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1 Operation Procedure For Steam Turbine
1 Operation Procedure For Steam Turbine
1 Operation Procedure For Steam Turbine
PART 1
DEC, 2015
Table of Contents
1
BAYAH 2×60MW POWER PLANT (PHASE I) .................................................................................................................. 1
Operation Procedure for Steam Turbine ............................................................................................................................. 1
Table of Contents .......................................................................................................................................................... 1
General ............................................................................................................................................................. 1
Regulations on Important Operations .......................................................................................................... 2
Part I Operation Procedure for Steam Turbine ........................................................................................................... 4
Chapter 1 Technical Specifications and Characteristics of Turbo-generator ............................................................. 4
Section I Technical Specifications and Characteristics of Steam Turbine .............................................. 4
1.1 General ...................................................................................................................................................................... 4
1.2 Main Parameters ...................................................................................................................................................... 4
1.5.2 Rotor ....................................................................................................................................................................... 6
1.5.8 Revolution equipment ........................................................................................................................................... 9
1.5.9 Regulating valve and cam type steam distribution device .............................................................................. 9
Section II Working principle of control system and unit technical specifications .............................. 12
2.5.1.4 Solenoid-operated protections .................................................................................................................. 19
2.5.1.5 Calibration of valve position in DEH control system .............................................................................. 19
2.5.1.7 Closing test of other valves ....................................................................................................................... 20
2.5.2.2 Mechanical over-speed test Conditions for over-speed test ........................................................... 20
2.5.2.3 Nozzle test valve test ................................................................................................................................. 20
2.5.2.4 Test of start-up latch device ....................................................................................................................... 21
2.5.2.5 Test of solenoid-operated protections ...................................................................................................... 21
2.5.2.6 Leakage test of MSV and regulating valve ............................................................................................. 21
2.5.2.7 Load-rejection test ...................................................................................................................................... 21
2.5.2.8 Closing test of other valves ....................................................................................................................... 21
Section III Accessories .............................................................................................................................. 56
Chapter 2 Turbine Startup ........................................................................................................................................ 63
Section I Important Operating Principles ................................................................................................ 63
2 Startup of a unit is forbidden in the following conditions: ........................................................................... 64
Section II Preparation before Startup ...................................................................................................... 64
Section III Check before Startup .............................................................................................................. 65
3.2 Main steam pipe and its drainage system ..................................................................................................... 65
3.3 Extraction system ................................................................................................................................................ 66
3.4 Steam seal system ............................................................................................................................................... 66
3.5 Water-jet ejecting system ................................................................................................................................... 66
3.6 Condensate system ............................................................................................................................................. 67
3.7 Check of flange bolt heating device ................................................................................................................ 67
3.8 Check of circulating water and service water system ................................................................................ 67
Section IV Tests of Auxiliary Oil Pump and Regulating System .......................................................... 67
4.2. Switch to turning gear ....................................................................................................................................... 68
4.5 Speed-regulating system test ........................................................................................................................... 68
Section V Pipe Heating ............................................................................................................................. 69
Section VI Startup and Switching of Auxiliary Devices ....................................................................... 69
6.1 Start condensing system and vacuumize ...................................................................................................... 69
Section VII Startup and Speedup (at sliding parameters) .................................................................. 70
7.2 Requirements on the startup at sliding parameters ................................................................................... 71
7.3 Principled startup parameters and definitions ............................................................................................. 71
A Cool state .................................................................................................................................................................... 72
B Hot state ..................................................................................................................................................................... 72
2
7.3.2 Notes regarding the startup at sliding parameters ...................................................................................... 73
7.4 Conduct the speedup and machine-heating as per the following requirements ................................ 73
Section VIII Parallel Operation and with Load ....................................................................................... 75
8.4 Switch to other protections .................................................................................................................................... 75
A Cool state .................................................................................................................................................................. 75
B Hot state .................................................................................................................................................................... 76
Section IX Requirements on Hot-State Startup of the Unit ................................................................ 76
Chapter 3 Tests of Turbine Unit ............................................................................................................................ 77
Section I Notes regarding the tests ......................................................................................................... 77
Section II Test Items and Period ............................................................................................................ 78
Weekly items ................................................................................................................................................................ 78
Monthly items .............................................................................................................................................................. 78
2.1.5 Switching of the condensate pump by the day shift on every 10th day ....................................................... 78
2.1.7 Switching of the feedwater pump by the day shift on every 20th day .......................................................... 78
2.1.9 Clean the rubble ball every 8th and 23rd day for 10 hours at each side ...................................................... 79
2.2 Test items for startup and shutdown .............................................................................................................. 79
2.2.2 Tests before the unit’s shutdown for maintenance .................................................................................. 79
Section III Test Method .............................................................................................................................. 80
3.1.1 Trial run of oil pump ......................................................................................................................................... 80
3.1.2 Turning gear test ............................................................................................................................................... 80
3.1.3 Pumps interlock tests ...................................................................................................................................... 80
3.1.4 Water pump’s low water pressure interlock test ...................................................................................... 80
3.2 Turbine’s tests before startup ........................................................................................................................... 81
3.2.4 Protection test in case of large axial displacement ................................................................................. 82
3.2.5 Protection test in case of large differential expansion ........................................................................... 82
3.2.6 Protection test in case of high temperature of bearing .......................................................................... 83
3.2.7 Test of turbine’s emergency trip button...................................................................................................... 83
3.2.8 Differential protection test .............................................................................................................................. 83
3.2.5 Protection test in case of low vacuum ........................................................................................................ 83
3.2.10 Low oil pressure interlock test ................................................................................................................... 83
3.2.11 Test of manual shutdown button ................................................................................................................ 84
3.2.12.2 Composite valve test .................................................................................................................................. 84
3.3.4 Overspeed test .................................................................................................................................................. 87
3.3.5 Load shedding test ........................................................................................................................................... 88
3.3.6 Vacuum leakage test ........................................................................................................................................ 88
Chapter 4 Turbine Shutdown .............................................................................................................................. 89
Section I Normal shutdown ....................................................................................................................... 89
Section II Shutdown at Sliding Parameters ............................................................................................ 91
Chapter 5 Maintenance of Turbine in Operation ................................................................................................ 92
Section I Limits of Normal Operation ...................................................................................................... 92
Section II General Operation Maintenance .......................................................................................... 96
Chapter 6 Turbine’s Accident Prevention and Handling.......................................................................................... 97
Section I Principles of Accident Handling ............................................................................................... 97
Section II Shutdown in Case of Failure ................................................................................................... 98
Section III Handling of abnormality of Steam Temperature and Pressure.......................................... 100
3.7 Steam pressure decrease ................................................................................................................................ 101
Section IV Condenser’s Vacuum Declination ...................................................................................... 102
Main reasons for the vacuum declination: ......................................................................................................... 103
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Section V Oil system abnormal ................................................................................................................. 106
5.1.2 Oil level limit value ......................................................................................................................................... 106
5.2 Handling of auxiliary oil pump operation abnormal ................................................................................. 107
5.3 Handling of oil system on fire ......................................................................................................................... 107
1) Check whether the oil gauge float is free, eliminate the leak point ................................................................. 108
Section VI Load rejection .................................................................................................................... 109
When the unit is found rejecting load, report it immediately to the monitor. ........................................... 109
2) The unit vibration and internal sound .................................................................................................................. 109
4) Open vacuum breaking valve according to the speed decrease situation .................................................... 109
Section VII Unit running out of synchronization ................................................................................... 109
7.2 Generator running out of synchronization, high cycle operation occurred ....................................... 109
7.2.1.3 Make adjustment of the shaft seal steam supply and recirculation ........................................................ 109
Section VIII Water impact........................................................................................................................ 110
8.1.4 Handle it immediately according to breaking vacuum emergency shutdown .......................................... 110
8.2 Preventive measures for water impact .............................................................................................................. 110
8.2.5 When extraction pipe stops operating, pipe water drain has to be opened ............................................. 110
Section IX Increase of axial displacement.......................................................................................... 110
9.1.1 Thrust bearing temperature and thrust pad temperature ............................................................................ 110
9.1.3 Whether the axial displacement indicator is normal .................................................................................... 111
Section X Steam turbine severe overspeed ......................................................................................... 111
Section XI Generator, exciter has smoke or on fire ............................................................................ 111
Section XII Abnormal vibration and abnormal sound of turbine unit ................................................ 112
Section XIII Main stop valve, governing valve, rotary diaphragm operation abnormal.................. 112
Automatic main stop valve fault: .......................................................................................................................... 113
Valve jamming ............................................................................................................................................................. 113
Section XIV Piping fault ....................................................................................................................... 114
Section XV Service power interrupted .................................................................................................. 114
15.3 Service power partially interrupted ............................................................................................................. 115
Section XVI DEH system fault.............................................................................................................. 115
Section XVII Handling of auxiliary equipment fault ............................................................................. 116
17.1.2 Bearing has smoke and is on fire ................................................................................................................. 116
17.1.5.4 Rolling bearing lubricated by grease without cooling water device: 100℃ ........................................ 116
17.3 Method for emergency stop of auxiliary equipment ...................................................................................... 116
17.4 Auxiliary equipment automatic trip ................................................................................................................... 117
Section XVIII Heater water level rising ................................................................................................. 117
Part II Operation procedure of auxiliary equipment ............................................................................................... 119
Chapter I Operation of oil system .......................................................................................................................... 119
1.2.1 Operation and maintenance of oil cooler ....................................................................................................... 120
Prepare measures and monitor well when switching over oil cooler. ........................................................ 121
Chapter II Operation of jacking oil pump and turning gear................................................................................ 121
2.1.1 Start of jacking oil pump and turning gear ..................................................................................................... 121
2.1.1.5 Start of jacking oil pump ................................................................................................................................ 121
2.1.2 Stop of jacking oil pump and turning gear ..................................................................................................... 122
Chapter III Operation of circulating water system ............................................................................................. 122
3.1.1 Operation of condenser water side ................................................................................................................ 122
3.1.2 Stop of condenser water side .......................................................................................................................... 122
3.2 Half stop and operation of operating condenser .................................................................................... 122
3.2.2 Operation of the stopped side condenser ..................................................................................................... 123
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Chapter IV Operation of condensate system ......................................................................................................... 123
4.1.1 Every thing is checked before start ................................................................................................................ 123
Chapter V Operation of shaft seal system ........................................................................................................... 123
5.1.1 Supply steam to shaft seal .............................................................................................................................. 123
Chapter VI Operation of vacuum, water jet system .......................................................................................... 124
Chapter VII Operation of air cooler .................................................................................................................... 125
7.1.1 Start of air cooler ............................................................................................................................................... 125
7.1.2 Maintenance during operation ........................................................................................................................ 125
7.1.3 Stop of air cooler ............................................................................................................................................... 125
Chapter VIII Use of flange bolt heating appliance ............................................................................................. 125
8.1 Precautions for putting flange bolt heating appliance into operation ................................................. 125
8.1.4 Conditions to put it into operation ................................................................................................................... 126
8.2 Operation of putting flange bolt heating appliance into operation ....................................................... 126
8.3 Stop of flange bolt heating appliance ........................................................................................................... 126
Chapter IX Start and stop of pump ..................................................................................................................... 127
9.1.1 Check before start ............................................................................................................................................. 127
9.1.2 Start .................................................................................................................................................................... 127
9.1.2.4 Put another pump interlock standby according to the needs .................................................................. 127
Chapter X Operation of low pressure (LP) heater ........................................................................................... 128
10.1 Operation and maintenance of LP heater .................................................................................................. 128
10.1.2 Putting into operation .................................................................................................................................. 128
10.1.3 Stop .................................................................................................................................................................. 129
Chapter XI Operation of high pressure (HP) heater ......................................................................................... 129
11.1.1 Inspection and preparation prior to startup and relevant provisions ....................................................... 129
11.1.3 Stop .................................................................................................................................................................. 130
Part III Operation procedure of feedwater pump ................................................................................................. 131
Chapter I Start and stop of feedwater pump ...................................................................................................... 131
1.4 Inspection before start ...................................................................................................................................... 132
1.5 Pump warming .................................................................................................................................................... 132
1.6 Start........................................................................................................................................................................ 132
1.7 Stop of feedwater pump ................................................................................................................................... 133
Chapter II Operation and maintenance of feedwater pump ................................................................................... 133
Chapter III Accident treatment for feedwater pump ........................................................................................ 136
Section I Accident treatment principle................................................................................................. 136
Section II Emergency stop of feedwater pump .................................................................................... 136
2.2 Emergency stop steps for pump .................................................................................................................... 136
Section III Abnormal pressure of feedwater header ........................................................................... 137
3.2 Treatment ............................................................................................................................................................. 137
3.3 Cause for feedwater header pressure rise .................................................................................................. 137
Section IV Vaporization of feedwater pump ............................................................................................ 138
4.2 Water vaporization ............................................................................................................................................. 138
4.3 Pump vaporizztion treatment .......................................................................................................................... 138
Section V Feedwater pump auxiliary power failure............................................................................ 138
5.2 Treatment ............................................................................................................................................................. 139
Section VI Failure of feedwater pump oil system ............................................................................... 139
6.2 Oil tank oil level decreases .............................................................................................................................. 139
Section VII Interruption of feedwater pump cooling water ............................................................... 140
Chapter IV Test of feedwater pump .................................................................................................................. 140
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Section I Feedwater pump oil pump interlock test .............................................................................. 140
1.2 Standby feedwater pump oil pump interlock .............................................................................................. 141
Section II Feedwater pump interlock test ............................................................................................ 141
2.2 Feedwater pump interlock test ....................................................................................................................... 141
Section III Feedwater pump protection test.......................................................................................... 141
3 Conduct the following tests (static and dynamic test) ............................................................................. 141
Part IV Operation procedure of deaerator equipment .................................................................................... 142
Chapter I Basic characteristics and technical data ............................................................................................. 142
Chapter II Start and stop of HP deaerator ....................................................................................................... 143
2.1 Steam sourcew ................................................................................................................................................... 143
2.6 Stop ........................................................................................................................................................................ 144
Chapter III Operation and maintenance of deaerator equipment...................................................................... 145
3.2 Normal operation limits .................................................................................................................................... 145
Chapter IV HP deaerator safety valve test ........................................................................................................ 145
Chapter V Start and stop of drain tank drain pump ......................................................................................... 146
5.3 Stop ........................................................................................................................................................................ 146
Chapter VI Accident treatment of deaerator ..................................................................................................... 146
Section I Accident treatment principle................................................................................................... 146
Section II Accident treatment of deaerator ........................................................................................... 147
2.2 Reduced internal steam pressure of deaerator .......................................................................................... 147
2.3 Increased deaerator level ................................................................................................................................. 148
2.4 Decreased deaerator level ............................................................................................................................... 148
Part V Operation of attemperating and pressure reducing device................................................................... 149
Chapter I characteristics and relevant requirements on attemperating and pressure reducing device ................ 149
Chapter II Putting into operation, operation and stop of attemperating and pressure reducing device ......... 151
Motor-driven admission valve of attemperating and pressure reducing devic .................................................. 151
2.3 Stop of attemperating and pressure reducing device .............................................................................. 152
2.4 Hot standby of attemperating and pressure reducing device ................................................................ 152
Schedule I Saturated pressure MPa corresponding to saturated temperature t ............................ 153
Schedule II Saturated steam pressure-temperature sheet P (MPa)t(℃) .................................... 154
6
General
1 Operating personnel must stand fast at his post, and execute orders form higher level accurately and
immediately.
2 At the time of unit failure, operating personnel shall take action in the following sequence to eliminate
faults:
2.1 Confirm the failure according to instrument indications and external displays.
2.2 Remove promptly dangers to person and equipment, and immediately take the faulty equipment off-line if
necessary.
2.3 Ascertain at once the nature, location and damage extent of the fault.
2.4 Guarantee that all non faulty equipment can operate properly.
2.5 In case of failure, operating personnel shall work in accordance with the Procedure, and report to the
shift chief-operator and turbine supervisor or turbine engineer as quick as possible for timely and correct
3 Be quick-moving in fault elimination and correct in mission performance; repeat an order after acceptance
and make detailed inquiries if not understand, report to the order giver immediately after execution.
4 The team leader is under the leadership of shift chief-operator during troubleshooting, he shall join in the
fault elimination immediately and report to shift chief-operator to the best of his ability.
5 The turbine supervisor shall arrive on site to supervise the site fault elimination once he learns about the
fault.
6 Operating personnel shall not leave his post without authorization from occurrence of fault till unit
recovering.If the fault happens at the relief of a shift, the shift handing over shall be delayed. The handing
over personnel shall continue working, while the taking over personnel give assistance to the troubleshooting
under the leadership of handing over team leader and shift chief-operator until the unit returns to normal, or
only having accepted the taking over order from the shift chief-operator,can he sign the daily account of
7 In case of faults not specified in the Procedure, operating personnel ought to take counter-measures based
on his knowledge and judgment, and report to the master operator or shift chief-operator to the best of his
ability. When operating personnel finds out phenomena which he does not know, he must report to the
master operator in a timely manner and make jointly on-the-spot observation and study. If it is impossible to
ascertain the facts, report to the shift chief-operator and take action according to his instructions.
8 For unit start-up after failure, it is imperative to inspect it in an all-round way taking into account the
1
phenomena of the accident, and only by confirmation of the unit conditions can operating personnel start the
machine. strengthen inspections during start-up, and shut down in case of abnormalities and report.
10 strengthen control of metal temperature during unit start-up, run up, run down and shutdown, take strict
precautions against the excess of temperature difference over specified values, and try to avert equipment
11 Unit System is applied for the set, part of the common systems shall be given overall consideration during
1 The following work are to be done under the guardianship of turbine supervisor or person assigned
1.1 Start of steam turbine set after overhaul and minor repair.
1.2 Periodical oil filling pressure test of emergency governor during operation.
1.3 Governing system tests, including tightness test of MSV, GV and rotary diaphragm.
1.6 The first start-up of equipment after major improvement or the initial trial of new technology.
2 The switch-over of critical equipment shall be performed with operation permit and under the
supervision of guardian. Before giving switch-over order, review the predetermined operation procedure
against relevant system diagrams to ensure correctness. All the switch-over and supervision of critical
equipment shall be undertaken by competent personnel and the lower level can not monitor the operation by
3 When taking system isolation measures, do not use valves on LP side for isolating whenever HP
and LP sides are connected in series without non-return valves. Valves on HP side shall be closed first and
only after they are confirmed tight can those on LP side be closed; even with non-return valves, valves on HP
side shall be closed first and only after the HP side valves and non-return valves are confirmed tight can
those on LP side be closed. If the HP valves are not tight or the non-return valves leak, precautions shall be
extended for thorough isolation of HP system to prevent piping and valve breakage due to pressure
accumulation.
4 In the following cases, elimination measures shall be taken for turbine, otherwise, start is prohibited
2
(for special cases, the management is held the responsibility for making decision and laying down
4.2 Motor-operated MSVs, automatic MSVs,governing valves and extraction check valves function
abnormally.
4.3 Turbine rotor swinging value exceed 0.254mm over original value;
4.4 Governing system can’t maintain no-load operation or control speed after full-load rejection;
4.7 Unacceptable oil quality or oil temperature lower than specified limit value;
4.9 Metal temperature difference between upper and lower casing exceeds 50℃;
Notes: 1. Major gauges refer to :main steam temperature gauges, steam gauges, flow meters,
2. Automatic protections refer to: I&C protections which can automatically shut down the unit in case of
unit failure, such as low oil pressure, axial displacement, MSV interlocks, etc.
3
Part I Operation Procedure for Steam Turbine
1.1 General
1 Model N60-8.83-8
4 Serial no.
Note: Unless otherwise specified, all the pressures in the Procedure are indicated in absolute ones.
4
Item Unit Maximum Normal Minimum
MSV
before MSV
operating condition
1.3 0.589 MPa Extraction parameters (with deaerator running at constant pressure and unit under
No. of
1 2 3 4 5 6
extractions
Extraction
1.127 0.332 0.144 0.047
steam 2.84 MPa 1.66 MPa
MPa MPa MPa MPa
pressure
Extraction
temperature
17.909 10.323
Flow 12.914t/h 9.375 t/h 11.12 t/h 10.44 t/h
t/h t/h
Steam pressure drop before MSV is 8.83MPa, main steam temperature decreases to 535℃, and
1.5.1 General
The steam turbine is composed of stationary part and rotating part;the stationary part includes front,
middle and exhaust hoods, diaphragm sleeve, diaphragm, front& rear bearing pedestals, front & rear
5
bearings and front & rear gland seals. The flow part of turbine consists of one single row control stage and 21
pressure stages. The front bearing point,relative dead point of the unit, is a combined journal-thrust bearing
installed in front pedestal; the rear bearing is a journal bearing installed in exhaust hood. The turbine is
Turbine front cylinder is provided with a pair of claws extended from lower casing flanges, touching the
sliding pins on both sides of front pedestal. Inside sliding pins there are cooling water chambers for insulating
heat transfer from claw to front pedestal. The front pedestal is supported on front stand, to ensure free
expansion and alignment of unit during operation, the front stand is arranged with axial guiding pins, and
axial guide plates are provided at the tail end of exhaust hood and vertical pins between front cylinder and
front pedestal. The exhaust hood is supported on rear stand, which consists of three pairs of bases (middle,
rear and side), among which the left and right side bases are provided with traverse pins, the point of
intersection with turbine center-line determines the unit expansion dead point.
nside turbine front pedestal are installed parts such as front thrust bearing, main oil pump, main oil
pump coupling,emergency governor, emergency governor shaft, internal oil piping of front pedestal; speed
measuring devices and axial displacement measuring probes, and brackets for eccentricity probes are also
installed in front pedestal. On the front base is installed thermal expansion indicator to show the absolute
thermal expansion of turbine stationary part. Brackets of differential expansion probes are installed at
exhaust hood couplings and vibration speed sensors are installed on bearing cap.
1.5.2 Rotor
The turbine rotor is of integrally-forged - shrinking fit structure. Control stage and the first 16 pressure
stages are of integrally-forged structure; while stages no.17-21 are of shrinking fit structure. Radial pins are
assembled between shrinking fir impellers, and there is no key-way in bore, greatly increasing the strength of
The blades of control stage and the first 13 pressure stages are of “T”type root,with uniform
cross-section profile; stages no.14-18 adopt “T”type straddle root expanded tight with shims. Stage no.19
adopts 3-finger fork type root, stages no. 20-21 adopt 4-finger fork type root, and stage no.21 uses lacing
wire. The straight moving blades of stages no.0-13 all have shroud rings installed on top and the moving
Segmental nozzle group control is applied for the unit. HP nozzles are divided into 4 groups and
embedded into four nozzle chambers via “T” type key-ways, they are located with radial pins and installed
with seal keys. Meridian plane contracting stationary blade nozzles of nozzle segment are welded in inner
6
and outer shroud rings, with surfaced nitrogen treated, extending the service life.
The turbine has seven diaphragm sleeves, diaphragm of stages no. 1-19 are installed respectively in
Application of diaphragm sleeve can reduce the axial length, and help improve start-up and load change.
The split surfaces of diaphragm sleeves are fixed with locating pins and connecting screws, separating from
upper casing.
Suspension pins are used for the connection between diaphragm and diaphragm sleeve, diaphragm
sleeve and cylinder; there are fix stoppers in the middle at the bottom of diaphragm and diaphragm sleeve to
ensure the aligning of stator and rotor at expansion. All diaphragms are of welded structure, HP stages
no.1-3 adopt splitter blading consisting of narrow nozzle and wide profile blade, reduce effectively the loss of
flow while maintaining diaphragm rigidity and strength. Diaphragms of stages no. 1-16 straight blades are all
of shroud ring welded type. Stages no. 17-21 diaphragm stationary blades use compound lead blades, and
stationary blades are welded directly on diaphragm inner and outer rings, without use of traditional cast-in
1.5.4 Cylinder
The steam turbine is of single cylinder type composing of front, middle and rear cylinders.
The front cylinder is made of ZG20CrMoV with bellows-type flanges, and flange heating appliance are
provided for quick start-up. Steam chambers are welded with nozzle chambers as one piece and assembled
with front cylinder. There are guiding pins between nozzle chamber and front cylinder for thermal expansion.
Four steam chambers are arranged separately on the left, upper left, upper right, and right side of front
cylinder with regulating valves installed inside, and connected with main steam piping via four steam leads.
In addition, two extraction openings are cut in front cylinder, leading to HP heater no.1 and 2 respectively.
The middle cylinder is made of ZG25, and its lower casing is cut with extractions openings, leading to
deaerator and LP heaters no.1-3 respectively. On the vertical flange surface connecting front to middle
cylinder, a section of sealing slot is opened each on left and right side; after cylinder covering on site, seal
paint ( which can resist a temperature > 300℃ and a pressure > 0.7MPa)is injected to strengthen the air
The exhaust hood is welded and made of Q235-A. It has customized diffuser with better aerodynamic
characteristics and rigidity. On the upper part of exhaust hood is installed air-relief device, when the back
pressure is higher than the atmospheric pressure, it can automatically open, protecting exhaust hood and
condenser.
1.5.5 Bearing
7
The turbine has two elliptical journal bearings. The thrust bearing and turbine front bearing composite a
combined journal and thrust bearing, which is an elliptical bearing of three-layer spherical structure and
installed in front bearing pedestal. The rear bearing is an elliptical bearing of two-layer cylindrical structure.
On lower half of each bearing, oil-through holes are provided for HP jacking oil, around which oil pockets are
scraped as the pressure zone for rotor jacking. Tilted thrust pads are adopted for thrust bearing, and each
main thrust pad and journal bearing pad has temperature sensors and white metal temperature can be
monitored during operation. In addition, temperature sensors are provided to indicate bearing return oil
temperature.
MSV consists of main steam stop valve, auto-closing gear and valve seat. Steam coming from boiler
enters to MSV steam chamber via main steam piping, and flows to regulating valves in 4 lines after passing
through strainers and valves. MSV is of single valve seat type, and pressurized pilot valve structure is
adopted to reduce the lifting force on valve disk. On valve chest, measuring points for upstream pressure,
downstream pressure and temperature, as well as valve chest wall temperature are provided. Valve lever
MSV is installed on the seat support with certain flexibility, which can be taken as dead point to support
the piping thrust upstream of MSV, thus the thrust will not directly act on turbine proper to avoid impacts on
unit dynamic centering due to large piping thrust. Downstream MSV there are four steam leads, connecting
with four regulating valves respectively. The steam leads have certain flexibility to absorb the thermal
expansion deformation of itself and the thermal expansion displacement of the whole cylinder.
Automatic closing gear consists of servomotor and stop pilot oil valve. Safety oil from main oil pump is
applied on lower part of pilot oil valve, and enters to lower part of servomotor piston when oil inlet of the
servomotor is opened against spring resistance. MSV will be opened when the oil pressure is adequate. The
servomotor travel is feed back to pilot oil valve piston via lever, making it stop at any intermediate position for
a better self-stability. Automatic closing gear is provided with movable test pilot valve, which can actuate
MSV for anti-jamming during long-term operation. Under the servomotor shell there are cooling water
During turbine start-up, no-load or low load operation, the exhaust hood temperature is liable to rise
and result in a series of problems such as cylinder deformation, cylinder rotor center line misalignment due to
small steam flow and impossibility to take away the heat generated by friction blowing in LP cylinder. Water
spray attemperator is arranged on the exhaust hood of the turbine,and when exhaust steam temperature is
8
higher than 65℃,cooling water can be introduced to reduce it to ensure safe operation of the exhaust hood
and condenser.
