STEAM TURBINE

OPERATING
PROCEDURES

By K Rangarao
 Operation philosophy

• 100 times you operate a valve or motor or

process success rate should be 100 times.

• If you failed 1 time out of 100 people will

remember about that only

• Consequences of operation failures have

cascading effect on personal, equipment
and life of plant.
STEAM TURBINE NAME PLATE DATA

TYPE TC 153 MV 142

TURBINE Nr. E 301044

POWER 128540 KW

SPEED 3000RPM

INLET PRESSURE 86.72 Bar abs

INLET TEMPERATURE 510.6 deg.

EXHAUST PRESSURE 0.098 Bar abs

 The Operation Modes

In open cycle: one or two gas turbines are in

operation and the steam turbine is stopped

Combined cycle mode (both gas turbine) and steam

turbine in operation : the flue gases of the GT are
routed to the HRSG

It can also operate only when one gas turbine and

the steam turbine in combined cycle mode.

In case of house load configuration, the steam

turbine trips.
 Cold start-up:

It corresponds to a steam turbine casing temperature under 150°C

warm start-up:

It corresponds to a steam turbine casing temperature between 150°C and 350°C.

It occurs after a medium standstill period.(after about 20 H shut down)

Hot start-up:

It corresponds to a steam turbine casing temperature above 350°C.

It occurs after a short standstill period. (after about 5 H shut down).

The average of Casing top and bottom temperatures TE 207 & 208 is considered
for above temperature criteria
 SPEED RATE
Condition Turbine casing Approximate holding time Speeding rate Time taken to reach
temperature at warm-up speed synchronising speed
(1200 RPM)
Cold <=150⁰C 30 min 300 RPM 40 min
Warm >150⁰C & <350⁰C 20 min 300 RPM 30 min
Hot >=350⁰C 0 min 300 RPM 10 min

LOAD RATE
Condition Turbine casing Initial Load Loading rate Load Time Total time
temperature load reached MW taken taken to
reach Base
load
Cold <=150⁰C 0% 5% 5% /min 6.4 1 min 2hrs
5% 35% 0.33% /min 45.0 94 min
35% 100% 2.56% /min 128.7 25 min
Warm >150⁰C & <350⁰C 0% 5% 5% /min 6.4 1 min 1hr 30min
5% 35% 0.5% /min 45.0 59 min
35% 100% 2.18% /min 128.7 30 min
Hot >=350⁰C 0% 5% 5% /min 6.4 1 min 30min
5% 100% 3.17% /min 128.7 29 min
 ST COLD START UP PROCEDURE
PREREQUISITES
All work permits are returned and normalised

Balance of plant is fully operational i.e. Instrument air supply, Auxiliary

power supply, DM water is available & DM transfer pump running

Power block equipment HP/IP/LP BFPs, MCW pumps, ACW pumps, CCW
pumps, Condensate extraction pumps are in service

Generator electrical system is ready and 220 KV switch yard is normalized and

ready for synchronization after ST rolling

Lead HRSG is ready in all aspects

HP/IP/LP steam and feed water systems, condensate system, CPH, Deaerator

are lined
Check up properly.
condenser vaccum line up and keep vaccum pumps ready

All drains and vents are properly lined up

 STG AUXILIARY SYSTEMS

Line up STG Lube oil system completely and ensure enough level of lube oil in

lubeup
Line oil STG
tankJacking oil and turning gear system

Line up STG Gland sealing system

Line up STG Control fluid system . Check level of Fyrquill oil in EHC tank

Overhead lube oil system is lined up

Check for all casing drains of STG are open and on auto

Check Exhaust hood spray valve is on auto

 TURBINE GENERATOR

CCW OUT

CCW IN

Accumulator
Duplex type From Overhead
Lube Oil lube oil tank
coolers

Typ. For all pumps

AMOT Cooler
bypass valve
Duplex type
Lube Oil filters

Auxiliary Lube Emergency lube STG LUBE OIL SYSTEM

oil pumps oil pumps
LUBE OIL TANK
 STEAM TURBINE GENERATOR OVERHEAD LUBE OIL TANK
OHT OVERFLOW LINE

OVER HEAD LUBE OIL

TANK CAPACITY
8000 LTRS OHT FILLING CUM LUBE OIL SUPPLY LUBE OIL SUPPLY
TO BEARING HEADER LINE LINE TO OHT
THROUGH ORIFICE

