 Confidential

Qurayyah CCPP Project

Fail Free Commissioning
- STEAM TURBINE GENERATOR
EPC) Commissioning Management Team

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copying of this document are strictly prohibited.
 SYNOPSIS
 INTRODUCTION ABOUT STG

 TURNING GEAR SYSTEM

 GLAND STEAM SYSTEM

 STEAM PURITY FOR ADMISSION

 BYPASS OPERATION

 STEAM TURBINE ROLLING

 ROLL TO FSNL

 FSNL TO SYNCHRONISATION

 STEAM TURBINE LOADING

 STEAM TURBINE PROTECTIONS

 STEAM TURBINE NORMAL PARAMETERS

2
INTRODUCTION ABOUT STG
STEAM TURBINE

1. Type of ST : D11
2. Make : General Electric.,
3. D11 classify with 10 stages in HP, 8 stages in IP and 6 stage double flow LP ,
Single reheat impulse type steam turbine
INTRODUCTION ABOUT STG
GENERATOR

TYPE : Hydrogen Cooled Generator (324)

MAKE : General Electric.,

SPECIFICATIONS

CAPACITY : 335.5 MVA

STATOR AMPS :10761 A
STATOR VOLTS :18 KV
FIELD AMPS :1609A
EXCITOR VOLTS :700V
POWER FACTOR :0.85
SPEED :3600 RPM
GAS PR RATING :60PSIg/413.7KPa
MAX. AMBIENT TEMP :50°C
MIN. AMBIENT TEMP : 5°C
MODE OF EXCITATION : SELF EXCITATION SYSTEM.

4
INTRODUCTION ABOUT STG

OPERATING PARAMETERS AT FULL LOAD

SECTIONS PRESSURE TEMPERATURE FLOW

HP STEAM 126.91 bar 567°C 53 kg/s

HRH STEAM 35.25 bar 565°C 175.9kg/s

LP STEAM 5.70 bar 299°C 199.6kg/s

5
INTRODUCTION ABOUT STG
.
FEATURES OF D11 MACHINE
1. Single Shell HP & IP sections.
2. Horizontally split with bolted joint flanges & cast from Low Alloy Steel.
3. Stop and Control valves are located off the shell and are separately supported with the main
steam piping system.
4. Free expansion of both rotating and stationary parts in all directions

6
INTRODUCTION ABOUT STG
FEATURES OF D11 MACHINE

1) HP/LP outer shell is supported at the centerline by 4 symmetrically arranged upper

shell arm that rest on the adjacent turbine structure.

2) 360°C arc first stage nozzle plate diaphragms are centerline supported.

3) The design concepts incorporates the free expansion on both stationary and rotating
parts in all directions.

4) Allowing expansion will evenly distributed around the center of the unit where the
signals are critical with respect to rotor.

5) During start ups or rapid load swings, the casings are expand free in both axial and
radial direction while diaphragms remains concentric with the rotor.

6) Two rotors, each supported on its own bearings. HP/IP are connected with solid bolt
coupling and LP rotor has a solid integral coupling for generator field.

7
INTRODUCTION ABOUT STG
STEAM TURBINE ROTOR (D11)
1) Forged Alloy steel rotor uses wheel construction that is an integral part of the shaft.
2) It is designed to carry the centrifugal load of the mechanically attached buckets.
3) This design results in small inter-stage shaft diameters and therefore decreases the sealing
diameter of the inter-stage packing which reduces leakage from the steam path & increase
the efficiency.
4) Integral wheel construction allows for thinner wheel thickness which minimizes thermal
stress across the wheel and the dovetail.
N2 PACKINGS
BUCKETS
NOZZLE

CRH

8
INTRODUCTION ABOUT STG
STEAM TURBINE WHEELS & BUCKETS
1) Machined surface of the outer surface of a wheel to which buckets are securely fixed.
2) Mechanical balance grooves are frequently located on rotor wheels to reduce the turbine
vibration.
3) Different shapes and size of the dovetails are cut into the wheel depending on the
locations.
4) Buckets transmits steam forces to the rotor assembly resulting in the rotation of the rotor.

