1399 Operation and Maintenance-Turbine Operation Part

GUANGDONG POWER ENGINEERING CORPORATION
PLTU 2 SUMATERA UTARA 2×200MW MEDAN
Operation and Maintenance
Turbine Operation Part

Contents
1 GENERAL RULES........................................................................................................................................ 5
1.1 GENERAL RULES FOR ACTIVATION OF AUXILIARY SYSTEM...................................................................... 5
1.2 GENERAL REGULATIONS FOR ACTIVATION OF AUXILIARY ROTARY MACHINE ........................................... 5
2 OPERATION OF CIRCULATED COOLING WATER SYSTEM................................................................. 9
2.1 OVERVIEW OF THE SYSTEM .................................................................................................................. 9
2.2 CIRCULATING WATER SYSTEM ACTIVATION ........................................................................................... 9
2.3 NORMAL MAINTENANCE CONTENTS FOR THE CIRCULATING WATER SYSTEM ......................................... 10
2.4 THE CIRCULATING WATER SYSTEM SHUTDOWN .................................................................................. 10
2.5 TROUBLESHOOTING FOR THE CIRCULATING WATER SYSTEM ................................................................ 10
2.6 REGULAR WORK ................................................................................................................................ 12
3 CONDENSER.............................................................................................................................................. 13
3.1 MAIN FUNCTION AND WORKING PROCESS OF CONDENSER.......................................................................... 13
3.2 CONDENSER TEST .......................................................................................................................................... 13
3.3 THE DISCONNECTION AND ACTIVATION OF THE HALF CONDENSER .............................................................. 15
3.4 GENERAL REQUIREMENTS FOR CONDENSER OPERATION AND MAINTENANCE ............................................ 15
3.5 OPERATION OF CONDENSER RUBBER BALL CLEANING DEVICE ................................................................... 16
4 OPERATION OF OCCW&CCCW SYSTEM(OPEN-CYCLE & CLOSE-CYCLE COOLING WATER ) .. 18
4.1 OVERVIEW OF THE SYSTEM ............................................................................................................................ 18
4.2 THE OPERATION OF COOLING WATER SYSTEM............................................................................................. 18
4.3 THE NORMAL MAINTENANCE ITEMS OF COOLING WATER SYSTEM .............................................................. 19
4.4 SHUTDOWN OF COOLING WATER SYSTEM .................................................................................................... 19
4.5 COMMON FAULTS, CAUSES AND SOLUTIONS ................................................................................................. 19
4.6 REGULAR WORK ............................................................................................................................................. 21
5 AUXILIARY STEAM SYSTEM OPERATION ............................................................................................ 22
5.2 ACTIVATION OF THE AUXILIARY STEAM SYSTEM ............................................................................................ 22
5.3 NORMAL MAINTENANCE ITEMS FOR THE AUXILIARY STEAM SYSTEM ........................................................... 23
5.4 AUXILIARY STEAM SOURCE STOP .................................................................................................................. 23
6 LUBE OIL SYSTEM OPERATION............................................................................................................. 24
6.2 THE OPERATION OF LUBE OIL ....................................................................................................................... 24
6.3 NORMAL MAINTENANCE FOR LUBE OIL SYSTEM .......................................................................................... 25
6.4 SHUTDOWN OF LUBE OIL SYSTEM................................................................................................................ 25
6.5 COMMON TROUBLE SHOOTING FOR LUBE OIL SYSTEM............................................................................... 26
6.6 OPERATION REGULATIONS FOR TURNING GEAR ........................................................................................... 29
6.7 OPERATION OF OIL PURIFYING DEVICE. ........................................................................................................ 30
7 OPERATION OF GENERATOR SEALING OIL SYSTEM........................................................................ 32
7.2 ACTIVATION OF THE SYSTEM .......................................................................................................................... 32
7.3 NORMAL OPERATION AND MAINTENANCE OF THE SYSTEM ........................................................................... 32
7.4 SHUTDOWN OF SEALING OIL SYSTEM ............................................................................................................ 33
7.5 FAULTS OF GENERATOR SEALING OIL SYSTEM ............................................................................................. 33
8 OPERATION OF HYDROGEN SYSTEM .................................................................................................. 36
8.1 SAFETY REGULATIONS ................................................................................................................................... 36
8.2 GENERATOR GAS REPLACEMENT .................................................................................................................. 36
8.3 OPERATION AND MAINTENANCE OF HYDROGEN SYSTEM ............................................................................. 39
8.4 ABNORMAL OPERATION SOLUTIONS OF HYDROGEN SYSTEM ....................................................................... 40
9 OPERATION & MAINTENANCE OF CONDENSATE SYSTEM.............................................................. 42
9.2 ACTIVATION OF CONDENSATE WATER SYSTEM ............................................................................................. 42
9.3 NORMAL MAINTENANCE .................................................................................................................................. 43
9.4 DEACTIVATION OF CONDENSATE PUMP ......................................................................................................... 43
9.5 STARTUP AND SHUTDOWN SEQUENCE OF CONDENSATE WATER PUMP ...................................................... 44
10 OPERATION OF LP HEATER ................................................................................................................... 45
10.2 ACTIVATION OF LP HEATER............................................................................................................................ 45
10.3 OPERATION AND MAINTENANCE OF LP HEATER ............................................................................................ 46
10.4 LP HEATER SHUTDOWN ACCORDING TO TURBINE SLIDING PARAMETERS .................................................. 46
10.5 FAULT SHUTDOWN OF LP HEATER................................................................................................................. 47
11 OPERATION OF DEAERATOR................................................................................................................. 48
11.2 ACTIVATION OF DEAERATOR .......................................................................................................................... 48
11.3 NORMAL OPERATION & MAINTENANCE OF DEAERATOR................................................................................ 49
11.4 SHUTDOWN OF DEAERATOR SYSTEM ............................................................................................................ 49
11.5 TROUBLESHOOTING FOR DEAERATOR ........................................................................................................... 50
12 OPERATION OF MOTOR-DRIVEN FEEDWATER PUMP ....................................................................... 52
12.2 STARTUP OF MOTOR-DRIVEN FEEDWATER PUMP .......................................................................................... 52
12.3 NORMAL OPERATION & MAINTENANCE OF MOTOR-DRIVEN FEEDWATER PUMP .......................................... 53
12.4 SHUTDOWN OF MOTOR-DRIVEN FEEDWATER PUMP...................................................................................... 53
12.5 SOLUTIONS FOR FAULTS................................................................................................................................. 54
13 OPERATION OF HP HEATER................................................................................................................... 57
13.2 ACTIVATION OF HP HEATER............................................................................................................................ 57
13.3 MAINTENANCE OF HP HEATER ....................................................................................................................... 58
13.4 SHUTDOWN OF HP HEATER ........................................................................................................................... 58
13.5 HP HEATER TROUBLESHOOTING ................................................................................................................... 59
14 OPERATION OF FIRE RESISTANT OIL SYSTEM .................................................................................. 61
14.2 TECHNICAL SPECIFICATIONS .......................................................................................................................... 61
14.3 ELECTRO‐HYDRAULIC CONTROL PUMP (EHC PUMP )ACTIVATION ............................................................ 61
14.4 MAINTENANCE & INSPECTION DURING OPERATION....................................................................................... 61
14.5 SHUTDOWN OF THE SYSTEM .......................................................................................................................... 62
14.6 REGULAR WORK ............................................................................................................................................. 62
15 WATER RING VACUUM PUMP OPERATION ......................................................................................... 63
15.2 STARTUP OF WATER RING VACUUM PUMP .................................................................................................... 63
15.3 NORMAL OPERATION & MAINTENANCE .......................................................................................................... 63
15.4 SHUTDOWN OF WATER RING VACUUM PUMP ................................................................................................ 64
15.5 REGULAR WORK .............................................................................................................................................. 64
16 GLAND SEAL STEAM SUPPLY SYSTEM ............................................................................................... 65
16.2 ACTIVATION OF GLAND SEAL STEAM SUPPLY SYSTEM ................................................................................. 65
16.3 MAINTENANCE DURING NORMAL OPERATION................................................................................................ 66
16.4 SHUTDOWN OF GLAND SEAL SYSTEM ............................................................................................................ 66
17 OPERATION OF BYPASS SYSTEM......................................................................................................... 67
17.2 ACTIVATION OF BYPASS SYSTEM ................................................................................................................... 67
17.3 MAINTENANCE DURING NORMAL OPERATION ................................................................................................ 69
18 STEAM-DRIVEN FEEDWATER PUMP OPERATION .............................................................................. 71
18.2 STEAM-DRIVEN FEEDWATER PUMP TECHNICAL SPECIFICATIONS ................................................................. 73
18.3 STARTUP OF STEAM-DRIVEN FEEDWATER PUMP SET ................................................................................... 74
18.4 OPERATION AND MAINTENANCE OF STEAM-DRIVEN FEEDWATER PUMP ...................................................... 77
18.5 SHUTDOWN OF STEAM-DRIVEN FEEDWATER PUMP ...................................................................................... 78
18.6 ISOLATION OF STEAM-DRIVEN FEEDWATER PUMP SET DURING TURBINE OPERATION ............................... 79
18.7 SMALL TURBINE TEST ..................................................................................................................................... 79
19 CLASSROOM GIST ON STEAM TURBINE OPERATION....................................................................... 84
19.1 SYSTEM COMPONENTS AND THEIR FUNCTIONS ................................................................................... 84
19.2 TURBINE CONSTRUCTION, THEORETICAL KNOWLEDGE, MONITORED OPERATION PARAMETERS AND
ACCIDENT CASES........................................................................................................................................... 86
19.3 TURBINE OIL SYSTEM, STRUCTURES AND FEATURES ........................................................................... 87
19.4 PRINCIPLES AND COMPONENTS OF ETS AND CCS .............................................................................. 87
19.5 STRUCTURE, THEORETICAL KNOWLEDGE OF VARIOUS HEATERS AND REAL APPLICATIONS .................... 88
19.6 COMPONENTS AND OPERATION PRINCIPLES OF SEALING OIL SYSTEM .................................................. 90
19.7 ACCIDENT & OPERATION CAUTIONS FOR FEEDWATER AND CIRCULATING WATER SYSTEM .................... 90
19.8 OPERATION AND CALCULATION KNOWLEDGE OF GENERATOR HYDROGEN SYSTEM ............................... 91
1 General Rules
1.1 General Rules for Activation of Auxiliary System

(1) The maintenance work has been finished; the work permit has been ended; the
safety measures have been dismantled and the site is clean.
(2) The path is free, the stair and railing is good, the there is sufficient illumination.
(3) The pipe insulation is complete, the hanging bracket is adequate, and the anchor
bolts are fixed, the motor isolation is qualified and the shell earthing is also good.
(4) Check that all the man holes are closed tightly.
(5) The oil level in each oil tank and each rotary mechanical bearing oil chamber is
normal and the oil quality meets the requirements, the cooling water goes
smoothly.
(6) The water is supplied to each water tank till the normal water level and the water
quality meets the requirements.
(7) Supply power and steam to the auxiliary equipment and the relevant valves; test
that the rotating direction is right.
(8) Supply power to the relevant meters, signals, controls and protections, and
check that the light indication on CRT and the annunciator display panel is right.
(9) Check whether the system valve position is right according to the “valve
inspection card”.
(10) Main operator should direct the inspection of each auxiliary system before
normal activation, and the patrol operator of each specialization attend for the
complete inspection.
(11) Interlock and automatic device tests for the auxiliary equipment before activation
are normal and the set value is accurate.
(12) Normal startup and shutdown of the standby equipment must be informed by the
unit leader or the foreman, and report to the commander after the operation, for
the important operation, there should be guardian.
(13) If any abnormal condition after activation, report to the relevant leader and
immediately inform the relevant operator to handle.
1.2 General Regulations for Activation of Auxiliary Rotary Machine

1.2.1 Inspections before Startup of Auxiliary Rotary Machine
(1) I & C and electric static tests must be conducted to the auxiliaries after
maintenance and after tests are qualified and is put into operation, it is allowed
to do trial operation and acceptance. After the acceptance is qualified and work
permit is finished, it can be put into normal operation. Standby auxiliaries should
be in state to start up in any minute. Except for trouble handling, standby
auxiliaries must be inspected thoroughly before startup.
(2) Finish the local inspection, make sure that the appearance of the equipment is
complete, there is no person working around, the site is clean and tidy, no object
that will impede the operation.
(3) Inspect that auxiliaries and their motors are well grounded, anchor bolts and
connecting bolts are tightened. The grounding wire is in a good condition, the
coupler has no damage and can be connected well, the shield for rotary parts is
complete, and the cooling water system of each auxiliary rotary machine is
normal.
(4) Measure the insulation to be qualified strictly following the electrical regulations.
(5) Inspect auxiliary rotary machines and meters for each system are complete and
in a good condition and can be put into operation timely.
(6) Inspect each part of auxiliary rotary machine has been filled with lube oil and
grease lubricant, the oil level is normal and oil quality is qualified. Lube oil
system should be put into operation at least two hours before startup of auxiliary
rotary machine.
(7) For auxiliary rotary machine which is allowed to be turned manually, turn it first to
ensure it can rotate flexibly and without any blockage.
(8) Check the actuator for each air valve and damper is complete: the link lever is
reliable and can move flexibly, there is no blockage, position limit device can be
operated correctly and relevant indicating lights can indicate normally, the local
opening degree indicator coordinate with the indication on CRT in centralized
control room.
(9) All control circuits related to dampers and valves of auxiliaries, automatic device,
I&C interlock, protection and mechanism device and pneumatic device should
be calibrated according to their own regulation in advance.
(10) After inspection before startup of auxiliaries has been finished, and has met the
requirement for activation, dynamic power and control power for auxiliaries and
relevant equipment can be supplied.
1.2.2 Inspection after Startup of Auxiliary Rotary Machine
(1) When the auxiliary rotary machine starts up, there should be special person to
monitor the whole startup process, and any found abnormality need to be
reported, use emergency button when necessary. The patrol inspector can not
leave the site until the auxiliary rotary machine operates normally.
(2) Operators should monitor the whole process of startup after the auxiliary rotary
machine is started up, including startup time and startup current, inspect each
parameter of related system is normal.
(3) For auxiliary rotary machine started up in emergency, or started up automatically
because of I&C or electric interlock, patrol inspector need to go to local to check
the operation status of the machine after it is started up.
(4) The temperature rise of both the bearing (bearing pad) and gearbox of all rotary
equipment need to meet the requirement.
(5) Vibration of auxiliaries and gland temperature should meet the requirements
(6) The bearing temperature rise of motor and current meet requirements.
(7) Oil level of each lube oil tank and bearing is normal, without oil leakage and oil
ejection.
(8) There is no abnormal sound or friction sound of rotary equipment and motor.
(9) The mechanical connection of each regulating device should be complete and in
good condition, without any drop off.
(10) The inlet and outlet pressure and flow of transferring medium equipment should
be normal.
(11) Make sure that all interlocks and automatic regulating device are put into
operation normally.
(12) There is no water leakage, steam (air) leakage, oil leakage, gas leakage or
powder leakage that belongs to auxiliary rotary machine system.
(13) Check the causes and eliminate the faults if there is trip after the startup of
auxiliary rotary machine.
(14) Continuous startup times of motors should be carried out on the basis of relevant
electric regulations.
1.2.3 Normal Operation of Auxiliary Rotary Machine
(1) The patrol inspection regulation should be carried out strictly in normal operation,
inspect and monitor carefully. Report timely if any problem is found, and fill in
defect table if any defect is found and inform maintenance group to maintain and
eliminate the defect as soon as possible.
(2) Scheduled switch over and tests should be carried out based on relevant
regulations in normal operation.
(3) The operation of auxiliary rotary machine and motor is stable, without any
abnormal sound, no overheating on motor and vibration does not exceed the
limit.
(4) The lubrication of bearings are in good condition, oil quality is in good condition,
temperature is normal, gland temperature is normal, and cooling water is smooth
without any leakage.
(5) Fill oil timely according to the oil level of bearing, and keep the oil level in normal
range.
1.2.4 Deactivation of Auxiliary Rotary Machine
(1) Before the deactivation of auxiliary rotary machine, consider the condition of
relevant system and equipment to avoid any unnecessary condition.
(2) For large auxiliary rotary machines, record their idling time when shutdown.
1.2.5 Emergency shutdown conditions for auxiliary rotary machine:
(1) When condition that threatens the safety of personnel or equipment occurs:
(2) Fierce vibration of rotary machine;
(3) There is clear metal friction in the machine;
(4) The temperature of bearing increases sharply and exceed rated value;
(5) Motor or bearing has smoke or is on fire;
1.2.6 Operation for Emergency Fault Shutdown of Auxiliary Rotary Machine
(1) Press the emergency button to shut down the fault rotary machine, check its
current and outlet pressure; make sure they have already decreased to zero.
(2) Check that the standby rotary machine start up automatically, if not, start up
standby equipment manually, and check that the current and pressure is normal.
(3) Close outlet valve of fault rotary machine.
(4) Finish normal switch over operation, isolate fault rotary machine, and
de-energize relevant equipment, and then inform maintenance group to deal
with.
(5) Report to the superior and make record.
1.2.7 Shutdown Conditions of Auxiliary Rotary Machine under Common Faults
(1) Vibration value of auxiliary rotary machine exceeds rated value in operation.
(2) When bearing temperature increases abnormally to alarm value and keep
increasing after some measures are taken.
(3) Packing set has overheating, slight smoke or large amount of oil (water) leakage
and regulation doesn’t work.
(4) The current of motor exceeds allowable value, and can not recover to normal
state after regulation.
(5) When coil temperature of motor exceeds allowable value.
1.2.8 General Emergent Deactivation Operations of Auxiliary Rotary Machine.
(1) Report to unit leader to ask for shutdown of faulted rotary machine;
(2) Start up standby rotary machine, inspect its current and outlet pressure are
normal.
(3) Shut down fault rotary machine and close outlet valve;
(4) Take relevant safety measures and inform the maintenance personnel to deal
with it.
(5) Report to the leader and record the faults and fault corrections.
2 Operation of Circulated Cooling Water System
2.1 Overview of the System

The cooling water system for the 2×300MW unit adopts the direct flow sea water as
the cooling water, and the water supply system is the direct flow water supply system
of enlarging unit system. It is mainly used to supply the cooling water to the condenser
and auxiliary equipment.
2.2 Circulating Water System Activation

2.2.1 The Permitting Conditions for the Circulating Water Pump Startup
(1) The cooling water flow of the circulating pump guiding bearing is not low.
(2) The cooling water flow of the circulating pump thrust bearing is not low.
(3) The motor winding temperature of the circulating pump is not high .
(4) The bearing of the circulating pump and motor bearing is not high .
(5) No electric trip, no interlock trip, no forbidden operation, no local control.
(6) Open the motor-driven outlet and inlet valve at any side of condenser water side.
2.2.2 The Tripping Conditions for the Circulating Water Pump Protection
(1) The outlet valve has not opened 30S after the circulating pump startup.
(2) Motor coil temperature of circulation pump;
(3) Guidance bearing temperature of circulation pump motor ﹥80℃；
(4) Thrust bearing temperature of circulation pump motor ﹥80℃；
(5) Lower bearing temperature of circulation pump motor ﹥90℃；
(6) Circulation pump in operation, the outlet valve closed, delay 2 seconds;
2.2.3 Inspection before System Activation
(1) Check that relevant valves of the system are operated to required position
according to Valve Checking Card.
(2) Carry out auxiliary system activation rule.
(3) Circulation water pump interlock test is normal.
(4) Water filling condition at inlet of circulation pump is normal.
(5) Movable dirt cleaner and rotary strainer in water inlet passage of circulation
water pump is normal and available; foreign materials are absent, and water inlet
filter net is clean and intact.
(6) Check whether the non-electric control valve on the cooling lubricating water
pipeline is fully opened and whether there is water flowing through it (the valve
on bypass pipeline is closed).
(7) Hydraulic station of outlet butterfly valve of circulation water pump satisfies the
requirement of startup.
(8) Check the water chamber vacuum pump is in normal standby condition.
(9) The vent valve of the front and back water chamber of the condenser is open.
(10) Water discharging valves of the condenser water chamber and circulating water
system are all closed.
2.2.4 Circulating Pump Startup
(1) The cooling water main valve from industrial water to circulating water pump
bearing and motor bearing is open, and the cooling water returning main valve is
open.
(2) The startup of the cooling water branch valve of each circulating water pump
bearing and motor bearing is normal.
(3) Open the outlet butterfly valve of the circulating water and the inlet valve of the
condenser.
(4) Close the inlet valve of the rubber ball pump and the outlet valve of the ball
chamber.
(5) The water filling to circulation water pipes by back flushing pump is finished, and
the air exhaustion valve on front and back water chamber of condenser are
closed, and water chamber vacuum pump is stopped.
(6) Start up circulation pump: operate START on the display; motors and solenoid
valves of pump cooling and lube water system are open; open the outlet butterfly
valve of circulation water pump at 15 degree; start circulation water pump, and
the outlet butterfly automatically open up.
2.3 Normal Maintenance Contents for the Circulating Water System

(1) Current of each pump is in normal arrange, and the rated current of circulation
pump is A.
(2) Outlet pressure of circulation water pump is MPa.
(3) Allowable vibration value of pump unit is ±0.07mm; there is sound of pump and
water leakage of packing is normal.
(4) Cooling water of each bearing is normal.
(5) Temperature of motor oil is normal.
(6) Front and back water levels of strainer are normal.
(7) The circulation pump is forbidden to be restarted immediately after a failed
startup to prevent water hammer, it is only proper to be started up in 30 seconds
after the outlet valve of the pump is closed.
2.4 The Circulating Water System Shutdown

(1) If the “linkage” standby circulating pump is put into operation, release the
interlock switch.
(2) Press the pump stop button, close the outlet butterfly valve to 15°opening, the
motor loses power and the pump stops running.
(3) Close the outlet butterfly valve within 30s.
(4) Shutdown finished.
2.5 Troubleshooting for the Circulating Water System

