TURBINE

COMMISSIONING

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COMMISSIONING OF
LPH & HPH

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Regenerative System

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 Preparations
• It to
t be
b ensured d that
th t dirt,
di t rustt oil,
il grease, weld
ld slag
l iis
removed
• Hydraulic tests of the entire system must have been
completed
• Discharge valves of BFP and condensate pumps
must beb closed
l d properly
l prior
i to flflushing
hi
• Sufficient quantity of water should be available
• Steam at 8 8-10
10 kg/cm and 150150- 200oC is available
• All valves in the steam lines of deareator should be
closed

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 Flushing of regenerative heaters
Preparation
• All safety valves to be removed from HP heaters, air vents
to be ensured for venting in all heaters
• Ensure that no cutting and welding work will be required
after the flushing is completed.
• All orifices
ifi and
d nozzles
l are removed d
• Shell side and tube sides are flushed
e e gauges and
• All level a d level
e e sswitches
c es a
are
e isolated
so a ed be
before
oe
start of flushing
• Internals of regulating valves are removed before alkali
flushing
• All instruments accept those required for measurements
during flushing should be isolated.

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 Flushing of regenerative heaters
Procedure
• First flushing is done with cold raw water. Flushing is done
till the affluent is clear
• After this the system is flushed with hot water at 80oC. The
flushing is deemed complete when the turbidity and
conductivity of water at inlet and outlet is same
same. (at least
for 8 hrs)
• Alkaline flushing is done using trisodium phosphate,
sodium
di hydroxide
h d id
• Start alkali pump and fill the system, raise the temperature
to 50oC
• Keep the loop under recirculation for 10hrs
• The samples taken should be analyzed for mechanical
impurities iron content and ph value
impurities,
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 Flushing of regenerative heaters
Rinsing
• Drain the circuit and the loop should be rinsed with DM
water to remove alkalinity
• The rinsing process is deemed to be completed when pH
value are same at inlet and outlet.
• Again
A i flflush h with
ith DM water
t
Shell side & drain lines of heaters
• The e sshell
e sside
de oof HP heaters
ea e s is
s flushed
us ed by filling
g individual
d dua
heaters and draining the system by opening shell side
drained
• Theflushing is done with cold water and hot water
respectively
• After flushing the remove the temporary lines

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 Safety and precaution

• Alkaline solution causes skin burning should be done

with care
• Rubber-gloves,
R bb l eyes protection,
t ti aprons gum b boots
t
masks should be used
• Flange tightening should be done greatest care
• Manhole may be kept opened for 8-10 hours and air
may be forced in deareator during the period
• No drilling, welding or cutting operation are allowed
during the process

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 Commissioning
LPH
• Ensure that water side is through and all bypass
valves are closed.
• Check cascading drains of all extraction are in open
condition
• FC NRV water side id iis kkept charged
h d condition
di i
• Ensure that cascading of drains is through
• Open slightly the steam extraction electrically
operated valve bypass for warming up the extraction
upto heaters
• After proper warming up open gradually open the
steam observing level in the gauge glass
• If level starts increasing more than normal then bring
level controller into circuit.
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 Commissioning
HPH
• Ensure that water side is through and all bypass valves are
closed.
• Check cascading drains of all extraction are in open condition,
shell side drains are closed
• Check drains between NRVs and heaters is closed. Check
cascading drains are through
• Ensure that cascading of drains is through
• Check that de-areation of heaters on shell side are connected to
condenser thru LPH
• Check proper functioning of group protection valve
• Open slightly the steam extraction electrically operated valve
bypass for warming up the extraction upto heaters
• After proper warming up open gradually open the steam
observing
obse g level
e e in tthe
e gauge glass
g ass
• If level starts increasing more than normal then bring level
controller into circuit.
• Ensure whether heater drips are diverted to de-areator at high
load.
load

