OPERATION & MAINTENANCE MANUAL

For

KHARTOUM NORTH POWER STATION-

PHASE III (2×100MW) PROJECT

Section 04

Section Name: Steam Turbine Body Equipment

Volume 02

Volume Name: Steam Turbine Operation

Document No. KNPS-OM0402

Version G

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 Table of contents

1 .   SUMMARY OF STEAM TURB INE STARTUP ................................................................................. 3 

1.1  S TA R T U P M E T H O D S AND T I M E R E Q U I R E M E N T S  ................................................................................ 3 

1.2  S TA R T U P T I M E R E Q U I R E M E N T S : ............................................................................................................ 6 
1.3  S TA R T U P S T E AM P A R A M E T E R S : ............................................................................................................. 6 
1.4  S T E A M T U R B I N E S A F E T Y M O N I T O R I N G S Y S T E M  ............................................................................... 6 

2  STEAM TURBINE STARTUP ....................................................................................................................... 8 

2.1  GENERAL RULES FOR STEAM TURBINE STARTUP ........................................................................................... 8 

2.2  BASIC REQUIREMENTS BEFORE UNIT STARTUP .............................................................................................. 8 
2.3  CONDITIONS FORBIDDING STEAM TURBINE STARTUP ..................................................................................... 8 
2.4  PREPARATION BEFORE STEAM TURBINE STARTUP: ....................................................................................... 9 
2.5  PREPARATION BEFORE BOILER IGNITION: ..................................................................................................... 10 
2.6  PREPARATION AFTER BOILER IGNITION: ........................................................................................................ 11 
2.7  COLD STATE STARTUP OPERATION OF TURBINE .......................................................................................... 13 
2.8  PRECAUTIONS DURING ROLLING, SPEED-UP, AND LOAD-INCREASING: ....................................................... 15 
2.9  WARM STATE AND HOT STATE STARTUP OF TURBINE .................................................................................. 17 

3  TU RB INE SHUTD OWN......................................................................................................................... 19 

3.1  SELECTION OF TURBINE SHUTDOWN MODE ................................................................................................... 19 

3.2  MAINTENANCE AFTER TURBINE SHUTDOWN .................................................................................................. 21 

4  STARTUP  AN D  S HU T DOW N  D R AWI N G S O F U NI T ............................................................................... 23 

Appendix 1 Startup and shutdown curves of unit

Appendix 2 43A.000.1J(D)(B)-3 Thermal characteristics from HTC

Appendix 3 43A.000.5SM(B)-3 Turbine startup & operation instructions from HTC

Appendix 4 43A.504SM(B)-3 Instruction of LP spray from HTC

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1. Summary of Steam Turbine Startup

As conditions of unit are different, steam turbine startup can be divided

into different states. The division is aimed at determining the mode and
speed of steam turbine startup to get the fastest speed and economical
effects. Based on different temperatures of the rotor, unit startup can
be divided into four types: cold state, warm state, hot state and
super-hot state.

1.1 Startup Methods and Time Requirements

Divide by the metal wall temperature at the upper casing of governing stage

(1) Cold state startup (shutdown for more than 72 hours), metal temperature of
casing is lower than 40% of full-load temperature of this measuring point; (150℃) 300 times

(2) Warm state startup (shutdown for 10～72 hours) metal temperature of casing
1000 times
is about 40%～80% of full-load temperature of this measuring point; (150-300℃)

(3) Hot state startup (shutdown within 10 hours) metal temperature of casing is
6000 times
higher than 80% of full-load temperature of this measuring point;(above 300℃)

(4) Super-hot state startup (shutdown for less than 1 hour) metal temperature of
casing is close to the full-load temperature of this measuring point; (above 400℃) 300 times

(5) Load step (>10%T-MCR) 12000 times

There are three startup modes on DCS: cold state, hot state and
super-hot state.

1.1.1 Startup Operation Mode: (no reference)

DEH－ IIIA has three basic operation modes: operator automatic

operation (auto)—this is main operation mode; remote automatic
operation and manual operation.

1) Operator automatic operation (auto)

Operator automatic operation is called auto for short, and this is

the main operation mode for operator in power plant to control
turbo-generation unit. Under this mode, operator can make the
following controls:

a During speed rising period of turbine, the rising speed rate and target value
of rotary speed of turbo-generator unit can be confirmed or modified.

b When unit reaches to synchronous rotary speed, put “auto synchronous”

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 into service.

c After synchronization of unit, modify the target value and load changing
rate of unit at any time.

d Decide whether to put power feedback loop and governing stage pressure
loop into service according to the real operation condition.

e After synchronization, put rotary speed loop (primary frequency regulating)

can be put into service.

f Remote operation can be put into service.

g LP Extraction control (put it into service when load is more than 12 MW

and HP Extraction control put it into service when load is more than 30 MW
and shut down when load is less than 20MW).