2.5.1 The fault pump should be stopped if the following conditions happen:
(1) When there is personnel accident.
(2) The pump has serious vibration suddenly or there is obvious metal friction sound
(3) The bearing smokes or catches fire.
(4) The motor smokes or has fire.
2.5.2 Faults, Causes & Solutions
Faults Causes Solutions
Motor or power supply The special personnel carry out
system fault maintenance to the motor or power supply
There is foreign matters in equipment
Can not start moving parts Clean the rotor components
up The bearing is blocked Check bearing and make sure whether it
Insufficient startup conditions needs to be replaced
Check and make sure the startup
conditions are satisfied.
There is sundries blocked at Clean the blocking matters of the strainer,
the suction side or the outlet suction bell, impeller, guiding blade,
side discharging pipeline and valve system.
The clearance between the Adjust the clearance and replace the
impeller and impeller relevant components if necessary.
The flow is clearance are too big Replace the impeller
not enough Blade damage Calibrate the rotating direction
or there is no The rotating direction is not Measure the voltage, frequency and check
outlet water right the motor
The rotating speed is too low Increase the water level in suction tank
The air is sucked in and there (pool) and adjust the working conditions
is cavitations Decrease the system resistance and adjust
The device lifting head is too the working conditions.
high
Bearing damage Replace the bearing
There is foreign matters in the Clean and remove the sundries
pump Adjust the clearance between the impeller
There is friction between the and impeller chamber
impeller and impeller Loosen the stuffing
chamber Check the voltage and frequency, check
The stuffing is pressed too the motor and make adjustment
Overload tight Professional person to check and clean
The rotating speed is too Professional person to check and clean
quick
The voltage decreases or the
electric has fault
The circuit breakage of the
first phase, single phase is in
operation
The rotating direction is not Calibrate the rotating direction
Load right
decreasing Check the frequency and motor by special
The rotating speed is too low personnel, and make adjustment
The air is sucked and there is Increase the water level in suction
cavitations tank(pool), and adjust the working
There is sundries blocked at conditions
the suction side Clean the sundries blocked at the suction
side of the flowing system
The single side of he stuffing Loosen it first and then fasten it again,
pressing cover is fastened or make sure there is continuous water drop
The stuffing the fastness is excessive leaked
box The assembly is not good; Check and calibrate
generates the eccentricity of the shaft Replace the stuffing
heat center is too big.
The aging of the stuffing, the
failure of the self-lubrication
The lifting head is too high Decrease the system resistance, and
The lifting head is too low adjust the working condition
The rotating direction is not Adjust the working conditions
right Calibrate the rotating direction
There is cavitation Increase the water level in suction tank
The assembly accuracy is not (pool), eliminate the eddy
high Improve the assemble accuracy
Bearing damage Replace the bearing
Abnormal Shaft bending Alignment
vibration and The looseness or damage of Tighten or replace the connecting bolt
noise he connecting bolt of the Check and calibrate the balance
coupler Check and remove its influence
Unbalanced components of The special personnel carries out the
rotor maintenance
The deformation force of the Reinforce the base
discharging pipe and the load
cause the deformation of the
pump
Motor fault
The base is not fixed
2.6 Regular Work

(1) The pump without long term operation should start up for 30min.
(2) Each shift should periodically check the water level of sewage well in circulating
water pump house, periodically check the sewage discharge pump and put the
sewage discharge pump at the auto position.
3 Condenser
3.1 Main Function and Working Process of Condenser

The condenser is one of the most important devices of the steam turbine auxiliary
equipments, its main function is to coagulate the exhaust steam of steam turbine using
the circulated cooling water, produce the required vacuum in the steam discharging
space of the steam turbine, and recycle the pure condensate to provide for the boiler
as feedwater.
During normal operation, the cooling water is input into the two front water chambers in
the middle through the circulating water pump, and then the water flows into the back
water chamber through the two external tube bundles of the condenser after changing
direction. The steam enters into the condenser through the exhaust outlet of the
turbine, and then it is distributed on the whole length of the pipe evenly, the steam can
completely enters into the main tube bundle area through the center channel and two
sides channel of the tube bundle, after heat exchange between the pipe wall of the
cooling water pipe and cooling water, then the steam is condensed. Partial steam
enters into the hot well through the center and two sides’ channels to reheat the
condensate water, which can eliminate the sub-cooling degree and plays the
deoxidization function. The residual steam air mixer will carry out the heat exchange
through air cooling section, then the little on-condensed steam and air mixer is
extracted through the extraction outlet by evacuation equipment. The condensate is
collected in the hot well, and be extracted by condensate pump, then be input into the
main condensate system after pressure increasing.
The lower part of the casing is hot well, the condenser uses the hot well and casing
combined type, the outlet of condensate is installed at the bottom of hot well, eddy
eliminating device is installed at the outlet of the condensate pipe.
The man holes are set up on the condenser throat, lower part of shell, and on the
water chamber for condenser maintenance and repairmen. The drain hole and vent
holes are also provided on water chamber.
The condenser is connected flexibly with the exhaust opening through the stainless
expansion joint. The condenser bottom is on the rigid support. So when in operation,
the vertical expansion of condenser is compensated by corrugated expansion joints on
the throat. One fixed support and four sliding supports are provided considering the
condenser expansion caused with the load and work conditions changing, the
supports on four corners are sliding type, the sliding surfaces adopt PTFE plates. The
fixed support is set up in the middle of the condenser bottom to fix the condenser on
the foundation. The fixed support location is in accordance with the dead point.
3.2 Condenser Test

In order to ensure the operating characteristics of the unit, before the normal activation
of the condenser, the hydraulic test must be carried out to the water side and water
filling test to the steam side, and the air leakage test must be carried out to the vacuum
system.
3.2.1 Hydraulic Test at Water Side
The pressure for the condenser hydraulic test is 0.5MPa，the water temperature for
hydraulic test should not be less than 15℃，the test steps are as follows:
1) Close all the valves connected with the water chamber.
2) Fill clean water until the pressure reaches 0.5MPa (at the bottom of the water
chamber)
3) Keep this pressure for 30 min.
During test, note whether there is water leakage in the flange of the water chamber,
man-hole and the connecting welding seam, and whether the water chamber has
deformation. If there is any fault, stop the test immediately and take remedial
measures. If the whole inspection work can not be finished within the specified time,
the pressure maintaining time should be delayed.
3.2.2 Water Filling Test at Steam Side
In order to check the installation condition of the shell and cooling pipe, the water filling
test is necessary before the operation of the condenser, but it can not be carried out at
the same time with the hydraulic test at water side. The water temperature for water
filling test should not be less than 15℃， install the temporary support to the
condenser during water filling test. The water filling test should also be carried out
during the re-startup after turbine maintenance. The test steps are as follows:
1) Close all the valves connected with the shell.
2) Fill the clean water, the filling height should be 300mm higher than the
connecting place between the condenser and LP casing.
3) Keep this height for 24h.
During test, if there is water leakage at the connecting place between the cooling pipe
and end tube plate or the outer wall of the whole shell has deformation, the test should
be stopped immediately, and then completely discharge the clean water for inspection,
find out the causes and adopt the treating measures.
3.2.3 Air LeakageTest for the Vacuum System
1) After installation, maintenance or the shutdown time exceeds 15 days; the air
leakage test should be carried out three days after unit activation.
2) During the normal operation of the unit, the air leakage test should be carried out
once a month.
3) The methods and requirements for leakage test.
a) During test, the unit load should be kept stable at above 80% rated load.
Close the air extraction outlet valve of he condenser, make record 30s after
deactivation of the air extraction equipment (e.g.: vacuum pump, extractor and
so on ), the recording time is 8 min, calculate the vacuum average decreasing
value per one minute through the later 5 minutes vacuum decreasing value.
4) The vacuum system leakage evaluation is shown in the following table
Vacuum System Leakage Evaluation Criteria
Vacuum decreasing velocity
Evaluation criteria
KPa/min
≤0.40 Qualified
≤0.27 Good
≤0.13 Excellent
3.3 The Disconnection and Activation of the Half Condenser
3.3.1 Half Condenser Disconnection
1) Decrease the unit load to 50% of the rated load
2) Close the steam side air valve at condenser disconnection side, pay attention to
the vacuum value change, and stop the operation if the vacuum decreases
suddenly.
3) Close the circulating water inlet and outlet valve on condenser disconnection
side.
4) Check and close the rubber ball cleaning inlet and outlet valve at condenser
disconnection side.
5) Open the water side air and water discharging valve of the condenser at
disconnection side.
6) Cut off the power supply of the condenser circulating motor-driven valve and
rubber ball pump.
7) Stop one circulating pump according to the conditions.
8) Pay attention to monitoring the vibration, oil temperature and metal temperature
change of the No.3 and No.4 bearing.
3.3.2 Activation of Condenser Half Side
1) Make sure that the half side cleaning and leakage inspection has been finished,
and there is no tool, substance or person left. Tighten the man hole.
2) Close the water discharging valve at water side of condenser on same side.
3) Supply power to the circulating motor-driven valve and rubber ball pump of
condenser on same side.
4) Slightly open the circulating water inlet valve of condenser on the same side to
fill water, and close the air valve after there is water flowing through the air
discharging valve at water side, and fully open the circulating water outlet valve
of the condenser.
5) Open the steam side air valve of condenser on the same side, note that the
vacuum value of the condenser should increase.
6) Increase the load to the normal value gradually.
3.4 General Requirements for Condenser Operation and Maintenance

(1) The vacuum system leakage test is qualified.
(2) The cleaning state of the condenser is good.
(3) The cooling water flow satisfies the designing requirements.
(4) The gland seal steam pressure of the turbine is normal, the operation of steam
seal system is normal.
(5) The water level in hot well is normal.
(6) The air extraction equipment is normal.
(7) The operation of water sealing system is normal.
(8) The instrument indication and continuous protection are normal.
(9) The over-cooling degree of the condensate is qualified.
(10) Water quality of the condensate is qualified.
(11) Heat transferring end difference is good.
(12) Unit shutdown time exceeds three days; the cooling water in condenser water
chamber and condensate in hot well should be discharged.
(13) When the unit shutdown time exceeds one month, carry out the following drying
maintenance measures to the condenser.
3.5 Operation of Condenser Rubber Ball Cleaning Device

3.5.1 Overview of the System
This system is set with rubber ball cleaning system which includes the water inlet pipe
from rubber ball pump to condenser, the cooling water pipe of he condenser, and then
to the water outlet pipe of the condenser, and finally to the equipment, valve and pipes
of the ball collecting net.
The rubber ball cleaning system is installed with two sets of independent rubber ball
cleaning equipment; each set is corresponding to half side of condenser. The
condenser titanium pipe can be circulated cleaning when the unit doesn’t reduce the
load, to improve the steam turbine heating efficiency to buffer the corrosion in the inner
side of the steel pipes.
3.5.2 Activation of Rubber Ball Cleaning Device
3.5.2.1 Inspection before Startup
(1) Check the rubber ball cleaning system and ensure there is no any maintenance
work, the equipment connection is good, and all water discharging valves are
closed.
(2) Rotate the rotor of the rubber ball pump, and it should be flexible without
swinging and blockage.
(3) The insurance in the rubber ball cleaning control box is good, close the main
switch of he power supply, the power indication light on the control box is on.
The net barrier is open, ball chambers closed, the rubber ball pump is closed,
and the outlet valve of the rubber ball pump and the water filling valve of the ball
chamber are closed.
(4) Check that the outlet valve of the rubber ball pump is closed, and the inlet valve
is open.
(5) Check that the ball chamber has no water, the ball chamber is at closed position,
open the cover of the ball chamber, and then fill 900 qualified rubber balls, tightly
close the cover. Slightly open the outlet valve of the rubber ball pump and air
discharging valve of the ball chamber to fill water, and then close the outlet valve
and air discharging valve after the top cover has no leakage.
(6) Check that the ball collecting net is at open position, and the governing valve can
rotate flexibly, the system water filling and air discharging are normal.
3.5.2.2 Activation of the Rubber Ball Cleaning Device
Press the START button, then the cleaning device will run automatically according to
the procedure: grilling closes —→ rubber ball pump outlet valve open—→ rubber ball
pump start—→ball chamber open—→water filling valve of the ball chamber open,
check the switch of each valve is at the right position and the operation is normal. The
procedure runs cleaning for 20 min, and after 20 min ball collecting, the cleaning is
finished.
3.5.3 Shutdown of the Rubber Ball Cleaning Device
Press STOP button, check that the device procedure is stopped: ball chamber
close—→water filling valve of the ball chamber is closed 20 min after ball
collecting—→rubber ball pump stop—→rubber ball pump outlet valve close—→ball
collecting net open. Check that the switch of each valve is at the right position, cut off
the main power of the control box, open the air and water discharging valve of the ball
chamber, after the water is fully discharged, open the top cover of the ball chamber,
count the ball number and record the ball collecting ratio, cleaning time and so on.
3.5.4 Rubber Ball Cleaning Precautions:
(1) The rubber ball cleaning must be carried out after the operation of the circulating
water system is normal, generally more than 2 circulating pumps should be put
into operation, or the cleaning effect will be influenced.
(2) Check that the ball collecting net is in closed position during activation.
(3) During cleaning, monitor the rubber ball moving condition from the monitoring
window, the monitoring time is 15 min, during this time, it is normal if there is
continuous ball retuning back. Each side should be cleaned for 20 min.
(4) Report to the on-duty operator before cleaning, pay attention to the condenser
vacuum, circulating water temperature increase, end difference, pressure
change before and after the ball collecting net, and make record, if there is
problem, report to the leader and take measures.
(5) Check the rubber ball abrasion conditions every time, and replace the broken
rubber ball in time.
(6) After cleaning, every time completely discharge the water in the pipe and
equipment.
(7) Before long time shutdown of rubber ball system, try to recollect the rubber ball
in the condenser. During shutdown, periodically activate each operating handle
to prevent the blockage of the rotating shaft.
(8) During cleaning, if there is fault, stop the operation of the system, and put it into
operation after fault elimination.
(9) During cleaning, each side can be cleaned once. Before cleaning， pour the
filling water first, and then carry out cleaning after the air in the system is
completely discharged.
3.5.5 Rubber Ball System Arrangement
4 Operation of Open-type & Closed-type Cooling Water System

The path of open-type circulation cooling water system is that the cooling water flows
from circulation water entry pipe to closed-type circulation water heat exchanger and
water ring vacuum pump cooler through motor-driven water filter and it finally returns
to circulation water return pump.
The working scope of closed-type circulating cooling water system is from closed-type
circulating cooling water pump to closed-type circulating water heat exchanger. Its
working process is that the cooling water is transferred into generator hydrogen cooler,
hydrogen dryer, seal oil vacuum pump, , LP drain pump, condensate pump thrust
bearing, condensate motor cooler, external water supply for condensate gland seal,
cooler for motor-driven water pump regulator, bearing of motor-driven pump booster
pump, lube oil cooler for motor-driven feedwater pump, working oil cooler for
motor-driven feedwater pump, motor-driven pump motor, working oil cooler for
steam-driven pump small turbine, lube oil cooler for steam-driven pump small turbine,
steam-driven pump booster pump sealing, FD fan cooler, ID fan cooler, primary fan
cooler, seal fan bearing, mill lube oil station, air preheater guide bearing oil station, oil
purifying cooler, E-H oil cooler, turbine generator lube oil cooler, fluidized air fan house,
ESP air compressor, slag handling valve cooler, and sample cooler. After flowing
through all these equipment in turn and finally, it returns to closed-type circulating
cooling water pump. This system is connected with the plant cooling water pipe and
cooling water system of No.2 turbine. Besides, closed-type circulating cooling water
system also has a closed-type circulating water flash tank of 10m3, whose normal
water source is condensate, and the first make up water source is from condensate
make up water tank.
Closed-type circulation cooling water system has 2 closed-type circulation cooling
water pumps of 100% capacity, one of which is in operation and the other serves as
standby, and 2 closed-type circulation cooling water heat exchanger (plate type) of
100% capacity.
4.2 The Operation of Cooling Water System

Enclosed circulation cooling water system can be put into operation only after open
type circulating cooling water was put into operation normally,
4.2.1 Check and Preparation before System Activation
(1) Turn the related valves to required position according to VALVE CHECK CARD.
(2) General principles to put auxiliaries systems into operation
(3) Check circulation pump has been put into operation
(4) Check feed water tank water level of condensate water is normal and connect
with chemical personnel to produce water strongly
(5) Actuate general rules of put auxiliaries rotating machines into operation, Check
the open and closed cooling water pump has met the requirements to start up.
4.2.2 Activation of Cooling Water System
4.2.2.1 Activation of open cooling water system
1) Open air exhaust valve of open cooling water system
2) Open inlet & outlet valves of each cooler
3) Slowly open cooling water inlet filter MOV (before) and feed water to the system
4) Check and close air exhaust valve when water out from the air exhaust valve
5) Fully open open-cooling water inlet filter MOV (before)
6) Check open cooling water was drained to circulating water return pipelines
4.2.2.2 Activation of closed cooling water system
1) Open air exhaust valve of enclosed cooling water system
2) Feed water to enclosed cooling water expansion water tank
3) Slowly open enclosed cooling water expansion water tank to enclosed cooling
water pump inlet pipeline make-up water valve to feed water.
4) After water level in enclosed cooling water expansion water tank is normal, put
water level control system in to operation
5) Start up one set enclosed cooling water pump and slowly open outlet mov to
feed water m and exhaust air to the system.
6) After air has been exhausted fully, close air exhaust valve
7) Check the following items in normal condition: current of enclosed cooling water
pump returning time, pump units vibration, main pipe pressure, bearing
temperature and packing temperature.
8) Start up standby pump outlet motor valve and activate interlock switch
9) Connect with each user accordance with needing
4.3 The Normal Maintenance Items of Cooling Water System

(1) Check open and closed cooling water pump operates in normal condition.
Note that the bearing temperature should not be 35°C more than the ambient
temperature. The highest temperature should be no more than 75°C. Pump units
vibration and panel root temperature is normal.
(2) Periodically check the elastic shaft coupler. Pay attention to the temperature
rise of motor bearing. Motor has no strange sound.
(3) Check main pipeline pressure and expansion water tank water level of open and
closed cooling water is normal. Each user works normally
4.4 Shutdown of Cooling Water System
(1) Ensure none user of enclosed cooling water system do not use water and the
condition for shutdown enclosed cooling water system has been satisfied
(2) Free standby pump interlock and shut down enclosed cooling water pump
(3) Fully drain the storage water in each user water room and pipes of cooling water
system by drain valve and then close it
(4) If it needs maintenance after shutdown, follow the safety measures in work
permit
4.5 Common Faults, Causes and Solutions
Faults Causes Solutions

The pump does not
extract water. The The water flow into the pump is
pointer of pressure not enough Inject more water into the pump
gauge and vacuum There is air leakage of certain Tighten or block the leaking point
gauge jumps water intake pipe and instrument
violently.
The bottom valve is not open or
Maintain or replace the bottom
it has been blocked
The pump does not valve
extract water and the Too much resistance of water
Clean or change suction pipes.
vacuum gauge absorption tube
shows high vacuum Decrease the water absorption
The water absorption attitude is
attitude
too large
Too much resistance of outlet
Check and shorten the water outlet
There is pressure in pipe. pipe.
pressure gauge The rotating direction is not
water pump outlet, correct. Change the motor rotating
but there is still no direction.
water flowing out of The impeller is jammed. Clean the impeller.
the pump. The pump rotating speed is not
Increase the pump rotating speed.
large enough.
The pump is stagnated.
Too much abrasion of sealing Clean the pump and pipeline.
ring.
Replace the sealing ring.
The flow is less than The rotating speed is not
that being predicted Increase the pump rotating speed
enough.
Change the operation parameter
Too much resistance of the
and working condition point.
pipeline. The pump is operated
in small flow area.
The power that the Impeller abrasion. Replace the impeller.

pump consumed is The water supply of pump is Adjust gear valve to reduce the
too large. increased. flow.
The openness of gear valve is

too big.
Adjust the gear valve to decrease
Too much resistance of the the flow.
Circumstances such
water absorption pipe.
as noise, flow Check the absorption pipe and
decrease until no The water absorption attitude is bottom valve.
water flow out too large.
Reduce the water absorption lift.
occurs during the
There is air that comes into the
pump working, Close or block the leaking point.
absorption part.
Decrease liquid temperature.
The temperature of the feed
liquid is too high.
The pump shaft and motor shaft Align the centers of pump shaft
are not in a same centerline. and motor shaft.
The pump is
The bearing is worn. Replace the bearing.
chattering
The rotor grazes the shell, and Disassembly the pump and
the base becomes loose. reinforce the base.
There is no lubricant on the Fill lubricant or change the

The bearing is too bearing or the Lube oil is dirty. lubricant
hot. The pump shaft and motor shaft Align the centers of pump shaft
are not in a same centerline. and motor shaft.
4.6 Regular Work

4.6.1 Schedule
The switchover for closed type cooling water pumps are arranged to the day shift on
the 15th of every month.
4.6.2 Switchover between Closed Cooling Water Pump
(1) Check to ensure standby pump is in normal standby condition
(2) Deactivate the interlock of standby pump
(3) Start up standby pump and check to ensure it works properly
(4) Shut down raw operation pump, pay attention to the difference of main pipe
pressure and check pump does not run reverse, or else close its outlet motor
valves.
(5) After normally switch pumps, activate interlock switch。
5 Auxiliary Steam System Operation

In this project, every unit is set with one auxiliary steam header, and the connecting
main pipe is set among 2 units. The steam source is the 4th -stage extraction of the
turbine, low temperature reheated steam and auxiliary steam of the near turbine. The
startup steam of the #1 unit is supplied by the startup boiler, and the steam source of
each auxiliary steam is connected with the auxiliary steam header, and then supply
steam to the steam supply object through header. The steam source of the auxiliary
steam can be different steam source according to the different working condition.
The auxiliary steam system supplies steam to the following equipment during unit
startup and low load operation: deaerator, steam-driven small turbine, turbine gland
seal system, fuel purging, hopper, coal mill fire-fighting, and air preheater sootblowing
and so on.
5.2 Activation of the Auxiliary Steam System

5.2.1 Preparation before the activation of the auxiliary steam system
(1) Make sure that the operation of the compressed air system is normal.
(2) Make sure that the operation of the condensate system is normal (or the
operation of the condensate transmitting pump and the desuperheating water
are normal).
(3) Supply power to motor-driven valve and governing valve of the system.
(4) Check that the valve position is right according to the system valve checking
card.
(5) General rules for activating auxiliary systems should be followed
(6) Drain water system can be putted into operation
(7) Check to ensure actuation pressure calibration of auxiliary steam system safety
valve is normal
5.2.2 Steam Supply for Startup Boiler
5.2.2.1 Pipe warming
1) When the pressure of startup boiler reaches 0.2MPa, slowly open the startup
boiler steam supply valve to pre-warm the steam supply main pipe, and put the
drainage into operation.
2) Slowly open the steam supply motor valve to auxiliary steam header, for
warming up. Pay attention to the fully drainage and prevent the pipe vibration.
According to the vacuum evacuation condition of condenser and drain water to
condenser, the water should meet the standards.
3) During tank and pipe warming, the steam pressure should be kept at 0.2MPa;
the time is 30 min, par attention to monitor the pipe vibration and system
leakage.
4) After pipe warming, close all the drainage valves and drainer bypass valves on
the pipe and header, and then put the drainer into operation.
5.2.2.2 As the temperature and pressure of the startup boiler increases, when the startup
boiler reaches to the rated parameters, adjust the steam supply from startup boiler to
the auxiliary header, and then increase the pressure and temperature gradually, keep
the HP auxiliary steam header pressure at 0.7～1.27MPa，and the temperature
should not be more than 350℃.
5.2.2.3 According to the user requirements, open each valve to the user, note that before
supply steam to the user, completely drain the water and warm up the pipe to avoid
vibration.
5.2.3 Operating Mode of the Auxiliary Steam Source
(1) The steam source of the auxiliary steam system is the forth stage extraction of
the turbine, low temperature reheated steam and auxiliary steam of the near
turbine.
(2) The startup steam for #1 unit is supplied by startup boiler.
(3) During normal operation, the steam is supplied by the 4th stage extraction.
(4) During low load, the steam is supplied by the reheated steam.
(5) During unit startup, the steam is supplied by the auxiliary steam of the near
turbine.
5.3 Normal Maintenance Items for the Auxiliary Steam System

