MODEL N15-6.

275 15MW
CONDENSING STEAM
TURBINE

INSTALLATION AND OPERATION MANUAL

（1）
0-1004-1760-0000-06

QINGDAO JIENENG STEAM TURBINE CO., LTD.

OCTOBER,2007
 INSTALLATION AND 0-1004-1760-0000- 06
QINGDAO JIENENG STEAM
OPERATION MANUAL
URBINE CO., LTD.
MODEL N15-6.275 15MW
CONDENSING STEAM TURBINE Page: of

Contents
1. Scope of application
2. Specifications---------------------------------------------1
3. Main auxiliary equipment--------------------------------5
4.Main data on installation
1. Sliding key system----------------------------------------------9
2. Flow passage----------------------------------------------------11
3. Gland seals-------------------------------------------------------12
4. Stationary parts and steam valves----------------------------14
5. Bearings---------------------------------------------------------- 16
6. Safety device and sensors--------------------------------------20
7. Alignment--------------------------------------------------------22
8. Hot tightening valve for casing flanges-----------------------23
9. Lift of steam governing valve disks----------------------------23
5. Parameters of gauging points---------------------------------------24
6. Drawings
Diagrammatic thermodynamic drawing------------------------------29
Condition curve----------------------------------------------------------30
Initial pressure correction curve---------------------------------------31
Initial temperature correction curve-----------------------------------32
Cooling water temperature correction curve-------------------------33
Rated condition balance curve-----------------------------------------34
Max. condition balance curve-------------------------------------------35
Cold start-up curve-------------------------------------------------------36
Hot start-up curve--------------------------------------------------------37

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 Preface

This manual deals only with the specifications, auxiliary equipment and data on
installation of the steam turbine, while the details such as the description of the
construction of the steam turbine proper, governing and safety system, oil system ,
auxiliary system and installation are stated in the Volume 2 of Installation and
Operation Manual., and the running of the steam turbine and the operation of the
electric governor in the Volume 3 of Installation and Operation Manual.

1. Scope of Application

Featuring a function of cogeneration, this steam turbine is applicable to the

electric utility as well as the self-sustained power stations of such industries as
chemistry, petroleum, metallurgy, fertilizer, sugar refinery, paper mill and waste
disposal, etc.
2. Specifications
2-1 Main data

Code of steam turbine K1760

Model of steam turbine N15-6.275

Rated power KW 15000

Economic power KW 15000

Max. power KW 15750

Rated speed r/min 3000

Rotation hand ckw, seeing in the direction of

steam flow
Rated inlet press. and variation range MPa
6.275-0.10.10 (abs)
Rated inlet temp. and variation range ℃ 480-55
Rated t/h 60.9
Inlet flow
Max. t/h 63.9

condensate t/h

I Rated steam extraction press. and MPa (abs)

range
Extraction temp. at rated working ℃
condition
Rated/max. steam extraction flow t/h

II Rated steam extraction press. and MPa

range
Extraction temp. at rated working ℃
condition
Rated/max. steam extraction flow t/h

Cooling water temp. Normal ℃ 33

Max. ℃
Rated exhaust pressure MPa 0.011 (abs)

Number of feed-water regenerative stage 1CY+1JD

Feed-water temp. ℃ ~145

Steam rate Rated working condition kg/kw.h 4.06

Straight condensing condition kg/kw.h

Heat rate Rated working condition kj/kw.h 11208

Straight condensing condition

kj/kw.h

k1760-06 1
Critical speed
r/min ~1917
Vibration amplitude of bearing housing at
mm ≤0.03
rated speed(double-amplitude)
Vibration amplitude of bearing housing at
mm ≤0.15
critical speed(double-amplitude)
Rotational intertia
kg-m2 ~1193
Weight of the steam turbine proper
t ~60
Max. lift for installation
t ~30
Max. lift for overhaul
t ~30
Weight of rotor
t ~14.62
Dimensions of steam turbine(above the 6.700×4.205×2.840
m
operating floor) （L×W×H）
Central elevation of steam turbine(from the
m 0.75
operating floor)
Speed of turning gear
r/min ~9
Max. temp. of casing when turning gear stops
℃ 150
Max. temp. of rotor when turning gear stops
℃ 150
Min. high for suspending
m 4.5

k1760-06 2
2-2. Governing, safety and lubrication system

Speed variation
r/min ≤15
Speed regulation
% 3~6
Dead bend of speed governing
% ≤0.25
Extraction press regulation
I %
Insensitivity of extraction press
%
regulation
Extraction press regulation
II %
Insensitivity of extraction press
%
regulation
Speed governing range of governor
%
synchronizer in no-load operation
Speed governing range
r/min 0~3180（adjustable）
Press increment of main oil pump
MPa 1.9
Difference between the I pulse oil press and
MPa 0.9
the inlet oil press of main oil pump
Difference between the II pulse oil press and
MPa
the inlet oil press of main oil pump
Difference between the III pulse oil press and
MPa
the inlet oil press of main oil pump
Electronic governing over-speed protection
r/min 3270
Speed of emergency governor
r/min 3300~3360
Over-speed protection of instrument
r/min 3390~3420
Relative displacement of rotor which cause
mm 1.5
the axial displacement limit device trip off
Limit of HP servomotor
mm 65
Limit of MP servomotor
mm
Limit of LP servomotor
mm
Lubricating oil pressure
MPa 0.08~0.12
Jacking oil press
MPa ~11.5
Charging pressure of accumulator
MPa
Designation of turbine oil
L-TSA46

k1760-06 3
2-3. Setting

Higher alarm valve of exhausting press

MPa 0.015 （abs）
Higher alarm valve of exhausting temp
℃ 80
Actuating press of extraction safety
MPa （abs）
valve
I
Lower alarm valve of extraction press
MPa （abs）
Actuating press of extraction safety
MPa （abs）
valve
II
Lower alarm valve of extraction press
MPa （abs）

Outlet press of main oil pump when the

MPa ≤1.7 （g）
motor-driven HP oil pump auto-start
Outlet press of main oil pump when the
MPa ≥1.9 （g）
motor-driven HP oil pump auto-shut

Low lube oil Alarm

MPa 0.055 （g）
press
protection LP Motor-driven oil pump
MPa 0.04 （g）
switches in
Shut-down
MPa 0.03 （g）
Motor-driven turning gear
MPa 0.015 （g）
mustn’t go into service
High Alarm Scavenge oil
temp ℃ 65
bearing temp
protection Temp of bearing
liner ℃ 85
Shut-down Scavenge oil temp
℃ 70
Temp of bearing
liner ℃ 100

k1760-06 4
3. Main auxiliary equipment

Quantity Set. 1

Main oil pump Pressure increment MPa 1.9

Capacity 1/min 2000

Model 100AY120×2A

Quantity Set. 1
Motor-driven HP
Pressure （raising） MPa (205)

Flow m3/h 93
oil pump
Power KW 110
Motor
Voltage V 415AC

Model KCB-633

Quantity Set. 1
AC auxiliary oil
Pressure MPa 0.28

Flow m3/h 38
pump
Power KW 11
Motor
Voltage V 415 AC

Model KCB-633

Quantity Set. 1
DC auxiliary oil
Pressure MPa 0.28

Flow m3/h 38
pump
Power KW 10
Motor
Voltage V 110 DC

Model V20F-1S13S-1C11K-22

Quantity 2

Pressure bar 172.5

Exhaust flow ml/r 42.5

Jacking oil pump Power KW 15

Motor
Voltage V 415AC

k1760-06 5
 1
Quantity Set.

oil ejector（I） Outlet press MPa 0.25

Outlet flow l/min 1000

Quantity Set. 1

Oil ejector（II） Outlet press MPa 0.15

Outlet flow l/min 1500

Model TL650KBILx73

Quantity Set. 2

Cooling surface area m2 ~60

Cooling oil flow l/min ~1000

Cooling water flow t/h ~120

Oil cooler
Cooling water temp（max） ℃ 43

Water resistance bar 0.024

Volume m3 12
Oil tank
Vacuum above oil level MPa 0.001

Model TD-375A

Quantity Set. 2

Power KW 0.375
Gas exhauster Motor
Voltage V 415AC

Model LQ-40

Quantity Set. 1
Shaft gland
Heating area m2 40

Press in water side（max） MPa 1.5

cooler Water resistance MPa <0.019

Cooling water flow t/h 55~75

Exhaust fan Power KW 2.2

(2 set ) Voltage V 415AC

k1760-06 6
 Model N-1250

Type Two flow and double channel surface type

Cooling surface area m2 1250

Steam pressure(rated) MPa 0.011 （abs）

Steam flow(rated) t/h 51~54

Cooling water flow(rated) t/h 2600~3600

Condenser Cooling water temp. ℃ 33

Water resistance MPa 0.047

Cooling water MPa 0.35 （g）

pressure（max.）
Tube material HSn70-1A

Tube size mm Φ20×1.5，Φ20×1.0

Net weight without water t ~27.7

Model

Type

Quantity
HP heater
Heating area m2

Press in steam side(max.) MPa

Press in water side(max.) MPa

Tube material

Tube size mm

Model JD-65

Type Vertical U-shape tube

Quantity 1

Heating area m2 65
LP heater
Press in steam side(max.) MPa 0.6 （g）

Press in water side(max.) MPa 1.2 (g)

Tube material 0Cr18Ni9

Tube size mm Φ20×1

k1760-06 7
 Model CD-40

Starting Quantity 1

Working Press. MPa 1.2 ~ 1.6

air ejector water flow Temp. ℃ 340

Working steam flow kg/h 600

Dry-air flow for extraction kg/h 40

Model C-40

Two-stage Quantity 2

Working Press. MPa 1.2 ~ 1.6

steam water flow Temp. ℃ 340

Working steam flow kg/h 400

ejector
Dry-air flow for extraction kg/h 40

Model Y132M2-6

Quantity 1

Power KW 5.5
Turning
motor Voltage 415AC
V

Mounting way B5

Speed of rotor r/min ~9

Oil Model
straining Quantity
device
Separating flow l/min

Power KW
Motor
Voltage V

k1760-06 8
8. Hot tightening values for the bolts of casing flange

Out.dia of Flange Rotation Rotation arc

Bolt size nut thick. angle length
D (mm) H α(°) L (mm)
(mm)
M76×4×280 110 195 31.58 30.32

M56×4×260 85 195 40.88 30.32

M56×4×200 85 145 13.76 10.21

9. Steam governing valve raising table

HP steam governing valve

Valve NO Pathway（D）mm Raising h±0.1 mm

1 φ50（pear） 3.5
2 φ50（ball） 10.79
3 φ50（ball） 17.16
4 φ50（ball） 24.81
5 φ50（ball） 32.46