2) Remote-control operation

Usually, remote-control operation is put into service under

operator auto mode. Once it is under remote-control mode, target
value of DEH is decided by remote control source and load is
controlled by DEH according to remote control command. But
operator can press remote key to quit remote control at any time.

a Automatic synchronization

Automatic synchronization is a special remote-control operation. Under

this mode, target value and set value is adjusted by the input of contacts of
automatic synchronization increase and automatic synchronization
decrease until turbo-generator reaches synchronous rotary speed, and
makes preparation for synchronization of unit. To adopt this remote mode,
the control system should meet the following requirements:

a) DEH is in “auto” mode.

b) DEH is in “HP governing valve” control mode.

c) Main transformer circuit breaker is disconnected (no

synchronization).

d) Automatic synchronization allows contact to close.

e) Turbine rotary speed is in synchronous scope.

At this time, operator presses “automatic synchronous”, light of this key will
be on, which indicates that the above conditions are satisfied, and control
system is in this control mode. DEH changes target value according to the
increasing contact and decreasing contact sent out by synchronous device,
and operator can not change the target value and lifting speed rate by
keyboard.

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 During operation period of this mode, if main transformer circuit
breaker closes or “automatic synchronous control permission” contact
disconnects, control system will switch from “auto synchronization” to
“operator auto”. If control system switches to “manual operation”, “auto
synchronization” operation mode will terminate automatically.

b Remote control (coordinate) mode

Coordinating control is the uppermost remote control mode of DEH device.
To adopt this mode, the following conditions should be satisfied:
a) DEH must operate under auto mode.

b) G-C.B must be closed.

c) Remote control permission contact must be closed.

After the above conditions are satisfied, operator presses “remote control”,
the light of key will be on, which indicates that control device has been put
into coordinate control mode, and “remote control input” contact is sent to
CCS control device, which indicates DEH can receive increasing and
decreasing load pulse from CCS. At this time, operator can not change
target value of load and variable load rate. Once target value reaches
upper limit and lower limit, DEH will also send “remote control upper limit
locking” or “remote control lower limit locking” contact signal to CCS device,
and limit set value of DEH, at this point, resending pulse is useless.
Generally, when put CCS control into service, the power and regulating
stage pressure loop of DEH are cut off, DEH becomes valve position
control device that only put into primary frequency modulation
loop, and CCS finishes closed loop control.
During coordinate control period, when oil switch or remote control
permission contact disconnects, DEH will turn to “auto mode” immediately.
Operator can press “remote control” to quit “remote control” mode, and
enter “auto” to operate.
3) Manual operation of turbine

When the basic computer control, such as DPU11 and DPU31 are
failure, or VCC has partial failure, then DEH will switch to manual,
and “manual” light on hard operation disc will be on. At this time,
operator should switch “auto/manual” key switch to “manual”
position.

When DEH controller is in “manual”, if operator is required to

switch from “manual” to “auto”, he should firstly inspect whether
DPU11, DPU31, VCC part and MCP are normal on display. If there
is no alarm, switch key switch to “auto” position, and upgrades to
“auto” mode by “auto” button. The above upgrades are often
carried out after unit synchronization and on load. During speed
rising step, rotating speed can not be controlled precisely by open

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 loop control, so it is not recommended to cut off the manual
control. If there are any faults or emergency situations, switch to
“manual”, when the actual rotating speed drops below 2800r/min,
put the “auto” into operation again to prevent over-speed.

Button of manual operation is divided into “HP governing valve

increase” and “HP governing valve decrease”. Press any key, the
key light will be on, and then the positions of relevant valves can
be monitored on hard operation disc strip table or pictures of
“valve command and feedback”.

1.2 Startup Time Requirements:

(a) Cold state startup ≤360 minutes

(b) Warm state startup ≤160 minutes

(c) Hot state startup ≤25 minutes

1.3 Startup Steam Parameters:

Unit Cold state Warm state Hot state Super-hot state

Main steam Mpa(a) 1 4 5.5 6.7

pressure

Main steam ℃ 280 400 480 535

temperature

Rated flow of main t/h 41 35 33 30

steam

1.4 Steam Turbine Safety Monitoring System

Monitoring parameters of this system include:

a) Monitoring of the unit’s rotation speed.