Geared motor for primary gear reduction is applied for revolution equipment, which is installed on
upper cover of rear bearing pedestal. The unit adopts low speed (4 rpm)turning gear. However, before
starting the turning gear, it is necessary to start first HP jacking oil system of bearing to lift up rotor to reduce
significantly start-up friction torque and protect white metal from damage, and then, put revolution equipment
The unit is provided with four regulating valves, all of single valve seat structure with pressure-relief
pre-lift valve to minimize lifting force. Servomotors control the opening sequence and lift of the four valves via
cam type steam distribution device. There is a cooling water chamber under the cam type steam distribution
The four regulating valves are welded respectively on the left, upper left, upper right and right side of
the front cylinder. The opening sequence of them are shown in the diagram below:
The purpose of applying the above mode is to unify the temperature field of front cylinder and stabilize
bearing stress points during unit start-up and non-design-based operating condition.
Serrate-type steam seals are adopted for turbine front, rear and diaphragm seals. The high and low
slot teeth of such rotor seal structure fit with the long and short teeth of seal ring, forming the labyrinth seal.
The long and short seal teeth of seal ring are rigid in strength with good sealing performance, and in
addition, it is easier for maintenance and repair. The rubber washer of front gland seal is an integral structure
9
1.6 Thermal cycle
The steam piping from boiler superheater outlet header to turbine inlet, as well as the steam branches
from steam headers to various auxiliaries are all main steam piping. Sectional header system is applied for
the future extension of the plant, when necessary, the boiler and turbine can be independent unit by
switching over of isolation valves. This system is characterized by simple structure and easier management
and maintenance.
The main Feed-water system ranges from deaerator outlet to economizer Feed-water inlet header. Two
motor-driven BFW pumps are furnished for this phase of project, one running and the other standby. The
output of each BFW pump is approximately 110% the evaporation of a single boiler. Single sectional header
system is adopted for the Feed-water piping. LP Feed-water is routed to HP Feed-water cold header after
being pumped by the Feed-water pumps, and the cold HP Feed-water is heated by turbine HP heaters to
215℃, and then routed to hot HP Feed-water header, the hot HP Feed-water is again connected to boiler
economizer and attemperators via Feed-water operating console. Recirculation line is provided at BFW
After expanding and doing work in the turbine, the steam is exhausted to condenser where it
condenses. The condensate builds up pressure via the condensate pump and then goes into the deaerator
through the gland steam condenser and LP heaters. 2x110% (maximum condensate capacity) condensate
pumps are furnished for the turbine, one running and the other standby. The hotwell level of the main
The extraction-condensing turbine has 6 extraction stages. Stage 1 and 2 extraction steam is supplied
to HP heaters and the drains heating the steam is sent back to deaerator; another line of stage 2 extraction is
connected to stage 3 extraction steam header through pressure reducing valve. Stage 3 extraction steam is
supplied to deaerator while those of stage 4, 5 and 6 are supplied to LP heaters. Electric control valves are
installed at the inlet of deaerator heating steam pipeline for control of deaerator operating pressure
The Feed-water deaeration system is provided with one 286t/h spinning film type deaerator which
operates at constant pressure of 0.588MPa. The water storage tank has a total volume of 80m3, which can
satisfy the water demand of a single boiler at rated evaporation for 30 minutes. The steam for deaerator
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heating is supplied by the heating steam header. The condensate is fed to the deaerator by the condensate
pump via gland steam condenser and LP heaters, and the chemical make-up water is connected to the
deaerator.
Turbine evacuation system consists of 1x100% water ejectors, 2x100% water jet pumps, one water jet
After entering into the main building from water treatment plant, one line of the chemical make-up water
goes to the drain tank directly for the purpose of system make-up and boiler filling; a second line to deaerator
through make-up water flow control valve. The water level control of the drain tank is interlocked with the
drain pump. In addition, there is another line of chemical make-up water enters into the condenser for filling
The plant is provided with one 30m3 drain tank and one 1.5m3 drain flash tank. The condensate or
drains of LP equipment and piping, and chemical maker-up water go directly to the drain tank. The drains of
higher pressure equipment and piping enter into HP drain header, and then to the drain tank via the drain
flash tank. The deaerator is provided with one overflow header, when the auto level control of deaerator
water storage tank fails at unduly high level, the water in the storage tank is discharged via the header to
flash tank first and then to the drain tank.The volume of the flash tank can satisfy the need of discharge for
Two drain pumps are installed in the drain system, one running and one standby. During normal
operation, the water in the drain tank is pumped up by the drain pump to the deaerator; at boiler filling prior to
start-up, the drain pump delivers the water in the drain tank directly to boiler drum through boiler filling
The heater drain system ensures the smooth water discharge of heaters as well as the safety of
heaters and the unit under various unit operating conditions, recovering heat of drain as much as possible, to
increase unit thermal economics. Drains from HP heaters are routed to deaerator while those from LP
The plant is provided with one 5.5m3 continuous blowdown flash tank. The indirect steam generated by
the flashing of blowdown in the continuous blowdown flash tank is routed to deaerator via steam equalizing
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The plant is provided with one 12m3 intermittent blowdown flash tank. The blowdown water from the
continuous blowdown flash tank flashes and reduces temperature over again in the intermittent blowdown
flash tank; the steam produced is vented to the atmosphere while the blowdown is discharged to rain
sewerage after temperature reduction. Emergency discharges of boiler and HP heaters are routed to
The turbine oil supply system partly supplies lube oil to various bearings of turbo-generator unit and
pressure oil to control and protection system via main oil pump, and partly supplies oil to electro-hydraulic
servo valve in DEH system through oil filter via main oil pump. It is recommend to use turbine oil L-TSA46
specified in GB11120-2011, and in case that cooling water temperature is frequently below 15℃, it is allowed
2.1. For main technical specifications of turbine control and protection system,refer to the table below.
specifications
1 Turbine rated speed r/min 3000
Negative
10 Rotor axial displacement alarm value (positioning) mm +1.0 or -0.6
means reverse
12 Low lube oil pressure alarm (start AC lube oil pump) MPa 0.055
13 Low lube oil pressure alarm (start DC lube oil pump) MPa 0.04
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15 Low lube oil pressure protection valve (stop turning MPa 0.015
16 High lube oil pressure alarm value (stop AC lube oil MPa 0.16
17 Low oil pressure at main oil pump discharge alarm value MPa 1.3
The turbine oil supply system partly supplies lube oil to various bearings of turbo-generator unit and
pressure oil to governor system via main oil pump, and partly supplies oil to electro-hydraulic servo valve in
DEH system through oil filter via main oil pump. It is recommend to use turbine oil L-TSA46 specified in
GB11120-2011, and in case that cooling water temperature is frequently below 15℃, it is allowed to use
Mainly include main oil pump, oil injector I, oil injector II, oil drain valve at start-up of main oil pump, HP
AC oil pump, AC/DC lube oil pumps, oil tank, oil cooler, oil filter, lube oil pressure controller and overpressure
valves, etc.
Centrifugal main oil pump is driven by turbine main shaft, during normal operation, the oil pressure at
main oil pump discharge is 1.57MPa and oil pump capacity is 3.0m3/min. The pressure oil is supplied mostly
to two oil injectors besides control and protection system. The two oil injectors are connected in parallel, the
oil pressure at outlet of oil injector I is 0.10-0.15MPa for oil supply to main oil pump suction while oil pressure
at outlet of oil injector II is 0.22MPa for oil supply to lube oil system via oil cooler and oil filter.
LP AC lube oil pumps shall be started first at unit start-up, to remove air inside oil piping and various
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parts under low pressure. Then, start HP AC oil pump for test and adjustment of control and protection
system and unit start-up. During turbine start-up, HP motor-driven AC oil pumps supply oil to control and
protection system and also lube oil to each bearing via oil injector. To prevent pressure oil from leaking via
main oil pump, non-return valve is installed at main oil pump discharge.And also installed are oil drain valve
at start-up of main oil pump for smooth oil flow during main oil pump priming. When turbine speed rises up to
rated speed (oil pressure at discharge of main oil pump is higher than the oil pressure at discharge of
motor-driven oil pump), oil supply capacity can be reduced with the valve in discharge piping, and the pump
is stopped afterwards, main oil pump is used to supply oil to the control and protection system and lubrication
system of the whole unit. At the time of shutting down, HP motor-driven oil pumps may be started first and
switched over to AC lube oil pumps during turning gear operation after turbine shutdown.
In order to prevent shut-down accident of control system due to reduction of oil pressure, when oil
pressure at main oil pump discharge declines to 1.3MPa, HP AC oil pump is put into operation automatically
by pressure switch.
At the time of failure during operation and lube oil pressure decrease, AC lube oil pump is started
automatically by lube oil pressure controller, the system is provided with another DC lube oil pump, which is
automatically started by lube oil pressure controller when lube oil pressure declines and AC lube oil pump
Note: Motor-driven auxiliary oil pumps shall all stop running during unit normal operation, only for
One LP oil overpressure valve is installed in lube oil piping, which can automatically open when lube oil
pressure is higher than 0.15MPa and drain excess oil back to oil tank to make sure that the lube oil
The oil discharged from servomotor is directly routed into suction of oil pump group, thus, in case
servomotor is quickly actuated due to load rejection or emergency shut-down, the oil pressure at pump
discharge will not be impacted, and unit load rejection characteristic is improved.
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The control and protection system of the unit consists of start-up latch device, servo actuators,
Operating principles of MSV automatic closing gear and start-up latch device are shown in the diagram
below:The start-up latch device consists of shell, start pilot valve and latch pilot valve and two solenoid
valves. Being energized, the latch solenoid valve establishes reset oil pressure which can reset the
emergency trip oil valve in front pedestal after actuation, meanwhile reset the latch pilot valve after loss
of safety oil; After latch pilot valve is pressed down by reset oil, the pressure oil established safety oil
via throttle of latch pilot valve and meantime safety oil presses down latch pilot valve, and keep latch
pilot valve position unchanged after loss of reset oil.After safety oil pressure is established, start pilot
valve is pressed down for setting up of start oil pressure to open MSV automatic closing gear. During
shutdown, safety oil is drained off, shut off start oil via start pilot valve and drain the oil in oil cylinder of
automatic closing gear and make MSV close quickly, Normally the MSV test solenoid valve is not
energized, it switches pressure oil of start oil circuit over to return oil when energized, decreasing start
oil pressure can slowly close MSV automatic closing gear. Throttle size can be adjusted for variation of
closing speed of MSV automatic closing gear, as well as for MSV tightness test or activities, in addition,
the movable test hand dog on automatic closing gear can also actuate MSV.
Electro-hydraulic servo valves are solenoid proportional valves made by MOOG. For DDV
electro-hydraulic servo system, refer to the diagram below: Pressure oil acts on above and down pilot
valve of servomotor pilot oil valve, the upper action surface is half of that of lower surface, upper oil
pressure is the same as oil pressure at main oil pump discharge, lower oil pressure intakes oil via pilot
oil valve sleeve – dynamic oil inlet, and drain oil via external adjustable throttle, resulting in basic flow
balance for establishment of control oil, and meanwhile the oil pressure is about half of that of pressure
oil, this oil is called impulse control oil. For the valve position command signals given by DEH, after
servo amplifier,DDV servo valve converts electrical signals to impulse oil pressure signals and controls
dynamic oil feeding and directly controls servomotor to actuate regulating valves to change unit speed
or power. When servomotor moves, it drives LVDT displacement sensor, adding to valve position
command signal as negative feedback signal. When the two electrical signals are in balance, the
output of servo amplifier will stay with original stable value, at this time DDV valve returns to original
balanced position, keeping impulse oil pressure unchanged, the servomotor stays at a new operating
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position. OPC solenoid valve group in the system provides over-speed protection, AST solenoid valve
group is for shutdown. Adjustable throttles are used to adjust the bias of pilot oil valve of servomotor
The system consists of two parts, namely hydro-mechanical protections and electrical protections. The
unit is provided with three sets of trip devices: emergency trip device for manual emergency shutdown
by operating personnel on site; emergency governor and emergency trip oil valve of
protections include over-speed, axial displacement, low lube oil pressure, high return oil temperature,
oil switch trip, DEH protection shutdown. In case of protection (shutdown) signal, close MSV and
regulating valve immediately and give alarm; at the time of OPC signal from DEH system, close
Emergency governor of protection ring type is installed on HP/IP rotor stub extended forward in turbine
front pedestal. The stub is connected rigidly with turbine rotor by screws.
The eccentric mass of emergency governor eccentric ring generates centrifugal force under high speed,
when the centrifugal force is greater than the pre-tightening force of contact spring. the eccentric ring
launches an attack and rams the dog of emergency trip oil valve, causing it to trip and release safety oil
quickly, thus close MSV and regulating valves, achieving the goal of emergency shutdown. After the
closing of steam valves, the turbine speed goes down rapidly, the protection ring of emergency
There are two crescent oil sinks in symmetry on the eccentric ring for oil collection during nozzle test to
increase the weight and eccentricity of the ring,so that the ring can launch an attack at a relatively low
speed. After oil spraying,the oil in the sink flows out of the small holes on top of the sink by centrifugal
When testing the emergency governor for over-speed, if the attacking speed does not comply with the
requirements, nuts can be adjusted to change the spring pretightening force for carrying out the test
again and for the actuation speed compliance with the specified requirements. By calculation, each
Emergency trip oil valve is the over-speed protection actuator in turbine protection system, which
controls the safety oil pressure. It consists of dog, pin roll, piston, spring and shell.
At the time of emergency governor function, protection ring attacks the dog and trip it, the piston moves
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upward under the spring force, resulting the connecting through of safety oil chamber with return oil,
thus MSV is closed. To reset the emergency trip oil valve, it is only necessary to supply reset oil into
upper part of piston and press down the piston, and meantime the dog (under the torsional spring force)
Nozzle test device and nozzle test valve are the devices which can be used for over-speed trip test
Normally the nozzle test devices are in racked-in position, at this time, safety oil is directly sent to
emergency trip oil valve via nozzle test device. In case of over-speed, the emergency governor
actuates, and attacks the dog of emergency trip oil valve and trip it, release safety oil, and thus all MSV
At the time of nozzle test, sent the simulated safety oil after the test to emergency governor indicator.
During the test, pull out the dog of nozzle test valve and inject the HP oil from nozzle test device to the
oil sinks on eccentric ring of emergency governor to increase the weight and eccentricity of the ring,
allowing it to attack at a relatively low speed and simulate an actual over-speed trip operation, and
indicate the over-speed trip through emergency governor indicator. Push the pusher tug to reset after
Clap the trip handle, causing MSV and regulating valves to close, emergency governor indicator
indicates “tripped”.It is necessary to pull out the trip handle before reset.
Solenoid-operated protections consists of two AST solenoid valves in parallel and two OPC solenoid
valves in parallel, both AST and OPC valves actuate when energized. AST valves accept shutdown
signals from various sources (i.e. ETS system shutdown signals), the solenoid valves actuate when
energized, and discharge AST oil and next the safety oil, thus close MSV, shut down turbine steam
admission and cause it to shut down. Protection signals may be originated from speed over-limit, axial
displacement over-limit, low lube oil pressure, high bearing return oil temperature or high bearing pad
temperature, or manual switch shutdown signals. OPC solenoid valves accept OPC signals and close
When unit speed reaches 110-120% of rated speed, the emergency governor actuates, and shuts
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When DEH digital controller sends out shutdown signal, the unit shuts down immediately.
When any of the following 7 monitoring parameters exceeds the specified value, the solenoid valve will
In case of other abnormalities which operating personnel think a must for shutdown, or during normal
condition, operating personnel think it is necessary to shut down the unit, he can clap locally the trip
handle of emergency governor installed in front pedestal end face or manually press the shutdown
button in MCR remotely. It is not allowed to remove protection power supply before the unit shuts down
safely and after the remote shutdown signals has been given.
The TSI system selected for the unit is described as follows: TSI of the unit can continuously indicate
and make record of turbine rotor and cylinder mechanical parameters and valve displacement during
turbine turning, start-up, operation and over-speed test as well as shutdown, give alarm when the
preset operating limits are exceed,and automatically stop the unit when preset dangerous limits are
exceed. Th system consists of instruments and corresponding pre-amplifiers and wired sensors
Sensors (probes) installed in turbine pedestals are connected to corresponding pre-amplifiers via
lengthening cable, which are locally installed in junction box next to the pedestal and then wired to
Eddy current type probes and pre-amplifiers are used to detect various turbine variables, generating a
signal in proportional to the distance to probe and monitored surface, this signal is input to
monitor,which converts the input signal to readings of meter and provide output signal for DC recorder.
Displacement transducer is used to measure the absolute expansion of the unit; speed sensor is used
Major parts of turbine control and protection system are tested at the manufacturer before leaving the
factory. In order to make sure that the unit runs reliably, it is necessary to carry out test after the
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installation at the plant.
Commissioning can be commenced after the unit installation is all completed, the site is cleaned up
Clap the trip handle(travel 12mm),release safety oil,MSV and regulating valves shall close, and
Move emergency trip oil valve dog with hand via hand hole in front pedestal and make it trip.
Emergency governor indicator indicates “tripped”, MSV and regulating valves close, and then operate
emergency trip and reset handle or latch the solenoid, emergency trip oil valve resets, emergency
At the time of emergency trip oil valve manually trip or after AST solenoid valve actuation, system may
be reset or latched with energization of latch solenoid valve, MSV opens and regulating valves close.
With movable solenoid valve of MSV energized, MSV may tested for closing or actuation, the closing
When remote shutdown button or ETS system sends out shutdown signals, AST solenoid valves are
energized and actuate, MSV and regulating valves close. When OPC signals are sent out in DEH
Electrical parts of DEH system must be wired correctly, especially the HV,LV circuits, dry contact circuit
and relay circuit, otherwise the electrical parts may be damaged when switched on, with unit start-up
and oil pump start-up, adjust control oil throttle to close servomotor (at this moment,DDV valve is not
powered and its plug can be pulled out)for minimum position calibration of valve position controller;
adjust control oil throttle to fully open the servomotor for the maximum position calibration of valve
position controller. After calibration, adjust control oil throttle to move servomotor toward closing
direction slowly, at this moment, tighten the locking nut of throttle. And then calibrate the servomotor
Note: To ensure unit safety, with DDV valve deenergized (plug may be pulled out), adjust the throttle,
making servomotor slowly move toward closing direction and lock the adjusting screw, make sure that
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when DDV valve is deenergized, the servomotor is closed.
If the valves in extraction steam system or steam make-up system are controlled by safeguard oil
After turbine static test is acceptable, and turning off is ready, turbine starts loading up and dynamic test
Clap the trip handle(travel 12mm),release safety oil,MSV and regulating valves shall close, and
Speed up the turbine via operating control system, when speed rises up to a value within
3300-3360rpm, the protection ring of emergency governor shall fly away, otherwise, adjusting screws
of emergency governor shall be adjusted. The speed of protection ring can be adjusted via adjusting
screws, each 450 change of adjusting screw, the actuation speed of eccentric ring varies about 50rpm.
The protection ring fly-away is based on the closing of MSV and regulating valves at test and indication
of “tripped” of emergency governor indicator. Mechanical over-speed test is done three times, and the
actuation speed meets design requirements. Although the emergency governor reset speed may not
Nozzle test is carried out at rated speed. Reduce speed to about 2800rpm under turbine no-load
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condition, before test, pull out the handle of nozzle test device, slowly pull the dog of nozzle test valve,
test oil is filled in the protection ring of emergency governor, and then raise speed to 2920±30 rpm, the
protection ring shall fly out actuating the emergency trip oil valve, at the same time, emergency
governor indicator indicate “tripped”. When nozzle test valve block is racked in, the emergency
governor indicator indicate “normal”, it means emergency trip oil valve is latched. Rack out the handle
At the time of emergency trip oil valve manually trip or after AST solenoid valve actuation, system may
be reset or latched with energization of latch solenoid valve, MSV opens and regulating valves close.
With movable solenoid valve of MSV energized, MSV may be tested for closing or actuation, the
When remote shutdown button or ETS system sends out shutdown signals, AST solenoid valves are
energized and actuate, MSV and regulating valves close. When OPC signals are sent out in DEH
The test shall be carried out under rated steam pressure, normal vacuum and turbine no-load operating
condition.
During the test, when MSV and regulating valve fully closes respectively while the other valve fully
opens, the turbine speed shall be guaranteed not to reduce below 1000rpm, and the declining speed
Unit and grid shall be provided with the ground and prefect precautions before the test. Decision for the
test is made by the Customer himself, and it is not a mandatory requirement from the manufacturer.
If the valves in extraction steam system or steam make-up system are controlled by safeguard oil
Installation clearance for emergency governor and emergency trip oil valve
A=1.0±0.2
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Turbine monitoring protection devices include speed, axial displacement, differential expansion,
vibration and thermal expansion. Speed measuring devices used for the speed and axial displacement probe
are installed in the front bearing pedestal and differential expansion probes ares installed at exhaust hood
coupling with the use of suitable mounting support. For installation clearance between the probe and the
measured object and instrument commissioning, refer to the operation instructions of instrument.
Pay more attention to the servo actuator and the oil supply system during operation of DEH system.
The elements of servo oil supply system oil filter are required to be cleaned or replaced periodically at the
Oil pressures at all points shall reach the design value. During normal operation, the reset oil pressure
shall not be larger than 0.05MPa and can be adjusted via the reset oil drain hole. During shutdown, it’s
required that the pressure should not be larger than 0.05MPa after safety oil is discharged.
Prior to every unit start-up, check the servo-motor position: given that the DEH order is zero, it’s
required that the valve should be fully closed; if there is any deviation, calibrate the valve again; conduct
protection system test. After the protection parts operate, ensure all valves are closed and all security oil
In case of the following circumstances for the turbine control and protection system, it is forbidden to
turn off the turbine or connect with the grid with load.
b. Any one of the important valves including all MSV and regulating valves cannot be closed quickly or
tightly or jammed.
d. Any of the start-up oil pump and lube oil pump fails or self-start interlock fails.
f. Control system cannot maintain turbine idling (i.e. speed is not stable).
During turbine operation, monitor that the turbine protection system oil pressures for correctness.
Control and protection system signals not to DCS or DEH system shall be inspected periodically. The MSV
shall be subject to movement test periodically. Speed signals must be normal during operation. If not , reduce
load or shut down . During operation, important protection items of ETS system shall not be removed.
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2.7.3 Precautions during turbine shutdown.
If any part seizure is found during load reduction of turbine, try to eliminate it. At this moment, do not
take off-line the generator first. If necessary, trip the turbine or close motor-driven MSV or automatic MSV.
After confirming that the load is zero, take the generator off-line.
After taking off-line the turbine, observe the speed change. In case of abnormal speed increase,
If extraction valve or make-up steam valve are stuck or cannot be tightly closed, close other stop valves
in the corresponding pipes, to prevent turbine over-speed arsing from steam backflow. If shutdown is
implemented via remote shutdown button or ETS, security power supply cannot be removed during the
DEH-NTK turbine digital electro-hydraulic control system consists of the digital electronic part and
hydraulic part. The system has high control accuracy and automation level, can increase speed (manual or
auto), coordinate with electrical synchronization, electrical load control (valve position control or power
control) and other auxiliary controls and communicate with DCS and have the function of on-line adjustment
of control parameters and over-speed protection etc. With the DEH system, turbine can adapt to various
DEH is one real-time distributed control system. It adopts highly reliable and redundant high speed
data communication networks. Two high speed data communication networks run at the same time so
that even if one network fails, data communication can be maintained smoothly. DEH device hardware
includes: distributed processing unit (DPU), related I/O cards, control cabinet, redundant power
supplies, backup field communicator, printer, operator station and engineer station. DEH device has
the site signals (speed, pressure and travel etc) treated in input cards, then sends them to DPU for
calculation and the calculated results to field equipment via the output cards to perform the control
tasks. The adoption of pure digital electro-hydraulic governing system can meet high reliability
requirements for turbine control. With opening adjustment of valves and rotary diaphragm, DEH can
use proportional and integral closed-loop control to realize accurate control on speed and load.
The main purpose of DEH control system is to control speed and power of the turbo-generator set so
The unit DEH control system can also control heat supply pressure or flow. DEH system is also
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provided with basic control circuits such as speed control circuit, load control circuit, extraction control
circuit, main steam pressure control circuit and over-speed protection circuit as well as logic circuits
such as synchronization, frequency modulation limit, decoupling algorithm, signal filtering and judging.
DEH system controls respectively the HP and LP valves via the electro-hydraulic servo valves, to
achieve the goal of controlling the unit speed, power and extraction pressure.
During unit start-up and normal operation, DEH accepts CCS order or the operator collects the
turbo-generator set speed, power and control valve position feedback signals based on the increase
and decrease orders issued from HMI, to analyze and process, make comprehensive arithmetic, output
control signals to electro-hydraulic servo valves and change opening of the control valve so as to
During speed increase of the unit (i.e. before synchronization), DEH control system controls the unit
speed via speed regulation loop and the power control loop doesn’t work. With the loop, DEH control system
receives turbine speed signal from the field, after being processed in 2/3 logic as speed feedback signal, the
speed signal is PID arithmetically calculated with speed setpoint, the given opening signal of servo-motor is
output to the servo card. In the servo card, the given signal is compared with servo-motor position, and
outputs control signal to electro-hydraulic servo valve and adjusts servo-motor opening to change the steam
admission so as to control the unit speed. In the process, the operator can set target speed and speed
increase rate. After the unit synchronization, the system is switched to the load control loop and the turbine
speed takes part in the control as the primary frequency modulated signal. Load control has the following two
regulation modes:
(1) Valve position control mode (i.e. power feedback not in-service):
Under the circumstance, load setting is controlled by the operator through setting the percentage. After
the required opening is set, DEH outputs valve opening signal to the servo card to adjust the servo-motor
opening and change the steam admission. Under this mode, power takes the valve opening as internal
feedback, and there may be error in actual operation, but the mode doesn’t have high requirements for
valve characteristics. Note that the maximum valve opening of the extraction turbine under condensing
Under the circumstance, load loop regulator works. DEH receives field power signal, compares it with
the given power, sends it to load loop regulator for amplification of the difference, makes comprehensive
arithmetic, outputs valve opening signal to the servo card, regulates the unit steam admission and meets the
power requirement. The above two regulation modes can be changed over during operation based on actual
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needs. Note when power control mode is adopted, turbine regulating valve shall have suitable flow
characteristics. When turbine regulating valve flow characteristics is not linear, nonlinearity of site control
valve can be compensated through DEH internal correction. In case of unit trip, set the given signal of valve
opening to zero and close all valves. DEH control system is provided with OPC protections, valve position
limit and fast cut back protections. Primary frequency modulation threshold (deadband), upper and lower
Island control mode DEH control system has three operating modes, namely turbine remote control,
DEH system is provided with extraction control loop. It takes the operator setting pressure as the given
signal and the actual extraction pressure as the feedback signal and controls the extraction pressure through
PID regulator. The output and that of the power regulator are sent together to decoupling arithmetic logic for
decoupling arithmetic, to realize cogeneration regulation and static self –tuning. The coupling relation is
obtained from decoupling arithmetic of control valve opening based on main equipment thermal
As DEH auxiliary control loop, the main steam pressure control loop takes the operator setpoint as the
given signal and the actual main steam pressure as the feedback signal and realizes closed-loop control on
turbine side main steam pressure through PID regulator. For header system unit, it’s suggested not to put
This is the most common operation mode. Under this mode, the following operations can be made:
speed control, power control or valve position control, main steam pressure control and extraction control
etc.
The manual control with field communicator mode is that the field communicator control the servo card
via hard wire (switch value) and finally controls the valve opening under emergency condition.
Coordinated control operation mode is that DEH accepts coordination order switch governing valve
pulse (or analog value) under the valve position. For detailed description of the above control modes, refer to
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relevant sections below.
ETS is emergency trip system of turbine, and is used to monitor some parameters which have
significant impact on the unit safety, so that all admission valves of turbine are closed through the system
when the parameters exceed the safety limits to realize emergency shutdown.
ETS system has various protection operation and clearing, automatic trip protection and first-out cause
memory functions. When any shutdown conditions appears, ETS can send turbine trip signal to activate AST
solenoid valve and realize emergency shutdown. Note: during operation, important protection items of ETS
system shall not be removed and ETS power supply cannot be disconnected before cutting steam channel
before MSV.
