Indian Salaya Project 2x600MW Power Station Training Manual

Indian Salaya Project 2x600MW Power Station Training Manual
2x600MW Training Manual
（20110223）
中国哈尔滨汇通电力工程有限公司发布
Issued by Harbin Huitong Electric Power Engineering Co., Ltd.
Indian Salaya Project 2x600MW Power Station
Training Manual of Turbine
ESSAR Group
哈尔滨电站工程有限责任公司
HARBIN POWER ENGINEERING COMPANY LIMITED
哈尔滨汇通电力工程有限公司
Harbin Huitong Electric Power Engineering Co., Ltd.

600MW Training Manual of Turbine
CONTENT
1 Turbine Design Parameter and Operation Conditions .........................................................................................7
1.1 Main Parameter of Turbine .............................................................................................................................7
1.2 Main Design Characteristics ...........................................................................................................................8
1.3 Account Data Table of Prospective Function for Turbine ....................................................................................8
2 Turbine Body Structure ..................................................................................................................................8
2.1 Steam Flow Path ...........................................................................................................................................8
2.2 HP and IP Valves ...........................................................................................................................................9
2.3 HIP Casing ...................................................................................................................................................9
2.4 LP Casing................................................................................................................................................... 10
2.4.1 LP Casing Design ........................................................................................................................................ 10
2.4.2 Rear Casing Spray System............................................................................................................................ 11
2.5 Rotor ......................................................................................................................................................... 12
2.6 Slide Pin System ......................................................................................................................................... 12
2.7 Relief Valve ................................................................................................................................................ 13
2.8 Oil Control Tripping Valve ........................................................................................................................... 14
2.9 Steam Gland ............................................................................................................................................... 14
2.10 Turbine Barring Gear ................................................................................................................................... 14
3 Water and Steam System of Turbine............................................................................................................... 15
3.1 Main Steam and Bypass System .................................................................................................................... 15
3.1.1 Main Steam ................................................................................................................................................ 15
3.1.2 Reheat Steam System................................................................................................................................... 15
3.1.3 Bypass Steam System .................................................................................................................................. 16
3.2 Condenser Extracting Vacuum System ........................................................................................................... 16
3.3 The Condensate Water System ...................................................................................................................... 16
3.4 HP LP Heater System................................................................................................................................... 17
3.4.1 HP Heater System ....................................................................................................................................... 17
3.4.2 LP Heater System........................................................................................................................................ 18
3.5 Deaerator ................................................................................................................................................... 18
3.6 Feed Water System ...................................................................................................................................... 19
3.7 Recirculating Cooling Water System .............................................................................................................. 22
3.8 Auxiliary Steam System ............................................................................................................................... 22
3.9 Extraction Steam Drainage System ................................................................................................................ 23
3.9.1 Extraction Steam and Drainage of Turbine...................................................................................................... 23
3.9.2 Turbine Drainage ........................................................................................................................................ 23
4 Turbine Auxiliary System ............................................................................................................................. 26
4.1 Lubrication Oil and Jacking Oil System for Turbine......................................................................................... 26
4.2 EH Fire Resistant Oil and Purifying Oil System .............................................................................................. 26
4.2.1 EH (Electro-Hydraulic) System Operation Principle ........................................................................................ 26
4.2.2 Basic Composition of EH Control System ...................................................................................................... 26
4.2.3 EH Fluid Supply System .............................................................................................................................. 27
4.2.4 Actuators.................................................................................................................................................... 27
4.2.5 Emergency Trip Protection System ................................................................................................................ 29
4.2.6 Mechanical Over Speed and Manual Trip Device ............................................................................................ 29
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4.2.7 Oil Conditioning System .............................................................................................................................. 30

4.3 Shaft Sealing System: .................................................................................................................................. 31
4.4 Hydrogen Cooling System for Generator ........................................................................................................ 32
4.4.1 Cooling Type .............................................................................................................................................. 32
4.4.2 Technical Parameter of the Hydrogen Control System. ..................................................................................... 32
4.4.3 The Gas Replacement Method of the Generator is Medium Gas-Assistant Replacement. ...................................... 33
4.4.4 Feeding and Draining the Hydrogen in the Normal Operation of the Generator.................................................... 34
4.4.5 Main Equipments ........................................................................................................................................ 34
4.5 Cooling Water System for Generator Stator .................................................................................................... 35
4.5.1 Operation Principle of the Stator Cooling Water System ................................................................................... 35
4.5.2 Main Equipments ........................................................................................................................................ 36
4.6 Sealing Oil System ...................................................................................................................................... 37
4.6.1 Sealing Principles ........................................................................................................................................ 37
4.6.2 Constituents of Seal Oil System .................................................................................................................... 37
4.6.3 Operation Mode of Seal Oil System ............................................................................................................... 37
4.6.4 Design Parameter ........................................................................................................................................ 37
4.7 Industrial Cooling Water System ................................................................................................................... 38
4.8 Closed Cycle Cooling Water System .............................................................................................................. 38
4.9 Open Cooling Water System ......................................................................................................................... 39
5 Turbine Start............................................................................................................................................... 39
5.1 Inspection Operation Regulation before Start for Turbine Body System.............................................................. 39
5.1.1 Check Operation Regulation before Turbine Startup ........................................................................................ 39
5.1.2 The Conditions of Turbine Proper is Prohibited to Start. ................................................................................... 40
5.1.3 Every System’s Inspection before Rolling the Turbine. ..................................................................................... 40
5.1.4 Turbine Start............................................................................................................................................... 42
5.2 Start Parameter and Attention of Different State .............................................................................................. 51
5.3 Attention of Hot and Warm Start for the Unit .................................................................................................. 52
6 Adjustment of Turbine Operation Adjusting .................................................................................................... 53
6.1 Turbine Operation ....................................................................................................................................... 53
6.1.1 TSI Turbine Supervisory Instruments (TSI) .................................................................................................... 53
6.1.2 Steam and Metal Thermocouples ................................................................................................................... 55
6.2 Supervision and Protection System ................................................................................................................ 56
6.2.1 Items of Turbine Supervision Instrument ........................................................................................................ 56
6.2.2 Safety System Guaranteed Performance ......................................................................................................... 56
6.3 Set Values for Turbine Control ...................................................................................................................... 56
6.4 Turbine Operation Control............................................................................................................................ 56
6.4.1 Load Control .............................................................................................................................................. 56
6.4.2 Main Steam Pressure Control ........................................................................................................................ 57
6.4.3 Shut Down by Accident................................................................................................................................ 57
6.4.4 Auto Turbine Control (ATC) ......................................................................................................................... 58
6.4.5 Auto Turbine Control (ATC) ......................................................................................................................... 59
6.5 Attention of Turbine Operation ..................................................................................................................... 59
6.5.1 General Attention ........................................................................................................................................ 59
6.5.2 Gland System Attention ............................................................................................................................... 61
6.5.3 LP Exhaust and Exhaust Spray Attention ........................................................................................................ 62
6.5.4 Drainage System Attention ........................................................................................................................... 64
6.5.5 Temperature Limits for Bearing Metal............................................................................................................ 65
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6.5.6 Emergency Power Supply Attention............................................................................................................... 65

6.5.7 Turbine Bypass System Attention .................................................................................................................. 66
6.5.8 Desuperheating-Purpose Water Spray Attention............................................................................................... 66
6.5.9 Weekly Inspection ....................................................................................................................................... 66
7 Turbine Shutdown ....................................................................................................................................... 67
7.1 Turbine Normal Shutdown............................................................................................................................ 67
7.2 Forced Cooling for Turbine Maintenance........................................................................................................ 71
8 Turbine Accident and Handling ..................................................................................................................... 72
8.1 The Conditions of Vacuum Break Shutdown and No Vacuum Break, Handling and Attention after Shutdown ......... 72
8.1.1 Conditions for Breaking Vacuum Emergency Shutdown................................................................................... 72
8.1.2 Conditions for Non-vacuum Breaking Emergency Shutdown ............................................................................ 73
8.1.3 Unit Emergency Shutdown Operation ............................................................................................................ 73
8.2 Condenser Vacuum Decline (not reach to the low value of turbine trip) .............................................................. 74
8.2.1 Phenomenon ............................................................................................................................................... 74
8.2.2 Reason ....................................................................................................................................................... 75
8.2.3 Treatment................................................................................................................................................... 75
8.3 Water Attack Accident.................................................................................................................................. 76
8.3.1 Phenomenon ............................................................................................................................................... 76
8.3.2 Reason ....................................................................................................................................................... 76
8.3.3 Treatment................................................................................................................................................... 76
8.4 Severe Overspeed of Unit ............................................................................................................................. 77
8.4.1 Phenomenon ............................................................................................................................................... 77
8.4.2 Reason ....................................................................................................................................................... 77
8.4.3 Treatment................................................................................................................................................... 78
8.5 Turbine Vibration Severe Vibration ................................................................................................................ 78
8.5.1 Phenomenon ............................................................................................................................................... 78
8.5.2 Reason ....................................................................................................................................................... 78
8.5.3 Treatment................................................................................................................................................... 79
8.6 Blade Broken of Turbine .............................................................................................................................. 79
8.6.1 Phenomenon ............................................................................................................................................... 79
8.6.2 Treatment................................................................................................................................................... 79
8.7 High Temperature of Turbine Bearing ............................................................................................................ 80
8.7.1 Phenomenon ............................................................................................................................................... 80
8.7.2 Reason ....................................................................................................................................................... 80
8.7.3 Treatment................................................................................................................................................... 80
8.8 Abnormal Axial Displacement of Turbine ....................................................................................................... 81
8.8.1 Phenomenon ............................................................................................................................................... 81
8.8.2 Reason ....................................................................................................................................................... 81
8.8.3 Treatment................................................................................................................................................... 81
8.9 Accident Disposal Principle .......................................................................................................................... 82
8.9.1 Accident Handling Principles ........................................................................................................................ 82
8.9.2 Key Points during Accident .......................................................................................................................... 82
8.10 Main Turbine Lubrication Oil System Breakdown ........................................................................................... 83
8.10.1 Oil Tank Oil Level Declines or Rises ............................................................................................................. 83
8.10.2 Oil Level Indication Abnormal ...................................................................................................................... 84
8.10.3 Oil Pressure Declines ................................................................................................................................... 84
8.11 EH Oil System Breakdown ........................................................................................................................... 86
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8.11.1 Common Fault Phenomenon ......................................................................................................................... 86

8.11.2 Fault Reason............................................................................................................................................... 86
8.11.3 Treatment for EH Oil System Common Fault .................................................................................................. 86
8.12 Closed Cooling Water Fault .......................................................................................................................... 87
8.12.1 Common Fault ............................................................................................................................................ 87
8.12.2 Fault Treatment........................................................................................................................................... 87
8.13 Sealing Oil Fault ......................................................................................................................................... 88
8.13.1 Phenomenon ............................................................................................................................................... 88
8.13.2 Reason ....................................................................................................................................................... 88
8.13.3 Treatment................................................................................................................................................... 89
8.14 Hydrogen System Fault ................................................................................................................................ 89
8.15 Stator Cooling Water Interrupted ................................................................................................................... 91
8.15.1 Phenomenon ............................................................................................................................................... 91
8.15.2 Reason ....................................................................................................................................................... 91
8.15.3 Treatment................................................................................................................................................... 91
8.16 Stator Cooling Water Degree of Conducting is High ........................................................................................ 92
8.16.1 Phenomenon ............................................................................................................................................... 92
8.16.2 Reason ....................................................................................................................................................... 92
8.16.3 Treatment................................................................................................................................................... 92
9 Attachment ................................................................................................................................................. 93
Attachment 1 Control Set Value Turbine Operation................................................................................................... 93
Attachment 2 Reference Curve of Unit Startup ......................................................................................................... 99
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Training Material of Turbine for Indian Salaya Project
1 Turbine Design Parameter and Operation Conditions
Turbine Manufacturer: Haebin Turbine Co., Ltd.
This product is sub-critical, single reheat, single shaft, 3-casing, 4-flow and condensing type of turbine.
Style： N600-16.7/538/538
1.1 Main Parameter of Turbine
Rated Power: 600MW（TMCR condition+0%rate of make up water，heat consumption firm condition）
Maximum Power: 649.74MW （VWO condition+0%rate of make up water）
Main Steam Parameter of Rated Condition (front main steam valve of HP)
Pressure: 16.7MPa (a)
Temperature: 538℃
Flow Rate: 1866.68t/h
Reheat Steam Parameter of Rated Condition (front combine steam valve of IP):
Pressure: 3.423MPa (a)
Temperature: 538℃
Flow Rate: 1572.73t/h
Exhaust Pressure of Rated Condition for HP Casing: 3.804MPa (a)
Maximum Admission of Main Steam: 2060t/h （VWO condition）
Average Exhaust Pressure of LP Casing: 9.60 kappa (a)
Steam Distributing Mode: Nozzle Governing
Temperature of Recycling Cooling Water: 33℃
Feed Water Temperature of Rated Condition: 275.3℃
Rated Revolution: 3000r/min
Heat Consumption of Rated Condition (heat consumption firm condition): 8122.4kJ/kW.h
Blade Length of Last Stage for Low Pressure: 680mm
Regeneration System: three high, four low, one deaerator
Heater Stage 8
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1.2 Main Design Characteristics
Eight stage regeneration system consists of single reheat, three stage high pressure heater, single deaerator and four
stage low pressure heater, each stage drain water of heater flows naturally stage by stage. Two LP casings of turbine
exhaust steam into two-pressure condenser.
The forth stage bled steam is used for heating deaerator, diven for feed water of turbine and auxiliary steam system of
power plant. Back of diven feed water pump of turbine adopt cooling reheat steam and auxiliary steam. Booster pump
of turbo-feed pump is driven by electric motor. Driven feed water pump of turbine exhausts main condenser.
The requirements of steam quality for accessing turbine are following:
Sodium <10μg/kg
Silica <20μg/kg
Electrical conductivity 25℃ <0.30μS/cm
Iron ≤20μg/kg
Copper ≤5μg/kg
Start and operation mode: combined start of HIP casing
1.3 Account Data Table of Prospective Function for Turbine
See the attachment
2 Turbine Body Structure
2.1 Steam Flow Path
The steam turbine uses combined impulse and reactive design. The live steam will enter the combined main stop and
control valve supported by fixed bearings at both sides and discharge from two control valves at each side. After 4
pieces of HP pipe, the steam will enter the HP turbine. Two pieces of pipings are located on both upper half and lower
half respectively. The steam after passing one control stage and 9 HP stages will discharge from the outlets on lower
half of outer casing and then enter the reheater. The reheat steam will enter the two combined reheat stop and intercept
valves at both sides and discharge from two IP control valves at each side. After 4 pieces of IP piping, the steam will
enter the IP turbine from the middle inlet. The IP inlet pip ings are located with two pieces on both lower and upper half
respectively. The steam after passing 6 reactive stages in IP turbine will discharge from the upper outlet of IP turbine
and then enters No.1 and No.2 LP turbine respectively at the middle inlet after passing the IP and LP crossover piping.
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Both of the LP turbines are with double flow structure which means the steam will enter from the middle inlet and flow
to the exhaust hood at each end after separately passing through 6 stages both positive and reverse stages. Then, the
steam will be exhausted downward
2.2 HP and IP Valves
The combined reheat stop and intercept valve casing is the integral casting by alloy. There are two reheat stop and
intercept valves for one unit which are located on each side of HIP turbine respectively. Each combined reheat stop and
intercept valve consists of one staggering main stop valve and two control valves. The openings of these valves are
controlled by its servo motor which is controlled by DEH system.
2.3 HIP Casing
HIP casing structure mode and supporting mode should be fully considered during design. It can be kept with the free
and symmetric shrinkages and expansions of casing while the heating state being changed. Meanwhile, the
deformation having possibility to be occurred will be reduced to the lowest limit. HIP external casing cast by alloy
steel will be formed with the upper half and lower half through horizontal joint. Likewise, the inner casing will be alloy
steel casting and be formed with the upper half and low er half through horizontal joint. The inner casing will be
supported at the joint surface of outer casing, and be oriented with the upper and lower locating pins so as to make the
casing keep the correct position with the shafting line of steam turbine, and make the casing shrink and expand freely
following the variations of temperature at the same time.
The nozzle of HP turbine will be also cast with alloy steel, and be formed with the upper and lower half through
horizontal joint. It will be applied with the centerline to locate, and be supported at the joint face of inner casing. The
axial position of nozzle chamber will be located with the fixation of grooves and convex shoulders of upper and lower
half inner casing. The upper half and lower half inner c asing will have sliding keys to determine the transverse position
of nozzle chamber. This structure can ensure the nozzle chamber to shrink or expand on the basis of the main steam
temperature variation along correct axial pos ition of steam turbine. The main steam admission pipe and nozzle
chamber will be connected with seal ring through sliding so as to reduce the deformation caused of temperature to
reach the lowest limitation. The upper half of outer casing and the lower half of inner casing can be applied with the
jacking screw to run up until the steam admission pipe and nozzle chamber will be completely separated, and then to
lift them with the hoist according to the conventional method. It will keep the steam chamber shape at the admission
steal place as possible while disassembling the upper half of outer casing or the lower half of inner casing. On the other
hand, the casing will be concentric with the seal ring.
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HP diaphragm carrier and HIP admission balance ring for the steam turbine will be supported on the horizontal joint of
inner casing, and to be oriented with the locating pin at the upper and lower half of inner casing. IP No.1 diaphragm
carrier, IP No.2 diaphragm carrier and HP exhaust dummy ring for the steam turbine will be supported on the outer
casing, and the supporting mode will be same with that of inner casing.
The thermal shield is equipped for IP inner casing. The thermal shield is made of 12Cr2Mo1 steel plate by welding
with the upper half and lower half connected by flange. The inlet pipe of IP turbine is connected with the outer casing.
The inlet piping of thermal shielf is inserted into the inlet pipe of outer casing. Sealing device is provided at the joint.
After the 9 stages of HP turbine, the cooling steam will enter the clearance between IP outer casing and thermal shield
through the cooling holes and then enters IP flow path after passing through the cooling holes of thermal shield. The
thermal shield of IP turbine is to reduce the temperature difference between inlet steam and casing wall then to reduce
the stress of HIP outer casing. The structure of IP diaphragm carrier is preferable to the heating and expansion of IP
outer casing during start up with not only reduce the differential expansion of IP flow path but also to reduce the HP
differential expansion so as to reduce the start up time.
The upper and lower half of HIP casing will be connected with large size studs or locating studs on the horizontal joint.
In order to make each stud keep the correct stress, it must perform the initial tightening to them to receive certain
pre-stress. The correct tightening method will be described in the instruction manual ―bolt tightening‖. After finishing,
the casing will be conduct hydraulic test in compliance with the standard program and its joint face will not be painted
with the seal oil to so as to ensure the casing steam not to be leaked. But the joint face will be necessary to paint with
the good quality seal oil while assembling steam turbine and preparing to put into the operation in the power plant.
2.4 LP Casing
2.4.1 LP Casing Design
There are total two LP casings. LP outer casing will be completely welded with the steel plate to reduce the
temperature grads to design three-layer casing. The upper half and lower half of casing are divided into 3 parts
vertically. The flange of upper half of casing will be connected permanently with the bolt through to form an integral
structure which can be lifted as a whole during erection.
The 1st and 2nd diaphragm on the governor end of LP turbine is installed in the diaphragm carrier which is supported
on the No.1 inner casing. The 3rd, 4th and 5th diaphragm is installed in the No.1 inner casing and 6th and 7th
diaphragms are installed in the No.2 inner casing which is supported on the outer casing and which level is slightly
lower than the horizontal joint.
The 1st to 3rd diaphragm at generator end of LP turbine is installed in diaphragm carrier which is supported on the
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No.1 inner casing. The 4th diaphragm is installed in No. 1 inner casing and 5th and 6th diaphragms are installed in
No.2 inner casing which is supported on the outer casing and which level is slightly lower than the horizontal joint.
Each LP casing is supported on the base plate by the skirt which is integral with lower half of outer casing. The
position of LP casing is located by the four keys on both supports and lower half of diffusion section. The location of
keys are as follows: each key is arranged on the vertical centerline on each end of LP casing to locate the casing at
horizontal direction to allow the free vertical expansion of casing. Each key on both sides of each casing is arranged on
the transverse centerline to allow the free transverse expansion of casing. Two transverse locating key on four sides of
each LP casing and two axial locating pins form the independent dead point. There are 3 dead points totally. Another
one is located at both sides of lower half of 2# bearing pedestal where the HIP module will expand forward.
According to the operation characteristics of unit, the LP casing and bearing pedestal are on dependent foundation to
avoid the influence on bearing elevation by the variation of exhaust temperature and to ensure the bearing stability.
Meanwhile, the shaft glands of LP casing are fixed on the bearing pedestal by 3 support arms. Both horizontal and
vertical keys are provided.
2.4.2 Rear Casing Spray System
The water spray system is automatically put into operation when rotating speed of rotor reaches 600r/min or the
temperature of the LP exhaust reaching 90℃ and it continuously operates until the unit is put on 15% rated load.
When the turbine speed reaches 600r/min and the control switch at automatic position, the solenoid valve is driven by
one signal from turbine control system or by manual switch. The solenoid is open through powering the solenoid valve
to open the pneumatic valve. The water will be supplied by condensate pump to water spraying system.
The condensate flow through spray nozzle is controlled by pneumatic valve. Usually, the pneumatic valve is closed.
The solenoid valve is opened by air from regulator or air equipment when the solenoid valve is put into action through
automatic switch or manual operation. A pressure regulator, which is of mechanic device, controls the air supply to the
pneumatic valve. The pressure regulator, which uses constant pressure air, produces a variable output. And even water
flow is supplied to each water spray nozzle.
Under the steam flow with idle load and full vacuum, no rear casting overheating is expected. The bad vacuum
condition will cause the overheating of casing, just like the situation that the steam flow during moving backward is
much lower than the flow during idle load. If the temperature exceeds 90℃, the load in creasing or vacuum
improvement will occur to reduce the casing temperature. The limit temperature of casing is 120℃. If the temperature
reaches this value, the failure shall be eliminated by shutdown. In addition, one bypass valve is installed on water
spraying control valve. This bypass valve is only be used when the control valve is damaged or is in repair. In order to
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maintain the control pressure, the bypass valve shall be open big enough. In order to prevent the turbine from damage,
the bypass valve shall not be open when the turbine is in operation without water spraying.
2.5 Rotor
HIP rotor is of solid forging structure without bore. The shaft with main oil pump impeller and overspeed tripping
device is connected with HIP rotor at governor end by flanged bolts. There is thrust collar on impeller of main oil
pump.
LP rotor is of solid forging structure without bore.
All rotors with balding are finish machined and shall be performed with accurate high speed dynamic balancing test
and running test.
The couplings are provided between HIP rotor and 1# LP rotor, 1# LP rotor and #2 LP rotor as well as the 2# LP rotor
and generator rotors for rigid connection.
The shafting system is located by the thrust bearing in front pedestal. There are total 8 bearings for supporting
(including 2 for generator)
2.6 Slide Pin System
The temperature of each part of turbine will be greatly changed during the startup or shutdown. Proper sliding key
system is designed for the 600MW unit in order to guarantee the correct expansion, shrinkage and alignment of turbine
component.
From the speed governor end to generator, there are 1# bearing pedestal, HIP casing, 2# bearing pedestal, No.1 LP
casing, 3# bearing pedestal and 4# bearing pedestal. There are 3 absolute dead points which are located at middle part
of 2# bearing pedestal, No.1 and No.2 LP casings. The No.1 and No.2 LP casing are fixed by two transverse locating
keys and two axial locating keys which are embedded in the foundation to limit the center movement and to form the
absolute dead point. 3# and 4# bearing pedestal are fixed by two axial transverse locating keys and two axial locating
pins to form the self dead point. The self dead point will be kept standee during the shafting expansion (or contraction)
of two bearing pedestals.
The No.1 and No.2 LP casing will expand freely along the axial and transverse direction by taking the dead point as the
center. HIP casing is supported by 4 lugs which are located on the bearing pedestal. Keys are provided between lugs
and bearing pedestal. The lugs could move freely on keys.
The front and rear parts of HIP casing are connected with 1# and 2# bearing pedestals by locating center beam at
horizontal joints. During the expansion, the 2# bearing pedestal will lead the HIP casing and the stationary part of front
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bearing pedestal to expand towards the governor end. 1# bearing pedestal will be limited by the guide key on base
foundation and could move freely at axial direction but not transverse direction. The cover plate at side of bearing
pedestal will limit the any banking or elevation of bearing pedestal. It is proved that this sliding system is of the good
expansion and good effect.
There are rigid connection of flange type between HIP rotor and LP rotor, LP rotor and generator rotor. All these rotors
form the shaft system of the unit. The axial location of the shaft system is decided by the thrust collar in the governor
end of HP rotor. The thrust collar is in the thrust bearing and therefore forms the relative dead point of rotating and
stationary parts. When the stationary parts expands and contracts, the 1# bearing pedestal of the thrust bearing moves
accordingly. Therefore, the thrust bearing or the location of the shaft system also moves accordingly. The dead point
between rotating and stationary parts is called the relat ive dead point of the unit.
Expansion of stator parts
Mount of trust bearing
insulation bed plate