9
INTRODUCTION ABOUT STG

INTERSTAGE
PACKINGS

RADIAL SPILL
STRIPS

10
INTRODUCTION ABOUT STG
ATMOSPHERIC RELIF DIAPHRAGMS
1) Atmospheric Relief Diaphragms located at the upper half of the low pressure sections of the
Steam Turbine.
2) It will release excessive positive pressure steam from the low pressure turbine.
3) Atmospheric Relief Diaphragms will protect against pressurization of both Exhaust hood &
Condenser.
4) At 0.35 bar positive pressure, knife cut the diaphragm.

11
INTRODUCTION ABOUT STG
SCHEMATIC VIEW OF THE STG MCV/MSV

IV/CRV

12
INTRODUCTION ABOUT STG
SCHEMATIC VIEW OF STG

ASV/ACV

13
 TURNING GEAR SYSTEM
1) The main purpose of turning gear is to avoid the uneven temperature distribution and to get the
easy moment of inertia.
2) This turning has clash pinion engagement with bull gear.
3) PNEUMATIC ACTUATED CYLINDER is used to engage both clash pinion and bull gear.
4) RPM of this turning gear is 6.3 rpm

1) Make : Durst
AC

2) Input rpm :1800

DC
3) Ratio :287:1

4) H.P :10

5) O/P rpm :6.3

14
TURNING GEAR SYSTEM
1) Turning Gear is the ILLINOIS GEAR TYPE, electric motor drive assembly.

2) T.G is located in the mid standard between L.P rotor and Generator.

3) The primary function of T.G is to slowly rotate the turbine during start up & shutdown when
rotor temperature change occurs.

4) To ensure that no temporary bow in rotor while restart.

5) T.G should be in service for 4 hours before start up.

6) If eccentricity is high, the rotor has to rotate 180°A from the shaft stopped position (10 times) to
correct the bow.

7) Flow of oil should be normal while machine in hot stand still position to prevent the rubbing of
bearings.

8) Rolling with high eccentricity will leads to permanent bow.

9) On T.G, the lube oil temperature must be 27°C to 32°C

15
 TURNING GEAR SYSTEM
ENGAGEMENT OF TURNING GEAR
1) The Turning Gear can be engaged manually or remote electro pneumatic engage mechanism
using local push button or auto electro pneumatic engage mechanism.

2) The turning gear can be started by putting control switch in auto mode through one low speed
switch.

3) The pre-engagement motor will start first and after certain rpm Bull Gear will engage with
pinion.
4) During shutdown the T.G will engage at 2 rpm

16
TURNING GEAR SYSTEM
T.G LCP & MODE OF CONTROL
1) JOG switch is the three position switch located in the LCP.
2) The position are JOG, START,STANDBY,STOP.
3) Normal position of the switch is STANDBY.
4) JOG switch enables when operator needs.

Turning gear can be run both AUTO mode & REMOTE MANUAL mode.

17
TURNING GEAR SYSTEM
PUTTING THE TURNING GEAR INTO OPERATION
1) Turning Gear motor is assumed to be in STOP position.

2) Turbine is assumed to be at rest with zero speed lamp on.

3) Make sure the lube oil pressure is normal.

4) At MCC, turn the T.G motor to run or auto switch position.

5) The T.G will start and engage automatically.

6) Normal operation will indicate with the sequence of display light.

7) After roll off, T.G will disengage when turbine speed exceeds the T.G speed.

8) T.G motor should be turned off.

9) If manual T.G operation, T.G motor switch must be turned to RUN.

10) Manual PB pushed for manual engage mode then manual engagement will accomplished.

18
TURNING GEAR SYSTEM
FAILURE TO TURN THE T.G
1) We have electro pneumatic engage mechanism to engage the T.G
2) Two limit switch available to indicate the engage & disengage position.
3) Manual barring should be put by hand until temperature of rotor comes down.

PROCEDURE:
4) Remove the thimble from the top cover of the motor.
5) Place the torque wrench with long handle to rotate.
6) Manually engage the gear with spring operated lever.
7) Rotate the turning gear till re-energize of the pre-engage motor starts.