TSI is used to monitor online parameters which have great impact on unit safety, so that when the
parameters exceed the safety limits, safe shutdown of turbine can be realized through DEH and ETS.
DEH-NTK system has two processing modes for TSI system. One is that special card is used to
receive TSI sensor signal and analyze and process it in the software for measurement, display and alarm
protection. The other one is that TSI system analog value and switch value outputs are collected through AI
and DI channels of DEH independently. How to process TSI system by DEH system supplied along with the
DEH and ETS parts of the system adopt NT6000 distributed control system hardware platform made by
Invensys. The hardware configuration mainly consists of: one control cabinet, one operator station, one
engineer station and one color inkjet. DEH system is provided with one pair of DPUs and I/O cards. ETS
DPU connects with the operator station and the engineer station via Ethernet to communicate the
DEH and ETS systems adopt two-layer network architecture. The first layer is eNet control network to
perform data communication between DPUs and between DPU and MMI station. eNet is highly reliable and
redundant peer-to-peer network and adopts real-time Ethernet technology with communication rate of
100M/1000M. Based on two independent sets of industrial Ethernet switches, in the transmission layer, two
sets of data sessions are sent out by two independent sets of physical layers to realize redundancy of
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network.
The second layer network is eBus bus and performs data scanning between DPU and I/O cards. eBus
is master/slave type high speed redundant communication bus with simple structure, communication rate of
3.125Mbps and minimum cycle of 5ms and is divided into 12 physically isolated branches. Every branch has
two independent communication interfaces to directly scan the I/O card respectively via independent bus.
There is one DEH control cabinet in the system. The cabinet structure complies with NEMA standard
(NEMA12<IP52>), 2200 (H)×800 (W)×600 (D) by default. The cabinet has front and rear doors and is
designed to cable entry and exit from bottom. The terminal block shall be installed to facilitate wiring, keep a
distance not less than 400mm from the cabinet bottom and not less than 150mm from the cabinet top. The
space between the terminal blocks shall not be less than 200mm. Electric elements in the cabinet, such as
relay, circuit breaker, operation and clearing switch and DC power supply shall adopt imported products. The
cabinet shall be provided with exhaust fan or internal circulation fan, and temperature detection elements.
The cabinet is provided with grounding busbar for protection and shielding grounding. The grounding
system shall be grounded at a single point in strict accordance with requirement and connected to the
electrical main grounding via a cable not less than 35mm2. The grounding resistance shall be less than 2Ω.
The user shall provide two circuits of AC 220V±10%, 10A, 50Hz±1Hz single-phase power supplies
(one circuit from UPS power supply and the other form auxiliary security power supply) and one circuit of DC
220V/4A power supply to the control cabinet. The two circuits of AC power supplies back up each other and
failure of any one circuit of power supply will not cause loss of power of the control cabinet. Failure of any
circuits of power supply will activate alarm. DC 220V power supply mainly supplies power to OPC solenoid
valve and AST solenoid valve (solenoid valve supply voltage is given in the drawing).
(1) Controller module DPU (KM951A): adopt POWERPC processor, VxWorks real-time operating
system and CF card for data storage, fully isolated, high anti-interference, low power consumption and
fan-free operation, duplicate redundancy, automatic bumpless transfer and hot swapping etc. DPU supports
online configuration and online download and offline simulation, supports field bus communication interface
of Modbus RTU, Modbus TCP, Profibus DP, HART standards, can reach 5ms quick processing capability and
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(2) I/O modules of DEH system mainly have the following functions and performance parameters:
KM331A: 8-channel analog current input module which inputs basic control analog value (4~20mAa), such
as power, main steam pressure, control stage pressure measuring point etc. Every channel can supply
power externally and the channel is not isolated. Input signal range: 0~24mA. Accuracy:±0.1%. A/D
conversion resolution is 16-bit. KM332A: 8-channel RTD input module which inputs basic control analog
value (RTD), such as oil temperature, pad temperature measuring points. The channels are mutually isolated
with isolation voltage >30V. Input signal range: 0~325Ω. Accuracy: ±0.2%. A/D conversion resolution is
16-bit. KM333A: 8-channel thermocouple input module which inputs basic control analog value (TC), such as
main steam temperature and cylinder temperature measuring points. The channels are mutually isolated
with isolation voltage >400V. Input signal range: -100mV~100mV. Accuracy: ±0.2%. A/D conversion
resolution is 16-bit.
KM333B : 16-channel thermocouple input module which inputs basic control analog value (TC), such
as main steam temperature and cylinder temperature measuring points. The channels are mutually isolated
with isolation voltage >400V. Input signal range: -100mV~100mV. Accuracy: ±0.2%. A/D conversion
resolution is 16-bit.
KM334A: 16-channel digital input module which isolates basic control switch value inputs. Signal input
requirement: ON condition: 100Ω; OFF condition: >100kΩ. 4ms anti-flutter. SOE resolution ≤ 1ms. KM335A:
8-channel relay output module which isolates the basic control switch value outputs. Contact output capacity:
1A/30VDC, 1A/AC230V. KM336A: 6-channel current output module which makes 4~20mA conversion of
DPU output analog value and outputs. The channels are mutually isolated with isolation voltage>1000V. The
output signal range: 3~23mA. Accuracy: ±0.2%. D/A resolution is 14-bit. Maximum output load is 580Ω.
KM531A: LVDT input module, which mainly collects LVDT signals, such as MSV servo motor travel etc,
supports 3-wire or 6-wire LVDT. Accuracy: ±0.5%. A/D conversion resolution is 16-bit.
KM532A: valve control module. Valve control card is one of the most important cards of DEH. The
valve control cards form the valve servo control system of DEH. Valve control card has its control orders from
DPU and receives field governing valve feedback signal (feedback via LVDT normally). Every valve position
controller controls one regulating valve, i.e. one servo-motor. Servo current output (optional): -10mA~+10mA,
-40mA~+40mA, -80mA~+80mA, -150mA~+150mA, -10V~+10V. The control cycle is 4ms. KM533A (OPC
card): over-speed measurement and over-speed protection module, used to measure turbine speed, and
judge over-speed condition (103% and 110%), quickly send over-speed protection signal.
Power supply module (KB434A): provide DC24V power supply to site DDV634V servo valve (SAV9
servo valve doesn’t need energized) and distribute DC220V power supply or AC220V power supply to other
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special modules in the cabinet.
OPC module (KB434B): process the 103% over-speed protection signals from over-speed
measurement and over-speed protection modules based on 2/3 logic and output the signal to OPC solenoid
valve to prevent turbine over-speed. Meanwhile, perform relay signal extension function, such as MSV
closure signal, latch solenoid valve and reset solenoid valve functions.
ETS module (KB434C): realize turbine emergency shutdown through activation of AST solenoid valve
when the conditions are met. For instance, 110% over-speed protection signals sent from three speed
measurement and over-speed protection modules are processed by two out of three logic and are true;
press the double buttons of manual shutdown at the same time; ETS system protection signal output etc.
(non-condensate). Note: The quantity of modules for each item are not always the same.
Operator station is HMI for operators to operate and monitor system operation. One set of industrial
control computer, mainly consisting of main board, hard disk, display card, redundant Ethernet card etc.
Engineer station and operation station have almost the same configuration. The engineer station is the
tool dedicated for engineer design, configuration, commissioning and monitoring of systems.
DEH-NTK system has strong communication function. The communication protocol is standard
MODBUS communication protocol (RTU and ASCII protocols are optional). Data communicate with the
external systems via operator station serial port. At ex-factory, it is RS232 level (maximum communication
distance is 15m) and after level conversion, RS485 or RS422 level can be used to realize long-distance
DEH-NTK communication has strong flexibility and can be configured as master station and slave
station. The communication baud rate can be set and data length, communication address and
The software platform of NT6000 distributed control system made by SCIYON is used for DEH-NTK
control system . The software is an engineering development platform with Windows XP as the operating
system and includes configuration files, graphics, pictures and control software functions.
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● Remote, automatic latch-on before turbine rolling
● Load control
● CCS control
● Load limit
● Fast Run-back
● Overspeed control
● Online test
2.8.9.1 Latch-on
Latch-on means that the unit is reset, the main throttle valve is opened and turbine rolling is able to be
conducted. Only when at least two of the following three conditions are met and no safety failure occurs on
the rotational speed channel during disconnection, can the unit be able to be latched on: ①the travel switch
is not on the “close” position, ②the starting oil pressure is set up, and ③the travel of the main throttle valve
The system can realize remote latch-on, and the latch-on action is realized through the resetting of the
latch-on electromagnet after being energized. Attention: As for manual latch, after it is switched on, the
latch-on electromagnet will be energized and reset. Therefore, when the unit is under normal running, it is
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2.8.9.2 Setting the Static Relation of the Servosystem (valve test)
The purpose for setting the static relation of the servosystem is to make the oil servo-motor be able to
be controlled during its whole travel. The relation between the valve setting signal and the lift range of the oil
In order to maintain good linearity of the corresponding relationship, it is required that the iron core of
the LVDT which is used to provide feedback on the oil servo-motor should maintain linear movement in the
middle section.
The setting of the oil servo-motor is operated on the DEH-NTK operator station through the valve test
on the interface. Only when the following three conditions, are simultaneously met, can the setting be
allowed: (1) the rotating speed is lower than 500rmp; (2) the unit is not connected to the grid; (3) the button of
“starting valve position calibration test” is pressed down. After the setting is finished, click the button of
“cutting off valve position calibration test”, then all the valve orders will be automatically reset. Attention:
Before starting the valve position calibration, it shall be endured to cut off the steam channels.
The start-up procedure of the turbine is a heating process for the cylinder and the rotor, etc. In order to
reduce the heat stress in the start-up process and make it be applicable to different initial temperatures, it is
At each latch-on, DEH can choose the thermal state according to the temperature of the cylinder wall of
Before the turbine generator is synchronized with the power network, DEH is a close-loop, no-deviating
regulation system for rotating speed, with the given rotating speed as the setpoint. After the difference
between the given rotating speed and the actual rotating speed is calculated through the PID regulator, it will
control the start-up degree of the oil servo-motor through the servo system, so as to make the actual rotating
After setting the target rotating speed, the given rotating speed will approach to the target rotating
speed at the given speed up rate. When entering into the critical rotating speed zone, the speed up rate will
be automatically changed to 600r/min (which can be set), so as to pass through the critical zone rapidly. In
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the process of speed up, it is usually required to conduct medium-speed or high-speed heating of turbine, so
Except that the operator can set a target rotating speed through the panel, under the following
When the turbine is just latched on, the target rotating speed is the current rotating speed; when the oil
switch is switched off, the target rotating speed is 3000r/min; and when the turbine has tripped out, the target
If the speed up rate is set by the operator, its value will be in the range of (0,500)r/min. In the critical
rotating speed zone, the speed up rate will be forcibly set as 600r/min. When approaching the rated rotating
speed, the speed up rate will be automatically lowered (It will be set as required).
The calculated value of the critical rotating speed of the shaft system shall refer to the main engine
specification. In order to avoid that the turbine remains in the critical rotating speed, DEH has set a critical
rotating speed zone. When the rotating speed of the turbine enters into the critical zone, DEH will
Attention: On the site, the critical rotating speed value and the warming-up speed plateau value shall
As the default warming-up rotating speeds of turbine are 500, 1200, 2500 and 3000r/min, its target
values are set as 500, 1200, 2500 and 3000r/min. When the target rotating speed is reached, the speed up
will be stopped to warm up the turbine. If it is required to stop speed up temporarily in the process of speed
Click the “maintain” button on the control screen with the mouse. When it is in the critical rotating speed
zone, the order maintains invalid, and it is only available to change the target rotating speed.
When the rotating speed of the turbine keeps stable at the speed of about 3000r/min, it is required to
After DEH automatically enters into the synchronization mode, the target rotating speed will change
with the change rate of 100r/min, based on the value when it just enters into the synchronization mode and
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according to the rotating speed up order sent from the synchronizing device, so as to make the frequency
and the phase of the electric generator reach the requirement for grid connection.
The rehearse grid connection test of electric generator is used to inspect the reliability and accuracy of
the automatic synchronized system. During the test, the disconnecting switch at the power grid side of the
electric generator sends a rehearse grid connection test signal. After receiving the signal, DEH will still
maintain the rotating speed control state, so as to cooperate with electric equipments to perform the ralted
tests.
2.8.9.5.1 Synchronize with power network for taking initial load. When all the synchronization
conditions have been met, the synchronizing device will send an order to switch on the oil switch, then DEH
will immediately increase the assigned value to make the electric generator take initial load, so as to avoid
appearing reverse-power. When one of the following situations occurs, it will automatically exit from the
synchronization mode:
After the steam turbine generator unit has synchronized with the power network, it can be put into use
when taking basic load. After being put into use, both the target value and the assigned value are shown in
the form of MW. When the power control is not put into use, the target value and the assigned value will be
shown in the form of the percentage of the rated condition. The load rate is set by the operator, with the value
Under the CCS control mode, the load varies as per the assigned value. The oil servo-motor varies
Power controller is a PI controller, which is used to compare the set value with the actual power and
control the governing steam valve after calculation. After all of the following conditions have been met, the
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● Grid connection has been completed;
If it is not in the “remote control mode”, when any of the following conditions is met, the power control
will be removed:
● The PID set value of the power greatly deviates from the measured value (over 10% of the rated
power);
When the turbine generator is under grid-connected operation, in order to ensure that the grid
frequency can meet the requirement of the power supply quality, the function of primary frequency
modulation can be put into use. When the rotating speed of the unit is within the dead zone, the frequency
modulation output will be zero, and the primary frequency modulation will not be actuated. When the rotating
speed is out of the dead zone, the primary frequency modulation will be actuated, and the assigned value of
the frequency modulation will vary with rotating speed as per the diversity factor (the default diversity factor
Usually, in order to allow the unit to bear rational primary frequency modulation, the diversity rate and
the dead zone of DEH are set consistently with the diversity factor and the delay rate of the hydraulic control
system.
● The range of dead zone is 3000± the dead zone value. Along with the increasing of the units that are
equipped with DEH system in the power grid in future, after this kind of units play a predominant role, the
dead zone can be gradually narrowed, so as to improve the power supply quality.
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When the unit is under single operation or isolated operation, secondary frequency modulation can be
put into use; this is also called isolated power system operation. When the unit is under isolated operation, it
is necessary to place the switch to the “ON” position first; and when the unit is synchronized with the power
1, The deviation of the actual rotating speed from the rated rotating speed is more than 30r/min;
3, OPC is actuated;
4, When the isolated operation is actuated manually (the indicator light of isolation operation turns
red), the target load can be manually increased or reduced on the isolated network control screen; also, it is
available to automatically increase or reduce load through the secondary frequency modulation function, so
As the rotor time constant of the turbine is relatively low, while the volume time constants of the steam
cylinder and the steam pipeline are relatively large; when load shedding occurs, the rotating speed of the
turbine will accelerate rapidly. If it just relies on the rotating speed feedback function of the system, the
maximum rotating speed may probably exceed 110%, which will lead to the occurrence of turbine breaking.
If load shedding occurs when the oil switch is switched off, the overspeed time relay will be switched on
to be energized, so as to rapidly acuate the overseed solenoid valve, close all the governing steam valves
and at the same time, change the target rotating speed and the assigned rotating speed to 3000r/min. When
the rotating speed is lower than 3000r/min, the overspeed limiting solenoid valve will lose power and the
control valves will recover to be controlled by the servo valve to recover the closed-loop control of rotating
speed. Finally, the rotating speed of the turbine will keep stable at 3000r/min, so as to achieve rapid grid
When the following conditions are met, the CCS control can be put into use by the operator:
● There is no ETS.
Under the mode of CCS, DEH will receive the signals assigned by CCS and remove the load feedback.
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The realization of CCS removal just needs to meet one of the following conditions:
● ETS is actuated;
When the turbine generator unit malfunctions, the valve opening will be rapidly reduced, so as to shed
off some loads and prevent the malfunction from expanding. During the period that the fast run-back function
is put into use, when DEH receives the input signal of fast run-back, it will immediately reduce the load to the
corresponding value as per the preset target value and load reducing rate. DEH-NTK has the function of fast
run-back, which is divided into automatic fast run-back and manual fast run-back. The automatic fast
run-back only has one grade, while the manual fast run-back has two grades, i.e., fast run-back rate 1 (which
will rapidly reduce 50% of the rated power per minute, with 20% of the rated power as the target load) and
fast run-back rate 2 (which will rapidly reduce 50% of the rated power per minute, with 50% of the rated
2.8.9.5.7.1.1 When the following conditions are simultanesouly met, the automatic fast run-back will
● RUNBACK is true;
● The assigned value of load shedding is over 20% of the rated power.
2.8.9.5.7.1.2 When one of the following conditions is met, the automatic fast run-back will be
removed:
● RUNBACK is false;
● The assigned value of load shedding is lower than 20% of the rated power.
2.8.9.5.7.1.3 When the following conditions are simultaneously met, the manual fast run-back rate 1
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2.8.9.5.7.1.4 When the following conditions are simultaneously met, the manual fast run-back rate 1
will be removed:
2.8.9.5.7.1.5 For putting the manual fast run-back rate 2 into operation, the following conditions shall
be simultaneously met:
2.8.9.5.7.1.6 When any one of the following conditions is met, the manual fast run-back rate 2 will be
removed:
● The “manual fast run-back reset” button has been pressed down;
If the load of the turbine generator unit is not expected to be very high during a period of time for some
reasons, the operator can set a high load limit to make the DEH target value keep lower than the
If the load of the turbine generator unit is not expected to be very low during a period of time for some
reasons, the operator can set a low load limit to make the DEH target value keep higher than the
If the valve opening of the turbine generator unit is not expected to be too large during a period of time
for some reasons, the operator can set a valve limit value.
The DEH-NTK system has the function of main steam pressure control (i.e., steam turbine pressure
regulating function), which can maintain the main steam pressure at the normal value through adjusting the
2.8.9.6.1 When the following conditions are simultanesouly met, the main steam pressure control can
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● It has been latched on;
● The “main steam pressure control switch-on” button has been pressed down;
2.8.9.6.2 When any one of the following conditions is met, the main steam pressure control will be
removed:
● The “main steam pressure control removal” button has been pressed down;
● The main steam pressure PID set value greatly deviates from the measured value.
In order to avoid that the turbine throttle pressure is over high, a steam pressure protection loop is set
to limit the change of the turbine throttle pressure within the preset pressure scope. When the main steam
pressure reaches to the preset upper limit value, the load increase will blocked; when the main steam
pressure is lower than the preset lower limit value, the valve will be gradually turned down till the main steam
2.8.9.7.1 The achieving of main steam pressure protection permission shall simultaneously meet the
following conditions:
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● The main steam pressure channel is trouble-free;
● The main steam pressure is within the scope of preset top and bottom limitations;
● The “main steam pressure protection switch-on” button has been pressed down.
2.8.9.7.2 The removal of main steam pressure protection just needs to meet one of the following
conditions:
● The “main steam pressure protection removal” button has been pressed down.
2.8.9.7.3 The acuation of main steam pressure high protection shall simultaneously meet the following
conditions:
● The “main steam pressure protection” has been put into use;
● If the main steam pressure is higher than the “preset upper limit value of the main steam pressure”, it
shall be noticed that after the main steam pressure high protection is actuated, the load increasing and
reducing will be blocked; that is, the target value of the load will not be able to be changed.
2.8.9.7.4 The actuation of main steam pressure low protection shall simultaneously meet the
following conditions:
●The “main steam pressure protection” has been put into use;
● If the main steam pressure is lower than the “preset lower limit value of the main steam pressure”, it
shall be noticed that after the main steam pressure low protection is actuated, it will be compulsively
switched into the valve control mode, and simultaneously, the load will be reduced at the rate of 0.5%/s;
when the actual load is 10% lower than the rated load (it is revisible), the main steam pressure low protection
When the unit is synchronized with the power network to keep stable operation and the load is 30%
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over the rated load, the steam extraction control loop can be put into use. After that, the operation personnel
can set the target value of steam extraction pressure through the operator station and control the openness
DEH-NTK steam extraction can be put into use in two steps: First, the set value of the steam extraction
pressure (which shall be 0.03MP higher than the steam extraction header pipe) shall be set; after clicking the
“steam extraction switch-on preparation” button, the unit enters into the steam extraction preparation status
and the steam extraction control valve will be gradually closed. Then, after the steam extraction pressure
approaches to the set value, the “steam extraction switch-on” button can be clicked, and DEH enters into the
steam extraction control status. The change of steam extraction pressure will simultaneously control the
control valve and the rotating diaphragm. At this time, the motor-operated steam extraction valve will be fully
When DEH-NTK steam extraction is removed, it is required to first lower the set value of the steam
extraction pressure to reduce the steam extraction amount, and at the same time, the motor-operated steam
extraction valve shall be gradually closed. After the motor-operated steam extraction valve is totally closed,
the “steam extraction removal” button shall be clicked to stop steam extraction.
The switch-on of steam extraction pressure control shall simultaneously meet the following conditions:
● The “steam extraction switch-on preparation” button has been pressed down.
If any one of the following conditions is met, the steam extraction pressure control will be removed:
● The “steam extraction removal preparation” button has been pressed down;
● The load is more than 30% and the “steam extraction switch-on” button has been pressed down;
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● The “ETS protection” has been actuated;
If any one of the following conditions is met, steam extraction will be removed:
● The deviation of the steam extraction PID instruction feedback is 50% over the rated value;
● The “steam extraction removal preparation” button has been pressed down;
In order to keep the safety and the reliability of the system, several grades of overspeed protection
Before grid connection, if the rotating speed is over 3090r/min, the OPC solenoid valve for overspeed
limitation will be rapidly actuated, and all control valves will be closed; when the rotating speed is lower than
3070r/min, the overspeed limitation solenoid valve will loose power, and the regulating valve will recover to
the be controlled by the servo valve, i.e., it will recover to be controlled by the regulating system. After grid
connection, if the rotating speed is over 3090r/min, the OPC solenoid valve for overspeed limitation will be
rapidly actuated, and all control valves will be closed; when the rotating speed is lower than 3070r/min, the
overspeed limitation solenoid valve will loose power, and the regulating valve will recover to the be controlled
by the servo valve, i.e., it will recover to be controlled by the regulating system.
When the rotating speed of the unit exceeds 3300 r/min, DEH will immediately sent a stopping signal
and rapidly close all the main steam valves and the regulating valves through the ETS system.
2.8.9.11.1.1 When the turbine is firstly installed or overhauled, it is required to conduct leakage test to
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main throttle valve.
2.8.9.11.1.2 The switch-on of the main throttle valve leakage test shall simultaneously meet the
following conditions:
● The main throttle valve leakage test switch-on button has been pressed down and is under the
automatic mode;
2.8.9.11.1.3 Test steps: Click the “main throttle valve leakage test switch-on” button on the overspeed
test screen, then the solenoid valve of the main throttle valve test will loose power after the test has been
started, the main throttle valve will close slowly. After the openness of the main throttle valve is lower than 5,
all control valves will be fully opened and the turbine will coast. At this time, observe whether the rotating
speed is lowered below 1000r/min. After the test is finished, click the button of “main throttle valve leakage
test reset” to exit from the main throttle valve leakage test.
2.8.9.11.2.1 When the turbine is firstly installed or overhauled, it is required to conduct leakage test to
● The control valve leakage test switch-on button has been pressed down and is under the automatic
mode;
2.8.9.11.2.3 Test steps: Click the “control valve leakage test switch-on” button on the overspeed test
screen, after the main throttle valve has been fully opened, all the control valves will be closed and the
turbine will coast. At this time, observe whether the rotating speed is lowered below 1000r/min. After the test
is finished, click the button of “control valve leakage test reset” to exit from the control valve leakage test.
2.8.9.11.3.1 In order to ensure the main throttle valve can move reliably when an accident occurs, the
DEH system has the function of providing online movement test for the main throttle valve. It is also available
to conduct local manually-operated main throttle valve movement test through the movable mand wheel on
● The “main throttle valve movement test switch-on” button has been pressed down;
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● The power control loop has not been put into use;
●The main steam control loop has not been put into use;
● The travel of the main throttle valve has passed over 98%;
2.8.9.11.4.3 Test steps: Clicck the “main throttle valve movement test switch-on” button on the
movement test screen; then when the solenoid valve of the main throttle valve test is energized after the test
is started, the travel of the main throttle valve will decrease. After the test is finished, click the “main throttle
valve movement test reset” button to exit from the main throttle valve movement test.
2.8.9.11.4.1 In order to ensure the flexibility of the control valves, it is available to provide movement
● The “control valve movement test start” button has been pressed down;
● The button of “selecting the valve for movement test” has been pressed down.
Click the button that requirs the test on the movement test screen, and then click the “test start” button.
After the openness of the control valve decreases, click the “test cancel” button. After the test is finished,
click the “test reset” button to exit from the control valve movement test.
When the turbine is firstly installed or overhauled, the accuracy of the overspeed protection action must
be verified, and each type of overspeed protection shall be verified through tests.
The overspeed protection of DEH system is achieved by 3 pieces of OPC overspeed protection cards
through the voting method of choosing two of the three. When the 110% electric overspeed test is put into
use, the overspeed protection constant value of the OPC card will automatically raise to 3302r/min; when the
112% mechanical overspeed test is put into use, the overspeed protection constant value will be
automatically raise to 3362r/min; and when the overspeed test exits, the overspeed protection constant value
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When the overspeed test screen shows that the unit is under the paralle off state and the rotating
speed is lower than 200r/min, click the button to send an OPC action signal (2s impulse), so as to test
When overspeed test screen shows that the unit is under the parallel off state, click the “103%
overspeed” button, then the target value of the rotating speed will automatically raise to 3095r/min. When the
actual rotating speed exceeds 3090r/min, the 103% overspeed protection will be actuated, then the target
value of the rotating speed will be automatically set as 3000r/min till the actual rotating speed decreases to
On the overspeed test screen, click the “110% overspeed” button, then the target value of the rotating
speed will be automatically set as 3305r/min. When the actual rotating speed exceeds 3090r/min, the 103%
overspeed protection will not be actuated; while when the actual rotating speed exceeds 3300r/min, the
110% overspeed protection action signal sent from the external to the ETS system will make the unit shut
down through the ETS system. At the same time, if the rotating speed exceeds 3302r/min, the OPC
On the overspeed test screen, click the “mechanical overspeed” button, then the target value of the
rotating speed will be automatically set as 3365r/min. At this time, both the 103% overspeed protection and
the 110% overspeed protection will be shielded. When the actual rotating speed exceeds 3362r/min, if the
emergency governor is not actuated, the OPC overspeed protection card will be actuated to send a
shutdown signal.
When performing the test, it is required to arrange operation personnel at the site to observe the
situation of the rotating speed and the actuation status of the emergency trip device.
2.8.9.11.5.5 Reset:
On the overspeed test screen, to click the “reset” button can suspend the ongoing overspeed
The control of the turbine can be achieved through the operator station. This chapter introduces the
operation of the operator station and the realization of its different functions.
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2.8.10.1.1.1 Second Validation
The second validation stated here means that many buttons on the interface will pop up a window after
Grey button means that the operation cannot be implemented. When the conditions are met, the grey
buttons will turn to the normal status and then the button can be operated normally.
The screen will line out the measurement points on the required positions according to the procedure,
so as to display the numerical values of the points in real time and dynamically, such as temperature,
The color of the measurement points will change with their status and the points will flash and flicker
Status of Status of
NO. Display NO. Display
Measurement Points Measurement Points
4 Green Normal
The screen includes simulated diagrams, operation screens, system configuration diagrams, bar charts
It is a general view screen, which provides the general situation of the whole system and some
important parameters during system operation. After the operator starts the unit, he or she will automatically
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It is the rotating speed control screen, which provides the frequently-used operations in the speed
raising process of the turbine, such as “latch-on”, setting “target value of rotating speed” and “speed up rate”,
“proceeding”, “maintaining”, “starting mode”, “valve position limitation” and “automatic synchronization”, etc.