Axial aligning key
Bed plate of electric machine
LP installation bed plate
LP LP HIP
Generator
Axial aligning key of generator
Horizontal aligning key
Center beam
Rotator expansion Trust bearing
2.7 Relief Valve
The relief valve will be installed on the upper part at sides of LP casing. Its function will automatically discharge the
steam when the pressure inside the LP casing exceeds the Max. design pressure.
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2.8 Oil Control Tripping Valve
This valve consists of control valve and servo motor which will be connected with control oil system.
The reheat stop valve will open while closing the over speed tripping valve and emergency tripping valve. The oil
servo motor will supply the pressure oil to make the tripping control valve closed, so as to stop the steam leakage of
bearing housing (see Fig. III) to produce a thrust force to the shaft and to tight a and b seal surface (see Figure 1), i.e.
The shaft will not only rotate to reduce the steam leakage.
The oil servo motor will discharge the oil while the over speed tripping device actuating, and meanwhile the tripping
control valve will open to discharge the steam leakage from bearing housing to eliminate the pressure effect on the
shaft end, so as to close reheat stop valve with min. force.
2.9 Steam Gland
The gland sealing is the main part to keep the high efficiency of steam turbine during the steam flow on blades. The
labyrinth flexible sealing ring could ensure the small radial clearance between stationary blade and moving blade to
minimize the steam leakage. The labyrinth sealing ring includes segments and springs in group. The slot for sealing
ring is machined. During installation, the spring location shall be determined according to the location of gland
segments. The installation of gland sealing form axial sealing due to the steam pressure pushing the sealing ring to the
sealing surface. Enough clearance is remained in the slot for sealing ring to allow the movement of sealing ring in the
slot. The spring sheet tighten the sealing ring at radial direction to make the clearance between rotor and sealing ring is
as small as possible. During the normal operation of unit, the gland will contact with rotor. The flexible sealing ring
can be compressed and released at normal working condition. This could prevent the serious friction of sealing ring
and rotor. If the clearance between gland and rotor becomes big, the sealing ring can be replaced or repaired by
machining the pressure side to ensure the original clearance.
2.10 Turbine Barring Gear
This device is chain, worm wheel, gear combined speed reducing and wave wheel meshing. The motor of this
equipment is mode YB280S¬―6B3, power is 45KW，980r/min，voltage is 415V, protection level is IP54, insulation
level is F, after speed reducing, turning speed is 3.35r/min.Its characteristic is:
 TG rotor is turning in low speed while shut down to avoid rotor heat bending.
 Fast start up in hot condition is allowable.
 TG unit could trip off automatically while impulse.
 Mounted on the lower half of LP casing, it is allowed to remove bearing cap or coupling cap without removing the
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turning device.
 TG rotor could be turned in both with bearing cap and without bearing cap condition
 Both Auto-turning and manual turning is available.
The motor of turning gear is YB280S―6B mode, 3 phrase asynchronous, power is 45kw, 980r/min, voltage is 415V,
protection level is IP54 ,insulation level is F, this motor is double shaft extension structure, the second shaft extension
is machined by factory into the hex ,and it’s relevant side width is 27 mm. to be us ed for manual turning. In order to
keep operator safety, there is a motor switch is mounted on motor shell second extension end to control motor start up.
When open the cap of second shaft extension, travel switch will cut the power off, motor will not run.
3 Water and Steam System of Turbine
3.1 Main Steam and Bypass System
3.1.1 Main Steam
Two main steam pipes are connected with the both sides of super-heater outlet header of the boiler, then joined together
and divided into two pipes again at front of turbine, finally connected to the two main stop valves. The material of
main steam pipe will be A335P91. Since the start-up boiler will not be set, and lacking of supplying steam from outside
BTG scope, the boiler super-heater outlet steam will be provided for unit starting-up while the steam parameter meet
the requirement.
3.1.2 Reheat Steam System
Two cold reheat steam pipes are connected with turbine HP cylinder exhausting pipes, joined together at front of
turbine and divided into two pipes again at front of boiler, then connected to inlet of boiler re-heater header. Two hot
reheat steam pipes are connected with two ends of outlet header of boiler re-heater and joined one pipe at front of
boiler, and divided into two pipes again at front of turbine, then connected with left and right IP steam valves. The
material of hot reheat steam pipe will be A335P22, cold reheat steam pipe will be A672B70CL32. Cold reheat steam
not only supplies steam to no.2 HP heater, but also supplies steam to aux. steam system and gland sealing system
during unit low load.
Electric gate valve will be installed at the outlet of the super-heater. Hydraulic test blankets which are used to isolating
pipes from boiler headers during boiler re-heater hydraulic testing, they are located at steam pipes. Spraying water
desuperheater during emergency condition will be installed
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3.1.3 Bypass Steam System
According to the characteristic local electric network system and the technical contract, the HP and LP turbine bypass
system with the 60% BMCR capacity shall be applied, the system will be capable to permit the matching of steam and
cylinder metal temperature during unit start-up condition, so as to reducing unit start-up time. And the system will be
received water during unit start-up condition and prevent boiler re-heater from superheating. And the system will be
capable to protect the unit duringemergency condition and the bypass system will be capable of operating on house
load during sudden total export load.
This system has perfect drainage system in order to prevent water ingress turbine, this system designing will be based
on the <<Recommended Practices for the Prevention of Water Damage to Steam Turbines Used for ASME TDP-1
Electric Power Generation>>.
3.2 Condenser Extracting Vacuum System
One set of condenser shall be supplied for each unit. Condenser shall be horizontal, double shells, and single flowing
pass type. The material of tubes is Ti.
This system will remove the non-condensed gas from the condenser steam space, to maintain the condenser vacuum,
and assure the unit normal operating. This system is equipped with three water-ringed vacuum pumps shall be
employed to extract non-condensed gas from condenser to maintain required vacuum; the capacity of each vacuum
pump is 50%. Two pumps or one are working and the other is standby under normal operating condition. Three pumps
are put into operation to set up vacuum quickly during unit start-up. Two proper drainage flash vessels will be provided
with the condenser. During unit normal operation and start-up operation, the flash vessel will be used to collect the
drainage of turbine proper drain, gland steam condenser drain, aux. steam drain, all kinds of thermal cycle pipe and
heaters emergency drain, etc.
In order to prevent water from ingressing to turbine and prevent drainage enter other drainage branch from one branch,
all the interface between drainage pipe and condenser will be above the hot well, at the same the drainage pipe with
close pressure will be merged to a header entering the flash vessel or condenser.
Each electric vacuum-breaking valve will be set on each condenser shell to destroy the vacuum of the condenser while
the turbine trips, which can reduce the turbine idle time.
3.3 The Condensate Water System
The condensate water system shall remove condensate water from the hot well and deliver it to the deaerator, beside
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these the system can also provide spraying water to reducing temperature, make-up cooling water and other
miscellaneous water, condensate water will be heated by turbine extracting steam, deaerated and chemical treated, to
improve the plant thermal efficiency and assure the plant safely operating.
The condensate system includes three 50% capacity condensate pump (two operating and one standby), four
low-pressure heaters (no.5 LP heater, no.6 LP heater, no.7 LP heater, no.8 LP heater), one gland steam condenser, one
deaerator and storage water tank, one condensate makeup water tank with the capacity of 280m3（supplied by the
owner）, and two condensate transfer pumps. Condensate polishing device will be select intermediate pressure (IP)
device, and this system has no booster pump.
No.5 LP heater and no.6 LP heater and condensate polishing device have individual bypass pipe, while no.7 LP heater
and no.8 LP heater have a common bypass pipe. The effective capacity of deaerator storage tank is 280m3(the water
volume between the normal water level and low -low water level), which equals to max. feed water consumption flow
of the boiler during 7 minutes under boiler BMCR condition. The effective capacity of deaerator storage tank can meet
the requirement of the technical contract (no less than 7 minutes feed w ater consumption flow under boiler BMCR
condition).
Condensate recirculating system is provided from manifold downstream of the gland steam condenser returning to
condenser with a regulating valve station. Recirculation flow shall be choosing the bigger va lue between condensate
pump and gland steam condenser min. flow. Regulating valve station will be applied at the inlet pipe of no.7 LP heater
and no.8 LP heater in order to controlling water level of deaerator.
The discharge branch with a gate valve and a check valve from condensate downstream of no.5 LP heater to
pressurized discharging water pipe is designed to discharge dirty condensate during unit start up or system cleaning.
The owner will supply filling water to condensate makeup water tank before unit start-up. Two condensate transfer
pumps will be provided to fill water to condensate system when unit start-up. Regulating valve supplied will be
employed in condensate makeup water pipe for adjusting water level of hot well. The makeup water storage tank also
be provided to receive condensate from hot well when water level is up to high level。Since there is no start-up boiler
in this project, so the filling water to the boiler will be demineralised water that is no deaerated and no heating.
3.4 HP LP Heater System
3.4.1 HP Heater System
Three horizontal high-pressure heaters shall be supplied; the heaters shall be welded type and U tubes, double flowing
heater. Each high-pressure heater shall be designed three exchanger zone; they are steam cooling zone, condensate
zone, drainage cooling zone.
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HP heaters drain and vent system
Normal drainage from three high-pressure heaters is cascaded to the deaerator during unit normal operation. The
emergency drain will be discharged into turbine proper drainage flash vessels by separately.
There are bleeding air pipe and filling nitrogen interface for protecting pipe during unit shut down at the steam side of
HP heater. Continuous operation exhausting steam from heaters will be discharged to the deaerator. There are internal
throttle orifices in the exhaust outlet of HP heaters, in order to control the flow of exhaust.
There are motor-driven stop valve, isolating valve and throttle orifice in the deaerator exhausting pipe. Motor-driven
bypass valve will open to ensure the deaerator exhaust smoothly while throttle orifice is blocked or unit operates at low
load.
This system refers to drawing no. F5161C-J-13, P&ID of HP heater drains and vents & deaerator system.
LP heaters drain and vent system
3.4.2 LP Heater System
Four low-pressure heaters shall be provided; they are horizontal arrangement and U tubes. No.7 LP heater and No.8 LP
heater are two sets (7A/8A, 7B/8B). Each low-pressure heater shall be designed two exchanger zone, they are
condensing zone, drainage cooling zone.
Normal drainage water of low pressure heaters will be cascaded to condenser. Emergency drainage water from each
low pressure heater will be discharged directly into the condenser by separately. The drainage water from gland st eam
condenser will flow automatically to condenser through water sealing.
All arrangement of drainage water regulating valve shall be close to the next LP heater, which accepts the drainage, in
order to reduce the pipeline length of two-phase flow. The pipe diameter shall be enlarged after regulating valve, this
part pipe shall be heavy thickness.
3.5 Deaerator
The deaerator is used to eliminate the oxygen and other no condensable gas in the boiler feedwater to guarantee the
quality of the feedwater. If the gas dissolved in the water, the metal contact the water will be eroded , meanwhile if the
gas accumulated in the thermal exchanger will increase the thermal resistance of the heat transfer, reduce the heat
transfer effect of the equipment. So it’s not good of any gas dissolved in the water, especially the oxygen, it will
directly threaten the safe operation of the equipment. The power plant adopts thermal deaeration. Deaerator itself is one
mixing heater of the feedwater regenerative system. Mean while the drainage of the HP heater, chemical makeup water
and qualified HP drainage of the whole plant, exhausting steam could be drained to the deaerator and for other usage. ,
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reduce the steam and water lost t of the power plant.
One set of deaerator & storage water tank shall be supplied for each unit.
Item Deaerator and feedwater tank
Pattern horizontal, spray-type
Type effective volume: 280 m3
Shell and tank material SA516
3.6 Feed Water System
Boiler feed water system shall supply feed water from deaerator to the boiler economizer header inlet with required
flow and flow rate under all operating conditions, and feed water will be heated by turbine extracting steam through HP
heaters. Besides, feed water system shall supply spraying water for super-heater attemperator, re-heater emergency
attemperator and HP bypass attemperator.
The system shall be designed in unit type. There are two 50% capability turbine-driven BFP and one 50% capability
motor-driven BFP unit in the system. Each of them has booster pump. During normal operation, two turbine-driven
BFP (TDBFP) are working and one motor-driven BFP(MDBFP) is standby. The MDBFP with 50% capacity is used for
unit start-up and for standby.
Three high-pressure heaters shall be applied with 100%BMCR capacity.
TDBFP will control feed water flow by regulating the rotation speed of BFP turbine, and MDBFP will control by
hydraulic coupling. A set of regulating valves for unit low load will be installed at the inlet bypass pipe of economizer.
Each set of min. flow regulating valve will be installed at pipe from the outlet of each feed water pump.
HP feed water heaters common bypass system will be comprise of two motor- driven three-way valves and one throttle
orifice with inner type The supplying steam for BFP turbine comes from 4th extraction steam during unit normal
operation, and steam source from aux. steam system during low load.
For the purpose of improving the plant thermal efficiency and reducing thermal damage, spraying water for superheat
steam and HP bypass comes from BFP-outlet common pipe. Spraying water for cold reheat steam comes from
intermediate extraction of boiler feed water pump (BFP).
S/N Item Parameter
1 Type: NGZ83.83.5/06
2 Pattern: Single case, signal shaft, single flow, auxiliary steam external switch, variable rotating
speed, impulse type, lower exhausting, straight condensing type turbine
3 Operation mode: variable parameter, variable power, variable rotating speed
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4 Designed power: kW (feedwater pump efficiency %, rotating speed is r/min)
5 Rated condition power: kW (feedwater pump efficiency %, rotating speed is r/min)
6 Inner efficiency: % (under TMCR condition), %( under TRL condition)
7 Maximum continuous power: 9MW
8 Rated inlet steam pressure: MPa Temperature ℃
9 Rated exhausting steam pressure: kPa Temperature ℃ (correspond with turbine rated condition point)
10 Rated rotating speed: r/min
11 Speed regulating range: 3100~5900 r/min
12 Overspeed protection, action rotating speed: single-span flexible first phase 2246r/min, single-span flexible
phase second phase.
13 Rotating speed: look from turbine head (along the steam flow) clockwise
14 LP steam source: using 4 sections exhausting under turbine THA
15 Pressure: 0.843Mpa
16 Temperature: 338.5℃
17 Flow: 46.48t/h
18 Maximum exhaust pressure: 0.0196MPa
19 Maximum exhaust temperature: ℃
The small turbine’s main machine and oil system are installed separately, condensing type. Itself doesn’t have
condenser but exhaust into main turbine’s condenser
Steam Source
The unit is equipped with independent steam source
LP steam source: introduced from the exhaust pipe at the end of turbine IP part, also called unit working steam
source.
Auxiliary steam source: used for startup, commissioning and backup. Switch mode – external switch.
When the main turbine is under the load of below the 40% power, LP working steam flow can not satisfy the
requirement of the feedwater pump power. At this time, by the action of control system, open the regulating valve on
the auxiliary steam source pipe let the auxiliary into and makeup power, to keep the balance of the power. At this time,
all 8 LP regulating valves should be fully opened. The main turbine load is under the 20% rated load, as the auxiliary
steam flow increases and pressure rises, the check valve closes to keep the LP steam from entering the turbine. By this
time, the mode is switched to auxiliary steam working alone.
Shaft Sealing
The front and rear shaft sealing of the small turbine both adopt labyrinth sealing which has good performance in shaft
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sealing. The structure type is comb type. Among it, the first section’s leaking steam of the steam sealing is introduced
to the front of 5th stage, continue working; other leaking steam are all pumped to main turbine shaft sealing cooler.
Valve Leaking Steam
Steam leaks from LP main steam valve stem and LP regulating valve stem are both connected to main turbine shaft
sealing cooler.
Valve Drainage
Valve seat front drainage of the LP main steam valve connected to the flash tank of the main turbine, valve seat rear
drainage connected to the exhausting outlet of the small turbine of the main turbine.
Pipe Drainage
Two drainage outlets are set at the lowest position of the 2 connected pipes between the front sealing’s first section
leaking steam and turbine fifth stage. One line leads to flash tank of main turbine, another leads to exhausting outlet of
the small turbine of main turbine.
System Operation
Before start the unit, all drainage valves should be opened fully, and keep it unit the main turbine’s load reaches the 40%
of rated load. During stop the unit, should be opened again when the main turbine load low down to 25%.
Exhausting Vacuum
Back pressure alarm value 25Kpa, stop value 30Kpa
Exhausting temperature
Normal 40~50℃, alarm value 90℃, stop value>12℃
Atmos valve is installed on the top of turbine rear. When the back pressure >= 0.136Mpa (absolute), the atmos valve
acts to protect the case rear; the manual check valve is installed on the exhaust pipe, so if necessary open the valve to
break the small turbine vacuum.
Rotor
The small turbine uses forged integral rotor. The total length is 3041. there are 6 disks of conical profiles.
Moving blade
6 Stages totally, the 1st ~ 3rd stage blades are constant section straight blade, the 4th ~ 6th stage blades are twisted
blades.
Dynamic Balance of Rotor
The rotor dynamic balance is realized by plugging the balance bolt into the balance screw holes on the rotor 1st stage
and 6th stage disks outside head face. If the power plant need renew the dynamic balance, could use the specific tools
to remove or add balance bolt through the preserved holes on the shaft sealing and exhaust hood, no necessary to open
the cylinder.
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Bearing
The journal bearing is made up by 5 tilting pads; thrusting bearing has 6 thrust pads pros and cons.
Barring Device
Using high speed barring, the rotating speed is 40.8r/min. before rolling the small turbine the barring should be put into
operation, the turning time should not less than 45 min. after stop the unit, keep turning until the rotor is complete cool
down. The barring gear is at the rear bearing box.
Cylinder
Single cylinder with horizontal split: Because of the technics, the cylinder is divided into front and rear two split, both
are fixed together by the vertical flange bolt.
The front part of the cylinder and LP steam chest are separately cast. The rear of the cylinder is welded structure. Its
inner is an exhaust spiral case welded with diversion device.
LP nozzle is installed in corresponding LP steam chest.
3.7 Recirculating Cooling Water System
This project will adopt the secondary cooling water system, the circulation water is from the seawater supply pipe
supplied by the owner. Two sets of sponge ball cleaning device will be installed at the water side of condenser.
Condenser type is double back-pressure, tube material is Ti. The circulating water enters into low back pressure
condenser through two DN2200mm pipes and motor driven butterfly valve, and then enters into high back-pressure
condenser, finally discharge to circulating water outlet pipe through sponge ball collector.
This system still provides cooling water for closed cycle cooling water heat exchanger, STG oil coolers, BFPT. oil
coolers, working/lube oil coolers of MDBFP, cooler of water ringed vacuum pumps. Cooling water for above
equipment’s coolers comes from the circulating water inlet pipe supplied by the owner, and then it guided through
electric filter, opened cycle cooling water pump and heat exchanger, finally it is discharged to circulating water outlet
pipe.Service water will be supplied by the owner. Service water system will offer the cooling water for the following
items: flushing water for air pre-heater, miscellaneous water in turbine hall and boiler house, flushing water for ESP
area and IDF area.
3.8 Auxiliary Steam System
Aux. steam system will provide steam source for this plant. One set of LP aux. steam header will be employed with
pressure 0.6~1.0 MPa(a), temperature 250~335 ℃ for each unit, and one set of HP aux. steam common pipe will be
employed with pressure ~1.6 MPa(a), temperature 250~335℃ for two units. The extended connection to aux. steam
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system of the extended unit will be provided in this phase.
Aux. steam comes from 4th extraction steam during normal operation and from the main steam pipe or the other unit
aux. steam system during unit. Start-up, and from cold reheat pipe during unit low load.
The LP aux. steam system will provide steam for commissioning and standby steam for BFP turbine, turbine gland
sealing, boiler secondary air heater, The HP aux. steam system will provide steam for fuel oil atomization, fuel oil
heating and etc.
3.9 Extraction Steam Drainage System
3.9.1 Extraction Steam and Drainage of Turbine
The drainage of the extraction after heating in the reheater, adopts stage self flow type. #1 HP heater flow into #2 by
the pressure difference, #2 HP heater drainage flow to #3 HP heater self, #3 HP heater drainage flow to deaerator. LP
heater after self flow by stage, finally flow to condenser from #8 LP heater. Because every stage’s heater is equipped
with drainage cooling section, could further cool the extraction condensate in the drainage cooling section, make the
drainage temperature lower than its saturation temperature, so could prevent drainage vaporization from crowding the
next stage heater extraction.
Turbine drain system is mainly made up by the following parts: low drain points on main steam, reheat steam pipe,
turbine cylinder, main steam regulating valve, HP loop pipe drain, exhaust pipe drain, feedwater pump turbine steam
supplying pipe drain, auxiliary steam, deaerator heating pipe drain, shaft sealing system drain and valve stem leaking
steam, other auxiliary system’ drainage.
3.9.2 Turbine Drainage
The function of the drain system is to prevent water from entering into turbine components or accumulating in the
turbine during start-up, loading, rejecting load and shutdown. The damage of turbine parts is inevitable when water
enters steam turbine. Water may cause thermal shock and mechanical shock. The incidents caused by these are damage
of blade, blade shrouding and thrust bearing, rotor cracking, diaphragm carrier cracking, permanently curved of rotor,
permanently curved of stationary parts and wearing the gland seal plate, etc.
To prevent water from getting into the turbine, the system is designed with perfect drainage system
Proper Flash Tank
Every turbine is equipped with 2 proper flash tanks, one at high back pressure condenser side and the other at low back
pressure condenser side. Every flash tank is equipped with water spraying device, water spraying control valve,
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exhaust pipe, drain pipe; exhaust connected to condenser throat, drain connected to the position above the highest level
of the hot well. Spraying water come from condensate
Main, Reheat Steam Pipe Drainage
The arrangement of the turbine main steam pipe is 2 – 1 – 2, main steam pipe through the B wall and enters the turbine
workshop elevation 11m, forms the wye. At the lowest point of the wye, set one drainage point on main steam pipe.
Left and right drainage steam pipes behind the rear are set with one drainage each. Every drain pipe has one pneumatic
drain valve and one manual valve used for drain the condensate the main steam pipe in front of the main steam valve.
Reheat steam pipe has the same arrangement with the main steam pipe, also 2 – 1 – 2. Wye rear right and left steam
pipe are set with one drain poin each, equipped with drain bag. Every drain pipe has one pneumatic valve and one
manual valve.
Besides, in front of HP bypass pressure reducing valve one drain point is set; in front of every pres sure reducing valve,
one drain point is set; every drain has one pneumatic drain valve and one manual valve. In front of HP bypass one pipe
warming pipe is connected and lead to reheat section pipeline, front of LP bypass valve also one pipe warming pipeline
is connected and leads to 4th section exhaust pipe, make the bypass system pipeline, valves at the hot standby, make
sure the bypass system could be put in anytime.
One HP cylinder exhaust and vent valve is set on the HP exhaust pipe and should be opened when start the IP cylinder,
reduce the heat generated by the blasting friction, prevent the HP cylinder exhaust steam temperature overhigh. At HP
exhaust check valve front HP cylinder exhaust manifold lowest point one drain point is set, two drain points are set at
the HP exhaust check valve rear pipeline lowest point. Drain bags are set at the above three points and equipped with
hydraulic level CB; when the level is high, it will automatically open the drain valve.
Proper Drain
The upper and lower valve seats of HP main steam valve both are equipped with drain valve, IP combined regulation
valve has too, all are pneumatic controlled. The lower part of 4 HP loop pipes are equipped with drain, and 4 drain
pipes integrate together, using one drain main. One accident exhaust valve is set at the #2 shaft sealing section in the
middle of HP/IP rotor, which will exhaust steam automatically when the unit trips, avoid overspeed of turbine. These
drain valves are all controlled by program, and can be manually controlled remotely. when the compressed air source
loss, all drain valve are automatically opened.
Exhaust Pipe Drain
Pneumatic drain valve on the exhaust pipe could be put into program control and manual control too.
Feedwater Pump Turbine Drainage
Following drain are arranged in small turbine: feedwater pump turbine LP admission motorized valve front, rear drain;
in front of feedwater pump exhaust motorized valve drain is set; feedwater pump turbine HP admission drain; cylinder
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drain.
One manual drain valve is set between 4th section exhaust pipe and deaerator heating motorized valve front; one drain
pneumatic valve is set between 4th exhaust pipe and auxiliary steam motorized valve front, one drain trap is set at
valve rear with bypass valve. One drain point is set at auxiliary steam header, equipped with drain trap; drain pipe is
equipped with one pneumatic drain valve, the drainage enter into the turbine main condenser.
Shaft Sealing System Drain
Shaft sealing admission pipe has one manual drain valve, HP shaft sealing steam supplying main has one manual drain
valve, lead to pressurized drain main for the use of shaft sealing system pipe warming. HP cylinder and shaft sealing
steam supplying pipe both have one filter, each filter has two manual normally closed drain valve. these drain valves
should start pipe warming when the shaft sealing put in.
2 HP main steam valve stem 1st section leaking steam connected shaft sealing steam supplying main; 2nd leaking
steam connected to shaft sealing return steam main. 4 main steam regulating valve 1st section valve stem leaking steam
connected to reheat cool section main. One check valve is set on the main; 2nd section valve stem leaking steam
connected to shaft sealing return steam main. IP combined steam valve stem leaking stem connected and shaft sealing
steam supplying main both are set one check valve. accident exhaust valve, HP cylinder ventilation valve stem 1st
section leaking stem connectected to reheat cool section pipe, 2nd section leaking steam conenctected to shaft sealing
steam supplying main.
All drain valves of steam turbine shall:
The drain valves remain opened after shutdown before cooling.
They shall be open before the startup of steam turbine and supplying the steam to gland system.
The valves are open during the loading. When the load reaches 10% of the rated load, the HP drain valves will be
closed. When load reaches 20% rated load, the IP drain valves will be closed.
Open the IP drain valve during the down loading of turbine to 20% of the rated load. When the load reaches 10% of the
rated load, the HP drain valve will be open.
Before opening the main drain valves, the vacuum shall not be broken. But this suggestion is not applicable to neither
the emergency condition under which the vacuum shall be broken immediately nor the drain valve for main steam pipe
of customer.
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4 Turbine Auxiliary System
4.1 Lubrication Oil and Jacking Oil System for Turbine
This system can satisfy the requirement of on-line purifying, off-line purifying, and storage for units lube oil.
The system includes mail oil tank, oil tanks for BFPT, lube oil transfer pump (common for two units) ，lube oil transfer
pumps of BFPT，lube oil storage tank (common for two units)，off-line oil purifier (common for two units)，on-line oil
purifier (each one per unit).
In operation，lube oil can go through on-line oil purifier and return to the main oil tank and lube oil tanks for BFPT.
While unit is shut-off，lube oil for steam turbine and BFPT will exhaust to lube oil storage tank and go through off-line
oil purifier， return to the lube oil storage tank at last. When the oil can satisfy the requirement，it can transferred to
the main oil tank and lube oil tanks for BFPT through lube oil transfer pump. The capacity of the lube oil storage tank
is designed as per total oil volume for one unit.
Turbine lubration oil storage and purification system reference for F5161C-J-20 turbine lubrication storage and
purification system drawing P&I
4.2 EH Fire Resistant Oil and Purifying Oil System
4.2.1 EH (Electro-Hydraulic) System Operation Principle
With the application of digital electro-hydraulic (DEH) control system to the unit, the HP fire-resistant fluid based on
the phosphate ester with 14 MPa pressure is used as the control fluid in the control system, while the LP turbine oil
with 0.7 MPa pressure as the mechanical protection oil. Each inlet steam valve has an actuator to control its open/close,
among which RSV (reheat stop valve) actuators are of ―ON-OFF Control‖ type and others are of ―Proportional Control‖
type. All the actuators can force their corresponding valve open by a hydraulic force and close by a spring force. The
valve close speed could be controlled by an adjustable needle valve at the end of actuator cylinder.
4.2.2 Basic Composition of EH Control System
As per the function, EH control system could be constituted of three parts, which are EH fluid supply system, actuators
and emergency trip part. EH fluid supply system can be further devided into EH fluid supply device, self-circulation
cooling system, fluid regeneration system as well as EH fluid piping & accessory.
Actuator part shall be constituted of two MSV (main stop valve) actuators, two RSV actuators, four GV (governor
valve) actuators and four ICV (reheat interceptor valve) actuators.

