the cylinder. Only in condition that the compressed air and flow are normal, can the heater be put in to operation and can air be supplied to the turbine after the air heater temperature becoming in accordance with the index. If discovering the air heater fails to control temperature, it shall close the air source to prevent cold water supplied to turbine. Precautions and parameter requirements: a. When the governing stage mental temperature is 350-300, the temperature decreasing rate shall be less than 3/h and the temperature difference between hot air and mental shall be less than 40. b. When the governing stage mental temperature is 300-250, the temperature decreasing rate shall be less than 4/h and the temperature difference between hot air and mental shall be less than 60. c. When the governing stage mental temperature is 250-200, the temperature decreasing rate shall be less than 5/h and the temperature difference between hot air and mental shall be less than 90. d. When the governing stage mental temperature is 200-150, the temperature decreasing rate shall be less than 5/h and the temperature difference between hot air and mental shall be less - 143 -
than 130. 12.4.12 When air temperature exceeds the deviation or the electric heater loses power, it shall raise the alarm and interlock close the inlet valve to prevent cold air from entering and cooling the cylinder excessively, meanwhile cut off the power supply of heater to prevent the heater from dry heating. 12.5 Stop of quick cooling system After finishing quick cooling, adjust the potentiometer to 0 point manually, stop the heater, open the power supply switch and continue to ventilate for 5~10 minutes, then close all valves. Slightly open of the blowdown valve to prevent air leak of air inlet valve from resulting in water entering the equipment.
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Appendix Part
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Appendix 1: Comparison Table of the Pressure [P] & Temperature [th] of Saturated Water & Steam
P MPa 0.0015 0.002 0.0025 0.003 0.0035 0.004 0.0045 0.005 0.006 0.007 0.008 0.009 0.01 0.011 0.012 0.013 0.014 0.015 0.02 0.025 0.03 0.04 0.05
th 13.036 17.513 21.096 24.1 26.694 28.963 31.035 32.898 36.183 39.025 41.534 43.787 45.833 47.71 49.446 51.062 52.574 53.997 60.86 64.992 69.124 75.886 81.345
P MPa 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29
th 89.595 93.512 96.713 99.683 102.32 104.8 107.13 109.32 111.37 113.32 115.17 116.93 118.62 120.23 121.78 123.27 124.71 126.09 127.43 128.73 129.98 131.20 132.39
P MPa 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
th 134.66 135.75 136.82 137.87 138.87 139.86 140.78 141.71 142.62 143.62 144.52 145.39 146.25 147.09 147.84 151.84 158.84 164.96 170.41 175.36 179.88 184.07 187.96
P MPa 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.2 3.4 3.6 3.8 4.0 4.2
th 195.04 198.29 201.37 204.31 207.11 209.80 212.37 214.85 217.24 219.55 221.78 223.94 226.04 228.07 230.05 231.97 233.84 237.45 240.88 244.16 247.31 250.33 253.24
P MPa 4.6 4.8 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 11 12 13 14 15 16 17 18 19 20
th 258.75 261.37 263.91 269.93 275.55 280.82 285.79 290.50 294.97 299.23 303.21 307.21 310.96 318.05 324.65 330.83 336.64 342.13 347.33 352.26 356.96 361.43 365.70
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0.06
85.945
0.30
133.54
1.3
191.61
4.4
256.05
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