MP steam governing valve

Valve NO Pathway（D）mm Raising h±0.1 mm

LP steam governing valve

Valve NO Pathway（D）mm Raising h±0.1 mm

1
2
3
4
5

k1760-06 2
5. Parameters at gauging points

Gauging point Unit Normal Alarm value Interlock remarks

value Upper Lower value
limit limit
Press before MSV MPa(a) 6.275 6.374 6.176
Press behind control stage MPa(a) ~2.91 Rated condition
Primary industrial MPa(a)
extraction press.
Secondary industrial MPa(a)
extraction press.
Press in exhaust chamber MPa(a) 0.011 0.012 0.042
Press variation range in MPa(a) 0.103~0.13
surge tank
Inlet press. of 1# LP heater MPa(a) 0.062 Rated condition
Inlet press. of 2# LP heater MPa(a) Rated condition
Inlet press. of 3# LP heater MPa(a) Rated condition
Inlet press. of 1# HP heater MPa(a) Rated condition
Inlet press. of 2# HP heater MPa(a) Rated condition
Press in the steam side of MPa(a) 0.095~0.097
shaft gland cooler
Press of blower for shaft MPa(a) 0.095~0.097
gland cooler
Working steam pressure for MPa(a)
gland heater
Press. in the steam side of MPa(a)
gland heater
Press. in mixing chamber of MPa(a)
water-jet air ejector
Inlet press of water-jet air MPa(a)
ejector
Working steam pressure for MPa(a) 1.2~1.6
starting ejector
Press in mixing chamber of MPa(a) 0.006
starting ejector
Working steam pressure for
MPa(a 1.2~1.6
two-stage steam ejector
Press in the mixing chamber of
MPa(a) 0.0045
two-stage steam ejector
Working steam pressure for MPa(a)
turbo-oil pump
Lube oil pressure MPa(g) 0.08~0.12 0.055 0.03
Low lube oil LP oil pump
MPa(g)
press switch-in 0.04
protection
Turning gear MPa(g) 0.015
mustn’t
switch-in

k1760-06 2
 Gauging points unit Normal Alarm value Interlock Remarks
value Upper Lower value
limit limit
Inlet press of main oil pump MPa(g) 0.1
Outlet press of main oil MPa(g) 2.0
pump
Outlet Auxiliary oil pump
shut-down
MPa(g)
pressure
protection Auxiliary oil pump
auto-start
MPa(g) ≤1.7
for main
oil pump
Control oil pressure for MPa(g) >1.2
MSV
Safety oil pressure MPa(g) 2.0 ≤1.0（electronic governing shut ）
1st pulse oil press MPa(g) ~1.0
2nd pulse oil press MPa(g)
3rd pulse oil press MPa(g)
Working oil press. for EH MPa(g) 2.0
system
Control oil press. for EH MPa(g) 0.25~0.6
system
Press. before the oil strainer MPa(g) 0.1
for jacking oil pump
Press. behind the oil strainer MPa(g) 0.1
for jacking oil pump
Jacking oil press. for front MPa(g) Measured
bearing of steam turbine
Jacking oil press. for rear MPa(g) Measured
bearing of steam turbine
Jacking oil press. for front MPa(g) Measured
bearing of generator
Jacking oil press. for rear MPa(g) Measured
bearing of generator
Outlet oil press. for turning MPa(g) ~11.5
jacking pump
Interlocking of Switch in MPa(g) >11.0
outlet oil press. turning
for turning gear
jacking pump
Scavenge oil temp. of ℃ <60 65 70
turbine front bearing
Scavenge oil temp. of ℃ <60 65 70
turbine rear bearing
Scavenge oil temp. of ℃ <60 65 70
thrust bearing
Scavenge oil temp. of ℃ <60 65 70
generator front bearing
Scavenge oil temp. of ℃ <60 65 70
generator rear bearing
Liner temp of turbine front ℃ <80 85 100
bearing
Liner temp of turbine rear ℃ <80 85 100
bearing

k1760-06 2
 Gauging points Unit Normal Alarm value Interlock remarks
value value
Upper Lower
limit limit
Thrust pad temp. ℃ <80 85 100
Liner temp of generator ℃ <80 85 100
front bearing
Liner temp of generator rear ℃ <80 85 100
bearing
Inlet oil temp. of oil cooler ℃ 45~55
Outlet oil temp. of oil cooler ℃ 35~45 50 25
Steam temp. before MSV ℃ 480 485 475
Temp. after control stage of ℃ ~405 Rated condition
turbine
Primary industrial ℃ Rated condition
extraction temp.
Secondary industrial ℃ Rated condition
extraction temp.
Temp of exhaust chamber ℃ ~48 80 Noload120℃
Inlet steam temp of ℃ ~48
condenser
Condensate temp. for ℃ ~48
condense
Temp. of air extraction ℃ ~51
chamber for condenser
Temp of surge tank ℃ <340
Inlet steam temp. of ℃ ~86 Rated condition
1# LP heater
Inlet steam temp. of ℃ Rated condition
2# LP heater
Inlet steam temp. of ℃ Rated condition
3# LP heater
Inlet steam temp. of ℃ Rated condition
1# HP heater
Inlet steam temp. of ℃ Rated condition
2# HP heater
Inlet water temp. of ℃ ~46 Rated condition
1# LP heater
Outlet water temp. of ℃ ~81 Rated condition
1# LP heater
Inlet water temp. of ℃ Rated condition
2# LP heater
Outlet water temp. of ℃ Rated condition
2# LP heater
Inlet water temp. of ℃ Rated condition
3# LP heater
Outlet water temp. of ℃ Rated condition
3# LP heater
Inlet water temp. of ℃ Rated condition
1# HP heater
Outlet water temp. of ℃ Rated condition
1# HP heater

k1760-06 2
 Gauging points Unit Normal Alarm value Interlock Remarks
value value
Upper Lower
limit limit
Inlet water temp. of ℃ Rated condition
2# HP heater
Outlet water temp. of ℃ Rated condition
2# HP heater
Inlet water temp. of ℃ 32~34
Oil cooler
Outlet water temp. of ℃ 38~40
Oil cooler
Inlet water temp. of ℃
water-jet air ejector
Temp. difference of upper ℃ ≤50 55
and lower half of casing
Temp. difference of upper ℃ ≤50 55
and lower flanges
1#LP water level mm 500 600 300 From base flange
Level in gland cooler mm 50 70 Fromcenterlineoflevelmeter
2#LP water level mm From base flange
3#LP water level mm From base flange
1#HP water level mm From base flange
2#HP water level mm From base flange
Water level of hot well for mm 650 800 500 Fromcondensateoutlet
condenser
Oil level in oil tank mm 300 150 450 From top plate of oil
tank
Axial displacement of rotor mm ≤1.0 ±1.0 ±1.5
for turbine
Differential expansion mm ~1.5 +3/-2 +4/-3
Vibration of turbine front um ≤0.03 0.05 0.07
bearing housing
Vibration of turbine rear um ≤0.03 0.05 0.07
bearing housing
Vibration of generator front um ≤0.03 0.05 0.07
bearing
Vibration of generator rear um ≤0.03 0.05 0.07
bearing
Vibration of turbine front um ≤0.080 0.16 0.25
bearing housing relatively
Vibration of turbine rear um ≤0.080 0.16 0.25
bearing housing relatively
Vibration of generator front um ≤0.080 0.16 0.25
bearing relatively
Vibration of generator rear um ≤0.080 0.16 0.25
bearing relatively
mm ~14 To be decided at
Absolute expansion
the site
Speed r/min 3000 3210 3270(DEH)
3360(TSI)

k1760-06 2
 Alarm value
Gauging points Unit Normal Interlock Remarks
Upper Lower
value limit limit value
Starting r/min ≤1
turning

Interlock Shut turning r/min ≥15

of turbine Start jacking r/min ≤200
speed oil pump
Shut jacking r/min ≥210
oil pump
Travel of HP servo piston mm 65
Travel of MP servo piston mm
Travel of LP servo piston mm

k1760-06 2
 MODEL N15-6.275 15MW
CONDENSING STEAM
TURBINE

INSTALLATION AND OPERATION MANUAL

（2）
0-1004-1760-0000-06

QINGDAO JIENENG STEAM TURBINE CO., LTD.

OCTOBER,2007
 INTRODUCTION

This manual mainly gives a description of the steam turbine on its construction,
governing and protection, oil and auxiliary systems as well as the requirements for
installation. For further details of the unit such as the specifications, auxiliary equipment,
data on installation and condition curves, please see the Volume 1; and as for the running
of the steam turbine and the operation of electrical governor, please see the Volume 3 of
Installation and Operation Manual.

1. Construction of the steam turbine proper

This is a condensing steam turbine with single casing, consisting of rotary part and
stationary part. The rotary part is composed of an integral rotor, wheels, blades,
coupling and propeller of main oil pump, and the stationary part is composed of a
casing, steam chamber, diaphragms, glands, bearings, bearing housings and steam
governing valve.

1.1 Casing

A single casing structure has been chosen for this unit. The casing is
composed of inlet casing and exhaust casing, which are integrated with each other
through vertical splits.

Both main stop valve and the steam chamber of HP steam governing valve are
integrated with the casing. Live steam enters the steam chamber of HP steam
governing valve directly via the two sides of the main stop valve.

Extraction ports are provided at the bottom of the casing. Since quick heat
radiation due to many extraction ducts can cause an excessive thermal difference
between the upper and lower halves of the casing easily, the lagging for the lower
half casing must be thickened properly and attention be paid to the quality of heat
insulation processing for fear a thermal distortion of casing would happen due to
excessive thermal difference between the upper and lower halves of casing.

A rigid connection is achieved between the exhaust chamber of casing and

exhaust adapter.

Inside the exhaust adapter is provided a water sparge pipe which, in case that
the temperature inside the exhaust chamber goes beyond a limit value, would spray
condensing water to lower exhaust temperature. The manhole in the upper half of
exhaust chamber can give an access to exhaust chamber and then, through the two
ladders on the inside walls of the exhaust pipe.

1
 Atop the exhaust chamber is a rupture disk, the rupture diaphragm of which
would break to relieve steam into atmosphere in case that the exhaust pressure
increases excessively to go over a limit value.

Inlet casing is supported on the front bearing housing with two lugs. The front
bearing housing is placed on the front base plate and can slide axially. Exhaust
casing is fixed to the rear base plate with footing flanges.

The unit has a sliding key system consisting of longitudinal, cross and vertical
keys. Longitudinal keys are placed along the center line of the steam turbine and
between the front bearing housing and front base plate. Cross keys are placed under
the front lugs and the footing flanges at the two sides of the exhaust casing. And the
vertical keys are placed between the front and rear bearing housings and the casing.
The intersection point formed by the center-line of the cross key and that of the
longitudinal key serves as the fixed point for thermal expansion of the unit. Front
bearing housing will be pushed to slide ahead by front lugs in case of thermal
expansion of casing. Oil grooves are provided on the sliding surfaces of the front
bearing housing and to be filled with lubricating oil regularly.

Pressure and temperature gauging holes are provided in the casing flanges and
behind the HP control stage, which are used to detect the steam pressure and
temperature inside the casing. In addition, gauging points for metal temperature are
provided in the casing flanges at the two sides of the casing and behind HP control
stage as well as at the top and bottom of casing barrel, which are used to detect the
variation of temperature difference of the casing flanges and casing walls between
the upper and lower halves of the casing. Of the gauging points, specification is
shown in the Arrangement Diagram of Gauging Points and locations in the Power
Plant Layout Diagram.

Drain ports are provided at the bottom of the lower casing as well as the
flanges at the two sides.

1.2 Steam chamber

Nozzle blocks are mounted in the steam chamber. The upper and lower halves
of the steam chamber are combined together with bolts. Steam chambers are
supported on the lower half casing with lugs at the two sides, with a securing key at
the bottom.

A self-sealing bush is provided between the HP steam chamber and the steam
regulating valve seat on the casing. In assembly, ensure that the clearance at the
sealing bush meets the requirements, so that the sealing bush can move freely in
cold

2
state.