P1 --AC LUBE OIL PUMP 1

SIGHT GLASS
P2 --AC LUBE OIL PUMP 2 NRV
P3 --DC LUBE OIL PUMP 1 STATION
P4 --DC LUBE OIL PUMP 2
LUBE OIL SUPPLY HEADER

LUBE OIL RETURN

P1 P2 P3 P4 HEADER

STG LUBE OIL TANK

CAPACITY 12000 LTRS
COLLECTING OIL
TANK CAPACITY
12000 LTRS
 Starting of Lube oil system

 Start-up of lube oil system sequence (*) GGR-GRE system

Lube oil sequence SET will start selected lube oil pump and Oil mist fan

Check oil pressure at discharge of motor pump and lube oil header. Lube-
oil sequence set (**)

Stand-by and emergency pumps test sequence (DC starter for emergency
lube oil pump available)

Check the availability of standby AC lube oil pump ( 4.5 bar)

Checking of pressure at pumps delivery (4.5 bar) and lube-oil header(2.2 bar)
 STEAM TURBINE GENERATOR JACKING OIL SCHEMATIC

TURBINE GENERATOR

Pressure indication
to DCS

Lube oil return header GGR PSH 025

LUBE OIL
TANK

JOP # 4 JOP # 5
 Starting of J O P and Turning gear

Start-up of lifting and turning gear. Sequence SET to be given

Selected J O P will start.

Check presure at local (140 bar). Check pressure at turbine and

generator bearings (85 to 90 bar)
Turning gear in operation, clutch engaged - TG speed 50 rpm

Check turning gear current on starter panel. Normal 14.5 Amps.

Current before break away 30 Amps

Check for vibrations, eccentricity and healthiness of all turbovisory

instruments while the ST on turning gear

Check locally for any abnormalities. Observe for any leaks or abnormal
noises
 GLAND STEAM SYSTEM
STOP VALVE
BLOCK

LP SEALING TURBINE HP SEALING

TCV 302

HV 315
TO ATMOSPHERE SEPERATOR FROM
CEP

BLOWERS DESUPERHEATER
LSH 330
TO CONDENSER

UY 330

TO CONDENSER
GLAND STEAM CONDENSER
PCV 301B HP STEAM

PCV 301A
 Starting of Gland steam system
Keep open all drains in Gland steam supply line to totally remove
the condensate

The HP steam pressure upstream of HP stop valves should reach 28 bar

The HP steam temperature should be above the autorisation limit displayed on

the Gland steam sequence SET screen (App 280 deg C)

Once these are satisfied the permissive will come for Sequence SET.

SET the Sequence and Observe for Gland steam supply valves open on Auto

&
Gland steam fan will take start
Wait for Gland steam pressure to raise to 1.2 bar Abs and LP side
temperature to raise to 180 deg C.
 Condenser Vaccum building
This will take few minutes .

Do not start vaccum pulling until the Gland steam parameters are reached

Observe STG casing temperatures

Start condenser Vaccum pulling by starting Vaccum pumps from

DCS
Close the Vaccum break valve

Observe for vaccum building in condenser. At 160 m bar one vaccum pump
will stop
Once the vaccum is built take HP/IP/LP steam into bypass with all
bypass set points in auto

Obtain cold rolling parameters of HP steam. 35 bar pressure and 320 deg C

Open IP steam header isolation valves and charge deaerator

 Start-up of control fluid system

Give sequence SET from GFR system

The selected EHC pump will start

 Observe for Pump discharge pressure (95 bar) and any system
abnormalities
 Turbine safety system setting Valve chest warming-up

Check for turbine seting authorisation

If all conditions are met, Give turbine SET

This will open HP IP and LP stop valves

STG fundamental safety tests can be done at this stage

when the stop valves are opened, the HP valves inlet block is
conditioned by the steam turbine drain on the inlet block through the
drain valve GPV UV401 (open position).
 TURBINE ROLLING
Give Auto start command from HMI Speed control graphic

The STG will select the respective startup curve depending

on the turbine casing metal temperature states

The respective status i.e. cold/warm/Hot is indicated in HMI

In cold start the turbine will accelerate @ 300rpm/min upto 1200 rpm and
casing is allowed to warm up there for 30 minutes.

