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SOP (Title) : TG Rolling and Synchronization

Ref No: SOMC/OPN/SOP/TG Rolling & Synchronization

Rev No: 0 335
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1.0 Purpose of the document:

The Purpose of this document is to provide general description and safe operating procedure of Turbine
rolling with necessary safety precautions.

2.0 Scope of coverage:

The document covers brief description of the preparatory steps, checklists and rolling procedure of turbine.
The usage of this document is limited only for the turbine rolling and synchronization procedure.

Personnel Qualification:
The operating person shall be minimum Diploma/Degree engineering qualified with basic understanding of
thermal power plant and its equipments. The responsibility is defined in section 4.0.

3.0 Definitions and abbreviations, specialized terms used

AOP : Auxiliary oil Pump

CCR : Central Control room
CF : Control Fluid
CRE : Control Room Engineer
CV : Control valve
CW : Cooling water
EPB : Emergency push button
GT : Generator transformer
HPT : High Pressure Turbine
HRH : Hot Reheat
IPT : Intermediate Pressure Turbine
JOP : Jacking oil Pump
LPT : Low Pressure Turbine
MCV : Main control valve
MOT : Main oil tank
PPA : Public Address system
PW : Primary water
SCE : Shift Charge Engineer
SGC : Subgroup control
SLC : Subloop control
SV : Stop valve
TSE : Turbine stress evaluator

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3.1 System Description:

Turbine rolling preparatory activities can be done parallely with the boiler drum pressure build up process.
The following systems are made available before turbine rolling process;
1. Condensate system
2. Feed water system
3. Gland seal system
4. Generator preparatory activity
5. Lube oil system
6. Control fluid and Governing system
7. CW system
8. HP-LP Bypass system.
The above systems can be made available by following its respective SOPs.

4.0 Procedure:
4.1. Turbine Protections:

Sl.no LOGIC/DESCRIPTION DELAY NORMAL ALARM TRIP

01 over speed trip device 1 -- -- -- --
02 over speed trip device 2 -- -- -- --
03 Low vacuum trip device -- -- -- --
04 Manual trip Device (Hand lever) -- -- -- --
05 Shaft vibration too High -- <50   >320
microns microns
06 condenser pressure protection VSP -- -- >0ksc >0ksc
07 condenser pressure protection FSP -- -- >0.2ksc >0.3ksc
08 lube oil pressure protection -- -- <4.5 ksc <1.2Ksc
09 Fire protection (switch operated.) -- --    
10 Fire protection (MOT tank level low -low) -- -- <1050 <1000mm
mm
11 HP Exhaust temp High -- -- >485 °C >500 °C
12 Main Steam temp. low -- -- <5000C <4800C
13 Axial shift very High -- +/- 0.3 mm +/- 0.5mm +/- 1 mm
14 HP casing top bottom Diff temp -- <55 0C >90 0C >100 0C
15 IP front top bottom Diff temp --   >30 0C >45 0C
16 IP rear top bottom Diff temp --   >30 0C >45 0C
17 TG bearing metal temp. trip 2 Sec 60-75 °C   >130 °C
18 Trip Switch Desk operated -- -- -- --
19 Trip Switch (console) operated -- -- -- --
20 Trip command from ATRS -- -- -- --
21 Generator mechanical protection -- -- -- --
22 Generator class B Electrical protection( Reverse -- -- -- --
power protection scheme )
23 Generator class A Electrical protection & -- -- -- --
Master Fuel relay Trip

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4.2 Operating Procedure:

Sl.no Activity Location Responsibility

A Prechecks:
1. Check all manholes in LPT, Cross around pipes,
Condenser, Generator are closed
2.Check all preservation devices like air dryer (if
any) are removed
3. Check power supply availability for drives, CCR/TG building Field Engineer/CRE
protective devices and supervisory equipments
4. Check levels of hotwell, MOT, control fluid tank,
are normal.
5. Check all the recorders are ready.
6. Filters and coolers are available.
7. Lube oil system in service from atleast 6 hours
before turbine start and now TG is put in barring
gear (refer SOP-11a).
8.CF system in service and temperature normal
(refer SOP-11c)
9. Condensate system in service (refer SOP-7a,7b).
10. Feed water system in service (refer
SOP-9a,9b,9c)
11. Vacuum system in service (refer SOP-11d).
12. Seal steam supply available (refer SOP-11e,13d).
Seal steam supplied to turbine seals once
condenser vacuum rises to -0.2 kg/cm2 .
13. Bypass system spray water available.
14. Vaccum Breaker water sealing done
15. CW system is available.
16. Hot well level normal.
17. Turbine Drain systems SLC ON and available
(refer SOP-11f)
18. Deaerator filled and steam charged (refer
SOP-13a)
19.LP dosing system available (refer SOP-16c)
20. CPU regeneration system available (refer SOP-
16a)
21. HP-LP Bypass system readiness
22. Hotwell level control and Deaerator level
control in auto mode. Take in manual mode if
necessary.