Additionally, it also has the functions such as valve test (valve position calibration), friction inspection and
overspeed test, etc., which can provid the operations during the system debugging stage.
It is a power control screen, which provides the frequently-used operations in steam extraction control
and the functions such as setting “target value of power” and “variable load rate”, “power loop switching”,
“main steam pressure control”, “main steam pressure protection”, “primary frequency modulation”,
“low-voltage steam extraction pressure setting”, “low-voltage steam extraction preparation switching”,
“low-voltage steam extraction loop switching”, “medium-voltage steam extraction pressure setting”,
“medium-voltage steam extraction preparation switching”, “medium-voltage steam extraction loop switching”,
“manual fast run-back”, “remote switching”, “valve position limitation” and “valve test”, etc.
It provides the switching operations under various protection conditions, the ETS general protection
switching, the ETS first-out memory reset, the ETS action reset and the interface manual shutdown
operation.
It provides the function of parameter monitoring for turbine security detection system.
It can tabulate to show a list of the measurement points of DEH system and ETS system, as well as
their real-time data and status. It is available to view the channel status of a module by clicking the specific
module.
It provides the real-time curve of some important parameters in the travel process of the turbine,
including rotating speed, power, main steam pressure, control valve command, openness of control valve,
etc. The time frame of the curve is 10 minutes (the content of the curve and the time of the trend chart can be
This screen shows the real-time alarming status of some important parameters in the system in the
form of light indicator, such as OPC action, ETS action and power-lossing alarm, etc.
46
The operations before grid connection are mainly completed on the rotating speed control screen.
Before starting the unit, it is required to check with valve position calibration whether the servo system
is under normal work condition. Click the “entering valve position calibration” button on the “rotating speed
control screen”, and then click the “test switch-on” button on the “valve position calibration” screen to set the
openness of the control valves. Click the “test removal” button after completing the valve position calibration.
DEH-NTK has the remote latch-on function. Click the “latch-on” button, then the latch-on solenoid valve
will be energized for 30s. During this period, if the latch-on conditions of the unit are met, the latch-on
solenoid valve will lose power. After the unit is latched on, the steam extraction control valve will be fully
opened.
DEH-NTK has three types of starting modes: local start, high-pressure control valve manual start and
If the unit is started for the first time, the starting mode of local start shall be adopted. Before selecting
the local start mode, it is required to confirm that the electric main steam valve and its bypasses have been
entirely closed. Click the “local start” button and then click the “proceeding” button. After the local start is put
into use, it will automatically set the target rotating speed as 2800, and at the same time, the high-pressure
Set the target rotating speed and the speed raising rate through clicking the “high-pressure control
valve manual start” button and then clicking the “rotating speed setting” button. Click the “proceeding” button
to make the unit run under the high-pressure control valve manual start mode.
Click the “high-pressure control valve curve start” button and then click to enter the curve selection
screen; select the corresponding speed up curves (curve 1 corresponds to cold state, curve 2 corresponds to
warm state, curve 3 corresponds to hot state and curve 4 corresponds to very hot state); and then click the
“proceeding” button to make the unit run under the high-pressure control valve curve start mode.
Attention: Before using the high-pressure control valve curve start mode, the speed raising curve shall
be set correctly.
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Click the “friction switch-on” button and then click the “proceeding” button to make the unit enter friction
inspection. After the friction inspection is finished, click the “friction switch-on” button to exit from the friction
inspection.
Click the “enter into overspeed test” button to enter into the overspeed test screen and then click the
“103% overspeed” button to enter the 103% overspeed test; then the target value of the rotating speed will
be automatically set as 3095. After the test is finished, click the reset button to exit from the test.
Place the overspeed protection switch in ETS to the switch-off position; click the “enter overspeed test”
button to enter into the overspeed test screen; and then click the “110% overspeed” button and then the
“proceed” button to enter into the 110% overspeed test. After that, the target value of the rotating speed will
be automatically set as 3305. After the test is finished, the system will exit from the test.
Place the “DEH overspeed shutdown (110%)” switch in ETS to the switch-off position; click the “enter
overspeed test” button to enter into the overspeed test screen; and then click the “mechanical overspeed”
button and then the “proceed” button to make the unit enter into the mechanical overspeed test. After that,
the target value of the rotating speed will be automatically set as 3365. After the test is finished, the system
When the “DEH synchronization control request” is true and the rotating speed is within the range of
2950~3050, click the “synchronization switch-on” button to make achieve automatic synchronization. The
unit will automatically exit from the synchronization status after grid connection.
Click the “enter valve position limitation” button to enter into the valve position limitation screen, so as
to set the maximum and the minimum openness of the control valve during the unit running.
The operation after grid connection is mainly completed on the power control screen.
Click the “enter power control” button to enter into the power control screen. After completing grid
connection, the unit will run under the “valve position closed-loop control” mode. Under this mode, the
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operator can set the load target value, the load increasing rate, the maximum load and the minimum load (all
settings shall be shown in percentage and 100% corresponds to the rated load).
Click the “enter power control” button to enter into the power control screen. When conditions for
putting the power closed-loop into service are satisfied, click the “power loop switch-on” button to enter into
the “power loop switch-on” status. Then, the operator can change the load target value, the load raising rate,
the maximum load and the minimum load (all settings take MW as the unit) as required.
Click the “enter main steam pressure protection” button to enter into the main steam pressure
protection screen. The operator can set the maximum main steam pressure and the minimum main steam
pressure, and then click the “main steam pressure protection” button to put the main steam pressure
protection into use. When the current pressure exceeds the limiting values, the main steam pressure high
Click the “enter main steam pressure control” button to enter into the main steam pressure control
screen. When the main steam pressure control is allowed to be put into operation, click the “main steam
pressure switch-on” button to make the unit enter into the main steam pressure closed-loop control.
Click the “enter fast run-back” button to enter into the fast run-back screen. When placing the automatic
fast run-back switch to the switch-on position and the “automatic fast run-back” signal is true, the fast
run-back 1 will be actuated. Press down the “manual fast run-back 1” button, and then the fast run-back 1 will
be actuated; press down the “manual fast run-back reset” button, and then the manual fast run-back will be
reset.
The primary frequency modulation can be put into operation by clicking the “frequency switch-on”
button.
Click the “medium-pressure extraction control” button to open the extraction control screen. Click the
“medium-pressure extraction switch-on preparation” button to enter into the extraction preparation status.
Set the extraction pressure set value a little bit higher than the heat supply network pressure and then click
the “confirm” button, the extraction valve will gradually close. When the actual pressure approaches to the
set value, click the “medium-pressure extraction switch-on” button to put the extraction into operation.
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2.8.10.3.7 Movement Test
Click the “enter movement test” button to open the movement test screen. Select the movement test
control valve and then click the “test start” button. After the control valve test is finished, click the “off-test
button”. After the test is finished, click the “test reset” button.
Click the “remote control” button to accept the external remote-control load increasing and reducing
commands.
On the isolated network control screen, swith on the “isolated network function” switch. When the
isolated network conditions are met, the unit will automatically enter into the isolated network operation. If
load adjustment is required, it is available to modify the “preset target value of isolated network load” to
modify the load target value. When needing to exit from the isolated network function, it is required to switch
off the “isolated network function” switch. (Attention, at this time, the isolated network function of DEH is
invalid.)
Click the “ETS” button at the bottom of the operation screen to enter into the switching monitoring
screen of ETS protection system. Different protections can be put into use according to the actual demands.
When the conditions of a protection action are satisfied, the ETS protection will be actuated and the
Click the “TSI” button at the bottom of the operation screen to enter into the TSI parameter screen,
which shows the status of various important parameters of the current unit.
2.8.10.4.3.1 The “system configuration” screen is mainly used to observe the status of all measurement
points.
2.8.10.4.3.2 The “trend” screen is mainly used to observe the curve of important parameters within 10
minutes.
2.8.10.4.3.3 The “alarm screen” is mainly used to observe whether there is any important parameter
alarm.
2.8.10.4.3.4 Click the “pop-up button” at the bottom right corner to pop up the parameter screen.
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2.8.11 Emergency Trip Protection System (ETS) of Turbine
The ETS system and the DEH system are located in the same control cabinet and are composed of a
pair of independent controller and corresponding I/O card. The ETS turbine emergency trip protection
system is used to monitor some parameters which have significant impacts on the unit safety, so as to close
all the inlet valves of the turbine and then realize emergency shutdown of the unit through the ETS system
when the parameters exceed the safety limits. The ETS system has the functions such as various protection
switching, automatical trip protection and first-out cause memory, etc. When an ETS protection is put into
use and the shutdown conditions are met, the ETS will send out a turbine trip signal to make the AST
solenoid valve be actuated (energized) to immediately close the automatic main steam valve and the control
valve and then to realize emergency shutdown of the unit. The main shutdown items include the ultralimit of
axial displacement caused by turnbine overspeed, low bearing lubricating oil pressure, high oil return
temperature, high bearing bush temperature, manual shutdown, electric generator failure and vibration
ultralimit.
It shall be paid attention that in actual operation, the switching of different protection conditions shall
base on the turbine operation protection instructions and the actual situations. The ETS operation is mainly
completed on the switching monitoring screen of the ETS protection system. After entering into the ETS
screen, the status of important parameters will be shown on the top of the screen, and the operator can
intuitively monitor the status of the pamaters sent into the ETS sytem, such as the shutdown signal caused
by low lubriacating oil pressure and the rotating speed and vibration of the main steam valve, etc. The
bottom of the ETS screen is the switching control and monitoring zone of ETS.
After two-out-of-three processing, three lubricating oil pressure shutdown switching values are “true”;
and when it is switched to ETS general protection and the protection against the low lubricating oil pressure,
send out the shutdown command for the protection against the low lubricating oil pressure.
electrical request for shutdown is “true”, and when it is switched to ETS general protection and the protection
against the generator-transformer unit malfunction, send out the shutdown command for the protection
Three rotating speed signals respectively determine whether the shutdown value (3300r/min) has been
exceeded. After two-out-of-three processing, three signals of shutdown status due to overspeed are “true”;
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when it is switched to ETS general protection and the protection against the steam turbine overspeed, send
out the shutdown command for the protection against the steam turbine overspeed.
When any one of four bearing’s return oil temperatures is higher than the shutdown value, and when it
is switched to ETS general protection and the protection against the bearing’s return oil temperature, send
out the shutdown command for the protection against the high return oil temperature. (If the channel sensor
When the return oil temperature of either positive thrust shoe or negative thrust shoe is higher than the
shutdown value, and when it is switched to ETS general protection and the protection against the thrust
shoe’s return oil temperature, send out the shutdown command for protection against the high return oil
temperature of thrust shoe. (If the channel sensor is disconnected, then the shutdown signal will not be sent
out).
When the axial displacement exceeds the shutdown value, and when it is switched to ETS general
protection and the protection against the axial displacement, send out the shutdown command for protection
When any one of ten thrust shoe temperatures is higher than the shutdown value, and when it is
switched to ETS general protection and the protection against the thrust shoe temperature, send out the
shutdown command for the protection against high temperature of thrust bearing. (If the channel sensor is
When any one of four radial bearing temperatures is higher than the shutdown value, and when it is
switched to ETS general protection and the protection against the high temperature of radial bearing, send
out the shutdown command for the protection against the high temperature of radial bearing. (If the channel
sensor is disconnected, then the shutdown signal will not be sent out).
Press emergency shutdown buttons on the console simultaneously; and the shutdown command will
be directly sent out, in which way the shutdown command can be sent out without switching to any protection
function.
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The on-screen emergency shutdown button is at the right lower part of ETS screen. When the button is
pressed and when it is switched to ETS general Protection, the shutdown command will be sent out.
ETS of DEH-NTK is equipped with “First Out” function, i.e. it can remember the first signal that causes
the shutdown of ETS and provides basis for user’s analysis on shutdown causes.
Users should determine whether they need to switch to one of ETS protection functions based on
instruction manual and actual conditions of the unit. When ETS actuates, “ETS Protection Actuation”
indicator is in red, meanwhile AST solenoid valve will actuate (power on) and the unit’s all control valves and
main steam valves will close. When ETS system detects the close of the main steam valves, it will
automatically reset AST solenoid valve (power off), at which time ETS protection devices still actuate. When
all conditions causing ETS are not met, the operator can press “ETS Reset” button to reset ETS, or ETS will
When one condition causing ETS actuation is met, the operator cannot reset ETS. Note that it shall be
guaranteed that the power supply of DC220V fed in ETS system should work properly and DC220V BC
Note: when ETS is not included in DEH-NTK system, the user should design the complete set and the
Refer to the adjustment system instruction manual for the adjustment and the test of hydraulic security
system
After successful commissioning of the oil system, mark the minimum and maximum position of the
oil-driven machine using valve position controller; then mark the valve position of the oil-driven machine with
The test refers to after the protection signal of the steam turbine is sent out, electromagnetic protection
devices will actuate and such protection valves as the main steam valve, the regulating steam valve, LP
After the completion of the commissioning of DEH system in static state, and when the steam turbine is
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under the startup condition, the unit can be started according to the startup procedure. When the rotating
speed of the unit is stable, the commissioning in operational state can be performed. After successful
electrical tests of the generator, the unit can be connected to the grid, with load.
2.8.12.2.1 Startup
After the pipe and the machine is heated according to procedures, start HP and LP oil system to supply
oil. Start the unit to the constant speed. During the speed-up process, when the outlet oil pressure of the
main oil pump is slight higher than the outlet oil pressure of the HP electric oil pump, gradually turn down the
outlet valve of the HP electric oil pump until the valve is about to be closed; and stop the HP electric oil pump.
It is recommended that onsite manual startup be utilized for the first start of a new unit. When the
minimum controlled rotating speed is reached, DEH system will control the unit to reach the constant speed.
After successful tightness test of the main steam valve and the steam control valve, manual startup by an
operator or automatic start can be utilized. The startup mode can be selected on LCD screen. During the
startup process, the speedup modes can be switched between “Hold” and “Proceed” for the speedup
process.
Before the unit is connected to the grid, the control system operates in the rotating-speed control mode,
at which time the pressure and power regulator are in tracking state. There are three ways for the system to
speed up: local start, manual start with HP control valve, and start with HP control valve curve. The three
ways are lockout between each other, i.e. in a certain state, the unit can only be started with one of the
modes. When the local start is performed, the automatic main steam valve and the HP control valve are
opened fully and the electrical main steam valve closes, so that the speedup is realized through a bypass
valve manually. When the rotating speed reaches 2800 rpm, it is switched to the manual start with the HP
control valve, at which time the HP control valve begin to close and the MP control valve is still opened fully.
Open the electrical main steam valve again. When the manual start by the HP control valve is performed, the
electric main steam valve, the automatic main steam valve and the LP control valve are opened fully and the
HP control valve is closed fully. The operator enters the target valve and the speedup rate, DEH controls the
rotating speed through adjusting the opening of the HP control valve; the operator may also make fine
The start with the HP control valve curve is similar to the manual start by the HP control valve, except
that the target value and the speedup rate do not need to be entered manually; but the operator only needs
to select a curve for the startup based on the current thermal state; the operator may also make fine
The rotating speed control circuit can guarantee that the unit will automatically and quickly pass the
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critical rotating speed range. After the steam turbine is connected to the grid, the turbine's power or steam
pressure is controlled with the main steam control valve as needed. DEH system has the interface which can
be connected with an automatic synchronizer, with which the automatic synchronization adjustment of the
generator is realized, making the turbine’s rotating speed adapted to the grid’s frequency, so as to realize the
realized by the operator with the help of the synchronization indicator. DEH receives the synchronous
increase and decrease signal from the automatic synchronization device and increase and decrease the
target value of the rotating speed (increase or decrease the target value by one rpm on receiving increase
and decrease rising edge one time), so that the unit’s output frequency, phase and other parameters are
constant with that of the grid to meet the requirements of the grid connection.
2.8.12.2.2 Main parameters evaluation and setting during the operation Observe some parameters
during the operation with constant speed to determine whether they are the design values.
The test aims to demonstrate the reliability of the hydraulic loop after there is protection signal in the
I&C protection circuit. The electromagnetic protection devices will actuate and such protection valves as the
main steam valve, the regulating steam valve, the LP rotating diaphragm (suitable for adjustable steam
extraction unit), supplementary steam valve (suitable for supplementary steam unit) will close. The signal
After the completion of no-load test, the unit can be connected to the grid, with load, according to the
operation procedures. The target load and rate can be set on the operating screen with the load control
function. The load control modes can be switched to power control or valve position control mode. The power
control mode is to feed back the actual power, while the valve position control mode is to feed back the valve
position control command. In the mode of valve position control, there will be some difference between the
target power and the actual power. These two load modes can be switched on in an on-line way. As to a
small unit, the valve position control mode is sufficient enough to meet the operation requirements.
The default mode of the controller is the valve position control mode. If the power feedback signal is
proper, the power control mode can be switched on. When the power signal fails, the valve position control
mode will be automatically switched on. It may participate in a frequency modulation or remove a frequency
Make good preparation before switching to steam extraction. The unit is with some load (30% rated
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load). Enter the required extraction pressure value. When the extraction pressure reaches the setting value,
the extraction control can be switched on, at which time, the steam can be supplied by opening the valve of
an extraction pipe. Note: the extraction switching process of the double extraction unit is the same as that of
Quantity of steel
Piece -
pipes
Nanjing Turbine
Manufacturer
Factory
3.2 Condenser
Model N-5100-6
Cooling water
Normally 33℃
temperature
56
Allowable 0.3MPa
pressure in water
chamber
Nanjing Turbine
Manufacturer
Factory
Manufacture
Date
date
Code
Item Unit
#1 #2
Design pressure
MPa 2.1 3.6
at steam side
Design pressure
MPa 18 18
at water side
Max. working
MPa 1.85/14.7 3.17/14.7
pressure
Pressure of the
MPa --/-- --/--
pressure test
Heat exchange
m2 260 260
area
Temperature (at
℃ 350/250 420/280
steam side)
Temperature (at
℃ 220 250
water side)
Code
Item Unit
57
2.5/0.8-170-3. 2.5/0.4-170-3. 2.5/0.1-185-3.
Design pressure
MPa 0.8 0.4 0.1
at steam side
Design pressure
MPa 2.5 2.5 2.5
at water side
Max. working
MPa 0.7/2.0 0.3/2.0 -0.05/2.0
pressure
Pressure of the
MPa --/-- --/-- --/--
pressure test
Heat exchange
m2 170 170 185
area
Temperature (at
℃ 260 180 95
steam side)
Temperature (at
℃ 165 135 85
water side)
Working water
℃ 20
temperature
Pressure in suction
MPa 0.004
chamber
58
Item Unit Code and data Remarks
Model JQ-46-5
Steam
℃ -
temperature
Pressure in
MPa 0.1
suction chamber
Cooling water
t/h 139.7
flow
Heating area ㎡ 46
Item Unit Code and data Item Unit Code and data
net positive
suction head
speed
speed
Efficiency % 70 Connection --
59
3.8 Feedwater pump and supporting motor
data
head
positive suction
head
speed
data
head
rotating
speed
60
3.10 Jacking oil pump and supporting motor
Item Unit Code and data Item Unit Code and data
L10VS045DR/31R-PPA12
Model Model YX3-180L-4(AC)/Z2-72(DC)
N00
Max.
Rated
working MPa -- kW 22
power
pressure
Outlet Rated
MPa -- A 55(AC)/232.6(DC)
pressure current
Factory Rated
V 400(AC)/110(DC)
No. voltage
Rated
speed
3.11 HP speed-regulating oil pump and supporting motor and main oil tank
Code and
Item Unit Item Unit Code and data
data
Pressure
m 150 Rated current A 187.5
head
Rotating
r/min 1000 Frequency HZ 50
speed
Volume of
m3 14 Weight kg 540
main oil tank
61
Pump Supporting motor
Code and
Item Unit Item Unit Code and data
data
Pressure
m 50 Rated current A 37.5
head
Rated rotating
Shaft power kW -- r/min 2950
speed
Rated rotating
Shaft power kW -- r/min 3000
speed
Supporting motor
Model Y13132M-4
Power kW 7.5
Voltage V 380-660
Current A 15.4/8.9
62
Rotating speed of
r/min 4.3
turning gear
data
power speed
data
head
power speed
1 The following operation can only be done with the participation of the supervisor of the
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1.1 First startup after an overhaul or a minor repair; first start up of a new unit.
2.1 When the actuation of the emergency security device is improper, and the automatic main steam
valve, the speed regulating valve and the extraction check valve is jamming or can not be closed tightly;
when the rotating diaphragm, electric-hydraulic converter is jamming or can not be closed tightly;
2.2 When there is obvious friction in the moving parts of the turbine or the generator;
2.3 When auxiliary oil pump, jacking oil pump system or turning gear is out of order;
2.4 In case that the temperature difference between the upper and the lower cylinder at the regulation
2.5 When such main instruments as the axial displacement meter, the relative expansion meter, the
revolution meter, the important metal thermometer, the main steam pressure gauge and thermometer is out
of order;
2.6 When the vacuum of the turbine can not be kept at -61kPa;
2.7 When the oil is unqualified or the oil level is lower than the normal level (0mm);
2.8 When the operation without load can not be kept or the rotating speed can not be controlled after
2.10 When shaft swinging value is not more than 0.03mm (the original swinging value permitted by the
2.13 When the return oil of any one of bearings is not proper.
1. The chief operator should notice the on-duty persons at each post after receiving the shift
2. The on-duty persons at each post should check the standby devices in detail before the startup.
Confirm that the maintenance has been completed, that the device and the site are tidy, and that the relevant
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3. Notice the I&C staff to supply each protection power supply and each instrument’s power supply,
switch to all alarm signal power supply for each meter and dial; the protection value should be correct and
4. Notice the I&C staff to energize DEH devices for two hours preheating; check if DPU (distributed
processing unit) and I/O (input and output interface) interface work properly; monitor if the voltage output of
5. Contact the relevant staff in the engineer station to check if the operator station works properly,
3.1.1 Discharge the accumulated water and sediments at the bottom of the oil tank and the oil cooler.
The blowdown valve of the oil tank should be closed and the emergency oil-drain valve should be closed
tightly.
3.1.2 The oil level in the oil tank should be proper and check the local oil level indicator.
3.1.3 Trial run of inlet of the speed-regulating oil pump (AC HP speed-regulating oil pump). LP AC and
3.1.4 Switch to open the oil inlet and outlet valve of the oil cooler, close the water inlet valve and open
the water outlet valve. As to the standby oil cooler, open the oil inlet valve, close the oil outlet valve, close the
water inlet valve, and open the water outlet valve. One side of the lubricating oil filter should be in operation
state, while the other side should be in standby state. Close the oil drain valve and the vent of the filter
screen.
3.2.1 The automatic main steam valve should be closed tightly and “Main Steam Valve Closed” indicator
3.2.2 Close the primary and the secondary valve of the electrical main steam valve and the bypass valve;
close the water drain valve and open the anti-corrosion valve.
3.2.3 Open the drain valve from the steam conduit, the speed regulating valve, the cylinder and each
stage’s extraction valve behind the main steam valve to the body’s drain flash tank (the relevant drain valves
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3.2.4 The relevant valves from the main steam to the flange bolt heating device should be closed.
3.2.5 Open the drain valve used for the startup and the normal drain valve along the main steam
pipeline. (The drain valve used for the startup is used to drain the accumulated water in the pipe before the
3.3.1 The pneumatic check valve of three-section extraction to the deaerator extraction header should
be in close position, with the electrical valve closed and the drain valve before the valve opened.
3.3.2 One, two, three and four-section extraction check valves should be in the close position, with the
3.3.3 Open the steam inlet valve of the LP heater #3, #2 and #1; and open the relevant drain valve.
3.3.4 The water inlet and outlet valve of HP heater #1 and #2 should be in open position. The water
drain valve should be closed. Open the valve of the drain valve of the HP heater #2 to the HP heater #1.
Open the drain valve of the HP heater to LP heater. Close the drain valve to the HP deaerator. Start the
automatic drainage regulation. Close the primary and secondary valve of the emergency drain valve. Close
3.3.6 Open the valve of the water drain of the LP heater #1 to the condenser.
3.3.7 Open the valve of the extraction check valve’s linkage system; close the blowdown valve of the
water filter.
3.4.1 Close the manual steam seal valve before a new steam header.
3.4.2 Close the manual valve of auxiliary steam to the front and rear steam seal.
3.4.3 Start the steam supply console of shaft seal, then drain the water;heat the pipe until the manual
3.5.1 After the water-jet pond has been supplemented with water, regulate the inlet and outlet valve so
3.5.2 Open the water inlet valve of water-jet pump #1 and #2, the water injection valve of the pump body,
and the vent of the pump body. After the water comes out of the vent, close the vent;
3.5.3 Open the air valves at both sides of the condenser. Close the vacuum breaking valve and apply
the water seal. Open the air valve of the water-jet ejector.
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3.6 Condensate system
3.6.1 Open the inlet valve of the condensate pump #1 and #2 and the vent of the condensate pump;
3.6.2 Open the water inlet and outlet valve of the steam seal heater and close the bypass valve (the
bypass valve can be used to restrict the flow depending on the flow condition).
3.6.3 Open the water inlet and outlet valve of each LP heater and close the bypass valve.
3.6.4 Open the water outlet valve used for the startup of the condensate pump, and close the valve to
underground drain.
3.7.1 Close the primary & secondary steam supply valve and the main valve of a new steam pipe.
3.7.2 Close the primary & secondary high-temperature steam inlet-valve of the flange heating header.
3.7.3 Close the steam return valve of the lower right flange and the one of the upper right flange; close
the steam return valve of the lower left flange and the one of the upper left flange. Close the steam return
valve of the right bolt and the one of the left bolt.
3.7.4 Open the valve of the drain of the header to the drain flash tank. Open the valve of the water drain
of the header to the condenser; close them after the drain valve has drained out the water.
3.8.1 Open the circulating water inlet valve of the condenser; restrict the flow of outlet valve.
3.8.2 Open the water inlet main valve of oil cooler and close the inlet valve.
3.8.3 Open the cooling water outlet valve of the oil cooler.
3.8.4 Close the air and the cooling water inlet valve of the generator and open the water outlet valve.
3.8.5 Open the service water main valve and open the cooling water valve to the bearing of each
auxiliary machine.
4.1 Trial run of the LP oil pump and the emergency oil pump respectively. Check if the operation
conditions are proper; gradually adequately open the oil outlet valve and perform the following
checks:
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4.1.2 The oil level in the tank is proper;
4.1.4 When the conditions are OK, keep the LP oil pump in operation and take the emergency oil pump
as an interlocking standby.
4.2.2 Open the oil inlet valve of the turning gear; separately start the motor of the turning gear and stop it
4.2.3 Run the motor, and pull the handwheel of the turning gear with a backgear anticlockwise, making
the handle move to the limit switch so that the turning gear are engaged in place;
4.2.4 Start the motor of the turning gear, and check if the moving parts of the turning gear and the turbine
4.2.5 It should not be less than 2 hours for the turning of the turbine in the cold-state startup; it should
not be less than 4 hours for the turning in the hot-state startup. Before switching to the turning, switch to the
jacking oil pump first. Check for the proper oil pressure and if there is oil leakage.
4.3 Start the HP oil pump. After checking for its proper function, adequately open the outlet valve; stop
the LP oil pump and check for the proper pilot oil pressure and proper oil flow in each pipe.
4.4 Conduct a low oil-pressure linkage test and a low oil-pressure trip test of the turning according to the
procedures. After the successful tests, keep the HP oil pump and the turning gear in operation. Switch to the
4.5.1 Complete “Close Main Steam Valve” program on the main screen of DEH and check for the state
②Indicator for “Close Main Steam Valve” should be on and other indicators should be off;
4.5.2 Local “Latch”. DEH should display “Latched” to indicate the completion of the latch. Check if the
HP control valve is in closed position and if the rotating diaphragm for steam extraction is in
adequate-opening position.