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 Boiler Feed Pump
Pre-commissioning test:
• Inspect all mechanical, electrical and instruments for proper
erection
• Ensure
Ens re tightness of pressure
press re parts
• Check all relief valve settings
• Flush the lube oil system
• Perform lubrication checks
• Check the IR value of motor, cables and insulation
• Check the DOR of motor
• Perform operational test of valves and fittings
• Ensure that de-aerator, BFP suction and discharge are properly
cleaned
• Perform protection and interlock checking
• Flush the cooling water system
• Start
S and
d check
h k the
h operationi off BFP and d associated
i d valves
l
• Check automatic starting ofPMIstandby
Revision 01
feed pump 11
 Turbine and auxiliaries
• Barring gear
– Preparation
– Trial run of motor
– Preparation for putting the barring gear in
operation

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TG On barring gear

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 TG on barring
gggear
• Objective:
j
– To rotate the turbine rotor system
continuously on low speed during start up
and shutdown of the machine.
– This is to over come the break away torque
during startup and enable uniform cooling of
the rotor system during shutdown to prevent
distortion of rotor
rotor.

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 Barring Gear
Preparation:
• Check that barring gear is erected properly ensuring required
clearance in the gear system
• Ensure proper oil flow for lubrication is all TG bearings and
also barring gear motor
• Check whether the protection for cutting off the barring gear at
low lube oil pressure is connected.
• Check the limit switch for cutting off the motor supply
whenever barring gear disengages is connected properly
Trial run of Motor
• Check DOR of the motor
• Run the motor for 8hrs
Putting into operation
• Couple the motor with barring gear

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 Barring Gear

• Check the freeness

• Ensure the lubricating oil pressure is normal
• Ensure that engaging and disengaging mechanism of barring
gear is working properly
• Check if bearing temperature
temperature, seal oil temperature indicating
and recording instruments are working properly
• Check turbovisory eccentricity instruments are working
properly
• Check the oil temperatures are normal.
• Start the barring gear motor after engaging it manually
• Note down the starting current and normal current
• Check for any abnormal noise from the turbine glands
• Watch the oil temperature
p and eccentricity
y values
• Stop the barring gear. Note down the coasting down period
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 Condenser flood test
and
Vacuum tightness test

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 Flood test
• Services required
– D.M water
– Flexible hose pipe
– Lighting
– Dewatering
D t i pump
– Wooden slippers for temporary support

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 Flood test
• State of the plant
– Condenser erection completed
– Flexible polythene hose fitted for level monitoring
– Jack bolts beneath condenser locked
– Wooden
W d planks l k kept
k t
– D.M Water line charged

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 Flood test
• Method
– All heater vents opened to vent out the air
– Start DM Water filling g
– Check leakages for every one meter raise in
level (in level indicator)
– Fill water up to the tip of LP Turbine blades
– Attend leakages
g
– Drain condenser, clean Hotwell and remove
wooden slippers and release jack bolts

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 Flood test
• Completion criteria
– Declared completed when all the identified
leakages attended satisfactorily

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 Vacuum tightness test
• Services required
– Cooling water available
– Power supply to CEP
CEP, Vacuum pumps and CW
Pumps available
– Auxiliary steam available

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 Vacuum tightness test
• State of the plant
– Vacuum pumps ready for operation
– GSB trial completed
– CEP commissioned, P&I checks done
– Condenser
C d CW water
t charged
h d
– Vacuum breaker commissioned
– TG is
i on barring
b i gear

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 Vacuum tightness test
• Method
– Put turbine on barring gear
– CEP is on recirculation
– Seal steam and GSC lined up
– GSB and dBBoth
th vacuum pumps started
t t d
– Charge seal steam after achieving 0.2Ksc
vacuum (Seal steam 0 01Ksc and >1600c temp)
0.01Ksc

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 Vacuum tightness test
– Check for air ingress and attend leakages
– Stop one vacuum pump at desired vacuum
– Check for holding with one pump
– If air ingress points are not detected then use
helium leak detection or steam pressurization
method (Raise steam space pressure up to
0.1Ksc.))