(1) The control parameters during operation: pressure: 0.7-1.27MPa, temperature:
335-350℃
(2) Adjust and make the pressure and temperature of auxiliary steam header to be
normal. During pipe activation, completely drain the water and avoid the pipe
vibration and flange leakage.
(3) Pay more attention to monitor the water level in flash tank, and note that the
drainage interlock should be normal.
(4) During the operation of the startup boiler steam supply, if the startup boiler is
fully filled with water, cut off the steam supply to the auxiliary steam header
immediately. And completely drain the water, the steam of the auxiliary steam
header is supplied by the near turbine or this turbine.
(5) During normal operation of the auxiliary steam, the drainer should be put into
operation normally. The low position drainage on other pipes should be open
properly according to the actual conditions.
(6) If the unit with auxiliary steam main pipe has fault, immediately supply steam to
auxiliary steam main pipe from the normal operating unit or start up boiler and
close the steam supply valve of the fault unit.
5.4 Auxiliary Steam Source Stop
(1) Make sure that all the auxiliary steam header users stop using the steam.
(2) Contact the startup boiler operator to prepare for boiler shutdown.
(3) Close all the steam supply valves from auxiliary steam to the users.
(4) Stop the desuperheater and put the automatic adjustment out of operation.
(5) Close the steam supply valve of auxiliary steam header
(6) Open the bypass valve of each drainage, and close the drainage inlet and
outlet valves.
6 Lube oil System Operation

This system is used to cool and lubricate each bearing of turbine proper; it is also used
to supply oil to turning gear and bearing jacking oil system.
When starting up and shutting down, AC oil pump is used to supply cooling Lube oil
to the turbine proper Lube oil system, at the same time, it also supply oil to turning
gear and bearing jacking oil system.
While during operation, main oil pump is used to supply oil to the same parts.
Only during shutdown or when there is no AC auxiliary power supply, can the DC oil
pump be used to supply cooling lube oil to turbine proper lube oil system.
The lube oil overpressure valve will open automatically on condition that the system oil
pressure is above 0.15Mpa; it will close automatically when the pressure is below
0.15Mpa.
6.2 The Operation of Lube oil

6.2.1 Inspection and Preparation before Operation
(1) Operate each valve to the required position;
(2) Carry out the general rule of auxiliary system activation;
(3) The oil level in main oil tank is higher than the normal level;
(4) Inspect that the oil cleanup system operates normally;
(5) Inspect that the instrument air system operates normally;
(6) Closed and open cooling water systems operate normally;
6.2.2 The Operation of Lube oil System
(1) Start up the AC oil pump to fill oil and exhaust air in the Lube oil system,
inspect the pump operates normally, the low oil pressure alarm disappears,
the main pipe pressure is normal;
(2) When the pressure of lube oil is higher than 0.08MPa, main oil tank gas
exhauster should open automatically;
(3) Inspect that the oil inlet pressure in each bearing is normal, and there is no
oil leaking in the system;
(4) Activate lube oil pump interlock;
(5) After the test on oil pump low oil pressure interlock is successful, keep the AC oil
pump operating.
6.2.3 The Operation of Jacking Oil System and Turning Gear System
6.2.3.1 Affirm the following conditions are fulfilled
1) Lube oil system operates normally; the main pipe pressure is higher than
0.08MPa;
2) Generator sealing oil system has been put into operation, and the pressure
difference between oil and hydrogen is higher than 0.03MPa, the oil inlet valve of
jacking oil pump was opened.
3) Local safety switch is at ON position.
4) Manual driven switch of turning gear is at the position of OFF.
6.2.3.2 Put the jacking oil turning gear function unit into operation
6.2.3.3 Inspect if motor of the jacking oil pump starts up normally, and inspect if jacking oil
pressure is normal.
6.2.3.4 Inspect that the turning gear starts up normally, and its rev is 54r/min, the return time of
current is normal.
6.2.3.5 Sound detection is normal, shaft shake degree is qualified, and the turning gear
current is normal.
6.2.3.6 Put turning gear interlock into service
6.3 Normal Maintenance for Lube oil System

6.3.1 When steam-generator rolling speeds up, signal of turning gear off should have
appeared otherwise shut down it.
6.3.2 Inspect that the main oil pump is in normal operation and oil level in main oil tank is
normal.
6.3.3 Inspect and make sure that the lube oil pressure and temperature are normal, the
temperature of back and front metal of each bearing is normal.
6.3.4 Inspect the oil cleaning system operates normally.
6.3.5 Strengthen the inspection on filter of turning gear, once block happens, immediately
switch over and inform for maintenance.
6.3.6 Turbine oil cooler switch
(1) Inspect that the water side of the standby oil cooler is filled with water.
(2) Start up the upper vent valve at the water side of the standby oil cooler;
shut it down after exhaustion.
(3) Inspect that the oil side of the standby oil cooler is filled with oil.
(4) Start up the oil cooler balanced valve and the vent valve at the oil side of the
standby oil cooler, shut down the vent valve after exhausting the air.
(5) Inspect that all the cooling water valves of the standby oil cooler are open.
(6) Switch the transfer valve of the oil cooler to the previous standby oil cooler,
inspect that the outlet oil temperature is increasing till the normal value.
(7) Shut down the balanced valve of the oil cooler.
(8) Strengthen the inspection on lube oil pressure, oil temperature and oil level in
main oil tank.
6.4 Shutdown of Lube oil System.

(1) When the highest mental temperature is lower than 50℃, turning gear operation
can be shut down.
(2) When the highest metal temperature in casing is below 50℃, Lube oil pump
operation can be shut down.
(3) When the turbine rotor become rest, and totally cooled, the jacking oil pump
operation can be shut down.
(4) When lube oil pressure is below 0.08MPa, after delaying 1 hour, smoke
exhauster of the main oil tank should be shut down automatically.
(5) Finish other related operation.
6.5 Common Trouble Shooting for Lube oil System

6.5.1 Decreased Oil Level in Main Oil Tank
6.5.1.1 Phenomenon
1) Indication of the oil level meter decreases
2) Alarm when the oil level in main oil tank is low.
3) Lube oil pressure may swings.
6.5.1.2 Causes
1) Oil leaking or creaking on the system pipelines.
2) Some valves in oil system are mistakenly closed or open.
3) Oil temperature in main oil tank decreases.
4) Indication of the oil level meter is out of order.
6.5.1.3 Solutions
1) Inspect whether the indication of each oil level meter is normal, if not, causes
should be found out and corresponding solutions should be done immediately,
emergency oil makeup is needed if necessary.
2) If the oil level decreases to mm quickly, emergency shutdown is needed.
3) Once it is caused by the crack of lube oil pipelines, the pipeline should be
isolated or the leakage should be stopped, and then maintenance is needed.
Depending on the exact situation, accidental shutdown or emergency shutdown
is needed.
4) If it is caused by oil leakage in sealing oil system, isolate it under the
precondition that it would not affect the safety operation of the unit, once it
cannot be isolated, it could be treated as commonly emergency shutdown.
5) If it is caused by the low oil temperature, it should be managed to increase it to
normal value.
6.5.2 Increased Oil Level in Main Oil Tank
6.5.2.1 Phenomena
1) Indication on oil level increases
2) Alarm on high oil level.
6.5.2.2 Causes
1) Gland seal steam leakage.
2) Oil cooler leakage.
3) Abnormal of the oil level meter indication.
6.5.2.3 Solutions
1) Inspect whether the indication of each oil level meter is normal.
2) When oil level increases, discharge the oil tank and check its bottom. In form the
chemical group to take sample for test. Inform the shift leader and require for
shutdown when the oil quality is seriously deteriotated.
3) Inspect whether the lube oil cleaning device works normally.
4) If the gland seal pressure is too high, decrease it properly.
5) If it is caused by oil cooler leakage, timely switch and isolation is needed, at the
same time, maintenance and leakage stoppage is also need to be done.
6) Strengthen the inspection on bearing vibration and bearing temperature.
6.5.3 Decreased Lube oil Pressure.
6.5.3.1 Phenomena
1) Lube oil pressure indication decreases.
2) Alarm on low lube oil pressure.
3) Bearing return oil temperature increases.
6.5.3.2 Causes
1) The operation of main oil pump is abnormal.
2) Oil level in main oil tank is too low.
3) Lube oil supply piping leakage.
4) The outlet check valve of AC or DC lube oil pump is with leakage.
5) Lube oil overpressure valve is mis-operated.
6) Lube oil filter is dirty.
6.5.3.3 Solutions
1) Inspect whether the main oil pump works normally, when the lube oil main pipe
pressure decreases to 0.08MPa, the mainframe trips, AC and DC lube oil
pump start up automatically, or they should be started up manually.
2) If it is caused by the low oil level in main oil tank, deal with it by pressing “oil level
drops”.
3) If the AC and DC lube oil pump check valve is not tight or overpressure valve is
misacted, timely inspection and maintenance is needed.
4) If the supply piping springs oil in large quantity and it is hard to be isolated,
accidental shutdown is needed, emergency shutdown can also be done if
necessary. At the same time, start up the jacking oil pump beforehand.
5) When the lube oil pressure decreases, intensify the inspection on bearings and
its return oil temperature and vibration.
6.5.4 Excessive High Lube Oil Temperature.
6.5.4.1 Phenomena
1) Indication on lube oil temperature increases.
2) Alarm on high lube oil temperature.
3) Bearing mental temperature increases and alarms.
4) Thrust bearing return oil temperature increases.
6.5.4.2 Causes
1) The temperature of cooling water increases, or the quantity of cooling water
decreases obviously.
2) Oil cooler is seriously contaminated.
3) Lube oil pressure is too low.
4) Lube oil constant temperature valve faults.
5) Oil quality deteriorated.
6.5.4.3 Treatment
1) If the oil temperature increases slowly, the cooling water pressure and
temperature should be inspected and then some proper solutions should be
done.
2) If it is caused by the failure of oil temperature adjustment, timely inspection and
maintenance should be done.
3) Because of the dirty oil cooler, timely switch, inspection and maintenance is
needed.
4) If the bearing temperature increase is caused by the high oil temperature, it
should be dealt the same with high bearing temperature.
6.5.5 Trouble-shooting for AC and DC Lube Oil Pump.
1) During turning bearing, if the oil pumps trip, it would lead to the trip of turning
gear and the linkage of DC oil pump. Inspect that once the lube Oil pressure
return to normal, start up the turning gear again, and then maintain it to recover
the operation of AC oil pump.
2) During the unit is speeding up, in principle, shutdown should be done once any
of the lube oil pump faults. If the rev＞3450rpm and the main oil pump operates
normally, increase the unit speed to 3600rpm, make it operate steadily till the
fault is removed, and then synchronization is allowed.
3) During speed decreasing when shutting down, if the AC Lube oil pump faults,
start up the DC pump, shutdown normally, at the same time, maintain the AC
pump immediately. If two of the lube oil pumps fault, emergency shutdown
should be done immediately.
6.5.6 Troubleshooting on Jacking Oil Pump
When turning gear, if one or two of the jacking oil pump fault, turning gear can still
operate, but pay much attention to the change of the bearing temperature and turning
gear current, at the same time, inform the maintenance man to inspect and maintain.
6.5.7 Trouble Shooting for Turning Gear Motor.
1) Inspect the causes of the trouble, and connect the maintenance men to treat.
2) If the mental temperature in casing ＞150℃, operate the turning gear manually
according to the following table.
Angle of the manual

Mental temperature Turning gear interval
turning gear
Turning gear
＞450℃ Non-stop
continuously
350℃～450℃ 15mins 180°every 15mins
250℃～350℃ 30mins 180 every 30mins
150℃～250℃ 1h 180°every hour
If the shaft should turn 180° every M minute, then the first 180° should be achieved
when the shafting is stopped for M/2 minute. After that, the turning gear should rotate
once every M minute, and continuous turning gear at M/2 minute after the last manual
turning.
3) Before the gear turns 180°, if the rotor static time is T minute for turning gear
fault, then, after the gear turns 180°, only in T minutes should the continuous
turning be activated.
4) For some causes, it is needed to realize a revolution of 1/m, then manually
turning gear 360°is needed before continuously turning gear.
5) When the turbine is at hot state, if the manual turning gear fails to act, it is
prohibited to turn gear. But it is needed to assure the jacking oil pump and the
AC lube oil pump operates normally. When the turbine is cool and the manual
turning gear is free of blocking, operate it according to item 3).
6.6 Operation Regulations for Turning Gear

(1) When the unit rotating speed is decreased to rpm during shutdown, check to
ensure turning gear device tooth automatically and the current is normal.
(2) Before turning gear is put into operation, the AC Lube oil pump and jacking oil
pump operates normally, the oil temperature should be kept in 30～35℃.
(3) If the motor current of the turning gear is too large or the rotor can not move, it is
not allowed to gear forcefully.
(4) After shutdown the unit, operation of turning gear should last continuously till
the inner wall metal temperature of high pressure governing stage
decreases to 200℃, the intermittent turning gear may be carried out to decrease
the temperature to 150℃, and then shut down the turning gear.
(5) After shutting down the turning gear, only when the highest mental temperature
in casing should be lower than 50℃the Lube oil pump can be shut down.
(6) When turning gear, if there is some abrasion or other abnormal conditions,
the continuous turning gear should be changed into intermittent turning gear.
Once hot curl happens, it should be eliminated by intermittent turning gear, and
then turn gear continuously for at least 4 hours.
(7) When turning gear, if the rotor eccentricity is bigger than 0.05mm, continue with
the operation until the eccentricity is smaller than 0.05mm.
(8) Before hot start, continuous turning gear time should be longer than 4 hours.
(9) When turning gear continuously in hot state, if it stopped due to certain causes,
make records of shutdown time. Generally, the downtime should be less than 10
minutes. When putting it into operation again, move the turning gear manually to
180° and keep it for the same time, then the continuous turning gear is allowed,
and extent turning gear for at least 2 hours.
(10) Once the unit is under the continuous turning gear condition, much attention
should be paid to the turning gear current, if turning gear current swings
periodically, an analysis and inspection is necessary.
(11) If the motor-driven turning gear has some problems and the manual one is
needed, make sure that the power supply is cut off, in order to prevent the
turning gear handle hurts the operator once the motor-driven turning gear put
into operation.
6.7 Operation of Oil Purifying Device.

6.7.1 Preparation before Operation.
(1) Each valve is at the required position in accordance with the “valve check card”.
(2) Carry out the general rule on auxiliary system operation.
(3) Oil level in main oil tank is normal.
6.7.2 Activation of Lubrication Oil Purifying System
6.7.2.1 Filtration operation mode
1) Auto water ejector operates normally, control valve for adjusting flow works well.
2) Inspect and put a secondary filter into operation.
3) Start up an air exhauster of the oil purifier.
4) Open the outlet main valve of the oil purifier.
5) Start up the oil feeding magnetic valve for the oil purifier.
6) Open the oil filling primary and secondary valve of the main oil tank.
7) Open the oil filtering valve of the main oil tank.
8) Observe that the oil filtering flow is proper and the oil flow is normal.
9) Inspect that the oil filtering pump has had the startup condition, start up the oil
filtering pump and open the outlet valve.
10) Check if the pressure and the flow of the system are normal, and there is no
leakage in the system.
6.7.2.2 Operation mode by comprehensive regeneration treatment.
1) When the acid value of the Lube oil is larger than 0.1～0.2mgKOH/g (original
measured valve), chemical adsorption tank should be put into operation.
2) Basic operational procedure is nearly the same to the previous one.
3) When putting the secondary filter into operation, chemical adsorption tank and
the auto backwashing filter unit should also been put into operation.
4) Check if the pressure and the flow of the system are normal, and there is no
leakage in system.
6.7.3 Maintenance during Operation.
(1) Oil level in main oil tank is normal.
(2) Outlet pressure of the filter pump is normal.
(3) Oil filtering flow≥5000L/h
(4) Oil level in oil storage room is normal.
(5) Pressure difference both in and out of secondary filter cartridge should be
≤0.35MPa, when the pressure difference reaches to 0.35—0.4MPa, the
secondary filter should be backwashed, and another secondary filter should be
switched to operate.
(6) There is no oil leakage in oil system.
(7) Periodic blow down to the oil purifier should be done.
6.7.4 Outage of Lube Oil Purification System
(1) Close the oil filtering valve of the main oil tank and the inlet magnetic valve of the
oil purifier.
(2) When oil in the oil storage rooms is discharged out, close the outlet valve of the
oil purifier, and stop the oil filtering pump.
(3) Close the oil filling primary and secondary valves of the main oil tank.
(4) Stop the air exhauster of the oil purifier.
(5) If the downtime is too long, exhaust all the left water in the system, and blow
down in order to protect the device.
(6) Cut off the power supply of the lube oil purifying device.
7 Operation of Generator Sealing Oil System

Sealing oil system (or sealing bush oil supply system): to ensure the sealing bush used
pressure oil (also the sealing oil) is supplies without interruption, and there is no
hydrogen leakage inside the generator.
7.2 Activation of the System

7.2.1 Inspections and Preparations before the Activation
(1) Turn each valve to the required position according to the “Valve Inspection
Card”.
(2) Carry out the General Principle of the auxiliary system activation.
(3) The activation of the turbine lube oil system is normal.
(4) The activation of the instrumental air system is normal.
7.2.2 Activation of Sealing Oil System
(1) Ensure the oil level of the sealing oil tank is normal. The oil level of the Lube oil
tank for the sealing oil vacuum pump is normal.
(2) Start up the main sealing oil pump. Check to ensure the current and voltage of
the pump are normal.
(3) Check to ensure the action of the governing valve for the pressure difference
between the oil and hydrogen of the sealing oil is normal. Maintain the
differential pressure at 35kPa.
(4) Start up the vacuum pump of the sealing oil. Regulate the vacuum in the sealing
oil tank at about 98kPa.
(5) Start up the sealing oil exhaust fan. Check to ensure the normal operation.
7.3 Normal Operation and Maintenance of the System

7.3.1 The pressure differential between the oil and hydrogen is normal.
7.3.2 The outlet pressure of the main sealing oil pump is normal.
7.3.3 The differential pressure of each strainer is normal.
7.3.4 The vacuum in the sealing oil tank is normal.
7.3.5 The oil level in sealing oil tank, returned oil tank on hydrogen side, returned oil tank on
air side, lube oil tank of vacuum pump is normal.
7.3.6 Closed Circulating Operation Mode of the Sealing Oil System
(1) If the lube oil system is shutdown and there is still pressure in the generator, the
closed circulating operation will be activated.
(2) Check to ensure the returning oil valves from the sealing oil returning tank to the
sealing oil tank are open.
(3) Check to ensure the following items are normal: the outlet pressure of the main
sealing oil pump, the pressure difference between the oil and hydrogen, and the
oil levels of each oil tank.
(4) Check to ensure the vacuum in the sealing oil tank is normal.
7.4 Shutdown of Sealing Oil System

(1) Ensure the following items: the hydrogen discharging of the generator is finished;
the pressure in the generator is zero; the turning gear of the turbine is shutdown.
(2) Close the feeding oil valves from the lube oil to sealing oil.
(3) Shut down the main sealing oil pump.
(4) Shut down the sealing oil vacuum pump and sealing oil exhaust fan.
(5) Finish other corresponding operations.
7.5 Faults of Generator Sealing Oil System

7.5.1 Low Pressure Difference of Sealing Oil/ Hydrogen
7.5.1.1 Causes
1) Sealing oil governing valve fails.
2) The output of the sealing oil pump is low or the sealing oil pump fails.
3) The regulation of the sealing oil recirculation is improper.
4) The main filter is seriously blocked.
5) The oil level of the sealing oil tank is low.
6) The oil pipe line leaks oil.
7.5.1.2 Solutions
1) When the pressure difference between the sealing oil and hydrogen is found low,
immediately report to the corresponding department and take corresponding
measures according to the different causes.
2) If the governing valve of the sealing oil differential pressure fails, switch to the
bypass valve to control and inform the maintenance personnel.
3) If the differential pressure of the main filter is big, correctly switch to the other
filter and inform the maintenance personnel to clean.
4) If the outlet pressure of the main sealing oil pump is lower than the normal value,
check the following items: the oil level of the sealing oil tank; the opening degree
of recirculation; the cleanness of the inlet strainer of the pump and the pump
operation conditions.
5) If the main sealing oil pump trips, check to ensure the AC and DC oil pumps start
up automatically; otherwise, manually activate the oil pumps to ensure the
pressure difference between the oil and hydrogen is normal.
6) When each sealing oil pump fails, the sealing oil of the generator will be directly
supplied by the lube oil system. At that time, drop the hydrogen pressure in time,
and reduce the load according to the coil temperature of the generator.
7) If the pressure difference between the oil and hydrogen is lower than 0.024 MPa,
the unit will trip. Treat it according to the tripping procedures.
7.5.2 High Pressure Difference of Sealing Oil/Hydrogen
7.5.2.1 Causes
1) The governing valve of sealing oil fails.
2) The bypass valve of governing valve is faulty opened.
3) The indication is abnormal.
7.5.2.2 Solutions
1) Check to ensure the bypass valve of the governing valve is at the closing
position; otherwise, close it.
2) If the governing valve fails, switch to the bypass valve to control and inform the
maintenance personnel.
3) Reinforce the supervision of the oil level of the main oil tank and the liquid
leaking level in the generator. Once the high liquid level alarms, discharge the
liquid on site.
7.5.3 Abnormal Oil Level of Returned Sealing Oil Tank
7.5.3.1 Causes
1) The float valve of sealing oil fails.
2) The oil level transmitter fails.
3) There is misoperation on the corresponding valves of the system.
7.5.3.2 Treatment
1) If the oil level is abnormal, immediately check the real oil level and the pressure
of hydrogen side. If both of them are normal, inform the I&C to handle.
2) If the float valve fails which makes the low oil level, regulate the oil level by
manual valve on the precondition that there is someone on site to monitor the oil
level.
3) If the float valve fails which makes the high oil level, isolate the valve. Activate
the valve after the trouble shooting. Reinforce the supervision and inspection on
the newly activated returning oil tank.
7.5.4 Abnormal Oil Level of Sealing Oil Tank
7.5.4.1 Causes
1) The oil level governing valve fails.
2) The feeding oil strainer is blocked.
3) The oil level sensor fails.
4) The lube oil system fails.
5) There is misoperation on the valve.
7.5.4.2 Solutions
1) When the oil level of the sealing oil tank is abnormal, check the local oil level
gauge. Meanwhile, check whether the vacuum pump and positions of the system
valves are normal.
2) If the oil level governing valve of oil tank fails which makes high oil level, in a
short time, manually adjust the level by the front isolating valve of oil level
governing valve. When the oil level rises to mm, check to ensure the
vacuum pump can shut down automatically.
3) If the oil level governing valve of oil tank fails which makes the low oil level, start
up the AC sealing oil pump, and shut down the main sealing oil pump. When oil
level of the oil tank drops to check and ensure that the vacuum pump shut down
automatically.
4) Check whether the instrumental air pressure is normal.
5) If the reason is the failure of oil level sensor, inform the I&C personnel to handle.
6) If the feeding oil strainer of sealing oil tank is blocked, report to the
corresponding leaders to decide whether it should be shutdown.
7.5.5 Trip of Sealing Oil Vacuum Pump
(1) Quickly find out the tripping causes, and restart up in time after taking measures
to eliminate the faults.
(2) Reinforce the supervision of vacuum and oil level in sealing oil tank and the
sealing oil pressure.
(3) Check whether the oil level of the vacuum pump lube oil tank is normal.
(4) Notice the changes of the hydrogen purity. When the outage time of the vacuum
pump is over 2 hours, reinforce the supervision of hydrogen purity and
intermittently analyze the hydrogen purity of the generator.
8 Operation of Hydrogen System
8.1 Safety Regulations