2) Monitoring of the unit’s zero rotation speed which causes automatic barring.

3) Monitoring of the rotor’s axial movement: used to monitor the axial movement of
the rotor’s thrust plate from the thrust bearing.

4) Monitoring of axis eccentricity (bending): used to monitor the peak of rotor

eccentricity: peak value and instantaneous value.

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5) Monitoring of unit expansion: used to monitor absolute expansion of the cylinder
and axial expansion difference between the rotor and cylinder (expansion
difference).

6) Monitoring of the unit’s axial vibration,

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2 Steam Turbine Startup

2.1 General Rules for Steam Turbine Startup

The following work should be hosted by the chief engineer or production manager
and attended by the production director and engineer:

1) Startup after unit overhaul

2) Steam turbine speed governing system test

3) Steam turbine over-speed test

4) Main machine load-rejection test

5) Equipment startup after great improvement or the first trial-operation about new
technology.

Notice: The detailed steps of tests which need to be done at the time of unit startup
and stoppage are shown in the volume 4 of this book.

2.2 Basic Requirements Before Unit Startup

1) All the working permits about maintenance have been finished for 36 hours
before startup. (24 hours after repairing).

2) Before startup, operators should be familiar with the change of equipment and
system.

3) Equipment at site should be clean, the nameplates of equipment and valves are
intact, hole covers are intact and well, the insulation is good and there is no
foreign matters obstructing the operation. All the lightings are well.

4) Turbine oil passes the test by oil group with test report. If the oil does not meet
the requirement, it is not allowed to fill in governing system.

2.3 Conditions Forbidding Steam Turbine Startup

1) When emergency governor acts abnormally, HP automatic main stop valve,

governing valves or extraction check valves are jammed or can not be closed
fully;

2) When obvious friction sound exists in rotary part of turbo-generator unit;

3) When speed governing system can not maintain the operation of turbine
without load, or after unit rejects load, it can not maintain the rotating speed
below the one at which emergency governor is actuated;

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 4) When main shaft vibration value is 0.02mm bigger than the original value (the
original swinging value in balanced state of rotor temperature is not more than
0.05mm);

5) When auxiliary oil pump, jacking oil system and turning gear device are
abnormal;

6) When EH oil or turbine oil is not qualified, and the oil temperature is lower than
the normal (after oil system is full of oil);

7) When insulation is not intact;

8) When main instruments (such as axial displacement, relative expansion,

tachometer and important metal thermometer, main steam pressure condenser
vacuum meter and thermometer, etc.) fail;

9) When the temperature between upper and lower casings of turbine governing
stage area exceeds 50℃.

10) When the static test of governing and emergency trip system does not meet the
requirement.

11) When vacuum of steam turbine can not keep at -0.067KPa.

2.4 Preparation Before Steam Turbine Startup:

1) After receiving turbine startup order, the turbine operator should fill the
operation permit carefully and contact with other operators related to this unit to
come to the site.

2) After all maintenance work has finished, all working permits have been taken
back with the detailed maintenance procedure listed.

3) All the covers for channels, pits, orifices and holes should be in good condition,
firm and reliable. Inflammable materials on site should be cleaned up; the
temporary safety facilities should be removed; the insulation of pipeline and
equipment should be good; the site should be clean and the road should be
smooth; lighting should be fine and communication equipment should work
well.

4) Prepare the instruments, tools and all kinds of record paper for startup.

5) Inform chemical water workshop to prepare enough qualified demineralized

water. The oil and the circulating water in cooling tower should be qualified after
test, and the water level should be normal, and then start up the demineralized
water pump to make up water to RFT and head water tank.

6) Put the circulating water system and closed cooling water into operation and

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 make sure the circulating water pressure in main workshop is normal, there is
blockage in mechanical part of dynamic equipment, and the lubricating oil of bearing,
cooling water and bearing sealing water are good.

7) Contact with I&C part to energize all protections, instruments, motor operated
valves and governing valves.

8) Cooperate with I & C operators to check whether the set points of all protections
and alarm signals are correct, and the action tests to motor operated valves and
governing valves are normal.

9) Contact with electric part, energize every motor after they passed insulation
tests, and the ‘interlock’ switches of all electric power equipment should be in
‘off’ positions.

10) Cooperate with I&C and electric operators to carry out the trial operation to
electric power equipment normally and with correct rotating direction. Interlock
test is correct and interlock test for 6KV electric power equipment only needs
static test.

11) Confirm that DCS, ETS and DEH work normally; display of LCD and alarm
correspond with the real-state meter of equipment.