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 Vacuum tightness test
• Completion criteria
– Stop both vacuum pumps at desired pressure
and observe rate of fall of vacuum
vacuum. (Should not
be >2to3 mmwcl per minute)
– Total hogging time for achieving desired vacuum
with both pumps and with individual pumps to be
noted

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 Vacuum tightness test
Objective to is carried out to find out leakages
leakages, if any
any, in the
system before rolling. Done in2 steps:
1. Filling up DM water up-to turbine gland
2. raising vacuum in the system
Preparation:
• casing
i ttemp<50 50oC
• Circuit which come under vacuum: HP cylinder, re-heater, IP
cylinder condenser flash tanks
cylinder, tanks, HP/LP Bypass systems
systems,
extraction lines, HP and LP heaters.
• Provide transparent tube upto 9 meters
• Props and jacks are to be provided for condenser for fill test
• Keep the condenser manhole open to check for any defective
tube
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 Vacuum tightness test
• Keep open the vacuum breaker in open position
• Keep open air line valves of various equipments so that air
escapes during filling up and there is no water locking
• Check the soundness of level indicating instruments
• Analyze the DM water before filling for pH and conductivity
• St t filling
Start filli up DM watert
• While filling check if there is any leak and arrest if noticed
• While filling up , check if the level in gauge glass matches
with level switches
• g
Fill the water up-to desired level check for leakages
thoroughly maintain the level and level of not more than 2-3
cm is allowed in 24 hours

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 Raising Vacuum in Condenser
• After draining the condenser remove the props and jacks
jacks,
removes dummies
• Start the lube oil system and charge the governing system
• Put barring gear into service
• Check if vacuum breaker is closed, atmospheric drains in
vacuum lines are closed
• Charge cooling water side of both condensers.
• Start one condensate pump and keep it under recirculation
• Warm the steam lines of GS cooler, ejector and gland steam
header
• Gradually pull vacuum

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 Raising Vacuum in Condenser
• Take both ejectors in service
• While raising vacuum check whether vacuum alarm gets
reset
• Wait till full vacuum is reached and cut off one of the main
ejector
• Check the following points for
– parting planes of LP casing
– Explosion diaphragms
– LP exhaust hood dummy plugs
– Cross over pipes, joints of IP exhaust and LP inlet

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Preparation for first rolling of turbine
Preparation:
p
• Check HT & LT power supply
• Check DM water stock
• Check conductivity of DM water
• Fill condenser hot-well
• Check
C all annunciation circuits are working
• Check that all turbovisory instruments are working
properly and showing correct value
• Charge the CW circuit
• Chargeg the Lube oil system
y and open
p I/C of g
gov.
system
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Preparation for first rolling of turbine
• Put seal oil system into service
• Engage barring gear into service
• Always keep watch on: Bearing temperatures, axial
shift,
hift differential
diff ti l expansion
i lube
l b oilil ttemp, metal
t l
temperature, eccentricity
su e healthiness
• Ensure ea ess o
of go
governing
e g sys
system e
• Check if all the necessary drain valves are open
• Solenoid valves of FCNRV should be in charged
condition

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Preparation for first rolling of turbine
• Ensure proper sealing of valves coming in vacuum
circuit
• Warm up steam lines
• Start pulling vacuum
• After attaining full vacuum check protections
• Set temp set point of HP Bypass, put Pr controller in
manual mode
mode, put LP by pass in auto and set its pr
and temp set points
• Take HP bypass into service
• All the lines to warm up
• Gradually open the IVs and ESVs of IP turbine and
bring steam pressure in the reheater
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Preparation for first rolling of turbine
• Do not allow turbine speed to shoot up
• Keepp watch on turovisoryyp
parameters and metal
temperatures
• Open LPBP system and dump steam into condenser
• After 50oC superheat is available heating of HP
turbine line can be done
• Gradually open the ESVs
ESVs, ensure that turbine control
valves are closed
• Gradually warm up the lines
• Open the interceptor valve slightly and allow warm of
turbine pipelines

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 Checklist for rolling
• Start rolling
g in SGC or raise starting
g device
position to open stop valves
• Check that all steps are satisfied
• Soak the turbine at 360rpm
p
• Cross critical speed at set acceleration
• Be ready for synchronization after achieving
3000rpm

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THANK YOU

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