For the reason that hydrogen is flammable and explosive, all the personnel on site
should follow the regulations below:
8.1.1 No flame; no smoking; no shoes with nails and no acrylic clothes.
8.1.2 Do not work on site with flame. If it is necessary, ask the leader for permission. The
following preparations should be done before operation:
a) Prepare sufficient CO2 and dry powder fire extinguisher.
b) Protective plate should be installed to prevent sparks from spreading.
c) The hydrogen content in the area with flame should be less than 1％.
8.2 Generator Gas Replacement

8.2.1 Regulations for Gas Replacement:
(1) Before gas replacement, generator tightness test must meet the requirement
and the seal oil system must work in normal condition.
(2) Gas replacement should be carried out when the rotator is in static condition. It is
forbidden to be done during start up process.
(3) Hydrogen, compressed air, CO2 gas need to be introduced from specified inlet
of gas control station. It is forbidden to make mistake in interface.
(4) During gas replacement (especially hydrogen replaces CO2), the gas flow speed
should be controlled (not good if too fast) and there should be special personnel
to adjust seal oil pressure.
(5) During gas replacement, it is forbidden for electrical personnel to do any test.t is
forbidden to work in open flame condition within 20 m and the alarm board
should be hung.
(6) During the whole replace process, generator should keep 0.01 ～ 0.03MPa
pressure.
(7) It is strictly forbidden to mix replace hydrogen and air directly in generator.
(8) When fill hydrogen to generator, the hydrogen must be fresh hydrogen and the
purity must be satisfied with the requirement and the temperature should be
normal.
8.2.2 Inspections and Preparations before Activation
(1) Turn each valve to the required position according to the Valve Inspection Card.
(2) The generator is at static state and maintains the atmosphere pressure.
(3) Corresponding I&C instruments and alarming devices can meet the
requirements.
(4) The hydrogen concentration around the hydrogen system is normal. There is no
hot work.
(5) The activation of generator sealing oil system is normal.
(6) The activation of compressed air system is normal.
(7) CO2 source is enough. The power of the electric heating is energized.
8.2.3 Hydrogen Charging for Generator
8.2.3.1 Fill the generator with CO2 to discharge air.
1) Check to ensure each valve of the CO2 system is at correct position and
ready to be activated.
2) Activate the CO2 heating device. Heat the water tank until the temperature
reaches 60℃.
3) Turn the CO2 triple valve to the CO2 filling side.
4) Activate the CO2 bottle. Adjust the pressure governing valve of CO2 bottle to
make the post-valve pressure at 0.15MPa.
5) Slowly open the air inlet valve of the CO2 heater.
6) Adjust the pressure governing valve of the CO2 heater to make the post-valve
pressure at 0.03MPa.
7) Activate the CO2 analyzer. Adjust the flow which passes through the analyzer is
150cm3/min.
8) Slightly open the general exhaust valve of generator. Maintain the pressure
inside the generator at 0.03 MPa.
9) Maintain the sealing oil pressure 0.05 MPa higher than the pressure inside the
generator.
10) When the purity of CO2 inside the generator is more than 70%, open the
following dead angle discharging valve, then close after several seconds: the
water discharging valves at the bottom of air exhaust pipe; leaking inspection
valves of the generator proper; leaking inspection valves at the end of the
generator and the water discharging valves at the hydrogen side of each
hydrogen cooler.
11) Close the hydrogen discharging valves of generator and the general exhaust
valve of generator.
12) Shut down CO2 heater. Close the air inlet valve of CO2 heater.
13) Close the outlet valve of CO2 bottle.
14) Shut down the CO2 analyzer.
15) Close each isolating valve of CO2 filling system.
8.2.3.2 Hydrogen Charching and CO2 Discharging of Generator
1) Connect the hydrogen feeding pipe by the soft pipe.
2) Switch the three-way valve of the main hydrogen pipe to the hydrogen feeding
position.
3) Switch the CO2 triple valve to the CO2 discharging side.
4) Open the primary and secondary hydrogen feeding valves of generator.
5) Adjust the pressure governing valve of hydrogen feeding to make the rear
pressure is 0.4MPa.
6) Activate the CO2 analyzer and H2 analyzer. Adjust the passing flow at
150cm3/min.
7) Slightly open the generator exhaust valve of generator. Maintain the pressure
inside the generator at 0.03MPa.
8) Check to ensure the action of differential pressure valve is normal, and the
pressure difference between the oil and hydrogen is 0.05MPa.
9) When the CO2 analyzer indicates the hydrogen purity of generator reaches 85%,
open each discharging dead angle valve for several seconds, then close them.
11) Open the normal air inlet valve of H2 analyzer.
12) When the H2 analyzer indicates the purity of hydrogen inside of the generator
reaches 98%, close the exhaust valve of generator.
13) Increase the hydrogen pressure to 0.37MPa. Close all of the hydrogen feeding
valves.
14) Activate the hydrogen dryer.
15) Activate the insulating overheat monitor.
16) Activate the hydrogen leakage monitor.
17) Activate the hydrogen moisture on-line monitor.
8.2.4 Hydrogen Discharging of Generator
8.2.4.1 Ensure the turbo generator unit is shutdown.
8.2.4.2 Close the chemical general hydrogen feeding valve.
8.2.4.3 Open the hydrogen discharging valve of generator.
8.2.4.4 Slowly open the exhaust valve of generator. Decrease the hydrogen pressure to
0.03MPa, and then close it.
8.2.4.5 Fill CO2 to discharge hydrogen.
1) Close the normal air inlet valve of H2 analyzer.
2) Activate the CO2 analyzer.
3) Open the CO2 filling valve of generator.
4) Turn the CO2 triple valve to the CO2 filling side.
5) Activate the CO2 heating device. Heat the temperature of the water tank to 60℃.
6) Activate the CO2 bottle, and adjust the pressure governing valve of CO2 bottle
to make the post-valve pressure at 0.15MPa.
7) Slowly open the air inlet valve of CO2 heater.
8) Adjust the pressure governing valve of CO2 heater to make the post-valve
pressure at 0.03MPa.
inside the generator at 0.03MPa.
10) Maintain the pressure of sealing oil 0.05 MPa higher than the pressure inside of
the generator.
11) After the CO2 purity inside of the generator is more than 90%--95%, open the
following dead angle discharging valves, then close them after several seconds:
water discharging valves on the bottom of exhaust pipe, leakage inspection
valves of generator proper, leakage inspection valve at the end of generator and
water discharging valves on the hydrogen side of each hydrogen cooler.
12) Close the hydrogen discharging valve of generator and the general exhaust
valve of generator.
13) Close the outlet valve of CO2 bottle.
14) Shut down the CO2 heater. Close the air inlet valve of CO2 heater.
15) Close each isolating valve of CO2 filling system.
8.2.4.6 Air Charging and CO2 Discharging of Generator
1) Connect the air feeding pipe by soft pipe.
2) Switch the triple valve of main hydrogen pipe at the air filling position.
3) Switch the CO2 triple valve to the CO2 discharging side.
4) Open the air filling primary and secondary valves of generator.
5) Adjust the pressure governing valve of hydrogen feeding to make the rear
pressure at 0.4MPa.
inside of the generator at 0.03MPa.
7) Check to maintain the differential pressure of hydrogen and oil at 0.05MPa.
8) When the air purity of generator reaches 95%, open each dead angle
discharging valve, then close them after several seconds.
9) Continuously fill the air for at least one hour. Maintain the air pressure of
generator at zero by exhaust valve.
11) Shut down the hydrogen dryer and cut off the power.
12) Shut down the insulating overheat monitor and cut off the power.
13) Shut down the hydrogen leakage monitor and cut off the power.
14) Shut down the hydrogen moisture on-line monitor and cut off the power.
8.3 Operation and Maintenance of Hydrogen System

(1) Check to ensure the hydrogen pressure of generator is about MPa.
(2) When the hydrogen pressure is high, exhaust part of hydrogen by atmosphere
exhaust valve. Drop the pressure to the normal value.
(3) When the hydrogen pressure is low, fill hydrogen to the generator in time.
(4) Check to maintain the hydrogen purity of generator above 98%. If the purity is
lower than 96%, replace the hydrogen in time to increase the purity.
(5) Check to ensure the activation of hydrogen cooler is normal. The temperature
of hydrogen is normal.
(6) Check to ensure the operation of hydrogen dryer is normal.
(7) Check to ensure the temperature of hydrogen dew point is normal.
(8) Check to ensure the coil temperature is normal.
(9) Check to ensure the liquid level of generator is normal.
8.4 Abnormal Operation Solutions of Hydrogen System

8.4.1 Low Hydrogen Pressure in Generator
8.4.1.1 Phenomenon
1) The indication of hydrogen pressure drops.
2) The makeup amount of hydrogen clearly increases.
3) The flow of hydrogen leakage monitor of stator cooling water increases.
8.4.1.2 Causes
1) The pressure of sealing oil drops.
2) The load of unit drops.
3) The hydrogen system leaks.
8.4.1.3 Solutions
1) When the hydrogen pressure drops, check he hydrogen temperature and
immediately find the causes on site. Add the hydrogen makeup amount to
maintain hydrogen pressure.
2) In the case that heavy hydrogen leakage happens and the leaking point can not
be eliminated immediately, decrease the load when the hydrogen pressure
drops. If the operation cannot be maintained after the pressure dropping, apply
for the shutdown. Handle after discharge the hydrogen.
3) If the reason is the pressure of sealing oil drops, handle according to “the drop of
the pressure of sealing oil”.
4) If the hydrogen supply pressure is low during the hydrogen makeup, inform the
chemical personnel to increase the hydrogen supply pressure.
5) If the hydrogen pressure in the generator drops quickly and the electric
conductivity of stator cooling water increases, report to the shift leader and
require shutdown.
8.4.2 The temperature of hydrogen rises or drops.
8.4.2.1 Phenomena
1) The indication of hydrogen temperature rises or drops.
2) The temperature of stator iron core rises or drops.
8.4.2.2 Causes
1) The adjustment of cooling water of hydrogen cooler is improper.
2) The pressure and flow of the industrial water change.
3) The load of the unit suddenly drops or rises.
8.4.2.3 Solutions
1) If the hydrogen temperature rises or drops, find the causes and eliminate them to
recover the normal operation.
2) Check whether the temperature, flow and pressure of cooling water of the
hydrogen cooler is normal. If not, adjust them to the normal range.
3) Reinforce the supervision of the hydrogen pressure and temperature of stator
iron core. If the hydrogen temperature rises, report to the shift leader to reduce
the load according to the temperature of the iron core to make the temperature
of the hot hydrogen lower than 60℃.
9 Operation & Maintenance of Condensate System

Each unit is equipped with following items: two condensate pumps of 100% capacity,
one set of 100% IP condensate polishing device, four LP heaters, one gland seal
cooler, one deaerator, one condensate makeup water tank and 2 condensate
conveying pumps.
The minimum flow recirculation pipe is led out from the condensate pipe at the outlet of
the steam seal cooler. Then it goes back to the condenser through the governing valve
of minimum flow to ensure the operation of the condensate pump with minimum flow
during the startup and low load, and to prevent the steam corrosion of the condensate
pump. Meanwhile, this can ensure there is enough condensate passing through the
steam seal cooler during the startup and low load to maintain the vacuum of the steam
seal cooler.
9.2 Activation of Condensate Water System

9.2.1 Inspections and Preparations before Activation
(1) Turn each valve of the system to the required position according to the Valve
Inspection Card.
(2) Carry out the General Regulation of auxiliary system activation.
(3) Normally activate the instrumental air system
(4) The activation of the chemical demineralized water system is normal.
(5) The activation of cooling water system of closed type and open type is normal.
(6) The condensate polishing system is standby and can be activated.
(7) The water level of the condensate storage tank is normal. The water quality
meets the requirement.
(8) The condenser is prepared to be fed with water.
9.2.2 Activation of Condensate System
(1) Check to ensure the condensate conveying pump is ready to be started up.
(2) Start up condensate conveying pump. Notice the return time of the current
should be normal.
(3) Check to ensure the following items are normal: the vibration and temperature of
each shaft, outlet pressure and operation of the pump.
(4) Slowly open the outlet valve of condensate conveying pump and feed water
valve to condensate water system. Feed water and discharge air for the
condensate system. Wash the condenser. After the water quality meets the
requirement, feed water to the normal water level.
(5) Open the outlet water discharging valve of #5LP heater. Wash the condensate
system. After the water quality meets the requirements, open the outlet valve of
#5LP heater. Feed water to the deaerator.
(6) Open seal water valve from condensate water conveying pump to condensate
water pump. Adjust the seal water of condensate water pump pressure to normal.
Open inlet air extract valve of condensate water pump. Adjust cooling water of
bearing to normal
(7) Check to ensure the condensate pump is ready to be started up. Start up the
condensate pump. Check to ensure the outlet motor driven valve opens
automatically. The condensate recirculating valve opens normally. Check
pressure, flow, current should be in normal and switch water supply of seal water
of condensate water to outlet condensate water of condensate water pump
(8) When the flow of condensate is ＞250t/h, check to ensure the condensate
recirculating valve closes automatically.
(9) Check to ensure the pressure of main condensate pipe is normal.
(10) Open the outlet motor driven valve of the standby pump.
(11) Activate the interlock switch of the standby pump.
(12) When polishing device is allowed to be activated, slightly open the outlet valve of
the polishing device. Inform the chemical personnel to discharge the air of the
polishing device. Then slowly open the inlet and outlet valves of the polishing
device. When the flow is normal, gradually turn down the bypass valve and
notice the changes of the current of the condensate pump, the pressure of the
main pipe and the flow.
9.2.3 Switchover of Condensate Pump
(1) Ensure the standby pump is at standby status.
(2) Start up the standby pump. Check to ensure the operation is normal. Switch the
choosing switch to the startup position.
(3) Shut down the original operating pump. Check to ensure the outlet motor driven
valve closes automatically. Reopen the outlet motor driven valve. Check to
ensure the pump does not rotate reversely.
9.3 Normal Maintenance

(1) The water level of condensate storage tank and condenser is normal.
(2) The differential pressure of the inlet strainer of condensate pump is normal. The
inlet vacuum value is normal.
(3) The vibration of pump group and the operation of sealing parts are normal.
(4) The temperature of the bearing and packing is normal.
(5) The current of the motor and the pressure of the main condensate pipe are
normal.
(6) The coil temperature of the motor is normal.
(7) The pressure and flow of bearing cooling water are normal.
9.4 Deactivation of Condensate Pump

(1) After the unit is shutdown, ensure each condensate consumer doesn’t need
water, and then shut down the condensate pump.
(2) Disconnect the interlock switch. Shut down the condensate pump. Check to
ensure the outlet motor driven valve closes automatically.
(3) If the pump needs to be maintained after the deactivation, maintain it according
to the safety measures in the work permit.
9.5 Startup and Shutdown Sequence of Condensate Water Pump
9.5.1 Start up sequence of condensate water pump
1) Open inlet valve
2) Start up condensate water pump
3) Open outlet valve
9.5.2 Shutdown sequence of condensate water pump
1) Shut down condensate water pump
2) Close outlet valve
3) Close inlet valve
10 Operation of LP Heater

The system is equipped with four LP heaters. The drainage adopts the step-by-step
mode to the drainage tank of #7 LP heater. Then the drainage is pumped to the main
condensate pipe at the outlet of #7 LP heater by the LP heater drainage pump. The
drainage of #8 LP heater flows to the condenser through the U type water seal by
itself.
10.2 Activation of LP Heater

10.2.1 Inspection and preparation before activation
(1) Put all valves of the system to the required positions based on the VALVE
INSPECTION CARD.
(2) Carry out the activation general rules of auxiliary system.
(3) The instrument air system has been put into operation.
(4) The condensate system is put into operation normally.
(5) The drain water system can be put into operation.
(6) The deaerator system can be put into operation.
(7) All LP heater water level meters have been put into use.
10.2.2 Put LP heater water side into operation.
(1) Both water injection and venting at water side of LP heater and water injection
and venting of condensate system can be done from low to high in order at the
same time.
(2) Inspect and make sure the inlet and outlet water valves at water side of LP
heater are fully open and the bypass valve is closed.
(3) Slightly open the water level adjusting valve of deaerator and fill water to all
water sides of LP heaters and vent.
(4) Open the all vent valves at water side of HP heaters and then close them.
(5) Pay attention to the change of feed water pumps current, main pipe pressure
and water level of all LP heaters.
10.2.3 The steam side of LP heater is started and put into operation following the turbine.
(1) The emergency system of the main equipment is put into operation and inspect
and make sure the steam extraction check valve of 5th -6th stage are
automatically unlocked.
(2) Open the steam extraction electric valve of 5th -6th stage in order.
(3) Open the air valves from all LP heaters to condenser.
(4) As the inlet steam of the main equipment increases, the temperature rise at
water sides of all heaters should be normal.
(5) Inspect the drain water valves of all LP heaters work normally and the water
level is in normal range.
(6) Close the drain water pneumatic valves of 5th -6th stage of steam extraction
pipeline.
(7) When the load rises to about 20%, inspect and make sure the water level and
water quality of drain water tank are normal, and put the drain water pump into
operation.
10.2.4 Activation of LP Heater on Steam Side in Unit Operation
(1) First put water side into use and then steam side.
(2) Slowly open the inlet water valve at water side of LP heater and open the vent
valve of water side.
(3) After venting at water side of LP heater is over, close the vent valve and slowly
open the outlet water valve at water side of LP heater.
(4) Slowly close the bypass valve at water side of LP heater.
(5) Pay attention to the current change of condensate pump, main pipe pressure
and water level of LP heater.
(6) After the water side has been put into operation for about 15 minutes, the steam
side of LP heater can be put into operation.
(7) Open the steam extraction check valve of all LP heaters.
(8) Slowly open the steam inlet electric valves of all LP heaters to the completely
opening position from low to high in order, and control the outlet water
temperature rising rate of each LP heater is less than 1℃/min.
(9) Open the air valves from all LP heaters to condenser, and pay attention to the
change of condenser vacuum.
(10) Inspect and make sure the drain water valves of all LP heaters work normally
and the water level of LP heater is normal.
(11) Inspect and make sure drain water pneumatic valve of LP heater steam
extraction pipe is automatically closed, and pay attention to the water level
changes all LP heaters.
10.3 Operation and Maintenance of LP Heater

(1) Inspect the drain water adjusting valves of all LP heaters work correctly and all
water level gauges indicate normally.
(2) All steam and water pipeline of heaters have no vibration or leakage.
(3) The drain water pump current, pressure, bearing and gland packing temperature
are normal.
(4) The inlet steam pressure and temperature of each heater and inlet and outlet
condensate temperature difference and end difference are normal.
10.4 LP Heater Shutdown According to Turbine Sliding Parameters

(1) When the unit load decreases to 20% of the rated load, inspect and make sure
the drain water valves of all LP heater steam extraction pipelines are open.
(2) When the water level of the drain water tank decreases to －550mm, inspect
and make sure preselected drain water pump automatically stops.
(3) After the turbine trips, inspect and make sure the steam extraction electric valves
and check valves of all LP heaters are automatically closed.
(4) If maintenance is required after shutdown, please safety measures in the work
permit should be carried out.
(5) Relative maintenance measures should be taken according to the outage time.
10.5 Fault Shutdown of LP Heater