LIMITSWITCH

MANUAL
ENGAGE

19
TURNING GEAR SYSTEM

20
GLAND STEAM SYSTEM
1) The main purpose of gland steam is to arrest the steam leak in HP side and ingress of air in
the LP side.
2) At start up, introducing steam through intermediate packing rings and coming out from
outer packing rings to GSC.
3) S.T load increases , steam flow out from HP,RH packs are sufficient to seal LP packs.
Then it is said to be “self – sealed”
4) Constant set value for seal steam is 129 kpa /360°C

21
GLAND STEAM SYSTEM
1) Excess of steam from HP packing above the requirement of LP section will dumped to
condenser through dump valve (SSDV).

2) Seal steam can apply only when the machine in T.G to avoid the temporary thermal bow in
rotor.

SSFV

SSDV

22
GLAND STEAM SYSTEM

23
GLAND STEAM SYSTEM
LABYRINTH SEAL ASSEMBLY

LABYRINTH
TOOTH

24
STEAM PURITY FOR ADMISSION
1. To minimize deposits and corrosion throughout the entire steam path including HRSG, ST and condenser.
2. Requires short term operation in action level impurity levels to fully clean up the HRSG or Steam
generator.
PARAMETERS FOR REHEAT STEAM PURITY FOR DRUM TYPE BOILER WITH REHEAT USING AVT
(ALL VOLATILE TREATMENT).

PARAMETER SAMPLE NORMAL ACTIVE ACTIVE ACTIVE

LE VEL 1 LE VEL 2 LE VEL 3
SODIUM ppb C ≤3 >3≤6 >6≤12 >12

C.C µs/cm C ≤0.15 >0.15≤0.25 >0.25≤0.45 >0.45

SILICA ppb T ≤10 >10≤20 >20≤40 >40

CHLORIEDE T ≤3 >6≤12 >12

>3≤6

SULPHATE T ≤3 >3≤6 >6≤12 >12

TOTAL ORGANIC W ≤100 >100 - -

CARBON ppb

25
BY PASS OPERATIONS

1) HP main steam line is warmed up by opening the HP steam stop valve.

2) HP Bypass will open for 10% to allow the steam into HP bypass line.

3) After that HP Bypass will control the minimum HP set pressure (49.64 barg) &
temperature is 450°C.

4) Bypass valve will maintain 50 bar which will ready to admit the steam.

5) RH steam vent to atmosphere till HRH Bypass valve (215°C)start to open.

6) Besides we can warm up the IP & LP steam line.

7) When the condenser pressure below 0.5 barA, HRH Bypass & LP Bypass will open..

26
STEAM TURBINE ROLLING

ALLOWABLE STEAM TEMPERARTURE BEFORE ROLLING

The start type can be determined by looking out the BOWL METAL TEMPERATURE at the time
the unit is rolled.

COLD STARTS
BOWL METAL TEMPERATURE : BOWL METAL <400°F

WARM STARTS
BOWL METAL TEMPERATURE: 400°F<BOWLMETAL<700°F

HOT STARTS
BOWL METAL TEMPERATURE: BOWL METAL>700°F

27
STEAM TURBINE ROLLING
PRE CHECKS BEFORE ROLLING THE S.T
1) HPU must not running before energizing the steam turbine control cabinet.
2) Turn off all the HPU and energize the ST control cabinet.
3) Verify the turbine tripped status at the ST control operator interface.
4) All turbine steam valves should be closed.
5) Excitation controls, Generator controls and Generator breaker should be ready for operation.
6) Generator and Exciter protective relays should be reset.
7) All the protective trip functions enabled after resetting the turbine controls.
8) Off line ETD (Electrical Tripping Devices) functional check should be performed.
9) Bearing oil must be established prior to put the unit in TG.
 one AC oil pump must indicate running.
 Second oil pump and DC oil pump must be in auto start.
 Bearing oil header pressure should be above the minimum of 25±3psig (172.4±20.7 kpa)
 Put the unit in turning gear.
10) Place the HPU in service.
 One hydraulic pump should run.
 Another pump should be ready for standby condition.
 Hydraulic pressure should be with in the limit.
 Cooling flow must be established.
 Oil temperature in the tank must be normal.