1.3 Nozzle blocks

Nozzle block takes an assembly welding construction, with milled nozzle

blades being inserted into the steam chamber directly.

1.4 Diaphragms

This steam turbine is provided with 15 stages of diaphragm, all of which are of
shroud welding type. The diaphragms are supported inside the casing with
suspension pins, with a securing key at the bottom. The upper halves of diaphragms
are fixed inside the upper half casing, with sealing keys and securing keys at the
splits between the upper and lower halves of diaphragms.

1.5 Glands

Glands are divided into flow passage glands, diaphragm glands and front and
rear glands.
Flow passage glands consist of the radial and axial glands at the shroud band of
moving blades, and those at the roots of moving blades.
Diaphragm gland ring is fixed to the bore of the diaphragm of each stage. A
gland ring is composed of 6 arc sections, and each arc section is accompanied by a
holddown spring. Front and rear glands have the same construction as that of the
diaphragm gland. This kind of gland is constituted by grooves cut in the rotor and
seal teeth, thus forming a labyrinth gland.

Front and rear glands are placed in multi-stage sections, and the cavities
behind individual stage sections are connected with steam pipes of different
pressure to recover leak steam from the glands and maintain vacuum in the exhaust
chamber.

1.6 Rotor

A combined rotor, i.e. integral and shrunk-on rotor, has been chosen for this
steam turbine. The wheels of last 4 stages and coupling are shrunk on an integral
rotor. Both a propeller of main oil pump and emergency governor are fixed to the
front end of the main shaft. The rotor includes 16 stages of moving blade in total,
consisting of 1 double-row control stage and 15 pressure stages (the last two stages
are twisted stages). The rotor is linked with the generator rotor through a butt-muff
coupling.
3
 The rotor is to pass a strict dynamic test in the manufacturer’s work shop.

Wheel of main oil pump is mounted on the front of rotor.

1.7 Front bearing housing

In this housing is mounted a thrust-journal bearing, main oil pump, regulating

slide valve, safety devices, servo motor etc. The housing is mounted on the front
base plate, on the joint face of which are lubrication oil grooves.

A longitudinal sliding key is provided along the centerline, allowing of an axial

sliding of the front bearing housing, and Molykote is used as lubricant. Both angle
pins and a thermal expansion indicator are attached at the two sides of the sliding
plane. Metallic flexible hoses are attached to the scavenge oil port of the front
bearing housing as well as to both the oil inlet of main oil pump and the return
lubricating oil port to rid the bearing housing of additional force from oil piping.

The lower half of the inlet casing rests, with lugs, on the support feet of the
front bearing housing. Between the lower half of the inlet casing and that of the
front bearing housing is a guide plate, which serves as a vertical pin. Lubricating oil
inlets at the two sides are under the support feet, and both HP oil outlet and return
port of lubricating oil are in the front bearing housing.

Inside the front bearing housing are fixed various probes, the lead wires of
which go out though lead connectors. Platinum thermistors are connected through
plug sockets, the practical positions of which are shown in the drawing of front
bearing housing.

1.8. Rear bearing housing

This rear bearing housing is separated from the exhaust casing, thus to prevent
the thermal expansion of the exhaust casing from affecting the center of the unit.
Inside the rear bearing housing is mounted the rear bearing of steam turbine, front
bearing of generator, turning gear, solenoid valve for turning gear, guard for coupling,
etc. Either side of the rear bearing housing is provided with inlet and outlet of
lubricating oil, allowing of a leftwards or rightwards layout of the unit.

After rear bearing housing is placed and fixed to the base plate, drill and ream
holes for locating pins in the surfaces of footing flanges

Inside the rear bearing housing are fixed various probes, the lead wires of which go
out though lead connectors. Platinum thermistors are connected through plug sockets,
the practical positions of which are shown in the drawing of front bearing housing.

4
1.9 Bearings

The steam turbine front bearing is integrated with thrust bearing to form a
combined bearing. The thrust bearing is a type of pivoted shoe bearing, and the
thrust pads of which are fixed with thermistors, and the conducting wire is led out
from the wire grooves. In assembly, is ware that the wires will be in such position as
not to hamper swinging of the thrust pads. Atop the bearing body is a temperature
measuring hole for scavenge oil. Inside the scavenge oil port is an orifice plate, size
of which can be changed to regulate the lubricating oil flow for the thrust bearing.

In assembling thrust pads, be ware to examine the thickness of the pads, the
thickness difference in between will be limited to 0.02mm.

Elliptical bearings are chosen as front and rear journal bearings as well as the
front bearing of generator. There is a jacking oil recess in the lower half of bearing
liner. To turn the rotor, start the jacking oil pump to produce hydrostatic oil film.
The jacking oil recess must not be scraped or dressed at will. In addition, there is a
thermistor in the lower half of bearing liner. After the thermistor is fixed, fasten the
conducting wire well.

After putting the rotor of steam turbine in alignment with that of generator,
substitute the spacer shims beneath each of the adjusting blocks around the
circumference of a bearing with 2 or 3 steel gaskets. Set the bearing seat’s tightening
force upon the bearing to the requirements.

1.10 Turning gear

This steam turbine is equipped with a worm wheel-gear mechanical turning

gear. The pinion of the turning gear is shrunk on the worm with spiral grooves. The
turning gear can be put into service manually or automatically through a switch-in
device. Simultaneously with the start-up of turning gear motor, a solenoid valve in
the lubricating oil line for turning gear will be put through for lubrication.

Warn:
Before putting the turning gear into service, start the jacking oil pump and
examine the jacking oil pressure for meeting the requirements.

1.10.1 Manual switch-in of turning gear

Hold down the handle of the turning gear device while rotating the hand wheel
of the worm cckw until the pinion engages with the bull gear on the rotor
completely, and then switch on the turning bear motor to put the turning gear into
running.

5
1.10.2 Automatic switch-in of turning gear

Put through the switch-in solenoid valve for turning gear and meanwhile, start
the turning gear motor. After the pinion is engaged with the bull gear of the turning
gear completely, rotate the rotor, and then, disconnect the switch-in solenoid valve.

Only after the turning gear passes a manual switch-in test can the turning gear
go into running automatically.

1.11 Cleading

Dismantling cleading has been chosen for this unit, composed of steel plate
and frame. There is enough space in the cleading for entering the steam turbine
through doors of two sides, when it is working.

Cleading takes a structure of separate loading and entire. The two

symmetrical parts split at the centerline of cleading were grouped for an entire part
by bolts.

6
2. Governing and safety systems

This steam turbine is equipped with a digital electro-hydraulic (DEH) system,

consisting mainly of a digital governor, current-pressure converter (CPC), hydraulic
servo mechanism and steam governing valve.

A safety system featuring redundancy protection has been chosen for this unit,
in which, an electrical protection of the EHC devices and instrument monitoring
system is added to the conventional mechanical-hydraulic protection system. The
safety system is composed of emergency governor, emergency governor pilot valve,
trial control valve, solenoid valve, main stop valve, TSI instrument monitoring
system and over-speed protection of electrical governor, and so on.

2.1 Governing system

2.1.1 Digital governor

A modular computer control system with microprocessor as its core, the

governor can make configuration (programming) on the basis of the operation
parameters and requirements offered by a user to control the operation of the
unit by receiving and exporting the signals of analogue value and switching
value via the input and output interfaces.

The governor features the following functions:

 Speed governing
 Load allocation
 Initialization of required power value
 Droop initialization
 Initialization for automatic hot or cold start-up program
 Control over crossing the critical speed
 Over-speed test and protection
 Trail run switch-in at zero speed
 External input for shut-down
 RS232/RS422/RS485communicating interface
 Graphics display
 Self-diagnosis, monitor input and output analog
 Switch-over between manual and automatic operation modes.

The governor receives the speed signals from speed sensor, feed steam
pressure signal from pressure sensor and electric power signal from power sensor as
well as the control signals from procedure control and auxiliary control circuits, and
then, after finding out a solution, send out standard current signals to current-
pressure converter.

Note: For the details of the digital governor, refer to the instruction of
the purchased DEH governor.
7
2.1.2 Current-pressure converter (CPC)

Once receiving the standard current signals from the governor, the converter
will send out the conditioning signal oil pressure in correspondence to the
input current signal.

2.1.3 The hydraulic servo mechanism is composed of a regulating slide valve, pilot
valve, servomotor and starting valve. The conditioning signal oil pressure will, after
being amplified by this mechanism, control the motion of the servo piston and,
through the medium of an adjusting lever, change the opening of the steam
governing valve to regulate the steam flow into HP and LP sections of the steam
turbine.

2.1.4 Steam governing valve

The control over the steam flow into the steam turbine will be achieved by
changing the opening of the steam governing valve. In case of a demand for varied
electric load, the servo motor will drive the steam distribution device to change the
position of the cross bar, and accordingly, the valve discs fixed to the cross bar will
be opened and closed in the travel lift and curve in order for steam distribution, with
the result that the inlet flow into individual sections of steam turbine will be changed
to meet the load demand.

2.1.5 Operating sequence of the governing system

The oil supply to the governing and safety systems will be made by the main
oil pump for a normal running and by a starting oil pump during the start-up
procedure of the steam turbine.

After putting the starting oil pump into operation, switch in the safety
devices, turn off the hand wheel of the starting valve to the extreme to put
through the safety oil line; and, once receiving the start-up signal, turn on the
hand wheel of the starting valve slowly to open the main stop valve.

Push the OPERATION key on the operating panel of electrical governor, as a

result, the unit will run in a programmed operation procedure, i.e. automatic speed-
up, warming-up, crossing the critical speed, until rated speed.

With the turbine speed increasing, the outlet pressure of the main oil pump
will rise up gradually. Once the outlet pressure of main oil pump exceeds that
8
of the

9
motor-driven oil pump, the system will switch over to main oil pump automatically
for oil supply and the starting oil pump will stop its working manually or
automatically.

2.2 Safety system

The safety system is composed of mechanical hydraulic control (MHC) safety

system and electrical safety system.

2.2.1 MHC safety system and devices

The MHC safety system is composed mainly of emergency governor,

emergency governor pilot valve, trial control valve, starting valve, main stop
valve.

2.2.1.1. Functions of MHC safety system

In case of a trip-off action of any one safety device, the safety oil line will be cut
out and the safety oil pressure drop to zero, resulting in a speedy closure of all the
main stop valve, steam governing valve, and feeding valve.

 Over-speed protection

In case of turbine speed exceeding the rated speed by 10 ～12%, the emergency
governor and its pilot valve will function to cut out the safety oil line.

 Axial displacement protection

In case of a rotor displacement exceeding a specified value, the emergency

governor pilot valve will function to cut out safety oil line.

 Manual shutdown

Push the shut-down button on the trial control valve with hand to cut out safety
oil line.

2.2.1.2 Safety devices

 Emergency governor
This device is of fly-weight structure and fixed to the body of main oil pump
shaft at the front end of the rotor. In case of rotor speed 110～ 112% of the rated
speed, the fly-weights will fly outward to strike off the latch hook of the emergency
governor pilot valve due to a centrifugal force overbalancing the packing force of
spring, causing the plunger of emergency governor pilot valve move to cut out
safety oil line.

1
The fly-weights will be reset when the rotor speed down to 102% of the rated

1
speed.

Emergency governor may be put to an on-line action test through a trial control
valve. During a normal running of steam turbine, this test can be conducted to check
the emergency governor for its normal function without increasing speed.