12) Check whether leakage occurs in oil system, oil tank, oil pipes and oil cooler;
the level in oil tank is normal, the oil discharged valves of oil tank and oil cooler
close tightly; the inlet and outlet oil valves of oil cooler are in ‘open’ position; the
AC and DC electric lubricating oil pumps and HP startup oil pumps are standby.

13) Motor-operated main gate valves and other bypass valves are in ‘close’
position;

14) Auto main steam valves and governing valves are in ‘close’ position;

15) Drain valves of pipeline and casing proper are in ‘open’ position;

16) Each check valve of steam extraction pipeline is in ‘close’ position;

17) Inlet oil temperature of bearing is no less than 35℃；

18) Valves of EH oil resource are in right status, oil temperature rises above 20℃,
and the pressure of EH oil system is adjusted to 14MPa.

19) Start the bypass EH oil system.

20) Start the instrumental FGD air compressor.

2.5 Preparation Before Boiler Ignition:

1) Put generator cooling system into operation;

2) Start up lube oil vapor extraction fan;

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 3) Start up AC lubricating oil pump to make lubricating oil system began to
circulate;

4) After oil circulation is maintained for 10 minutes, start up HP oil pump;

5) Start up jacking oil pump. Check whether jacking oil pressure of each bearing is
normal, and then put turning gear into operation, measure the vibration degree
of main shaft and listen to the sound of unit inner part (it should be put into
operation before 2 hours in cold state and 4 hours in hot state);

6) Strictly check the structure and parameters of oil system, or it may cause
serious accident;

7) Check whether the protection system is normal;;

8) Start up one condensate pump and open the recirculation valve;

9) Put the attemperating water of steam exhaust casing into service;

10) Start up vacuum pump to vacuumize, when vacuum reaches below -15KPa,
open all drain valves of pipeline and proper.

2.6 Preparation after Boiler Ignition:

1) Start up one feed water pump;

2) Increase the temperature and pressure after boiler ignition;

3) When main steam pressure reaches 0.98MPa and temperature reaches 250℃,
send steam to gland seal. Steam conveying pressure is 30～50Kpa and
temperature is 150℃.

4) Put the gland seal system into operation.

a These should be noticed when supplying steam to gland seal: for cold state
startup, extract the vacuum before supplying steam to gland seal; for hot
state startup, supply steam to gland seal before extracting vacuum.

b For super-hot state startup, it’s better to use main steam as gland seal
steam resource.

c Start up one gland seal vapor fan, the other is in “auto” position.

d Adjust the steam supply main pipe pressure of gland seal in the range of
0.101～0.127Mpa（a） ，check whether there is steam leakage at gland seal
port; do not extract steam too much. The steam temperature of gland seal is
about 150℃. If it is above 180℃, put the attemperator of gland seal into
operation with auto position.

e When steam temperature in main pipe of gland seal reaches above 125℃,

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 close all drain valves in gland seal system.

5) After warming the pipes in bypass, put the bypass system into operation
according to the requirements to boiler.

6) LP heater is started up sliding with turbine.

7) Contact with I&C operator to put the following protections into operation:

Over-speed, axial displacement, expansion difference, high returned oil

temperature of bearing, bearing vibration, low lubricating oil pressure and DEH
fault.

8) DEH panel inspection

a Auto main stop valves, governing valves are in close position;

b Indicating light of turning gear is on, and it shows that its rotating speed is
4.6r/min;

c Indicating light of trip is on;

d Auto/manual key switch is at ‘auto’ position;

e Over-speed protection key switch is at ‘run’ position;

f ‘Single valve control’ light is on;

g ‘Power feedback signal run’, ‘pressure feedback signal run’ are at ‘quit’
position, ‘rotating speed feedback signal’ is at ‘run’ position; the power
points at 0;

h Quit all TPC modes.

i “Emergency shutdown” button and “remote shutdown” button are normal.

9) DCS panel inspection

a Confirm all the drain valves from the turbine proper to its drain flash tank are
open, the water flow of HP and LP heaters are normal; LP drain system
adopts self-flow mode stage by stage, and emergency drainage
motor-operated valves of all heaters are in “auto” position.

b Check whether LP casing water spray valve is in “auto” position, the

condensate water pressure is normal, and the condensate water
recirculation valve is in “auto” position.

c Check whether the water level in hot well of condenser is in “auto” position,
and it is normal.

d Check whether the recirculation valve of feed water pump is in “auto”

position.