28
STEAM TURBINE ROLLING
TURBINE STATUS PRIOR TO ROLL
1) Turning Gear - ENGAGED

2) Steam seals -ON

3) Steam seal feed valve -OPEN

4) Drains -OPEN

5) Condenser vacuum -AVAILABLE

6) HP Evacuation valves -OPEN

7) Main control valves -CLOSED

8) Main stop valves -OPEN

9) Reheat stop valves -CLOSED

10) Intercept control valves - CLOSED

11) LP Admission control valve -CLOSED

12) LP Admission stop valve -OPEN

29
STEAM TURBINE ROLLING
PERMISSIVES TO ROLL THE S.T
PARAMETERS MENTIONED BELOW SHOULD BE IN ALLOWABLE RANGE
1) Shaft Eccentricity Rate of Change.
2) Lube oil temperature.
3) Reheat steam temperature.
4) Steam seal temperature.
5) HP steam temperature.
6) Reheat pressure.
7) Main steam pressure.
8) DCS permissive satisfied.
9) HP/IP differential expansions.
10) Turbine drain conditions satisfied.
11) Turbine instrument health satisfied.
12) Turbine reset
13) condenser pressure below the alarm limit.
14) HP & RH bowl metal temperature above the minimum temperature.

30
STEAM TURBINE ROLLING
EFFECT OF STARTING ST WITH THERMAL BOW IN ROTOR

ECCENTRICY HIGH

31
STEAM TURBINE ROLLING
RATE OF CHANGE OF SHAFT ECCENTRICITY

1)Rolling the turbine with temporary thermal bow will leads to elevated
vibration, radial rubs and ultimately to vibration trips
2)This permissive can be manually overridden if no thermal bow in the rotor is
concluded.
3)The permissive should not be overridden if the unit in turning gear and
thermal bow remaining in it.
4)If long term eccentricity is flat but data appears noisy, then there is no thermal
bow.
5)Eccentricity probes don’t properly sense the small range near to probe and
axial location and large range far from the probe.
6)Mark Vie calculates the rate of change of eccentricity until the value comes
below the specified limits for the permissive to roll the ST.
7)Operators should wait for eccentricity rate of change will come to 0.0mils/min
and till remaining bow go away.

32
STEAM TURBINE ROLLING
LUBE OIL TEMPERATURE

1) Viscosity of oil will increases with decrease in lube oil temperature. Due to this,
film thickness between rotor and journal will increase. So during acceleration , oil
film instability and vibration will occur.

2) High lube oil temperature decreases the oil viscosity and decrease the film
thickness between rotor and journal bearings.

3) At turning gear speed , this condition results in damage of journal bearings.

4) Ensure the lube oil temperature is greater than the control system limit to avoid the
high speed hold.

5) To get consistent fast start times, the high speed hold is avoided.

6) It also minimizes the amount of time spent in low flow operation .

7) High flow operation will encounter the radial rub induced vibration

33
STEAM TURBINE ROLLING
REHEAT STEAM TEMPERATURE
1) Reheat steam temperature should be in allowable range to roll the steam turbine. It can be
taken from Reheat steam to metal temperature matching curve
2) The lower temperature set is to prevent wet steam and water induction into turbine.
3) The upper temperature set is to prevent rotor stress , long rotor differential expansion
and radial rub induced vibration.
4) For cold start , the minimum steam temperature condition to be achieved prior to roll as
long as steam remains superheated.
5) RH steam temperature should be greater than the RH upper bowl metal temperature
to prevent forced cooling, quenching of parts leads radial rubbing, differential
expansion move towards short rotor limits. Imparts reverse stress cycle on rotor

6) It will increases the start up time because additional time is required to reheat the parts
which just cooled.
7) For hot start, the acceptable negative mismatch in temperature is allowed to start the roll.
8) The limits for the reheat steam to metal temperature has configured with this
considerations.
9) when combined with the low flow conditions associated with FSNL operation elevated the
temperature in the latter LP stages may be encountered.
10) In this condition, load has to be increased.
34
STEAM TURBINE ROLLING
RH STEAM TO METAL TEMPERATURE MATCHING CURVE