In case the trip speed of emergency governor fails to meet the requirement, turn
the adjusting nut atop the emergency governor for an adjustment.

 Emergency governor pilot valve

Inside the front bearing housing, this pilot valve can receive the trip-off signals
of emergency governor or axial displacement for an emergency shut-down.

When the fly-weights flies outward to strike off the latch hook at the front end
of the emergency governor pilot valve, the plunger of the pilot valve will move due
to the spring force to cut out safety oil line.

In case of an axial displacement of turbine rotor in either direction, a shoulder on

the main oil pump shaft and close to the latch hook will detach off the latch hook to
result in an emergency shut-down.

After a trip-off action, this device can be switched in once again by pulling the
handle of the reset valve in the trial control valve.

 Trial control valve

This is a multi-valve consisting of a hand shutdown valve, oil injection test

valve and reset valve.

The handle of the hand shutdown valve can be pushed down to cause a manual
shut-down of the unit, and, pulled back to switch in this trial control valve
once again.

The oil injection test valve is a test device for the emergency governor,
consisting of a switch-over valve and oil injection valve.

If an oil injection test on emergency governor is needed during a normal

running of the steam turbine, push down the handle of the switch-over valve to relieve
the emergency governor pilot valve from the safety system, and meanwhile, turn the
handle of oil injection valve to bring the plunger down to the extreme. As a result, oil
will gush into the bottom of the emergency governor via the shaft of main oil pump
and the fly-weights of the emergency governor will, due to the centrifugal force
and oil
1
pressure, fly outward to strike off the latch hook of the emergency governor pilot valve.

After a trip-off action of the emergency governor, close the oil injection valve and
switch in the emergency governor pilot valve through reset valve first, and then,
loose the handle of the switch-over valve to put the emergency governor pilot valve
into the safety system once again.
.
Reset valve is used for the switch-in of emergency governor pilot valve and will
take effect only after the oil injection valve is switched off. Pull the handle of
emergency governor pilot valve to switch in the emergency governor pilot valve.

 Main stop valve (MSV)

MSV is mounted to the side of the steam chamber of casing directly, thus
achieving a very simple layout of pipeline of the unit. Open-and-shut action of the
MSV is controlled by a power cylinder. The piston rod of the power cylinder links
with the MSV rod through a two-half connector. To open the MSV, switch in all
safety devices and then, turn off the hand wheel of starting valve ckw to the extreme
and, after the safety oil pressure is established turn on the hand wheel of starting
valve cckw slowly to result in a gradual increase of oil pressure inside the chamber
under the piston of power cylinder. When the said oil pressure reaches up to a
specified value, the piston starts moving to open the MSV.

Once a safety device trips off, the safety oil pressure will disappear, as a result, a
spring above the piston will cause the MSV shut off immediately.

To prevent the MSV rod from being seized up, the MSV rod may be tested on
its action, during which, put through the trial solenoid valve to make the power
cylinder piston move for a less stroke.

 Extraction valve

This is a hydraulically controlled check valve, which functions to stop the

steam in the extraction piping from flowing back to the casing. On-off action of the
power cylinder in the extraction valve is controlled by a single-way valve in the
safety oil line. After a safety oil pressure is established, the power cylinder keeps the
extraction valve open; and when steam flows in the extraction piping, the force of
steam flow keeps the check valve open. Once the safety system trips off, the single-
way valve will works to sluice off the pressure oil inside the power cylinder and the
extraction valve disc will shut off due to the spring force of the power cylinder,
deadweight of the valve disc and the reversed steam flow.

A travel switch is fixed to the extraction valve for indicating a shut-off state of the
extraction valve.

1
2.2.2 Electric safety system
This system is composed of Turbine Supervisory Instrument (TSI), over-speed
protection of electric governor and solenoid valves, and so on.

(1) Turbine Supervisory Instrument (TSI)

This system offers following monitoring data:

 Zero speed of steam turbine

 Axial displacement of steam turbine
 Shaft vibration of steam turbine
 Bearing vibration of steam turbine
 Differential expansion of steam turbine
 Key phase

Note: For details, refer to the instruction of the TSI monitoring system
for steam turbine.

(2) Over-speed protection of electric governor

The electric governor possesses an over-speed protection function in

addition to governing function, with which, alarm and shut-down points at over-
speed can be initialized.

(3) Solenoid valve

This steam turbine is provided with two safety solenoid valves, either
of which can function to cut the safety oil line. At the end of a solenoid valve is a
button for the motion of plunger.

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3．Oil system

This system is composed of a main oil pump, starting oil pump, lubricating oil
pump, emergency oil pump, oil ejectors, oil cooler, oil tank, etc.

3.1 Main oil pump

This oil pump is linked with the turbine rotor directly and supplied with oil by a
LP oil ejector. In assembly, is ware that the floating ring of the oil pump shaft must
not be held down and a floating clearance is to be ensured.

3.2 Starting oil pump

This is an AC motor-driven HP oil pump for oil supply during the start-up of
steam turbine. After the unit starts, once the oil pressure of the main oil pump
overbalances that of the starting oil pump, this starting oil pump will stop its work
automatically.

3.3 Lubricating oil pump

This is an AC motor-driven LP oil pump for oil supply when turning the rotor.

3.4 Emergency oil pump

This is a DC motor-driven LP oil pump, which will supply lubricating oil in case
that the AC power supply is cut and the AC motor-driven oil pump can’t work.

3.5 Jacking oil pump

This is a HP wing pump for supplying oil to jacking system when turning the
rotor.
Jacking oil from the lubricating system passes through an oil strainer to enter the
jacking oil pump and then, after being boosted, goes into the jacking oil recesses on
the lower half liners of journal bearings through individual branch pipes.

Before each bearing is mounted a check valve and throttle valve, and the throttle
valve functions to adjust the jacking height of the rotor.

To put the turning gear into operation, the jacking oil pump must be started and
ensure that the jacking oil pressure meet the requirements in advance. After the
rotor is jogged and speeds up to above 200 r/min, stop the working of the jacking oil
pump.

3.6 Oil ejectors

In the oil system are provided two oil ejectors in parallel, i.e. LP oil ejector for
1
supplying oil to main oil pump and HP oil ejector for supplying oil to lubricating
system.

3.7 Oil cooler

In the lubricating oil circuit are provided two oil coolers for lowering lubricating
oil temperature, which can run singly or in parallel.

3.8 Oil tank

The oil tank functions to separate moisture, impurity and foam as well as to
store the oil for the system.

A vertical strainer gauze is used to divide the inside of oil tank into two parts,
return oil compartment and clean oil compartment. The screen plate can be drawn
out for cleaning. A self-sealing mesh is fixed to the oil outlet to be connected with
an auxiliary oil pump, and, in case of blockage, the gauze can be drawn out for
cleaning, needing not to sluice off the oil in the oil tank.

Atop the oil tank is provided with an interface for ventilator pump and air
purifier as well as oil ejectors.

At the lowest position is provided an emergency oil drainer through which both
moisture and impurities that have been separated can be discharged from the oil
tank, or an oil purifier can he connected.

Oil level inside the oil tank can be supervised with a local level meter, which is
fixed to the side of oil tank, and a remote level meter, which is inserted into the oil
tank from the top cover of the oil tank.

Both an oil overflow gate and oil-in are provided to the side of the oil tank,
which are to be sealed with blank flanges in case that no high-low level oil tank
would be available.

3.9 Lower oil tank

Lower oil tank is used store turbine oil overflowing from main oil tank when the
unit has shut. There are three ports for this oil tank. Oil inlet port is used to collect
oil overflowing from main oil tank, oil outlet port is used to inject oil from oil pump
or oil purifier to main oil tank and oil drain port is used to drain impurity at the
bottom of oil tank or emergency oil drain.

3.10 Higher oil tank

1
 Higher oil tank is used to store turbine oil injected from lubricating oil pipeline
when the unit is operating. Oil inlet port is used to collect lubricating oil from
lubricating oil pipeline; oil outlet port is used to supply oil for bearing when the
stand-by lubricating oil pump fails, and oil drain port is used to drain impurity at the
bottom of oil tank or emergency oil drain.

3.11 Oil purifier (Not supply)

An oil purifier is essential to mount, for purifying the oil and eliminating the
moisture and impurity in the oil tank to make the oil good.

4. Auxiliary system

The auxiliary system of this steam turbine is composed of condensing system,

regenerative system, drain system and gland system.

4.1 Condensation system

This system consists mainly of a condenser, water eductor and condensate

pump. The exhaust steam from the steam turbine is cooled to condensing water in
the condenser and then collected into the hot well. After being boosted by a
condensate pump, the condensing water will pass through a shaft gland cooler, air
ejector and other back heating system to enter a boiler.

The water eductor maintains vacuum inside the condenser.

4.1.1 Condenser

A set of two-flow, two-channel surface type condenser has been provided for
this steam turbine. Inside the condenser, the water side is divided into two
independent cooling zones. So, the water side of the condenser can be repaired or
cleaned respectively, if necessary, with the turbine load being reduced. There is a
manhole in the end cover of water chamber, for inspecting the water chamber for
cleanliness. The pipe bundle in the condenser is designed rationally to guarantee a
lower steam resistance and condenser depression.
Because of transportation limit, the body will be welded with the steam
admission chamber, hot well and circulating water inlet and outlet at the site. After
welding, put in heat exchange tubes, which are expanded, followed by a hydrostatic
test.

1
 A rigid connection will be achieved between the condenser and exhaust adapter,
and a elastic supporting between the condenser and foundation, with 4×2 pieces of
supporting springs under the bottom of the condenser.
A circulating water inlet is mounted vertically at the lower part and circulating
water outlet is mounted horizontally at the upper part of the water chamber. Air
extraction ports are mounted at the two sides of the body of steam side, which must
be put through in mounting. There are two condensate outlets at the lower parts of
the hot well, either of which can be chosen for connecting condensate flow
according to
practical condition. A float-type level meter is used for measuring water level, with
output of 4～20mA standard signal. There is a manhole at the side of hot well, and
interfaces at the top, bottom and sides for other steam and water pipelines.

4.1.2 Air ejector, and starting ejector

Starting ejector, has a high efficiency of air ejection, simple construction and
reliable operation. Air ejector is a two-stage steam ejector. During the start-up of the
unit, the main air ejector and starting ejector run together; and, once the start-up
procedure is finished and a normal vacuum is achieved inside the condenser, the
starting ejector will stop working.
4.2 Regenerative system
The regenerative system of this steam turbine is 1CY+1JD.
LP heater drain grade by grade to condenser
4.2.1 LP heater

This is a vertical, U-tube surface heater of 6 flows.

4.3 Gland system

Of the front gland, the leakage steam from the 1 st section goes to the balance tube
of deaerator, that from the 2nd section goes to the surge tank, and that from the 3 rd section
goes to the shaft gland cooler.
Of the rear gland, the leakage steam from the 1 st section goes to the surge tank,
and that from the 2nd section goes to the shaft gland cooler.
4. 3.1 Surge tank

This device functions to supply sealing steam to the shaft glands at the two
ends of the steam turbine. The pressure inside the surge tank is kept at the pressure
0.103 ～ 0.13MPa(abs.) by the pressure regulating valves at the steam inlet and
outlet.