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Emergency trip protection system shall be constituted of OPC/AST solenoid valve unit, diaphragm valve, emergency
governor, pilot valve of emergency governor, safety operation device and manual injection stop valve.
4.2.3 EH Fluid Supply System
The main function of EH fluid supply system shall be to supply necessary hydraulic power to actuators, and maintain
the normal physical chemistry characteristics of hydraulic fluid.
Electric power requirement for EH fluid supply system:
Two main oil pumps shall be of 45KW, 415VAC, 50HZ, three-phase,
One circulating pump shall be of 1.5KW, 415VAC, 50HZ, three-phase,
One regenerating pump shall be of 0.75KW, 415VAC,50HZ, three-phase,
three-phase
Warning: for high requirement of EH fluid cleanness and viscosity for variable displacement piston pump, the pump
shall not be started until fluid temperature higher than 20℃ has been confirmed.
EH fluid supply system has two independent groups of pump, between which one is for working and the other one is
for standby during normal operation. When more flow is needed for EH control system or system pressure is too low
for some reason, the other oil pump could be started through interlock start to meet system flow and pressure
requirement.
All sealing parts of the device shall be of fluorin rubber, while the accumulator bladder shall be of butyl rubber and the
paint shall be the special polyurethane paint.
Warning: sealing parts shall be the lifeline of hydraulic system, so nitrile rubber sealing parts shall be kept away from
the system.
For ensuring fluid performance, the self-circulation cooling and heating system and fluid regenerating system shall be
prepared for the system. Fluid regenerating system shall be of two stages filter arrangement, one of which is resin filter
and the other is cellulose filter.
4.2.4 Actuators
1) RSV actuator
Two RSV actuators equipped with valve activity testing solenoid valve shall be installed on RSV at unit side.
RSV actuator shall be of ―ON-OFF Control‖ type.
RSV actuator will receive the control signal from DEH system, and a plug-in type dump valve is installed on the
actuator. Should emergency condition occur during steam turbine operation, auto stop emergency trip (AST ) fluid
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is discharged so that dump valve will open immediately to discharge the pressure fluid at working chamber of
actuator cylinder and RSV will close quickly by spring force.
There is an activity testing solenoid valve (2 positions, 2 ways) on actuator, which is connected with cylinder
working chamber and return fluid. When valve activity test is performed, DEH control device will send out a
signal to make the solenoid valve open for discharging part of pressure fluid in cylinder working chamber, then
RSV is closed by spring force to perform valve activity test.
2) MSV actuator
MSV actuator is ―Proportional Control‖ type actuator, which can control MSV at any position and control steam
admission to meet steam turbine operation requirement according to control requirement.
DEH control signal drives servo valve to move main valve core and control servo valve pass to make HP fire
resistant fluid go into actuator working chamber to move actuator piston, and finally to open MSV or to discharge
pressure fluid from working chamber to close MSV through piston converse movement by spring force. When
actuator piston moves, it will drive two linear displacement transducers (LVDT) to transform actuator piston
displacement into electrical signal (as feedback signal) plus the aforesaid signal after computer treatment;
however, it’s actually minus each other because of the opposite polarity. Only in the condition of original input
signal plus feedback signal to make input servoamplifier signal zero and main pilot valve of servo valve be back
to center position without high-pressure fluid coming into working chamber, MSV will stop moving and remain at
a new working position.
A plug-in type dump valve is installed on MSV actuator. Should emergency stop condition occur during steam
turbine operation, emergency trip system will act to discharge AST header fluid so that dump valve will open
immediately to discharge the pressure fluid at working chamber of actuator cylinder and MSV will all close
quickly by spring force.
3) GV actuator
GV actuator is ―Proportional Control‖ type actuator, which can control GV at any position and control steam
admission to meet steam turbine operation requirement according to control requirement.
The control principle of servo valve shall be the same as that of MSV actuator.
The GV actuator is equipped with one plug-in type dump valve. When steam turbine running speed exceeds 103%
of rated speed or emergency stop caused by failure happens, after emergency trip system acts overspeed
protection control (OPC) header fluid will be discharged, dump valve will open immediately to discharge pressure
fluid inside actuator working chamber and each GV will be closed quickly by spring force.
4) ICV actuator Refer to GV actuator.
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4.2.5 Emergency Trip Protection System
For avoiding serious damage accident of unit caused by failure of some equipment during steam turbine operation,
emergency trip protection system shall be prepared for the unit.
1) Emergency trip testing device
Emergency trip testing device shall be constituted of one EH oil pressure test block, one bearing oil pressure test
block, two condenser vacuum test block and two BOP & EOP start test block, which could be on-line tested and
maintained.
OPC/AST solenoid valve unit
OPC/AST solenoid valve unit consists of two OPC solenoid valves (20/OPC-1、2), two check valves, four AST
solenoid valves (20/AST-1、2、3、4) and one control block. Two OPC solenoid valves are in the parallel
arrangement, and four AST solenoid valves are in the series-parallel arrangement. When turbine speed exceeds
103% of rated speed, OPC acting signal will be sent out. OPC solenoid valves open when they are energized so
that OPC header fluid drains to EH fluid reservoir through no pressure return (DV) fluid line. In that case,
discharge valve of the corresponding control valve actuator will open fast so that each HP control valve will be
closed immediately.
When emergency happens to unit, AST signal will be sent out. Four AST solenoid valves will open for losing
power so that AST header fluid drains to EH fluid reservoir through DV fluid line. In that case, dump valves of
main steam valve actuator and control valve actuator will open fast to close each steam valve immediately.
2) Diaphragm valve
Diaphragm valve provides an interface between the HP fire-resistant hydraulic fluid and LP turbine oil, thus the LP
over speed tripping can be accomplished by the diaphragm valve to shutdown the steam turbine.
4.2.6 Mechanical over Speed and Manual Trip Device
Mechanical over speed and manual trip device consists of emergency governor, pilot valve of emergency governor and
safety operation device.
1) Emergency governor
Mechanical over speed and manual trip device consists of emergency governor, pilot valve of emergency
governor and safety operation device.
2) Emergency governor, pilot valve of emergency governor
Emergency governor shall be equipped with one set of centrifugal stop bolt, which controls pilot valve of
emergency governor. When steam turbine operation speed reaches to 110%-112% of rated speed, centrifugal force
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of centrifugal stop bolt overcomes the restriction force of spring and throws the centrifugal stop bolt outward
striking pilot valve trigger which make pilot valve move towards right and then protection oil is connected with
drain to open diaphragm valve rapidly.
Pilot valve of emergency governor that is installed inside front bearing housing is the control and test device in
emergency trip system, and it includes one trip pilot valve, one test isolation pilot valve, one manual trip lever and
one test lever.
Test isolation pilot valve could be used to isolate pilot valve of emergency governor from LP protection oil header.
During oil injection test, test stop valve could be opened by manual to allow pressure oil coming into the chamber
beneath centrifugal stop bolt through nozzle, and centrifugal stop bolt overcomes the restriction force of spring
flying off.
3) Safety operation device
Safety operation device provides remote reset solenoid valve and reset air cylinder for unit. When it receives DEH
reset signal and air cylinder moves upwards pushing connecting rod of emergency governor pilot valve, pilot
valve of emergency governor resets.
4.2.7 Oil Conditioning System
Type LYJ-8 centrifugal oil purifier can eliminate the water, soap, pigment, metal microparticles, sand, carbon particle
and other mechanical impurity in the oil with high efficiency, purify the unqualified oil, improve the oil quality,
guarantee the unit safe operation.
Technical parameter
Product type: LYJ-8
Nominal flow: L/H 7800
Working oil temperature ℃ 50~65
Heating power KW 48
Working noise dB(A) ≤98
Inlet and outlet caliber mm DN40
Maximum external dimens ion mm 1550×1300×1350
Net weight kg 1500
Technical performance index
The unit mainly uses centrifugal separation; make the purification quality reaches the international recognized, the
required highest API-1581 standard. The oil contents mass water (around 30%), with pollution level lower than class
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15, after processing of the unit can reach the following index:
External: diaphanous, no impurity, no free water
Mechanical impurity (filtration accuracy): ≤5μm
Water content: ≤50ppm
Purification cleanliness: ISO4406 15/21 class
Kinematic viscosity≤1.2×\u26032X oil standard value (50℃)
Lightening ≥180℃
4.3 Shaft Sealing System:
As high speed rotating turbine, there should be certain gap between its static and moving parts; to reduce the leakage,
anti-leaking device should be installed to increase the working efficiency of the turbine, such device called shaft
sealing. In structure principle, the sealing has three types: labyrinth seal, carboloy ring seal, water ring seal; carboloy
ring and water ring seal belong to contact type seal, only used in small unit. And what is widely used in the high power
turbine unit is non-contact type labyrinth type seal; this is what used in our plant.
Shaft Sealing Heater
Item Unit Parameter
Pattern： Horizontal, cooling water inner bypass
Heat transferring area m2
Cooling water flow t/h
Water side pressure MPa
Steam side working pressure MPa (absolute)
Shaft sealing air fan refer the design material for related parameter
Shaft Sealing Heater
Shaft sealing heater used in turbine shaft sealing system, its main function is using condensate to cool down the
steam-gas mixture exhaust from every section shaft sealing, HP/IP main steam regulating valve stem, create certain
vacuum in steam side chamber of the shaft sealing heater, avoid steam leaking from shaft sealing end, condensing the
steam in the mixture into water so retreat the working medium. Transfer the heat of steam-gas heat to the condensate;
increase the turbine thermal system’s economy. Meanwhile, reduce the mixture’s temperature to the allowed level
required by the shaft sealing heater air fan long time operation.
Power plant shaft sealing heater uses horizontal shaft sealing heater. The shaft sealing heater is made up by shell body,
pipe system, water box etc. cooling water inlet and outlet pipes are set on the water box. at the cooling water outlet side
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of the baffle plate in the shaft sealing heater water inlet outlet box, bypass valve is installed, allowed 100% cooling
water enter the shaft sealing heater water box, and guarantee the cooling water flow passing the pipe system is not less
than 500t/h.
Shaft Sealing Air Fan
The power plant is equipped with 2 100% capacity shaft sealing air fan, used to exhaust the incondensable gas in the
shaft sealing steam cooler. Two electrical motorized ventilation fans work as backup of each other.
LP Desuperheater & Diffuser
The LP gland steam desuperheater is used to reduce the temperature of supplied steam for LP gland sealing before
entering the condenser. The steam temperature of LP gland shall be remained at 121℃～177℃ to prevent the possible
damage of gland packing and rotor. The desuperheating of steam is achieved by the natural cooling in supplying piping
within the auxiliary space of condenser and controlled by water spraying system. The temperature of water spraying
system shall be felt in the LP gland. If the steam temperature before entering desuperheater is about 260℃ or higher,
this system could make the temperature reduce to 121℃～177℃. However, if the temperature before entering
desuperheater is lower than 260℃ and close to 121℃～177℃, no water spraying is required. The natural cooling in
steam supplying piping is possible to reduce the temperature to 121℃ below.
4.4 Hydrogen Cooling System for Generator
4.4.1 Cooling Type
QFQS—600-2 steam turbine generator uses the way of water-cooling--- hydrogen-cooling —hydrogen-cooling. The
cooling method of the stator winding is water cooling, while that of the rotor winding and the iron core are hydrogen
interior cooling and external cooling respectively. When the machine set is turned on, turned off or in operation, the gas
control station of the hydrogen control system controls the gas -exchange, monitors the gas pressure inside the
generator and regulates the hydrogen pressure automatically. The gas station is of assembled type. In addition, the
hydrogen control system is equipped with hydrogen dryer, hydrogen purity analyzer, and hydrogen temperature and
humidity detector to monitor and control the hydrogen purity, in order to ensure that the generator operates safely and
completely. Instruction for the hydrogen system. (See the principle of the system)
4.4.2 Technical Parameter of the Hydrogen Control System
Rated hydrogen pressure: 0.40MPa (displayed on the meter)
Hydrogen purity:≥98%, normal;≤95%, alarm.
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Hydrogen humidity(dew-point): －5℃～－25℃(when the hydrogen pressure is 0.40MPa)
4.4.3 The Gas Replacement Method of the Generator is Medium Gas-Assistant Replacement.
The replacement goes only when the generator is shut-off, barring, or when the rotary speed is less than 1000r/min.
Before the hydrogen is to be filled, the air in the generator and the system pipeline should be replaced by medium gas
(carbon dioxide) first. Only when the purity of the medium gas is higher than 95% (the following percentage by
volume is the same), can the hydrogen be filled in to replace the medium gas. The hydrogen filling goes on until the
generator and the system pipeline is completely filled by hydrogen. The medium gas volume needed during this
procedure is 1.5 times of the holding capacity of the generator and the system pipeline, while the hydrogen volume
needed is about 2~3 times of the holding capacity of the generator and the system pipeline. The procedure is similar to
that mentioned above when the hydrogen is replaced by air. Before the hydrogen is to be replaced by the air, first, the
medium gas is filled to replace the hydrogen. When the medium gas volume is higher than 95%, air can be filled in to
replace the medium gas. When the medium gas quantity is reduce lower than 15%, the replacement can be stopped.
The gas volume needed during the replacement is 1.5~2 times of the holding capacity of the generator and the system
pipeline.
The gas volume and the time needed are in the table below:
The gas needed
The state of replacement
The gas volume needed
Time needed （h）
In operation
Shut-off operation
Carbon dioxide
Carbon dioxide (the procedure goes on until its purity is 95%) replaces the air V=180m3 V=120m3
Hydrogen
Hydrogen (the procedure goes on until its purity is 96%) replaces carbon dioxide V=320m3 V=240m3
Hydrogen
Hydrogen pressure rises to 0.40 MPa V=440m3 V=330m3
Carbon dioxide
Carbon dioxide (the procedure goes on until its purity is 95%) replaces hydrogen V=240m3 V=180m3
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4.4.4 Feeding and Draining the Hydrogen in the Normal Operation of the Generator
In the normal operation, feeding hydrogen is needed for the following reasons:
1) If the hydrogen is leaked, feeding hydrogen to keep the pressure of the generator.
2) Because there is dissolved air in the seal oil, the purity of the hydrogen in the generator will be reduced. So
feeding hydrogen to keep the purity is necessary.
3） In the normal operation, the specified parameter of the hydrogen decompressor is 0.40MPa; during the operation
of the generator, when the hydrogen pressure of the machine reduces to 0.38MPa, the pressure switch works and
sends out the alarm signal of ―low pressure‖. When the hydrogen pressure rises to 0.42MPa, the pressure switch
works and sends out the alarm signal of ―high pressure‖. Then adjust the hydrogen decompressor inlet by hand and
opening the vent valve to reduce the hydrogen pressure to 0.40MPa.
4.4.5 Main Equipments
1） Hydrogen dryer
During the generator operation, the hydrogen humidity will increase for the gas contacts with the seal oil, or some
other reasons. So the hydrogen dryer is equipped in the system. The hydrogen dryer inlet is connected with the
high pressure zone of the generator, while the outlet is connected with the low pressure zone. By the operation of
the hydrogen dryer, the water in the hydrogen could be released continuously so that the hydrogen humidity can
be reduced.
2） Hydrogen decompressor
The decompressor is equipped in the hydrogen control station to regulate the hydrogen pres sure. The
decompressor, which functions as reducing valve, is equipped in the hydrogen supply pipelines. The outlet
pressure of the decompressor should be set at 0.40MPa before the decompressor operates. When the hydrogen
pressure of the generator is higher than 0.42MPa, open the drain valve equipped behind the decompressor by hand
to release the hydrogen.
3） Hydrogen filter
Hydrogen filter is used to filter the impurities in the hydrogen. Made of the multi-porous powder metallurgy, the
filter element’s hardness is lower. Therefore, in the normal operation, the pressure difference of the two ends of
the filter element should not be more than 0.2MPa; otherwise the filter element will be destroyed.
4） Hydrogen purity analyzer
During the generator operation, the hydrogen purity in the generator will be decreased for the hydrogen contacts
with the seal oil, or some other reasons. The purity reduction will affect the efficiency of the generator directly,
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the hydrogen purity analyzer is equipped in the hydrogen system to monitor the hydrogen purity in the generator
and the medium gas purity during the replacement procedure.
5） Liquid detector
Liquid detector is equipped under the generator chassis and terminal box. The floater switch in the detector could
indicate the possible liquid leakage in the generator. In each detector there is a return line connected to the
generator chassis. A blow-down valve is also equipped to drain the accumulated water.
6） Hydrogen humidity sensor
The hydrogen humidity sensor is equipped in the hydrogen inlet pipeline of the hydrogen dryer. It monitors the
temperature and the humidity of the hydrogen on line.
4.5 Cooling Water System for Generator Stator
4.5.1 Operation Principle of the Stator Cooling Water System
A closed loop circulation system is applied on the cooling water control system, to make high purity water through the
stator hollow winding and carry off the heat produced by winding energy loss. The water supplied into the generator
stator is the acceptable salt-removed water which is directly drawn from the chemistry workshop. Water being feed into
the tank is through the electromagnetic valve and filter finally into the water tank. Before the start-up of the machine,
the pipelines, the valves, and the assembled units must be washed several times. Only when the chemistry salt-removed
water is proved to be acceptable by the laboratory examinations of the sample, can the salt-removed water be filled to
the generator stator. After its pressure is boosted in the acid-proof pump, the softened water in the water tank passes
through the tube-type cooler, the filter and the stator coil collecting pipe, and then returns to the water tank with the
hotness brought from the stator coil to finish the close-circulation.
To improve the quality of the water supplied to the generator stator coil, 5～10% of the total quantity of the
salt-removed water is continuously filled to the demineralizer to be treated. Then it returns back into the water tank.
Feeding and draining the hydrogen in the normal operation of the generator
In the normal operation, feeding hydrogen is needed for the following reasons:
1） If the hydrogen is leaked, feeding hydrogen to keep the pressure of the generator.
2） Because there is dissolved air in the seal oil, the purity of the hydrogen in the generator will be reduced. So
feeding hydrogen to keep the purity is necessary.
In the normal operation, the specified parameter of the hydrogen decompressor is 0.40MPa; during the operation of the
generator, when the hydrogen pressure of the machine reduces to 0.38MPa, the pressure switch works and sends out
the alarm signal of ―low pressure‖. When the hydrogen pressure rises to 0.42MPa, the pressure switch works and sends
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out the alarm signal of ―high pressure‖. Then adjust the hydrogen decompressor inlet by hand and opening the vent
valve to reduce the hydrogen pressure to 0.40MPa.
4.5.2 Main Equipments
1) Hydrogen dryer
During the generator operation, the hydrogen humidity will increase for the gas contacts with the seal oil, or some
other reasons. So the hydrogen dryer is equipped in the system. The hydrogen dryer inlet is connected with the
high pressure zone of the generator, while the outlet is connected with the low pressure zone. By the operation of
the hydrogen dryer, the water in the hydrogen could be released continuously so that the hydrogen humidity can
be reduced.
2) Hydrogen decompressor
The decompressor is equipped in the hydrogen control station to regulate the hydrogen pressure. The
decompressor, which functions as reducing valve, is equipped in the hydrogen supply pipelines. The outlet
pressure of the decompressor should be set at 0.40MPa before the decompressor operates. When the hydrogen
pressure of the generator is higher than 0.42MPa, open the drain valve equipped behind the decompressor by hand
to release the hydrogen.
3) Hydrogen filter
Hydrogen filter is used to filter the impurities in the hydrogen. Made of the multi-porous powder metallurgy, the
filter element’s hardness is lower. Therefore, in the normal operation, the pressure difference of the two ends of
the filter element should not be more than 0.2MPa; otherwise the filter element will be destroyed.
4) Hydrogen purity analyzer
During the generator operation, the hydrogen purity in the generator will be decreased for the hydrogen contacts
with the seal oil, or some other reasons. The purity reduction will affect the efficiency of the generator directly,
the hydrogen purity analyzer is equipped in the hydrogen system to monitor the hydrogen purity in the generator
and the medium gas purity during the replacement procedure.
5) Liquid detector
Liquid detector is equipped under the generator chassis and terminal box. The floater switch in the detector could
indicate the possible liquid leakage in the generator. In each detector there is a return line connected to the
generator chassis. A blow-down valve is also equipped to drain the accumulated water.
6) Hydrogen humidity sensor
The hydrogen humidity sensor is equipped in the hydrogen inlet pipeline of the hydrogen dryer. It monitors the
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temperature and the humidity of the hydrogen on line.
4.6 Sealing Oil System
4.6.1 Sealing Principles
This system is of packaging type, correspondent with the double shaft seal ring of the generator. In the shaft seal ring
of generator, there are two ring-type oil supply tanks. The oil, running out of the tank, running through the interior
shaft seal ring and the between-shafts radial clearance, flows out along the shaft. The oil pressure is higher than the
hydrogen pressure in the generator. In this way, the independent hydrogen-side and air-side seal oil systems form.
When the oil-supply pressures in the two systems are balanced, the oil will not flow betw een the two oil supply tanks.
The oil in the hydrogen-side of the seal oil system will flow along the shaft towards the direction of the generator,
while the oil in the air-side to the outer bearing direction. Duo to the pressure equilibrium between the tw o systems, the
oil flow keeps relatively still between the two oil supply tanks.
4.6.2 Constituents of Seal Oil System
This seal oil control system consists of the following components: air-side AC pump, air-side DC pump, hydrogen-side
AC pump, air-side DC pump, air-side filter, hydrogen-side filter, seal oil tank and oil level signal meter, oil-water
cooler, differential pressure regulator, equalizing valve, drain regulator, cut-off valve, check valve ,butterfly valve,
manometer, thermometer, pressure transmitter, linking pipelines, ect.. See the seal principle chart in details.
4.6.3 Operation Mode of Seal Oil System
When the seal oil control system works normally, the two lines of seal oil from the air -side and the hydrogen-side go
around the ring-type oil chambers of the generator shaft seal ring respectively, which seals the hydrogen in the
generator. Besides, the seal oil also has lubricating and cooling effect on the shaft seal ring.
This seal oil control system adopts the structure of double shaft seal ring. The hydrogen pressure is 0.40MPa in normal
working condition. When disorder occurs, the system can also work with hydrogen pressure being reduced. The shaft
seal oil-supply system can keep the difference of hydrogen and seal oil at 0.084MPa by itself and provides the
continuous seal oil for the shaft seal ring of the generator.
4.6.4 Design Parameter
Items
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Value
Unit
Specified differential pressure between seal oil pressure and hydrogen pressure 0.084±0.01 MPa
Total oil mass of air-side shaft seal ring 220 L/min
Total oil mass of hydrogen-side shaft seal ring 51 L/min
Inlet temperature of seal oil < 52 ℃
Outlet temperature of air-side seal oil < 56 ℃
Outlet temperature of hydrogen-side seal oil < 64 ℃
Working hydrogen pressure 0.4 MPa
Inlet temperature of the secondary cooling water ≤ 38° ℃
Inlet amount of the secondary cooling water(air / hydrogen side) 120/60 T/h
Pressure of the secondary cooling water0.15~0.3 MPa
Hydrogen purity ≥98 %
4.7 Industrial Cooling Water System
The owner provides resource of service water; service water system provides water to the following equipments:
flushing water of air heater, turbine room and water using in boiler house, flushing water of ash separator and the area
of suction fan and so on.
4.8 Closed Cycle Cooling Water System
Closed cycle cooling water system will offer the water to the following equipments: EH oil assembled device,
mechanical seal cooler of TDBFP booster pump, mechanical seal cooler of MDBFP, motor cooler of MDBFP,
sampling cooler of steam-water, generator oil sealing assembled device, hydrogen cooler of generator, stator water
cooler of generator, mechanical
seal cooler of condensate pump, oil station cooler of coal mill, cooling for bearing of PA fans, lubricated oil cooler of
FD fans, bearing cooler of circulating pump of boiler, lubricated oil cooler of air pre-heater, air cooler of induced draft
fan motor.
Closed cycle cooling water will enter closed cycle water heat exchanger after it is pumped by closed cycle water pump,
then it will be transferred to different consumers. Closed expansion tank will be installed at deaerator floor, the tank is
useful for stabilizer pressure, breathing and expansion, besides the tank will provide enough positive suction pressure
for closed cycle water pump. The make-up water is demineralized water. The closed cycle cooling water system will
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comprises two closed cycle water pumps, two 100% demineralized water/seawater heat exchangers, and one expansion
water tank with 10m3 capacity. A cooling pump and a heater exchanger can meet the demand of cooling water flow
during normal operation. The type of closed cycle heater exchanger is plate type. In order to regulate cooling water
flow and control temperature of cooling medium, regulating valves will be employed in the inlet or outlet of c ooling
water pipe.
Closed recirculating cooling water system reference for F5161C-J-19 closed recirculating cooling water s ystem
drawing P&I
4.9 Open Cooling Water System
Open cooling water system also provides cooling water to close cycle cooling water exchanger, turbine oil cooler,
feedwater pump turbine oil cooler, motorized feedwater pump working lubricating oil cooler, water-ring vacuum pump
cooler. The cooling water of above equipment is supplied from open water supplying pipe, through the pressure rising
by motorized water strainer and open cycle cooling water pump then drained to drain pipes.
Flow of open water cycle pump: 3819T/H, delivery head 15m H2O, motor 250KW, voltage 3.3KV
5 Turbine Start
5.1 Inspection Operation Regulation before Start for Turbine Body System
5.1.1 Check Operation Regulation before Turbine Startup
1) Check if turbine proper maintenance and other works ended, mechanical and electrical safety documents have
been log-off, safety measures have been recovered.
2) Check if turbine proper system with complete instruments, all pressure meters, transducers’ primary valves are
open; confirm all instruments are put in normally.
3) Check if the turbine proper system interlock protection test is qualified and put in normally.
4) All electricity accessories powers are correct.
5) Instrument compressed air system has been put in, connected to instrument and control system’s air supplying
pressure is normal.
6) All monitor instruments work well
7) All cooling system has been put in.
8) Start up the condensate pump and establish the cooling water flow to gland cooler.
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9) Open the relief outlet on water chamber of gland cooler until all residential gas being discharged into atmosphere.
10) Auxiliary equipment’s lubrication oil supply is normal.
11) All passage opening and inspection door are sealed
12) Hydraulic medium supplying of auxiliary equipment is normal.
5.1.2 The Conditions of Turbine Proper is Prohibited to Start
When the following conditions exist, turbine proper is prohibited to start.
1) Unit equipments have major hidden danger, defect, important auxiliary machines breakdown or interlock test
unqualified.
2) Any protection driving unqualified or any safety protection device fails.
3) Control power source or control gas source is abnormal, unreliable.
4) Control system is abnormal; basic auto action can’t be put in.
5) Bypass system can’t be put in normally.
6) Rotor eccentricity is bigger than 0.025mm
7) Turbine HP/IP cylinder expansion difference exceeds the regulated value
8) Any of HP/IP main steam valve, regulating valve, HP exhaust check valve jammed or can’t be tightly closed.
9) Speed regulation system is abnormal, system can’t maintain the idle running of the unit after load shedding
10) Any couple of HP/IP cylinder upper and lower temperature bigger than 35℃
11) Barring is abnormal or obvious friction sound heard during turning.
12) Turbine lubrication oil, EH oil is unqualified or the oil level is at the lowest limit. Lubrication oil, sealing oil,
jacking oil system is abnormal.
13) Any oil system breakdown or has leaking point.
14) Unit DCS system works abnormally, affecting the unit operation
15) Generator hydrogen purity is unqualified.
5.1.3 Every System’s Inspection before Rolling the Turbine
1) Check if circulating water system works normally, circulating water backup mode is normal.
2) Check if open water system works normally, open water pump backup mode is normal.
3) Check if sealing oil system works normally, set one sealing oil pump at operation mode while the other at backup,
sealing oil circulating pump, sealing oil vacuum pump work normally. Accident sealing oil pump interlock is at
backup, regulate the sealing oil main recycling manual valve, control main oil pressure is 0.85~0.95MPa, sealing
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oil system differential pressure regulating valve oil hydrogen differential pressure is 0.04~0.076MPa, sealing oil
temperature is 20~50℃
4) Check when the generator furnace inner gas displacement ends; keep the hydrogen pressure inside the generator at
0.2MPa (before rolling). Hydrogen purity should be over 98%, hydrogen temperature is not higher than 46%.
Temperature regulating valve at auto put in mode (set temperature at 40℃)
5) Check if generator stator cooling water system works normally, one stator cooling water pump works while the
other at interlock backup; ion exchanger should work normally. Keep the stator cooling water main pressure within
0.25~0.35MPa, stator cooling water flow 95~105T/H, stator cooling water temperature within 40~45℃. Pressure
regulating valve, temperature regulating valve at auto put in mode (pressure set at 0.30MPa, temperature set at
42℃)
6) Check the oil level in main oil tank. If oil level is lower than the low oil level, fill the oil tank to normal oil level.
7) Start up the oil pump, and make the oil pressure at bearing higher than 0.083Mpa (g). Start up jacking oil pump
and make the oil pressure up to 11.76～14.70Mpa(g).
8) Set the control switch of DC emergency oil pump at automatic -startup position.
9) Make sure that the cooling water of oil cooler is in operation and oil temperature at all oil cooler outlets are 30℃.
Check that the oil smoke extraction device on top of main oil tank and on seal circulating oil tank of generator is in
operation.
10) Confirm after the turbine lubrication oil system, jacking oil system, generator sealing oil system work normally,
barring operation time(before cool start the unit should turning at least 4 hours) meets the regulation, locally check
the turning process and find no abnormality
11) Check if the EH oil system works normally, one EH oil pump works while another at backup; one EH oil recycle
pump works while the other one at backup; keep the EH oil main pressure at 14MPa, EH oil temperature within
20~45℃, temperature regulating valve at auto mode (set the temperature at 40℃)
12) Check if the closed cooling water system works normally, one closed cooling water pump works while the other
one at interlock backup, keep the closed water heat exchanger outlet temperature within 20~30℃, closed water
pump outlet main pressure at 0.60~0.70MPa, closed water tank water level at 1400 – 1650mm, makeup water at
auto mode (water level set at 1600mm).
13) Check if condensate circuit works normally, condensate pump backup mode is normal.
14) Check if LP heater and deaerator system works normally.
15) Check if turbine proper drain valve and all steam pipes pipe warming drain valve opened and temperature
measuring inspection smoothly.
16) Check and confirm emergency valve is at the trip state; check and confirm turbine main steam valve and HP/LP
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regulating valve is closed.
5.1.4 Turbine Start
Put main turbine shaft sealing system into operation unit works normally, detail operation as following:
1) Confirm the draining system of gland cooler is open to main condenser.
2) Confirm the water level alarm of gland cooler is in operation and the check valve of instrument is open.
3) Open the control valve which supply the steam to gland cooler of LP turbine, open the manual check valve at each
side of control valve. Because no steam is required to be supplied to LP turbine, so the control valve shall be
closed and the bypass valve of control valve shall be closed.
4) Shaft seal system controller shall ensure that the pressure at shaft seal is about 0.007 Mpa(g) ～0.021Mpa(g). Shaft
seal steam pressure regulator can adjust the pressure of gland seal main pipe within a proper pressure range for
supplying steam to various gland seals.
5) Confirm the manual check valve and bypass valve on gland steam pressure control valve shall be closed. The
motor driven check valve shall be closed also.
6) Open the steam supply to control valve of each gland system.
7) The operator shall confirm the coordination between the auxiliary steam supplying temperature and HIP rotor
metal temperature. For the limit of gland steam temperature, please see the turbine operation manual.
8) After confirming there is no water in the steam supplying pipe at inlet of control valve and the supplied steam
temperature being within the specified range, confirm the bypass valve of control valve is closed. Open the manual
and motor driven check valve at both sides of control valve according to the sequence as follows:
9) When use auxiliary steam to supply steam for gland system:
 Overflow control valve
 Reheat control valve
 Auxiliary control valve
The manual and motor-driven check valves at both sides are closed until the self-sealing of gland system is
achieved.
10) After opening the auxiliary steam supplying check valve, the steam pressure in header is established. The pressure
of supplied steam shall be stabilized at the specific point of control valve.
11) Promptly start the fan of gland cooler after establishing the pressure in header.
12) Confirm the low vacuum of each gland of casing.
13) Confirm there is no steam of gland leaked into the atmosphere. In case any leakage found, increase the vacuum of
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gland cooler or regulate the setting value of control valve to reduce the steam pressure in header until it stops
supplying the steam.
14) Check if the temperature of gland steam is within 121℃～177℃ and confirm the continuous draining of header
between desuperheater and LP gland system is in process.
15) The gland steam temperature for LP gland system is 121～177℃. The setting value of LP gland temperature
controller is 150℃.
16) The gland system is not allowed to be actuated before turning gear to prevent the rotor from bending.
When the load exceeds the primary value, the steam required by external steam will be reduced. Uner the
load about 25% of the rated, the reheat steam supplying interface will provide all steam required. Under
higher load, the leakage from HP and IP gland system is possible to meet the steam requirements of LP gland.
While uner the high load, the steam pressure of header will reach the setting value of controller of reheat
steam supplying valve and this control valve will be closed. If the pressure in header continues increasing,
the overflow valve of header will open to allow extra steam leakage to flow into main condenser.
17) Put turbine vacuum pumping system into normal operation, detailed operation is below :
Close the vacuum breaking valve of main condenser. Start the steam extracting device. Establish the vacuum
in main condenser as high as possible. Before establishing the maximum flow of gland system, the required
steam flow shall be increased according to the vacuum change in main condenser.
18) After vacuum is established in condenser, open all drainage valves on turbine body (including main steam valve,
control valve, reheat main steam valve, main steam pipe, reheat main steam pipe and drainage valves on all steam
extraction pipings). Keep the valves open and close them until the turbine operates with 20% of rated load.
19) If the automatic turbine control (ATC) is used for turbine startup, the turning gear shall not be stopped under the
conditions as follows:
a) The temperature of HP gland steam is too low.
b) The temperature difference between gland steam and wall metal is too big.
c) The desuperheating of gland steam does not regulate the steam temperature to the range between max. and
min. value.
In case any of above condition is detected, the automatic turbine control program will actuate the failure alarm
indicator. The turning gear shall be continued before eliminating the failture or over-regulating alarm being given
by operator.
20) Check boiler side all auxiliary systems work normally, boiler ignition, pressure and temperature rising is normal.
Main turbine HP, LP bypass systems are normally opened make the steam parameter comply with the unit startup
curve gradually.
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21) Before rolling the turbine, when the regulating valve chamber inner wall or external wall metal temperature lower
than 150℃, need to preheat the HP regulating valve chamber. Preheat the regulating valve chamber through using
the #2 main steam valve’s pre-start valve.
22) Confirm the following condition before preheat the HP cylinder
a) Turbine barring has worked normally
b) Pressure inside the condenser should not higher than 13.3KPa (a)
c) Regulating stage rear HP cylinder inner metal temperature lower than 150℃
d) Confirm turbine is at the trip state, main steam valve is closed, HP exhaust check valve is closed, 1st section
exhaust motorized valve is closed.
e) Cool section reheat steam pressure higher than 0.7MPa
23) Preparation before preheat the HP cylinder
a) Fully open the 1st section exhaust check valve front extraction pipe drain valve.
b) If there are drain valves on the HP cylinder preheat pipe system, should be opened fully first, and keep 5min,
then tightly closed.
c) Fully open #1, #2 main steam valve lower valve seat drain valve.
d) Fully open IP combined regulating valv e lower valve seat drain valve.
e) Fully open reheat cool section all drain valves.
f) Fully open main steam pipe section all drain valves
g) Fully open HP regulating valve steam conduit drain valve (instruction ask for closing to 20%)
h) Record the inner surface temperature of turbine regulating valve shell.
24) HP cylinder preheating operation.
a) Open the HP cylinder primary radial flow valve, HP cylinder secondary radial flow valve slightly opened to
10% (control the cylinder temperature rising speed), confirm the HP extraction ventilation valve is at the
closed valve. by this time, HP cylinder preheating steam leads from reheater cool section to HP cylinder.
b) Keep the 10% opening of the HP cylinder preheating valve for 30min then increase to 30%
c) Keep the 30% opening of HP cylinder preheating for 20min, then increase the 30% opening to 55% opening,
keep it unit the inner metal temperature of HP cylinder first stage rear cylinder rises to 150℃.
d) Regulate the HP cylinder radial flow valve secondary valve’s opening, keep the HP cylinder inner wall
temperature rising speed lower than 0.5℃/min.
e) When regulating stage rear HP inner cylinder inner wall temperature reaches 150℃, carry out HP cylinder
holding. Holding time determined by the ―HP cylinder preheat holding time curve‖.
f) Watch that the preheating steam entering the HP cylinder is realized by motorized preheat valve. this valve is
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set on the bypass pipe of cold section reheating steam pipe, in front of back valve. steam temperature inside
the HP cylinder should increase to 390~490Kpa(g), realized by regulating the preheating valve and all drain
valves.
g) Watch the strictly control the temperature rising rate.
25) Operation after HP cylinder preheating ends
a) Fully open turbine regulating valve and drain valves on the HP steam conduit between cylinders.
b) Open drain valves in front of HP extraction back valve and on the start cold section reheat pipes.
c) Reduce the preheat valve opening to 10% and keep it for 5min, then gradually close the preheating unit fully
closed within 5min. when HP cylinder preheating valves are all closed tightly, check and open the HP
extraction ventilation valve.
d) Put HP extraction check valve front cold section reheating drain valve in ―Auto‖ mode, confirm reheating
cold section drain valve at the fully open state.
e) When the HP cylinder extraction pressure reaches -50KPa, put HP regulating steam conduit drain valve in
―Auto‖ mode, confirm HP regulating steam conduit drain valve at the fully open state.
26) Points of attention during preheating HP cylinder
a) HP cylinder preheating cylinder degree of superheat should not lower than 28℃, preheating steam pressure
should not higher than 0.7MPa, or the unit will generate extra thrust .
b) During warming HP cylinder, through regulating radial flow valve, steam conduit drain valve, HP extraction
front drain valve to regulate cylinder metal temperature rising rate, strictly keep the metal temperature rising
rate in the allowed scope.
c) During preheat the HP cylinder, should strictly according to the ―HP cylinder pre-warming cylinder time
curve‖.
27) Before rolling the turbine, when the regulating valve chamber inner wall or outer wall metal temperature lower
than 150℃, it must pre-warm the HP regulating valve chamber. Using #2 main steam valve pre-start valve to
pre-warm the regulating valve chamber.
a) Check and confirm emergency valve is at the tripping position, load limit setting is at closing position.
b) Check and confirm control EH oil pressure is normal.
c) Confirm the main steam temperature is higher than 271℃
d) Open the main steam valve drain valve and HP regulating steam conduit drain valve.
e) Click ―Alarm reset‖ button on the turbine control image, check if turbine DEH alarms all disappear; click
―Turbine rest‖ on operation port, press ―Execute‖. Confirm ―Turbine reset indicating lamp lights, means
successful turbine latching.