35
STEAM TURBINE ROLLING
STEAM SEAL TEMPERATURE
1) Steam seal temperature limit are set to prevent water/ wet steam induction, rotor
differential expansion, maintaining the radial clearance between rotating and
stationary parts.
2) To minimize the thermal fatigue of parts and prevent the turbine seals expose to
temperature above the limit.
SEAL STEAM TEMPERATURE LIMIT CURVE

36
STEAM TURBINE ROLLING
HP STEAM TEMPERATURE MATCH LIMIT CURVE

Main steam to HP bowl metal temperature matching limit curve which are built into the Mark
VIe system. Its similar to the RH system discussed in above slide

37
STEAM TURBINE ROLLING
REHEAT STEAM PRESSURE

1) RH steam pressure must be high so I.V can control acceleration without swinging to large
change in valve positions.
2) RH pressure low then I.V will open 100% to maintain the desired acceleration rate.
3) In this case, RH steam production increases then uncontrolled acceleration can occur.
4) I.V take some time to control that acceleration with in controlled range.
5) Optimal RH pressure for all type of start is the minimum pressure in which speed can be
controlled by I.Vs while maintain stability in RH Bypass system

MAIN STEAM PRESSURE

6) Acceleration and Initial loading performed by I.Vs with the HP section evacuated.
7) When turbine allow M.S , all conditions should be executed to transfer to HP flow mode
8) For more starts, floor pressure will be target value for throttle pressure.
9) All the unit specific limits will available in the permissive control screen.

38
STEAM TURBINE ROLLING
EXAMPLE FOR RH PRESSURE ABOVE THE LIMIT

OPENING OF IVs

HRH PR

39
STEAM TURBINE ROLLING
DCS PERMISSIVES

1) To deliver a consistent reliable in steam turbine start ups.

2) DCS controller determine the permissive to roll.

3) All permissive in DCS controller satisfied then only ST

HP/IP DIFFERENTIAL EXPANSION

4) HP/LP rotor limit must be below the long rotor alarm limit.

5) Due to additional heating during roll, long rotor differential expansion trip may occur and
leads to axial rubbing.

6) The differential expansion is above the limit when the machine on turning gear, the seal steam
temperature should be raised.

7) Installation of the probes should be proper.

40
STEAM TURBINE ROLLING
HP & RH BOWL METAL TEMPERATURE
1) Initial HP/RH bowl metal temperature must be above the minimum limit.
COLD ST RESPONSE TO STEAM SEAL WARMING

41
STEAM TURBINE ROLLING
STEPS TO ADMIT THE STEAM:
1) When the condenser pressure reaches 0.16 bar and HRH steam pressure reaches 13.84 bar.
Intercept valve of IP turbine will start to open.
2) IP turbine IV will admit the steam into turbine initially and turbine speed starts increase.
3) ST speed reaches 2400rpm, RFV(Reverse Flow Valve) and RFDV (Reverse Flow
Discharge Valve) will open to avoid overheating of HP turbine.
4) On this way, ST has reached FSNL through Acceleration Rates and Speed Holds.
HRH SUPPLY

C
R  C
V R
V

42
ROLL TO FSNL
TURBINE STATUS
1) STEAM SEALS -ON

2) STEAM SEAL FEED VALVE -OPEN

3) DRAINS -OPEN

4) HP EVACUATION VALVES -OPEN

5) MAIN CONTROL VALVES -CLOSED

6) MAIN STOP VALVES -OPEN

7) REHEAT STOP VALVES -OPEN

8) INTERCEPT CONTROL VALVES - OPEN & THROTTLING

9) LP ADMISSION CONTROL VALVE -CLOSED

10) LP ADMISSION STOP VALVE -OPEN

43
 ROLL TO FSNL
ACCELERATION RATES & SPEED HOLDS

1) Acceleration Rates are automatically selected by Turbine Control System (Mark VIe )
based on initial RH bowl temperature.
RH Start metal temp at ROLL Acceleration Rate
(%/min)

Temp < 148.9°C 6.7

148.9°C<Temp<315.6°C 10.0

Temp>315.6°C 20.0

2) The speed can be hold at either 1000 rpm / 3000 rpm for 60 Hz units.