4.5.3 Cooperate with the I&C and electric staff in relevant I&C protection and linkage tests.
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4.5.4 Cooperate the I&C staff in the static test of the HP and MP control valve and keep the records.
5.1 After the completion of each check performed before the startup, report to the shift supervisor. With
the permission from the shift supervisor, heat the pipe to the part before the electric main steam valve.
5.2 Gradually open the bypass valve of the main steam valve and gradually increase the pressure in the
pipe to 0.1961~0.2942MPa. Heat the pipe for 20~30 minutes, then gradually increase the main steam
pressure to the rated values as per the pressure-increase rates stipulated in the following table:
Pressure
MPa)
Pressure-incr
(in MPa/min)
5.3.1 Cooperate in the adjustment using the drain valve and steam inlet valve, and control the
5.3.2 Frequently check the steaming condition of the main steam pipe and anti-corrosion steam valve.
5.3.3 Check the pipe expansion and the hanger & support conditions.
5.3.4 During the temperature rise and pressure increase process, the water drain valve should be
5.3.5 When operating the bypass of the main steam valve, note that first open the primary valve, then
While heating the main steam pipe, the following operations can be conducted:
6.1.1 Refill the condenser with the water to 3/4 water level of the water gauge. Start the condensate
pump on DCS control screen and regulate the water level of the condenser to the normal value with the
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1) Close the vacuum breaking valve;
6.1.4 Supply the steam to the shaft seal (the duration should be proper to prevent the increase of
differential expansion); note that the temperature difference between the upper and the lower cylinder should
be ≤50℃.
1) Drain the water from all shaft seal’s steam sources and heat the whole pipeline (because there
are two lines of steam supply in the shaft seal’s steam supply system, before the operation, carefully
decide the way of steam supply based on the way of startup to ensure adequate pipe heating and
2) Switch to steam seal heater, at which time the pressure in the steam seal’s extraction chamber
(air and steam mixture chamber) is about 0.095MPa. Pay attention to regulate the water level in the shaft
heater.
2) Adjust the steam supply from the shaft seal’s steam inlet valve to the front and the rear shaft seal.
4) Keep the pressure of the steam seal between 0.03~0.08MPa. Monitor that the vacuum in the
7.1.1 The pressure in the boiler should be increased above 0.2~0.4MPa absolute pressure and with the
7.1.3 The regulating oil pressure should be 1.80-1.96MPa, while the lubricating oil pressure should be
7.1.4 The outlet oil temperature of the oil cooler should be above 35℃.
7.1.5 The jacking oil pressure at each bearing should be higher than 9.8MPa.
7.1.7 The turning gear should work properly and the swinging of rotor should be qualified.
7.1.9 Confirm that set the “Automatic/manual” switch to “Automatic”; set the “Overspeed Protection”
switch to “Switch”; and the length of travel of the speed-regulating valve is “0”.
7.1.9 Protection switches for axial displacement, low lubricating oil pressure, large differential expansion,
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high temperature of bearing return oil and high temperature of thrust shoe are in operation (The protection
against the low vacuum and the trip will be switched on after the generator is connected to the grid).
7.1.1 The main steam system of turbine and boiler should be separated in units for the operation. Start
7.1.2 It is required that the temperature rise and pressure increase of the boiler be done according to the
7.1.3 Under any pressure, the degree of superheat should be above 50℃, and the main steam
temperature should be higher than the temperature of the outer wall of the lower cylinder at the regulating
Start Startup
Definition Startup parameter
state time
Cool All except the hot state are cold temperature: 280±10℃;
210min
state state degree of superheat: 50℃
or above
(3) Open the automatic main steam valve and heat the pipe until before the control valve.
(4) The steam pressure should be 1.96MPa and the steam temperature should be above 280℃.
Properly turn down the drain valve of the steam conduit to make the preparation for the impulse starting.
(5) DEH should conduct the speedup as per the following table in principle.
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A Cool state
Speedup Duratio
No. Stage Remarks
rate n
Impulse starting
check
Heat the
2 500r/min 5min
“Maintain” machine
Heat the
4 1350r/min 15min
“Maintain” machine
DEH
automatically
and quickly
5 2300r/min 100r/min/min 10min
passes the
critical value of
300r/min
Heat the
6 2300r/min 15min
“Maintain” machine
Heat the
8 3000r/min 20min
“Maintain” machine
B Hot state
Speedup Duratio
No. Stage Remarks
rate n
Impulse starting
check
Heat the
2 500r/min 5min
“Maintain” machine
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3 3000r/min 150r/min/min 15min speedup
Heat the
4 3000r/min 5min
“Maintain” machine
(6) After the unit reaches its full speed, make a careful check. After the adequate machine-heating,
(7) After the successful tests, conduct an overall check to see if everything is OK. Conduct the following
(8) After the adequate machine-heating with the unit under the original load, continue to increase the
(1) When the rotating speed increases to 1300r/min, stabilize the steam temperature and pressure; if
the vibration of the unit is more than 0.03mm, trip the turbine.
(2) When the rotating speed increases to 2300r/min, stabilize the steam temperature and pressure;
(3) With the increase of the rotating speed, regulate the shaft seal pressure whenever necessary and
(4) During the speedup process, closely monitor the bearing vibration. If found anything abnormal,
reduce the rotating speed. The speed can only be increased again after the reasons have been found.
(5) Strictly control differential expansion, cylinder expansion, metal temperature and temperature rise
7.4 Conduct the speedup and machine-heating as per the following requirements
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Temperature rise rate of inner wall of
4℃/min
cylinder flange
As to the first startup after new installation and an overhaul, the speedup and the machine-heating
duration should be prolonged based on the cylinder metal temperature since there is moisture in the
7.5 Regulating work and considerations during the machine-heating and the speedup process
7.5.1 Listen to the sound inside the turbine-generator set. Immediately shut down the unit when finding
anything abnormal.
7.5.2 Measure each bearing vibration in three directions. During the speedup process, the unit vibration
should not exceed 0.03mm. Once the value is exceeded, reduce the rotating speed until the vibration is
eliminated. Maintain the operation at this rotating speed for 30min; then speed up again. If the vibration is still
not eliminated, again reduce the speed and run it for 120min; then speed up again. If the vibration is still not
eliminated, stop the unit for a check (0.10mm is permitted when passing the critical value)。After the rotor
stops, switch to sequential turning and check the shaft’s bending and swinging values. The reasons shall be
found out before re-start the unit. The critical rotating speed should be quickly and stably passed and the
7.5.3 Frequently pay attention to regulate the turbine’s rotating speed, the condenser’s water level, the
vacuum, the shaft seal’s steam pressure, the bearing oil temperature, the oil cooler and the air cooler.
7.5.5 During the startup process, control the metal temperature at each point, which should not exceed
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Section VIII Parallel Operation and with Load
8.1 Make an overall check to the unit. The turbine should work properly for 20 min with no load. The
temperature of the HP lower cylinder should be above 220℃. Contact the shift supervisor and the relevant
posts, and contact the electric staff to prepare for the parallel operation.
8.2 As per the electric requirements, press “Automatic Synchronization” button of DEH, and “Automatic
8.3 After the grid-connection, the unit is automatically with the original electric load. DEH automatically
switches to the valve control mode. The chief operator may control the opening of the control valve by setting
the valve position and the change rate of the valve position or by changing the given value of the valve
8.5 After the load exceeds the rated value by 10%, the load can be regulated by switching from “Valve
Control” to “Power Control”. The uninterrupted switching can be realized by pressing “Power Control” or
8.6 Switch to the air cooler of the generator. Depending on the leaked steam pressure of the stem,
arrange the assistant operator to switch the steam leakage of stem to the deaerator and close its water drain
valve. Close the drain valve of the main steam pipe. Close the drain valve of the steam conduit and the
control valve. Close the cylinder's drain valve based on the cylinder temperature.
8.7 After the condensate is qualified, arrange the assistant operator to switch to the deaerator and close
the condensate drain valve. When the electric load is less than 25MW, keep the proper opening of the
8.8 In principle, the following table should be followed for the unit’s load increase stage and the load
increase rate
A Cool state
Increase
2 ~6MW 1MW/ min 5min
the load
Heat the
3 6MW 30min
“Maintain” machine
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Increase
4 ~60MW 500kW/ min 100min
the load
B Hot state
Increase
1 ~30MW 2MW/ min 15min
the load
Heat the
2 30MW 20min
“Maintain” machine
Increase
3 ~60MW 4MW/ min 15min
the load
8.9.1 Regulating the drain valves of the steam conduit, the control valve, the cylinder, the extraction
8.9.2 Based on the leaked steam pressure of the stem, switch the steam leakage of the stem to the
8.9.3 Based on the working conditions of the steam seal heater, regulating its working steam.
8.9.4 During the load increase process, closely monitor the cylinder expansion, the relative expansion,
the axial displacement and the temperature of the thrust shoe; pay attention to regulate the oil temperature
8.9.5 The LP heater is randomly switched on. When the load reaches 30MW, switch to the steam side of
the HP heater (the water side shall be switched to firstly) and switch to the HP heater protection.
9.1.1 Regulate the temperature of the steam going into the turbine; this temperature should be higher
than that of the cylinder wall of the steam chamber (higher than 50℃).
9.1.2 Conduct the sequential turning at least for 2 hours before supplying the steam to the shaft seal.
The change of the rotor bending value, compared to the original value, should not be more than 0.03mm.
9.1.3 First supply the steam to the steam seal, then vacuumize it. The vacuum should be kept at
-0.08MPa or so. Supply high-temperature steam to the front steam seal, and the steam supply pressure
should be controlled at 0.15MPa; the temperature should be matched with the metal temperature of the
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lower-half inner wall in the front of the cylinder and the degree of the superheat should be kept above 50℃.
The steam supply pressure and temperature of the rear steam seal should be the same as those in the
9.1.4 The temperature difference between the upper and the lower wall at the regulating stage of the HP
9.1.5 The main steam temperature should be kept at the rated value as much as possible; at least it
should be higher than that of the metal at the regulating stage by 55℃ or more and the superheat should not
be less than 100℃. The condensate in the condenser shall be qualified to guarantee that in the parallel
9.1.6 In order to prevent the cooling contraction of the high-temperature parts and control the negative
differential expansion of the unit, quickly increase the speed or the load to the working conditions which
correspond to the metal temperature. Therefore, make good preparation before supplying the steam to the
shaft seal and contact the electric and boiler staff to prepare for the parallel operation.
9.1.7 During the startup process, special attention should be paid to monitor the sound and the vibration
of the turbine unit. If there is any abnormal sound or vibration, immediately and decidedly trip the turbine.
After the rotor stops, conduct the sequential turning and measure the swinging value of the rotor. Report to
the chief operator, the shift supervisor and the supervisor of the discipline and then decide whether to start it
again.
9.1.8 To facilitate the heating and draining of the cylinder, in case of hot-state start, the HP heater can be
started randomly. When the pressure inside the HP heater #2 is higher than 0.6MPa, switch to the HP
deaerator.
9.1.9 Based on the conditions of the unit, the flange heating device of the cylinder can be switched on.
9.1.10 The DEH operation for the hot-state startup should be done as per the procedures and each
regulation followed in the cold-state start with the rated parameters. However, as to the speed or load
increase before the working conditions that correspond to the metal temperature have been realized, the
1.1 All necessary tests should be reported to the supervisor of the discipline. With the permission of the
shift supervisor, they should be done under the monitor of the chief supervisor. (The first startup of a new unit
and after an overhaul) The tests should be hosted by the supervisor of the discipline or the professional
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technicians. The conditions and data of the performed tests should be recorded in the relevant technical
1.2 As to the loosening test of the electric valve, if a single pipe is used for the supply and there is no
other steam or water source, the test may be unnecessary; however, in case of the supply made by double
pipes, the test should be done by those on duty according to the regulations.
1.3.1 As to the tests which should be done as per the regulations, if they can not be done out of some
reasons, indicate the reasons in the record and report it to the team leader. However, in case of shutdown at
1.3.3 There is an obvious major failure in the device. It would cause the defect to become more serious
or cause the operation conditions to be worse in case of a test. The tests may be unnecessary after they are
reported to the superior, because of the weak operation mode and the weak system and because of the lack
1.3.4 As to the shift of the tests or the equipment, if they could not be done out of some reasons, every
time they are due, the permission from the shift supervisor and the team leader should be gained. The
reasons should be recorded in the technical records and the operation logs.
Weekly items
2.1.1 Measure the vibration of moving machine and drain the water from the main oil tank by the day
2.1.2 Fill each auxiliary machine with oil and switch to the oil filter for 48 hours operation by the middle
Monthly items
2.1.4 Startup test of the AC & DC oil pump and switching of circulating water pump by the day shift on
2.1.5 Switching of the condensate pump by the day shift on every 10th day
2.1.6 Switching of the water-jet pump by the day shift on every 15th day
2.1.7 Switching of the feedwater pump by the day shift on every 20th day
2.1.8 Switching of the service water pump by the day shift on every 1st day
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2.1.9 Clean the rubble ball every 8th and 23rd day for 10 hours at each side
Note: every test should be recorded in a special ledger. As to each motor test, the insulation should be
qualified before the switching. As to the monthly items, the switching may be unnecessary for those running
for less than 20 days; but the reasons should be recorded in the ledger. Other tests should be done before
2.2.1 Test items for the first startup after an overhaul of the unit:
2.2.1.1 The HP oil pump, the LP oil pump and the DC oil pump test.
2.2.1.8 Tightness test of the speed regulating valve and the automatic main steam valve
2.2.1.15 Emergency breaker’s overspeed test. (After the turbine’s overhaul or the speed-regulating
2.2.1.16 Check for the extraction safety valve (after the turbine’s overhaul or the safety valve’s
maintenance)
2.2.2.1 Record the important data of the oil system and the vibration conditions.
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Section III Test Method
After confirming that the maintenance has been completed, the work ticket has been cancelled, the
safety measures have been removed and the site is tidy, relevant professional staff will perform the following
3.1.1.1 Contact the electric staff to prepare for the trial run of the DC oil pump. After the startup, check if
the current is proper and if the outlet oil pressure is proper. Stop it for emergency use after confirming that
3.1.1.2 Start the AC lubricating oil pump to check if the current is proper. After the oil properly goes out,
check if the outlet oil pressure is OK. Stop it for emergency use after confirming that each part of the oil pump
works properly.
3.1.1.3 Before starting the speed-regulating oil pump, fill the speed-regulating system with the oil
through a lubricating oil pump. After it is filled with the oil, start the speed-regulating oil pump. Stop the
lubricating oil pump and check if the current and the oil pressure are proper.
3.1.2.1 Keep the pressure of the lubricating oil at 0.294MPa and open the oil inlet valve of the turning
gear.
3.1.2.3 Run the motor of the turning gear with no load; stop it after everything is proper.
Clockwise turn the handwheel and pulling handle of the turning gear. After the engagement of the
turning gear, start the motor and the turning gear should work properly.
3.1.3.1 After confirming that one pump is in operation and the standby one is in interlock standby state,
3.1.3.2 Press “operating pump accident” button and the pump trips. The standby pump interlocks with it.
3.1.3.4 Check that the trip pump does not run in a reverse direction.
3.1.3.5 After everything is OK, perform another pump’s interlock test with the same method.
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3.1.4.1 After confirming that one pump is in operation and the standby one is in interlock standby state,
3.1.4.2 Turn the pointer of the interlock pump’s pressure gauge, making it connected. Pay close
attention to the standby pump’s interlock. After the interlock, reset the switch.
3.1.4.3 Turn the pointer of the pressure gauge to the previous value.
The turbine should go through the following tests after its overhaul or maintenance, or after it is used as
The test should be done in other test items if it is not performed separately.
① Interlock test of the extraction check valve behind the automatic main steam valve
Open the automatic main steam valve to the graduation of 30mm. Fully open the extraction check valve,
(ask the electric staff to pull out the knife switch at the outlet of the generator and switch on the generator’s
main switch). Switch to the extraction check valve protection. Manually shut it down, and both the automatic
main steam valve and the extraction check valve should be closed; and send out the acoustic-optical signal.
②Interlock test of the extraction check valve after the generator trips
Open the extraction check valve and open the automatic main steam valve to the graduation of 30mm,
which is protected by the electric main trip switch and the extraction check valve. The extraction check valve
③ Interlock test of the extraction check valve in case of high water level in the HP heater
i) Contact the electric and the I&C staff to supply the power for the HP heater’s electric steam inlet valve
and electric emergency drain valve. Fully open the speed-regulating valve and open the automatic main
steam valve to the graduation of 30 mm. Switch to the protection switch of the extraction check valve;
ii) When connecting to the measuring point of water level value I in the HP heater, send out the alarm
signal for high water level value I in the HP heater. When connecting to II value measuring point, send out the
alarm signal for high water level value II in the HP heater and the electric emergency drain valve should be
opened automatically. When connecting to III value measuring point, send out the alarm signal for high water
level value III in the HP heater; the extraction check valve at I section and the extraction check valve at II
section should close; the interlock valve should actuate; the automatic bypass valve should be opened; the
through valve of the HP heater should be opened and the inlet & outlet water valve should be closed.
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3.2.2 Water-spray test performed at the throat in case of high exhaust temperature
3.2.2.2 After refill the condenser with water, start the condensate pump.
3.2.2.3 Manually switch to spray desuperheating solenoid valve of the exhaust cylinder, and the water
3.2.2.4 Stop the water spray at the cylinder’s throat. The I&C staff make the short connection between
the exhaust temperature and 80℃ contact. Connect the solenoid valve and it actuates. When the spray is
proper, the I&C staff gradually reduces the exhaust temperature to 65℃. The water spray stops when the
3.2.3 Test of the actuation of the safety valve at the mixed temperature header of the flange bolt
heating device
3.2.3.1 Check if the heating steam inlet valves of the right & left flange and bolt (i.e. the steam outlet
valve of the mixed temperature header) are in the closed position. Open the drain valve of the steam
collecting case (close it after completing the heating of the mixed temperature header).
3.2.3.2 With a new steam source, when the pressure regulator of the steam collecting case reaches
3.2.4.1 Contact the I&C staff to switch to the axial displacement protection;
3.2.4.2 Fully open the speed regulating valve and open the automatic main steam valve to 30~40mm;
3.2.4.3 The I&C staff respectively make connection to +0.8mm and -0.80mm contact of the axial
3.2.4.4 The I&C staff then respectively make connection to the +1.0mm and -1.0mm contact of the axial
displacement. The automatic main steam valve and the speed-regulating valve close and send out the
3.2.5.1 Fully open the speed regulating valve and open the automatic main steam valve to the
graduation of 30~40mm;
3.2.5.3 The I&C staff respectively make connection to the -1.0mm and +3.0mm contact of the differential
3.2.5.4 The I&C staff then respectively make connection to the -1.2mm and +4.0mm contact of the
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differential expansion and send out the acoustic-optical alarm signal. The automatic main steam valve and
3.2.6.2 Open the speed regulating valve and open the automatic main steam valve to 30~40mm;
3.2.6.3 The I&C staff makes short connection to 65℃ contact of oil temperature and send out the
3.2.5.4 The I&C staff then make connection to the 75℃ contact of oil temperature and send out the
acoustic-optical alarm signal. The speed-regulating valve and the automatic main steam valve close;
3.2.7.1 Contact the electric staff to switch on the generator’s main oil switch;
3.2.7.2 Press the generator’s emergency trip button, then the generator’s main oil switch should trip and
3.2.8.1 Contact the electric staff to switch on the main oil switch;
3.2.8.2 Supply the protection power supply and switch to the general protection;
3.2.8.3 Open the speed regulating valve and open the automatic main steam valve to 30~40mm;
3.2.8.4 Connect to the contact of the differential protection relay. The generator’s oil switch should trip.
The automatic main steam valve and the speed-regulating valve close.
3.2.9.1 Open the speed regulating valve and open the automatic main steam valve to 30~40mm;
3.2.9.2 Switch to the protection. The I&C staff makes short connection to -81kPa vacuum contact and
3.2.9.3 Then make short connection to the -67kPa vacuum contact. The automatic main steam valve
and the speed-regulating valve close. Send out the acoustic-optical alarm signal;
3.2.10.1 Contact the I&C and the electric staff to provide the speed-regulating oil pump, the AC & DC
3.2.10.2 After successful pump tests, keep the speed-regulating oil pump in operation and switch to the
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oil pump interlock;
3.2.10.3 Open the automatic main steam valve to 30~40mm and fully open the speed regulating valve;
3.2.10.5 The I&C limits the oil inlet valve of the low oil pressure relay of return lubricating oil, slowly open
the oil drain valve, making the lubricating oil pressure drops gradually;
3.2.10.6 When the lubricating oil pressure drops to 0.049MPa, send out the acoustic-optical alarm signal
and interlock with the AC lubricating oil pump. When it drops to 0.039MPa, interlock with the DC oil pump.
The automatic main steam valve and the speed-regulating valve close and send out the relevant
acoustic-optical alarm signal. When it drops to 0.029MPa, the turning gear automatically stops;
3.2.10.7 Reset the signal after successful test and close the oil drain valve of low oil pressure relay and
3.2.11.1 Open the speed regulating valve and open the automatic main steam valve to 30~40mm;
3.2.11.2 Press the remote-operational trip button, or manually hit the trip button at the head section; the
speed-regulating valve and the automatic main steam valve close and send out the acoustic-optical alarm
signal;
(1) Close the HP heater’s electric water inlet and outlet valve and the forced handwheel at the outlet of
(2) Close the drain valve of HP heater #1 and #2, the drain valve to the deaerator and LP heater #3,
(3) After manually slightly open the electric water inlet valve of the HP heater, open the drain valve of
the pipe connector at the water side. Open the water injection valve of the HP heater to fill the HP heater with
(4) When slowly increasing the pressure to 1.5MPa, close the water injection valve, the drain valve of
pipe connectors. Check if the pressure inside the HP heater (at water side) drops and check if the water level
(1) The composite valve test shall be performed after the successful leakage test of the HP heater.
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(4) Switch to protection and control water of the HP heater.
1) Close the water control drain valve of the composite valve and the manual valve before and behind
the solenoid.
2) Open the bypass valve of the water control solenoid, and fill the upper part of the composite valve’s
piston with water. When the water pressure reaches 0.6MPa, press down the composite valve’s piston,
3) After close the bypass valve, open the water control drain valve. After the control water pressure
drops, the composite valve’s piston raises, which indicates that the actuation of the composite valve’s piston
is proper.
(1) Switch to HP heater protection and switch to high water level alarm.
(2) The I&C staff connects the high water level signal or manually raises the water level. When
connecting to the measuring point of the high water level value I, send out the alarm signal for high water
level value I in the HP heater. When connecting to the measuring point of the high water level value II, send
out the alarm signal for high water level value II in the HP heater and the electric emergency drain valve
should open automatically. When connecting to the measuring point of the high water level value III, send out
the alarm signal for high water level value III in the HP heater; the extraction check valve at I section and the
extraction check valve at II section should close; the interlock valve should actuate; the automatic bypass
valve should be opened; the through valve of the HP heater should be opened (when the HP heater
Note: it is forbidden to switch to the HP heater if one of the above three tests fails.
1) Cooperate with the I&C staff in this test after the maintenance of DEH system or the maintenance of
2) The I&C staff should finish the channel test inside the DEH system, the ETS and AST channel test
3) Cooperate with the I&C staff in the united test. The test is preferred to be done with a simulator and in
the operator automatic mode, performing the simulation test for the whole startup process.
The turbine should go through the following tests after its overhaul or after it is used as a standby over
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1 month:
3.3.1.1 After the turbine’s rotating speed increases to 3000r/min, operate the handwheel with an
automatic closer to close the automatic main steam valve to the graduation of 30~40mm;
3.3.1.3 Manually hit the stop button at the head section or press the remote-operational stop button;
3.3.1.4 The automatic main steam valve and the speed-regulating valve should quickly close, without
jamming or jumping. The rotating speed drops and each signal display is correct. Send out the
acoustic-optical signal;
3.3.1.5 Open the automatic main steam valve and the speed regulating valve; regain the rotating speed
to 3000r/min.
3.3.2 Tightness test of the automatic main steam valve and the speed regulating valve
The conditions of the tightness test of the main control valve: rated parameters, generator not in
Test procedure:
(2) Click “Main Steam Valve Test” button, and the indicator of the button is on. Close the main steam
valve, and the rotor is in coasting operation; automatically record the duration of the coasting operation. Only
when the rotating speed is continuously reduced to 1000r/min or less, it is qualified. When the rotating
speed is reduced to an acceptable value, click “Test Stop” button and the test is completed.
(2) Click “Speed-regulating Valve Test” button, and the indicator of the button is on. Close the
speed-regulating valve, and the rotor is in coasting operation; automatically record the duration of the
coasting operation. Only when the rotating speed is continuously reduced to 1000r/min or less, it is
qualified. When the rotating speed is reduced to an acceptable value, click “Test Stop” button and the test is
completed.
3.3.3.1 Start the HP oil pump and keep the speed-regulating oil pressure at 1.96MPa;
3.3.3.2 The turbine’s rotating speed is reduced to 2850r/min. Contact the boiler staff to keep the main
steam pressure;
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3.3.3.3 Enter “Oil-injection Test” screen on the OIS. Click “Switch to Oil-injection Test” button and select
3.3.3.4 During the test, select the oil injection test of fly hammer #1 or #2. When the test is completed,
3.3.3.5 After the completion of the test, set “Switch to Oil-injection Test” button to “Remove”.
Before the overspeed test, the manual shutdown test, the automatic main steam valve and the
speed-regulating valve close test and the tightness test should be successful.
① Set “OPC” switch to test position, and keep the unit’s rotating speed at 3000r/min. Close the
② Open “Overspeed Test Window” at DEH operator station and select “OPC” test.
③ On the main screen of DEH, press “OPC Test” button; the unit will automatically speed up to
3090r/min (i.e. 103% rated speed); OPC solenoid will actuate and the turbine's HP speed-regulating valve
will close.
④ After the rotating speed reduces to 3000 r/min, open the control valve and keep the turbine’s
① Open “Overspeed Test Window” at DEH operator station and keep the unit’s operation at 3000r/min.
③ Press “Electric Overspeed Test” button, at which time “OPC” will automatically be isolated. The unit
will automatically speed up to 3300r/min (i.e. 110% rated speed); AST solenoid will actuate and the main
④ When the rotating speed reduces to 3000r/min, re-latch and start the turbine. Keep the turbine’s
① Keep the unit’s stable operation at 3000r/min. Close the automatic main steam valve to 30~40mm.
② Contact the boiler staff to keep the stable steam temperature and pressure of the turbine.
③ Open “Overspeed Test Window” at DEH operator station and select “Mechanical Overspeed Test”
button; “OPC” and “Electric Overspeed Test” will automatically be isolated and the unit will automatically
speed up to 3300~3360r/min (i.e. 110~112% rated speed). During the speedup process, if the actuation
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signal lamp of ram #1 on the local revolution meter is on, it indicates that the ram #1 actuates (record the
actuation speed and the main oil pressure). At this time, continue to speed up until the local revolution meter
goes up to ram #2’s actuation. (As to the mechanical overspeed test, the rotating speed shall not exceed
3360r/min, or the fly hammer’s spring position should be adjusted). During the test speedup process, if the
rotating speed reaches 3360r/min but the mechanical protection still does not actuate, immediately shut it
down manually.
④ The emergency breaker actuates, and the main steam valve, the HP speed-regulating valve and all
⑤ Record the rotating speed of the actuation and the main oil pressure value during the actuation.
3.3.5.1 Before the test, the overspeed test should be successful; and the unit should be in operation for
3.3.5.2 During the test, there should be a person standing in front of the unit to monitor it. Manually shut
3.3.5.4 Contact the electric staff to disconnect the generator’s trip interlock and close the main steam
valve protection.