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 e Drain valves of turbine proper and main steam pipe are controlled at “auto”
mode and in “open” position.

f Check the pressure of pneumatic control steam source is normal.

2.7 Cold State Startup Operation of Turbine

2.7.1 Conditions before turbine startup:

1) Main steam pressure is 0.98MPa, and main steam temperature is 250 ℃;

2) The oil temperature is 40-45 ℃; the lubricating oil pressure is

0.098±0.0196MPa; the governing oil pressures: the EH oil pressure is 14±0.2
MPa and turbine oil pressure is 1.96±0.1MPa;

3) Condenser pressure is 60-65kPa;

4) Turning gear is in normal operation, and the duration of turning gear should be
no less than 2 hours;

5) The vibration value of main shaft should not exceed 0.02mm of the original one.

2.7.2 Steam to set , Speed-up, Warm-up and Constant Speed

1) Put turbine protection device into operation before rolling.

Put main machine protection device into operation before rolling (do not put the low
vacuum protection and generator tripping protection into operation until
normally start up the unit).

2) Put the attemperator of steam exhaust casing into operation.

3) Rolling operation is as follow:

a After receiving the rolling order from shift leader, inform boiler, electric,
chemical, and turbine department to prepare for rolling.

Latch and Steam to set:

b After turbine satisfies the rolling condition, namely, when the steam pressure,
temperature and vacuum are satisfied, turbine will latch.

c Before latching, DEH should be in “auto” status. The ‘auto’ and

double-device running on DEH panel and the parameters such as rotating
speed power etc. on LCD indicate correctly. DEH is in normal status.

d When latching, it is better to monitor the valve position drawing on LCD.

e Enter OIS “auto. control” interface, press ‘turbine latch’ button with mouse,
or latch turbine through ‘turbine latch’ button on operation panel, the OIS
interface will display ‘turbine latch’, the original ‘shutdown’ (in red color) will

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 disappear, the light of ‘turbine latch’ on operation panel will be on and the
light of ‘shut down’ will be off.

f Reset ETS to energized the AST solenoid valve

g After reset ETS, the HP main steam stop valve will be opened.

h After latching, the valve limit becomes 100 automatically, which indicates the
valve can be opened.

i Press VALVE MODE to select GC and SINGLE valve.

j Press ‘target value’, input the target value with the number keys, namely,
press the target value and SP rate, then press ‘input’ key, meanwhile, keep
the light on.

k Press ‘GO; key, turbine will roll automatically.

l Set the target value of rotating speed as 500 rounds and the speed-up rate
as 100r/ min。

m After the unit is rolling, check that the turning gear should trip automatically
(otherwise the emergency button should be pushed immediately).

n raise the rotating speed of turbine to 500r/min by 100r/min speed-up rate，

check the unit completely under this speed, warm up turbine for 5 min.
When the turbine speed rises at 200r/min, stop the jacking oil pump
automatically.

o After everything becomes normal, increase the rotating speed to 1350r/min

by 100 r/min speed-up rate, and warm up turbine for 20 min.

p After warm up turbine with intermediate speed, increase the speed to

2500r/min with 100 r/min speed-up rate, warm up turbine for 10 min.

q Set the target value at 3000r/min，increase the rotating speed to 3000r/min

with 100 r/min speed-up rate, warm up turbine for 10 min, then check turbine
completely. Meanwhile, adjust the bypass according to the requirements to
boiler, and try to keep main steam pressure stable until bypass system is
closed completely.

r Do the test of pushing the emergency button, check whether main stop
valves, governing valves, and extraction check valves can be closed
normally; reset them after finishing the test.

s Check that the main oil pump can work normally; shut down the operation of
HP startup oil pump.

t The temperature of exhaust steam does not exceed 80℃，the vacuum is

above -0.0863Mpa and put the low vacuum protection into operation.

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 u After the unit speed is stable, make a complete inspection and make ensure
that everything is normal; carry out each relevant test according to the test
requirement on governing and emergency trip system; after the test meets
the requirement, the unit can be synchronized and run with load.

v Do the oil spray test after the temperature behind governing stage is beyond
150℃ and the unit operates without load for 30 min, or according to the real
situation on site. The over-speed test of emergency trip governor should be
carried out after the unit with 40% of rated load and warmed up for 2~4
hours. Make sure the rotor temperature is 70℃ higher or lower than the
material critical temperature.

2.7.3 Synchronization and On Load

1) After the unit speed is stable and the unit passes all the inspections and tests,
send the signal of allowing synchronization to electric department according to
the shift leader’s command.