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f) In turbine control picture, choose preheat function group put in, confirm #2 main steam valve ―Open‖ lamp
lights, slowly open #2 main steam valve slightly to ―21%‖. At this time, pre-warm the HP regulating valve
chamber.
g) When the inner and outer wall temperature difference of HP regulating valve higher than 80℃, in turbine
control interface, choose quit pre-warm function group, check if #2 HP main steam valve fully closed.
h) When HP regulating valve inner and outer metal temperature both rise above 180℃, and temperature
difference between inner and outer wall lower than 50℃, or has pre-warmed the steam chest for at least one
hour, then the HP regulating valve chamber pre-warming ends.
i) After HP regulating valve chamber preheating ends, turbine latches, check if IP main steam valves are all
closed.
28) Preparation before rolling the turbine, confirm the following items:
a) Start the turbine startup oil pump, check if the main oil pump inlet oil pressure is higher than 0.18MPa
b) Check if lubrication oil pump works normally, DC oil pump interlock at backup state.
c) Jacking oil pump, barring work normally, oil pump backup mode is correct.
d) Sealing oil system works normally, sealing oil pump backup mode is correct
e) EH oil pump works normally, backup mode link-action mode is correct
f) LP water spraying put in auto mode (set temperature at 50℃)
g) Confirm turbine HP extraction ventilation and accident ventilation valve are fully opened, HP extraction
check valve closed.
h) HP, LP bypass set at ―Auto‖ Mode
29) Put the following turbine shutdown protection into operation
a) LP cylinder extraction temperature is very high
b) Lubrication oil pressure is very low
c) TSI over speed shutdown
d) Fire-resistant oil pressure is very low
e) Condenser vacuum is very low
f) Turbine safety oil pressure is low
g) Axial displacement is large
h) HP cylinder differential expans ion is very high
i) LP cylinder differential expansion is very high
j) Supporting bearing metal temperature is very high
k) HP extraction metal temperature is over high