 At 600 rpm the turning gear and JOP will stop

 After warm up the turbine is accelerated to synchro level @ 300 rpm/min.

 At critical speed range 1300 to 2100 the turbine is acclerated @ 600

rpm/min

 The turbine will reach 3000rpm in 40 minutes (total time)

Observe for the following vital parameters while the turbine is
being accelerated

 Turbine and generator vibrations

Casing/rotor differential expansion

Overall casing expansion

Rotor eccentricity

Axial displacement

Casing temperatures

Shaft line temperatures

 SYNCHRONISING AND LOADING OF ST

Once after reaching full speed release Auto synch permissive from DCS

The turbine generator will synchronise and get loaded to spinning

reserve of 5 % load.

 Thereafter the turbine will load based on the cold/warm/hot start

condition

At 20% load on ST the exhaust hood spray valve CAR TV 303 is
closed.

At 20% HP casing drains GPR UV 401,402,403 and 404 ill be closed.

30 minutes after the above IP & LP casing drains GPR UV 405,406,407
408, 409 &410 will be closed.
When the ST 3rd wheel pressure reaches 15.6 bar the IP and LP steam
control valves will open and IP,LP steam injection will start.(App 28 MW)

 HP bypass CV is given plus 2.0 bar over the sliding pressure set point
recieved from STG PLC. Accordingly the bypass will close and the steam
is diverted to turbine for further loading.

Once the bypass valves are closed fully the STG loading is dépendant
on the GT loading on ST follow Gas turbine mode

 The limitation criteria 1,2 and stress Stability criteria are calculated from
casing temperatures and will stop loading of ST if the limit values are
reached
 STABILITY CRITERIA LIMITATI0N CRITERIA # 1

CS = (TE 207- TE 208) CL1 = (TE 206- TE 205)

50 120

CS value +1 to - 1 normal CL1 value +1 to - 1 normal

CS value <= -1 or >= + 1 Load Lock CL1 value <= -1 or >= + 1 Load Lock

LIMITATI0N CRITERIA # 2 TE 203 Upper Casing Outer temperature

TE 204 Upper Casing inner temperature
CL2 = (TE 203- TE 204) TE 205 External flange Outer temperature
120 TE 206 External flange inner temperature
CL2 value +1 to - 1 normal TE 207 Upper Casing Top temperature
TE 208 Upper Casing Bottom temperature
CL2 value <= -1 or >= + 1 Load Lock
S. Tag no Description Unit Alarm Trip
no
A. Shaft Line Bearing Temperatures
1 GMATT501 Inlet Bearing Temperature Deg C 110 120
2 GMATT502 Exhaust Bearing Temperature Deg C 110 120
3 GMATE503 Generator Bearing Temperature Deg C 110 115
4 GMATE504 Exciter Bearing Temperature Deg C 110 115
5 GMATT505 Inactive Thrust Bearing Temperature Deg C 110 125
6 GMATT506 Active Thrust Bearing Temperature Deg C 115 125
7 GMATT507 Active Thrust Bearing Temperature Deg C 115 125
B. Vibrations
8 GMAVE501 Inlet Bearing X Plane Micron 75 100
9 GMAVE502 Inlet Bearing Y Plane Micron 75 100
10 GMAVE503 Exhaust Bearing X Plane Micron 75 100
11 GMAVE504 Exhaust Bearing Y Plane Micron 75 100
12 GMAVE505 Generator Bearing X Plane Micron 160 240
13 GMAVE506 Generator Bearing Y Plane Micron 160 240

14 GMAVE507 Generator Exciter Bearing X Plane Micron 160 240

15 GMAVE508 Generator Exciter Bearing Y Plane Micron 160 240

Contd…
C. Turbovisory
16 GMAZT510 Differential Expansion MM -4.7, 2.7 -4, 3
17 GMAZT511 Thrust position MM -1.3, 0.3 -1, 0.6
18 GMAZT512 Absolute Expansion MM 16.2 16.5
19 GMAZT513 Absolute Expansion MM 16.2 16.5
20 GMAZT514 Eccentricity Micron 80, 120
21 CARTT301 Exhaust Temperature Deg C 80 100
22 CVI Exhaust vacuum Mbar A 400 450
PT229/230/231
MOUNTING OF TURBOVISORY INSTRUMENTS IN FRONT BEARING PEDESTAL
 STG cold startups
29th September
startup after C I of both GTs
2002