3.3.5.5 Contact the electric staff to trip the generator (making the main oil switch trip).
3.3.5.6 Pay attention to monitor the rotating speed increase; OPC actuates; the speed-regulating valve
and the extraction check valve close and send out the alarm signal.
3.3.5.7 After the rotating speed reduces to 3060r/min, the speed-regulating valve opens. The unit
keeps in operation at 3000r/min. Record the maximum rotating speed. If the rotating speed goes up to
3.3.6.1 Contact the electric staff to stabilize the working conditions under 80%-100% load and record
3.3.6.2 Close the air valve of the ejector and begin to record the duration and the vacuum values after
30 sec.
3.3.6.4 After the fifth minute, the test is completed. Open the air valve of the ejector.
3.3.6.5 During the test, in case of sudden loss of the vacuum (or when it is lower than 0.086MPa),
immediately stop the test and open the air valve of the ejector.
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3.3.6.6 As to the rate of the vacuum loss, take the average between the third minute and the fifth
minute.
3.3.6.8 If the rate of vacuum loss is larger than 0.67 kPa/min, shut it down to find out reasons. Start it
3.3.7 Movement test of the automatic main steam valve and the speed regulating valve
① Contact the shift supervisor and boiler staff, and pay attention to the load and steam pressure
change.
② Enter “Valve Test” screen on OIS, click “Valve Movement Test” button and set it to “Switch”;
③ The selected main steam valve begins to close; it will re-open after reaching the set position. The
test is completed.
① Enter “Valve Test” screen on OIS, click “Valve Movement Test” button and set it to “Switch”;
③ The selected control valve begins to close; it will re-open after reaching the set position. The test is
completed.
④ After the completion of the test, set “Valve Movement Test” button to “Remove”.
1.1 After receiving the shutdown order from the shift supervisor, notice each post to make good
1.1.1 Trial run of the HP oil pump, the AC lubricating oil pump, the DC oil pump and the turning gear’s
1.1.2 Check the automatic main steam valve’s condition. The stem should not be jammed.
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1.2 Reduce the load at the normal shutdown speed of 500~1000kW/min.
1.3 When the load is reduced to 33 MW, after obtaining the permission from the shift supervisor, stop
HP heater #1 and #2; or when the pressure of HP heater #1 is reduced to 0.6MPa, switch the drain of the HP
1.4 When the load is reduced to 20MW, open the drain valve of the condenser based on the water level
in LP heater #1.
1.5 During the load reduction process, open the condensate recirculating valve based on the drop of
1.6 When the electric load is reduced to 6 MW, exit “Power Control” mode. When the load is reduced to
1.5MW or so, contact the electric staff to prepare for the shutdown. After obtain the permission from the shift
supervisor, start the AC oil pump; manually pull the emergency breaker’s handle. Check if the main steam
valve, HP control valve, rotating diaphragm and each extraction check valve close and the generator’s
“Reverse Power” is in operation. If the generator’s “Reverse Power” protection does not actuate, contact the
electric staff to trip the generator and shut it down! If after the automatic main steam valve closes, the
1.8 Close the water outlet valve of LP heater #3. Maintain the water level in the condenser with
1.9 Fully close the valve of the steam leakage of the stem to the deaerator; open the drain valve of the
pipeline.
1.10 Stop the water-jet pump and regulate the vacuum breaking valve so that when the rotor stops, the
2. The drain valve behind the control valve and other drain valves;
3. The drain valve at the bottom of and behind the extraction check valve of each section.
1.12 The following should be noted during the load reduction and the rotating speed reduction:
3. The unit’s sound, vibration, bearing oil pressure, oil temperature and oil flow;
4. Regulate the condenser’s water level and the pressure of the supply steam of the shaft seal;
5. Regulate the oil, the air and the water temperature until the oil cooler or the air cooler stops.
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1.13.1 After the vacuum reaches zero, stop supplying steam to the shaft seal. Close the adjusting valve
of the shaft seal; close the general steam valve of the shaft seal. Open the drain valve of the steam supply
1.13.2 After the rotor stops, start the turning gear and conduct the continuous turning. Measure the
rotor’s bending value and listen to the sound of each moving part of the turbine.
1.13.3 During the continuous turning, record one metal temperature value every 30 minutes.
1.13.4 Record the duration when the rotor stops rotating and compare to the coasting duration. If find
anything abnormal, promptly report the team leader, the shift supervisor and the supervisor of the discipline.
1.13.5 When the steam pressure behind the automatic main steam valve drops to 0.5MPa or below,
open the anti-corrosion steam valve and close the automatic main steam valve and the main cooling water
1.13.6 Stop the condensate pump and check if the water spraying device of the LP cylinder has
stopped.
1.13.7 After the rotor has been static for one hour and the exhaust temperature reduces to 50℃ or
below, contact the team leader to close the circulating water inlet valve and stop the circulating water pump
as necessary.
1.13.8 When necessary, isolate the main steam pipe and release the pressure; close the main steam
valve; and open the drain valve. When the pressure reduces to 0.5MPa or below, drain the water to the ditch.
1.13.9 When the metal temperature of the upper cylinder’s inner wall at the regulating stage reduces to
150℃, stop the turning gear, the oil pump and the fume exhauster. However, the continuous turning duration
at least should not be less than 24 h. In case of special conditions which causes the turning can not be
continuous, in the first 8 hours, turn the rotor 180 degree every 15 minutes. After the 8 hours, turn the rotor
1 After receiving the order of shutdown at sliding parameters from the shift supervisor, the chief
2. Contact the boiler staff to reduce the temperature and the pressure according to the sliding
parameter curve:
Cooling rate of the cylinder’s metal: 0.6-1.0℃/min. The main steam temperature at least should be with
the degree of superheat over 50℃ to prevent the steam bringing the water.
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Pressure decrease speed: 0.02-0.03MPa/min
3.1 It is required that the steam temperature and pressure should be stably reduced; they should not be
3.2 When the main steam temperature is below 350℃, open the drain valve of the cylinder and
3.3 When the temperature of the main steam is lower than that of the inner wall by 30℃ or more, the
reduction at sliding parameters should be stopped. Stay for a period before doing it again.
3.4 Special attention should be paid to the axial displacement and the differentiate expansion change,
3.5 During the process of the shutdown at sliding parameters, if the boiler is not properly regulated,
causing the sudden drop of the steam temperature, immediately reduce the load and shut it down;
3.6 When the main steam temperature is at 250℃, notice the boiler staff for flameout and conduct the
Main steam
℃ 535 540 525
temperature
1st extraction
MPa 2.84
pressure
2nd extraction
MPa 1.66
pressure
3rd extraction
MPa 1.27
pressure
4th extraction
MPa 0.332
pressure
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pressure
6th extraction
MPa 0.047
pressure
Exhaust pressure
kPa 9.5
(abs.)
Exhaust temperature
℃ 120
(no-load)
Exhaust temperature
℃ 65
(full-load)
Speed-regulating
MPa 1.57 1.3
oil pressure
Lubricating oil
℃ 38~55 75 35
temperature
Return oil
bearing
Return oil
bearing
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white metal of thrust
shoe
oil tank
Inlet air
℃ 30~40 45 20
temperature
Outlet air
℃ <65 75
temperature
Temperature of
℃ 120
iron core’s gear part
Temperature of
℃ 140
iron core’s yoke part
Coil temperature ℃ 90
1.5 Others
1.5.1 Miscellaneous
Vacuum of steam
kPa 3~30 3
seal heater
Degree of
supercooling of ℃ 1 2 -7
condensate
Hardness of During
Epb ≤1
condensate start-up ≤10
End difference of
℃ 6~10
condenser
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oxygen of condensate
Water level of
mm 3750 1500
water-jet case
speed
n value
oil tank
screen
1.6 During each pump’s operation, the current shall not exceed the rated values
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DC oil pump 53.8
2.1 As to the unit’s operation, the regular inspection and supervision should be done as per the
inspection tour system, the regular supervision and switching system. If find anything abnormal, quickly find
out its reasons, timely handle it according to this specification, and immediately report it to the team leader
2.2 There should be no noise in the turbine-generator set. The vibration should not exceed 0.05mm.
2.4 The normal oil level of the main oil tank is 0~100mm. The difference between the oil level before
and behind the filter screen should not be more than 50mm; or contact the maintenance staff to clean the
filter screen.
2.5 The regulating system should work properly, without jamming or jumping. The oil pressure of each
2.6 Record the indicated values of each meter on time and analyze them. If find any problem, find out
reasons and timely eliminate them. If find any defect, timely report it to the team leader and record it in the
defect record.
2.7 According to the parameter requirements, timely switch to HP & LP oil pump, condensate pump,
water jet pump and water drain pump. Do not arbitrarily disconnect the interlock switch and the main
machine protection switch. If the switching can be done due to special reasons, report it to the shift
2.8.1 The water should be timely drained from the heater. The level of the water drain should be 300~
500mm.
2.8.3 The heater’s steam inlet valve and the extraction check valve should be opened fully.
2.9.1 There should not be noise in each part. The vibration should not exceed the setting value.
2.9.2 Note that there should not be water in each bearing. The oil level should be at 2/3 of the oil level
indicator. The oil should be qualified, without water. The bushing temperature should not exceed the setting
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value.
2.9.3 During each pump’s operation, the current shall not exceed the rated value.
2.10 When the turbine is in the standby period, there should be a specially-assigned person to maintain
and check it regularly, so as to ensure the unit can be started at any time.
2.11 The turbine’s start, stop, normal maintenance and change should all be recorded in detail.
1.1 In case of the equipment’s failure, the operator should quickly eliminate the danger to human and
equipment, find out the reasons, eliminate the failure, and keep the equipment in continuous operation.
1.2 In case of the equipment’s failure, the operator should timely report it to the chief operator and the
shift supervisor, should quickly carry out the superior’s instructions and reinforce the contact between each
post. The assistants should not operate the equipment without authorization, but should cooperate in the
handling under the guidance of the chief operator and the shift supervisor, and try to guarantee the normal
heat and power supply for users, especially to guarantee the service power.
1.3 During the accident handling, the operator should quickly, accurately and calmly analyze it. If
he/she finds it is out of this specification, he/she should make the judgment based on their own knowledge
and experience, take active actions and report it to the chief operator and the shift supervisor as quickly as
possible.
1.4 In case of the unit’s failure, the operator should conduct the work in the following order.
1.4.1 Based on the indicated values of the meters and judging from the reliability of the meters and the
external phenomenon of the unit, determine that the equipment has failed. Correctly judge the failure’s
nature, location and range, and quickly handle it according to this specification.
1.4.2 Quickly eliminate the danger to human and equipment. When necessary, stop the failed
1.4.4 Each stage of the failure handling should be quickly reported to the chief operator, the shift
supervisor and the supervisor of the discipline, so as to timely take actions to prevent the failure spread.
1.5 From the failure occurrence to the recovery, the operator should not leave his/her post without
authorization. If the failure occurs during the shift change, the shift change should be delayed until the
handling comes to the end of a stage. The staff of the next shift should assist the previous shift in the
accident handling.
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1.6 When the unit fails, the supervisor of the discipline shall go to the site and supervise the failure
handling, give the operator necessary instructions, which can not be in conflict with the shift supervisor’s
order. When he/she finds the chief operator is unqualified for the failure handling, he/she is entitled to
announce that he/she will lead the accident handling within their own discipline. The chief operator should
assist the leader of the discipline to handle the failure and immediately report it to the shift supervisor.
1.7 After the completion of the failure handling, the operator should truly record the accident’s reasons,
the detailed handling process in the shift-change record. Conduct the shift change in written form and report
to the superior level by level. When necessary, keep the original state of the site to facilitate the accident
analysis. The shift supervisor and the supervisor of the discipline should timely call up the relevant staff and
hold a meeting for the accident investigation and analysis to find out the reasons, sum up experience, learn
2.1.1 There is sudden strong vibration or metal clash in the turbine-generator set.
2.1.2 The turbine’s rotating speed increases to 3360r/min, but the emergency security device does not
actuate.
2.1.4 There is a spark and obvious friction noise in the shaft seal.
2.1.5 There is fuel-outage or smoke in any one of bearings of the turbine-generator set. The return oil
2.1.6 The temperature rise of the return oil of the bearing exceeds 75℃; or that of the bushing exceeds
2.1.7 The oil system is on fire, which can not be extinguished quickly and threatens the safe operation
of the unit.
2.1.8 When the oil level of the main oil tank sharply goes down below the min. level, which can not be
recovered.
2.1.9 When the lubricating oil pressure drops to 0.0196MPa; each bearing’s oil flow reduces; the oil
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2.1.13 The exhaust valve of the rear cylinder actuates.
2.2.1 The pressure of the inlet steam of the turbine is higher than 9.8MPa, or the temperature of the
2.2.2 The pressure of the inlet steam of the turbine is lower than 5.88MPa, or the temperature of the
2.2.4 All of the control valves close. The generator turns to motor operation mode and drives the
2.3.1 Manually pull the emergency breaker’s handle or press the remote-operational stop button.
Check if the automatic main steam valve, the speed-regulating valve, the extraction check valve are all
2.3.2 Start the lubricating oil pump and check if the rotating speed decreases.
2.3.3 Close the electric main valve and the pressure regulator of the deaerator.
2.3.4 Stop the water jet pump and fully open the vacuum breaking valve.
2.3.5 Open the condensate recirculating valve; stop the deaerator and keep the water level in the hot
well.
2.3.6 Exit the HP and the LP heater; close the valve of the condensate to the deaerator.
2.3.7 Regulating the pressure of the shaft seal, check the unit’s conditions and check the vibration by
2.3.8 After the vacuum reduces to zero, close the steam supply valve of the shaft seal.
2.3.9 After the rotor stops, switch to continuous turning, and record the rotor’s coasting duration.
2.3.10 Perform other shutdown procedures as per the shutdown order stipulated in the operation
procedure.
Note: the above are the procedures for emergency shutdown by breaking the vacuum. There are
different special operations depending on different shutdown conditions, e.g. opening emergency oil drain
2.4 The emergency shutdown should be conducted not by breaking the vacuum in case of the
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2.4.1 The pressure of the turbines’ inlet steam is lower than 6MPa, but higher than 5.88MPa.
2.4.2 The temperature of the turbines’ inlet steam is lower than 485℃, but higher than 480℃.
2.4.3 The vacuum in the condenser is lower than -73 kPa, but higher than -62.7 kPa.
3.1 During the operation, when finding the main steam pressure or temperature is out of the rated
parameters, timely contact the boiler staff and ask them to quickly recover it and report the team leader and
the shift supervisor to take emergency actions. Moreover, pay close attention to the unit’s vibration sound,
check the cylinder’s expansion, the rotor’s expansion relative to the cylinder, the axial displacement, the
thrust shoe temperature, as well as the temperature and the change of temperature difference of turbine’s
each part.
3.2 In case of temperature increase or decrease of the main steam, handle it mainly based on the
mixed steam temperature behind the automatic main steam valve. However, if the sudden temperature
decrease in a single pipe exceeds 50℃ or there is water impact, conduct the emergency shutdown based on
the steam temperature in the single pipe and fully open the main steam pipe and the cylinder’s drain valve.
3.3 In case of simultaneous decrease of steam temperature and pressure, handle it mainly based on
Steam
℃ 525 521 517 513 509 505 500 495
temperature
Steam
MPa 8.4 8.2 8.0 7.8 7.6 7.4 7.2 7.0
pressure
Inlet steam
t/h 370 342 314 283 258 230 202 174
flow
Steam
℃ 490 485 480 475 470 465 <465
temperature
Steam
MPa 6.8 6.6 6.4 6.2 6.0 5.9 <5.9
pressure
Inlet steam
MPa 146 118 90 62 34 20 shutdown
flow
3.4 In case that the main steam temperature is higher than 540℃, contact and ask the boiler staff to
quickly decrease it to the normal value. When the steam temperature between 545~550℃ can not be
decreased after 30 min continuous operation, conduct the emergency shutdown. When the steam
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temperature is higher than 550℃, immediately conduct the emergency shutdown.
When the main steam temperature decreases to 505℃, immediately contract and ask the boiler stoker
to quickly recover it to the normal value. When the steam temperature decreases to 505℃, open the water
drain valve of the conduit before the electric main valve; and the temperature continues to decrease to 495℃.
Open the drain valve behind the speed-regulating valve and the cylinder’s drain valve. When the steam
temperature decreases below 465℃, quickly reduce the load to zero. When the steam temperature
decreases to 460℃ but still can not be recovered, report it to the shift supervisor for the emergency
℃ MW t/h ℃ MW t/h
Shutdown
495 45 80 460
due to fault
When the main steam pressure increases to 9.4MPa or above, contact the boiler staff to reduce the
load. When it increases to 9.9MPa or above, report it to the team leader and the shift supervisor. Use two
electric main valves to restrict the flow, so as to keep the steam after the electric main valve no higher than
9.9MPa. After the steam pressure recovers, fully open the electric main valve. In case of 30 minutes or more
operation with the steam after the electric main valve over 9.9MPa but without any decrease, conduct the
emergency shutdown.
In case of the steam decrease, reduce the load as per the following principles. When the steam
pressure reduces below 5.9MPa but can not be recovered, conduct the emergency shutdown. Reduce the
Attached: the principles for the steam pressure decrease and the load reduction:
101
MPa MW t/h MPa MW t/h
7.7 36 90 6.3 8
7.6 34 80 6.2 6
7.5 32 70 6.1 4
7.4 30 50 6.0 2
7.3 28 0 5.9 0
due to fault
7.1 24 0
4.1 If find the declination of the vacuum, check the following meters and find out the reasons.
4.1.1 The condenser’s vacuum meter, the autographic recorder of exhaust temperature and the
thermometer of exhaust cylinder; conduct cross-reference to determine that the vacuum has declined.
4.1.2 The pressure gauge of the condenser’s circulating water inlet and outlet, the thermometer, and
4.1.4 The condensate pressure and flow meter; the condensate pump’s ammeter.
4.1.5 The pressure gauge of water-jet pump water outlet; the ejector’s vacuum meter.
4.2 Confirm the declination against the meters, timely notice the assistant operator to find out
the reasons and handle it together, and report it to the chief operator and the shift supervisor as
soon as possible.
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Main reasons for the vacuum declination:
4.2.2 Decrease of the steam supply of the shaft seal or failure of the shaft seal’s heater.
4.2.4 Malfunction of the water-jet pump and the water-jet ejector; temperature increase of the water-jet
tank.
4.3 When the vacuum declined to -86kPa, send out “Pay Attention” and “Reduce Load” order to the
master controller; meanwhile start the standby water-jet pump and the water-jet ejector to increase the
4.4 The exhaust temperature under load condition should not exceed 65℃; it should not exceed 120℃
under no-load condition. Switch to water spay at the exhaust cylinder’s throat depending on the exhaust
temperature.
4.5 When the vacuum declines, reduce the load as per the following table during the reason-finding
Load MW 55 40 30 20 10 0
When the load is reduced to “zero” and the vacuum declines below -0.0627MPa, conduct the
emergency shutdown.
4.6. When the vacuum declines, there are following handling methods:
4.6.1 Under the following conditions, it is allowed for the unit to temporarily operate with the
original load:
4.6.1.4 The pressure in the monitored section does not exceed the setting value;
4.6.1.5 If under the above conditions, the vacuum can not be recovered over 30 min but the above four
4.6.2.1 Phenomenon:
The pressure of the condenser water inlet is zero; the outlet pressure is zero; and the vacuum sharply
declines.
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4.6.2.2 Handling:
2) Open the oil cooler’s service water valve, and close the oil cooler’s circulating water inlet valve.
3) Open the exhaust cylinder’s water spray device. When the exhaust temperature increases to 120℃,
4) When the exhaust temperature decreases to 50℃, the circulating water can be introduced to the
condenser.
4.6.3 Phenomenon and handling of vacuum declination due to circulating water shortage
4.6.3.1 Phenomenon
2) Under the same load and water inlet temperature condition, the temperature of the condenser’s
4.6.3.2 Handling
1) Open widely the condenser’s inlet valve to increase the circulating water flow;
4.6.4.1 Phenomenon
3) Under the same load and water inlet temperature condition, the temperature of the condenser’s
4.6.4.2 Handling
2) Open widely the inlet valve, close the water outlet valve (Do not close it off), exhaust the air and
3) After the air has been exhausted, close the vent, open widely water outlet valve and regain the
original operation mode (slightly increase the circulating water flow). If the siphon at both sides is broken
4.6.5 Phenomenon and handling of vacuum declination due to too high water level in the
condenser
4.6.5.1 Phenomenon:
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1) The condenser’s water level goes up so that the water level indicator can not reflect the water level,
at which time the water outlet pressure and the current of the condensate pump increase.
2) In case of the failure of the condensate pump, the motor’s current reduces and the outlet water
4) When the condenser’s pipe is broken, the hardness of the condensate increases.
5) The condensate’s recirculating water valve is wrongly opened and the demineralized water refill
6) The relevant valve to the deaerator’s condensate pipe section is wrongly turned down or the valve
spool drops, at which time the condensate pressure increases and the current reduces; and the end
7) The check valve of the standby condensate pump is not tight, making the condensate return.
8) When there is air leakage in the condensate pump’s water inlet pipe and the standby water pump,
9) The LP heater’s copper pipe breaks, causing a large amount of water return to the condenser
4.6.5.2 Handling:
1) In case of the failure of the condensate pump, quickly open the standby condensate pump.
2) Properly turn down the recirculating water valve and the water refill valve.
3) If the LP heater’s copper pipe breaks, guide the condensate to the through valve to exit from the
operation.
4) If the outlet check valve of the standby condensate pump is not tight, close the water outlet valve.
5) If there is air leakage in the standby pump or the pump in operation, try to eliminate it, check the
6) In case of the leakage of the condenser’s copper pipe, start the standby condensate pump and
timely stop the condenser's leakage. Conduct the shutdown when necessary.
4.6.6 In case of the vacuum declination due to malfunction of the ejector, timely switch the
operation mode and check the water-jet pump’s operation condition and the water-jet tank’s water
level.
4.6.7 Phenomenon and handling of vacuum declination due to air leakage caused by
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1) The vacuum declines and the exhaust temperature increases;
2) Whether the vacuum breaking valve’s water seal, the condensate pump’s water seal or the vacuum
3) Whether there is air leakage in the condenser or the LP heater’s water level indicator.
4) The packing of each valve of each pipeline under the vacuum condition or the flanged joint is not
tight.
5) The water drain valve of the condenser’s hot well is not tight or the flanged joint is not tight.
6) If the vacuum declines under the low load, but the vacuum recovers to the normal condition under
the high load, the usual reason for the vacuum declination is the leakage at the LP cylinder’s joint.
4.6.7.2 Handling
If find the above problems, timely handle it by checking the source of water seal, tightening the screws,
5.1.1.1 When governing oil pressure is dropped to 1.96MPa, the governing oil pump interlocks; when
the lube oil pressure is dropped to 0.055MPa, the AC lube oil pump interlocks.
5.1.1.2 When lube oil pressure is dropped to 0.04MPa, the DC oil pump interlocks.
5.1.1.3 When lube oil pressure is dropped to 0.02MPa, turbine is shut down automatically.
5.1.1.4 When lube oil pressure is dropped to 0.015MPa, turning gear is interlocked and tripped.
5.1.2.1 When oil level is suddenly 5~10mm dropped, the master operator shall notify the assistant
5.1.2.2 When oil level is dropped to -50mm, try to contact to top the oil, and report it to the master
5.1.2.3 When oil level is dropped to -180mm, no any methods are effective, but break vacuum and shut
5.1.3.1 When any bearing return oil temperature suddenly rising 2~3℃, locate the reasons.
5.1.3.2 When any bearing return oil temperature rising to 65℃, report it to the master operator and
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the shift supervisor, try to lower the temperature and monitor it closely, if it is impossible to lower, when the oil
temperature rising to 75℃, break vacuum and shut down the turbine emergently.
5.1.3.3 When thrust pad temperature rising to 80℃, report it to the master operator, it is continues to
rise to 90℃, notify the shift supervisor, adjust the electrical heat load; if any spot of the thrust pad
temperature exceeds 110℃ or two spots exceeded 95℃ simultaneously, trip and shut down the turbine
immediately.
5.2.1 During turbine startup or shutdown, when governing oil pump is fault, start the AC lube oil pump
5.2.2 During turbine startup, when the speed is below 2300r/m, if the governing oil pump is fault, and oil
pressure drops with it, start the AC lube oil pump or DC oil pump immediately (if the AC lube oil pump and the
DC oil pump are fault simultaneously, break vacuum immediately, shut down the turbine), lower the speed,
shut down the turbine. If the speed is above 2300r/m, start the AC lube oil pump or DC oil pump immediately,
and increase rapidly the turbine speed till the main oil pump can maintain normal pressure.
5.3.1 When oil system is on fire, locate the reasons without delay, and take measures to wipe out the
fire with fire-fighting equipment quickly; report it to the shift supervisor immediately according to the situation,
5.3.2 If the fire cannot be controlled, and the unit safe operation is threatened, then break vacuum
immediately, shut down the turbine emergently, start the lube oil pump, disconnect the governing oil pump
5.3.3 If the fire continues to spread and the main oil tank is endangered, isolate the oil tank from the
fire with fire hydrant after the turbine is tripped and the generator is disconnected. In 5min, open fully the
emergency oil drain valve to drain oil (close the emergency oil drain valve after the fire is wiped out), stop the
lube oil pump immediately after the rotor is stopped, and turn the shaft manually, so as to prevent bending of
the shaft.
5.3.4 When electrical equipment operation safety is threatened, cut off its power supply.
5.4 Oil pressure, oil level change causes and remedies (the causes and the remedies are in
5.4.1.1 Causes:
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2) Oil cooler copper tube leakage
5.4.1.2 Remedies:
2) Stop the leaking oil cooler to eliminate the leakage and maintain the lube oil pressure and quantity,
make the return oil temperature of each bearing not exceed 75℃.
5.4.2.1 Causes:
1) Oil level meter failed, oil cooler and pressure oil pipe have slight leak.
2) Oil tank filter screen is clogged, which makes the oil level difference before and after the screen
bigger.
3) Return oil pipe is leaking, emergency oil drain valve or oil tank water drain valve is leaking. Auxiliary
5.4.2.2 Remedies:
1) Check whether the oil gauge float is free, eliminate the leak point
3) Eliminate the oil leak point, such as, clip, tighten the screws. Close tightly the valve or use oil pan to
5.4.3.1 Causes
5.4.3.2 Remedies
4) Start the governing oil or lube oil pump to restore oil pressure, if the pressure cannot be restored, then
5) The mechanical maintenance team adjusts the overflow oil valve, with the professional director or
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Section VI Load rejection
When the unit is found rejecting load, report it immediately to the monitor.
6.1 Generator is tripped, load is rejected to “0”, and automatic main stop valve is closed. OPC operated,
the rotary diaphragms are closed simultaneously, extraction check valve closed
6.1.1 Phenomena:
“Generator trip”, “automatic main stop valve closed” alarm, load to “0”.
6.1.2 Handling:
6.1.2.1 Start the AC lube oil pump, stop the deaerator, open the condensate recirculation, adjust the
condenser water level and shaft seal pressure, and check the extraction check valve interlock close.
6.1.2.2 Report it to the department leader, locate the fault, and get ready to speed up again.
1) The axial displacement, relative expansion, turbine each metal temperature, and temperature
3) The governing oil pressure and the lube oil pressure, each bearing oil temperature, thrust bearing
7.1.1 Handling:
7.1.1.1 Start the AC oil pump immediately, so as to prevent oil interrupted and pad burnt.
7.1.1.2 Maintain appropriate opening of the governing valve, and require limiting the power load.
7.1.1.3 Check comprehensively the operation condition of each part of the unit, and make
corresponding adjustment, pay particular attention to axial displacement and each bearing oil pressure and
oil temperature.