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l) MTS acts and shutdown the turbine
m) Turbine/generator shaft vibration is very strong
n) BUG acts
o) Generator trips
p) Boiler main fuel trips
q) Remote shutdown button.
30) According to the requirement of ―Unit cold startup curve – IP cylinder startup‖, confirm the unit meets the cold
rolling parameter.
a) Main steam pressure lowest pressure is about 5Mpa, degree of superheat 56℃,highest temperature is not
higher than 430℃.
b) The vacuum degree reach maximum value, properly open the main steam valve to speed rotor upto 400rpm.
c) Reheat steam pressure is 0.824MPa, reheat steam temperature 330℃
d) Condenser vacuum is higher than -90KPa
e) HP bypass flow is higher than 200T/h
f) All attached auxiliary systems of turbine, boiler and generator work normally.
31) Turbine rolling operation
a) Reset and latch turbine: choose latch in turbine control interface, confirm IP main steam valve opened
normally, turbine latching successful.
b) Check on turbine control interface: startup mode and warming mode, valve position is correct, target rotating
speed is set at 200rpm, speed rising rate set at100rpm/min
c) Check if the turbine starts accelerating the speed.
d) Check and confirm barring gear trips normally, motor has stop running automatically, green light lights.
32) Turbine friction inspection
a) When the turbine rotating speed is kept stably at 200rpm, click ―full close the valve‖ on turbine control
interface, check if HP main steam valve, regulating valve are all closed.
b) Locally check if the sound of turbine coasting operation is normal.
c) Check and confirm friction check has completed and HP regulating valve and IP regulating valve have been
closed tightly.
d) At the speed of about 600rpm, eccentricity recorder will disengage automatically and vibration recorder will
start to work. The eccentricity value shall be inspected finally at the speed of 400-600rpm.
33) Turbine 2000rpm warm-up
a) Speed up to 2000rpm with speed raising rate of 150rpm/min. If shutting down to inspect turbine auxiliary
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equipment during intermediate speed, it will take longer time.
b) In this process, the inlet temperature can rise up, but the temperature rise rate should not exceed 55℃/h.
c) Keep the speed of 2000rpm for more than 150 min.
d) Check turbine: shaft vibration, bearing seat vibration should be normal, journal bearing, thrust bearing
temperature should be normal, cylinder expansion is normal.
34) When finishing the warm-up, speed up to 3000rpm with speed raising rate of 150rpm/min.
a) Check if turbine rotating speed rises, close the HP valve regulating speed gradually unit full closed. Turn on
the IP regulating valve gradually, turbine rotating speed increases.
b) When the rotating speed is higher than 2000rpm, check if jacking oil pump automatically stop (or manually
stop putting the jacking oil pump into backup)
c) Check if turbine vibrations, cylinder expansion, bearing return oil temperature, bearing temperature are all
normal.
d) When the turbine rotating speed 3000rpm, main oil pump outlet oil pressure should be normal, stop putting
AC auxiliary oil pump, turbine startup oil pump in backup.
35) Attention that during turbine accelerating speed.
a) Operator should be familiar with any critical rotating speed. Delay operation time within the critical rotating
speed zone is not allowed. When the turbine rotating speed is passing the critical speed zone should quickly
and stably accelerate the speed, so when the turbine is in critical rotating speed should not be limited by
EHG program.
b) Measure and control the following metal inner outer wall temperature difference within the regulated scope:
c) CV valve steam chamber inner metal temperature
d) CV valve steam chamber outer metal temperature
e) HP 1st stage cylinder inner wall metal temperature
f) HP 1st stage cylinder outer wall metal temperature
g) Reheat steam inlet cylinder inner wall metal temperature
h) Reheat steam inlet cylinder outer wall metal temperature
i) CV valve steam chamber inner wall metal temperature
j) Cylinder differential expans ion within the normal scope.
k) During start the turbine, usually the rotor won’t shorten, if the rotor rising the speed more quickly than
cylinder, then rotor will extend reversely. If the differential expansion close to red zone, should reduce the
steam temperature, rotating speed or reduce the load o decrease the differential expansion.
l) If HP-IP cylinder differential expansion enters the red zone, should shutdown the turbine and start the
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barring gear immediately, drive the shaft to rotate so make the cylinder temperature match the rotor
temperature.
m) If LP turbine differential expansion enters the orange zone, no need to shutdown the turbine but take other
measures unit the differential expansion lower than orange zone. Because unit trips in orange zone may
cause the rotor extend make the differential expansion enters the red zone.
n) Vibration detecting, check and confirm turbine supervision instrument’s detecting sensor is working
normally; this could be pointed by the recorder. If the vibration exceeds the standard should shutdown the
turbine.
o) Supervise and listen the friction sound, if heard severe friction sound, should shutdown the turbine and find
out the reason.
p) Normal vacuity, during normal operation and have normal vacuity, LP cylinder extraction temperature
should not exceed 80℃ before parallelization.
q) Bearing temperature should be normal, temperature of oil entering the bearing allowed to raise along with
the rotating speed raising, before reach the parallelization rotating speed, bearing oil inlet temperature should
not lower than 38℃
36) After the turbine rotating speed is constant, according to need, following test should be take
a) Turbine oil spraying test
b) ETS online test
c) Main isolating electromagnetic valve.
d) Valve tightness test
e) Overspeed test base on the situation
When the unit starts up initially after overhaul, overspeed test shall be performed on turbine to check the
overspeed trip device. The trip indicated value shall be set to the value given in instructions. During test, operator
shall wait in front of the manual trip bar in order to prevent the trip mechanism from failing in case that the speed
reaches 3300rpm. If the trip rotating speed is incorrect, then make necessary regulations according to
―instructions for overspeed trip mechanism‖ in guidebook for this equipment.
Note: before overspeed test, the equipment shall operate with load not less than 20% and reheat steam
temperature not less than 400℃ for at least 7 hours.
After the overspeed trip device is regulated to normal state, test the overspeed trip device through oil pressure test
when equipment operates at low load or as keeping the speed of 3000rpm (for test steps, please refer to ―guide for
oil pressure inspection of overspeed trip device‖.
37) When turbine test ends, check if turbine proper is normal

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38) Generator parallelization and bearing initial load 30MW
After the unit synchronizes, it is controlled by control valve and takes on an initial load of 5%. Determine the
maintaining time for load of 5% according to Figure 10-1. Load up fatherly according to Figure 10-2. Figure 10-2
is drawn provided that the temperature rise rate of governing stage chambers is 165℃/h. In this process, the
temperature rise rate of main steam temperature shall be controlled at no more than 83℃/h. When the temperature
rise rate of steam temperature drops to 14℃/10min, it indicates that main steam temperature has been stable, and
loading up rate can be raised to 10–20%. When the equipment has been synchronized and loaded up according to
the above steps, load and/or main steam temperature can increase in rates shown in Figure 10-2.
If steam inlet pressure and temperature change during speeding up process, reset the speeding up time under new
inlet conditions
39) After synchronization, because the steam flow and boiler combustion efficiency are increasing, so the steam
temperature tends to rise rapidly. At this time, should avoid or manage to slow down the metal temperature rapid
rising of small turbine
40) Regulate steam temperature and load to reduce the metal temperature difference (difference to the steam
temperature) indicated by the thermocouple, at this time, could add the load and/or rise steam temperature more
quickly; if the metal temperature is low (lower than steam temperature), at the moment, could maintain the current
steam temperature and increase load slowly.
41) Maintain the initial load until the LP cylinder exhausting outlet has been cooled down below 52℃.
42) Confirm the MSV valve upper seat and lower seat drain valves closed
43) The increasing of steam pressure, temperature and load is limited by the metal temperature difference of turbine
inner and outer wall and bigger differential expansion happens.
44) Cylinder transferring
On the turbine control interface, click ―Increase load‖, check if the IP regulating valve opened gradually until
fully opened, HP regulating valve begin to open, V. V valve closed, HP exhausting check valve opened. HP bypass
valve turns down automatically and keep the turbine main pressure at 5MPa, or switch to manual control and keep
the main steam pressure. When HP bypass are all closed, check A/B side LP bypass valve closed, check HP,LP
bypass attemperating water automatically closed.
When the unit load is higher than 120MW or HP bypass all closed, cylinder transferring ends.
45) When turbine cylinder transferring ends, turbine main control put in auto mode: check if the turbine main steam
pressure is 5MPa, click ―require remote control‖ on the unit main control interface, click ―auto‖ to put in, check if
the unit control mode is ―TF‖.
46) When the load is higher than 60MW, check if turbine proper HP side drain link closed, when the unit load is higher
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than 120MW, check if turbine LP side drain link closed, or close it manually.
47) When the load increase to over 20%, close other startup drain outlet, as following
a) CRV valve (IP combined valve) seat drain button
b) MSV valve upper valve seat drain button
c) MSV valve lower valve seat drain button
d) Drain button on the steam conduit between CV valve (regulating valve) and cylinder.
e) Close back valve front cold section reheat steam conduit drain valve
48) Put #3, #2，#1 HP heater by sequence
49) When the load is within 160~180MW, switch the small turbine steam source, deaerator steam source from
auxiliary steam to the turbine 4th section exhausting.
50) Rolling the first pneumatic pump and synchronized with system, when the steam parameter has been satisfied
increase the load to 300MW.
51) When the unit load is higher than 350MW or economizer inlet flow is higher than 1000T/H, synchronized with
second steam powered feedwater pump, stop the motorized feedwater pump put interlock in auto mode
52) When the load is higher than 400MW, put the feedwater main control in auto mode: on ―unit main control‖
interface click to put two steams powered feedwater pump in auto mode, correct the coal-ratio according to the
need.
53) When the unit load is within 450~500MW, watch that turbine gland sealing steam source switching should be
normal
54) Base on the situation, increase the load to 600MW, set the unit control mode at CCS: on the unit control interface,
set the boiler main control at ―auto‖, check if the unit control mode CCS light lights.
55) Verify if the operation sequence is correct, and report to the shift leader.
5.2 Start Parameter and Attention of Different State
1) Cold start-up: the first stage metal temperature＜120℃, for start-up after long time shutdown
2) Warm -1 start-up: 120℃≤the first stage metal temperature＜260℃, for start-up after shutdown more than 72
hours
Main/reheat steam temperature: 410/380℃，Main/reheat vapor pressure: 5/0.824MPa。
3) Hot start-up: 415℃≤the first stage metal temperature＜450℃, for start-up after shutdown of 1-10 hours.
4) Extreme hot start-up: 450℃≤the first stage metal temperature, for start-up after shutdown of less than 1 hour.
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5) During start up, to avoid resonance vibration, the turbine shall not operate at the speed within following ranges.
700-900rpm；
1300-1700rpm；
2100-2300rpm；
2650-2850rpm。
6) Loading curve of different state see attachment 1 turbine start curve
7) While the unit with rising load, before the load rise to 20% of the rating loads, the drain valve should always on.
Afterward, these drain valves should automatically shut off. Similarly, if the unit fails to load or is off and the load
falls to its 20%, the drain valve should automatically open up; the operator must confirm the drain valve could
automatically function. Otherwise, you must manually operator the drain valve.
5.3 Attention of Hot and Warm Start for the Unit
Turbine warm, hot, super hot start, the operation steps on turbine is basically the same with the cold start. Because the
turbine temperature is higher, the preheating time of turbine is shortened a lot. During turbine startup, the stress control
is easier relatively, there are less operation then cold startup. Rolling parameter should be executed according to the
relater startup curve. But notice the following points:
During turbine rolling, strictly monitor the expansion, differential expans ion of turbine, bearing temperature and unit
vibration, displacement of turbine. Treat any abnormality in time.
Boiler side main, reheat steam temperature should be higher than the maximum temperature 80℃ of turbine HP-IP
cylinder.
Before put shaft sealing system into operation prohibit pumping vacuum. Shaft sealing temperature should match with
turbine cylinder temperature（difference should not higher than 80℃）.
During warm startup of unit, rolling parameter should be executed according to the related warm or hot startup curve.
During hot startup, prohibit the turbine resetting, latching, and rolling in the critical rotating speed zone.
According to the HP cylinder temperature status, turbine could skip the HP cylinder radial flow valve shell
pre-warming, medium speed warming turbine, rolling the turbine quickly to the 3000rpm
Unit hot (warm) startup should open all steam water entering proof valves, guarantee the smooth drainage of the
turbine.
Turbine side main, reheat steam temperature and turbine HP-IP cylinder temperature difference should not over 50℃.
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6 Adjustment of Turbine Operation Adjusting
6.1 Turbine Operation
6.1.1 TSI Turbine Supervisory Instruments (TSI)
600MW sub-critical steam turbine is equipped with various supervisory instruments mentioned in this section, which
are used to observe the unit’s start, operation & shut-down conditions. The outputs from these supervisory instruments
are recorded by chart recorder. For their alarm and trip limits, please refer to ―Operation Limits‖ in this instruction. To
know about the specific TSI configuration for this project, please refer to relevant drawings.
1) Casing Expans ion Measurement
If this device can’t indicate and record the changes of expansion value, operator should inspect for the reason
immediately. Generally, this expansion value is fixed under certain steam state, load and condenser vacuum
conditions, and it is important to compare this expansion value with empirical value.
When the unit turns into temperature rise and on-load conditions from cold condition, changes of temperature will
certainly cause casing expansion. Casing expansion measurement is performed to measure casing’s axial
expansion value in the direction from the dead point to front bearing box, and the front bearing box can move
freely along the longitudinal key for filling lubricants. When casing expansion occurs, if the movement of unit’s
free end on the guide key is blocked, the unit will be severely damaged.
Actually, casing expansion measurement is performed to measure the movement value of bearing box relative to
the dead point (foundation) and record casing’s expansion & contraction values under start-up, shut-down and
load & temperature change conditions of the unit. If the indicated values are abnormal under these transient
conditions, then operation personnel shall analyze them. Under similar load, steam parameters and vacuum
conditions, the relative positions of front bearing box indicated by this instrument shall be identical basically.
Casing expansion has no alarm or trip limits. The casing’s expansion value indicated by instruments shall be
compared with that measured under the same operation conditions before. If there are great differences between
these two values, operators shall make judgment then. Typically, this can be treated by adding lubricating grease
to LP casing foot, bearing box seat and bed-plate contact surface. Sometimes, it is also necessary to adjust the
bearing seat in order to achieve smooth expansion.
2) Axial Displacement Measurement
This device indicates and records the axial displacement of rotor thrust disc relative to the axial position of
bearing seat, to monitor the abrasion conditions along the thrust direction and of thrust bearing pad. For the
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existence of steam, thrust disc applies axial pressure to the thrust pads on its two sides, which will cause bearing
pad abrasion, and the axial displacement due to this bearing pad abrasion will be displayed on TSI measurement
device. Each measurement block is equipped with alarm and trip switching value outputs, w hich will alarm
automatically once the rotor’s axial displacement exceeds the first preset position. If the rotor’s axial displacement
value exceeds the second preset position, then tripping relay will operate to trip out the turbine.
For the set alarm and trip values, please refer to ―Operation Limits‖ of this instruction.
3) Differential Expans ion Measurement
When steam enters into turbine, the rotating & static parts will expand along with steam. For the rotor can be
heated, it will also expand faster. Although the axial clearances between rotating and static parts allow certain
differential expans ion ins ide the turbine, it will cause abrasion and even crash of rotating and static parts if the
differential expansion exceeds allowable limits.
Differential expans ion measurement is performed to show the relative displacement of rotating and static parts,
and continuously indicate the axial clearances of turbine during operation. The measurement blocks are equipped
with alarm and trip outputs, and the relay will operate when axial clearances reach the limits due to differential
expansion. After a transient process, temperatures of rotating and static parts will gradually tend to be the same,
and differential expansion reduces accordingly. Then, it is permitted to change the steam flow and temperature for
another time.
For the set differential expansion alarm and trip value, please refer to ―Operation Limits‖ in this instruction.
4) Rotor Eccentricity Measurement
During unit shut-down, if the temperature of upper casing is higher than that of lower casing, rotor can bend for
uneven cooling. Barring gear is used to rotate the rotor slowly to make rotor’s temperature tend to be even, which
therefore can reduce the rotor’s bending.
This device is used to indicate and record the rotor eccentricity with a rotating speed less than 600rpm. When
turbine’s rotating speed is more than 600rpm, this device can be switched off automatically by rotating speed
signal controls.
If it is possible to measure at bearing oil retainer with portable rotor eccentricity meter, the double amplitude
eccentricity value measured before turbine rotation impulsing should not exceed 0.025mm.
The rotor eccentricity measurement is equipped with alarm signal outputs, which will alarm when eccentricity
value reaches the limits.
If the unit’s barring gear needs to be shut down, rotor’s roach back shall be positioned at the rotor’s lower part in
order to reduce the temperature gradient between rotor’s upper and lower parts. The best rest position of rotor is
where the instantaneous value measured by eccentricity meter is the lowest.