4. 3.2 Shaft gland cooler

This device functions to recover and stop the leakage steam from the shaft
glands from entering the bearing housing. The pressure inside the shaft cooler will
1
be maintained at 0.097～0.099MPa(abs.) with a mechanical pump.

1
4.4 Drainage system

Water drained from the steam turbine proper and extraction piping, in
different pressure rating, is discharged to flash tank where it flashes to steam, and,
the steam thus formed goes to the top and the water to the bottom of the condenser.

5. Description of installation

5.1 Mounting the condenser

5.1.1 Expanding tubes at the job site

5.1.1.1 Place and level the condenser body on its right position, be sure that it is
kept level and stable.

5.1.1.2 Examine the copper tubes on quality, which have to be tested for their
processing properties.

5.1.1.3 Wash and clean the holes in the tube plates, see that no rust, corrosion,
grease mark, scratch or burr exists in the holes.

5.1.1.4 Expand the tubes on trial according to the requirements listed in the tube plate
drawing. The expanding part of the tube is not allowed to exceed the in wall of the
tube plate. Only after the above said trial expansion of the tube meets the
requirements can the formal tube expansion be conducted. Pay attention to the
difference in the flanging area for copper tubes between the front and rear tube plates.

5.1.1.5 After the assembly of the condenser is completed, conduct water filling test in
the steam side and thereafter, completely drain away the water in time. Before the
test, the condenser is to be supported with some makeshift props.

5.1.2 Welding the exhaust adapter

After fixing the casing finally, connect the condenser with the casing. In
welding, the condenser will be in a free state with no water in the steam side and
connecting no pipe. In welding the exhaust adapter into the exhaust casing, the
adjusting screws in

2
the elastic supports will be used for adjustment. When mounting the permanent
wedge blocks beneath theelastic supports after the condenser is fixed, must not
change the decrement of spring. The wedge blocks will contact the base plates and
supports closely and solidly.

5.2 Mounting the steam turbine

5.2.1 Examination of foundation and arrangement of wedge blocks

5.2.1.1 The foundation surfaces will be flat and clean, free of exposed stiffen ribs,
claws, honeycomb and pitting surface.

5.2.1.2 Elevation of the plane beneath the mounting base plate for the steam turbine
will meet the requirements.

5.2.1.3 The foundation bolt holes will meet the requirements for perpendicularity.
Embedded steel pipes must not be higher than concrete plane.

5.2.1.4 Both the longitudinal and cross centerlines will meet the requirements as
stated in the drawings, and all foundation bolt holes will not prevent the foundation
bolts from being inserted smoothly.

5.2.1.5 Place the wedge blocks according to Wedge Block Arrangement Drawing, and
the surfaces of the wedge blocks must be flat and clean.

5.2.2 Mounting the base plate, bearing housings and lower half casing

5.2.2.1 Hoist and place the front and rear base plates on the wedge blocks for a
preliminary level and true-up. Check the contact between the wedge block and base
plates and, as a rule, a feeler gauge of 0.05mm thick can’t be inserted in between. In
adjustment, the staggered parts of the wedge blocks mustn’t exceed 25% of the
effective area. After being placed, the wedge blocks will be welded fast before the
2nd grouting.

5.2.2.2 Put in foundation bolts and screw in upper nut with the end of foundation
bolt being 5～10mm lower than the plane of the base plate. A lune-shaped block will
be added between the upper nut and the sunk spot of the base plate and spot-welded
for fear the upper nut would rotate when screwing up the lower nut.

5.2.2.3 Hoist the front and rear bearing housings on the base plates and put in angle
pin (for the front bearing housing) and, locating pin and set bolt (for the rear bearing
housing).

Be sure an allowance for thermal expansion is to be reserved at the front end of

the slide face between the front bearing housing and the front base plate.

2
5.2.2.4 Correct the bearings for centerline, spacing, level and elevation. For the front
and rear bearings, the spacing deviation from the centerline is limited to be
±0.50mm. And for the front and rear bearing housings, the cross deviation is
limited to be
±0.20mm and cross level deviation ±0.20mm, and, the longitudinal level and
elevation will be decided according to the installation rising of the rotor.

5.2.2.5 After a preliminary mounting and adjustment of bearing housings, make an

initiative correction of the position and elevation of individual bed plate of the base
plate and then, hoist and mount the lower half casing. After placing the lower half
lower casing in its right position, correct the casing for centerline, level and
elevation. While correcting the centerline and longitudinal level, hoist and put the
rotor into the casing and then, adjust the elevation of the bearing housings and align
the rotor at the front and rear gland grooves of the casing.

After correcting the casing, fix and spot-weld the vertical pins, and, screw up the
foundation bolts.

5.2.2.6 Check the installation quality

1、 Cross level deviation of the casing is limited to 0.20mm/m. The

difference between the cross level of the casing and that of the bearing
housing is limited to 0.10mm/m.

b. Longitudinal level of the casing will meet the requirements for installation
rising.

c. The axiality of gland groove and rotor will meet the requirements as stated in
the Volume 1 of the Installation and Operation Manual.

d. The load allocation on the casing will be as following, with the lower half
casing being empty, and the drooping arc method is to be used for
examination:

For the front lugs, load deviation between the left and right will be limited to
0.10mm;

Difference of drooping arc values between the left and right lugs will be less
than 5% of the mean value of their drooping arc values.

e. Front and rear base plates will meet the bearing housings and casing evenly
to the extent that a feeler gauge of 0.05mm can’t be inserted into their

2
joint

2
 around the 4 sides.

f. 0.04～0.08mm will be the clearances at the connecting nut at the angle pin of
front bearing
housing and at the foundation flanges of exhaust casing.

5.2.3 Mounting the rotor on trial

This process will be conducted with the correction of casing alternatively.

5.2.3.1 Check the surface state and sizes of individual location, and compare the data
thus obtained against those recorded by the manufacturer
.
5.2.3.2 Steadily and slowly hoist and level the rotor, then place it into the casing,
while any swinging and collision of the rotor must be avoided. And special attention
will be paid not to scratch the surfaces of the bearing pads. Spread lube oil on the
bearing liner and turn the rotor slowly for check-up.

5.2.3.3 After being spotted, the rotor will satisfy the following requirements:

(1) Both the rotor centering and journal rising meet the stipulated requirements;
(2) Load allocation on the casing meets the stipulated requirements;
(3) Contact condition of bearing liner and adjusting block of bearing meets the
stipulated requirements;
(4) Contact surfaces between the base plate and bearing housing and
foundation flange of casing meet the stipulated requirements;

(5) Contact surfaces between the casing lugs and cross pins and adjustable
shim plates meet the stipulated requirements;
(6) Propeller of the main oil pump has been spotted complying the stipulated
requirement;
(7) Couplings have been aligned complying the stipulated requirements;
(8) Both the face and radial run-out at individual positions of the rotor meet
the stipulated requirements.

5.2.3.4 Spot-weld the wedge blocks fast and initially tighten up the foundation bolts.

5.2.3.5 Lift the rotor out of the casing for cleaning.

5.2.4 Mounting the diaphragms and steam chamber

5.2.4.1 Clean and check all diaphragms and steam chamber.

2
5.2.4.2 Mount the diaphragms into the upper and lower halves of casing respectively
and apply a layer of dry powdered black lead on the contacting surfaces between
them and the casing

5.2.4.3 Mount the lower half of the steam chamber into the lower half casing while
examining the contacting condition and clearance between the lugs and the casing,
and applying a layer of dry powdered black lead on the bearing surfaces.

5.2.4.4 Measure the axial and radial clearances between them and the casing.

5.2.4.5 Recheck the groove centerlines of all stages.

5.2.5 Mounting bearings

Bearings are to be mounted after the true-up of bearing housings and before
putting the rotor in position, and in compliance with following requirements:

5.2.5.1 A bearing will comply with the relevant requirements as stated in the Volume
1 of the Installation and Operation Manual in the clearances and fit at individual
positions.

5.2.5.2 The journals of rotor will contact the bearing liners evenly in full length.
Thrust collar will contact the thrust pads evenly, with contact area not less than 75%
of the total area.

5.2.5.3 The horizontal faying surfaces of bearing will contact evenly with each other
to the extent that a feeler gauge of 0.05mm thick can’t be inserted into between.

5.2.5.4 The adjusting block of bearing will contact the grooves of bearing housing
evenly with contact area not less than 65% of the total area. After the rotor is put in, 3
pieces of adjusting block for the lower half bearing will contact the groove of
bearing housing concurrently.
And before the rotor is put in, a clearance 0.03mm will be reserved between the
adjusting block at the bottom and the groove.

5.2.5.5 It is forbidden to change the size and depth of the jacking oil recess at will.
The oil recess will contact the journal closely with its surrounding. The jacking oil inlet
will be protected carefully from impurities coming in. Before final mounting the rotor
into the casing, put through oil flow to clear the oil path of impurities for fear the
impurities would damage the surface of pads.

5.2.6 Mounting the rotor

2
5.2.6.1 Hoist and put the rotor into the casing. Both the journal and bearing liner
will be cleaned, and poured lubricating oil on.

5.2.6.2 Force the thrust collar nestles against the main thrust pads while measuring the
following clearances:

a. Clearances between the main and auxiliary thrust pads and the thrust collar;

b. Radial and axial clearances at the tooth tips of the front and rear glands;

c. Radial and axial clearances at the tooth tips of diaphragm glands;

d. Clearances at the oil seals of bearings and at the oil scraper rings of the
bearing housings;

e. Clearances between the moving and stationary blades in the flow passage;

4、 Clearances between the journal and a bridge gauge;

5.2.7 Mounting the upper half of steam chamber

5.2.7.1 Mount the upper half on trial while checking the clearances at the split and
sealing rings.

5.2.7.2 Clean the inside. Remount the upper half and tighten up bolts. See that the
seal ring of the steam governing valve atop the HP steam chamber will be
concentric with the steam valve port inside the upper half casing.

5.2.8 Mounting the steam governing valve

5.2.8.1 Examine the operating sequence and lift of individual valve discs according
to the drawing. The lift of each valve disc has been set before delivery.

5.2.8.2 Tighten up the bolts of the steam chamber cover (flange). Apply a layer of
seal gum on the splits.

5.2.9 Mounting the main stop valve

5.2.9.1 Special bolts will be used to assemble the spring of servomotor.

5.2.9.2 Tighten up the bolts for the self-sealing binding ring symmetrically and
evenly, for fear the bolts wouldn’t run true.

5.2.9.3 In putting in carbon seal rings, both the valve spindle and seal rings must be

2
kept clean and free of greasy dirt.

5.2.9.4 A clearance will be kept at the locating collar between the valve spindle and
piston rod.

5.2.10 Putting the upper half casing on the lower half casing

5.2.10.1 Confirm that all inside components are qualified and have been
mounted, and with complete and correct record for inspection. Smear lubricating oil
on the surface of the pillars.

5.2.10.2 Place the upper half casing on trial. In doing so, see that the seal ring of the
steam governing valve in the HP steam chamber will be concentric with the steam
valve port of the casing in order not to damage the seal ring under pressure..

a. Check the diaphragms for the relative position between their upper and
lower halves.
b. Evenly tighten up one of every three bolts for the splits, on which no seal
gum is coated.
Checking the clearance at the splits of the casing, as following:

Inlet casing: a feeler gauge of 0.03mm thick can’t be inserted into the
split at
the inside and outside;

Exhaust casing: a feeler gauge of 0.10mm thick can’t be inserted into the

split at inside and outside;

the

5.2.10.3 Hoist the upper half casing. Apply a layer of seal gum on the contacting
surface of the lower half casing and then place the upper half casing in position once
again. When the upper half casing is lowered to where the two contacting surfaces
are 1-2mm apart, insert the dowels and then fully rest the upper half casing on the
lower half casing.