(1) Stop the steam side of LP heater first and then water side should be followed. At
the same time, control the load limit according to the conditions. Close the steam
extraction electric valve of the fault heater and pay attention to the changes of
heater outlet water temperature, deaerator pressure and unit load.
(2) Inspect and make sure the drain water electric valve of fault LP heater steam
extraction pipeline is open.
(3) Close the air valve from the fault LP heater to the condenser.
(4) Open the emergency drain water valve of the LP heater of last stage, close the
drain water isolating valves from last stage to this stage, and pay attention to the
emergency drain water valve of the LP heater of last stage should work normally.
(5) Open the bypass valve on water side of fault LP heater.
(6) Close the inlet and outlet valves of water side of fault LP heater, and pay
attention to the change of condensate flow.
(7) Close the normal drainage and emergency drainage isolating valve of the fault
LP heater.
(8) Open drainage and vent valves on steam and water side of the faulted LP heater,
and inspect and make sure the pressure should decrease to zero.
(9) Complete other relative safety measures.
11 Operation of Deaerator
The deaerator is YCS-1100/180 thermal atomization water spray type deaerator. In

normal operation, the heating steam of the deaerator is from the 4th -stage steam
extraction. The steam form the auxiliary steam system is taken as startup and standby
heating steam.
This equipment is applicable to constant pressure and sliding pressure operation
under the set pressure. Constant pressure operation is under the set pressure. The
heating steam of Assistance enters the deaerator through the motor operated adjust
valve. According to the internal set pressure (0.147Mpa.a) of the deaerator, it will
automatically adjust the valve opening to control the flow of the inlet heating steam.
According to the flowing direction of the water, from top to bottom, the high pressure
deaerator is divided into steam venting section, spray device (consisting of water inlet
pipe assembly and nozzle), space section and packing section. The main condensed
water, feedwater make-up and all other qualified drains enter the spray device of the
deaerator. Under the effect of pressure difference, the rotational water sprays down
like the shape of membrane from the several spring coils spray a mouth. Heat steam
from pour the water dish filler layer on the side into, at pour the water dish fold to flow
to wear a line. The primary heating steam rises from the bottom of the packing,
passing through the packing and the water distribution spacers, it passes through the
hollow part and outside surface of the water skirt inside, and gradually meets the inlet
water to perform heat exchange. When the inlet water is heated to the saturation
steam temperature corresponding to the operation pressure of the deaerator, the
oxygen and other incondensable gases dissolved in the water will be isolated from the
water and vented to the atmosphere through the vent pipe of the steam/water
separator at the top of the desecrator. The inlet water implements the first
deoxygenation in the spray atomization section and finishes the second deoxygenation
in the packing. The deoxygenated water flows down in the deaerator, passing through
the water distribution pipe of the storage tank. It is collected in the storage tank.
Establish H.P. heater drain inlet at the end of deaerator , For reduce H.P. heater
drain inlet to in addition to the impact of the piece inside the oxygen machine, Establish
the stainless steel blocks plank, H.P. heater drain inlet to carry on separation towards
enter of highly. The heat transfer coefficient of this kind of deaerator is high; it can heat
the water to satisfy the requirements in short time and reach the deoxygenation and
heating effect.
11.2 Activation of Deaerator

11.2.1 Inspection and preparation before activation of deaerator
(1) Put all valves to the required positions based on the VALVE INSPECTION
CARD.
(2) Carry out the activation general rules of auxiliary system.
(3) The instrument air system has been put into operation.
(4) The condensate system is put into operation normally.
(5) The condensate system has been put into operation normally and the water
quality is good.
(6) The deaerator cleaning is good.
(7) The water level gauge of deaerator has been put into use normally.
(8) The operating pressure of the deaerator safety valve has been calibrated and it
meets the standard.
11.2.2 Activation of Deaerator
(1) Open the water level adjusting valve of the deaerator and close it when water is
filled to the deaerator to the normal water level.
(2) Open the electric valves from the auxiliary steam header to the deaerator. Adjust
the steam governing valve from auxiliary steam header to deaerator, and pay
attention that the temperature of deaerator should raise slowly. Maintain the
pressure of deaerator within 0.147Mpa, and the water temperature of it satisfies
the feeding water requirement for boiler.
(3) After the deaerator is started up, keep the deaerator pressure at about
0.147MPa.
(4) When the pressure of extraction steam of the 4th stage is more than or equal to
0.147MPa, inspect and make sure the electric valve and the check valve of the
extraction steam of the 4th stage are automatically open.
(5) When the unit load is more than 20% of the rated load, the drainage valve of
extraction steam pipeline of the 4th stage is automatically closed.
11.3 Normal Operation & Maintenance of Deaerator

(1) The deaerator pressure is normal.
(2) The water temperature of deaerator is normal.
(3) The water level of deaerator is normal.
(4) The oxygen content of deaerator outlet water is normal.
(5) The deaerator steam and water system has no vibration and no leakage.
(6) When the deaerator is in cold state startup, cooling water of 25% of the
deaerator capacity with temperature at 20℃ should be filled into it, and then it
can be heated.
(7) Strictly follow the specified temperature and pressure raising speed.
11.4 Shutdown of Deaerator System

(1) The deaerator stops following the shutdown of the unit.
(2) When the pressure of extraction steam of the 4th stage is less than or
equal to 0.147MPa, inspect and make sure the electric valve and check
valve of the extraction steam of the 4th stage are automatically closed.
Inspect the pneumatic adjusting valve of auxiliary steam to the deaerator is
automatically opened, and adjust the deaerator pressure at 0.147MPa.
(3) If there is no water supplied to the boiler, the heating steam source of the
deaerator can be deactivated.
(4) Take relative maintenance measures according to the shutdown time.
11.5 Troubleshooting for Deaerator
11.5.1 The deaerator pressure rises.
11.5.1.1 Causes
1) The unit is in overload operation.
2) The steam flow from continuous blowdown system is too high.
3) The drain water capacity of HP heater is too high or it contains steam.
4) The deaerator water level adjusting valve is closed due to misoperation.
5) The adjusting valve from the auxiliary steam header to the deaerator is opened
due to misoperation.
6) The meters are out of work or the transmitter is in fault.
11.5.1.2 Solutions
1) If the deaerator pressure rises, check the meter to see whether the deaerator
pressure really rises.
2) If the automatic control of deaerator water level is in fault, it should be switched
to manual mode to keep the deaerator water level normal.
3) If the unit load increases too quickly or the unit operates in overload condition,
the unit load should be decreased.
4) Inspect whether the adjusting valve of auxiliary steam to the deaerator works
normally, close it if necessary.
5) If it is ineffective after trouble shooting and the pressure continuously rises, the
continuous blowdown and HP heater steam side should be deactivated, the unit
load should be decreased, and the electric overflow water valve of deaerator to
prevent the deaerator exceeds pressure severely.
11.5.2 Increased Water Level of Deaerator
11.5.2.1 Phenomena
1) The water level indication of the deaerator rises.
2) The deaerator water level high alarms.
3) The overflow electric deaerator works.
11.5.2.2 Causes
1) The deaerator water level automatic control is in fault or the bypass valve is
opened due to misoperation.
2) The feed water system is in fault.
3) The water level gauge of the deaerator is in fault.
11.5.2.3 Solutions
1) Calibrate the water level gauge to judge whether water level really rises.
2) Inspect whether the water level adjusting valve of the deaerator works normally.
If necessary, switch it to manual mode. If the bypass valve is opened due to
misoperation, it should be closed.
3) If the water level increases to 2800mm, the overflow valve should work. If it
refuses to work, it should be manually opened. If necessary, open the water
discharge valve at the bottom of the deaerator to let water get to the normal
level.
4) When the water level continuously increases to 300mm, inspect and make sure
the electric valve and the check valve of the extraction steam of the 4th stage
and the inlet water adjusting valve of the deaerator are closed, relevant drainage
valve is automativally opened, or it should be manually operated.
5) Inspect whether condensate, feed water flow and condenser and drum water
levels are normal.
6) If it is ineffective after trouble shooting above, it should be reported to the shift
leader to require for shutdown trouble shooting.
11.5.3 Low Level of deaerator.
11.5.3.1 Phenomena
1) The water level indication of the deaerator decreases.
2) The deaerator water level low alarms.
11.5.3.2 Causes
1) The deaerator water level automatic control or water level gauge is in fault.
2) The water discharge valve and safety valve of condensate system are opened
due to misoperation.
3) The water discharge valve at the bottom of the deaerator is opened due to
misoperation.
4) The boiler is in tube explosion state or the feed water system has leakage.
5) The output of the condensate pump is insufficient or the condensate pump is in
fault.
11.5.3.3 Solutions
1) Calibrate the meter to see whether the water level really decreases.
2) If the water level automatic control is in fault, it should be switched to manual
mode. If necessary, open the bypass valve of the water level adjusting valve to
recover the deaerator to normal water level.
3) If the condensate pump is in fault, it should be switched to the standby pump.
4) Inspect whether the water discharge valve at the bottom of the deaerator and the
relevant valve of the feed water system are tightly closed or opened due to
misoperation.
5) Inspect whether the condensate and feed water flow and the condenser and
drum water levels are normal or not.
6) When the deaerator water level decreases to 500mm and it delays for 2 seconds,
the feed water pump trips.
12 Operation of Motor-driven FeedWater Pump
12.1 Overview of the system

The system has type speed adjusting feed water pumps. In normal
operation, the single one is matched with the 200MW turbine-generator unit with
% capacity.
12.2 Startup of Motor-driven Feedwater pump

12.2.1 Inspection Before Startup
(1) Confirm the maintenance of electric feed water pump is over, the site is clean
and the heat protection of pipelines is good.
(2) Inspect all instruments are correctly connected and inspect and make sure the
instrument connecting wires and pipe connection are stable and secure.
(3) The electrical circuit and motor insulation tests meet the standards.
(4) All interlock protection tests of electric feed water pump have been done and
meet the standard.
(5) Start the auxiliary lubrication oil pump, and inspect and make sure the operation
condition is good, the oil system has no oil leakage, the oil return of all bearings
is clear, the pressure of main pipe after the lubrication oil filter is above MPa,
the oil level in oil tank is normal, the lubrication oil filter is put into use and the
hydraulic coupler is normal.
(6) Confirm the deaerator water level is normal and its water quality is good, the
temperature of water in deaerator water tank met required temperature of
supplied boiler water.
(7) Confirm the condensate pump has been started up and is in normal operation,
and put the electric pump sealing water system into operation.
(8) The closed type and open type cooling water systems are put into operation
normally.
(9) Slightly open the inlet valve of the booster pump to fill water to the electric feed
water pump; open the air vent valve and close it when there is water out of it.
(10) Fully open the inlet valve of the booster pump and pay attention to monitor the
sealing water differential pressure should be at about 0.1MPa.
(11) Open the minimum flow recirculation adjusting valve of the electric feed water
pump.
(12) Inspect and make sure the electric pump rotation speed control device is in
MANUAL and the rotation speed regulator is put at the minimum value position.
12.2.2 Startup
(1) Deactivate the interlock for motor-driven pump and adjust the opening of spoon
tube of the hydraulic coupler to zero.
(2) Start up the lubrication oil pump and inspect and make sure the oil return of all
bearings are clear and the lubrication oil pressure is above 0.17MPa.
(3) Put the cooling water of feedwater pump into operation.
(4) Put sealing and cooling water of feed water booster pump into use.
(5) Start up the feed water pump and pay attention to the current return time and the
recirculation valve opening is normal.
(6) When the lubrication oil pressure is more than 0.25MPa, inspect and make sure
the auxiliary oil pump automatically stops.
(7) Put the lubrication oil, operation oil coolers and motor air cooler into service in
time and ensure the outlet temperature of each heat exchanger is within normal
range.
(8) Open the outlet electric valve of the feed water pump and the manual valve of
the intermediate tap.
(9) Gradually increase the rotation speed of the feed water pump and ensure the
feed water pressure and flow meet the requirements of boiler, and put the spoon
tube in the automatic control mode.
(10) When the feed water flow is t/h, inspect and make sure the recirculation
valve of feed water pump should be automatically closed.
(11) The first steam-driven feed water pump can be started according to load of unit.
12.3 Normal Operation & Maintenance of Motor-driven Feedwater Pump

12.3.1 Current of motor and outlet pressure of pump are normal.
12.3.2 Level of oil tank, pressure and temperature of working oil and lube oil are normal.
12.3.3 Temperature of bearing and motor winding is normal.
12.3.4 Differential pressure and temperature of sealing water are normal.
12.3.5 Pump and motor have no abnormal sound and vibration.
12.3.6 Dosing valve of running pump is opened; dosing valve of standby pump is closed.
12.3.7 Check state of standby pump is normal.
(1) Operation of auxiliary lube oil pump is normal.
(2) Outlet motor of feed water is opened, and feed water pump cannot rotate
reversely.
(3) Check that intermediate tapping insolating valve is opened.
(4) Operation of feed water pump sealing water is normal.
12.4 Shutdown of Motor-driven Feedwater Pump

(1) Opening degree of spoon tube of feed water pump needs to be shut down is
switched to manual, decrease opening degree to zero gradually, pay attention to
main pipe pressure and change of flow.
(2) When feed water flow is less than 138t/h, check the recirculation valve should be
opened automatically.
(3) Release interlock of feed water pump, start auxiliary oil pump, shut down feed
water pump.
(4) Close outlet motor valve.
(5) Stop cooler water supply.
(6) Operation of pump group meets the requirements.
12.5 Solutions for Faults

12.5.1 Emergency Shutdown Conditions of Motor-driven Feed Water Pump
(1) Pump group vibrates greatly or there is obvious metal friction sound inside
pump.
(2) Motor smokes and gets on fire.
(3) When oil system is on fire and cannot be put out which threaten safety of pump
group.
(4) Any one of the bearing in pump unit smokes.
(5) Feed water pump is corroded by steam greatly.
(6) Pipeline of feed water pump breaks and cannot be isolated.
(7) Pump tripping protection value has been arrived but feed water pump refused to
act.
(8) When it endangers safety of equipment and personnel.
12.5.2 Emergency Shutdown Operation of Pump
(1) Press emergency button or press shutdown button of pump.
(2) Check that auxiliary oil pump starts normally and oil pressure is normal, or start
oil pump manually.
(3) Check standby feed water pump starts automatically, and current and pressure
are normal, but feed water pipe is broken, and it is forbidden to start the pump.
(4) Close outlet motor valve of fault pump and intermediate tap insolating valve and
spoon tube is set to be zero.
(5) Record the coasting time of feed water pump.
(6) Complete other operation related to shutdown of pump.
12.5.3 Conditions of Fault Shutdown of Pump
(1) Pressure after balancing disc exceeds limit and axial displacement and
current of motor exceed limit obviously.
(2) Vibration of any one bearing of pump unit exceeds allowable value.
(3) Spoon tube is blocking and automatic regulation is out of control.
(4) Feed water system leaks, but it is not threatening operation of pump group.
(5) Inlet oil temperature of working oil cooler is more than 100℃, measures are
taken in vain.
(6) Inlet oil temperature of lube oil cooler is more than 75℃.
(7) Bearing temperature of pump group is more than 80 ℃ or thrust bearing
temperature is more than 85℃.
(8) Motor winding temperature is more than 120℃.
(9) Pressure difference of inlet strainer of feed water pump is more than 0.06MPa.
(10) Level of oil tank increases abnormally or oil level is excessively low and
cannot be recovered in time.
12.5.4 Emergency Shutdown Procedure of Pump
(1) Report to unit leader or shift leader for preparation of emergent shutdown.
(2) Start standby pump and check if the operation is normal.
(3) Complete other operation of normal startup of pump.
(4) Shut down fault pump, and set the pump to be state which is needed.
12.5.5 Motor-driven feed water pump lubrication oil pressure is low
12.5.5.1 Phenomena
1) Indication of lube oil pressure gauge decreases.
2) Temperature of bearings in feed water pump group increases, alarming for high
temperature.
12.5.5.2 Causes
1) Main oil pump is out of control.
2) Oil filter is dirty.
3) Pipe (with pressure) leaks or breaks.
4) Oil level of oil tank is low or oil quality is unqualified.
5) Sequence valve and relief valve are in trouble.
6) Check valve of auxiliary oil pump is not tight.
12.5.5.3 Solutions
1) When lube oil pressure decreases to 0.1MPa, alarm for low oil pressure and
auxiliary oil pump started automatically, or started manually
2) When pressure difference of oil filter is 0.06MPa, there should be alarm, and
switch to standby oil filter as well as inform the maintenance for solutions at the
same time.
3) When oil pressure decreases, monitor temperature of bearings strictly, when
temperature of bearing exceeds limitation, shutdown for failure.
4) If lube oil pressure decreases to 0.08MPa, feed water pump trips or shut down
the pump emergently.
12.5.6 Excessive High Temperature of Lube Oil for Feedwater Pump
12.5.6.1 Phenomena
1) Indication on temperature gauge of lube oil increases.
2) Temperature of bearings increases and alarm for high temperature
12.5.6.2 Causes
1) Lube oil pressure is low.
2) Cooling water flow is not sufficient.
3) Lube oil cooler is dirty.
4) Fusible plug melts.
12.5.6.3 Solutions
1) Increase cooling water flow.
3) If lube oil pressure is excessively low, treat as oil pressure decreasing.
3) If oil temperature is high or temperature of bearing exceeds limitation, shut down
pump for failure.
12.5.7 Operation of hydraulic coupler is abnormal
12.5.7.1 Phenomena
1) Temperature of working oil cooler inlet increases abnormally.
2) Working oil pressure is low.
3) There is abnormal sound or great vibration in coupler
4) After startup of pump group, speed failed to increases, temperature of working
oil cooler inlet exceeds limitation or coupler smokes.
12.5.7.1 Solutions
1) If working oil pressure is low, check position of spoon tube, overpressure valve
and fusible plug and so on.
2) If working oil temperature increases, increase cooling water flow, check out
causes of failure, try to eliminate failure.
3) Temperature of working oil cooler inlet increases to 130℃, feed water pump
trips.
12.5.8 Feed Water steam corrosion
12.5.7.1 Phenomena
1) The current of feed water pump swings and decreases.
2) Outlet pressure of feed water pump swings and decreases.
3) Flow of feed water pump and decreases.
4) There is noise inside of feed water pump and vibration of pump group increases
12.5.8.2 Causes
1) Water level of deaerator is low and pump have not trip.
2) Inlet strainer of feed water pump or booster pump is blocked.
3) Flow of feed water pump is low and recirculation valve have not opened.
12.5.8.2 Solutions
If feed water pump is corroded by steam, shut down the pump for emergency.
13 Operation of HP heater

HP heater adopts big bypass, when any one of three HP heaters is in trouble, open the
bypass to supply to economizer. Compared with small bypass, the system can be
simplified, adoption of valve can be reduced, and reducing cost. HP heater drainage is
cascade drainage mode, that means from heater with higher pressure discharge to
heater with lower pressure and then to deaerator. For HP heaters drainage, there is an
emergency drainage pipeline connected to HP heater emergency drainage expander.
13.2 Activation of HP heater

13.2.1 Checking and preparation before startup
(1) All valves are set to needed position according to “valve inspection valve”.
(2) Execute startup general rule of auxiliary system
(3) Flushing of heater and pipeline is qualified.
(4) Corresponding interlock protection test is qualified.
(5) Startup of instrument air system is normal.
(6) Startup of condensate system is normal.
(7) Drainage system can be started.
(8) Startup of feed water deoxidize system is normal.
(9) Check HP heater safety valve triggering pressure is normal.
(10) Water levels of all HP heaters were put into operation.
13.2.2 Water side of HP heater is put into operation
(1) Open primary and secondary water injection valves for HP heater.
(2) Open air vent primary and secondary valve of HP heater water side close the
valve after air is vent completely.
(3) Check if water level of steam side of HP heater increases ensures that if there is
leakage.
(4) HP water side pressure is the same as feed water pressure, close HP heater
inlet water injection valve.
13.2.3 Steam side of HP heater put into operation
(1) Outlet water temperature of HP heater is close to deaerated water temperature.
(2) Check that stage 1st-3rd stage extraction check valves have been unlocked.
(3) Check that stage 1st-3rd stage extraction pipeline drain valves are opened.
(4) Open stage 1st-3rd stage extraction motor valves slowly, temperature increasing
rate of HP heater water side should be controlled around 1 ℃/min.
(5) Open air valves from HP heater to deaerator slowly.
(6) After steam side of HP heater puts into operation; check that stage 1st-3rd stage
extraction drain valves are closed.
(7) Check that action of emergency drain valve is normal, which can keep water
level of HP heater within the normal range.
(8) When pressure of #3HP heater steam side is 0.2MPa more than pressure of
deaerator, HP heater drain water to deaerator.
(9) Check that normal drainage control valve acts normally, emergency drainage
control valve is closed, water level of HP heater is normal.
13.2.4 HP Heater Activaiton during Unit Normal Operation
(1) Startup of HP heater during normal operation of unit, the time for warming up
of HP heater should be longer.
(2) If trouble shooting only refers to steam side, and water side is still running,
startup of steam side of HP heater is carried according to steam side startup
procedures.
(3) If trouble shooting refers to steam side, after maintenance completes, the
system has to be recovered to the same state before startup,
(4) Startup of HP heater is carried out according to the procedures in items 13.3.2
and 13.3.3 strictly.
13.3 Maintenance of HP heater

(1) Check that water level change of HP heater, keep the normal water level, the
maximum change of water level should not be more than ±50mm, low water
level operation and high water level operation should be prevented.
(2) Check the difference between remote water level meter and local water level
meter.
(3) During operation, check if inlet and outlet temperature of HP heater feed water
and heater difference between is normal, if there is deviation, check if extraction
and water level is normal.
(4) Check opening degree of drainage control valve and action of the valve to detect
if there is leakage on HP heater.
(5) When water level increases quickly, and alarm for high water level, find out
causes, if emergency drainage valve is opened, and water level increases
continuously, and vibration and impact occur, this may caused by broken of HP
heater pipelines, disconnect HP heater right away.
(6) Equipment is without abnormal vibration or noise.
(7) No leakage occurs in safety valves.
13.4 Shutdown of HP Heater

13.4.1 HP Heater Shutdown According to the Sliding Parameters of Turbine
(1) When load of unit is reduced to 20%, close 1st-3rd stage extraction motor valves
in order.
(2) Check extraction pipeline drainage pneumatic valve is opened.
(3) Open HP heater emergency drainage control valve, keep water level is normal.
(4) Complete other shutdown operation according to requirements.
13.4.2 HP Heater Shutdown during Normal Operation of Unit
(1) Close stage 1st-3rd extraction motor valves slowly, check load of unit should be
less than 200MW, feed water temperature decreasing rate should be 1 ℃
/min and change of main and reheated steam temperature.
(2) Close 1st-3rd stage extraction check valve.
(3) Check 1st-3rd stage extraction pipeline drainage valves are opened.
(4) Open HP heater emergency drainage control valve to keep normal water level.
(5) Close insolating valve from HP drainage to deaerator.
(6) Close air valves from HP heater to deaerator.
(7) If isolating water side at the same time, wait until steam side is fully stopped and
pressure is released, water temperature of HP heater are the same, and then
close HP outlet three way valve to make water flow through bypass, strengthen
monitoring of feed water flow.
(8) Close the inlet motor-driven valve of HP heater.
(9) Open HP heater steam side and water side drain valve, air vent valve till
pressure of steam side and water side decreases to zero, and steam and water
are discharged completely, inform maintenance personnel to deal with.
13.5 HP Heater Troubleshooting