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5) Vibration Measurement
Vibration measurement instrument is used to measure and record vibration of rotors with rotating speed higher
than 600r／min. A couple of eddy current sensors vertical to each other and a bearing pad vibration probe fixed
vertically are installed at each bearing seat of this turbo-generator unit, and signals from sensors are connected to
turbine supervisory instruments, which will measure the rotor’s vibration value directly. Excessive vibration
indicates that accidents of turbine may occur or that turbine is operating abnormally. Each vibration measurement
is equipped with alarm and trip switching value outputs, and relay will operate accordingly when excessive
vibration value is measured on any bearing.
TSI can supply the vibration signals to vibration analysis and failure diagnos is system TDM via buffer outputs for
performing analysis diagnos is, dynamic balance, etc. of unit vibration.
The following table shows vibration limits (peak-peak value) (unit: mm):
Set value
Rotor vibration - alarm 12.5/100
Rotor vibration – shutdown 25/100
The above values also apply within critical rotating speed; When performing temporary measurement on bearing
seat, the vibration limits shall be one half of those in above table.
6) Key Phase Measurement
Key phase signals show the angular relation between the protruding position of certain bearing and one reference
point on the rotor. TDM system can accurately calculate the phase of rotor vibration via key phase signals.
7) Speed & Zero Speed Measurement
Speed indicator is provided with the function of monitoring the shaft rotating speed continuously. There is rotating
speed sensor arranged in front bearing box, and speed indicator receives signals from eddy current probe, after
that, it calculates the speed in RPM. When the speed drops to zero, it will send an interlock signal to automatic
barring gear to start the barring gear.
When the rotating speed exceeds certain preset value, relevant relay will operate to control water spray device and
jacking device of steam exhaust casing.
6.1.2 Steam and Metal Thermocouples
The thermocouples in following table represent thermocouples for HP-IP casing.
The thermocouples in following table represent thermocouples for LP casing.
See the instruction book of operation and maintenance for turbine startup
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6.2 Supervision and protection system
6.2.1 Items of Turbine Supervision Instrument
The supervision instrument shall monitor the items as follows and have the function of display, alarm and tripping.
1) Turbine speed supervision
2) Zero speed supervision
3) Turbine rotor axial displacement supervision
4) Relative expansion (LP) of turbine rotor
5) Turbine rotor vibration supervision （1#—9#）
6) The measurement of phase angle between peak and base point of turbine rotor vibration
7) Eccentricity supervision of turbine rotor
8) Turbine casing expansion supervision
9) Steam and metal temperature supervision
6.2.2 Safety System Guaranteed Performance
1) Centrifugal stop bolt: When the rotating speed of the steam turbine exceeds 10% - 12% of the rated speed (i.e.
3330 - 3360 r/min), the steam turbine is triggered to trip and cease to admit any steam.
2) During the emergency shutdown of the steam turbine, the time from the action of the safety system to the
full-clos ing of the main steam stop valve shall not exceed 0.3 seconds.
3) After the action of the centrifugal stop bolt, when the main steam stop valve is closed, all the regulating valves
and reheat system steam extraction non-return valves shall be also closed.
6.3 Set Values for Turbine Control
Temporarily lack of drawing information
6.4 Turbine Operation Control
6.4.1 Load Control
When the steam turbine on the mode of Automatic or Manual , its load change (elevates or reduces) must throughout
according to the load change graph which the steam turbine requested.
When the unit on the ATC control mode and the main breaker of generator is closed, the automatic control (ATC)
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procedure has the ability to control load. Since the load control can automatically choose the best rising load rate, we
prefer to process all the load changes with the ATC. The ATC procedure can continuously monitor all kinds of
parameters of the steam turbine and calculate the stress of rotor, and according to the then condition to select the
appropriate load rate of change. This rate of change is the minimum value among the load factor which selected by
operator and exterior input load factor and the best load factor which determined by compute the rotor stress. The
operator monitoring the utmost value rotor stress and the peak load value which measuring unit is megawatt. Whatever
control mode you are using to change the load, assuming the feed water heater or other supporting facilities are work
well.
1) Push the button ―Load rate of change‖ on DEH main control window.
2) Input the above value of load rate of change in the DEH control system.
3) Push the button Target Value on DEH main control window.
4) Input the desirable value.
5) If you want to complete all load changes under the ATC control mode. Push the button ATC, the unit will run on
ATC control mode, and it will control the rising load until complete. If do not want working on the ATC mode,
you may push the button GO on the mode of AUTO, the load will change according to the designated rising load
factor.
6) If need a little time to hold over the load during the load changing period, you may push the button GO/HOLD to
choose HOLD and the load should stop changing, if you want to change the load again, push GO, then the load
will change along with the designed rising load factor.
While Reference Value is equal to Target Value means the completion of load change.
6.4.2 Main Steam Pressure Control
1) When the main steam pressure achieved the rating pressure, the operator may push the button TPC in the DEH
main control window to loop in the main steam pressure circuit.
2) When the main steam pressure achieved 90% of the rating pressure, the operator may push the button TPR in the
DEH main control window to loop in the restricted main steam pressure circuit. This function assures that when
the main steam pressure is lower than designed value, DEH would rapidly shut down the control valve to ensure
the stability of the main steam pressure.
6.4.3 Shut Down by Accident
Disconnect from electric grid
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When the generator accidentally dumping the complete or partial power load, the remained steam energy will cause the
rotor accelerating, its acceleration is related with the load of the then generator.
DEH control system is equipped with the over-speed protection controller (OPC) and it has the following functions:
1) The function of load decreasing anticipator of OPC is to examine the dumping load quantity, and rapidly close up
all high-pressure regulating valves and the reheat regulation valves to limit the over-speed quantity of steam
turbine. But this function only works when the load over than its 30% and the main breaker is off.
After an interval, the rotational speed of unit lower to less than 103% of its rating speed, the signal disconnected
and causes the regulating valves and the reheat regulation valves slowly open up.
The steam remains in the reheat system is possibly over-speeds the steam turbine on the second time and it will
close up all the regulating valves and the reheat regulating valve again. After exhausted the remained steam in the
reheat system, the rotational speed of unit is lower to the rating speed. Under the rating speed, the regulating valve
will undertake to control the unit and will maintain the unit running under the rating speed.
2) The another function of OPC is to monitor the over-speed of steam turbine , when the rotational speed surpasses
103% of rating speed, it will close up all regulating valves and reheat regulation valves.-Its function is similar to
the function of load decreasing anticipator, it causes the regulating valve and reheat regulation valve to operate,
exhausted the steam in re-heater, thus enable the unit to achieve the synchronized rotational speed.
3） The function of rapidly shut down the reheat regulating valve
DEH System with the aid of comparing between the input power of steam turbine (exhaust pressure of
intermediate pressure cylinder) and the generator output (power sensor), it could monitor the partial dumping load
of unit. When the power of steam turbine surpasses approximately 30% of the generator power (the three-phase
breakdown in somewhere near by the power plant) the quick-shut logic function of the valve could rapidly reduce
the reheat regulating valve. The instant reducing on reheat regulation valve will correspondingly and instantly
reduce the power input of steam turbine as well as reduce the output of the generator, and synchronize the unit
with system. Whether put the quick-shut function of valve in service is up to the users.
6.4.4 Auto Turbine Control (ATC)
The turbine control mode can be switched from any auto mode to ATC mode only by clicking ―ATC‖ button on DEH
main control display. At this point, ―ATC‖ button will change color and the button for former mode will reconvert. This
kind of switching operation can be performed at any time and will not cause fluctuation of rotating speed and load.
If this kind of control mode is selected, the unit will be speed up from barring speed straight to synchronous speed by
ATC program, and various parameters and alarm values of the system will be monitored continuously at the same time.
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In this mode, ATC program can inspect the speed before rotation impulsing and determine if rotor needs to be warmed
up in order to choose the best speedup rate. In addition, it can make the unit’s speed keep away from the resonance
speed range of blades.
Besides of having the function of rotating speed control, ATC program also have the function of load control when
main circuit breaker of generator closes. The load control program can select the best loading-up rate for the unit
automatically in order to comply with the requirements for varying load of operators or external system. During turbine
operation, no matter speeding-up or on-load process, computers will monitor various parameters of turbine and
compare them with the limits, then display them on the screen.
Attention
During initial start-up of the unit, it is suggested to adopt operation personnel auto control mode, and ATC control
mode is not recommended. That is because in auto operation mode, it is possible to perform some auxiliary
measurements and observations, which are typically quite necessary for initial start-up.
6.4.5 Auto Turbine Control (ATC)
Turbine manual control mode means that operators shall determine valves’ position and observe the results, and it is
possible to regulate valve position if necessary to achieve desired results.
When turbine operates in manual control mode, DEH will be in a control state of open loop and the control accuracy of
closed loop regulation cannot be ensured; in addition, it will increase operator burden. Therefore, this mode is not
recommended to be used for start-up typically unless it cannot be avoided.
Select ―MANUAL‖ on ―MANUAL CONTROL‖ control mode on DEH ―AUTOLIM‖ display, then input the target
value for manual control, DEH will regulate the unit to corresponding valve position.
6.5 Attention of Turbine Operation
6.5.1 General Attention
1) When turbine is under fully heated and normal conditions, reducing load in short time will not cause damages,
however, operation under excessive low load is not suggested. If operation under excessive low load cannot be
avoided, it is necessary to prevent the turbine exhaust steam from being overheated.
2) After main load is rejected, turbine operation with auxiliary load shall not exceed several minutes.
3) When rotor is in rest state, it is necessary to prevent steam from leaking into steam casing.
4) In order to prevent air from entering at the gland seals when rotor is
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in rest state, the steam extraction device and vacuum pump shall not be started until sealing steam is filled into the
gland seals.
5) It is necessary to prevent turbine’s LP part from being heated improperly, for this can cause steam exhaust casing
expansion and stress generation because of LP casing centerline offset and further cause friction between gland
seals. Therefore, sealing steam shall be supplied when start up, and exhaust device shall be s tarted to maintain as
high vacuum degree as possible.
6) Although water spray device of steam exhaust casing is provided in the unit, it is suggested to use these water
spray devices as less as possible in order to maintain as high vacuum degree of condenser as possible.
7) In tripping or normal shutdown conditions, it is suggested that vacuum state is kept until the unit’s rotating speed
drops to 400rmp, except for emergency conditions during which the vacuum state shall be disturbed immediately
after unit tripping.
8) Operation of drainage valve
The drainage valve shall be opened before start-up and be kept fully opened until the unit load reaches 20% of
rated load.
When 20% of rated load is reached from normal shutdown condition, open all drainage valves.
After unit steps out, keep drainage valves fully open until turbine’s metal parts and pipings cool down.
If unit trips for emergency accidents, drainage valves shall be opened immediately.
9) As unit starts up, in order to keep identical temperatures between impulse stage metal and steam, it is suggested to
choose the steam parameters of main steam valve according to following methods:
a) Choose LP steam with temperature not exceeding 430℃ for cold condition start-up. If cold condition
start-up is selected, the steam superheating degree shall not lower than 56℃.
b) During warm start, steam shall be in LP high temperature state, in order to minimize temperature loss
caused by throttling action when steam passes the steam inlet valve.
10) Over speed trip test shall be performed in advance, and before test, the unit to be tested shall operate at least 7
hours under conditions in which unit load is not lower than 20% of rated load and reheat steam temperature is not
lower than 400℃, to make the rotor preheated thoroughly.
11) The turbo-generator unit is not permitted to operate under motoring condition in a long time, and the time for
operating under this condition should be limited within 1 minute to prevent blades from overheated for air
blasting and venting blocked.
12) If turbine hasn’t operated for a long period, the main steam valve shall be cut off in time after start-up to ensure
the tripping mechanism can function well.
13) During unit shutdown, the barring gear shall be kept operating. Please refer to ―Barring gear operation during unit
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shutdown‖ for details.
14) When lifting larger turbine parts, please refer to the ―Lifting device diagram‖ and pay attention to the specified
cable size and relevant Attention.
15) A complete steam pressure and temperature record shall be maintained, and any fluctuation relative to normal
value shall be analyzed and treated timely, which is especially important to steam pressure distribution under any
specified load.
16) Keep oil system clean and free from water.
It is suggested to extract small quantity of oil from the bottom of oil tank after long time of shutdown, for foreign
matters and water may settle at the bottom. It’s even better to extract the oil on batch basis and treat them before
reusing them in this system.
17) Oil leakage will not only affect unit appearance, but also cause fire danger at the part near high temperature steam.
This leaked oil shall be removed in time.
18) Keep the unit appearance clean from dust and foreign matter accumulation. It can ensure better unit operation to
provide overall unit servicing work well, including cleaning the unit and treating oil leakage and steam leakage.
6.5.2 Gland System Attention
1) Gland steam must have the superheat degree no lower than 14℃.
2) Steam supply system shall not be brought into service before barring gear operates in order to prevent rotor from
bending.
3) Steam supply temperature for LP casing shaft seal must be within 120℃～180℃. Temperature regulator of shaft
seal system is suggested to be set at 150℃.
4) To prevent the shaft seal part of rotor from being damaged due to thermal stress, the temperature difference
between shaft seal and rotor surfaces shall be minimized as much as possible during unit start-up and shutdown.
The temperature difference shall not exceed 110℃. If cases in which the temperature difference exceeds 110℃
are not more than the times indicated in curves of Figure 7-2, the maximum temperature difference can be up to
165℃.
5) During warm start up, if using auxiliary boiler to supply steam for shaft seal, it should be ensured that the
maximum temperature difference between steam and rotor will not exceed the allowable range.
6) While controlling the down loading, if the cold reheat pressure is high enough to maintain the steam pressure in
header to be higher than 24030Pa（0.246Kgf/cm²）（gauge pressure）, the steam required by gland system comes
from cold reheat pipe. When the pressure in header is lower than this value, the auxiliary steam supplying valve
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will open to maintain the pressure in header at 24030 Pa（0.246Kgf/cm²）（gauge pressure）.
7) During the down loading, the steam temperature for HP gland shall be controlled to minimize the stress (in gland
area) of rotor through the coordination of HP and IP rotor metal temperature.
8) One check valve is installed on the steam supplying pipe at the inlet of cold reheat control valve. When the cold
reheat pressure is lower than that in header, this check valve could prevent the returning of steam from header to
reheat piping.
6.5.3 LP Exhaust and Exhaust Spray Attention
1) Before supplying steam to shaft seal, the vacuum pump and shaft seal steam extraction fan should not be started
up.
2) Steam exhaust casing water spray shall be set under automatic control, and it should start to spray water when the
rotor rotating speed reaches 600r/m until the unit takes on 15% of rated load. During unit start-up, the control
switch shall be set on ―automatic‖ position. This switch shall also be provided with a ―manual‖ position.
3) Operator must make sure that steam exhaust casing water spray control valve will open for passing water when
turbine rotating speed is higher than 3r/m.
4) When steam exhaust temperature of LP casing reaches 70℃, water spray system shall be put into service. When
steam exhaust casing water spray is cut off, then the alarm value for LP steam exhaust casing temperature will be
80℃ if turbine continues to operate, or the temperature should not exceed 120℃ during short time operation
within 15 minutes. If temperature reaches 120℃, then the unit should be shutdown urgently to solve this problem.
Attention
When steam exhaust water spray is put into service, LP flow path will still have high temperature although the
steam exhaust temperature will not be excessively high. To prevent excessively high temperature of blades, it is
necessary to pay attention to back pressure limits.
5) Overheat phenomenon of LP steam exhaust casing is not expected to exist under the case of no-load flow,
condenser low back pressure and steam exhaust water spray switched off. When the unit rated rotating speed is
lower than no-load flow, overheat phenomenon will still occur if unit is allowed to operate in motoring conditions.
6) If the steam temperature of LP steam exhaust casing reaches 80℃, then operator must reduce this temperature by
increasing load or improving vacuum state.
7) When steam exhaust casing water spray is put into service, high back pressure will cause high steam temperature
of the through flow part, therefore, operator must pay attention to operation under this kind of condition in order
to prevent unallowable differential expansion or radial expansion between rotating and static parts of LP casing.
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8) Special attention shall be paid to differential expansion, vibration and the change of bearing metal temperature,
etc. during operating under higher steam exhaust temperature. When water spray device is switched off,
thermometer or thermocouple on steam exhaust casing can be used to measure the temperature; if steam exhaust
temperature has reached alarm value of 80℃, then operator must reduce this temperature by taking any of the
following measures.
a) Improve the vacuum state.
b) Increase load to 15％ of rated load if the unit operates under low load.
c) Reduce unit rotating speed to warm-up turning speed if the unit hasn’t been on-line.
d) Turn into barring rotating speed if the unit is at warm-up turning speed.
e) Put the water spray device into service.
9) The water spray control valve of steam exhaust casing is provided with a bypass valve, which is only used during
failure and maintenance of the control valve. This bypass valve is only opened to the extent which can maintain
the calculated water spray pressure. Please refer to the section ―Set values for turbine control‖.
Attention
To prevent turbine failure during start-up, this bypass valve should not be opened when it is unnecessary to put the
steam exhaust casing water spray device into operation.
10) For the set values of vacuum tripping, please refer to the section ―Set values for turbine control‖.
11) Vacuum Breaking
a) LP casing should break vacuum at the same time.
If only no emergency occurring during trip or normal shutdown of the unit, vacuum shall be maintained all
along until the unit slows down to less than 400rpm in coasting operation or the barring gear is put into
operation. If emergency occurs, then vacuum is required to be broken immediately after the main s team
valve is closed; generally, it is not expected to break the vacuum immediately after tripping shutdown, for
sudden increase in density of mediums of steam exhaust part will generate a braking action, which will cause
blade accidents. If it is necessary to reduce the coasting operation time to minimize potential accidents of the
unit, then vacuum shall be broken immediately after the unit tripping. The cases in which vacuum is required
to be broken immediately after tripping include: AC power-off, DC power-off, low lubricating oil pressure,
lubricating oil supply interruption, oil cooler water supply interruption, tripping caused by thrust bearing,
water entering into steam casing, friction existing between the rotating and static parts and excessive
vibration during unit coasting operation.
b) Vacuum should not be broken under any rotating speed if the following cases:
Before turbine tripping shutdown

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Before main stop valve is closed
Before turbine steps out
Before normal idle of turbo-generator unit
c) If the unit has been on-line and its rotating speed still maintains the rated rotating speed although main steam
valve is closed, then vacuum should not be broken. This case occurs when the unit operates in motoring
condition.
d) If the unit still maintains rated rotating speed by speed governing system and supplies service power
although it has rejected load, then vacuum should not be broken. In this case, the main steam valve is not
closed or the unit is not in normal idle actually although the generator has stepped out from power grid.
e) When steam supply for shaft seal is cut off, once the above situations mentioned in upper situation occur, it
is necessary to shut down immediately and break the vacuum.
f) Before the steam supply for shaft seal is cut off, the vacuum shall be reduced as soon as possible in order to
prevent cold air from entering into turbine insides through shaft seal and rotor which have a higher
temperature.
g) When unit load is within 0～100％ of rated load range, the allowable maximum back pressure is 60kpa for
alarm and 65kpa for shutdown. Ignoring the specified back pressure limits may cause blade damages or
frictions between turbine rotating and static parts, and further cause severe damages to turbine parts.
6.5.4 Drainage System Attention
All drainage valves of turbine shall be automatically operated under normal conditions. However, if it is necessary to
operate manually, these drainage valves and other drainage valves that may affect safe operation of turbine must:
1) Be open when turbine is shutdown but hasn’t been cooled down.
2) Be open before turbine is started up and steam for gland seal is supplied.
3) Be open before the turbine load increases to 20% of rated load.
4) Open when the unit load decreases to 20％ of rated load, and maintain the open state all along when unit load is
lower than this load.
5) Vacuum should be prevented from broken before opening main drainage valves. This regulation does not apply to
the emergency conditions that need to break the vacuum immediately, and it also does not apply to user’s main
steam piping drainage valve.
6) During initial start-up process, readings of pressure gauges on each drainage pipe shall be paid attention to and
recorded when the unit is in the barring, rotating speed and load maintaining period (generally at the load lower
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than 10％～20％ of rated load). If pressure of any pipe exceeds the pressure of minimum pressure source of this
pipe, the unit shall be shut down and treated for solving the problems.
6.5.5 Temperature Limits for Bearing Metal
1) The temperature of turbine bearing babbit alloy is generally between 66℃～107℃ depending on different oil
inlet temperature, oil inlet flow, bearing size and bearing load, etc. The alarm value of babbit alloy temperature is
107℃. Operation under temperature higher than this temperature shall be monitored carefully until the reasons is
determined. The turbine shall trip when metal temperature exceeds 113℃.
Attention
If bearing temperature fluctuates, the reasons causing this shall be determined immediately. If necessary, turbine
shall be shut down to analyze the reasons. Inspect the bearing and perform necessary maintenance, and make it in
compliance with relevant regulations in the section ―Barring gear operation during shutdown‖ according to the
degree of fault.
2) The temperature range of thrust bearing babbit alloy is from the temperature little higher than oil inlet temperature
to 99℃. Its alarm and tripping values are respectively 99℃ and 107℃. Operation under temperature between
alarm and tripping values shall be monitored carefully, until the reasons are determined.
6.5.6 Emergency Power Supply Attention
When turbine operates at any rotating speed after rotation impuls ing, it is important to provide a reliable emergency
power supply for standby. The unit typically has two kinds of bearing lubricating oil pumps: one of them is AC motor
oil pump, and the other is DC emergency standby oil pump. In emergency conditions, for example that AC power
supply fails, an emergency power supply is needed to supply power uninterruptedly at least until the unit shuts down
safely from coasting operation. Users shall be responsible for supplying uninterrupted power for these oil pump and the
unit’s damages caused due to power interruption.
If storage battery is used as the emergency pow er supply, its capacity must be able to maintain 45～60 minutes rated
power operation of emergency oil pump and make it keep supplying oil during the period from coasting operation to
shutdown, otherwise, the unit cannot be started up. The storage battery must be inspected frequently to ensure the unit
safety. The storage battery must be checked to see if there is still enough capacity after performing unit coasting
operation or testing emergency equipment and system (for example, DC emergency oil pump) using DC power supply.
Attention
DC emergency oil pump and its pressure switch shall be shut down immediately after being tested, and the switch shall
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be switched to ―automatic‖ position.
6.5.7 Turbine Bypass System Attention
During turbine operation with bypass system, the steam exhaust temperature of HP casing measured by thermocouple
shall not exceed 404℃, and the alarm value is 427℃.
1) When rotating speed is under stable control condition, it should be noted that the IP control valve shall be kept at
partially open position. If turbine rotating speed exceeds its set value, then valves shall close slowly; once the
rotating speed recovers, then the IP control valve shall return to partially open position again. This valve opening
can be displayed and observed on DEH control images.
2) After load is rejected, the reheat cold end pressure must decrease to 0.824 Mpa within 10 minutes if turbine
operates with no-load flow. If the load increases to more than 10％, then under any specific load, reheat cold end
pressure shall be the normally expected pressure values in relevant to this load.
3） During unit start-up with bypass system put into operation, the reheat cold end pressure shall be limited to 0.824
Mpa. However, with the decrease of inlet pressure, the throttle flow in bypass system will decrease accordingly,
which will limit the reheat cold end pressure.
6.5.8 Desuperheating-Purpose Water Spray Attention
When the release valve is closed or the pressure before the valve is low, one shall cut off all the
desuperheating-purpose water spray pipe lines from the release valves to the condenser, this will avoid the possibility
that water flows backwards to the steam turbine when any vacuum break of the condenser happens. In case that the
system malfunctions and water endangers the steam turbine, one shall immediately trigger the steam turbine to trip.
6.5.9 Weekly Inspection
Inspection items
The main stop valve and regulating valve stem flexibility test
For the reheat main stop valve and IP regulating valve stem action test；
Steam extraction non-return valve inspection
Auxiliary oil pump and controller
See the relevant manual for detailed operation
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7 Turbine Shutdown
7.1 Turbine Normal Shutdown
Main operation of turbine normal shutdown
Preparation before shutdown the turbine
Shift leader received the shutdown order and clearly know the shutdown reason, time, mode, then notify the technical
departments and all posts prepare shutdown the turbine.
Deputy shift leader should notify all posts’ operators to make a overall inspection to the charging equipment, system
and record the defects.
Restrain the coal feeding and raw coal bin level properly
Prepare the auxiliary steam, shaft sealing and deaerator steam source switching; pipe warming backup should be fine.
Start fuel oil pump, make an overall inspection to boiler front fuel oil system, confirm system backup is fine, fuel oil
storage satisfy the requirement of boiler shutdown.
Before shutdown the boiler should perform full soot blowing to the boiler heating surface.
Respectively carry on main machine AC auxiliary oil pump, main machine accident oil pump, AC startup oil pump,
jacking oil pump, small turbine DC oil pump, generator accident sealing oil pump, barring motor trial running, oil gun
trial operation, check if they are normal and backup is fine; if trial operation is unqualified, should defer the shutdown
under the fault shutdown condition.
Unit reducing the load to 600MW~450MW
According to the turbine-boiler sliding shutdown curve, begin to reduce load, control load changing rate.
Bearing load 540MW, watch that if unit sliding from constant pressure zone to sliding pressure zone, unit load low
down simultaneously along with sliding pressure curve.
Bearing load 480MW, make vacuum tightness test base on the situation.
Bearing load 450MW, check if all systems’ operation parameter is normal
Fire out one pulverizer raw coal and stop the pulverizer, keep three pulverizers running.
Make turbine steam valve turning test.
Unit load reducing load to 450MW~300MW
Preset target load 300MW, control the load changing rate.
Bearing load 400MW, check if main turbine shaft sealing pressure is normal and watch that if shaft sealing auto switch
following is normal, increase the air preheater sealing gap auto regulating to the maximum position, release the boiler
auto mode, maintain the TF mode.

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Bearing load 350MW, continue firing out one pulverizer raw coal bin, and stop this pulverizer, keep running two
pulverizers, start motorized feedwater pump; after combining pump operation is normal, quit one turbo-driven
feedwater pump.
Bearing load 300MW, main steam temperature 520℃, reheat steam temperature 540℃.
Unit reduces load 300MW~180MW
Load reducing rate should not higher than 9MW.
Bearing load 250MW, monitor boiler water circulation and separation water storage tank level.
Bearing load 210MW~250MW, when the economizer inlet flow is lower than 700T/H, put economizer inlet flow
regulation in, boiler dry-wet status switch complete.
Bearing 250MW, put layer one small oil gun into operation, properly low down the output of this layer burner
corresponding pulverizer, reduce the load slowly, air preheater put program controlled mode continuous soot blowing.
Bearing load 180MW, stop another turbine-driven pump, main steam temperature 500℃, reheat steam temperature
500℃.
Switch unit auxiliary steam to unit public auxiliary steam header supplying, and confirm auxiliary steam system works
normally, auxiliary steam pressure regulating valve of cool reheater to unit.
Unit reduces load to 180MW~60MW
Contact shift leader, report to dispatcher, generator prepare for disconnection.
Stable bearing load 180MW, burn out the raw coal bin of coal burner without putting oil for assisting firing, blow the
empty pulverizer.
Low down load to 150MW, keep one layer small oil gun and one pulverizer running, until this pulverizer raw coal bin
level is low, and prepare for the clearance of last pulverizer. Notify the de-ash desulfuration post to stop ESP.Low
down load to 120MW; main steam temperature 480℃; heat steam temperature 480℃. Check if turbine IP drain valves
group interlock opened, deaerator steam source switch from 4th section to being supplied by auxiliary steam, qui the
HP, LP heater steam side operation.
Open all drainage valves when operating under about 20% of rated load.
Check and confirm turbine LP cylinder water spraying auto put in, LP cylinder exhausting temperature is not higher
than 47℃.
Continue to low down load to 60MW, main steam temperature 450℃, reheat steam temperature 450℃. Check unit HP
drain valve should automatically open or do it manually.
Unit reduce load to 60MW~15MW
Contact shift leader, report to dispatcher, and disconnect the generator.
Blow out the last pulverizer, active power reduced under 30MW, reactive power reduce under 50MVar.
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Turbine tripps, watch the disconnection of generator reverse-power, or perform manual disconnection and de-excitation.
Check if HP, IP main steam valve, regulating valve closed, all stages exhausting check valve, HP exhausting valve
closed, BDV and VV valve opened, rotating speed begin to low down, record the idle time, check if the main turbine
AC auxiliary oil pump, startup oil pump interlock start, or manually start the operation.
Make sure to open auxiliary oil pump when bearing oil pressure drops to 0.083 Mpa (g).
Water supply for hydrogen cooler shall be performed according to the guidebook of generator.
In order to control barring gear remotely, it should be ensured that the rotating speed shall be lower than barring
rotating speed before control switch turns to ―start-up‖ position. At this point, oil will be supplied for barring gear as
described in ―barring gear‖ instruction.
Make sure to open DC emergency oil pump when bearing oil pump drops to 0.0755 Mpa.
Generator disconnected, check if auxiliary power 6KV bus’s voltage is normal.
Boiler flame out, confirm MFT action result is correct, perform purge by 30%MCR draft flow for 5~10MIN, then
holding the cylinder.
Preparation after disconnect the generator
If no special reason, prohibit opening the vacuum broking valve below the rotating speed of ( ) r/min. during
coasting operation, should monitor the lubrication oil pressure, temperature changing should be normal.
Base on the real situation, regulate or close HP, LP bypass.
When the rotating speed reaches 2000r/min, check if jacking oil pump automatically start, or manually start one of
them, check jacking oil main and all bearing jacking oil pressure is normal.
Open vacuum breaking valve when rotating speed drops to 400rpm. Close air removal equipment. Cut off sealing
steam at the control valve for shaft seal steam supply, and shut down air extraction fan of gland seal cooler.
Check if turbine rear cylinder water spraying valve acts correctly, LP cylinder exhausting temperature should not
higher than 47℃.
Close main steam conduit drain valve.
After boiler flame out, confirm bypass system isolated, no steam and pressurized drainage enter the condenser, stop
vacuum pump, open HP, LP condenser vacuum breaking valve.
Reduce condenser vacuum to zero, stop shaft sealing system.
Contact chemistry, stop condensate fine treatment device.
According to the requirement, perform stator cooling water back washing.
When there is no condensate user, could stop condensate pump running.
Turbine LP cylinder exhausting temperature is lower than 50℃, no high temperature steam water entering the
condenser, stop the last circulating pump according to the situation.