5.2.10.4 Jog the rotor for check-up.

5.2.10.5 Cold-tighten up the bolts for split with the moment of 1,000 ～ 1500N.m
(smaller moment values for the bolts of less diameters), which starts from the
middle of the casing, goes symmetrically right and left in several times.

5.2.10.6 Hot-tighten up the bolts for split with the moment as specified in the
Volume 1 of the Installation and Operation Manual.

2
5.2.10.7 Readjust the alignment of the two rotors and then fix the generator.

5.2.11 Second grouting for the foundation

5.2.11.1 The second grouting for the foundation will be completed at one goes.

5.2.11.2 Neither the mount or dismount of the big parts nor the collision to the
turbine is permissible before the strength of the second grouting cement reaches 50％
of the design value, and no further tightening the nuts onto the foundation bolts is
permissible before the above said strength reaches 80％ of the design value.

5.2.12 Connect the couplings and recheck the radial run-out of the couplings

If necessary, bolt holes of the couplings will be reamed at the site in following
steps:

5.2.12.1 Before the practice, make sure that the couplings have been aligned
qualifiedly and the strength of the second grouting cement reaches up to 70% of the
stipulated value.

5.2.12.2 The two couplings are in register with each other, and the deviation of
their face run-out are cancelled each other out as much as possible.

5.2.12.3 Before reaming the bolt holes, link the two couplings temporarily, and,
before and after that, measure their radial run-out, variation of which is limited to
0.02mm.

5.2.12.4 As a rule, reaming amount of feed will be 0.10～0.15mm, and mustn’t be

too great. And an allowance 0.05 ～ 0.07mm will be reserved for finish reaming,
with the bolt hole having allowable tolerance H7 and roughness 1.6 .

5.2.12.5 Both the connecting bolts and nuts are subject to a counterweight test in
order the connecting bolts and nut will have their mass distributed evenly

5.2.12.6 Tighten up the coupling bolts finally; recheck the radial run-out of the
coupling, variation of which is limited to 0.02mm.

5.2.13 Mounting the turning gear

The turning gear will be mounted to satisfy the following requirements:

5.2.13.1 Bearings for worm and worm gear shaft turn flexibly and smoothly,
lubricating oil path is unblocked, and the bearing box for worm gear shaft is filled
up

2
with calcium-sodium or lithium base grease.

5.2.13.2 15mm is the axial clearance between the pinion and the bull wheel of
turning gear when in OFF position.

5.2.13.3 Both tooth contacting and backlash of worm pair accord with the
requirements;

5.2.13.4 Both tooth contacting and backlash of gear pair accord with the requirements;
5.2.13.5 When switching in the turning bear manually and automatically, the pinion
slides freely and engages smoothly.

(2) Ream the holes of the mounting flange and fix locating pins into the holes.

5.2.14 Mounting the oil system

5.2.14.1 Mount the main oil pump. Be careful not to damage the O-ring at the
bottom outlet of the pump body. When putting on the top cover, see that the stopper
pins atop the floating ring and oil seal ring go into the pin holes for the top cover,
and both the floating ring and oil seal ring can float freely.

After the mounting, following requirements are to be satisfied:

(2) Both the horizontal split of the pump body and the clearance at the flanges
for inlet and outlet
are strict to the extent that a feeler gauge of 0.05mm thick can’t be inserted
into;
(3) Of the propeller, face run-out is limited to 0.10mm and radial run-out
0.05mm;
(4) Between the pump body and propeller, the error tolerance of axiality is
Ø0.10mm, and that of axial alignment is ±0.50mm.

5.2.14.2 Mount the oil tank; be sure that the outlet is led to out of the workshop
where no risk of explosion exists.

5.2.14.3 Mount the oil ejectors. Be careful not to fix the nozzle for HP and LP oil
ejectors by mistake.

5.2.14.4 Mount the oil cooler.

5.2.14.5 Mount the motor-driven oil pumps according to instruction book of oil pump.

5.2.14.6 Erect the oil pipeline.

2
 a. Minimize the number of flanged joint and weld joint in the oil pipeline;
b. Inlet pipe has an slope 1/1000 to oil pump; and return oil pipe will
incline to oil tank with a
slope not less than 5/1000;
c. Neither dead end nor up-bow exists in the pilot oil piping for fear air
would stagnate in the
pipe. ;
(5) It is forbidden to damage the surfaces of flexible metal hose and
expansion joint;
(6) A net distance not less than 150mm is left between the oil pipe
and the surface of insulation
for steam pipe.
f. A hand wheel of the valve in the lubricating oil line is fixed horizontally
or tilt down.
g. Before being erected, jacking oil pipe, joint and port will be blown clean.

5.2.14.8 Oil pipes will be chemically washed or mechanically cleaned before final
erection.

5.2.15 Auxiliary equipment will be mounted according to the Technical

Specifications for construction and Test Acceptance of Electric Power Projects,
Steam Turbine Section.

5.2.16 Piping will be erected and washed according to the Piping Section of the
above-said rules.

5.2.17 Both leakage test for the vacuum system and the commissioning of auxiliary
equipment will be conducted according to the Steam Turbine Section of the above-
said rules.

5.2.18 Completing the erection of pipelines, wash the oil system circularly.

5.2.18.1 Oil circulation may be conducted through the by-pass outside bearing, by-
pass inside bearing and normal running oil path.

5.2.18.2 Circulating oil washing usually takes following lines:

a. Inlet oil manifold of bearing Return oil manifold Oil tank

b. Inlet oil manifold of bearing Inlet and return oil pipe of bearing
Return
oil manifold Oil tank

c. Inlet pipe of main oil pump Main oil pump Front bearing housing

3
 d. Outlet pipe of main oil pump Main oil pump Front bearing housing

e. Outlet pipe of main oil pump Pipeline in governing system Front

bearing housing and oil tank

5.2.18.3 In order of circulating washing through the above-said lines, it is necessary

to remove some components and add temporary piping and switching valves
according to washing scheme. However, in doing so, following requirements must
be met:

(3)For the washing oil that passes through bearings, all bearing oil inlets will
be provided with
makeshift sieves, size of which must be not less than 100 mesh;
b. After washing clean all devices in jacking oil line, oil pipes and jacking oil
holes in bearing
liners respectively, combine the joints of oil inlet pipe in bearing for washing
together.

c. Only after washing clean the oil line in governing system will the oil pipes for
the regulating
slide valve and current-pressure converter (CPC) be connected therewith.

(4)A by-pass will be added when washing the oil strainer in the governing system.
The oil strainer
is to be washed independently.

5.2.18.4 Oil circulation usually falls into preliminary washing, circulating

washing and operating-duty washing. Preliminary washing aims to examine the oil
system for leakage as well as to discharge bigger foreign matter. Circulating
washing aims to clear the oil system of impurities thoroughly. And, operating-duty
washing aims to, after circulating washing passes, reset the pipeline in both the oil
system and governing system to operating mode for final washing.

5.2.18.5 During circulating washing, start HP oil pump and lubricating oil pump
alternately. In addition, such measures as hammering, impacting with compressed
air and changing oil temperature will be taken for a better washing effect.

5.2.18.6 The oil circulation will be judged acceptable upon condition the following
requirements are met.

a. Examine the oil samples obtained from the oil outlets of both the oil tank and
oil
coolers. The oil thus obtained must be transparent and the moisture content
therein

3
 comes up to the standard.

b. No sediments such as metal particle, rusty article or sand has been found in the
make-shift sieves after 4 hours of oil circulation, with only a trace of fiber being
found.

c. Remove all makeshift sieves once finishing the oil circulation.

6. Operation of the tools to be supplied along with the unit

6.1 Main stop valve remover
This tool can be used for three purposes, as following:
Disassemble and assemble the steam governing valve and the cross bar in
the link lever assembly;

The practical method for operation is shown in the Drawing of Main Stop Valve
Remover of drawing No. 0-0925-3001-0000-20

3
 MODEL N15-6.275 15MW
CONDENSING STEAM
TURBINE

INSTALLATION AND OPERATION MANUAL

（3）
0-1004-1760-0000-06

QINGDAO JIENENG STEAM TURBINE CO., LTD.

OCTOBER,2007
 INTRODUCTION

This manual mainly gives a description on the basic requirements for the
operation of the steam turbine, while the practical operation rules for the power plant
could be defined in accordance with the concrete condition of the user, in reference
to the operation rules for the boiler and generator and through tests.

1. Cold start-up at rated parameters

1.1 Preparatory work before start-up

1.1.1. Check carefully the steam turbine, generator and all auxiliaries to
ensure that the installation or maintenance has been completed and
finished.

1.1.2 Make free contact with the central control room, boiler section and
electric power section.

1.1.3 Following inspections will be taken for the oil system.

1.1.3.1 Oil piping and all devices in the oil system are in a perfect state and no
oil leakage in the oil system.

1.1.3.2 Inside the oil tank, oil level is normal, oil quality is good and the floater of
oil level gauge can move up and down freely

1.1.3.3 Oil drain valves of both oil tank and oil cooler are closed tightly.

1.1.3.4 Keep open both the oil inlet and outlet of the oil cooler, and precautions will
be made against any error operation. The oil inlet and outlet of stand-by oil cooler
will be closed.

1.1.3.5 Open the inlet and outlet valves of the motor-driven oil pumps.

1.1.3.6 Remove all of the makeshift sieves or blocking plates which have
been attached before the bearings before washing the pipelines.

1.1.4 Following check-ups will be taken for the steam and water systems:

1.1.4.1 In advance, the electric isolation valve in the main steam pipe has be
given a test on its manual and automatic close-and-open action.

1.1.4.2 Close all the isolation valves, main stop valve, check valve, safety valve
and open the direct drain valve and anti-corrosive valve in the main steam pipe
and extraction pipe. Open the direct water drain valve of casing.

1.1.4.3 Open the steam valve in the gland piping to the shaft gland cooler as well as
the drain valve of the shaft gland cooler.

1.1.4.4 All steam pipes will be allowed of a free expansion.

1
1.1.4.5 Open the main cooling water valve of the oil cooler. Close the water inlet
valve while opening the water outlet valve..

1.1.5 Following inspections will be taken for the governing and safety systems:

1.1.5.1 All components have been assembled properly and can act freely.

1.1.5.2 The steam governing valve complies with the requirement in pretension.

1.1.5.3 The electric governor passes its self-checking.

1.1.5.4 All safety devices are in switch-off position.

1.1.6 Check the sliding key system. All cold clearances at different positions will be
checked and the data thus obtained will be recorded. Fill lubricating oil to the sliding
plane between the front bearing housing and base plate.

1.1.7 Check all instruments, sensors, transmitters and signaling devices.

1.1.8 Open the valves in the signal pipes connecting to individual instruments.

1.1.9 Once the above inspections and preparations are completed and nothing wrong is
found, notify the boiler section to supply steam for pipe warming.

1.2 Warming-up (in front of the isolation valve)

.The time and procedure for the warming-up will be decided by such factors as the
initial temperature of the piping, initial steam condition, the thickness of pipe wall
and flanges, and the length of warming pipe, and so on. Warming-up falls into LP
warming-up and boosting warming-up.