13.5.1 Emergency Shutdown Condition
(1) The steam water pipes or valves of heater break and have the potential to
damage the human body or equipment.
(2) The water level of heater keeps on rising continuously and fails to be removed.
The water level rises to the high II value.
(3) All the level meters of heater fail and the water level cannot be monitored.
(4) Water level protection of heater fails.
13.5.2 Solutions for Heater Emergency Shutdown
(1) If any one of the emergency shutdown conditions happens, disconnect the fault
heater and the water side flow through the bypass and reduce the load properly
according to the regulation.
(2) When the heater was shut down, adjust the main and reheating steam and the
related parameters in the normal range.
(3) Check to ensure steam extraction motor valve and check valve of stopped
heater are closed, and the drainage valve is open.
(4) Finish other related operations.
13.5.3 Increased Water Level of Heater
13.5.3.1 Phenomena
1) The heater water level indication rises.
2) Heater water level alarms with a high level.
3) Heater output water temperature decreases.
13.5.3.2 Causes
1) Automation of drainage adjusting valve fails.
2) Heater leaks.
3) Water level meter fails.
13.5.3.3 Solutions
1) If the operator finds the heater water level is abnormal, he should check the local
water level meter.
2) Check whether the normal drainage pneumatic adjusting valve and emergency
drainage pneumatic valve work normally or not.
3) If the problem is the leakage of heater pipes, the heater should be shut down
and isolated. Contact with the maintenance personnel to treat the problem.
4) If the water level reaches high II value, the heater water level protection acts;
otherwise, shut down the heater manually.
14 Operation of Fire Resistant Oil System
14.2 Technical Specifications

Fire resistant oil pump motor
Motor power: 30KW
Motor voltage: 380V
Motor frequency: 60HZ
Rotation speed: 1760rpm
Power coefficient: 0.89
Fire resistant oil circulation pump motor
Motor power: 1.5KW
Motor voltage: 380V
Motor frequency: 60HZ
Power coefficient: 0.76
Fire resistant oil regeneration pump motor
Motor power: 0.55KW
Motor voltage: 380V
14.3 EHC Pump Activation

14.3.1 Inspections and Preparations before Startup
(1) Turn all the valves to the required position according to VALVE CHECK CARD.
(2) Implement auxiliary system operation general rules.
(3) Speed adjusting oil tank volume is over than 1200L.
(4) Put enclosed cooling water system into operation.
(5) Put the instrument compressed air system into operation.
14.3.2 Activation of System
(1) Start up fire resistant oil and check to ensure it operates normally.
(2) Start up fire resistant circulating pump and check the current is normal.
(3) If oil temperature in oil tank is over 35℃, shut down one set fire resistant
pump and check pressure normal.
(4) Put fire resistant system into interlock.
14.4 Maintenance & Inspection During Operation

(1) Oil level in fire resistant oil tank is normal.
(2) Fire resistant oil pump current is normal.
(3) Control oil, safety oil pressure is normal.
(4) Oil temperature control valve works normally.
(5) Fire resistant circulating pump operates well.
(6) Cooling regeneration system operates well, neutralization index ≤0.5mgKOH/g.
14.5 Shutdown of the System

(1) When turbine is tripped by operator, fire resistant oil pump can be shut down.
(2) After shut down, if no other maintenance work, the fire resistant oil
regeneration pump should keep long time operation.
(3) Finish all related operation
14.6 Regular Work

14.6.1 Schedule
14.6.2 Switching of fire resistant pump
(1) Check the interlock activation.
(2) Check to ensure standby fire resistant oil pump starting up normal.
(3) After standby fire resistant oil pump operates several minutes, switch the
selection switch to the pump, check operating pump shut down automatically
and fire resistant oil pressure is normal.
15 Water Ring Vacuum Pump Operation

There are three vacuum pumps in the vacuum pipe system of condenser. Two pumps
are main vacuum pumps with which the function is to extract the non-condensing gas
and partial steam that has not become condensate yet, and to build, maintain the
vacuum of vacuum system to make sure the normal operation of unit. The rest one
pump is a water chamber vacuum pump whose function is to extract out the air in the
chamber on water side of condenser before the unit startup, and to make the
circulating water fill the water side of the condenser in a short time, and to reduce the
startup time of unit. System is designed with pipes and valves which would be used for
the working water and makeup water from condensate system.
15.2 Startup of Water Ring Vacuum Pump

15.2.1 Inspection and Preparation before Activation
(1) System’s valves should be put to the position required in the Valve.Inspection
Card.
(2) Execute the auxiliary system activation general rules.
(3) The instrument air system activates normally.
(4) Open cooling water system activates normally.
(5) The condensate system activates normally and the gas water separator has
water filled to the high level.
(6) The condenser has the condition to extracting the vacuum.
(7) Implement operation general rules of auxiliary rotating machine
15.2.2 Activation of Vacuum System
(1) Start up one vacuum pump in order and make sure the sealing water pump
works normally and the vacuum pump operates normally.
(2) When the front and back pressure difference of secondary valve of vacuum
pump inlet is bigger than 4KPa, check the valve opens automatically and the
condenser vacuum rises gradually.
(3) Start up the second vacuum pump with the same method.
(4) When the condenser vacuum is bigger than 88KPa, shut down one vacuum
pump and put it into interlock.
(5) Check to make sure the bearing vibration, temperature, sound and gas water
separator water level of vacuum pump unit are normal.
15.2.3 The water chamber vacuum pump follows the same method.
15.3 Normal Operation & Maintenance

(1) Vacuum pump’s sealing water pump works normally. The sealing water pressure,
temperature and flow are normal.
(2) The current and temperature of vacuum pump motor are normal.
(3) The vacuum of condenser is normal.
(4) Gas water separator’s water level is normal.
(5) Vacuum pump cooler works normally.
(6) Vacuum pump bearing vibration and temperature are normal.
15.4 Shutdown of Water Ring Vacuum Pump

(1) Make sure that the main unit is shut down and the requirements for vacuum
pump shutdown are met.
(2) Release the interlock of vacuum pump.
(3) Shut down the vacuum pump in order; check to make sure that the secondary
valve at vacuum pump inlet is closed automatically and the vacuum pump is out
of service.
4) Close the water makeup valve of gas water separator.
(5) Shut down the vacuum pump’s cooler.
(6) If the pump needs repair after shutdown, execute the maintenance according to
the safety measurements prescribed in work permit.
(7) If the pump has been out of service for 2 days, discharge the residual water in
the pump and separator.
(8) If the pump has been shut down for more than two weeks, use the vacuum
method to dry the pump or rotate the coupler for several rounds manually.
15.5 Regular work

15.5.1 Schedule
15.5.2 Vacuum Pump Switchover
(1) Check to make sure the standby pump sealing water works normally and the
standby pump is in the normal standby state.
(2) Release the standby pump’s interlock.
(3) Activate the standby pump and check to make sure it works normally.
(4) Check to make sure the vacuum pump inlet primary valve opens normally.
(5) Shut down the operating pump and check to make sure the condenser vacuum
is normal.
(6) Put it into interlock.
16 Gland Seal Steam Supply System

The steam turbine gland seal steam system produced by Haerbin Heavy Type Motor
Plant uses self sealing system. When the unit is in normal operation, there is no need
to supply the steam from the external system, and the leaking steam from HP, IP gland
seal will be sent to LP gland seal after temperature reducing. The rest leaking steam
will have the over flow to the condenser. During the startup of unit, the standby steam
source will supply the steam to HP, IP and LP gland seal.
The gland seal system is automatic which can protect the steam turbine from water.
Each gland seal includes several gland seal discs which would be separated by the
ring chamber used to collect the leaking steam. The outside chamber of gland seal
should maintain some negative pressure to prevent the steam leakage. The gland seal
system has gland seal pressure and temperature automatic regulating device,
overflow pressure releasing device and the gland seal extraction device. The steam
source of gland seal system should meet the requirements of the cold state and hot
state startup and shutdown.
Auxiliary steam used by gland seal is from the auxiliary steam whose inlet has
permanent filtering net.
The adjustor controls the opening degree of the steam-supply adjusting valve and
maintains the steam supplying main pipe pressure at 0.105MPa. Since the mixed
temperature of leakage steam from HP and LP gland seal is over than the permitted
temperature of LP gland seal, and by way of preventing the LP rotor bending caused
by the LP gland seal heated by steam with the higher temperature, the steam supplied
to LP gland seal should have the temperature decreased through desuperheater;
therefore, a desuperheater is installed before the LP steam supplying main pipe. The
water source of spraying desuperheater is condensate. The spraying water amount is
controlled by the temperature adjustor. Maintain the steam supplied to LP heater is
150℃. When the load of unit reaches 50% of rated load and the leaking steam from
main steam valve’s rod and HP and IP gland seal is enough to supply the consuming
amount of HP and IP gland seal, the steam supplying adjusting valve are all closed.
There is one device which can adjust the temperature and pressure reliably and meet
the requirements of the steam supplying parameters of HP, IP and LP gland seals.
There is one 100% capacity gland seal cooler.
There are two 100% capacity electrical gland seal air fans that will discharge the
non-condensing gas in gland seal cooler. The two air fans are standby each other.
16.2 Activation of Gland Seal Steam Supply System

16.2.1 Preparation and Inspection before Activation
(1) System’s valves should be put to the position required in the Valve inspection
card.
(2) Execute the auxiliary system activation general rules.
(3) The air for instrument system activates normally.
(4) Auxiliary steam system activates normally.
(5) The condensate water system activates normally and the LP casing water spray
is activated.
(6) U type tube of gland seal cooler has water filled.
(7) The drainage system is activated.
(8) The turning-gear works normally.
(9) Condenser has filled with circulating water.
16.2.2 Activation of Gland Seal System
(1) The activation of gland seal air fan is normal and put into interlock.
(2) Open the gland seal steam supplying isolated valve.
(3) Open the gland seal steam supplying adjusting valve.
(4) Put the gland seal pressure adjusting valve and temperature adjusting valve
into automatic mode, check the action of the valves.
(5) After the enough warming of the gland seal steam main pipe, close the drainage
valve.
(6) Adjust the gland seal and temperature normal.
16.3 Maintenance During Normal Operation

(1) Gland seal cooler’s U type tube works normally.
(2) The temperature of steam supplied to LP gland seal is 150℃.
(3) LP gland seal main pipe pressure is 9.2kPa.
(4) Seal fan operates normally.
(5) Seal cooler negative pressure (around -0.5Kpa) normal.
16.4 Shutdown of Gland Seal System

(1) Make sure that the unit is shutdown and the vacuum is zero.
(2) Close the gland seal steam supply isolating valve and the control valve.
(3) Check if the LP gland seal temperature is lower than 150 ℃ , close the
temperature governing valve.
(4) Close the gland seal desuperheating water isolating valve.
(5) Gland seal fan shutdown
(6) Deactivate the automation of the glands seal pressure and temperature.
(7) Open the drain valve of the gland seal main pipe.
(8) Complete the other related operations.
17 Operation of Bypass System

This unit is equipped with the HP and LP bypass valve system. The steam turbine HP
bypass valve system capacity is 70% VWO main steam flow and the LP bypass valve
system capacity is 40%VWO main steam flow.
The scope for the HP bypass valve system is from the front of the main steam piping to
the reheat steam cold section. It includes the desuperheater, all the piping and all the
electrical-operated isolating valves and the drain valves on all the pipelines.
The scope for the HP bypass valve system is from the reheat steam hot section and
then divided into two paths to the condenser. It includes two desuperheaters, all the
piping and all the electrical-operated isolating valves and the drain valves on the
pipelines.
System should satisfy the following functions:
(1) Improve the unit startup performance, and when the unit uses the IP casing
startup under various working condition (cold, warm, hot and super hot state),
the bypass system is put into operation, it can control the boiler temperature and
make it match with the turbine casing metal temperature quickly so as to reduce
the unit startup time, reduce the steam discharge and reduce the consumption of
turbine circulating life time to realize the optimal unit startup.
(2) During unit normal operation. The HP bypass valve device should be equipped
with the overpressure safety protection function.
(3) The bypass should be adapt to the unit constant and sliding pressure operation
mode and cooperate with the unit control to realize the adjusting function.
(4) When the grid fails or the unit shedding the load due to faults, the bypass device
should act quickly to drive the service power, idle rotating, shutdown or maintain
the boiler minimum load operation function to make the unit re-synchronize and
restore the normal operation.
(5) During unit startup, load shedding and load decreasing, the reheaters arranged
at the flue gas high temperature area will be protected from being burnt.
(6) Withdraw the working medium and reduce the noise.
17.2 Activation of Bypass System

17.2.1 LP Bypass Valve
17.2.1.1 Inspection and preparation before unit activation
1) Each valve should be adjusted to the required position according to the Valve
Inspection Card.
2) Execute the general rule for auxiliary system activation.
3) Instrumental air system is put into operation.
4) Condensate system activation is normal.
5) Circulating water system activation is normal.
6) Vacuum system is activated and the condenser vacuum is more than 66KPa.
7) Main monitoring system is activated.
8) Turbine turning gear is put into continues operation.
9) LP bypass valve oil system is put into operation.
17.2.1.2 LP bypass valve oil supply system is put into operation.
1) Check if the oil level of oil tank is normal and if the oil temperature is normal.
2) Check if the LP bypass valve oil system is normal and if it can be put into
operation.
3) Start up an oil supply pump and check if the cooling pump is operating at the
same time.
4) Check if the oil pump outlet pressure and flow is normal.
5) Put the LP bypass valve oil system cooling water into operation.
6) Inform I & C personnel to switch the oil station to the Remote mode.
17.2.1.3 Activation of LP bypass valve system
1) Check if the requirements for LP bypass valve system activation are met.
2) Condenser vacuum is more than 66KPa.
3) Condenser hot well water temperature is lower than 80℃.
4) LP bypass valve desuperheating water pressure is more than 1.4MPa.
5) Put the LP bypass valve into auto mode on the central control panel and check if
its opening degree is zero.
6) Put the LP bypass valve temperature decreasing governing valve into auto mode
and check if its opening degree is zero.
7) With the boiler ignition and pressure increasing, when the reheater pressure
reaches to the setting value MPa, check if the LP bypass valve is opened to
the minimum opening degree (about 10% opening degree).
8) Check if the LP bypass valve and the desuperheating water valve acts normally
and if the temperature at the LP bypass valve rear part is normal or not.
17.2.2 HP Bypass
17.2.2.1 Inspection and preparation before activation
1) Each valve should be adjusted to the required position according to Valve
Inspection Card.
2) Execute the general rule for auxiliary system activation.
3) Instrumental air system is activated.
4) Feedwater system activation is normal.
5) Turbine monitoring system is put into operation.
6) Turbine turning gear is put into continues operation.
7) LP bypass valve can be put into operation.
8) Boiler is prepared for ignition or it is already ignited.
17.2.2.2 The activation of the HP bypass valve oil system is the same as the LP bypass valve
oil system.
17.2.2.3 Activation of HP bypass valve
1) Check if the requirements for HP bypass valve activation are met.
a. LP bypass valve is allowed to be activated.
b. HP bypass valve desuperheating water pressure is more than 18.0MPa.
2) Put the HP bypass valve valve into auto mode on the central control panel, and
check that its opening degree is zero.
3) Put the HP bypass valve temperature reducing adjust valve into the auto mode,
and check if the opening degree is zero.
4) With the boiler ignition and pressure increasing, when the reheater pressure
reaches to the setting value MPa, check if the HP bypass valve valve is
opened to the minimum opening degree (about 10% opening degree).
5) Slowly increase the HP bypass valve pressure to the rolling pressure (the value
will be different under different startup state)
6) Check if the main steam pressure gradually increases to the rolling pressure.
7) Check if the HP bypass valve and the desuperheating water valve work
normally.
8) When the steam enters the HP casing, close the HP bypass valve gradually until
it completely closed, and then the HP bypass valve would be in normal operation
state, and then the setting value would change automatically according to the
increasing of the main steam pressure.
17.3 Maintenance during Normal Operation

17.3.1 Normal operation and maintenance of LP bypass
1) Oil cooling pump operates normally and the strainer differential pressure and the
oil outlet flow are normal.
2) The oil supply pump operates normally, and the oil pressure is normal and there
is no leakage in the system.
3) Oil level and the oil temperature of oil tank are normal.
4) Temperature at the rear part of the LP bypass valve and the temperature of the
LP casing exhaust steam is normal.
5) Reheater pressure and condenser vacuum are normal.
6) Condensate system activation is normal.
17.3.2 Normal Operation and Maintenance of HP Bypass
1) Oil supply pump operates normally, oil pressure is normal, and there is no
leakage.
2) Oil level and oil temperature of oil tank are normal.
3) Regenerative strainer differential pressure is normal.
4) During the bypass system activation, each state indication and signal should be
normal, pressure and temperature should meet the requirements.
5) After the HP bypass valve is closed, check the temperature at rear part of the
valve and the temperature setting value should be normal.
6) Feedwater system activation is normal.
17.3.3 Alarm and protection of LP bypass valve (the following parameters undetermined)
1) Front pressure of LP bypass valve reaches to Mpa and alarms.
2) Front pressure of LP bypass valve reaches to Mpa, LP bypass valve quick
open.
3) Condenser vacuum reaches to 66KPa and alarms.
4) Condenser vacuum alarms when it reaches to 46Kpa and after delay 5 seconds,
LP bypass valve will quickly close.
5) Condensate water of condenser reached to 80℃, it will alarm and after delay 20
seconds, LP bypass valve quick close
6) When LP bypass valve attemperating water pressure reaches to low value, there
will be alarm.
7) When LP bypass valve attemperating water pressure reaches to the low-low
value, LP bypass valve will quickly close in a delay of 5 seconds.
8) When LP bypass valve quickly opens, the maximum limited open degree is 80%.
17.3.4 Alarm and Protection of HP bypass (the following parameters undetermined)
1) When the front pressure of HP bypass valve reaches to Mpa, it will alarm.
2) When the front pressure of HP bypass valve reaches to Mpa, HP bypass
valve quickly opens.
3) When the back pressure of HP bypass valve reaches to high value MPa, it
will alarm.
4) When the back pressure of HP bypass valve reaches to the highest value
MPa, HP bypass valve quickly closes.
5) Condenser vacuum reaches to 46Kpa, delay 5 seconds and HP bypass valve
quickly closes.
6) The differential between the back temperature of HP bypass valve and setting
value is ±10℃, it will alarm.
7) The differential between the back temperature of HP bypass valve and setting
value is ±30℃, HP bypass valve quick close
8) When attemperating water of HP bypass valve reaches to low value, it will alarm.
9) When attemperating water of HP bypass valve reaches to the lowest value, LP
bypass quickly closes in a delay of 5 seconds.
10) When the HP bypass quickly opens, the maximum limited open degree is 80%.
18 Steam-driven Feedwater Pump Operation

The feedwater is unit system. Each unit is set with two pneumatic feedwater pump with
50％ capacity and one electric speed governing feedwater pump with 40％ capacity.
During normal operation, the two pneumatic feedwater pumps are in operation, the
electric feedwater pump can be operated or in standby state. The two pneumatic
feedwater pumps are driven by variable speed turbine（short for small turbine) .
During normal operation, the driven steam source of the small turbine is the fourth
stage extraction of the turbine; the reheated cold stage steam is as the standby steam
source during startup and low load. When the main turbine load is less than 40%, and
the parameters of the fourth stage extraction can not satisfy the small turbine
requirements, the steam source will switch to reheated cold stage steam supply
automatically.
The feedwater pump turbine is produced by Hang Zhou Turbine Manufacturer, and the
feedwater pump small turbine is set with HP fire-resistant oil microcomputer
electro-hydraulic control system which is short for MEH. This MEH system takes the
HP fire-resistant oil as the working medium, and takes the electro-hydraulic servo
valve as the electro-hydraulic interface equipment, and the LP governing valve oil
motor is the actuator, which composes a whole set of completely electric governing
system to control the rotating speed of feedwater pump turbine and satisfy the user
requirements. So this system is reliable and the operation is simple, flexible and
convenient
During unit startup and normal operation, first the MEH outputs the control signal to the
servo plate, and then the servo plate will change oil actuator through servo valve to
change the opening of the governing valve and control the steam flow entering the
feedwater pump turbine, thus the rotating speed of the small turbine is changed. When
the rotating speed of the feedwater pump turbine changes, the rotating speed of the
feedwater pump controlled by it will also change and the outlet flow of the feedwater
pump changes, thus the requirement of the boiler feedwater flow is satisfied
This unit has two steam sources, one is working steam source and another is standby
steam source. Both of these two steam sources use the same steam chamber and the
same nozzle room, they adopt steam distribution by nozzle. The diagram of the steam
admission system is shown in the following drawing：
工作蒸汽进口
抽汽逆止阀
逆止阀
启动用低压
切换阀
蒸汽进口
抽汽逆止阀
备用蒸汽进口电动闸阀
低压主汽阀
低压调节阀锅
炉
给
水
给水泵汽轮机泵
This unit adopts LP auxiliary steam source for startup. During startup, the auxiliary
steam enter the feedwater pump turbine through check valve, electric gate valve, LP
main stop valve and LP governing valve, and at this time, the extraction check valve
and switch valve are closed. As the increase of turbine load, the working steam
parameters also increase. When the turbine load is more than the steam source switch
point, the working steam parameters can satisfy the feedwater flow requirement
required by main turbine power, the auxiliary startup steam source is cut off, that
means when the working condition is above the steam source switch point, the
working steam source (the fourth stage extraction of main turbine) will do work. Within
the range of operating rotating speed: continuous and steady operation within
2840r/min-5945r/min, the minimum rotating speed can maintain the minimum flow
circulating working condition of the feedwater pump. During the above process, the
rotating speed of feedwater pump turbine is controlled by LP governing valve.
When the turbine load decreases, the working steam parameters drop too. When the
load drops below the steam source switch point from high load, which means during
the continuous pressure operation of turbine, the boiler steam pressure keeps no
changing. When the turbine load drops below 40%, the rotating speed of the feedwater
pump should make sure that the boiler steam pressure keeps no changing. During
turbine sliding pressure operation, the boiler steam pressure will change as the change
of the load, and when the load drops below 30%, the minimum operation rotating
speed 2840r/min should be ensured.
When the opening of LP governing valve of feedwater pump turbine is more than 95%,
and the working steam parameters still can not satisfy the above requirements, the
steam source should be switched to standby steam source (cold terminal steam of the
reheater) . At this time, the rotating speed of the feedwater pump turbine is controlled
by switch valve, after the comparison of actual and rated rotating speed, one
difference value will be received, and after the calculation of PID, the opening order
signal of the valve is output to switch valve. When the switch valve opens, at the same
time, the LP governing valve will open until fully opened, and extraction valve on the
LP admission pipe will close automatically, that is to say the standby steam source
(cold terminal steam of the reheater)will do work after the steam admission of the
feedwater pump turbine is switched to it. When the actual rotating speed accords with
the rated rotating speed, that means the opening feedback signal of the switch valve
accords with the signal of valve opening, the electro-hydraulic servo valve on switch
valve will cut the oil inlet and oil discharging of the oil actuator, and the opening of
switch valve is maintained.
As the increase of the turbine load, the parameters of the working steam source and
standby steam source increase too. When the load increases above the steam source
switch point from low load, the working steam source parameters can satisfy the
feedwater flow requirement required by main turbine power, it will switch to working
steam source to do work. Because of the increase of he standby steam source
parameters, the switch valve will be closed gradually to satisfy the feedwater flow
requirement of the main turbine power, and the switch process will be began, during
the switch, the fourth stage extraction check valve of the main turbine will open
automatically, and after the switch valve is fully closed and the switch is finished, the
rotating speed of the feedwater pump turbine is controlled by the LP governing valve.
This unit is single casing, single shaft, and reaction pure condensate turbine without
accessory condenser. Exhausted steam flows into condenser on turbine through
steam exhaust pipe.
General description of structure: casing is composed of external casing (front casing)
and air exhaust casing (rear casing), which are connected by vertical central joint.
Horizontal joint is also between the front casing and rear casing, whose sealing is
tightened by bolts. Front casing is fastened on the front base through claw support.
Guide groove at bottom of the lower casing is matched with front base from to ensure a
fixed center when the casing expands vertically. The dead points for the whole casing
are on rear base. When turbine is heated, front bearing base expands forward with
casing and the rotor expands forward driven by thrust bearing. Rotor is heated and
expands backward taking thrust bearing as the original point. The relative expansion
value between casing and rotor is rather small.
18.2 Steam-driven Feedwater Pump Technical Specifications