3) The speed hold time request can be initiated by CCR operator.

4) If the speed hold request is initiated below low hold point , then Mark VIe will
accelerate the turbine to the low hold set point.

44
ROLL TO FSNL
ACCELERATION RATES & SPEED HOLDS

1) Listen abnormal sound for internal rubbing during acceleration of S.T towards low
speed hold set value.

2) If sound found, then stop the S.T and get down the machine to Zero speed.

3) Engage the turning gear for 2 to 4 hours operation to go for another start up

4) Observe the shaft eccentricity and vibration level before restart

5) If vibration & eccentricity more than the limits, then S.T should go for maintenance
with the vendor.
6) While synchro lube oil temperature should be >37.8°C.

45
ROLL TO FSNL

AUTO FUNCTIONS

 Select the Acceleration Rate

 Initiate speed hold

 Downshift to lower A.R based on rotor stress and actual A.R

MANUAL FUNCTIONS

 Initiate speed hold

46
FSNL TO SYNCHRONIZATION
TURBINE STATUS
1) STEAM SEALS -ON

2) STEAM SEAL FEED VALVE -OPEN

3) DRAINS -OPEN

4) HP EVACUATION VALVES -OPEN

5) MAIN CONTROL VALVES -CLOSED

6) MAIN STOP VALVES -OPEN

7) REHEAT STOP VALVES -OPEN

8) INTERCEPT CONTROL VALVES - OPEN & THROTTLING

9) LP ADMISSION CONTROL VALVE -CLOSED

10) LP ADMISSION STOP VALVE -OPEN

47
FSNL TO SYNCHRONIZATION
EXCITATION CONTROL

48
FSNL TO SYNCHRONIZATION
CAPABILITY CURVE

49
FSNL TO SYNCHRONIZATION
AUTO PERMISSIVES FOR SYNCHRONIZATION

All the permissive should glow RED.

52G should be opened conditions.
Sychro lock out (L86S)
Bus Voltage
Bus frequency
Generator voltage
Generator frequency
Difference in volts
Difference in frequency
Sequencing sychro permit
Auto synchro permit

NOTE: SLIP SETPOINT TO BE SET BEFORE SYNCH.

50
STEAM TURBINE LOADING
Now STG in SPINNING RESERVE.

1) Loading after synchronization will continue in REVERSE FLOW MODE.

2) Intercept valve only operate with change in load set point.
3) When the I.Vs demand exceed 50%, the loading will be transfer to FORWARD FLOW MODE
with a message.
4) NOTE: MARK VI e will predict HP rotor stress by seeing mismatch of steam & metal
temperature
5) Predicted stress is more than allowable it will give load hold command if ST in auto.
6) HP steam temperature and stress should reduce before transfer to forward flow mode.

IN AUTO MODE : The Turbine controls will automatically transfer to FORWARD FLOW
IN MANUAL MODE : Select FORWARD FLOW MODE while in REVERSE FLOW.
The status will be displayed in HMI.

51
STEAM TURBINE LOADING
REVERSE FLOW OPERATION

52
STEAM TURBINE LOADING
RATED RH TEMPERATURE AND PRESSURE LIMITS

565.5 C

34.6 bar 36.9 bar

53
STEAM TURBINE LOADING
RATED INLET PRESSURE AND TEMPERATURE CURVE

565.5 C

135.6 bar

129.2 bar

54
STEAM TURBINE LOADING

OBSERVATION WHILE S.T TRANSFER TO FORWARD FLOW

1) The MCVs open to their steady-state position in 15 sec approx.

2) RFV & RFDV will close.

3) Group-A drains will close (M.S lead drains, Main stop valve before and after seat drains, )

4) HP Bypass valve position decreases.

5) Generated MW will be increased.

6) Turbine will load by open the MCVs & IVs as increase in load reference until HP & LP
Bypass valve closed.