1.2.1 Fully open the atmospheric drain valve while raising the pressure in the
piping to 0.2～0.3 MPa(g) gradually, with metal temperature rise rate limited to 5℃
/min., then make a 20～30 minutes pause at the pressure for warming-up. Once
the steam temperature rises up to 130～150℃, stop the LP warming-up.

1.2.2 Boosting warming-up will be conducted according to following requirements:

Press. (MPa) Boost rate (MPa/min.) Temp. rise rate(℃/min)

0.3～0.6 0.05 5
0.6～1.5 0.1 5
1.5～4.0 0.2 5
4.0～6.376 0.5 5

2
 During the above boosting period, the opening of the water drain valve is to be
adjusted continuously in response to the drain water flow reached in order to
minimize the loss of working fluid.

1.3 Start the auxiliary oil pumps, and check the governing and safety systems under
static condition.

1.3.1 Start the motor-driven LP oil pump and check the followings:

1.3.1.1 Lubricating oil pressure and bearing oil flow

1.3.1.2 Leakage of the oil flow path.

1.3.1.3 Level in the oil tank. For the first starting of a new steam turbine unit or the
unit just having a general overhaul, sufficient oil will be prepared before filling oil
into the oil pipes in order to replenish the oil tank.

1.3.2 Start jacking oil pump and test turning gear as following:

1.3.2.1 Shut off the throttle valves in the branch jacking oil pipes in front of each
bearing and fully open the overflow valve in the general jacking oil pipe.

1.3.2.2 Start both the jacking oil pump and lubricating oil pump. Reduce the drain
oil flow from the overflow valve so that the pressure in the general jacking oil pipe
rises up to 12 MPa.

1.3.2.3 Respectively adjust the throttle valve in front of each bearing to jack up
journals by0.03～0.05mm. For the unit that starts up for the first time, both jacking
height and jacking oil pressure for individual journal. will be recorded after
adjustment.

1.3.2.4 Start the turning gear as following:

a. Inspect the rotation hand of motor;

b. Put turning gear into operation.

1.3.3 Start the motor-driven HP oil pump and test the safety devices for their trip-
off action, as follows:

1.3.3.1 Start the turning gear;

1.3.3.2 Switch in all safety devices;

1.3.3.3 Respectively open main stop valve and steam governing valve and make
each safety devices trip off, and then check main stop valve, steam governing valve
and extraction valve for a speedy closure as a result.

1.3.3.4 After confirming that everything comes up to standard through the above
tests, switch in all safety devices once again and turn down the hand wheel
of the starting valve to the extreme.

3
1.3.3.5 Check the MSV for tight closure.

1.3.3.6 Electrical reset

1.4 Warming-up (in front of the main stop valve)

Both the steam turbine and the main steam pipe from the isolation valve to the
main stop valve are to be warmed concurrently.

1.5 Start the condensing system for vacuum pumping.

1.5.1 Start the circulating water pump

1.5.1.1 Fully open the circulating water outlet valve while slightly open the inl
et valve of the condenser

1.5.1.2 Start the circulating water pump while open the inlet valve fully.

1.5.2 Open the valve in the condensate recirculating pipe and shut off the
condensate valve leading to the feed-water regenerative pipe.

1.5.3 Start on trial the two condensate pumps alternatively. Once the test on th
e linkage
device proves out, put either of the condensate pumps into service, as follow
s:

1.5.3.1 Fill condensing or chemically treated water into the steam side of the c
ondenser till to a position where 3/4 of total graduations of the water level ga
uge of the hot well.

1.5.3.2 Open the inlet valve of the condensate pump.

1.5.3.3 Open the valve in the air piping between the outer shell of the conden
sate pump
and the steam side of condenser.

1.5.3.4 Check if the condensate pump is full of water. Open the water inlet co
ck for the
packing of the pump. Start the condensate pump while slowly opening the outl
et valve of
the pump.

1.5.4 Put both starting ejector and steam ejector into operation for vacuum pu
mping.

1.5.5 It is forbidden to supply steam to shaft gland too early.

4
1.5.6 During start-up, vacuum will reaches to 0.055～0.06MPa (400～450mmHg).

5
1.6 Start-up

1.6.1 Start motor-driven HP oil pump with the outlet oil temperature of oil cooler
not less than
25℃.

1.6.2 Start jacking oil pump and put the turning gear into operation.

1.6.3 Put shaft gland cooler into operation to supply steam to shaft gland. When the
inlet steam temperature of surge tank exceeds 300℃, spray water for attemperation
and adjust the valve for a pressure 0.097～0.099MPa(abs.) in the steam side.

1.6.4 Open the by-pass valve for the isolation valve, which, during start-up and
warming-up, will be used to throttle steam flow for pressure reduction so that the
pressure before the main stop valve is 2.5～3.0MPa.

1.6.5 Make sure that the electric governor passes a self-checking and then turn the
hand wheel of the starting valve to FULL-OPEN position to open the main stop valve, at this
moment, the steam governing valve will shut off and no speed-up of rotor will be
allowed.

1.6.6 Reset the electric governor and start the unit manually or automatically. After
the rotor goes into rotation, check the flow passage, shaft glands and main oil pump
for abnormal noise, if any. Check if the turning gear detaches off and turning gear
motor stops running once the speed of rotor exceeds that of turning gear, and
jacking oil pump stops working once the speed of rotor exceeds 200r/min.

1.6.7 When the inlet oil temperature of a bearing is higher than 40 ～45℃, put the
oil cooler into
service so as to keep the outlet oil temperature of oil cooler at 35～45℃.

1.6.8 The control over acceleration of the steam turbine is as illustrated by the start-
up curve in the Volume 1 of Installation and Operation Manual.

1.6.9 During the speed-up period, supervise the followings closely:

(1) Oil temperature, pressure and level;

(2) Temperature and scavenge oil flowing condition of bearings;

(3) Working condition of oil pumps;

(4) Expansion of casing, axial displacement of rotor and expansion difference;

(5) Temperature difference between the upper and lower halves of the casing,
between the
inner and outer walls of flange.

(6) Vibration of the unit

6
1.6.10 During the speed-up period, pay attention to the followings:

1.6.10.1 Regulate the water drain valves in the main steam line, extraction line and the
casing proper to let out the drain water until it is exhausted completely, where after,
close the said drain valves.

1.6.10.2 In case of any abnormality found in the oil system, stop the acceleration to
find out the causes.

1.6.10.3 In case of any abnormal noise or vibration in the oil system, reduce the
speed for a check-up.

1.6.10.4 .In case of any abnormal thermal expansion, stop the acceleration
for a check-up.

1.6.10.5 Put the water spray header into operation once the exhaust chamber
exceeds 120℃.

1.6.10.6 Strictly control both the metal temperature rise rate and the metal
temperature difference of the casing., as follows:

Temperature rise rate of casing wall: < 4℃/min

Temperature difference between upper and lower halves of casing: <
50℃ Temperature difference between inner and outer walls of flange:
100℃ <

1.6.10.7 After warming-up process and a normal expansion of the unit is assured,
open the isolation valve gradually and close the by-pass valve.

1.6.11 When the rotor goes up to the rated speed, check the following

(1) Inlet and outlet oil pressure of the main oil pump

(2) Pulse oil pressure

(3) Temperature of bearing oil and pads, and lubricating oil pressure

(4) Complete the switch between main oil pump and starting oil pump.
Inlet valve for starting oil pump will be shut gradually during the first
switch.

1.6.12 While making each safety device trips off respectively, check the main
stop valve, steam governing valve and extraction valve for a rapid closure as a
result.

1.6.13 An over-speed test will be needed for the steam turbine that has the first
start-up, after a major overhaul or has a stoppage to be more than 1 month, which is
to be conducted after the turbine runs for 1 hour taking 20% of the rated load. In
doing so, reduce the load to zero and then do the following:
7
 1.6.13.1 Conduct an EHC over-speed test by raising the rotor speed to 3270 r/min, as
a result, EHC over-speed protection will trip off.

1.6.13.2 Conduct a MHC over-speed test by raising the turbine speed to 3300～3360
r/min, as a result, emergency governor will trip off, if not, hit the emergency governor
pilot valve with hand at once for a shut-down of the unit.(EHC system will cause an
automatic shut-down at the speed of 3390 r/min.)

1.6.13.3 After trip-off, emergency governor is to be reset when the rotor speeds
down to 3060～3030 rpm.

1.6.14Make sure that all are normal during start-up and then put the generator into
the power grid.

1.7 Taking load

1.7.1 Taking electric load

1.7.1.1 With the exception of some special demand, the turbine will not run in no-
load for a long time. Once the generator is put into the power grid, the unit will take
on an electrical load of 5％ the rated value. The temperature at the exhaust casing
is not allowed to exceed a value ranging 100～120℃ during no-load running, and a
value ranging 60～70℃ after the unit carries a load.

1.7.1.2 The control over the loading is illustrated by the loading curve in the
Volume 1 of the Installation and Operation Manual.

1.7.1.3 During loading procedure, be ware to control the metal temperature rise rate,
relative expansion, expansion difference and temperature difference, the control
indexes of which are same to the requirements for acceleration.

1.7.1.4 When loading, attention will be paid to the adjustment and switchover of
relevant systems and equipment.

1.7.1.5 Supervise closely the vibration of the unit. Stop the load-up process at any
increment of vibration and hold it at the load for 30 minutes. If it fails to eliminate
the vibration, reduce the load by 10 ～15 ％and hold it for more 30 minutes. If the
vibration still remains, an investigation to find out the causes will be required.

1.7.1.6 After the unit starts to take load, the LP heater can be put into operation with
HP heater according to the drain methods gradually.

2. Sliding pressure start-up

Preparatory work for the sliding pressure start-up is same to that for the start-up under rated
parameters, with the exception that for the former, during the start-up process, the steam condition
before the steam turbine will vary in response to the starting condition of boiler and the steam
turbine unit will start simultaneously with the boiler.

2.1 Preparatory work before the ignition of boiler

8
2.1.1 Open the motor-driven main gate valve and close both the main stop valve and
steam governing valve. Open the drain valves of the steam turbine proper.

2.1.2 Close the steam and attemperating water inlet valves in the temperature and
pressure reducing by-pass line to the LP heating network. Both the said steam and
water inlet valves will be put into operation according to pressure and temperature
during start-up.

2.1.3 Put circulating water and condensate systems into service.

2.1.4 Put oil system and turning gear into service.

2.1.5 Start water eductor for vacuum pumping.

2.2 Ignition and pressure rise of boiler

2.2.1 When the vacuum reaches to 0.0267MPa (200mmHg), ignite the boiler.

2.2.2 When the steam pressure rises up to balance with the pressure in the LP heating network,

open the steam inlet valve in the temperature and pressure reducing by-pass line.

2.3 Start-up

2.3.1When the steam pressure reaches up to 1.5MPa with temperature 250～300℃,

supply steam to shaft glands to maintain vacuum 0.06 ～ 0.067MPa(450 ～
500mmHg) in the condenser.

2.3.2 Start the unit and perform a warming –up practice according to speed-up curve.

2.3.3 Put the water spray header into operation.

2.3.4 When the unit goes up to rated speed, an overall inspection will be performed
and tests made on safety system.

2.3.5 Make sure that all are in normal condition, then put the unit into the power
grid, with the main steam condition being 2.0～2.5MPa and 300～350℃.