12th December
startup after GAIL condensate problem
2003

02nd Feb 2004 Startup after minor inspection

STG JOP & TG did not came during black
04th April 2005
out
26th November Black out . STG run without lube oil while
2006 coasting down.
 STEAM TURBINE SHUTDOWN

The steam turbine shutdown always results either from a

Normal shutdown

 To put the steam turbine in cold condition in order to allow

maintenance works.
 To restart the steam turbine as soon as possible
Forced outage

From an automatic tripping caused by the action of STG fundamental safties

or
overspeed protection
or
an intentional emergency shutdown by pressing the EPB.
 Normal shutdown procedure

Steam turbine unloading

This operation is controlled by the operator who reduces the steam
turbine load by acting on “ - HP ” local cubicle (or by unloading the
gas turbines).

Unloading of Gas turbines is the common practice being followed

Reduce the load on GTs to 50/50 MW or still less keeping in view the
combined cycle steam parameters (60MW if One GT is in service)

Close the Diverter dampers of both HRSGs to 60 to 70 in steps

  When the steam turbine load is less than 20% of the rated load (26MW):

check that the LP casing cover spraying valve (CAR TV303) is opened

 check that the HP drain valves on the steam turbine and HP conditioning line upstream
to the stop valves are opened.

 When the steam turbine load is less than 10%

 Trip STG from HMI

When the steam turbine trips, the stop valves get closed in approximately
0.3 s seconds.
Check for closing of all STOP and control valves and Generator breaker opening
 Shaftline slowing down(normal)

During the shaftline slowing down, up to the barring speed, delay the air
intakes into the steam turbine by

 keeping the steam turbine gland steam system supply running

keeping the condenser vacuum in service in order to avoid any problem

of cooling transient stage
 OBSERVE FOR THE FOLOWING PARAMETERS DURING COASTING DOWN

•Vibrations, Turbine exhaust temperature

•starting of the turning-gear motor and jacking oil pump selected at 509 rpm.

•clutching of the turning-gear at 50 rpm.

•Check the slow down time between the steam turbine trip and the barring speed
(45 to 50 minutes normal time)

-Isolate the steam turbine on LP bleeding.

-Stop the condenser vacuum system and watch the evolution of the condenser pressure.

-When the condenser pressure reaches 550 mbar abs., make sure that the HP by-pass valve
closes.

-When the condenser pressure reaches 900 mbar abs., stop the gland steam system through
CMS.

-On CMS, check that the supply valve CET PCV301A and the overflow valve CET PCV301B
close and that the condenser extraction fan selected (CET EXT301 or CET EXT302) has
stopped.

-Keep the CEPs and MCW pumps in running

 FORCED OUTAGE

The forced outage can be due to the action of following fundamental safties of
STG

Lube oil pressure low low 0.7 bar at rear end (from 2 out of 3 switches)
Turbine exhaust pressure high at 450 milli bar (from 2 out of 3 switches)

Turbine over speed trip at 105 % or 3150 rpm

Other protections of STG
Trip from turbovisory parameters like vibrations, expansions , bearing
temperatures
Generator tripping on electrical faults
EHC header pressure low low at 60 bar
EHC tank level low low
Lube oil tank level low low
STG exhaust temp very high at 100 deg C
 STG trips on process failure
 Both HRSGs tripped
HRSG 1 or 2 drum level hihi HP +230mm, IP and LP +180mm
Tripped HRSG HP/IP/LP drum level is hi hi and its steam side isolation valve
not closed
 HRSG outlet HP steam temperature > 540 deg C & that HRSG is in service
 HP bypass steam temperature > 270 degC
 HP bypass steam pressure > 17.85 bar

 IP bypass steam temperature > 250 degC

 IP bypass steam pressure > 11.5 bar
 Hot well level hihi at 864 mm
 FST level hihi at 2849 mm
 Both CEPs tripped (Condensate system trouble)

 All three HP BFPs or LP BFPs tripped

 All three MCW pumps tripped

 Shutdown forcing a fast slowing down of the shaftline
The opening of the vacuum breaker valve is an EXCEPTIONAL OPERATION.
Leave to the initiative of the operator.