7.2.1 Governing system can control the speed not exceed OPC operating speed:
7.2.1.1 Maintain normal cycle; contact the electrical to synchronize as quickly as possible.
7.2.1.3 Make adjustment of the shaft seal steam supply and recirculation
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7.2.1.4 Check comprehensively the operation condition of each part of the unit.
7.2.2 If service power is interrupted, start the DC oil pump, make shutdown treatment.
7.2.3 Speed is increased to emergency governor operating speed, but without operating:
8.1.2 Boiler water quality is not good, resulting in steam and water co-boiling, steam pressure sudden
8.1.3 Heater is full of water and the extraction check valve is not tight, water flows back to steam turbine
8.1.5 During shutdown, strengthen check of each part of the unit, pay attention to idling time of the rotor,
internal sound, thrust pad and bearing return oil temperature, axial displacement, etc.
8.1.6 When no abnormal condition is found, no abnormal sound under turning state, and the upper and
lower cylinder temperature difference and rotor swinging meet the specification, the professional director will
8.1.7 During startup, pay particular attention to monitoring axial displacement, thrust pad temperature,
relative expansion and metal temperature, if internal noise, friction, increase of axial displacement is found,
8.2.1 When the boiler or the main steam header is in parallel, monitor it closely with particular care,
operate slowly, fully heat the pipe and drain water according to the temperature.
8.2.2 Monitor frequently the steam temperature and steam pressure change, contact the boiler timely.
8.2.3 Pay attention to strengthening heating pipe and thorough water drain before the unit startup.
8.2.4 Always pay attention to the heater water level, when the internal pipe is ruptured, shut down the
turbine immediately.
8.2.5 When extraction pipe stops operating, pipe water drain has to be opened
9.1 When axial displacement is increased than the normal, make the following checks:
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9.1.2 Listen to the unit internal sound and vibration of each part; check whether the high pressure, low
9.1.4 Whether the main steam flow, pressure, temperature, each pressure and vacuum of monitoring
9.1.5 When the above meters and operating conditions indicating the meter failure, then report it to the
master operator, the shift supervisor, and contact the I&C to correct it quickly; disconnect the protection
switch temporarily.
9.2.1 When the axial displacement is 0.2mm increased than the normal, reduce the unit load.
9.2.2 When the axial displacement exceeded 1.3mm or -0.7mm, if the protection does not operate, then
break vacuum, shut down the turbine emergently. If the protection operates, vacuum breaking and shutdown
9.2.3 When axial displacement is increased, to disconnect the protection switch is strictly forbidden.
1) Load is to zero, the speed continues to rise after it reached the emergency governor operating speed;
the unit vibration is increased and unusually discordant sound is sent out.
10.2.1 Make emergency treatment according to the breaking vacuum emergency shutdown steps.
10.2.2 Check the automatic main stop valve, governing valve, IP rotary diaphragms, close each
extraction check valve, close electric main stop valve, close the electric isolation valve when necessary, and
cut off all steam sources connected with steam turbine immediately.
10.2.4 Rotor still, record the idling time, put continuous turning into operation, measure and listen
10.2.5 If restart is required, approval from the shift supervisor and the director must be obtained, and the
11.1 When generator internal core coil temperature is found locally rising during operation, notify the
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electrical master operator for treatment rapidly.
11.2.3 Report it to the monitor, the shift supervisor and the electrical on-duty operator, use carbon
dioxide and dry fire extinguisher to extinguish fire. Using foam fire extinguisher or sand is strictly forbidden.
11.2.4 After “generator switch-off” signal is obtained, and confirm the magnetic blow-out switch has been
disconnected, the driver may use water extinguisher to extinguish the fire in machine.
11.2.5 When the speed is dropped to 300r/m, maintain the rotor running at 300r/m, till the generator
stator and rotor are confirmed cooled after fire extinguished, can the generator be shut down.
12.1 When turbine suddenly has strong vibration and there is clear metal sound inside, break vacuum
12.2 Under the load changing condition, when the unit has not very strong vibration or has abnormal
sound, restore the load to the original normal load immediately and locate the reasons, and check:
12.2.1 Oil cooler return oil temperature is within 38~45℃, the oil pressure and oil flow are normal.
12.2.2 Main steam parameters shall conform to the specification, when they are not conformed, ask the
boiler to regulate.
12.2.3 Check the unit expansion condition, check whether the cylinder thermal insulation is in good
12.2.4 Check whether the steam exhaust hood temperature is too high. Adjust it when it is too high.
12.2.5 Check whether the cylinder upper and lower temperature difference is too big, locate the reasons
12.2.6 If not very clearly abnormal sound is found inside the unit cyclically, strengthen monitoring of the
unit operation condition, check the reasons carefully, and report it to the master operator, the shift supervisor
Section XIII Main stop valve, governing valve, rotary diaphragm operation abnormal
13.1.1 The valve stem is ruptured and the valve core is come off:
13.1.1.1 Judge the fault according to the pressure after the governing valve, check the governing valve
opening. Pay attention to the unit operation condition, and report it to the master operator, the shift
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supervisor and the professional management personnel. If the case is serious and should not operate for a
13.1.1.2 If #1 governing valve has fault and the unit load is low at that time, only the #1 governing valve
is opened, then the load will be rejected to zero, under the no-steam operating mode, increase the high
pressure servo-motor travel rapidly, open wider other governing valves to carry the load to maintain the unit
operating for the time being, then handle it according to the above regulations.
13.1.2 The valve or servo-motor is jammed, judge the fault by the governing valve servo-motor travel
When the governing valve servo-motor jamming is not serious, the jamming can be eliminated by
increasing/decreasing the load to move the servo-motor, when the jamming is serious, report it to the master
operator, the shift supervisor and the professional director, shut down the turbine according to the methods
below:
1) Reduce the load of the governing valve to the minimum possible degree.
2) Open full the bypass valve of the electric main stop valve, close the electric main stop valve, use the
3) After reducing the load to zero by the bypass valve of the electric main stop valve, disconnect the
generator, fully close the bypass valve, and stop the manual emergency governor manually.
Note: when #2, 3, and 4 control valve are jammed, the operation can be without heat load.
When the automatic main stop valve stem rupture or valve core come-off has been verified according to
the steam pressure before and after the main stop valve and external phenomenon of the automatic main
stop valve, reduce the load and make turbine fault shutdown.
Valve jamming
When the valve is found jammed through movable main stop valve, report it to the professional
management personnel and the shift supervisor; do not maintain operation under this condition.
Judge it according to the servo-motor travel switch and the steam extraction hood pressure. If the
jamming is not serious, eliminate the jamming by increasing and decreasing the heat supply load, when
necessary, may reduce power load, lower the adjusting steam extraction hood pressure to make it restored;
if the jamming is serious, try to make it fully open, no longer operate with the adjusting extraction steam;
before jamming is eliminated, limit operation load or reduce load and shut down according to the steam
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extraction hood pressure; note that do not make the safety valve operate.
14.1 When piping, three-way, valve body and nearby insulation layer is found steam leak and water leak,
report it to the monitor, and try to locate and judge the leak point and leak condition, report it to the shift
supervisor when necessary. It is strictly forbidden to locate the leakage by removing the insulation when the
piping is under high temperature and high pressure, so as to prevent rupture due to shock cooling of the
exposed position.
14.2 If penetrated crack is found on high pressure piping and the accessories (including welds), when
steam water is ejected from the crack or valve has crack and steam water leak, report it to the master
operator and the shift supervisor immediately, stop operation of this piping immediately, and open the drain
14.3 If stop of this piping involves boiler shutdown and turbine shutdown, insist on rapid stop, when
shutting down turbine, run down the load to “0” first, and handle it according to fault shutdown, so as to
prevent pressure fluctuation in the piping when closing the main stop valve.
14.4 Any steam water piping must be fully heated and water drained, so as to prevent piping vibration
14.5 If high pressure piping is ruptured, the workshop is fully filled with large amount of steam, open
14.6 When oil piping has leakage, report it to the monitor, the shift supervisor timely and correct it timely;
15.1.1 All the AC lighting lamps in the workshop go out, sound changes suddenly.
15.2.1 Make sure the service power is completely lost, make emergency shutdown immediately, and
15.2.2 Start the diesel generator, start DC oil pump immediately when shutting down turbine, put DC
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emergency lighting into operation, and use flash light.
15.2.3 When the service power is interrupted for over 1min and cannot be restored yet, release each AC
15.2.4 Complete other steps of shutdown operation, record the idling time. (When emergency power
supply is used, to start any motor must obtain approval from the monitor and shift supervisor, except the low
15.2.5 After rotor is stopped, if it cannot be put under continuous turning as the service power has not
been resumed, make marks on the rotor and put the rotor bending indicator into operation, set it to value “0”,
after the service power is restored, after recording the reading of the rotor bending indicator, turn the rotor by
180, when the rotor bending indicating value is restored to 1/2 of the recorded value, put it under continuous
turning, remember to measure the rotor bending value and listen to the sound before and after the bearing
15.2.6 After the service power is restored, start the turbine according to the state regulation, but note
that:
1) Start the circulating water pump, but the condenser inlet valve can be opened slowly only after the
2) When turbine is shut down due to interruption of the service power, the master operator shall report
it to the shift supervisor, the deaerator operating with steam and water stopped.
15.3.1 Check the corresponding linked standby equipment which shall be in normal operation, and reset
15.3.2 If the standby pump is not linked, start immediately the standby pump manually.
15.3.3 After the service power is partially interrupted, and the unit operation is seriously affected, handle
15.3.4 If power supply is interrupted, vacuum is dropped, handle it according to the relevant stipulations.
16.1.2 Handling:
16.1.2.1 After the fault phenomenon is found, the operator shall switch the key switch to “Man” position
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16.1.2.2 Report it to the shift supervisor, contact the I&C to correct the fault.
16.1.2.4 After the fault is corrected, restore the mode to DEH Auto mode.
17.1 Under the following situations, stop emergently the auxiliaries (condensate pump, water jet pump,
drain pump).
17.1.1 Strong vibration suddenly occurred and metal noise in the water pump is heard clearly
17.1.3 Water pump case has large fracture. Water pump axial moving is strong, and has impact sound.
17.1.5.3 Rolling bearing lubricated by grease with cooling water device: 80℃
17.1.5.4 Rolling bearing lubricated by grease without cooling water device: 100℃
17.2 Under following conditions, start the standby auxiliary equipment first, and then stop the fault
auxiliary equipment.
17.2.1 The sliding bearing ring is ruptured or stopped rotating (although toggled it, ineffective yet).
17.2.2 There is abnormal sound in the rolling bearing or bearing retainer ruptured sound is heard clearly
17.2.3 Water pump water is lost or vaporized (although regulated, ineffective yet)
17.2.4 Water pump packing has smoke (although treated, ineffective yet)
17.3.1 Press the fault auxiliary equipment “emergency button” (or with operation button) to stop the fault
17.3.2 Make sure the auxiliary equipment has been tripped, the standby auxiliary equipment linkage is
normal, notify the master operator to reset the operation button, and disconnect the linkage switch.
17.3.3 If the standby auxiliary equipment is not linked, notify the master operator to put the auxiliary
equipment into operation manually, if important auxiliary equipment can still not be started by starting twice in
succession, send out “fault alarm”, and report it to the master operator and the shift supervisor, and reduce
the load or shut down the machine according to the stipulations of the procedure (except the drain pump).
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17.3.4 Check the linked auxiliary equipment running is normal, the fault auxiliary equipment is without
17.3.5 Complete other relevant operations, if it is the electrical fault, notify the electrical personnel to
17.4.1 When auxiliary equipment trip is found, check immediately whether the standby auxiliary
equipment is interlocked, if not, then operate it manually; when there is no standby auxiliary equipment,
check the tripped auxiliary equipment, if no obvious fault, it may be started by force for one time, if it does not
work, report it to the master operator and the shift supervisor, reduce the load according to the condition, if it
is caused by power interruption, ask the electrical to restore the power supply rapidly, if impossible to restore
17.4.2 When the tripped auxiliary equipment and the motor are checked without obvious fault, notify the
18.1.1 When the water level gauge indication is found too high, the operator notify the assistant operator
to check whether the local water level is really risen, verify and check whether upper and lower valve of the
18.1.2 Check whether the drain valve is closed by mistake, make appropriate adjustment. Check
18.1.3 Check HP heater steam pressure; if the HP heater water level is normal, notify the deaerator
on-duty operator to check whether the HP heater drain to deaerator valve is normal, which shall be fully
opened.
18.1.4 If the HP heater water level is rising rapidly, cannot be lowered by opening the emergency drain
valve, and accompanied with heater outlet water temperature drop rapidly, or has impact, vibration, drain
pipe swinging, etc., stop the heater immediately, close the #1, 2 HP heater steam admission valve, close the
inlet, outlet water valve, feedwater takes the bypass, drain completely the steam side water, report it to the
monitor, the shift supervisor, and notify the boiler, notify the maintenance personnel to repair, and carry out
18.1.5 If the HP heater protection device is operated, check and handle it as per the clauses above. If
the protection is mal-operated, report it to the monitor, notify the I&C personnel to check and correct, locate
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the reasons, eliminate the fault, after every thing is checked normal, put the HP heater into service.
18.2.1 Check whether the steam liquid level regulator operation is normal, check whether the drain valve
18.2.3 Check whether the #1 HP heater to #3 LP heater drain valve is opened by mistake and whether
18.2.4 Check whether the upper, lower small valve position of the LP heater water level gauge is fully
opened, whether the water level indication is consistent with the local water level.
18.2.5 If the LP heater water level rising rapidly to full water, open the emergency drain valve to
condenser, when the water level still cannot be lowered but the heater outlet water temperature drops rapidly,
or has impact, vibration, stop this heater immediately, close the steam admission valve, air valve. Open fully
the water side bypass valve, close the inlet, outlet water valve, report it to the monitor, and notify the
18.2.6 1# LP heater should not be stopped for a long time when it is in operation, if it has to be stopped
for a long time, its better to shut down the turbine; if #2, #3 LP heater have to be stopped simultaneously
when they are in operation, notify the deaerator on-duty operator to increase the HP deaerator steam
admission quantity, so as to avoid drop of the HP deaerator steam pressure, and also pay attention to the
deaerator vibration.
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Part II Operation procedure of auxiliary equipment
1.1.1.2 The governing oil pump, lube oil pump, emergency oil pump low oil pressure interlocking is
normal.
1.1.1.3 The main oil tank oil level is at -100~+50mm, the oil level gauge is freely and in good
condition.
1.1.1.4 Confirm each oil pump and vapor exhaust fan motor is energized.
1.1.1.6 After the above conditions are satisfied, make trial run of the DC emergency oil pump, AC lube
oil pump and governing oil pump respectively, check whether each pump indicator-lamp and current are
pressure (MPa)
pressure (MPa)
1.1.1.7 Check the system has no oil leakage, each oil pump operation is normal; maintain the AC lube
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1.1.1.8 Start operation of the vapor exhaust fan.
1.1.1.9 When the oil temperature reaches 45℃, put the cooling water of the oil cooler into operation.
(1) Open slowly the operating oil cooler inlet valve, close the air valve after the air vent valve has overflow
water.
(2) Open the operating oil cooler water outlet valve, pay attention to the oil cooler pressure, which shall
1.1.1.10 Governing oil pump shall be put into operation before rolling.
1.1.2.1 Stop of oil system is the stop after the turbine shutdown.
1.1.2.2 Before stop of the oil system, confirm the turning gear, jacking oil pump have met the stop
conditions first.
1.1.2.3 After the turning gear, jacking oil pump are stopped, stop the oil system as per the steps below:
2) Stop the oil pump, the pump stop indicator-lamp is ON, confirm the lube oil pressure is dropped to
1.2.1.1 Check all meters and gauges are complete, the indications are clear;
1.2.1.2 One of the two oil coolers is in operation, one on operation, one on standby;
1.2.1.3 Before unit startup, operate the oil cooler oil inlet valve, oil outlet valve; open the water outlet
1.2.1.4 Close the standby oil cooler water inlet valve, close the oil outlet valve; open the water outlet
1.2.1.6 After turbine rolling, when the total oil outlet temperature after the oil cooler reaches 42℃, put the
1.2.1.7 The oil cooler cooling water is supplied by the circulating water or industrial water.
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Prepare measures and monitor well when switching over oil cooler.
1.2.2.1 Open slightly the oil outlet valve and water inlet valve of the standby oil cooler; close slightly the
oil outlet valve and the water inlet valve of the operating oil cooler.
1.2.2.2 Carry out the above two operations alternately, make the load of operating oil cooler transfer to
the standby oil cooler slowly and stably, till the oil outlet valve of the standby oil cooler is fully opened, the
water inlet valve is appropriately opened, the inlet water valve and oil outlet valve of the operating oil cooler
1.2.2.3 Monitor closely whether the oil cooler outlet header oil temperature and oil pressure are normal
during switching over. The operating oil cooler oil outlet valve can be fully closed only after the standby oil
2.1 Start and stop of jacking oil pump and turning gear
2.1.1.2 The unit must be at continuous turning status before hot start.
2.1.1.3 The jacking oil pump and the turning gear can be started only after the lube oil system operation
is normal.
2.1.1.4 Put the jacking oil system into operation before starting the turning gear.
(1) Open the main oil valve from the lube oil to the jacking oil pump inlet, and the jacking oil pump oil
(3) Start the jacking oil pump, check the jacking oil pump operation is normal, control the jacking oil
(2) Confirm each bearing jacking oil pressure is 12MPa, open the turning gear lube oil valve oil inlet
valve;
(3) Rotate the hand wheel, and pull the hand lever toward the working position, after the turning gear is
(4) After turning gear is started, observe the rotor swinging is not higher than original value 0.02mm,
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listen to the dynamic and static position for any friction sound.
2.1.2.1 After start, after the unit speed reaches 1200r/min, stop the jacking oil pump.
2.1.2.2 When stopping, the stop operation can be made only when the turbine cylinder temperature
2.1.2.3 Press “stop switch” on the local control box, the indicator-lamp is ON, the turning gear stops.
2.1.2.4 After the rotor becomes still, stop the jacking oil pump.
3.1.1.1 Confirm the maintenance work is completed, the work permit has been cancelled, and the site
3.1.1.2 Check the system meters and gauges are complete; the indications are correct and clear.
3.1.1.3 Check the condenser air vent valve is opened, the condenser drain valve, inlet valve, water
3.1.1.4 After checking, put the water side into operation, complete the following operations:
(1) Open slightly the inlet valve, when the air valve has large amount overflow water, close the air valve;
(2) Open the circulating water outlet valve, make the outlet water pressure on two sides of circulating
(3) Adjust the water inlet, outlet valve, keep certain proportion;
(4) Pay attention to making the circulating water total inlet water pressure not lower than 0.05MPa.
3.1.2.1 Only when the exhaust cylinder temperature is lower than 50℃ after turbine shutdown, can the
inlet valve, outlet valve of the condenser circulating water be closed, the air valve opened.
3.1.2.2 After stop, open the drain valve on the water side to drain the accumulated water.
3.2.1.1 Report to the shift supervisor the condenser has to be half stopped for copper tube cleaning or
3.2.1.2 After consent is obtained from the shift supervisor, notify the maintenance to get ready for
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3.2.1.3 Reduce the unit load to 30MW (can be determined according to the vacuum degree at that time)
operation.
3.2.1.4 Open fully the water outlet valve of the operating side condenser circulating water, pay attention
(2) Close the stopped side condenser circulating water inlet valve and outlet valve;
(3) Open the stopped side condenser water side outlet air vent valve and water chamber drain valve.
(4) Monitor closely the vacuum during use, the vacuum must not be lower than -86kPa; otherwise,
reduce the load, guarantee the exhaust temperature not higher than 65℃.
3.2.2.1 Check and confirm the maintenance has been completed, the work permit has been cancelled,
3.2.2.2 When the exhaust temperature is lower than 50℃, close the water chamber drain valve, open
slightly the circulating water inlet valve till the condenser is fully filled with water, close the air valve after air is
completely vented.
4.1.2 Make up the hot well level to about 3/4 after the condenser is flushed qualified.
4.1.3 Make trial run of the two condensate pumps respectively, and make linkage test, start another
pump.
4.1.4 Open the operating pump outlet valve to full open. Adjust the cooling water seal water.
4.1.5 Open the standby pump outlet valve, check its outlet valve is normal, and put interlock into
operation.
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5.1.1.1 Shaft seal supply of this turbine is steam balance, three steam extractions, and live steam (live
5.1.1.2 Heat the pipe before putting the shaft seal steam supply into operation, the steam can be
5.1.1.3 Shaft seal steam can be supplied only after rotor has been turning for over 2h, supply steam to
5.1.1.4 Check the stop valve after the shaft seal adjusting valve is at open position, open the stop
valve before the adjusting valve, use the adjusting valve to adjust the shaft seal steam pressure to make
the shaft seal steam pressure at about 0.05MPa, open the steam admission valve for adjusting front and
5.1.1.5 Adjust the shaft seal heater work steam (gland steam condenser water side shall be put into
operation before it), make the gland steam condenser steam mixing chamber vacuum be at about -0.03MPa.
5.1.2.1 Only after the shaft is still, condenser vacuum reaches zero, can the shaft seal steam supply be
stopped.
5.1.2.4 Open drain valves and vent valves of shaft seal header.
5.1.3.1 Check the shaft seal steam supply header pressure from time to time, which shall be between
0.04~0.13MPa, each shaft seal shall not have steam run out.
5.1.3.2 Gland steam condenser steam mixing chamber (bleeding chamber) pressure is -0.03~0.05Mpa.
5.1.3.3 The gland steam condenser water level is kept at about 1/2.
6.1.2 Start water jet pump, after the water jet pump operation is normal, open one water jet air ejector
water inlet valve (another one on standby), put another water jet pump into linkage.
6.1.3 Open the operating water jet air ejector air valve, check the condenser vacuum, which shall be
increasing gradually.
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6.1.4 During operation, pay attention to the water jet air ejector inlet water pressure, which shall not be
7.1.1.1 Check and confirm the air cooler inlet water path is not blocked.
7.1.1.2 Open the air valve on the air cooler outlet water pipe.
7.1.1.3 Open slightly the air cooler inlet valve, when there is plenty of water out of the air valve, close the
air valve
7.1.1.4 Open water outlet valve, and adjust the inlet valve, make the generator inlet air temperature
7.1.2.1 Pay attention to the generator inlet air temperature, which shall be kept between 30~40℃ in
operation
7.1.2.2 Pay attention to the air cooler inlet, outlet water temperature change, the inlet water temperature
7.1.2.3 Check the cold air chamber regularly, when air cooler water leakage is found, report it
7.1.3.1 After turbine shutdown, when the generator inlet air temperature is dropped to 30℃, the air
7.1.3.2 Close the main water inlet, outlet valve of the air cooler.
The heating steam source of the flange bolt heating appliance of this unit is from live steam. The heating
steam enters flange and bolt respectively through temperature mixing header.
8.1 Precautions for putting flange bolt heating appliance into operation
8.1.1 When putting the heating appliance into operation, there must be dedicated person to operate and
8.1.2 Before putting it into operation, complete the system check, and confirm the steam admission
valves of live steam to the left, right flange bolt heating appliance are closed.
8.1.3 Open the temperature mixing header drain valve, the left and right flange bolt return steam valve
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and drain valve.
(1) The cylinder, flange inner and outer wall temperature difference exceeds 80℃;
8.1.5 Before putting it into operation, heat the pipe to the temperature mixing header first, when heating
the pipe, open slightly the high temperature, low temperature steam valve first, heat the temperature mixing
header for 5min, pressurize gradually to 0.2~0.4MPa, and adjust appropriately the temperature mixing
header drain valve, when the steam temperature in the header is 50~80℃ higher than the regulation stage
8.2.1 Confirm first the return steam valve of each flange bolt is slightly opened, the drain valve is
opened.
8.2.2 Open slightly the left and right valve and bolt steam admission valve to heat the flange and the bolt
system pipe.
8.2.3 Adjust the left, right flange bolt return steam valve according to the metal temperature difference
8.2.4 Adjust the temperature mixing header steam admission valve according to the heating process
and metal temperature; adjust the steam temperature and steam pressure in the temperature mixing header;
during adjusting, the low temperature and high temperature steam supply can be used in combination, keep
the steam temperature in the header over 50℃ higher than the regulation stage metal (or the hottest part)
temperature, but the steam pressure in the temperature mixing header shall not exceed 0.98MPa.
8.2.5 In the process of putting the flange bolt heating appliance into operation, the following indexes
must be controlled:
(1) Always keep the expansion difference not lower than +0.1mm;
(2) Temperature difference between the left and right flange is not higher than 20℃;
(4) The outer wall temperature higher than the inner wall temperature, the flange temperature higher
than the cylinder temperature, and the bolt temperature higher than the flange temperature are not allowed.
8.3.1 The appliance can be stopped when the lower cylinder outer wall temperature at regulation stage
is higher than 300℃, and the flange inner and outer wall temperature difference is lower than 50℃ during
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turbine startup.
8.3.2 Close the temperature mixing header steam admission valve, the left, right flange bolt steam
admission valve.
8.3.3 Close each flange bolt return steam valve and each drain valve on left and right.
9.1.1.1 The rotor turning is freely and the gauges and meters are complete.
9.1.1.3 Open the bearing cooling water, seal water, have small amount of water flowing out.
9.1.1.4 Open fully the inlet valve, close the water outlet valve, open the pump body air vent valve and
close it after the air is completely vented (air valve of the condensate pump must be still fully opened)
9.1.1.6 Confirm the motor insulation is qualified, the shell grounding is in good condition, connect the
power supply.
9.1.1.7 For the pump (such as condensate pump) with the inlet under vacuum condition, open the air
9.1.2 Start
9.1.2.1 Close the operation switch, start the motor, pay attention to checking the current, outlet pressure,
water pump and motor sound and vibration, shaft seal and bearing temperature, and oil ring rotating
condition.
9.1.2.2 Check every thing is normal, open the water outlet valve gradually, pay attention to the outlet
9.1.2.3 After condensate pump is started, pay attention to the condenser water level normal; after water
jet pump is started, pay attention to the water tank water level normal; after oil pump is started, pay attention
to the main oil tank oil level normal and the oil system free of oil leakage.
9.1.3.1 The equipment is normal, meet the start condition, can be started any time.
9.1.3.2 Linkage test and low water pressure linkage test are good.
9.1.3.3 When pump is used as interlock standby, open the cooling water valve and the water seal valve,
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open fully the inlet valve (the water outlet check valve must be tight), water is fully filled in the pump, close
the pump body air vent valve (condensate pump air valve must be opened) after air is completely vented.
10.1.1.2 In operation of the unit, put LP heater at water side into operation first and then the steam side.
10.1.1.3 If the copper tube leaks or hydraulic steam extraction non-return valve cannot be closed, don’t
10.1.1.4 The gland condenser cannot be stopped. If it cannot operate due to failure, unit shutdown must
be done.
10.1.1.5 Put the heaters into operation based on the sequence of #1, 2 and 3 according to the
condensate flow direction and reverse the sequence while stopping the heaters.
(1) Check that all instruments are normal and ready to be put into operation.
(4) Contact with the deaerator on-duty personnel and pay attention to deaerator pressure and level.
10.1.2.1 Open the inlet valve and outlet valve of the heater sufficiently open and close the bypass valve.
At this moment, pay attention to the heater water level and ensure the heater copper tubes don’t leak.
10.1.2.2 After the check that the drain trench valve is closed, slowly open the air valve sufficiently open
10.1.2.3 Check that the extraction non-return valve is fully opened, the bottom and rear drain valves are
10.1.2.4 Progressively open the admission valve (note that time is needed to warm the tube).
10.1.2.5 Progressively open to the next-stage heater drain valve, close drain bypass valve and pay
10.1.2.6 Close the drain valve at bottom and rear of the extraction non-return valve.
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10.1.2.7 The heater drain is automatically put into service based on the heater water level.