2) After synchronization, keep the steam pressure of boiler stably; increase the
load by opening up the governing valves until fully open. Firstly, carry the initial
load about 5MW, and then raise the pressure and temperature of boiler
according to sliding parameters cold-state startup curve, consequently, the load
will increase and the detailed process is as follow:

0MW→10MW： 30min

10MW warm up 20min

10MW→40MW： 80min

40MW warm up： 40min

40MW→100MW： 82min

3) The stages of synchronization and on load stage are carried out under control
of DEH system as well as rolling and speed-up stages.

2.8 Precautions during Steam to set, Speed-up, and Load-Increasing:

2.8.1 Notices during Steam to set and Speed-up:

1) During the process of warm-up and speed-up, listen to the sound in the turbine
frequently, and assign special staff to measure the vibration. Check that the
metal temperature, bearing bush and thrust bearing temperatures, returned oil
temperature, casing expansion and expansion difference are normal. Push the
emergency button immediately when the bearing pad vibration exceeds 40 μm
and the rotating speed below 1350r/min, or when the bearing bush vibration
exceeds 50 μm and the rotating speed is higher than 1350r/min. When passing

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 the critical rotating speed, the bearing cover vibration should not exceed
0.05mm (the first stage critical rotating speed of each rotor in the shafting under
elastic supporting: HP: 2009r/min;LP:1573r/min;generator rotor ： 975r/min).
Otherwise, shut down turbine and find out the reasons. It is strictly forbidden to
warm up by the critical rotating speed and by low speed. During startup process,
if the unit is shut down due to exceed vibration limitation, return to the turning
gear state. Restart the turning gear no less than 4 hours after start up
conditions are satisfied.

2) When unit starts up in cold state, record all the warm-up rotating speeds and
the metal temperature at the lower governing stage of the HP inner casing with
load as the basis for restarting up the unit after shutdown;

3) When steam to set parameters reach to the set points, roll immediately. During
rolling, the steam temperature and pressure should not increase or decrease
greatly, keep the superheating degree of main steam temperature above 50℃,
otherwise contact with boiler operator to make adjustment and adjust the
bypass according to the requirements to boiler.

4) When the turbine shaft speed is 500r/min, 1350r/min, 2500r/min and 3000r/min,
measure vibration of three directions of bearing respectively. During speed-up
or load-increasing process, if abnormal condition occurs, push the emergency
button and trip immediately, or decrease the rotating speed a little, or decrease
the load until the vibration is normal.

5) During speed-up process, operators can set the target rotating speed by
“target/setting” button on “auto control” menu by OIS according to the changes
of casing temperature, casing expansion and expansion difference, select the
suitable speed-up rate by ‘speed rate’ button to interfere, then press ‘run/hold’
key on OIS “auto control” menu and set it in ‘run’ state, DEH will get close to
target value with the selected speed-up rate and finally become stable at the
target value to warm up.

6) The exhaust steam temperature in LP casing should not exceed 80℃.

7) Pay attention to water levels in condenser, heater and deaerator, and make
adjustment in time.

8) During speed-up process, notice that there is no water shock in turbine and
pipeline, avoid cold water and cold steam entering turbine, and adjust the main
pipe pressure of seal steam to avoid gland seal steam stopping steam and
letting cold air in.

9) Pay attention to the condenser vacuum; adjust air temperature of generator and
outlet oil temperature of oil cooler in time.

10) After synchronizing, all LP heaters can be put into operation, the drain water is

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 back to condenser, and LP heater is started up in sliding mode with turbine.

2.8.2 Precautions during Load-Increasing Process:

During load-increasing process of unit, when the bearing bush vibration reaches
50μm and confirms it locally, stop increasing load, decrease load until the vibration
is less than 50μm, and then continue to warm up the turbine. If load is falling to
lowest, and vibration still exceeds 50μm, push the emergency button, put turning
gear into operation and find out the causes. After the startup conditions are satisfied,
turning gear should be operated for no less than 4 hours before starting again.

2.8.3 Control the following upper limit value during the process of speed rising and
load increasing:

Temperature rising rate of main steam is 2.5℃/min.

Temperature rising rate of main steam pipe wall is 7℃/min.

Temperature rising rate of HP main stop valves and governing valves is 5℃/min.

Temperature rising rate of casing and flange metal 2.5℃/min

Temperature difference between upper and lower casings should be no more than
50℃

Temperature difference between left and right flanges is 15℃

Temperature difference between upper and lower flanges is 20℃

Temperature difference between casing and the inner and outer walls of flange is
80℃.

Temperature difference between flange and casing is 80℃.

