Steam Turbine Serious Faults

Operation Fault Tracing

Introduction Many of the criteria refer not only extreme

Many operating faults require the monitoring
staff to take immediate appropriate action if
serious reductions in the availability,
operating reliability and service life of the
turbine are to be averted.
The following criteria and instruction must be
included in the intensive schooling and
training program for the monitoring staff.
conditions requiring immediate action but
also to the trends of the process transients,
which must also be taken into consideration.
The turbine is in danger not only when the
specified limits of a process parameter are
reached but also when the process
parameter deviates markedly or rapidly from
the normal values otherwise observed.

Fault Cause Remedy

ƒ Other symptoms
Load rejection
ƒ Turbine generator remains
in operation after short
time rise in speed.
ƒ Excess steam from steam
generator is dumped to the
condenser through the
bypass valves.
ƒ Prolonged operation at
rated speed with or without
residual load.
Load rejection with turbine
trip
ƒ Turbine speed reaches trip
speed of overspeed trip.
Breaker opens as a result of
an internal or external fault.
Normal procedure
Beaker opens as a result of an
internal or external fault.
Control valves and extraction
valves closed by the turbine
governor to stop the steam
flow through the turbine.
Manual intervention is not
possible as automatic shut
down is too fast.
Reduce steam generator to
minimum output immediately, if
this is not done automatically
by the unit control.
Operation may continue
indefinitely.
Limits specified in 6.1-0101
must not be exceeded.
Set reference speed setter to
rated speed.
Reduce main steam
temperature or load turbine if
HP turbine exhaust steam
temperature approaches to
limits.
General rule: determine cause
of shut-down. Synchronize
generator if permitted by
results of fault tracing.
See also Turbine Trip.
Refer 6.2-0450.

BHEL, Hardwar 6.2-0410-00/1

 Fault Cause
ƒ Other symptoms
Adverse condition during load
rejection
Control malfunction
Turbine trip
ƒ Turbine trip by protective
devices
ƒ Turbine-generator unit in
imminent danger
ƒ Excess steam from steam
generator is dumped to the
condenser through the
bypass valves
Overspeed after load rejection.
Shaft displacement in thrust
bearing due to damage to
bearing.
Condenser vacuum reduced
due to fault in condenser plant.
Remote trip by protective
devices in steam supply
system, turbine or generator.
BHEL, Hardwar
Remedy
Investigate conditions, e.g.
load and speed prior to load
rejection.
Check control and attend
malfunction.
Stop and control valves and
extraction valves close.
Generator disconnected from
system by reverse power
protection relay.
Speed drops;
Auxiliary oil pump cuts in due
to loss of pressure as speed
drops, turning gear operation
commences.
Reduce condenser vacuum to
shorten coast down.
− Open vacuum beaker
− Stop air extraction
− Allow air to condenser
plant.
Reduce steam generator to
minimum output immediately if
this is not done automatically
by the unit control.
General rule: determine cause
of trip. See also 6.2-0450.
See load rejection with turbine
trip.
Inspect thrust bearing and, if
necessary, repair, see also
6.2-0421. Refer to fault tracing
instructions and eliminate fault.
Refer to relevant fault tracing
instructions and eliminate fault.
Refer to relevant fault tracing
instructions and eliminate fault.
6.2-0410-00/2
 Fault
ƒ Other symptoms
Reverse power protection
relay fails to open generator
breaker
ƒ Turbine control valves
closed by control as load
removed
The following parameters
exceed the permissible
limits even though remedial
measures have been taken
as prescribed in the relevant
fault tracing instructions
ƒ Vibration high
BHEL, Hardwar
Cause Remedy
Suspected that steam is still Attention: do not open
entering the turbine. generator breaker manually
(danger of impermissible
overspeed).
Check position of control and
extraction valves (Desired
position: 0%).
Trip turbine.
Observe closing of stop
valves, check steam pressure
in turbine, check output
display, reduce condenser
vacuum:
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant
Open turbine drains
Open drains between stop and
control valves
Shut down steam generator;
reduce steam pressure in
steam supply lines.
Fault in reverse power If reverse power protection
protection relay relay is not actuated by all or
some of the above mentioned
measures, it is very probable
that there is a fault in the
reverse power protection relay.
In this case, disconnect the
generator from the supply
system by opening the
breaker.
Use load limiting device to
reduce load on turbine
generator unit from any
operating mode to no-load
and/or shut-down unit by
actuating main trip valve.
See 6.2-0420 Reduce condenser vacuum to
shorten coast down.
6.2-0410-00/3
 Fault
ƒ Other symptoms
ƒ Casing differential
temperatures high
ƒ Bearing metal
temperatures high
ƒ Temperature differences
between parallel steam
supply lines high
ƒ Rapid, large drop in inlet
stream temperature
ƒ Condensate level in
condenser very high
Cause Remedy
See 6.2-0423 Note: The decision whether
the load limiting device should
be used to further reduce load
See 6.2-0421
before the main trip valve is
actuated will depend both on
the seriousness of the danger
and on the amount by which
the limits are exceeded.