Generator checks:
1. Excitation system ready
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2. Seal oil system in operation

3. PW system in operation
4. Hydrogen gas filled
5. No Protection acted
6. No liquid in generator
7. Vapor extractor fans in operation.
8. Availability of CO2 and H2 cylinders.
9. Availability of Gas Drier.
10. PW temperature control ON
12. H2 temperature control ON
B Boiler light up done and pressure build up in CCR CRE
progress through startup-vent.
C 1. Electrohydraulic Governing system ON. CCR CRE
2. Speed reference value < Barring gear speed
3.Set Point for Starting & load limiting device- 0%
4.Speed setter Hydraulic governor- 100%
5. TSE ON and ready
6. Turbine Protection reset and ready
7.Turbine Casing differential temperature normal
HPT center top/bottom casing < 90 deg.cel
IPT front top/bottom < 30 deg.cel
IPT rear top/bottom < 30 deg.cel
D Check the status of following Drains: CCR CRE
1.MCV upstream drain: OPEN
2.HP outer casing drain: OPEN (<300 deg.cel)
3.CRH swing check NRV upstream drain: OPEN
4.Drain before and after IPCV: OPEN (< -20 deg.cel)
5.Drains ahead of HPCV: CLOSED
E 1. Check the valves below are CLOSED: CCR CRE
MS stop valve, Reheat SV, HPCV, IPCV, Extraction
valves, Swing check valve at CRH.
2. Open HP bypass line drains, MS to APRDS line
drains to IBD.
3. Open HP bypass warm up line valves
F At boiler pressure of 7-8bar slowly charge the MS CCR CRE
line. Criteria for opening MS stop valve fulfilled
(refer Annexure-1) OR MS stop valve temperature
<1000c
2. Open MS stop valve. Close the MS line drains
once the MS line steam is superheated and after
vacuum pulling.
3. Once the condenser vacuum rises to -0.8 kg/cm2,
HP-LP bypass system can be charged
4. Close the HP bypass warm up and drain valves
after the HP bypass stop valve is opened

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5. When the MS line pressure is 25-30 kg/cm2 and

criteria is fulfilled (ref: annexure-2), TG is ready for
rolling.

G 1.Set Starting & load limiting device >42% CCR CRE

H 1.SLC warm-up control and Tracking device: ON CCR CRE

2. SLC drains system: ON
3.Raise Starting & loading device set point to >56%
4.Reheat line stop valves: OPEN
I Control valve drains should be opened or closed CCR CRE
manually if the auto system fails to check the
temperature allowance of TSC/TSE channel.
J Set Load reference value >10% CCR CRE
K Set Speed reference value > 650 rpm CCR CRE
Note: Set value should be above minimum barring
gear speed range (i.e >510rpm)
Speed should be reduced if the TSE/TSC allowance
is reduced to zero.
L Check automatic closing of turning gear valve at CCR CRE
speed> 240rpm
M Check JOP cut off at speed > 540 rpm CCR CRE
N Check the following: CCR CRE
1.Steam Temperature criteria for superheat
(ref:Annexure-3)
2.Operational values of Turbine- normal
3. Turbine stress margin > 30
4. Bearing vibration: normal
5. Shaft vibration: normal
6. Bearing temperature: normal
O 1. Switch off warm-up control CCR CRE
2.Set Speed reference value > 3000 rpm
Note: Critical speed has to be crossed
quickly.TSE/TSC allowance has to be monitored.
P 1. Close Drains ahead of HPCV CCR CRE
2. Switch OFF Auxiliary oil pump
Q TG speed= 3000 rpm. CCR CRE
Check all the turbo supervisory parameters
R Generator Synchronization and loading: CCR CRE
1.Speed of TG set = 3000rpm
2.H2 Gas system normal
3. Seal oil system normal
4. PW system normal
5. No liquid in Generator
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6. Steam Temperature criteria fulfilled (ref:

annexure-4)
7. Excitation system in operation
8. Auto-synchronizer ON
9. Generator Voltage control ON
10. Starting and Load limit device 100%
Generator load > 10%
Speed reference value: High
Note: TSE at a minimum load changes from
temperature to Load scale.
11. GT breaker Closed once the synchronization
criteria achieved.
12. Check the auto closure of turbine casing drains.
13. Close the extraction line drains if Open.
14. Heaters in Operation
15. Extraction valve OPEN

S Check Bypass control and stop valve is closed and CCR CRE
Boiler/Turbine Load relation is 1.

4.3 Communication
 The SCE/CRE instructs the field operator to line up and check the readiness of various systems.
 After the line up and noting down the initial monitoring parameters, the operator gives feedback to
the CRE/SCE and awaits for the clearance.
 The internal communication shall be through Walkie-Talkies / Mobile Phones / PPA.
 Always ensure that, the communication instruments are in healthy condition.

5.0 Health and Safety Considerations

 Always wear Personal Protective Equipment (PPE).
 Ensure that, the maintenance works shall be performed with PTW under continuous supervision.

6.0 Approving Authority and Review

 Document shall be reviewed and approved for adequacy by the Head of Project /CEO prior to issue.
 SOPs should be also systematically reviewed on a periodic basis, e.g. every 1-2 years or as and when
required.

7.0 References
 Write up for Automatic Turbine Run-up System(ATRS) , Dwg no: 4-18000-1A-402
 Turbine O&M manual
 ATRS logics- Dwg.no: 4-18000-1A-071, 4-18000-1A-072
8.0 Data and Records Management
 The Master copy of the SOP shall be maintained with MTP department (library)
 Checklist to be maintained by the operator is attached in annexure-2

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Annexure-1: Criteria for opening of MS Stop Valve:

a)Minimum main steam temperature:

1. Ɵms > Ɵs (ref: fig-1)
Ɵms= Main steam temperature at boiler outlet
Ɵs= Saturated steam temperature at given MS pressure

2. Ɵms> f(Ɵmcv 50%) (ref:fig-2)

Ɵms= Main steam temperature at boiler outlet
Ɵmcv50%= Middle wall temperature of main control valve casing

b)Maximum main steam saturation temperature before turbine:

1. Ɵs> f(Ɵmcv 50%) (ref:fig-3)

Ɵs= Maximum main steam saturation temperature before turbine
Ɵmcv50%= Middle wall temperature of main control valve casing

Fig-1

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Fig-2

Fig-3

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Annexure-2: Criteria for starting turbine:

When the main control valves are opened, the main steam and reheat steam temperature should
fulfill the following criteria:
a) Minimum Main steam temperature:
1. Ɵms > Ɵs (ref: fig-1)
Ɵms= Main steam temperature at boiler outlet
Ɵs= Saturated steam temperature at given MS pressure

2. Ɵms> f(ƟHT 50%) (ref:fig-4)

Ɵms= Main steam temperature at boiler outlet
ƟHT 50% = Middle wall temperature of HP casing or simulated middle phase shaft temperature
b)Minimum reheat temperature:
1. Ɵreh > f (ƟIT 50%) (ref:fig-5)
Ɵreh = HRH line steam temperature
ƟIT 50% = Simulated midwall temperature of IP shaft

Fig-4

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Fig-5

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Annexure-3: Speeding up criteria:

Before bringing the turbine to rated speed, the main steam temperature before turbine should meet the
following criteria:
Minimum Main steam temperature:
1. Ɵms < f(ƟHT 50%) (ref: fig-6)
Ɵms= Main steam temperature at boiler outlet
ƟHT 50% = Middle wall temperature of HP casing or simulated midwall temperature of HP shaft

Fig-6

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Annexure-4: Loading Criteria:

Before the turbine is loaded the reheat temperature before turbine should fulfill the following criteria:
1. Ɵreh > f (ƟIT 50%) (ref:fig-7)
Ɵreh = HRH line steam temperature
ƟIT 50% = Simulated midwall temperature of IP shaft

Fig-7

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