2.4 Taking load

2.4.1Once being put into the power grid, the unit will take 5% of the rated load,
while gradually closing the steam inlet valve in the temperature and pressure
reducing by-pass line.

2.4.2 After the steam governing valve is fully opened, the unit load will be increased
through temperature and pressure rise of the boiler. Main steam pressure rise rate is
limited to 0.2～0.3MPa/min, temperature rise rate to 2～3℃/min. and load-up rate
250KW/min.

9
2.4.3 Strictly follow the indices of casing metal temperature rise rate, relative expansion,

difference of expansion and temperature, etc.

3．Hot start-up

The metal temperature 150℃ of the casing inner wall behind governing stage. is
used as the demarcation line for defining hot start-up, namely, the start-up at
higher than 150℃ is defined as hot start-up, and that at less than 150℃ as
cold start-up. And, hot start-up can be classified further to hot start-up and
warm start-up according to the stoppage time or the metal temperature of the
casing inner wall. The restarting of the unit will be defined as hot start-up in
the case that it has just finished a stoppage time of less than 24 hours or the
metal temperature of the casing inner wall is higher than 300℃; and that defined
as warm start-up in the case that the unit has just finished a stoppage time of
less than 48 hours or the metal temperature of the casing inner wall is greater
than 150℃.

3.1 Principle for hot start-up

3.1.1 Bending of the rotor is not greater than 0.06mm;

3.1.2 Metal temperature difference between the upper and lower halves of casing is
less
than 50℃;

3.1.3 Inlet temperature is 50℃ higher than the temperature of the hottest
component of the steam turbine, for fear that the component in high temperature
state would be cooled;

3.1.4With the rotor being rotated by the turning gear, supply steam to the shaft
gland and then, make the vacuum pumping there. High temperature steam will be
supplied to shaft gland.

3.1.5 The turning gear will work for not less than 1 hour;

3.1.6 In case of any vibration amplitude greater than 0.03mm when the unit runs at
less than middle speed, shut down the steam turbine immediately and put the turning
gear into running once again.

3.1.7 Closely supervise the variation of expansion difference.

3.2 Operation of hot start-up

3.2.1 The hot start-up manner is same to cold start-up manner under rated condition,
with the exception of shorter time of speed-up and load taking, see the Volume 1 of
Installation and Operation Manual.

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3.2.2 Vacuum in the condenser will be kept above 0.067MPa (500mmHg).

3.2.3 Lubricating oil temperature will be not less than 40℃ before jogging the rotor.

4 Maintenance and inspection during normal operation of steam turbine

4.1 Keep the equipment clean and take care of the insulation.

4.2 Record the readings of instruments regularly.

4.3 Check and calibrate instruments periodically.

4. 4 Check the oil system periodically, as following.

4. 4.1 Keep the pipes clean, unblocked and free of oil leakage.

4. 4.2 Flush the oil cooler

4. 4.3 Analysis of oil quality

4. 4.4 Oil strainer will be switched over to stand-by oil strainer and the gauze be
washed clean in case of a pressure difference exceeding 0.05MPa between before
and behind the oil strainer.

4.4.5 Examine the operation of oil purifier.

4.4.6 Examine the oil level in oil tank, drain off sedimental water and oil residue,
and wash oil strainer gauze.

4.4.7 Check the motor-driven oil pump for automatic starting.

4.5 Lubricating oil and grease will be injected regularly into pin joints of levers and
sliding plane between front bearing housing and base plate. Apply oily molykote at
positions of high temperature..

4.6 Flush the oil strainer gauze periodically.

4.7 Test the safety system periodically.

4.8. Move up and down the valve spindles of key valves such as the main stop
valve and electrical- operated isolation valves one or two times every day for
preventing valve spindle from any seizure, this practice must be done with the unit
taking a smaller load.

4..9 For the steam turbine which often takes a constant load, the steam governing valve is to be

examined periodically on its open-and-close action by means of fluctuating the load within a

short time periodically.

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4.10 Frequency is limited to 48.5～50.5Hz.

4.11 The inlet oil temperature of all bearings will be kept in a range 35～45℃,
and generally, the
temperature rise will not exceed 10～15℃. The lubricating oil pressure will be kept in
a range 0.08～ 0.12 MPa(g).

4.12 Test the vacuum system for leakage and wash the water side of
condenser regularly.

4.13 With the exception of special causes, the regenerative system must not stop its service.

.
4.14 Following measures will be adopted for putting the stand-by oil cooler into
service:

4.14.1 Open the oil drain valve and check the oil discharging therefrom. Be sure that
neither sedimental water nor oil residue exists in the oil side of the stand-by oil
cooler.

4.14.2 Slowly open the oil inlet valve of the stand-by oil cooler to fill in oil, and
meanwhile, open the air relief valve at the oil side to vent off air completely. See
that no oil pressure fluctuation occurs in the oil system during oil filling.

4.14.3 Open both the air relief valve and the water inlet valve at the water side of the
stand- by oil cooler following that the water outlet valve is opened, in order to let
water into the water side. As soon as the air has been exhausted, close the air relief
valve.

4.14.4 Slowly open both the oil outlet valve at the oil side and the water inlet valve
at the water side, be sure no fluctuation of lubricating oil pressure and
temperature occurs in doing so.

4.14.5 To stop an oil cooler in service, be ware to close the valves at the oil side and
water side slowly. For the water side, close the water inlet valve first and then the
water outlet valve.

4.14.6 Of the oil cooler, the pressure in the oil side will be higher than that in the
water side, with the water inlet valve being used to regulate the cooling water flow.

5. Shut-down

There are two manners of shut-down, normal shut-down and emergency shut-
down.

5.1 Normal shut-down

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5.1.1 Before the load reduction, notify all relevant sections for preparation.

5.1.2 Test all auxiliary oil pumps.

5.1.3 Test turning gear motor and jacking oil pump.

5.1.4 Check main stop valve and steam governing valve for any seizure appearing at
the valve spindles.

5.1.5 Check the temperature and pressure reducing by-pass line.

5.1.6 Load reduction. For the unit which needs a restarting after a outage of short
time, a quick load reduction manner is to be adopted, by which the load will be
reduced to zero in 25 minutes; and for that after a outage of longer time, a slow load
reduction manner is to be adopted, by which the load will be reduced at the rate of
250KW/min to its 10～15% first, and then reject the remains.

5.1.6 In reducing load, following measures will be adopted:

(1) The casing metal temperature fall rate does not exceed 1.5℃/min.

(2) According to the water level in the hot well, adjust the opening of main
condensate recirculating valve.

(3) According to the load reduction and variation of extraction pressure, separate
heaters in order from HP side, and stop the working of drain valve.

(4) Supervise closely the expansion, expansion difference and vibration of the
unit at all time.

(5) Regulate the steam supply to shaft gland.

(6) In case that the valve is found to be stuck, which can not be eradicated
during the operation, gradually shut off the main stop valve or the electric
isolation valve to reduce the load until stoppage.

5.1.7 Reduce the load to zero. Once receiving a signal for parallel-off, strike the
small spring cover atop the emergency governor pilot valve to close the main stop
valve. Check if the main stop valve has been closed tightly.

5.1.8 During the speed-down and shut-down procedure, check if the motor-driven oil
pumps go into service automatically, if not, start the starting oil pumps manually in
order to keep a lubricating oil pressure not less than 0.055 MPag.

5.1.9 Stop the working of air ejectors to reduce the vacuum gradually, and then stop
the condensate pump.

5.1.10 As soon as the vacuum drops to zero and the rotor stops rotating, cut the
steam supply to shaft gland.

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5.1.11 Once the rotor stops rotating completely, put the turning gear into service.
Before that, start the jacking oil pump. Make sure that the rotor has been jacked up
before putting the turning gear into operation. Turn the rotor continuously till the
casing metal temperature drops to 200℃, which then switches over to a routine
turning until the steam turbine becomes completely cold, i.e. the metal temperature
of the casing drops to less than 150 ℃.

5.1.12 During the turning gear operation, the lubricating oil pump will take over its
service, until the unit becomes completely cold.

5.1.13 During the lubricating oil pump operation, adjust the outlet oil temperature of
the oil cooler to 35～40℃.

5.1.14 Stop the service of the circulating water pump when the temperature of
the exhaust chamber drops to 50 ℃or less after the rotor rests for 1 hour.
A stand-by water source will be used instead to supply water to oil cooler
for the turning gear later.

5.1.15 Once the oil inlet temperature of oil cooler drops to less than 35℃, stop
the working of oil cooler.

5.1.16 Close all the valves in steam and water lines while opening the direct drain
valves. Close the drain valve connected to the casing proper and take strict
measures to stop leak steam from entering the casing

5.2 Emergency shut-down

In case of an abnormal situation with the unit, an emergency shut-down will be

conducted, during which the steam admission will be cut out and total load rejected
immediately. As for emergency shut-down, following principle will be adopted:

5.2.1 An estimate of the nature and scope of accident will be made in the shortest
time.

5.2.2 Rapidly rid person and equipment of danger.

5.2.3 Resume power supply as soon as possible under condition that equipment is
guaranteed not to be damaged.

5.2.4 Avoid error operation.

6. Precaution and handling of accidents and failures

6.1 Emergency shut-down

An immediate shut-down will be affected under following circumstances:

6.1.1 The emergency governor fails to trip off when the turbine speed exceeds

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3360r/min..

6.1.2 Vibration amplitude of a bearing housing exceeds 0.07 mm.

6.1.3 Something goes wrong with the main oil pump.

6.1.4 Governing system works abnormally.

6.1.5 The axial displacement limiting device or axial displacement monitor fails to
act when the rotor axial displacement exceeds a limit value.

6.1.6 Temperature of bearing scavenger oil exceeds 70℃ or the metal temperature of a
bearing liner exceeds 100℃.

6.1.7 Oil system catches fire, which can not be extinguished immediately.

6.1.8 The oil level in the oil tank drops below the lower limit position suddenly.

6.1.9 Water hammer accident occurs.

6.1.10 Any abnormal sounds from inside the steam turbine have become audible.

6.1.11 A burst occurs in the main steam pipe.

6.1.12 The vacuum inside the air-cooler drops below 0.06 MPa (450 mmHg).

6.2 Following measures will be adopted in case that the main steam pressure and
temperature. Exceed specified values:

6.2.1 When the main steam pressure exceeds the upper limit of a permissible range,
the steam flow will be throttled to reduce the pressure. If not, an outage is
necessary.

6.2.2 Reduce the load in case the main steam pressure drops to 0.2 MPag less than
the lower limit of a permissible range.

6.2.3 An emergency shut-down will be necessary in case that the main steam
temperature is 5℃ higher than the upper limit of a permissible range and can’t be
reduced after running for 30 minutes under this condition The accumulated working
time under this condition must not exceed 400 hours annually..

6.2.4 Reduce the load in case that the main steam temperature is 5℃ less than the
lower limit of permissible range.

6.3 Rules for the vacuum drop inside the condenser are as follows:

6.3.1 When the unit takes more than 40％ of the rated load, the vacuum must
be not less
than 0.0867 MPa (650 mmHg).

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6.3.2 When the unit takes 20～40％ of the rated load, the vacuum must be no
t less than
0.0800MPa (600 mmHg).

6.3.3 When the unit takes less than 20％ of the rated load, the vacuum must
be not less
than 0.0720MPa (540 mmHg).

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