The following parameters

exceed the permissible
limits
ƒ Inlet steam pressure high, Steam generator output too Reduce steam generator
pressures and duration of high output or increase turbine load
exposure to excessive
pressures limited as
specified in 6.1-0100.
ƒ Inlet steam temperatures Fault in steam generator Change steam generator
high. Temperatures and operation, eliminate fault if
duration of exposure to necessary.
excessive temperature
limited is specified in
6.1-0100.
ƒ Steam pressure upstream Load too high Reduce turbine load
of blading and/or extraction
steam pressure high. Irregularities in the turbine e.g. Measure stage pressures and
Pressures and duration of blade choking. compare with normal values
under identical operating
exposure to excessive
pressure limited as conditions.
specified in 6.1-0100. Measure internal efficiency.
ƒ HP exhausts temperature Reduce main steam
high during no-load or low temperature or increase
load operation. turbine load.
If these measure do not
reduce the temperature,
initiate turbine trip.
ƒ LP turbine exhausts Ventilation heating through Start injection into LP turbine
temperature high during no blading. or increase load.
load or low load operation.
ƒ Bypass stream Condenser vacuum low. Check condensate pumps.
temperature high during Injection water pressure too Reduce steam generator
bypass operation low. Bypass steam flow rate output.
too high.

BHEL, Hardwar 6.2-0410-00/4

 Fault Cause Remedy
ƒ Other symptoms
Control valve or stop valve
fails to open again after
testing with automatic
turbine tester
ƒ All measures as Fault in valve or turbine tester. The turbine plant may be
prescribed in 6.2-0455 fail. operated with defective valve
for max.1 week.
If necessary, the output must
be reduced so that the limits
as prescribed in 6.1-0100 are
not exceeded.
Drain steam line upstream and
downstream of defective valve
thoroughly.
Observe limits for temperature
difference between parallel
steam supply lines.
Shaft assembly runs down
without lubricating oil
ƒ Fault in auxiliary and Check bearing metal
emergency oil pumps. temperatures, if impermissibly
Jacking oil pumps in high, inspect bearings.
operation
ƒ Fault in jacking oil Danger of bearing whipping.
pump(s). Check bearing metal
temperatures. Check bearings.
Fire or fire hazard during Set off fire alarm. Follow fire
operation protection rules. if
necessary, initiate fire
fighting measures.
At the same time:
ƒ Escape of control fluid Leakage in piping or other Press fire protection
turbine components pushbutton 1
or
Switch off sub-loop control for
the control fluid pumps
immediately and shut-down
(operating) pump (result:
turbine generator unit trips).
ƒ Escape of oil from the Leakage in piping or other Press fire protection
lubricating oil system turbine components pushbutton 2 (pressing fire
protection pushbutton 2
automatically initiate fire
protection 1 measures), result:
turbine generator unit trips.

BHEL, Hardwar 6.2-0410-00/5

 Fault Cause Remedy
ƒ Other symptoms
or
Shut down turbine generator
unit. Depressurize control fluid
system (measures as above).
Switch off sub loop control for
jacking oil pumps.
Start up jacking oil pumps.
Switch off subloop control for
auxiliary oil pump. If
necessary, shut down auxiliary
oil pump(s). Check to ensure
that subloop control cuts-in
emergency oil pump as oil
pressure drops. Close turning
gear oil valve. Reduce
condenser vacuum to shorten
coast down.
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant
ƒ Shaft comes to a standstill Shut down DC lubricating oil
when fire protection pump. Keep jacking oil pump
measures are initiated in operation if no leakage from
the jacking oil system.
Turn shaft through 180 degree
at intervals of approx. 10
minutes. For treatment of
turbine after complete
standstill shaft see 6.2-0460.
Eliminate leak and perform
hydrostatic pressure test.
Acknowledge initiation of fire
protection measures.
Restart lubricating and control
fluid system.
Commence turning gear
operation.
Replace insulating materials
soaked with escaped fluid.
Start up turbine generator unit.

BHEL, Hardwar 6.2-0410-00/6

 Fault
ƒ Other symptoms
Fire or fire hazard during
turning gear operation
ƒ Escape of control fluid
ƒ Escape of oil from the
lubricating oil system
ƒ Escape of oil from the
jacking oil system
Lubricating or control fluid
loss annunciated by level
monitoring circuit
ƒ Separate control fluid
system
Alarm: fluid level low or very
low (2-out-of-3)
ƒ Oil system
Alarm: oil level low
ƒ Oil system
Turbine trip due to oil level
very low (2-out-of-3)
BHEL, Hardwar
Cause Remedy
Set off fire alarm.
Follow fire protection rules.
If necessary, initiate fire
fighting measures.
Leakage in piping or other Measures as for fire or fire
turbine components hazard during operation.
Leakage in piping or other Jacking oil pump stays in
turbine components operation.
Close turning gear oil valve.
Switch off sub-loop control for
auxiliary oil pumps.
Shut down auxiliary oil pumps.
Check to ensure that, sub-loop
control cuts in the lubricating
oil pumps as oil pressure
drops. For further measures
see: Fire or fire hazard during
operation.
Leakage in piping or other Shut down jacking oil pump
turbine components (risk of bearing damage is
minor if turning gear stays in
operation).
Isolate and eliminate leak.
Start up jacking oil pump.
The system must be checked
immediately for leakage if this
alarm is generated in rapid
succession. A leak must be
assumed and appropriate fire
protection measures taken.
The system must be checked
immediately for leakage if this
alarm is generated.
Fire protection measures
initiated automatically.
Note: The trip system is
inoperative during turning gear
operation.
6.2-0410-00/7
 Fault Cause Remedy
ƒ Other symptoms
Escape of steam Leakage in piping or other Isolate steam leakage area
turbine components immediately and depressurize
system concerned, if possible.
If there is a rupture hazard
(pre-rupture leak), shut down
turbine generator unit
immediately.
Carefully consider risk of
erosion at sealing surfaces
and decide on time of shut
down.

Earthquake Unload and shut down turbine

generator unit rapidly.
Observe response on bearing
and shaft vibrations.
If necessary, check bearings
and alignment.
Check valve supports.
Check pipe hangers and tank
supports.

BHEL, Hardwar 6.2-0410-00/8