10.1.3 Stop
10.1.3.2 Close the admission valve, open the drain valve at the bottom and rear of the extraction
10.1.3.3 Shift the condensate to bypass operation based on specific conditions. Open bypass valve and
10.1.3.4 After the condensate is fully drained, close the drain valve and extraction non-return valve.
10.1.4.1 Frequently check that the drain condition and heater water level are normal.
10.1.4.2 Under specific load, the terminal temperature difference of the heater shall not exceed 8℃.
11.1.1.1 HP heater can be started together with the unit and drains to the trench. When internal pressure
11.1.1.2 When electric load in operation is above 42MW, contact with the shift supervisor and boiler to
11.1.1.3 Don’t put HP heater into operation when HP heater steel tube leaks or extraction non-return
valve cannot be tightly closed and HP heater protection doesn’t operate normally.
11.1.1.4 HP heater emergency drain valve shall pass the test and the electric valve shall be at
interlocked position.
(1) Check that all valves are at normal positions, ensure the feedwater has been switched and HP
(2) Check that all water level gauges are intact and are correctly put into service.
(3) Conduct HP heater protection test jointly with the thermal discipline and ensure the test is qualified.
(4) Notify the deaerator position personnel to be ready for putting HP heater into operation.
11.1.2.1 Confirm that HP heater protection test and leakage detection test are qualified.
11.1.2.2 Open HP heater filling valve to fill water to the HP heater water side and pay attension to the
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increase of feedwater pressure. When feedwater pressure reaches full pressure, close the filling valve and
11.1.2.3 Progressively open the HP heater inlet and outlet water valves to full opening position.
11.1.2.5 Slightly open #1 and 2 HP heater admission valve; maintain the steam pressure at 0.2~0.3MPa
11.1.2.6 Close the HP heater drain trench valve. Slowly open the air valve sufficiently open and pay
11.1.2.7 Progressively open the admission valve, close the drain valve at bottom and rear of the
extraction non-return valve and check that the feedwater temperature slowly rises.
11.1.2.8 When internal steam pressure of #2 HP heater exceeds 0.65MPa, contact with the deaerator
positon to switch the drain to deaerator. Check that the heater water level is normal.
11.1.2.10 Contact with thermal discipline, flush and cablibrate the electric-contact water level gauge and
11.1.3 Stop
11.1.3.1 Contact with shift supervisor, boiler and deaerator feedwater positions to be ready for stopping
the HP heater.
11.1.3.3 Contact witht eh deaerator position, close the drain valve to the deaerator or the stage-by-stage
11.1.3.4 Open the HP heater air valve and the drain valve at bottom and rear of extraction non-return
valve.
11.1.3.5 Stop water side of HP heater (first open HP feedwater bypass valve and then close the inlet and
outlet water valves) based on conditions and check that the filling valve is closed.
Note: frequently correct HP local water level gauge and electric-contact level indicator to
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Part III Operation procedure of feedwater pump
1.1 The equipment must not be put into operation under the following circumstances; otherwise,
approval must be obtained from relevant leaders and safety measures shall be developed before
1.1.1 The discharge non-return valve and discharge valve of feedwater pump are not normal.
1.1.6 Main working instruments (such as ampere meter, balance pressure gauge, bearing lube oil
1.1.7 Oil tank has disqualified oil and too low oil level.
1.2 The conditions for feedwater pump at hot standby condition include:
1.2.1 Suction valve is fuly opened and discharge electric valve is fully closed.
1.2.2 Feedwater re-circulating valve is opened sufficiently, automatic re-circulation device is normal and
1.2.3 Slightly open the pump warming valve and maintain the suction water temperature not lower than
120℃.
1.2.5 Oil cooer and air cooler have closed inlet valve and fully opened outlet valve.
1.3 There shall be one feedwater pump at interlocked standby condition which requires hot
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1.3.3 Feedwaer pump switch is at interlocked position.
1.3.4 Auxiliary oil pump is operating and oil temperature and pressure are normal.
1.4.1 Thoroughly inspect the equipment condition, especially the maintained parts and confirm that the
maintenance work has been completed and the space around the equipment has been cleaned.
1.4.2 Check that all monitoring instruments of the water pump are normal and at start position and the
interlock switch is at “disconnected” position. Thermal instrument current and audible and visible signals are
normal.
1.4.3 Check the oil pipe, oil tank and oil cooler. The oil pump shall be at good condition and the oil tank
shall have normal oil level and good oil quality. Turn the rotor which shall be flexible without seizure.
1.4.4 Air cooler compartment damper has been closed and no water is accumulated in the compartment.
1.4.5 For new installation or first start after overhaul, confirm that the following work has been done.
1.4.5.1 Test the feedwater pump motor which shall be at good condition and have correct rotation
direction.
1.4.5.2 Make oil circulation operation in oil system, check there shall be no oil leaking place and the oil
1.4.5.4 Position limit test for relevant electric valves shall be ok and the valves shall operate normally.
1.5.1 Slightly open the suction valve, maintain the suction water pressure at 0.1~0.2MPa(1~2 gauge)
and warm the pump for 15~20min. When suction water temperature is above 120℃, progressively open the
suction valve fully open, close the discharge valve and reduce the opening of pump warming valve.
1.5.2.1 Temperature difference between the upper and lower parts of the pump case shall be <15℃.
1.5.2.2 Temperature difference between the pump case upper part and feedwater shall be <8~10℃.
1.5.2.3 Deviation between the upper and lower parts of the coupling for the pump and the motor shall be
<0.05mm.
1.5.2.4 Start auxiliary oil pump, check that bearing oil pressure and oil flow are normal without oil
leakage.
1.6 Start
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1.6.1 Contact with relevant positions.
1.6.3 Start the feedwater pump, check whether the current, vibration, axial displacement, sound, inlet
water pressure, balance chamber pressure and shaft seal leakage are normal and whether the feedwater
recirculation is normal.
1.6.5 After everything is ok, progressively open the discharge electric valve to full opening position.
1.6.7 Place the water pump interlock switch at work position and place the standaby feedwater pump at
“standby” position.
1.7.1 After receiving notifice from the main operator, contact with relevant positions to be ready for
1.7.2 Progressively open the recirculation wider and reduce the discharge valve opening until the
1.7.3 Disconnect the interlock, progressively reduce the feedwater pump speed. Note that the feedwater
1.7.4 Stop feedwater pump, record the coasting time which shall not be less than 50s. Water pump shall
1.7.5 Take low oil pressure interlock switch out of service. After 15min, stop operation of the auxiliary oil
pump.
1.7.6 Close inlet water valve of oil cooler and air cooler and close shaft seal cooling water at the high
1.8 After stop of the water pump, place the pump at interlocked standby or hot standby condition based
on specific conditions.
I.
Feedewater
133
pump:
Discharge
MPa 15
pressure
Feedwater
t/h 396
flow
Feedwater
pressure
轴向位移
Axial mm 0.5~1 2
displacement
II. Motor
Rated
A 132.23
current
Inlet and
outlet air
Inlet air
℃ 25~35 40 20 temperature
temperature
difference
20~30
Outlet air
℃ <60 70
temperarture
Motor
temperature
rise
Motor coil
℃
temperature
III. Oil
system
134
temperature
Bearing return
℃ <60 70
oil temperature
Oil tank
3/5 4/5 2/5
level
Bearing ⊥<0.06
mm <0.05
vibration -<0.08
2.2.1 After the motor-driven feedwater pump is put into operation, the on-duty personnel shall frequently
monitor the suction water pressure which shall not be lower than 0.65MPa (g) (suction pressure shall
normally be 110% higher than internal pressure of deaerator). The motor current shall not exceed the
allowable value and the discharge pressure shall be stable without great fluctuation.
2.2.2 Frequently check that the feedwater pump balance chamber pressure is within the specified range.
Water pressure after the balance disc shall be 0.05~0.1Mpa higher than the suction pressure with pressure
2.2.3 Frequently check there shall be no metal friction sound or other abnormal sound inside the water
pump and the water pump and motor shall not be subject strong vibration.
2.2.5 Frequently check that the pump body at both sides are not overheated and without vaporization.
2.2.6 If feedwater header pressure is lower than 11.2MPa, regulation doesn’t work and interlock device
fails to operate, when the standby pump is put into operation, timely start the standby pump to ensure the
2.2.7 During operation, the feedwater pump work flow must be larger than the allowable minimum flow
2.2.8 Periodically test the audible and visible signals. All motor indicators shall indicate operation or
standby condition. If any abnormal condition is found, contact with electrical discipline for treatment.
2.2.9 Continuous startup of motor-driven feedwater pump is not allowed. Under normal condition, the
second startup can be carried out after stop for 30min. Under emergency condition, one forced startup is
allowed. If one normal operation is not successful, contact with the electrical or water pump discipline for
maintenance and troubleshooting before second startup. Note: one startup is allowed under hot condition
2.2.10 Frequently assure cleanliness and integrity of the equipment, and conduct switching test based
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on the periodic switching provision.
1.1 In case of failure, the on-duty personnel shall quickly judge the failure cause based on the
indications and phenomenon of the instruments, correctly and quickly treat the accident and ensure
1.2 When any accident happens, the on-duty personnel must stay on the position, strengthen
equipment inspection, closely monitor change of instruments, timely report to the shift leader and shift
supervisor. Different positions shall communicate information with each other, coordinate closely and obey
1.3 After the accident is treated, the on-duty personnel shall record the accident process and
treatment in the operation logbook and timely report to the upper level. If necessary, the original condition
2.1.1 The pump body experiences strong vibration and metal friction sound from the pump can be
heard clearly.
2.1.2 The pump body has strong axial play and gives off crashing noise.
2.1.5 Motor has failure which endangers human and equipment safety.
2.1.6 The pump has serious vaporization, and the water pressure and current drop dramatically and
swing.
① Oil tank level drops to “0” and cannot be recovered even when oil is filled.
② The bearing lube oil pressure drops below 0.05MPa and the bearing oil flow decreases. Start of
③ Oil system gets on fire which cannot be extinguished quickly and imposes great threat on the water
pump safety.
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2.2.1 Press “emergency button” of the failed pump or operate switch to stop the pump. Observe the
2.2.2 The standby pump shall be started because of interlock; otherwise, start it manually, open
electric outlet water valve based on interlock or immediately open the electric discharge valve. After it is
2.2.3 Close electric discharge valve of the failed pump, and note that the pump shall have no reverse
running.
2.2.4 When the feedwater pump has no standby pump, immediately notify the main operator and shift
2.2.5 Inspect the operating pump and ensure the feedwater header pressure is normal.
2.2.6 Follow other pump stop operation procedure and putting into service operation procedure.
2.2.7 If it is electrical failure, notify the electrical on-duty personnel to treat on site.
3.2 Treatment
When feedwater header pressure drops to normal allowable minimum pressure of 11.2MPa and
regulation doesn’t work, immediately start the standby feedwater pump. Then check the header pressure
drop cause and adopt suitable treatment measures based on specific conditions.
3.4 Treatment
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When the header pressure rises to the maximum allowable pressure, timely adjust the pump speed to
mainatain normal pressure; otherwise, open re-circulation, reduce water pressure or take suitable
4.1.3 Suction water strainer is blocked, suction water pressure reduces and suction water flow
reduces.
4.1.4 Discharge water flow is too small and re-circulation water valve fails to open timely.
4.1.6 Turbine generator suddenly rejects load so that the deaerator heating steam source is not
4.2.1 Feedwater pump current and discharge water pressure drop and swing.
4.2.2 Suction water pressure and balance disc pressure drop and swing.
4.2.3 Pump has noise and pump body has increased vibration.
4.3.1 Timely start the standby pump and maintain the feedwater header pressure normal.
4.3.2 Start the vaporization pump re-circulation valve and stop the evaporization pump based on
specific condition.
4.3.3 Check the deaerator level and pressure and quickly restore them.
4.3.4 If vaporization is caused because of reduced water pump flow, open the re-circulation valve. The
4.3.5 Based on conditions, if the pump is needed to be stopped, pay attention to the sound in the
pump, record the coasting time and report it to the main operator and shift supervisor.
5.1 Phenomona
5.1.2 The red light is off and the green light is on for the operating pumps and the red light flashes and
the green light is off (the pump is standstill and doesn’t start)for the interlocked standby pump, emergency
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horn sounds and indication lamp is off.
5.1.3 Sound in the machine room changes suddenly, work lighting is off and emergency lighting is on.
5.2 Treatment
5.2.1 Disconnect operation switch of all pumps, link the switch and manually close the discharge
valve.
5.2.2 Close the inlet valve of relevant heat exchanger based on conditions.
5.2.3 Check stop condition of the tripped pump and quickly place it at the condition ready to start.
5.2.4 After the power supply is restored, start the feedwater pump based on the order of the main
6.1.1 The operating oil pump fails or the standby oil pump non-return valve is not tight.
6.1.3 Oil cooler leaks a large amount of oil and the strainer is clogged.
Treatment:
When oil pressure falls below 0.09MPa, adjust the oil overflow valve to restore the pressure. When
the pressure falls to 0.08MPa, the standby oil pump will start based on interlock and when the pressure
6.2.1 When oil tank level suddenly descreases by 2cm, check the cause for oil level decrease.
6.2.2 When the oil tank level drops below 1/2, report to the main operator and shift supervisor and fill
oil.
6.2.3 When the oil tank level drops to “0”, implement emergency stop of the pump.
When it’s found that the oil tank level increases, check whether there is a large amount of leaking
water from water pump shaft seal to the oil tank. Open the water drain valve of the oil tank to drain water.
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Contact with chemical discipline to test the oil quality.
6.4.1 When the return oil temperature suddenly increases by 2~3℃, find out the cause and open the
oil cooler inlet water valve wide to regulate the oil temperature.
6.4.2 When return oil temperature rises to 65℃, report to the shift leader, monitor the temperature
6.4.3 When return oil temperature rises to 70℃, implement emergency stop of pump.
② Bearing failure.
③ Oil cooler leaks a large amount of oil and the strainer is clogged.
④ Shaft seal leaks a large amount of water which enters the oil and affects the oil quality.
7.1 When it’s found that the feedwater pump oil temperature rises, open the oil cooler cooling water
7.2 Check that the oil cooler works normally and system valves are not operated by mistake.
7.3 If the oil temperature continues to rise, check if the industrial water is smooth; otherwise, change
7.4 When the industrial water is interrupted, if there is standby water source, change to the standby
water. If the oil temperature rises to the upper limit, implement emergency stop of pump.
7.5 The main operator provides uniform commanding and the on-duty personnel implement
independent treatment.
1.1.1 Check that the oil pump interlock switch has been put into service.
1.1.2 When turning the oil pressure pinter below the setpoint of 0.08MPa, the standby oil pump
operates based on interlock. Reset the switch and chedck the oil supply is normal.
1.1.3 Restore the bearing oil pressure gauge contact to the original place and stop the standby oil
pump.
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1.1.4 Main oil pump and auxiliary oil pump back up each other.
1.2.1 When putting oil pump interlock switch into service at standstill, the oil pump should be put into
2.1.1 Check the test pump is at “standby” condition, put water pump low pressure protection device
2.1.2 When turning the feedwater header pressure gauge pointer below the setpoint (11.2MPa), the
interlocked standby feedwater pump shall be put into operation. Reset the switch and restore the atual
2.1.3 If static test is conducted, take the power supply of the motor out of service and provide the
operation power supply. The test method is the same with above. Judge whether the pump is put into
① Deliver the operation power supply of the feedwater pump and take the power supply out of sercie.
② Check the standby pump is at “standby” position (judge by relying on the indicator).
③ Press “emergency button” of the operating pumps. At the moment, the standby pump at “standby”
condition shall be put into operation automatically (operating pump green lamp flashes and standby pump
④ If another feedwater pump is subject to the test, the test method is the same.
If dynamic test is conducted, provide the power supply for the feedwater pump and oil pump. Put oil
pump for the two pumps into operation and start re-circulation. The test method is the same with that for
static test.
Start the feedwater pump and the discharge electric valve opens based on interlock.
3.1 Low oil pressure protection test: Pump trip test when lube oil pressure is below 0.05MPa.
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3.2 Differential protection test.
1.1 HP deaerator
Model cy-286t/h-80/100 M3
number
142
Design MP 0.9
pressure a
Work MP 0.588(a)
pressure a
Work ℃ 320/158
temperature
Effective M3 80
volume of water
tank
Design ℃ 350/250
temperature
model number
2.1.1 Steam from stage III turbine extraction to heating steam header.
2.3.1 Confirm that the equipment and pipes are in good condition.
2.3.2 Water level and pressure regulation valve, pressure reducing valve and safety valve are flexible
without seizure. The safety valve is intact and closed. The pressure gauge and water level gauge are
complete and in good condition. Primary valve is opened and put into operation. Contact with thermal
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discipline to deliver power supply for relevant regulation valves and instruments.
2.3.3 Slightly open vent valve and close the overflow water valve.
2.3.4 Contact with chemical discipline to be ready for starting HP deaerator, preparing sufficient
2.4 HP deaerator shall not be put into operation under the following circumstances
2.4.2 Water level gauge fails and cannot monitor the water level.
2.5 Start
2.5.1 Notify the main operaqtor, contact with relevant positions, determine the operation mode of
2.5.2 Start main condensate or water from drain tank drain pump to supply water to deaerator. Contact
with chemical discipline to test the water quality. If the water is not qualified, flush until water quality is ok.
2.5.3 Progressively open the admission valve wider, slightly open the regulation valve, maintain the
condition that vent valve slightly releases steam, warm for 15min and close the admission pipe drain valve.
2.5.4 Slowly open the regulation vavle and increase to full pressure within 30min. When the water
temperature is at 50℃ and water level is above 160cm, verify the safety valve based on needs.
2.5.5 Open re-boiling valve and slowly increase water temperature based on conditions.
2.6 Stop
2.6.1 After receiving the order to stop HP deaerator, fill the operation permit. Suitably increase the
2.6.3 Close HP drain valve to the deaerator and change HP drain to LP heater.
2.6.5 Close the feedwater re-circulation valve and close the drain pump charging valve.
2.6.6 Close the deaerator discharge valve and pay attention to the pump operation condition,
2.6.7 Close admission regulation valve, close condensate inlet valve and close all steam-water
valves.
2.6.9 If HP deaerator is stopped for a long time, open the drain valve and drain completely.
2.7 During stoppage of HP deaerator, there shall be no steam or water leaking in.
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Chapter III Operation and maintenance of deaerator equipment
3.1 During normal operation, the on-duty personnel shall pay attention to the following
3.1.1 HP deaerator water tank level is an important monitoring item and the level fluctuation shall not
be too large.
3.1.2 All pipes inside the deaerator and connected with the deaerator shall not have abnormal water
3.1.3 Correctly adjust steam and water amount so that the deaerator operation becomes balanced
and stable to ensure normal operation of the deaerator and feedwater pump.
3.1.4 The operation personnel shall record the meter reading and make tour inspection. If there is any
temperature
level
tank level
4.1 The operating value for safety valve shall be set at 0.75/1.5MPa.
4.2 Check the safety valve shall be in good condition and internal pressure of deaerator progressively
rises. Pay attention to the safety valve operation. If internal pressure of deaerator exceeds 0.75/1.5MPa
MPa without operation of the safety valve, reduce the opening of admission regulation valve and reduce
the pressure. Adjust the safety valve again until the operation is normal.
4.3 Verify the safety valve. First verify the one with higher operating pressure and then other safety
valves. Take break measure. After the first safety valve is verified, verify the other safety valves based on
the method.
4.4 When the operating pressure is not qualified, it shall be adjusted by maintenance personnel.
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4.5 During verification of safety valves, non-related personnel shall keep away from the site and
5.1.1 Check the equipment and pipes are at good condition and bearing oil level, oil quality and oi ring
are normal.
5.1.2 All monitoring instruments operate normally and are at start position.
5.1.3 Water pump rotor can be turned quickly and flexibly without seizure.
5.1.5 Shaft seal cooling water valve is opened and water flow is normal.
5.2 Start
5.2.1 Check the drain tank leve is normal. Vent air in the pump body.
5.2.2 Start the motor, check the current is normal, vibration is normal and discharge pressure is
5.2.3 After checking that everything is ok, start the discharge valev and note to check the drain tank
level.
5.2.5 The standby pump discharge valve is opened and the standby pump cannot run reversely.
5.3 Stop
5.3.1 After confirming that the standby pump operates normally, disconnect the interlock.
5.3.2 Progressively close the discharge valve and pay attention to the discharge pressure.
5.3.4 Put the pump interlock into operation and open the discharge valve based on needs.
5.3.5 If maintenance is carried out, disconnect the motor power supply and close the discharge valve
1.1 In case of failure, the on-duty personnel shall quickly judge the failure cause based on the
146
indications and phenomenon of the instruments, correctly and quickly treat the accident and ensure
1.2 When any accident happens, the on-duty personnel must stay on the position, strengthen
equipment inspection, closely monitor change of instruments, timely report to the shift leader and shift
supervisor. Different positions shall communicate information with each other, coordinate closely and obey
1.3 After the accident is treated, the on-duty personnel shall record the accident process and
treatment in the operation logbook and timely report to the upper level. If necessary, the original condition
2.1.1 When it’s found that internal pressure of deaerator rises, reduce the opening of admission
regulation valve, and find the cause and deal with it.
2.1.2.1 Drain tank drain pump trips, drain tank drain pump valve to the boiler boiler opens by fault and
drain tank lacks water. Check the drain pump, start standby pump, check that the valve to the boiler is
2.1.2.2 In case of loss of condensate or reduced condensate flow, contact with the driver for
treatment.
2.1.2.3 The steam water regulation valve fails. Change the regulation mode in a reasonable manner.
2.1.2.4 Other steam sources suddenly increase. If necessary, contact with relevant discipline to
2.1.2.5 When system valves change over, fault operation happens. Timely inspect and correct.
2.2.1 When it’s found that the internal pressure of deaerator reduces, suitable open the admission
valve wider. If the operation still doesn’t help, check whether the heating steam header pressure is normal;
if not, contact with the shift leader or relevant driver to increase the steam pressure properly.
2.2.2 Reduce the inlet water amount properly, maintain the deaerator at normal pressure, maintain
water level within the range, and then deal with the problem based on the cause.
2.2.3.1 If drain tank drain pump discharge water amount increases suddenly, reduce the opening of
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the regulation valve properly.
2.2.3.2 If the condensate is increased, increase the admission and maintain the normal pressure and
level.
2.2.3.3 If the LP drain pump water amount increases, reduce the opening of regulation valve properly.
2.2.3.4 If the heating steam header pressure reduces or the header ruptures, open the admission
2.2.3.5 If the steam pressure regulation valve fails, change the regulation mode properly.
2.2.3.6 If fault operation happens in case of system valve changeover, timely inpsect and correct.
2.2.3.7 If the safety valve operates, contact with the maintenance discipline.
2.3.1 If deaerator level increases, timely adjust the inlet water valve or admission valve. If the level
rises to upper limit of the water level gauge, open the high level drain valve to drain water and then deal
2.3.2.1 If the feedwater pump fails and trips, start the standby feedwater pump to ensure the water
supply.
2.3.2.2 If other water amount suddenly increases, find out the cause and implement suitable control.
2.3.2.3 If fault operation happens at the time of system valve changeover, timely inspect and correct.
2.3.2.4 If the valve core falls off, timely switch the system and notify the maintenance discipline.
2.4.1 If the deaerator level falls to the normal minimum value, open the water inlet valve wider and pay
2.4.2 Check if drain tank drain pump, condensate pump, LP heater drain pump, return watrer pump
2.4.3 When deaerator level drops to 1400cm, immediately report to the shift leader and shift
supervisor and deal with it based on the cause for reduced level:
2.4.3.1 If drain pump fails and trips, timely start the standby pump.
2.4.3.3 If the system valves operate by mistake, timely inspect and correct.
2.4.3.4 If the water pipe ruptures, immediately isolate the failed pipe.
2.4.3.5 If the condensate system fails, immediately notify the driver to deal with it.
148
Part V Operation of attemperating and pressure reducing device
Chapter I characteristics and relevant requirements on attemperating and pressure reducing device
attemperating and
attemperating and
149
Temperature after ℃ 155
attemperating and
pressure
temperature
manufacturer
attemperating and
attemperating and
attemperating and
pressure
Desuperheated water ℃ 51
temperature
1.3 The attemperating and pressure reducing device shall be provided with the following
1.3.1 Remote auto and manual pressure and temperature regulation device.
1.3.2 The low pressure side steam pipe shall be provided with security devices such as safety valve
which can drain all attemperated and pressure reduced steam flow. When there is no safety valve or the
safety valve doesn’t operate normally, the attemperating and pressure reducing device shall not be put into
150
service.
1.3.3 Pressure gauge and thermometer for high pressure and low pressure side steam.
1.3.4 Steam flow measuring device, pressure gauge, thermometer and flow device for
desuperheated water.
Chapter II Putting into operation, operation and stop of attemperating and pressure reducing
device
2.1 Preparation work prior to startup of attemperating and pressure reducing device
2.1.1 Check all meters are complete and reliable and the automatic pressure and temperature
regulation devices are complete and can be put into operation normally;
2.1.2 Confirm the maintenance work has been done and the site is clean and tidy;
2.1.3 Confirm that the safety valve operates normally, the auto, manual devices of protection
2.1.4 Steam temperature and pressure alarm devices at HP and LP sides are normal;
Iolation valve before and after attemperating and pressure reducing devic
2.1.7 The attemperating and pressure reducing regulation devices shall be manual position;
2.2.1 Start pipe warming of attemperating and pressure reducing device and open outlet motor-driven
valve of attemperating and pressure reducing device, slightly open the motor-driven steam admission
2.2.2 Control the admission regulaton valve, increase the pressure before admission regulation
valveto rated pressure within 5min and fully open the motor-driven admission valve.
2.2.3 Ensure 0.1~0.2MPa, warm the pipe for 20min, then increase the pressure to 0.8MPa within
2.2.4 Progressively put temperature regulation into operation (manual) based on temperature rise at
outlet of attemperating and pressure reducing device, to ensure normal outlet temperature.
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2.2.5 When attemperating and pressure reducing device outlet steam temperature is above 175ºC,
Outlet steam
0.98/0.65
pressure MPa
Outlet steam
200
temperature ℃
Desuperheated
2.2.7 The operation of attemperating and pressure reducing device is affected by the admission
parameters. Pay attention to the change of pressure and temperature at the HP side and pressure and
2.3.1 Contact with relevant positions, and prepare for stopping the attemperating and pressure
reducing device.
2.3.2 Change automatic regulation of pressure reduction and desupeheated water to manual
regulation;
2.3.3 Progresssively regulate the outlet steam pressure and temperature to maintain the parameters
stable; reduce opening of the pressure regulation valve to zero and reduce opening of the attemperating
2.3.4 When receiving the disconnection notifce, the on-duty personnel can close the pressure
reduced main steam valve and outlet steam valve. During disconnection operation, note to prevent
over-pressure of attemperating and pressure reducing device and timely open relevant drain valves of the
system.
Outlet motor-driven valve of attemperating and pressure reducing device, general valve of
desuperheated water, isolation valve before and after the attemperating and pressure reducing device;
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admission regulation valve of attemperating and pressure reducing device is opened slightly.
Motor-driven admission valve of attemperating and pressure reducing device, water inlet regulation
2.4.3 Drain valve of the system controls the discharge steam temperature not lower than 220ºC;
2.4.4 For the system instrument, automatic regulation devices, relevant protection facilities shall have
the same requirement on putting into operation with the above mentioned requirements.
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130 0.27 360 18.674
P t P t P t P t
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0.015 54.00 0.30 133.54 3.0 233.84 17.0 352.26
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Absolute Absolute Absolute
Vacuum Exhaust Vacuum Exhaust Vacuum Exhaust
pressure pressure pressure
-kpa temperature ℃ -kpa temperature ℃ -kpa temperature ℃
mpa mpa mpa
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