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When the inner wall metal temperature of HP cylinder is lower than 150℃, stop the barring gear, when the rotor stops,
stop the jacking oil pump. 8 hours after stop the barring gear, could stop supplying lubrication oil
Usually, the generator gas replacement is required to be carried out when the turbine continuous turning stop; during
replacement, should strictly monitor oil level changing of sealing oil tanks, and prevent oil from entering the generator.
Only when gas replacement ends and barring gear stops that could stop running the sealing oil system.
Make the maintenance and isolation work of equipment after shutdown the turbine.
Points of notice of unit normal shutdown
Watch the changing of upper and lower temperature difference of cylinder, LP cylinder exhausting temperature, rotor
eccentricity, bearing vibration, differential expans ion, bearing metal temperature and other parameters.
Listen to the turbine periodically to check if there is any dynamic, static friction sound.
Turbine oil system should work normally, before replace the hydrogen should notice that the sealing oil system should
work normally.
Confirm the turbine idle time is normal, or should find out the reason during slide shutdown, enhance the monitor to
the main reheat steam parameter, guarantee that the degree of super heat should be higher than 56℃, if lower than
56℃, should shutdown the turbine.
During slide shutdown, reheat steam temperature declining speed should manage to match the declining speed of main
steam temperature, main, reheat steam temperature difference should meet the requirement of the main, reheat steam
temperature deviation curve, or should shutdown the turbine immediately.
During reducing the load, notice that the all HP, LP heaters water level should be normal; feedwater pump minimum
flow valve could be opened manually according to the load.
After manually trip the turbine, check HP-IP main steam valve, HP-IP regulating valve, all stages’ exhausting check
valves, HP extraction check valves closed, VV valve and BDV valve opened.
Record the rotor idle time, 30s after rotor stops check if barring gear motor start automatically, 10s later check if
barring bear automatically engaged, or manual start the barring. After turbine barring gear starts operation, periodically
record the rotor eccentricity and HP-IP cylinder expansion, differential expansion, HP-IP cylinder first stage
temperature, axial displacement. During operation of barring, strictly monitor cylinder metal temperature changing
tendency, prevent cold steam, cold water from entering the turbine.
If due to some kind of reason the barring can’t start operation, then manually turn the barring immediately, turn the
rotor by 180° every 15~20min, and manage to recover the operation of continuous barring. If barring trips during
operation, then should make trial operation once immediately, if it fails and confirmed it’s caused by strong resistance,
that means the rotor has bended, so should use periodical 180°manual barring instead, prohibit starting continuous
barring, meanwhile check the cylinder drain system, find out the reason.
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During operation of barring, lubrication oil temperature should be within 27~40℃, keep the normal operation of
generator sealing oil system. Listen to the sound of HP, LP shaft sealing sound periodically.
Barring should work continuously until HP cylinder 1st stage metal inner wall temperature is lower than 180℃, when
the wall temperature here is lower than 120℃, if generator has carried on gas replacement and sealing oil system stop
operation, could stop the turbine AC lubrication oil pump.
Due to barring breakdown or other maintenance require stop barring operation immediately, after barring operation
stops, should mark on the corresponding position on the rotor, and record the time stop the barring.
When the HP 1st stage inner wall temperature is above 350℃, barring stop time should not over 3min; when stop for
1min, should perform 10 min continuous turning, until the rotor eccentricity return normal.
When HP cylinder 1st stage inner wall temperature is above 220℃, if need emergency work, when stop every 30min,
should turn 180°or turning continuously until the rotor eccentricity return to normal.
Under normal situation of disconnection, trip and close the main steam valve firstly, reveres power protection will act
and disconnect the generator and system.
When barring operation interrupted, could turn the rotor by 180°before recover the continuous barring. When half of
barring stops time passed, carry on continuous barring. At this time should pay special attention to the rotor eccentricity,
barring current should not rise too much or fluctuate.
During continuous turning, if there is obvious friction sound inside the cylinder, and the barring current fluctuates
heavily (not caused by barring gear fault) should stop the continuous barring immediately, using manual turning
instead until the barring gear can recover operation.
If rotor jammed, prohibit forced barring.
After shutdown, watch the upper, lower cylinder temperature difference, upper and lower temperature difference of
main; reheat steam conduit, vessel water level and pressure, temperature changing. If find upper, lower cylinder
temperature difference increases rapidly, should find out the reason of water entering or cold steam entering, and cut
off the source of water, steam, remove deposit water.
Verify the operation sequence, report to shift leader.
7.2 Forced Cooling for Turbine Maintenance
During turbine common accident shutdown, the first stage metal temperature is higher, it needs 210~230h to cool down
to 180℃ naturally. Even adopting sliding shutdown, the first stage metal temperature may be lower, still need
12-~130h to cool down to 180℃ so could stop barring and lubrication system. Unit using steam or air for forced
cooling to shorten the cooling time after shutdown the turbine becomes more and more common.
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This turbine has reserved forced cooling port in design. Detailed forced cooling operation method has to be made after
the local installation commissioning is confirmed because the shortage o detailed material.
8 Turbine Accident and Handling
8.1 The Conditions of Vacuum Break, Shutdown and No Vacuum Break, Handling and Attention
after Shutdown
After turbine trips, rotor ’s rotating speed declines and enter coast operation, at this time usually the vacuum won’t be
broke，because one side to avoid exhausting part medium density increasing suddenly and trigger one brake action then
cause blade accident; the other side, to reduce the heat generated by the final stage’s blasting friction which is in favor
of controlling the exhausting temperature during shutdown the turbine and drain the deposit water in the cylinder. If it’s
necessary to shorten the idle time to reduce possible accidents of small unit, the vacuum should be broken after unit
trips. Cases required immediate breaking vacuum after tripping: AC power interrupted, DC power interrupted,
lubrication oil pressure is low, lubrication oil interrupted, oil cooler out of water supply, tripping caused by thrust
bearing, water entering the cylinder, dynamic/static part friction and heavy vibration during unit coasting operation.
8.1.1 Conditions for Breaking Vacuum Emergency Shutdown
1) Rotating speed of turbine exceeds 3300rpm, but emergency stop valve missing operation
2) Water attack happens in turbine
3) Unit vibrates strongly, reaches protection action value but protection won’t act
4) Obvious metal impact sound heard inside the turbine
5) Any supporting bearing of turbine oil interrupted and smokes, or any supporting bearing metal temperature
reaches the protection action value but protection won’t act
6) Turbine bearing or end shaft sealing rubs and sparkles
7) Bearing lubrication oil pressure declines to 0.07MPa, but protection won’t act
8) Generator and excitation system smokes, sparkles.
9) Unit surroundings or oil system catches fire, and can’t be extinguished and severely threaten the personnel or
equipment safety
10) Generator hydrogen cooling system catches fire or explodes.
11) Axial displacement and other protection missing operation could damage the turbine due to the high rotating
speed.
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8.1.2 Conditions for Non-vacuum Breaking Emergency Shutdown
Turbine fault shutdown conditions (when the turbine hit any of the following situation, should perform non-vacuum
breaking shutdown)
1) Main, reheat steam temperature exceeds the regulated value but can’t be recovered within the regulated time.
2) Under rated load unit operation main steam temperature declines to 490℃, reheat steam temperature declines to
510℃, but can’t be recovered within the regulated time.
3) LP cylinder A or B exhausting temperature is higher than 80℃, and the treatment fails, continue rising to 107℃
but action won’t act.
4) Two EH oil pump are running, but EH oil pressure is still lower than 7.8MPa, after treatment can’t recover normal
level still.
5) Generator stator cooling water conduction degree is 9.9μs/cm or stator cooling water interrupted but action won’t
act, or generator stator coil leaks water and can’t be treated.
6) During normal operation, turbine main oil pump works severely abnormally, AC auxiliary oil pump keeps
working, and fault reason can’t be found out. By this time should trip and shutdown the turbine.
7) DEH, TSI system breakdown, cause some important parameters out of supervision, can’t maintain the normal unit
operation.
8) HP cylinder exhausting chamber inner wall metal temperature is higher than 420℃, but protection won’t act
9) Generator hydrogen or sealing oil system with leakage, unit normal operation can’t be maintained.
10) Condenser vacuum rapidly drops to 25.3KPa, but protection won’t act
11) Auxiliary power all loss, can’t be recovered
12) Main steam conduit, HP feedwater pipeline or other steam, water, oil pipes broken, can’t maintain the normal unit
operation, threaten the unit safety.
13) Generator sealing oil system oil hydrogen pressure difference loss, generator sealing pad leaks hydrogen heavily.
14) During operation, any cylinder of turbine admission interrupted.
15) Operation reverse power operation exceeds 30s
16) Other severe accident endanger the turbine equipment safety
8.1.3 Unit Emergency Shutdown Operation
1) Any emergency condition of turbine, boiler, generator satisfied, should press corresponding ―emergency shutdown‖
button manually immediately, using interlock to stop unit operation
2) Check if boiler, turbine, generator interlock action is correct, if boiler main fuel won’t trip, should immediately
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manually trip it. Turbine main steam valve, regulating valve all closed. Generator outlet CB should trip.
3) Turbine HP section drain, IP section drain, LP section drain should automatically open, or open it manually.
4) Check proper flash tan cooling water auto put into normally, or manually put in.
5) Check if other interlock action is correct after tripping according to the content of unit tripping interlock, or do it
manually, and notify the thermal engineer for treatment.
6) Check if turbine AC auxiliary oil pump, jacking oil pump automatically start, generator sealing oil pump works
normally, or manually start it immediately. Check if oil pressure, oil temperature are normal.
7) Check if condenser, deaerator water level auto regulation is normal, or manually regulate it to maintain the
condenser, deaerator normal water level.
8) Check main machine lubrication oil temperature, sealing oil temperature, generator air temperature, inner cooling
water temperature should be normal. If necessary, disconnect cooler cooling water.
9) After unit tripped, should quickly switch shaft sealing steam source to auxiliary steam. Regulate the shaft sealing
supplying steam pressure, vacuum to zero, stop shaft sealing steam, disconnect shaft sealing attemperating water
10) Watch the turbine coasting operation situation, differential expansion, vibration, axial displacement, cylinder
expansion and temperature difference of upper and lower cylinder, listen to the inside sound of turbine to check if
it’s normal. When the rotating speed is zero put the barring gear into operation, check if barring current is normal
11) Reduce the excitation regulator auto/manual control mode to the minimum
12) Break the generator outlet isolating switch
13) Check if auxiliary power system works normally
14) Check if LP cylinder water spraying put into normally.
15) Complete other normal outage operation of unit
16) Report the fault to the dispatcher and related company leaders
17) Print and safe keep the related curve, accident record, make accident in shift dialog.
8.2 Condenser Vacuum Decline (not reach to the low value of turbine trip)
Condenser vacuum decline is one of the most common affairs during operation. Detail reason analysis and operation as
following:
8.2.1 Phenomenon
1) Vacuum decline, LP cylinder exhausting temperature rises
2) Unit load reduces
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3) Axial displacement
4) Main steam flow increases
8.2.2 Reason
1) Circulating water interrupted or insufficient
2) Circulating water inlet temperature rises
3) Vacuum system leaks
4) Condenser with high water level
5) Shaft sealing steam supplying is insufficient or interrupted
6) Vacuum pump breakdown
7) Vacuum system valve improper operation or mis-operation
8) Water-sealed valve closed by mistake during operation, water-entering proof protection malfunction or condenser
thermal load is over high.
9) Vacuum breaking valve opened by mistake or vacuum-breaking valve water seal is abnormal.
10) LP cylinder safety valve film damaged.
8.2.3 Treatment
1) When find vacuum declines, firstly should check related meter and quickly find out the reason and make
treatment, report to shift leader at the same time.
2) Start backup vacuum pump, if the vacuum still dec lines, should contatct shift leader to start reducing the load and
maintain the vacuum above -81.5KPa (not lower than -76KPa). Load reducing speed ratio upon the vacuum
declining speed.
3) If unit has reduced the load to zero, vacuum still can’t be recovered, and continue to decline to -76KPa, should
report to shift leader and fault shutdown the turbine immediately, close HP, LP bypass; prohibit opening main,
reheat steam conduit drain.
4) When vacuum declines, watch the turbine-driven feedwater pump operation, if necessary switch to motorized
feedwater pump operation.
5) Watch the change of LP exhausting temperature, when it reaches 52℃, LP cylinder water spraying begin
operation, full open the 80℃ alarm water spraying valve; If it continue rising to 121℃, protection acts and trips
the turbine.
During accident disposal, should strictly monitor the following items
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1) All sections’ pressure should not exceed the allowed value, or should reduce the load to the allowed value
2) Listen to the unit sound, watch the unit vibration, differential expansion, axial displacement, thrust bearing metal
temperature, and return oil temperature changing.
8.3 Water Attack Accident
8.3.1 Phenomenon
1) Unit vibrates strongly, the sound is abnormal, main steam, reheat steam conduit temperature and all exhausting
pipe temperature reduces, turbine cylinder temperature reduces.
2) Turbine upper and lower cylinder temperature difference increase and trigger alarm
3) HP, IP main steam valve, HP, IP regulating valve or any exhausting motorized valve, exhausting valve stem leak
white steam
4) Axial displacement, thrust bearing metal temperature and thrust return oil temperature increase rapidly, cylinder
and rotor metal temperature drops suddenly, differential expansion reduce and develops toward negative direction.
5) First stage admission pressure fluctuation increases.
8.3.2 Reason
1) Improper boiler regulation, steam water separator or pulverizing system tripping not spotted.
2) Main, reheat steam attemperating water improper regulation
3) Unit load changes rapidly; main, reheat steam temperature reduces rapidly.
4) Turbine proper bad drain
5) Steam conduit drain unsmooth
6) Deaerator or HP, LP heater filled with water.
8.3.3 Treatment
1) Main steam temperature drops by 50℃ within one minute, emergency shutdown. Under rated condition, turbine
main steam temperature should not lower than 485℃.
2) When water attack is confirmed, should break vacuum and emergency shutdown, manage to cut off related s team,
water source as soon as possible; enhance main, reheat steam conduit, proper exhausting pipe, shaft sealing steam
main and related system’s drain.
3) When find turbine upper lower cylinder temperature difference reaches 40℃ should report to shift leader in time.
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Strictly monitor main, reheat steam temperature, axial displacement, thrust bearing temperature, thrust bearing
return oil temperature, expansion difference and unit vibration.
4) If water entering is caused by heater or deaerator filled with water should isolated the faulted heater or open
deaerator accident drain, and enhance exhaust pipe drain.
5) When the turbine stopped by the water attack, should perform manual turning, confirm the unit without
abnormality, then could put in continuous barring.
6) During turbine emergency shutdown due to water attack, if along with axial displacement big alarm or trip signal,
after shutdown the turbine should ask maintenance personnel to disassemble the thrust bearing and check, or
prohibit starting turbine.
7) During turbine emergency shutdown, if the idle time shortened obviously and along with metal impact sound,
should open the cylinder for check, or prohibit starting the turbine.
8) Within 24 hours after shutdown the turbine prohibit starting; when restart the turbine, should confirm the upper
lower cylinder temperature difference is lower than 35℃.
9) If turbine dynamic and static part jammed, it cannot be turned, perform turbine ―cylinder holding‖, when it’s easy
to turn manually, put continuous barring into operation.
8.4 Severe Overspeed of Unit
8.4.1 Phenomenon
1) Unit load suddenly cut back to zero, the rotate speed exceeds 3000rpm and increases continuously, and even that
the rotated speed exceeds protection setting value without protection action.
2) The sound of turbine is abnormal, with vibration increased.
3) DEH electric over speed, TSI electric over speed and mechanical over speed protection are acted, with alarm
sended out.
8.4.2 Reason
1) Generator load rejection
2) Circuit breaker of main transformer high side is tripped.
3) DEH system control is disordered.
4) Main steam valves of turbine high-medium pressure does not been closed tightly.
5) Extraction check valve and motorized valve donot be closed or donot be closed tightly when unit tripped.
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6) Protection device is acted normally, but main steam valve, regulating valve or extraction check valve are jammed
without tight closure.
8.4.3 Treatment
1) When turbine rotated speed exceeds 3330rpm without protection action, it is necessary to emergently shut down
turbine manually in time, confirm all the high-medium pressure main steam valves and high-medium pressure
regulating valves are closed. Create vacumm if rotated speed increases continuously.
2) Immediately shut down boiler with pressure release, forbidden to open HP/LP bypass.
3) Available to restart up unit only when all links matching equipments in over-speed security system without any
obvious damaged phenomena, no unit abnormal conditions during unit shutdown, and after qualified closure tests
for main steam valve, regulating valve and extraction check valve and other valves.
4) When differential expansion, vibration or abnormal sound in the unit or obvious damage in all links matching
equipments of regulating protection system during unit shutdown, the reasons should be identified, to restart up
turbine after defects eliminated.
5) During restart up unit, take focus on inspection and monitoring for turbine vibration, internal sound, bearing
temperature, axial displacement, trust pad temperature and others, to stop the startup when abnormal conditions
found.
8.5 Turbine Vibration Severe Vibration
8.5.1 Phenomenon
1) TSI all bears vibration indication increases, local real measuring also increases.
2) Bearing strongly vibrates felt by hand, unit with abnormal sound
3) Bearing temperature rises for certain degree.
8.5.2 Reason
1) Lubrication oil pressure, oil temperature abnormal or oil film fluctuates
2) Unit warming is insufficient; cylinder expands unsmooth or bad drain.
3) Turbine main shaft bends
4) Operation parameter, condition changed a lot, make the thrust changes abnormally
5) Blade broken or turbine inner mechanical components damaged, falls off
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6) Main turbine bearing damaged
7) Cold steam, cold water enter the turbine or water attack happens
8) Vacuum declines cause turbine axial center line deviates or final stage blade vibrates
9) During start, stop turbine, unit rotating speed at the critical rotating speed zone
10) Unit vibration caused by the generator part, like magnetic field unbalance
8.5.3 Treatment
1) When unit vibration abnormally increases to protection action value the turbine should trip, or manually stop the
turbine
2) Check if lubrication oil pressure, oil temperature is normal, if bearing metal temperature and return oil
temperature is normal. If not should make regulation.
3) If the vibration is caused by water attack, should isolate cold steam, water source, and enhance the proper drain
4) If vibration is caused by generator, should reduce unit load and make observation for further treatment.
8.6 Blade Broken of Turbine
8.6.1 Phenomenon
1) Obvious metal friction sound heard inside the turbine
2) Unit vibration obvious ly increase
3) Monitor section pressure is abnormal, axial displacement, thrust bearing metal temperature changes abnormally
4) Condensate hardness, conducting degree increases.
8.6.2 Treatment
1) Turbine blade damaged or falls off during operation, won’t always cause the above all phenomenon. If obvious
metal friction sound heard inside the turbine or unit vibrates strongly should break vacuum and emergency
shutdown.
2) During normal operation if find any regulating stage pressure or any section exhausting pressure difference
changes abnormally, should make comprehensive analysis, if it’s along with condition reduces, load reduce, axial
displacement, obvious temperature changing of thrust pad or corresponding bearing vibration increases, should
apply for reducing load and shutdown turbine as soon as possible.
3) Turbine LP blade broken and breaks condenser stainless steel pipe, make the condensate hardness, conducting
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degree increases, but the unit has no abnormal sound, vibration doesn’t increase obviously. It should be treated by
the following method:
4) If condensate hardness increases slightly, and doesn’t exceed standard, should report to shift leader to make
half-side isolation and plugging.
5) If condenser water level rises, then start backup condensate pump.
8.7 High Temperature of Turbine Bearing
8.7.1 Phenomenon
1) One or more bearings metal temperature rise
2) One or more bearings return oil temperature rise
8.7.2 Reason
1) Lubrication oil temperature rises or temperature reduces, oil is unqualified
2) There is impurity in the bearing or outlet, inlet jammed
3) Bearing dynamic static part friction
4) Shaft sealing leaks steam heavily
8.7.3 Treatment
1) When bearing return oil temperature rises by 2~3℃, should overall check
a） This bearing’s metal temperature
b） Other bearing’s metal temperature and return oil temperature
c） Lubrication oil pressure and oil temperature
d） All bearing vibration
e） Shaft sealing supplying steam pressure
f） Shaft sealing cooler inner vacuum
2) If there is sundries inside the bearing or outlet, inlet jammed, make the bearing metal temperature, return oil
temperature rises, should report to shift leader, start AC lubrication oil pump and backup sealing oil pump,
properly rise lubrication oil temperature. After taking measures and fail, it continue rises to the protection action
value, should break vacuum emergency shutdown the turbine.
3) When lubrication oil temperature rising make all bearing metal temperature, return oil temperature rise should
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immediately find out the reason of lubrication oil temperature rising; if cooling water interrupted or cooling water
pressure reduces, should manage to recover it; if opened water filter jammed, should clean it immediately; if
regulating valve failure, should contact thermal engineer for treatment, if main turbine oil cooler cooling water
valve closed by mistake, should open it immediately; if oil tank heater malfunction, should stop it immediately.
4) Lubrication oil temperature reduces, should start auxiliary lubrication oil pumps or backup sealing oil pump
immediately, and find out the reason, make treatment
5) Shaft sealing pressure rising or shaft sealing cooler vacuum reducing, should start backup shaft sealing heater
immediately and find out the reason as soon as possible
6) When turbine unit any bearing metal temperature reaches 121℃ but protection won’t act, should break vacuum
and emergency shutdown immediately.
8.8 Abnormal Axial Displacement of Turbine
8.8.1 Phenomenon
1) Axial displacement indication increase
2) Thrust bearing metal temperature rises
3) Unit vibration may increase
8.8.2 Reason
1) Inlet steam parameter low, steam flow is big, turbine blade is overloaded
2) Turbine flow passage fouling severely or blade fall off
3) Water hammer happens in turbine
4) Thrust bearing oil interruption, thrust pad abrasion
5) Heater fault cut off
6) Condenser vacuum drops
8.8.3 Treatment
1) Find the axial displacement is big, should immediately check: unit load; HP, LP heater operation; main, reheat
steam parameter; condenser vacuum; regulating stage pressure and all monitor section pressure; thrust pads all
metal temperature and return oil temperature; differential expansion; vibration; unit inner sound.
2) Due to main steam, reheat steam parameter declines, cause unit overload, should report to shift leader, notify the
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boiler operator to increase boiler parameter, properly reduce the unit load
3) Unit overload, should contact boiler, reduce the load to normal value immediately.
4) When turbine blade fouling, should report to shift leader to reduce unit output, make the axial displacement and
all monitor section pressure return to normal.
5) When water hammer happens in turbine, should break the vacuum and shutdown the turbine.
6) When the axial displacement is bigger than 1.4mm or smaller than -1.4mm and tripping value protection won’t act
and along with abnormal sound or strong vibration, should broke vac uum and emergency shutdown.
8.9 Accident Dis posal Principle
8.9.1 Accident Handling Principles
1) When accident happens, the disposal should base on the principal of ―keep personnel, keep grid, keep equipment‖.
2) When accident happens, operator should restrain the development of the accident quickly, release the safety threat
to the personnel and equipment, and eliminate the accident root. Use every means to keep the normal power
supply to consumers.
8.9.2 Key Points during Accident
1) During accident disposal, operator should guarantee the auxiliary power system normal operation.
2) During accident disposal, operator should stick to the post and focus, guarantee the equipment normal operation,
eliminate abnormal phenomenon; correctly, quickly, calmly execute the orders.
3) When unit breakdown, operator usually should follow the below steps for treatment, eliminate fault.
a) According to light sound alarm and CRT parameter indication and unit equipment external phenomenon, find
out the accident nature; no matter what kind of accident, operator should confirm it locally, take
corresponding measures.
b) Quickly eliminate threats to the personnel and equipment, if necessary should stop the breakdown
equipment.
c) Quickly find out the fault nature, happening site and scope, then make decisive treatment and report.
d) Keep the normal operation of healthy equipment and unit.
e) During every phase of fault treatment, manage to report to shift leader, main operator and related principal,
in favor of timely, correctly making countermeasures, avoid accident expansion.
f) When fault happens, every post should notify each other with status, under the unify command of shift lead,
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main operator, coordinate closely, treat the accident quickly in favor of recovery unit operation as soon as
possible.
g) When it’s clear its system and other equipments fault, should take measures to keep the unit working, in
favor of recovering the unit normal operation as soon as possible.
h) During fault treatment, strictly execute order repeat and record system; during receiving order if there is any
doubt, should ask the commander and make it clear; operation should be correct, quick and calm. When the
order has been executed, should report to commander quickly.
i) If the operator think the received order is incorrect, should explain to commander, and whether execute it or
nor should be decided by commander, if commander insist his decision then should execute it in principle.
But if the execution of this order will endanger the personnel and equipment safety, should refuse,
meanwhile send the refusing reason and order modification content report to commander and senior leader.
4) During accident treatment, main operator is under the lead of shift leader. When fault happens, main operator
should make quick treatment, and manage to notify the shift leader ahead, meanwhile report to shift leader and
local related principal with measures taken by self.
5) Generation department principal, specific engineer, safety personnel, when unit breakdown, should present at site
and assist shift leader in accident disposal and monitor it, but not allowed to give order to operator directly.
6) When accident breakdown and during accident treatment, operator should not leave work post privately. if the
accident happens in the shift time, shift should be delayed. Before making shift process, shift taking personnel
should under the unify lead of handing over shift leader, assist the handing over personnel for fault treatment until
it comes to conclusion then carry on shifting.
7) Personnel unrelated to fault treatment should not stay at the fault site
8) After fault happens, should contact thermal engineer to come to the site, keep the related record and parameter in
favor of accident analysis.
9) After eliminate the fault, shift leader, main operator and on duty personnel should make correct, real, detailed
record to accident phenomenon, happening process and time, measures taken to treat the fault.
8.10 Main Turbine Lubrication Oil System Breakdown
8.10.1 Oil Tank Oil Level Declines or Rises
Phenomenon
1) Oil level indication rises or decline
2) Main oil tank oil level low or high alarm
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Reason
1) Main turbine lubrication oil system, oil purify system, oil treatment system, sealing oil system leaks oil or pipe
broken, oil enter the generator.
2) Misoperation of above system valves causing oil tank oil level declines
Oil tank oil level rising mainly caused by two reasons: turbine shaft sealing with over big gap, shaft sealing system
pressure abnormal leads to oil contents water, oil transferring pump malfunction, oil cooler leaks
8.10.2 Oil Level Indication Abnormal
Treatment
1) Verify the local oil level indicat ion, confirm the main oil tank oil level is abnormal, and check abnormal oil level
reason and make corresponding treatment.
2) If main oil tank oil level declines to normal oil lelve-80mm, should feed the oil. If the oil level declines too fast
should feed the oil in time.
3) If the main oil tank oil level keep declining to normal oil level-100mm, taking all measures but still can’t maintain
the oil level, should break vacuum and emergency shutdown.
4) If oil pipe broken and leaks oil, should take measures to prevent oil from splashing to high temperature pipe or
equipment and causing fire.
5) If the oil level rises, should perform oil tank bottom draining and notify chemical personnel to take samples for
test; if necessary, contact maintenance personnel to filtrate oil.
6) If shaft sealing steam pressure is too high or shaft sealing heater vacuum is too low causing heavy steam leakage,
should regulate shaft sealing steam pressure or shaft sealing heater vacuum, reduce steam leakage.
7) If oil cooler leaks, should changeover the oil cooler, isolate it, find out the leaking point and notify the
maintenance for treatment.
8) Due to misoperation of system causing abnormal oil level, should switch to normal operation mode;
9) If main oil tank return oil filter jammed, contact maintenance to clean the filter
10) Check and regulate the vapor extractor to make it work normally
8.10.3 Oil Pressure Declines
Phenomenon
1) Lubrication oil pressure indication declines
2) Lubrication oil pressure low alarm
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3) Bearing metal temperature and return oil temperature may rises
4) Unit vibration may increases
5) Axial displacement may increases
Reason
1) Main oil pump or oil turbine pump works abnormally
2) Main oil tank oil level too low
3) AC auxiliary oil pump, DC accident oil pump outlet check valve isn’t tight.
4) Pressure pipe leaks
5) Lubrication oil system valve misoperation
6) Oil turbine pump outlet overflow valve action without blowback or regulate improperly.
7) Meter indicates abnormally.
Treatment
1) Verify all lubrication oil pressure meters, confirm lubrication oil pressure declines.
2) Check main oil pump inlet outlet oil pressure, judge whether the main oil pump and oil turbine pump works
normally. If necessary, start AC auxiliary oil pump and startup oil pump, watch the oil pressure changing.
3) Check if main oil tank oil level is normal, if oil level declines should feed water in time;
4) Check backup oil pump outlet check valve is tight, and start the oil pump whose outlet check valve doesn’t close
tightly, if necessary notify the maintenance personnel to eliminate the defect.
5) If oil system valve misoperation, should be corrected immediately;
6) When the oil turbine pump outlet overflow valve breakdown and can’t blow back, should notify the maintenance
personnel to fix it. Meanwhile, strictly monitor the lubrication oil pressure, and make treatment according to the
oil pressure.
7) When the lubrication oil pressure declines to 0.103MPa, AC auxiliary oil pump should automatically start, or do it
manually; when the main oil pump oil pressure is lower than 1.2005MPa, startup oil pump should automatically
start, or do it manually. Check if lubrication oil pressure is normal, apply for shutdown.
8) When the lubrication oil pressure declines to 0.069MPa, turbine will trip; DC accident oil pump should
automatically start, or do it manually. If rotating speed is lower than 2000r/min should treat it as vacuum breaking
emergency shutdown, and find out the reason system oil pressure declines.
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8.11 EH Oil System Breakdown
8.11.1 Common Fault Phenomenon
1) EH oil leaks, EH oil tank oil level declines
2) EH oil pressure fluctuates or declines
3) EH oil temperature rises or declines
8.11.2 Fault Reason
1) EH oil system pipe, equipment broken and leaks oil
2) EH oil system oil, water drain valve opened by mistake
3) Overflow valve action is incorrect, oil relay servo valve leaks
4) EH oil pump breakdown or inlet outlet filter jammed, stained
5) Accumulator breakdown
6) Regenerative device fails, EH oil is unqualified
7) Oil relay servo valve leaks
8) Meter fails
8.11.3 Treatment for EH Oil System Common Fault
1) If find EH oil pressure declines, should verify the local meter, confirm the EH oil pressure declines, and quickly
find out the reason and make corresponding treatment.
2) When the EH oil pressure declines to 9.2MPa, backup pump should automatically start, and maintain the oil
supplying pressure at 11.2MPa, or start the backup pump manually
3) If EH oil pump breakdown, should start backup pump, stop original working pump, report to centralized control
shift leader, and isolate the faulted pump, contact the maintenance personnel for treatment.
4) Check pump outlet overflow action, if action pressure is low, should report to centralized control shift leader, and
notify the maintenance personnel to regulate it. Check if EH oil pump outlet filter differential pressure is normal,
if backup pump outlet check valve is tight; if necessary switch the EH oil pump operation.
5) EH oil pressure fluctuates, should check the small turbine operation, if necessary start the motorized pump, and
regulates the unit load to not higher than 30%.
6) Check if there is any valve of EH oil system opened, and close it.
7) Check if there is any leakage of EH oil system, if it is, isolate the leaking point taking the pre-condtion of
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guarantee the system operation, and watch the EH oil tank oil level changing, oil tank level declines to oil level
alarming, should contact the maintenance to feed oil.
8) If small turbine EH pipe leaks, should start the motorized pump immediately, regulate unit load, stop the turbine
driven pump leaking EH oil, and make the corresponding isolating.
9) If system leakage can’t be isolated, oil tank oil level declines, and all measures fail, affect the EH oil pressure and
threaten the safe operation of the unit, when the EH oil pressure declines to 7.8MPa, turbine should trip, or
manually trip and shutdown the turbine, and stop the EH oil system.
10) If oil relay servo valve leaks, should report to centralized control shift leader, shift leader, and ask for reducing
unit load according to the situation, make isolation, then contact the maintenance for treatment
11) If oil pipe broken and leaks oil, should take measures to prevent oil from splashing to high temperature pipe and
possible catching fire.
12) EH oil temperature fluctuates abnormally, should check if EH oil recycling system works normally, and make
manual regulation.
8.12 Closed Cooling Water Fault
8.12.1 Common Fault
1) Closed cooling water interrupted
2) Closed cooling water main pressure declines or fluctuates
3) Closed cooling water tank water level low
4) Closed cooling water pump vibrates strongly.
5) Closed cooling water pump motor’s current increases abnormally
6) Closed cooling water system pipe leaks
7) Closed cooling water quality deteriorates
8.12.2 Fault Treatment
1) Closed cooling water interrupted due to some kind of reason, should be recovered as soon as possible, meanwhile
strictly monitor closed water user, if exceed operation limit, and can’t maintain unit normal operation, should fault
shutdown the turbine.
2) Closed cooling water main pressure declines, should check closed pump operation, if closed cooling water t ank
water level is low, system drain valve closed tightly. If pump output is insufficient or outlet pressure is lower than
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0.45MPa, confirm backup pump automatically startup, or manually start it, and find out the reason.
3) Closed cooling water main pressure with big fluctuation, and along with motor current fluctuation, usually caused
by the closed cooling water tank water level low or air entering the pump. If it’s caused by water tank low level,
should makeup the water until recover the normal level; if it’s caused by air entering the pump, should open
related ventilation valve. if vaporization is severe should switch to backup pump operation immediately.
4) Closed cooling water pump vibrates strongly, should check if pump hits vaporization, filter jammed, if there is
any abnormal sound in pump group bearing and pump. If above situation happens should switch to backup pump
operation immediately.
5) Motor current indication increasing should be measured at site to find if it really increases. It may be caused by
two phase operation or bearing damage, should switch to backup pump operation, contact maintenance for
treatment
6) Closed cooling water breakdown, backup pump should automatically put in, or do it manually. Isolate the faulted
pump, contact maintenance personnel for treatment.
7) Pump motor current increases abnormally, should switch to backup pump operation.
8) If closed cooling water system pipe leaks, should manage to isolate it, meanwhile feed water to closed cooling
water tank. If it can’t be isolated and maintained operation, should fault shutdown.
9) If closed cooling water deteriorates, it may because the make-up water source’s been polluted, or closed cooling
water heater exchanger tube bunch leakage. If it’s caused by the former, should regulate make-up water quality. If
it’s later, should switch to another heat exchanger operation, and isolate the leaking heat exchanger, meanwhile
replace the water of closed water system, regulate closed cooling water quality.
8.13 Sealing Oil Fault
8.13.1 Phenomenon
1) Air side or hydrogen side sealing oil pressure indication declines, alarms
2) Sealing ring inlet oil pressure declines
3) Oil, hydrogen pressure difference indication reduces or alarms
4) Air, hydrogen side sealing oil pressure difference increases.
8.13.2 Reason
1) Air side, hydrogen side oil pump fault
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2) Sealing oil pipeline leaks.
3) Air, hydrogen side sealing oil filter jammed
4) Air side sealing oil pressure difference regulating valve acts incorrectly
5) Hydrogen side sealing oil balance valve acts incorrectly
6) Hydrogen side oil tank oil level is too low
7) Sealing oil system valves misoperation
8.13.3 Treatment
1) When find sealing oil pressure reduces, should verify the hydrogen pressure immediately, find out the reason and
fix it.
2) When the oil, hydrogen differential pressure reduces to 0.056MPa,sealing oil backup differential pressure
regulating valve should automatically open and maintain oil, hydrogen differential pressure at 0.056MPa; when
backup differential pressure regulating valve regulation fails should immediately start air side DC oil pump, if
backup oil pressure is over low should immediately start HP sealing backup oil pump, if due to backup differential
pressure valve missing operation should immediately open its bypass valve, regulate the hydrogen oil differential
pressure at the normal scope, and contact maintenance personnel for treatment.
3) If sealing oil pipe leaks, should make isolation immediately, and take measures to prevent catching fire; if it can’t
be isolated and threaten the unit safe operation, should fault shutdown.
4) When air side oil hydrogen differential pressure reduce to 0.035MPa, while giving alarm also air side DC sealing
oil pump should automatically start, or do it manually, report to shift leader, main operator.
5) If after the above treatment the air side sealing oil pressure still declines, should reduce the unit load until
disconnect generator immediately; when only the LP sealing oil source is available, should reduce the generator
inner hydrogen pressure under 0.014MPa, at this time should notice if defoaming tank oil level rises.
6) If hydrogen side AC sealing oil pump fault notify the maintenance personnel for treatment, manage to recover the
operation as soon as possible, check if hydrogen side DC side sealing oil pump should interlock start.
8.14 Hydrogen System Fault
During operation hydrogen pressure inside the generator declines due to heavy hydrogen leakage, and need frequent
hydrogen make-up to maintain operation, should take the following measures:
 Check hydrogen pressure gauge tube and meter. If find out that the gauge tube jammed, joint leaks or meter
failure, should be replaced immediately.
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 Check if sealing oil pressure is too low, oil is interrupted. After taking measures, still cannot rise oil pressure and
maintain the lowest pressure operation, should shutdown the turbine.
 When hydrogen content in the stator cooling water tank exceeds 3% (volume content), should enhance the
monitor to the generator, if the defect isn’t removed within 120h or hydrogen content rises to 20% should
shutdown the turbine for treatment.
 Find out the hydrogen leaking location; quickly eliminate it or providing reference for shutdown the turbine.
 Evaluate hydrogen leaking quantity according to the hydrogen reducing range any time, if hydrogen leaking
quantity exceeds 20m3/d, and can’t be stopped in the short time, it’d better shutdown the turbine. Strengthen the
safety prevention and ventilation of hydrogen leaking site, avoid the explosion caused by the hydrogen
accumulation.
 During operation, when the hydrogen pressure inside the generator and exceeds the rated standard, should
immediately open the blowdown valve to recover the hydrogen pressure to the rated value, then find out the
reason and fix it.
 During operation, if the purity of hydrogen inside the generator lower than 96%, or oxygen content exceeds 1.2%,
should perform blowdown immediately, then make up qualified hydrogen, make the hydrogen purity recover to
normal value and find out the reason. During blowdown, should check and confirm there is no fire operation near
blowdown outlet to avoid hydrogen explosion
 During operation, when the hydrogen dew point exceeds the allowed value, firstly should put hydrogen drying
device. If it fails, should contact maintenance personnel to check the hydrogen drying device, and use
bleed-and-feed hydrogen method, if it fails, should find out reason in the following aspects, and eliminate it:
 Check the humidity of hydrogen inside the hydrogen supplying main is qualified
 Check the water content of liquid bleed out from blowdown pipe, and appreciate the water source.
 Check if hydrogen cooler has water leakage or not
 Check if stator cooling water system has leakage or not
 Check if there is any deposit water inside the main oil tank, and take samples for testing the water content of oil.
 Should check stator cooling water temperature, if it’s lower than hydrogen temperature, should rise the inner
cooling water temperature immediately, and keep the inner cooling water temperature higher than hydrogen
temperature.
 Check if the drying device works normally
 During operation, if in the liquid bleed out of the blowdown valve, water occupies the main part, and according to
the water test and other abnormality judge that the hydrogen cooler leaks water, should find out the cooler leaks
the water, contact maintenance personnel for treatment.