Temperature difference between the intermediate wall of outer casing and bolt is
50℃.

The relative expansion of HP casing should not exceed +5.0～-2mm.

The relative expansion of LP casing should not exceed +9.0～-6.0mm.

2.9 Warm State and Hot State Startup of Turbine

2.9.1 The division of warm state startup and hot state startup of steam turbine and
steam to set parameters

1) Main steam is in super-heated state, the temperature is 50～100℃ higher than

the hottest metal part of turbine.

2) The superheating degree of live steam is higher than 50℃.

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 3) The vibration degree of main shaft should be the same as that of cold state
startup.

4) The temperature difference between upper and lower HP casings is within

50℃.

5) The expansion difference of HP and LP casing is in the allowable range.

6) The eccentricity of rotor of shaft should not exceed 0.05mm.

2.9.2 Precautions

1) After put the turning gear into operation, supply steam to gland seal firstly, and
then vacuumize.

2) When the pressure of condenser reaches -75kPa, ignite boiler, and put the
bypass system into operation according to the requirements of boiler.

3) Before rolling turbine, the pressure of condenser is kept within 60～65kPa.

4) After the conditions for hot state startup rolling are satisfied, open the proper
drain valve, put the attemperator of exhaust steam casing into operation, DEH
system opens the automatic main stop valves and governing valves impact the
rotor to rotate.

5) After the speed has increased to 500r/min under control of DEH system, warm
up the turbine for 5min with low speed, check the turbine and notice the sound,
after make sure that there are no abnormal situations, raise the speed to
3000r/min.

6) Under the constant speed, the unit is synchronized and runs on load, speed up
the process that increasing load to metal temperature in lower part governing
stage region of HP casing during shutdown of last time, and later process of
load increasing can be continued to conduct according to the procedure of cold
state startup.

7) The main stop valves and governing valves, etc will be cooled rapidly after
shutdown, at the initial stage of hot state startup, pay attention to the
temperature rising speed of these parts so as to avoid quick heating.

8) During the speed-up process, the vibration of unit should be taken special
notices, if the vibration increases obviously, push the emergency button to shut
down the turbine. Determine whether to start up again after ascertaining the
causes.

9) As for hot start up curve, refer to drawing 6 in appendix 1.

18
3 Turbine Shutdown

3.1 Selection of Turbine Shutdown Mode

3.1.1 Sliding parameters shutdown (the temperature and pressure slide drop at the
same time)

1) Test the AC lubricating oil pump, DC lubricating oil pump, jacking oil pump and
turning gear device before shutting down the turbine.

2) Boiler decreases temperature, pressure and load according to the sliding

shutdown curve. As the steam parameter decreases, open the governing
valves to full opening gradually, firstly decrease the load to 75MW, when the
steam temperature decreases to 515℃ and the unit maintains running stably
for 15min, measure its vibration, after the metal temperature of HP casing
decreases, continue decreasing the temperature and pressure according to the
sliding parameters shutdown curve, consequently, the load will drop.

3) When the load decreases to 30MW, open condensate recirculation water valve.

4) When main steam temperature decreases to 350℃, open the drain valves of
guide steam tube, casing and steam extraction pipeline.

5) Put the attemperator of exhaust steam casing into operation according to the
temperature in exhaust steam chamber so as to ensure the temperature is
below 350℃.

6) According to the requirement of boiler, make preparation for rapid load drop.

7) When main steam pressure decreases to 1.471MPa, temperature decreases to

260℃, reduce the load to zero, and after disconnection of generator, push the
emergency button to shutdown.

8) Record the coasting time of rotor, and check whether the main stop valves and
the regulating valves are blocked and closed tightly, and return the trigger valve
to zero level.

9) Start up the AC lubricating oil pump, when the rotating speed drops below
200r/min, start the jacking oil pump. After the main shaft stops, put the turning
gear into operation and record the vibration degree of main shaft.

10) Run the turning gear continuously until the temperature of the lower half inner
wall of HP casing drops below 250℃, then turn it 180° every 30min (or turning
continuously) until the casing temperature is lower than 150℃, and then stop
the turning gear.

11) Stop the condensate pump when the temperature in exhaust steam chamber is

19
 lower than 50℃

12) Precautions during the process of sliding shutdown:

a The drop speed of main steam temperature should not be more than
1.5℃/min；

b The drop speed of main steam pressure is 0.049～0.098MPa/min；

c The temperature difference between the HP casing wall and flange should
be not more than 40℃，other temperature difference limits are the same as
those during start-up.

d The superheating degree of main steam should be above 50℃;

e When the main steam temperature is 35℃ lower than that of lower half inner
wall of HP casing, stop decreasing temperature and pressure;

f When the relative expansion value between HP and LP casing is close to

the allowable value, stop decreasing temperature, pressure and load.

g As for sliding parameters shutdown curve, refer to fig.2 in appendix 1.