18.2.1 Requirements on the Performance of Feedwater Pump & Its Booster Pump
1) Steam-driven feedwater pump and motor-driven feedwater pump share the
same character, which will ensure the parallel operation between each other.
When flow decreases, the lift curve for water pump should rise stably.
2) The pump should be designed to bear thermal shock. After load rejection of
turbine, the allowable feedwater temperature decrease rate is 28℃/S.
3) The double-amplitude value of pump set bearing in all directions should be
below 0.035mm.
4) The coupling between pump and motor should be of gear structure.
5) The cylinder should be welded on piping and the support for central line should
be on pump base of steel structure. The internal components should be
designed as that can be taken out from pump cylinder in a whole set and can be
replaced with core. The core includes all the components of the pump.
6) All the area inside the cylinder flushed by high speed water flow should be
welded with austenite stainless steel to prevent flush corrosion. Protect all the
contact joints in the same way.
7) Pump shaft should be rigid rotor and of relatively high accuracy. Static deflection
should be below 0.02mm.
8) Heat pump should be designed to keep feedwater pump is without thermal
layers which can cause cylinder deformation.
9) Lube oil for steam-driven pump is supplied by small turbine lube oil system.
10) Requirements to service life: the complete pump service life is 30 years. The
service life of mechanical sealing components is 8000 hours.
11) The noise at the point of 1.5m from the shell should be below 85db. (With
sound-proof cover)
18.3 Startup of Steam-driven Feedwater Pump Set

18.3.1 State Specifications of Steam-driven Feedwater Pump Set
The auxiliary steam-driven pump has two startup modes: hot state startup and cold
state startup. When shutdown under the rated load, if startup within half an hour, it is
called hot state startup; if startup 12 h later, it is the cold state startup.
18.3.2 Forbidden Startup Conditions:
1) Speed can’t be controlled within the activation speed of emergency governor
due to power adjustment failure.
2) Abnormal working of emergency governor.
3) Failure of any one of the main I＆C protection devices.
4) Main instrument failure (such as tachometer, vibration instrument and axial
displacement meter)
5) Automatic main stop valve and control valve can’t be closed tightly.
6) Low oil level in the oil tank and oil doesn’t meet the requirements.
7) Clear metallic frication sound can be heard at pump rotating part.
8) Temper difference between the upper and lower pump is over 30℃.
9) Failure of any main oil pumps.
18.3.3 Cold State Startup
18.3.3.1 Equipment and system are complete. Check to see all the valve positions are correct.
18.3.3.2 Contact the I＆C and electrical operators to carry out the relative power supply, and
check the auxiliary compressed air has been supplied.
18.3.3.3 New equipment installation is finished, and the oil system must be flushed and
calibrated to make the turbo oil meet the manufacturer’s requirements. Steam pipes for
HP and LP main stop valves should be flushed clearly before commissioning, and the
it is recommended to use the steam with the parameters of Pmaz=1.373MPa, and
Tmaz=230℃, for 3-5 min each flushing and the flushing interval should be within 10-15
min. Connect the pipes and do the thermal insulation work well after the pipe steam
blowing is finished.
18.3.3.4 Activation of Oil System
1) Start up the fume exhauster of the auxiliary steam-driven oil tank.
2) Start up one main oil pump for oil circulation and check the outlet oil pressure,
motor current, bearing vibration and sound are normal. The Lube oil pressure
is within 0.08-0.25MPa and oil return of each part is normal. Put the oil tank
electric heater or adjust the oil cooler temperature at 40±5℃. Check the oil filter
front and rear pressure difference is less than 0.08 MPa.
3) After pump normal operation, put the other main oil pump and DC emergency oil
pump interlock into operation.
18.3.3.5 Water side of feedwater pump unit has been restored and the steam-driven pump
reverse warming is activated.
18.3.3.6 Turning Gear Startu
1) Confirm turning gear lubrication is normal and joggle the turning gear to confirm
the rotating direction is correct.
2) Rectify turning gear pressure switch and when lube oil pressure on the gauge is
over 0.0785 MPa, turning gear is allowed to put into operation. Otherwise, lock
turning gear startup.
3) Start up turning gear motor to make the turning gear automatic meshed and then
start up the turning gear.
4) After turning gear startup, perform the continuous turning gear operation to the
turbine rotor. To avoid turbine rotor deformation and the vibration should not be
produced after rolling, turning gear should be in continuous operation at least for
45 min.
18.3.3.7 Open gland seal main steam supply valve and drainage valve after the valve of the
auxiliary steam-driven pump. Perform the pipe warming of the gland seal to the branch
steam supply valve.
18.3.3.8 When turbine load is around ８0 MW and fourth extraction pressure is about 0.3 MPa,
open steam return branch valve, main steam return valve and gland seal steam inlet
branch valve of the auxiliary steam-driven pump, maintain the gland seal steam supply
pressure within 0.06-0.07Mpa and steam supply temperature 121-177℃. Note: there
should not be steam leakage at the shaft end and air suction. Otherwise, adjust
through steam return branch valve or the main valve.
18.3.3.9 Slowly open the steam exhaust butterfly bypass of the auxiliary steam-driven pump
and pay attention to the steam-driven pump vacuum condition. When vacuum of the
auxiliary steam-driven pump is approaching that of the steam-driven pump, fully open
the steam exhaust butterfly valve of the auxiliary steam-driven pump and close the
bypass valve of steam exhaust butterfly valve. Note: vacuum of the steam-driven
pump should not decrease, otherwise, ascertain the causes and eliminate the faults.
18.3.3.10 Open the HP and LP electric main stop valve and slightly open the drainage after the
valves. Warm the pipe until the pipes before the HP and LP main stop valves.
18.3.3.11 Open the casing and steam valve shell drain valves of the auxiliary steam-drive valves.
18.3.3.12 Booster Pump Startup:
① Startup conditions:
1) Deaerator water level reaches 2000 mm.
2) Inlet valve of the booster pump is opened and open the pump unit
recirculation valve.
3) Lubricating pressure of steam-driven pump is normal.
4) Warming of the booster pump and main pump is good and upper and
lower pump body differential temperature is less than 30℃.
5) Activation of the mechanical seals and cooling water is in normal operation.
6) Check the oil level, oil pressure and oil cooler are in normal operation.
② Startup and inspection:
A Close the pump warming valve of the steam-driven pump
B Close the booster pump operation switch.
C Check the current sound and vibration are normal and each bearing
temperature is normal.
D Check the inlet and outlet pressure of the booster pump are normal and the
outlet pressure should no less than 1.4 MPa.
18.3.3.13 Steam-driven Feedwater Pump Startup
① Rolling Conditions:
1) Auxiliary steam-driven vacuum is over
A Pump upper and lower temperature difference is less than 30℃.
B Lube oil pressure is within 0.08-0.25 and oil temperature within 40±3℃.
C LP steam source steam pressure is within 0.829-1.275 Mpa and steam
temperature is within 336-350℃
D Each protection test is normal and is put into operation.
② Startup and inspection
1) Restore the emergency governor manually or through the remote operation,
build up primary safety oil pressure, TURBINE RESET indicator light is on
and TURBINE TRIP indicator light is off, meaning the success of latch-on.
2) Open the LP main stop valve manually. Inspect the main stop valve is fully
opened locally and remotely.
3) Set the target rotating speed at 800r/min. Then start speed rising and
perform local thorough inspection.
4) When using the cold state startup, the auxiliary steam-driven pump should
stay for 40 min when at the speed of 800r/min, and then thoroughly check
the unit vibration sound is normal.
5) Set the target rotating speed at 6000 rpm on the MEH operation panel, then
operate the sign △ on the electrical adjustment operation panel and the
speed rising rate is within 300-350r/min. When thoroughly inspecting the
turbine operational condition is normal, the one critical rotating speed can
be crossed quickly.
6) When control signal comes from the MCS and is allowed to put into
operation, BOILER AUTOMATIC indicator light is on and SPEED
AUTOMATIC indicator is off. Then, turbine speed varies from the feedwater
amount signal from the feedwater coordinated control system. In addition,
speed variable rate is automatically limited at 1000rpm/min.
7) When using the hot state startup, when warning up at 600 rpm, it should not
be over 5 min. And then increase the speed to 3000 rpm in a speed rising
rate of 300rpm/min.
8) 4—20mADC feedwater signal from the MCS system can be given
automatically or manually given on the governor. When steam-driven pump
is increased to feedwater outlet pressure which approaches the main pipe
pressure, open the outlet electric valve and pump. Open the feedwater tap
water valve according to boiler requirements.
9) When the speed over 3000 rpm, gradually close the drain valves at all
places. However, the drain valves from the rear casing bottom and main
shaft seal pipe to the condenser should be opened a little.
10) Adjust lube oil temperature timely after the speed is increased. Pay attention
that each bearing return oil temperature should be less than 65℃.
11) During the speed increase process, control unit vibration under 0.08 mm
and the vibration when crossing the critical speed should not be over 0.12
mm.
12) When feedwater flow is over 304t/h, feedwater automatic recirculation valve
should be closed automatically. Otherwise, force it to be closed.
18.4 Operation and Maintenance of Steam-driven Feedwater Pump

1) Check parameters of the steam-driven pump unit are normal and copy readings
on the instruments on time.
2) Check the system has no oil leakage. Water leakage and steam leakage
regularly. If the problems exist, contact the maintenance person for elimination
and take record.
3) Check the bearing vibration, cooling water. Sealing water temperature and
bearing return oil temperature of all the equipment are normal, and smooth.
4) Feedwater mechanical sealing water filter should be switched over timely
according to the water temperature conditions.
5) When lube oil filter differential pressure is 0.08 MPa, switch over timely and
contact the maintenance operator for treatment.
6) Operation mode of seam driven water pump
① Pump Fixed Pressure Operation
When there is one steam-driven pump in operation, the max. Operational
load is 65% of the rated load.
When two in operation, the operational load should be over 40﹪ due to the
limit of the minimum flow. When it is under 40﹪ of the main pump, the
auxiliary steam driven pump has a rotating speed of 4700rpm.
② Pump Sliding Pressure Operation
a) When one steam driven pump in operation, the minimum operational
load is 30%Ne of the main pump due to the limit of turbine minimum
operational speed of 3000 rpm.
b) When two in operation, the minimum operational load is 40%Ne of the
main pump and the auxiliary steam driven pump rotating speed is
around 3250 rpm.
Maintenance Parameters of the Main Pump and Booster Pump
Normal
Name Unit Remarks
range
Bearing temperature of main 100 ℃ pump
℃ 〈90
pump and booster pump shutdown
Mechanical sealing water ℃ 〈80 95 ℃ pump
temperature of main pump
and booster pump shutdown
Differential pressure of
MPa 〈0.06
sealing water filter
Main pump inlet filter
MPa 〈0.06
differential pressure
18.5 Shutdown of Steam-Driven Feedwater Pump

1) Confirm that the steam driven pump has delivered its load to other pump units
before shutdown (Contact the boiler operator to remove AUTOMATIC
FEEDWATER, and then decrease the load gradually and transfer the load).
2) Confirm the operating feedwater pump intermediate tap water valve is opened
and close the tap water valve of the feedwater pump to be shutdown.
3) When feedwater flow is less than 130t/h, open the recirculation water valve.
Otherwise, do it manually.
4) When the feedwater flow is reduced to zero and speed decreased to 3000 rpm,
close the electric valve at the feedwater pump outlet.
5) When the feedwater pump is to be shutdown together with the main turbine,
turbine speed will be decreased from the rated value to 3000 rpm, which could
be done by the feedwater CCS automatically.
6) Press the TRIP button on the control panel or trip the small turbine locally.
LATCH ON indicator light is off and TRIP indicator light is on. Close the main
stop valve and the control valve quickly and the corresponding indicator light are
on and the speed decreases from 3000 rpm. The drainage before the LP main
stop valve will be in operation automatically.
7) Switch the small turbine operation mode to manual again, to be ready for
re-startup.
8) Close the steam exhaust butterfly valve; open the water seal of the exhaust
butterfly valve and the shaft seal is stopped from operation.
9) Record the idling time, stop the booster pump from operating and close the HP
and LP startup electric main stop valve of the shutdown small turbine.
10) When the rotating speed is 1r/min, zero speed detecting relay will be activated,
and the turning gear will be activated automatically. Otherwise, when the speed
is zero, put the turning gear into operation.
11) Open the drainage of the casing and all the steam pipes.
12) When vacuum is zero. Close and leave a little opening of the auxiliary steam
driven pump drainage.
13) When oil temperature is reduced to 35℃, stop the water side of the oil cooler
from operation.
14) Stop the turning gear and AC main oil pump from operation according to the
situations and requirements.
15) If the steam driven pump is in standby state, the shaft seal and turning gear
should be in continuous operation. Open the steam exhaust butterfly valve and
keep the auxiliary steam driven pump in warming up state. The turning gear is
forbidden to be used when during the shaft seal steam supply stage of the
auxiliary steam driven pump.
16) If the steam driven pump is withdrawn from the standby state, open the water
seal valve of the butterfly valve and de-energize the steam exhaust butterfly
valve.
17) When the turbine condenser vacuum is broken, the water seal of the steam
exhaust butterfly can be stopped from operation.
18) If the auxiliary steam driven pump to be shutdown for a long time, the MEH
controller loop should be removed（when restarting the unit, the controller loop
should be connected one hour earlier）, and take effective measures to keep the
auxiliary steam driven pump dry.
18.6 Isolation of Steam-Driven Feedwater Pump Set During Turbine Operation
1) Close the HP and LP electric main stop valve and LP steam source manual
valve.
2) Close shaft seal steam inlet and return valve.
3) Close steam exhaust butterfly valve and bypass valve and put the steam
exhaust butterfly valve water seal into operation.
4) After the drain water is completely discharged, close all the drain valves and
bypass valves.
5) Close the electric valve at the outlet of feedwater pump and then de-energize.
Close the reverse warming tap water valve and attach the tags.
6) Close the inlet valve of the steam pump booster pump and attach the signs. Note
that pressure inside the pump should not be increased.
7) Close the electric recirculation valve, governing valve and stop valve of the
feedwater pump.
8) Open the relevant water discharge and air vent valves of the pump unit.
9) When the pump body temperature is below 80℃, stop the mechanical seal
cooling water supply, stop the lube oil pump and disconnect the power supply.
10) Close the main water inlet and outlet valves of the pump unit.
11) De-energize the booster pump and motor, namely de-energize the main pump of
the electric pump and motor, and attach the warning boards.
12) The maintenance can be carried out when water pressure inside the pump is
zero.
18.7 Small Turbine Test

18.7.1 MEH Static Test for Small Turbine Test
1) Test conditions
MEH static test should be conducted after the overhaul of small turbine or
maintenance of regulating system.
A Check oil level in the tank for small turbine is normal. Oil quality meets the
standards and position of all the valves in oil system is correct.
B Start up flue gas exhaust air fan for small turbine oil tank.
C Start up one AC main oil pump and check the returned oil in the system is
normal without leakage. Activate oil tank electric heater or oil cooler, keep
lube oil temperature within the range of 40±5℃.
D Check all the parts of small turbine regulating safety system are correct:
MEH electro-hydraulic control system supply power. The key switch for
electric overspeed protection test is in the position of NORMAL. CRT
emergency trip indicator is in the position of TRIP. All the HP & LP main
steam valves and control valves are closed. Lights are with normal
indication. The control mode is in the mode of MANUAL.
E Call I&C personnel to deactivate steam pump protection.
F Tests should be conducted before main turbine startup with the supervision
of foreman and the head of operation division on site.
2) Test procedure
A Reset the small turbine by local or remote control. TRIP indicating light is off.
B Press LPSV light button in ETS operation display for small turbine. Main
steam valve will be open fully and LPSV lights are on.
C Manually open steam-driven control valve. Check the control valve is open
slowly and evenly, without jamming. Check valve position indication on MEH
operation panel is matched with local valve openness. After that, turn down
control valve.
D Press TRIP button to stop small turbine. Check main steam valve and
control valve should be closed quickly.
E When static test meets the standards, recover the deactivated protection.
18.7.2 Interlock Test for Low Oil Pressure of Small Turbine Oil Pump
1) Make sure the startup conditions for small turbine main oil pump are prepared.
2) Start up one main oil pump on BTG panel. Activate the interlock switch for oil
pump. Stop main oil pump and the standby pump should be started up by
interlock automatically. Restore one main oil pump operation, the other one is
standby.
3) Press MAIN OIL PUMP TEST button matched with main oil pump in standby
condition on ETS panel. When standby oil pump outlet oil pressure drops to
883Kpa, standby pump is activated by interlock. Red light flashes. Reset START
button indication to be on.
4) Stop the originally running main oil pump. Check the other main oil pump
interlock is normal by the same method. Keep one main oil pump running after
that and activate oil pump interlock.
5) Press EMERGENCY OIL PUMP TEST button on ETS panel. If the pressure
before the tested solenoid valve for DC emergency oil pump drops to 55Kpa, the
DC emergency oil pump will be started up automatically. Restore the tested
button. Stop the DC oil pump.
6) After test, return to the condition before test.
18.7.3 Low Lube Oil Pressure Trip Protection Test for Small Turbine
1) Test conditions:
A Conduct the tests after the overhaul or maintenance of small turbine and the
maintenance of protection system.
B Tests should be conducted before turbine startup.
C Make sure oil system for small turbine is normal. Turning gear meets the
conditions of startup. Deactivate small turbine and other trip protection.
2) Test method:
A Make sure small turbine meets the trip requirements, stop it. Check main
steam valve is open.
B Start up turning gear device on ETS panel or local control panel. Activate
turning gear interlock.
C Disconnect main oil pump interlock switch and oil inlet valve for the low
pressure auto-start pressure switch for the main oil pump outlet. Stop main
oil pump.
D When lube oil pressure drops to 55Kpa, small turbine trips. Make sure main
steam valve should be closed quickly. TRIP lights on ETS & MEH panel are
on. DC oil pump is started up automatically by interlock.
E Close oil inlet valves for the auto-start pressure switch on low pressure of
the main oil pump outlet. Stop the DC oil pump.
F When lube oil pressure drops to 15Kpa, turning gear device trips. TURNING
GEAR green lights on ETS panel are on.
G After the test, return to the conditions before test.
18.7.4 Other Trip Protection Tests for Small Turbine
1) Test condition:
A It is as the same as low oil pressure trip test. Small turbine oil system is
running normally. Contact I & C personnel to deactivate other protective
functions beyond this test.
2) Test procedure:
A Make sure when the small turbine trip conditions are met, stop small turbine
and check main steam valve should be open.
B Contact I & C personnel to connect the protective trip singles of low vacuum,
axial displacement, booster trip small turbine, excessive axial vibration of
small turbine, and low oil level in tank etc by short-circuit. Small turbine
should trip. Make sure main steam valve is closed quickly. Small turbine
TRIP light is on. The relevant protection indication lights are on.
C During low vacuum protection test, disconnect all the trip protection
including low vacuum protection. After open main steam valve, call I&C
personnel to connect the vacuum joints by short-circuit. Then activate low
vacuum protection. Small turbine trips while protection is activated. Low
vacuum protection indicating lights are on.
D When conducting booster pump trip small turbine interlock test, turn the
booster pump power supply to test position. After booster pump is started up,
stop booster pump or send booster pump trip single to realize small turbine
trip.
E After test is finished, return to the condition before test.
18.7.5 Oil Atomization Test for Emergency Trip Device
1) Decrease small turbine speed below 4000rpm.
2) Pull out the isolation handle on the restore device on emergency trip device.
3) Open oil atomization valve slowly to charge oil to emergency trip device. The fly
ball activates and trip indicator change to TRIP position. Take down test
pressure gauge indication.
4) Close oil atomization valve, restore emergency trip device oil valve by reset
button. After trip indicator shows NORMAL, restore isolation handle. Take
records of fly ball restore oil pressure.
5) Compare oil atomization pressure when fly ball activates to the data in last test.
If the difference is huge, find out causes.
18.7.6 Small Turbine Overspeed Protection Test
1) Regulations
A It should be conducted on single turbine. It is a must to disassemble water
pump coupling.
B It should be conducted if the turbine has been running for 6 months or
re-startup one month after maintenance for speed control system.
C Do not conduct overspeed test immediately after oil atomization test.
D Permission from the foreman is a must before the test. Head of operation
division should be involved. It should be supervised by foreman.
E Call I&C personnel to isolate electric overspeed protection for small turbine
during overspeed test.
2) Test procedure:
a) Small turbine overspeed protection value is 6300±50rpm. Overspeed protection
includes mechanical protection and electric protection. Mechanical overspeed
protection test should be conducted twice with the speed difference of 30rpm
between each other.
b) Call I&C personnel to disconnect booster pump and latch small turbine
protection. Activate other protection for small turbine. Do not start up booster
pump and main pump.
3) MEH controller is under SPEED AUTO mode. Make small turbine speed rise to
3000rpm by SPEED AUTO button.
4) Trip manually once manually. Check high and low main steam valves and
control valve are closed quickly. Rotary speed drops.
5) Restore small turbine to 3000rpm. Call I&C personnel to isolate electric
overspeed protection signal.
6) Increase small turbine speed slowly to around 6300rpm and the mechanical
overspeed protection activates. Emergency trip device fly ball activates. Take
record the activation rotary speed.
7) Restore small turbine, repeat mechanical overspeed test for once.
8) Reset small turbine again. Pull out the isolation handles for emergency trip
device and reset device. MOD OFF lights are on. Isolate mechanical overspeed
protection pass.
9) Increase the speed of small turbine until electric overspeed protection device
activates in the above way. (The activation speed is around 6300 rpm.)
10) If small turbine speed is above 6300rpm/min, overspeed protection fails to
activate, trip turbine manually. Call maintenance personnel to handle until test
meets the standards.
11) When the test is finished, turn key switch the overspeed test to normal position.
Connect main pump to small turbine coupling.
18.7.7 Activation Test for Small Turbine Main Steam Valve
It can not be conducted in normal operation for the HP steam source of turbine has
been disconnected. Activate motor-driven pump and trip steam-driven pump to check
whether main steam valve activates normally.
19 Classroom Gist on Steam Turbine Operation
19.1 System Components and Their Functions