90 / 105
 When the generator oil system, inside main oil tank, metal enclosed busbar envelop ins ide hydrogen content
exceeds 1% (volume content), should stop the generator, find out the leaking point and eliminate it. When the
hydrogen volume content of inner cooling water tank, give alarm; if it can’t be eliminated within 120h, or the
hydrogen content exceeds 20%， should fix it immediately.
8.15 Stator Cooling Water Inte rrupted
8.15.1 Phenomenon
1) DCS gives ―generator stator cooling water temperature high‖, ―generator stator cooling water differential pressure
low‖ alarm
2) Generator stator coil temperature rises abnormally.
3) Generator stator cooling water pressure abnormally decline
8.15.2 Reason
1) Stator cooling water pump breakdown.
2) Stator cooling water filter jammed
3) System improper regulation
4) Water tank water level too low
5) Cooler leaks.
8.15.3 Treatment
1) When stator cooling water pump breakdown, start the backup pump, if it fails, and water supply inter rupted for
30s, generator should be disconnected.
2) Stator cooling water filter jammed, switch to backup filter and clean the filter
3) Check stator cooling water system all valves should be normal, regulate water level, pressure, and flow to normal
level.
4) After the water has been recovered should slowly supply the water to generator and vent the air.
5) If cooler leaks, should switch to backup cooler.
91 / 105
8.16 Stator Cooling Water Degree of Conducting is High
8.16.1 Phenomenon
DCS interphase ―ion exchanger outlet water degree of conducting high‖ alarm
8.16.2 Reason
Impure cooling water enters stator cooling water.
8.16.3 Treatment
1) During startup or normal operation, when generator ―ion exchanger outlet water degree of conducting high‖
appears, firstly should eliminate the meter fault then make further analysis.
2) Find out the generator hydrogen leaking point, make timly treatment and report.
3) Check if ion exchanger works normally, if the water inlet flow is too smll, should regulate ion exchanger
inlet/outlet water valve.
4) Check if ion exchanger resin fails, if it is should replace timely. When the degree of conducting increases to
1.5μS/cm, should replace the resin of ion exchange, and replace the water of water tank. When the degree of
conducting reaches 9.5μS/cm, after confirm the meter is correct, should apply for shutdown. Check stator cooler
cooling water and stator cooling water differential pressure is normal, regulate generator stator cooling water inlet
valve of cooler inlet valve, make the stator cooling water pressure higher than cooling water pressure, check and
judge is there any leakage. If find any leakage of cooler should switch to backup cooler operation, and contact
maintenance personnel for treatment.
92 / 105
9 Attachment
Attachme nt 1 Control Set Value Turbine Operation
Item Application Limits Remarks
Double amplitude value(1/100mm)

Eccentricity
Eccentricity recorder indicates 0 – 600rpm

﹤5
Portable recorder indicates ﹤2.5 0 – 600rpm
Alarm ﹤7.5 0 – 600rpm
Running well ﹤7.5

On-load
Able to continue running 7.5 – 12.5 balancing at proper time
Able to run for short-term ﹥12.5

vibration
Shut down 25
alarm 12.5
Rated speed
Start-up
Shut down 25
alarm 12.5
Overspeed
Shut down 25
alarm 12.5
others (include
Shut down 25
critical speed)
From thrust center line
Position of
Rotor position indicator alarm

±0.9mm
rotor
+ thrust end
Form thrust center line
- backward thrust end Shut down
±1.0mm
Casing expansion -
HP/IP casing expansion +10.3mm Rotor elongation

Casing expansion difference
alarm
difference - 4.5 mm Rotor shortening
Rotor elongation
shut down (if +11.1mm
Rotor shortening
any) - 5.1 mm
Rotor elongation
LP casing expansion difference +27mm
alarm
-3.5mm Rotor shortening
Rotor elongation
shut down (if +27.8mm
any) -4.3mm Rotor shortening
Item Application Limits remarks
94 / 105
Radial journal bearing metal alarm 107℃

Temperature of bearing
Shut down (manually) 113℃
Thrust bearing metal alarm 99℃
Shut down (manually) 107℃
Bearing oil drain alarm 77℃
Lower limit of bearing oil feeding temperature 21℃ (for reference) When barring
Tempera
exhaust steam
alarm 80℃ (for reference)

ture of
Shut down (manually) 120℃ (for reference)
Set value of steam exhaust casing water spray 70℃ (for reference)
Main steam and reheated steam
Continuously operation value Rated temperature
(turbine inlet)
Maximum value for continuous operation +8℃
Allowable value under accident +14℃ 400hrs/year

Main steam
conditions
15mins (continuously)
Maximum value of restriction operation +28℃
80hrs/year
Main steam pressure Continuous operation value +5%
(turbine inlet ) Maximum value of continuous operation +10%
95 / 105
Allowable value under accident +30% 12hrs/year
conditions
Reheat pressure under cold 1.25 times rated reheat
condition pressure under cold condition
Start-up Superheat degree of main steam ﹥56℃
cold condition start-up (metal temperature Main steam temperature﹤ Superheat degree﹥56℃
of 1st stage outlet<120℃) 430℃
Hot condition start-up Temperature difference between temperatures of steam and

st
metal at 1 stage outlet is +110℃～-56℃.
Temperatu Steam at 1st stage outlet ±165℃/H
re change rate
Gland sealing steam Superheat degree ﹥14℃

Temperature difference
Each MSV/Each ICV 14℃ Normal operation
28℃ Several minutes
42℃ 15mins for every 4hrs
Deviation (TMS-TRH) between rated temperature values of ﹤±28℃ Normal operation
main steam TMS and reheat steam TRH, refer to Figure A** ﹤+42℃ Low reheat temperature
96 / 105
﹤+83℃ Start-up and low load operation

Steam and metal
Limits +140℃～-83℃ Normal operation
temperature
Recommended value +110℃～-56℃
(impulse chamber)
Flange and bolt +140℃～-30℃
Upper & lower parts of HP casing 42℃ Normal operation
Upper & lower parts of IP casing 42℃ Normal operation
External and internal metal of Steam chamber 83℃
Gland sealing steam and rotor ﹤±110℃ Normal operation
﹤±165℃ 25 times/year
vacuum alarm 60kPa(a)

Condenser
vacuum
Shut down 65kPa(a)
Vacuum breaking valve Open at 400rpm Not applicable for emergency
conditions
＜111%
oth
Overspeed shut-down
ers
Minimum load 5～10% of rated load
97 / 105
Sudden load change ＜25% of rated load
MSV/GV valve rod test ＜70% of rated load
Switching operation from MSV to GV Internal wall temperature is higher than saturation temperature under main steam pressure.
Turbine drainage valve operates 20% of rated load
Oil ～900rpm 40℃
temperature of Control the lubricating oil temperature of oil cooler outlet

according to following figure:1000
oil cooler
outlet bearing 900rpm～rated speed 50℃
Note: The limits listed in this table is for general requirements, and after successful operation test, they can be adjusted according to the characteristics of each unit.
98 / 105
Attachme nt 2 Reference Curve of Unit Startup
Chart 1
99 / 105
100 / 105
101 / 105
Chart 10-3 steam state of turbine entrance “cold start”
Inlet temperature of main steam valve

Chart 4 Warm Start Curves 1
First stage metal temperature
Start parameter with no considering effect of boiler
102 / 105
Chart 10-5 Warm Start Curve
103 / 105
Chart 7 Hot Start Curve
104 / 105
Chart 8 Extreme Very Hot Start Curves
105 / 105

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Indian Salaya Project 2x600MW Power Station Training Manual

2x600MW Training Manual

HARBIN POWER ENGINEERING COMPANY LIMITED

Harbin Huitong Electric Power Engineering Co., Ltd.

4.2.7 Oil Conditioning System .............................................................................................................................. 30

6.5.6 Emergency Power Supply Attention............................................................................................................... 65

8.11.1 Common Fault Phenomenon ......................................................................................................................... 86

Training Material of Turbine for Indian Salaya Project

1 Turbine Design Parameter and Operation Conditions

Turbine Manufacturer: Haebin Turbine Co., Ltd.

1.1 Main Parameter of Turbine

Rated Power: 600MW（TMCR condition+0%rate of make up water，heat consumption firm condition）

Maximum Power: 649.74MW （VWO condition+0%rate of make up water）

Pressure: 16.7MPa (a)

Flow Rate: 1866.68t/h

Pressure: 3.423MPa (a)

Flow Rate: 1572.73t/h

Exhaust Pressure of Rated Condition for HP Casing: 3.804MPa (a)

Maximum Admission of Main Steam: 2060t/h （VWO condition）

Average Exhaust Pressure of LP Casing: 9.60 kappa (a)

Steam Distributing Mode: Nozzle Governing

Temperature of Recycling Cooling Water: 33℃

Feed Water Temperature of Rated Condition: 275.3℃

Rated Revolution: 3000r/min

Heat Consumption of Rated Condition (heat consumption firm condition): 8122.4kJ/kW.h

Blade Length of Last Stage for Low Pressure: 680mm

Regeneration System: three high, four low, one deaerator

1.2 Main Design Characteristics

exhaust steam into two-pressure condenser.

The requirements of steam quality for accessing turbine are following:

Electrical conductivity 25℃ <0.30μS/cm

Start and operation mode: combined start of HIP casing

1.3 Account Data Table of Prospective Function for Turbine

See the attachment

2 Turbine Body Structure

2.1 Steam Flow Path

steam will be exhausted downward

2.2 HP and IP Valves

controlled by its servo motor which is controlled by DEH system.

2.3 HIP Casing

following the variations of temperature at the same time.

hand, the casing will be concentric with the seal ring.

differential expansion so as to reduce the start up time.

2.4.1 LP Casing Design

structure which can be lifted as a whole during erection.

lower than the horizontal joint.

vertical keys are provided.

2.4.2 Rear Casing Spray System

flow is supplied to each water spray nozzle.

LP rotor is of solid forging structure without bore.

and running test.

and generator rotors for rigid connection.

(including 2 for generator)

2.6 Slide Pin System

of two bearing pedestals.

and bearing pedestal. The lugs could move freely on keys.

expansion and good effect.

Expansion of stator parts

Mount of trust bearing

insulation bed plate

Axial aligning key of generator

Horizontal aligning key