The main cases are

complete loss of the lube-oil (lube-oil pressure in the common pipe
under 0.4 bar)

high level of vibration

In that case, after the tripping of the steam turbine, the operator opens the
Vacuum breaker valve and stops the condenser vacuum system.
The gland steam system is still in operation.

Less than ten seconds after the vacuum-breaker valve has opened,
the condenser pressure increases from 0.2 to 0.5 abs. bar, which
fastly reduces the shaftline rotation.
As soon as the opening of the vacuum breaker valve is ordered,
the operator must watch the parameters on the main instruments, especially:

•vibrations,

•absolute and differential expansion,

•LP exhaust casing cover temperature,

•condenser pressure,

•starting of the turning-gear motor and jacking oil pump at 600 rpm,

•clutching of the turning-gear at 50 rpm

The slowing down time, with a vacuum broken in the condenser, between the turbine
trip and the barring speed must also be checked.
 COMPLETE SHUTDOWN OF STEAM TURBINE
In the case of a complete shutdown, the following operations could be done

Stop the control fluid pump in operation

 Watch the evolution of the casing temperature of the steam turbine

(through GRE TE208 and TE207) at barring speed.

When the casing temperature is under 100°C, stop the turning gear and check, on
CMS display, that the turning-gear motor has stopped, the turning gear is disengaged,
after final complete slow-down of the shaft line, stop the jacking oil pump.

The condenser circulating pump can also be stopped

 When the shaftline is completely stopped, the lube oil system can be stopped.

 The time for coasting down from 50 to zero speed is 15 minutes

STG COOLING
 Black-out of the power plant

In case of electrical black out trip the steam turbine. Most of motors
stopped (for instance the Gland steam condenser exhaust fan CET
EXT301 or CET EXT302). Manually isolate the steam turbine from
process. In order to limit any risk of damage on steam turbine, use the
“ fast slowing down ” procedure.

As soon as the vacuum is broken, manually stop the gland steam supply
 Operation under abnormal conditions

Pressure

Pressure must not exceed 105% of the nominal pressure(86.7 bar abs)

Momentary raise at120% of nominal pressure < 12 hrs / year.

Temperature

Temperature must not exceed 8.3 deg. C of nominal value ( 510.6 deg C)

 Between 8.3 deg. C to 14 deg. C above nominal value < 400 hours / year.

 Between 14 deg. C to 28 deg. C above nominal value < 80 hours / year.

Never should it increase above 28deg. C above nominal value.

Acceptable Temperature drop is a 50 deg. C instantaneous drop followed by 5 deg. C / min.

 STG Fail safe conditions

INSTRUMENT AIR CONTROL SUPPLY

CODE EQUIPMENT
FAILURE FAILURE

STG Gland steam

CET PCV 301 A OPEN OPEN
supply valve

STG excess Gland

CET PCV 301 B CLOSE CLOSE
steam dump valve

LP gland steam
CET TCV 302 OPEN OPEN
desuperheating valve

Condensate level
CET UY 330 controller in LP gland NA OPEN
steam supply line

STG exhaust hood

CAR TV 303 OPEN OPEN
spray

GPV UV 401 to 410 STG casing drains OPEN OPEN

 INCIDENT DATED 20TH AUGUST 2006 (IR 213)
 Station blackout happened due to disturbance in kondapalli sub station

 All three units tripped

 AC emergency board lost supply and running AC lube oil pump tripped

 EDG started on auto sensing power failure

 Station DC supply failed due to the opening of one cell in Station battery

 Due to DC failure the ACEMB incomer 1 did not close and there is no power supply
to critical drives
 Stand by AC lube oil pump from STG MCC did not start as there is no power supply
to STG MCC
 DC lube oil pump did not start as Station DC supply is not available

 Lube oil supply is not there for turbine and generator bearings
 STG came to standstill in 9 minutes with major damage to bearings and rotor
 Yes

Questions ?
No
Thank You