In power plant, the steam turbine converts the thermal energy of steam which
produced in boiler into mechanical energy. In the generator, the mechanical energy is
converted into power energy. Three main equipments in power plants are boiler, steam
turbine, and generator. The subject of steam turbine by its name is an operation which
taking steam turbine as the center. System components of steam turbine subject can
be divided into the following parts: Main Steam and Reheat Steam System; Boiler
Feedwater System; Condensate System; Circulating Cooling Water System (CCW);
Closed Circulating Cooling Water System (CCCW); Open Circulating Cooling Water
System (OCCW); Vacuum System; High Pressure (HP) Heater System; Low Pressure
(LP) Heater System; Drainage System; Deaerator System; Turbine Proper and Steam
Extraction System; Lubricating System; EH Oil System; Generator Sealing Oil System;
Generator Stator Cooling Water System; Generator Hydrogen System; DEH、DCS、
TSI、MEH System and etc.
Main Steam and Reheat Steam System: it is composed of main steam and reheat
steam pipe, high and low pressure bypass, main steam and reheat steam drainage
pipe and valve, thermal instrument. The function of this system is to provide steam
transfer passage, meanwhile, high and low pressure bypass in cooperation with unit to
provide appropriate steam parameter during unit startup, the system also collect
working medium, facilitate unit startup speed, protect boiler reheat steam and boiler
overpressure. (More details on functions will be explained in class)
Boiler Feedwater System: this system is made up of boiler feedwater pump (including
motor-driven boiler feedwater pump, small turbine, turbine-driven boiler feedwater
pump, booster pump of feedwater pump), feedwater pump oil supply system,
deaerator water tank, system-related valve and thermal instrument, etc. This system
mainly provide water working medium which is used to produce steam for boiler and
maintain boiler normal operation, thus meet with the steam requirement for steam
turbine operation.
Condensate System: it is composed of condensate pump, condensate make-up pump,
condensate make-up tank, condensate polishing, condensate pipe, different valve and
thermal instrument of condensate user and so on. The function of condensate system
is to collect condensed working medium of exhaust from steam turbine which had
done work, it also provide attemperating water (low pressure bypass, low pressure
casing spray water, vacuum pump water make-up and low pressure steam
attemperating water) to all users.
Circulating Cooling Water System: it consists of circulating cooling water pump,
condenser water side, rotating type screen, mobile trash remover, pump pit blowdown
pump, rotating type screen flushing pump, secondary screen, rubber ball cleaning
system, thermal instrument and so on. Its main function is to cool steam turbine
exhaust and build up condenser vacuum. It also supply water for vacuum pump and
open circulating cooling water system.
Open Circulating Cooling Water System: it is composed of OCCCW pump (some unit
doesn’t has) CCCW heat exchanger OCCW side, OCCCW pipe and valve, thermal
instrument and so on. Its function mainly is to cool closed water.
Vacuum System: it is made up of water ring vacuum pump (some unit is water-jet
pump), vacuum breaking valve, vacuum pump working water cooler, pipe and valve,
thermal instrument and so on. Its function is to build up condenser vacuum in the initial
stage of startup and maintain condenser vacuum during operation.
High Pressure (HP) Heater System: it is composed of HP heater, HP drainage valve,
HP accident drainage valve, composite valve (some unit has) pipe and related valve,
thermal instrument and etc. Its function is to improve unit cycle thermal efficiency by
heating feedwater through unit steam extraction, by doing that, boiler service condition
has been improved as well as its service life.
Low Pressure (LP) Heater System: it consists of LP heater, LP heater drainage valve,
LP accident drainage valve, pipe and related valve, thermal instrument and etc. Its
function is to improve unit cycle thermal efficiency and reduce heat lose through
circulating water by heating condensate through unit steam extraction.
Drainage System: it is made up of drainage expansion tank, LP drainage tank,
drainage pump, pipe and valve, thermal instrument and etc. Its function is to collect
system drainage, which can reduce loss of working medium, it also collect parts of
heat energy, which can reduce heat loss.
Deaerator System: it is composed of deaerator header, deaerated water tank,
deaerator water inlet valve, deaerator accident water discharge valve, deaerator water
filling valve, deaerator heating steam valve, HP cascaded drainage valve, boiler row
interconnection valve, oxygen exhaust valve, thermal instrument and etc. Its function is
to remove oxygen and other gas in boiler feedwater, lessen oxidation corrosion of pipe
and equipment, protect the equipment; it also improves heat transfer efficiency of heat
transfer surface. (The deaeration principle will be explained in class).
Steam Turbine Proper and Steam Extraction System: it is composed of steam turbine
body, all the steam inlet of steam turbine, extraction pipe in all sections of steam
turbine, extraction check valve, motor-operated steam extraction valve, involved
drainage valve and thermal instrument and etc. The main function of steam turbine is
to converts the thermal energy of steam into mechanical energy while it rotates. The
function of extraction system is to improve unit cycle thermal efficiency by heating
working medium through steam extraction.
Lubricating System: it consists of main oil pump, lubrication oil pump, lubrication oil
accident oil pump, lubrication oil purification device, jacking oil packaging device,
turning gear, lubrication oil pipeline, and thermal instrument and so on. Its function is to
provide lubrication oil for all bearing pad and take away working heat of bearing pad,
jacking oil hold the main shaft. The function of turning gear is to balance heat and cold
of rotor during unit startup and shutdown, which can reduce thermal bending.
EH Oil System: it is composed of EH oil pump, EH oil tank, power accumulator, EH oil
regeneration device, EH oil cooler, EH oil emergency governor system, thermal
instrument and so on. Its function is providing pilot oil for steam turbine governing
system and guarantee safe oil for unit.
Generator Sealing Oil System: it is made up of sealing oil pump, auxiliary sealing oil
pump, DC sealing oil pump, oil hydrogen differential pressure valve, sealing oil sump,
sealing oil main oil tank, sealing oil screen, pipe, valve, thermal instrument and etc. its
function is seal hydrogen in generator and prevent hydrogen leakage. (If it is double
flow ring type system, it will be talked on site).
Generator Hydrogen System: it consists of hydrogen purity on-line monitoring panel,
carbon dioxide heating device, gas inlet pipeline, leakage instrument, other thermal
instrument and valve etc. its main function is charge gas into generator, exchange gas
and monitor gas purity and other parameters in generator.
Steam Turbine End Sealing System: it is made up of gland heater, gland heater fan
(steam air ejector), pipe, valve, thermal instrument and etc. its main function is to seal
steam turbine end gland sealing, prevent steam of high pressure end from leaking into
motor room, prevent air from flowing into low pressure end which would affect unit
vacuum, it also collects working medium and some heat energy.
Generator Stator Cooling Water System: (if this system is included, it will be talked on
site)
DEH、DCS、TSI、MEH System: (Teach based on site situation)
19.2 Turbine Construction, Theoretical Knowledge, Monitored Operation Parameters

and Accident Cases
Turbine Proper
Turbine unit mainly consists of turbine rotor, casing, speed regulating system, steam
seal, bearing pad, control instruments and other relevant components (explained with
graphical aid in class).
Turbine is classified into single/double casing, impulse/reaction type. As the names
suggest, single/double casing turbine simply means the turbine is of single casing or
double casing respectively.
Turbine stage: each assembly of front baffle nozzle and rear moving blade together
forms one stage.
Impulse and reaction turbine is classified by reaction degree. Reaction degree is the
ratio of stagnant enthalpy drop of moving blade with respect to enthalpy drop of steam
over entire stage. Stage is reaction type if reaction degree is ≥0.5, and impulse type if
opposite. Enthalpy is a terminology used in thermodynamics to define capability of
steam to do work.
While turbine is in operation, the following parameters should be monitored: bearing
pad vibration, bearing pad temperature, return oil temperature, vacuum, rotation speed,
axial displacement, different expansion, casing temperature, casing expansion, steam
temperature & pressure and etc.
Distinguishing casing expansion and differential expansion
Casing expansion is defined as swelling of turbine casing under high temperature. In
contrast, differential expansion is the difference between rotor expansion and casing
expansion. If rotor expansion is larger than casing expansion, differential expansion
will be positive. Otherwise differential will be negative.
Shaft Vibration and Pad Vibration
Shaft vibration is defined as vibration of turbine main shaft. Shaft vibration is
determined by magnetoresistive sensors installed at two points 45° clockwise and
anticlockwise to the vertical line of shaft.
Pad vibration is measured by magnetoresistive sensors installed on each pad of
turbine along vertical and horizontal directions. Shaft vibration is relatively greater
(even up to more than 10 times) than pad vibration. Generally shaft vibration is the
more reliable parameter to indicate unit vibration condition, and adopted by most large
units.
Definition of steam temperature:
Saturation temperature is defined as the temperature when the last water droplet is
evaporated under specific pressure while being heated.
Superheated degree is defined as the temperature above saturation temperature
when water is completely evaporated.
For unit safety concerns, it is vital to closely monitor steam parameters during turbine
rolling and normal operation.
(Related accident cases will be explained in details during classroom).
19.3 Turbine Oil System, Structures and Features

Structure of oil system depends on type of turbine unit. The will distinguish the oil
systems of 300MW BEIZHONG steam and turbine and other common units (with flow
diagram and illustrated during classroom).
During normal operation, lube oil is supplied by unit main oil type. Most turbine units in
China adopt centrifugal main oil pump. However certain BEIZHONG turbine adopts
gear pump as main oil pump. Turning gear is also different. For BEIZHONG turbines,
turning gear is attached by hydraulic coupler and thus cranking main shaft. Turning
gear of other units is often directly engaged by gears, or motor driven.
Details are illustrated in diagram.
19.4 Principles and Components of ETS and CCS

ETS is composed of 4 AST solenoid valves, 2 OPC solenoid valves, 1 diaphragm
valve, 1 manual emergency handle and etc. During normal operation, 4 AST solenoid
valves are energized whereas 2 OPC solenoid valves are de-energized. While trip
signal is generated by ETS or TSI, AST valves will be de-energized and safety oil will
be removed from steam valves and unloading valves of governing valve. Governing oil
is directed to pressurized return oil loop. Meanwhile steam valves will be instantly
closed due to spring action. If turbine rotation speed exceeds 103% or subject to
sudden load shedding, OPC valves will be energized. In this case safety oil is removed
from unloading valves of governing valve. Governing oil and pressurized return oil will
be conducted and governing valves are closed. Next OPC valves will be energized
again and maintain turbine rated rotation speed/load.
Normally ETS will be activated in case of the following conditions:
1 Unit vacuum low
2 Turbine lube oil pressure low
3 EH oil pressure low
4 Turbine differential expansion over limit
5 Turbine axial displacement over limit
6 Unit vibration high
7 Unit bearing pad temperature high
8 Turbine pressure ratio low
9 HP exhaust temperature high
10 Turbine DEH overspeed
11 Turbine TSI overspeed
12 Generator fault
13 Boiler MFT
The made-in-China unit is also equipped with mechanical overspeed and manual trip
protection device. Lube oil pressure overcomes spring force atop of diaphragm valve.
The safety oil route to non-pressurized return oil loop is closed. In case of mechanical
trip or local manual trip, mechanical emergency device will remove LP safety oil of
diaphragm valve and thus open diaphragm valve. As as result, safety oil will be
unloaded to stop turbine. (Details will be illustrated in class with aid of diagram)
CCS is defined as the system which boiler, turbine and electric specialties are
automatically coordinated and achieve desired final target. CCS has the following
control modes: basic TF mode, basic BF mode, boiler-turbine coordinated mode,
coordinated TF mode, coordinated BF mode, basic turbine-boiler remote control mode,
AGC mode and etc.
Explanation of Modes:
Basic TF mode: turbine controller is set to auto, boiler controller is set to manual;
Turbine is automatically adjusted as per pressure of main steam valve.
Basic BF mode: boiler controller is set to auto, turbine controller is set to manual;
Boiler is automatically adjusted as per pressure of main steam valve.
Boiler-turbine coordinated mode: both turbine and boiler controllers are set to auto.
Boiler and turbine controllers will simultaneous adjust as per load target. At the same
time, theoretical DP across main steam valve will be sent to boiler and turbine
controllers as feedback to mitigate over-adjusting. The outcome is to smoothly
approach desired load.
Coordinated TF mode: both turbine and boiler controllers are set to auto. Boiler load is
primarily adjusted as per load target. Turbine controller will be automatically adjusted
according to pressure upstream main steam valve.
Coordinated BF mode: both turbine and boiler controllers are set to auto. Turbine load
is primarily adjusted as per load target. Boiler controller will be automatically adjusted
according to pressure upstream main steam valve.
Basic turbine-boiler remote control mode: both turbine and boiler controllers are set to
manual. Control is relied on manual operation.
AGC mode: automatic generation control. Grid load dispatch will send out command to
boiler and turbine controllers, which are set to auto. Next unit will be correspondingly
adjusted to load specified by grid dispatch in a coordinated manner.
19.5 Structure, Theoretical Knowledge of Various Heaters and Real Applications

Heater, a type of heat exchanger, is indispensable in power power. Heaters are
classified into the following types: surface heater and hybrid heaters. For turbine
system, the following heaters are used: gland seal heater, LP heaters, HP heaters (for
example condensate and closed circuit water heater are surface type heat exchanger
with cooling medium); One example of hybrid heater is deaerator.
Surface heat exchanger is using two or more mediums to conduct convective heat
exchanger with the third medium.
Hybrid heat exchanger is direct contacting heat exchanging of two or more mediums
without using the third medium.
Surface heater is normally classified into: steam condensing section, drain water
cooling section (HP heater and steam cooling section) and various working sections.
Classification of every working section is as per working medium: normally HP heater
is equipped with steam cooling section. Since degree of superheating of steam
entering HP heater is relatively high, cooling section is integrated to recycle working
medium and extract the most energy from recycled medium. In addition, cooling
section allows fewer application of superior metal within heater, thus lowering cost of
heaters.
Steam cooling section: as the name suggested, temperature of steam is cooled within
this section to lower degree of superheating.
Steam condensing section: heated steam starts to condense at this section, thus
called condensing section.
Drain water cooling section: to further cool down heated medium and recycle thermal
energy, conduct heat exchanger for relatively low temperature working medium just
entering heater and its drain water. This section is named as drain water cooling
section.
Typical arrangement of heaters: vertical (up-side down and upright), horizontal.
Both arrangement have their pros and cons. Upright vertical arrangement is
convenient for maintenance and space saving. However drain water cooling section
can be difficult to arrange. Thus the most optimized thermal energy recycling cannot
be achieved.
Up-side down arrangement: space saving but not convenient for maintenance.
However drain water cooling section is difficult to arrange, and thus will result higher
cost.
Horizontal heater: easy to arrange all working sections, reduced cost and improved
unit economicality. However this arrangement is not convenient for maintenance and
requiring larger space.
Deaerators can be classified into ones with or without head.
The distinction is whether there exists a deaerator head. Deaerator with head is to
remove dissolved oxygen and other gases by means of convective heat exchange.
Deaerator without head is to remove dissolved oxygen and other gases by means of
deep level heating.
Principle of deaeration: in a closed vessel, amount of dissolved gas is directly
proportional to gas partial pressure above liquid. When liquid is heated, partial
pressure of gas above liquid will gradually approach to zero when liquid reaches
saturation temperature and large amount of liquid is turned into steam. Meanwhile
dissolved gas will be released continuously and discharged via outlet.
Frequently monitored parameters for operation of heater: upper/lower end temperature
difference, temperature rise, degree of super-cooling and etc.
Upper end temperature difference of heater: difference between saturation
temperature of steam entered and outgoing water temperature.
Lower end temperature difference: difference between outlet temperature of drain
water and entering water temperature.
Temperature rise: increment of water temperature at outlet of heater
Degree of super-cooling: temperature difference between saturated temperature and
temperature of condensed water.
Study of the above parameters can be used for the following purposes:
For HP heaters of large unit: upper end temperature difference is normally -2°C - 1°C.
The negative value is observed because HP heater is located at steam cooling section
whereas degree of superheating of extracted steam is relative large. If temperature
difference is too large, water level of heater could be too high or full, or corresponding
pipeline is ruptured.
Lower end temperature difference is normally 3°C - 5°C. If lower end temperature
difference is too low, drain water level of heater may be relatively high. Consequently
area of heat exchange surface is reduced and resulting lower efficiency. If the
temperature difference is too high, the cause may be drain water level low or zero level.
In this case, steam may directly enter next stage and squeeze out steam entering next
stage and thermal efficiency is lowered. Presence of steam water mixture will flush
drain pipe elbows and valves and aggravate abrasion.
Temperature rise: this parameter can be used as reference data for heater. While
heater is operating, temperature rise should normally be ≤2.5°C. If temperature rise is
too large, heater may be overloaded and thus this parameter should be limited when
necessary.
Degree of super-cooling: this parameter is used as reference data for condenser. For
large unit, degree of super-cooling is normally not greater than 1.5°C. If degree of
super-cooling is large, vacuum of condenser might be insufficient which results poor
heat exchanging at condenser. Else it can be caused by high hot-well water level.
19.6 Components and Operation Principles of Sealing Oil System

Seal oil system is to seal internal hydrogen of generator and prevent hydrogen from
leakage. Various sealing methods are adopted for different units: single circulation and
double circulation. This manual only illustrates single circulation method.
Seal oil system has the following operation modes:
(1) Normal operation mode
(2) Emergency oil pump and standby seal oil pump operating
(3) Self sealed operation mode (meanwhile hydrogen pressure must be lowered to
50 KPa)
(All operation modes are illustrated during class with aid of diagrams, as well as
handling accidents).
19.7 Accident & Operation Cautions for Feedwater and Circulating Water System
Feedwater is vital to ensure safe operation of boiler. Operation feedwater is very
important among all steam-water systems. A significant proportion of plant accidents
are caused by failure of feedwater system.
Importation Operation Cautions of Feedwater System:
(1) Operating HP heater inter-connected valve
(2) Initiating parallel operation of TBFP
(3) Switchover of feedwater pump
Operation methods vary according to different operation systems. This will only explain
in details on relevant case studies. Regulatory operation will be explained onsite as
per actual condition.
Circulating water system is the main system for establishing condenser vacuum. Major
operations are: half condenser disconnection operation (detail procedure will be
illustrated in class), rubber ball cleansing procedure, traveling strainer operation
procedure and etc.
Rupture accident of circulating water pipe will be analyzed and discussed in class.
19.8 Operation and Calculation Knowledge of Generator Hydrogen System

Generator hydrogen system is used to supply cooling hydrogen to generator and
replace internal gas.
If CO2 is used to replace air, hydrogen replacement must not be started unless
concentration of CO2 is above 85%. Minimum hydrogen purity is 96%.
While discharging, make sure CO2 concentration has reached 90% prior to replacing
with air.
During normal operation of generator, dew point temperature of internal hydrogen
must be strictly controlled at 0-25°C. Dew point is defined as saturation temperature of
steam inside generator under specified partial pressure. If below dew point, steam will
condense into water droplets and drawn onto generator stator and rotor. This will
cause damage to internal insulation and lead to accident.
Thus dew point temperature must be strictly controlled at 0-25°C. If dew point is too
low, however, generator stator end support may be damaged and exacerbate
insulation toughness.
During normal operation of generator, hydrogen leakage should be monitored. Normal
leakage rate is 10m3/day. The formula used to calculate amount of leakage is pv/t.
Where: p - absolute pressure of hydrogen, v - hydrogen volume, t - absolute
temperature of hydrogen.
Method to calculate hydrogen leakage will be thoroughly explained in class.

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GUANGDONG POWER ENGINEERING CORPORATION

PLTU 2 SUMATERA UTARA 2×200MW MEDAN

Operation and Maintenance

Turbine Operation Part

GUANGDONG POWER ENGINEERING CORPORATION

1.1 General Rules for Activation of Auxiliary System

1.2 General Regulations for Activation of Auxiliary Rotary Machine

2 Operation of Circulated Cooling Water System

2.1 Overview of the System

2.2 Circulating Water System Activation

2.3 Normal Maintenance Contents for the Circulating Water System

2.4 The Circulating Water System Shutdown

2.5 Troubleshooting for the Circulating Water System

2.6 Regular Work

3.1 Main Function and Working Process of Condenser

3.2 Condenser Test

3.4 General Requirements for Condenser Operation and Maintenance

3.5 Operation of Condenser Rubber Ball Cleaning Device

4 Operation of Open-type & Closed-type Cooling Water System

4.1 Overview of the System

4.2 The Operation of Cooling Water System

4.3 The Normal Maintenance Items of Cooling Water System

4.5 Common Faults, Causes and Solutions

Faults Causes Solutions

The power that the Impeller abrasion. Replace the impeller.

The openness of gear valve is

There is no lubricant on the Fill lubricant or change the

4.6 Regular Work

5 Auxiliary Steam System Operation

5.1 Overview of the System

5.2 Activation of the Auxiliary Steam System

5.3 Normal Maintenance Items for the Auxiliary Steam System

6 Lube oil System Operation

6.1 Overview of the System

6.2 The Operation of Lube oil

6.3 Normal Maintenance for Lube oil System

6.4 Shutdown of Lube oil System.

6.5 Common Trouble Shooting for Lube oil System

Angle of the manual

350℃～450℃ 15mins 180°every 15mins

250℃～350℃ 30mins 180 every 30mins

150℃～250℃ 1h 180°every hour

6.6 Operation Regulations for Turning Gear

6.7 Operation of Oil Purifying Device.

7 Operation of Generator Sealing Oil System

7.1 Overview of the System

7.2 Activation of the System

7.3 Normal Operation and Maintenance of the System

7.4 Shutdown of Sealing Oil System

7.5 Faults of Generator Sealing Oil System

8 Operation of Hydrogen System

8.1 Safety Regulations

8.2 Generator Gas Replacement

8.3 Operation and Maintenance of Hydrogen System

8.4 Abnormal Operation Solutions of Hydrogen System

9 Operation & Maintenance of Condensate System

9.1 Overview of the System

9.2 Activation of Condensate Water System

9.3 Normal Maintenance

9.4 Deactivation of Condensate Pump

10.1 Overview of the System

10.2 Activation of LP Heater

10.3 Operation and Maintenance of LP Heater

10.4 LP Heater Shutdown According to Turbine Sliding Parameters