3.1.2 Rated Parameters Shutdown:

1) The preparation work for shutdown is the same as that during sliding shutdown.

2) Decrease the load by the speed of 5MW/min, and make sure that the relative
expansion between rotor and casing does not exceed the specified value.

3) The steam seal adjustment should be controlled by operators if necessary.

4) Decrease the load according to the condition of boiler.

5) During the process of load decreasing, regulate the supply steam pressure of
gland seal, the hot water level of condenser and the oil temperature and
pressure timely.

6) Take notice to the changes of the expansion difference between HP casing and
LP casing, if it increases to the negative value, slow down the load decreasing
speed, if it increase to the negative value sharply, the load decreasing should
be stopped or the gland seal HP steam resource should be put into operation.

7) When the load was reduced to zero, inform the electric operators to disconnect
and then push the emergency button to shut down.

8) When the rotating speed is over 500r/min, start up the jacking oil pump.

9) After the rotor stops rotating, supply the steam for gland seal until the vacuum
disappears completely, and then put the turning gear into operation.

10) Other operations are the same as those in sliding shutdown.

20
 11) As for normal shutdown curve, refer to fig.3 in appendix 1.

3.1.3 Emergency Shutdown:

1) Push “shutdown” button manually in the front of panel, or press the button on
turbine head manual shutdown device.

2) Confirm that main stop valves, governing valves and extraction check valves of
all stages are closed, inspect that motor power should be zero and disconnects.
Pay attention to the rotating speed, and it should decrease.

3) Put AC oil pump into operation immediately and if the AC oil pump has any fault,
immediately start up the DC lubricating oil pump.

4) Close inlet valve from condensate pump to deaerator, open condensate

recirculation water valve and put the attemperator of exhaust steam casing into
operation.

5） Release the vacuum pump interlock, stop the vacuum pump and open the
vacuum breaking valve.

6） Open turbine proper water drain valve and other drain valves to condenser and
close all the drain valves of turbine.

7） When the rotating speed drops to 200r/min, start up the jacking oil pump.

8） Pay attention to coasting time of unit, and adjust the gland seal pressure as
vacuum drops.

9） Finish other shutdown operations prescribed in the regulation.

3.2 Maintenance after Turbine Shutdown

1) After water cooler outage, make good preparation to avoid freezing of

equipment and pipelines in winter. As for the disconnected water and steam
system, the deposit water should be discharged completely.

2) If HP oil pump needs to be stopped after shutdown of turbine, start up AC

lubricating oil pump firstly.

3) When running the turning gear continuously, the jacking oil pump and
lubricating oil should work continuously, and the special personnel should be
assigned to monitor the panel and record the data according to the requirement
of operation permit.

4) If the continuous operation of turning gear stops because of faults, record the
shutdown time and mark it. Before putting continuous turning gear into
operation again, turn the rotor for 180o，and leave the time as same as the
shutdown time. When the turning gear can not be moved, do not turn the

21
 turning gear forcedly.

5) When HP inner casing upper half inner wall metal temperature falls to 200℃,
open drain valves of main steam pipe, proper and extraction pipeline. When
that temperature falls below 150℃, continuous operation of turning gear should
be stopped.

6) After shutdown, make precautions to avoid cold water and cold steam entering
casing.

7) Record all parameters according to the content of form in shutdown operation

permit every 30min, and monitor that metal temperature, temperature
difference, expansion difference, expansion, water levels in condenser,
deaerator and heater, the vibration degree of main shaft and current of turning
gear are normal.

22
4 Startup and shutdown curves of unit:

Pls. refer to Appendix 1 Startup and shutdown curves of unit.

Note:

For any information about maintenance and operation (drawing, technical data…, etc.) , please
refer to manufacturer documentation.

23
  
 
OM0402 
Appendix 1:   
Startup and shutdown curves of unit 
  
 
OM0402 
Appendix 2:   
43A.000.1J(D)(B)‐3 Thermal characteristics 
from HTC 
  
 
OM0402 
Appendix 3:   
43A.000.5SM(B)‐3 Turbine startup & 
operation instructions from HTC 
  
 
OM0402 
Appendix 4:   
43A.504SM(B)‐3 Instruction of LP spray 
from HTC