55
STEAM TURBINE LOADING
FORWARD FLOW OPERATION

56
STEAM TURBINE LOADING
SYNCHRONIZATION TO HP FLOW MODE
1) STEAM SEALS -ON

2) STEAM SEAL FEED VALVE -OPEN

3) GROUP A DRAINS -CLOSE AFTER TRANSFER TO HP FLOW MODE

4) GROUP B &LP ADMISSION DRAINS - OPEN

5) HP EVACUATION VALVES - CLOSE AFTER TRANSFER TO HP FLOW MODE

6) MAIN CONTROL VALVES -OPEN UPON TRANSFER TO HP FLOW MODE

7) MAIN STOP VALVES -OPEN

8) REHEAT STOP VALVES -OPEN

9) INTERCEPT CONTROL VALVES - OPEN

10) LP ADMISSION CONTROL VALVE -CLOSED

11) LP ADMISSION STOP VALVE -OPEN

57
STEAM TURBINE LOADING

N2 PACKING
1) The steam extracted from 6th stage of the HP turbine through the valve called (RHCV)
“First stage reheat cooling valve”.
2) It is used to cool N2 packing when the forward flow started with 41bar/462°C.
3) RHCV is energize to close. CSBV (Cooling Stage Block Valve) used for positive shut off.

RHCV CSBV

ORIFICE

58
STEAM TURBINE LOADING
N2 PACKING
CSBV CLOSE
1) when turbine tripped.
2) CVs & I.V closed due to over speed.
3) In reverse flow

CSBV OPEN
4) Speed<300 rpm to prevent coil burnt out

59
STEAM TURBINE LOADING
1) LP admission is enable after turbine reached around 15 to 25 % of load.
2) LP header pressure will be 3 barA.
3) Any variations in LP admission flow will not affect load as much.
4) LP section requires admission flow for cooling steam while S.T in light load.
5) Adjust admission pressure set point towards 100% through (Bypass target + bias)
6) Close the Group-B drains (CRH & HRH PIPING DRAINS, CRV AFTER SEAT DRAINS,
HP/IP TURBINE SHELL DRAINS) at 15% to 25% load.

LP ADMISSION
LINE
ACV/ASV

60
STEAM TURBINE LOADING
FORWARD FLOW + LP ADMISSION OPERATION

61
STEAM TURBINE LOADING
IPC CONTROL MODE
1) IPC means Inlet Pressure Control
2) IPC can be enabled at any time after turbine run in forward flow mode and generator load >
20%.
3) Give max. load set point in IPC then, IPC can respond full range of inlet pressure demand.
4) Verify IPC is out of service.
5) Check the pressure transmitters sensing line open and verify expected signal is coming or not in
operator interface.
6) Transition from speed /load to IPC is designed to be BUMPLESS.(no change in process output
during auto to manual selection.).
7) IPC will calculate the set point based on the control valve positions.
8) If the calculated set point is minimum than the allowable, then minimum set point is used.
9) Place IPC in service. IPC IN field on the display will turn to yellow.
10) In IPC mode, steam production will determine the position of MCVs.
11) Increase in steam flow will increase the turbine load.
12) If S.P left in one position, increase in steam flow will rise valve open and inlet pressure will rise .
13) Control will hold the load or temperature ramp rate to maintain the stress and differential
expansion with in a limits.

62
STEAM TURBINE LOADING
S.T IN FULL LOAD

63
STEAM TURBINE LOADING
The subject steam turbine was evaluated for cold, warm and hot starts.
The estimated startup times are based on following data and assumptions

1) HP rotor diameter
2) Boreless HP rotor
3) HP centrifugal bore stress at rated speed
4) IP rotor diameter
5) Boreless IP rotor
6) IP centrifugal bore stress at rated speed
7) HP/IP rotor material
8) First stage Bowl metal Temperature
Cold is 130F
Warm is 675F (typically after 60hrs shutdown)
Hot is 980F(typically after 8hrs shutdown)

The time taken by steam turbine to reach 100% load is as mentioned in table below:
Cold 175 mins
Warm 90 mins
Hot 30 mins

64
STEAM TURBINE LOADING
COLD START UP CURVE

65
STEAM TURBINE LOADING
WARM START UP CURVE

66
STEAM TURBINE LOADING
HOT START UP CURVE
HP/RH STEAM

67
STEAM TURBINE PROTECTION
AUXILLARY TRIP 1:

1) Low lube oil pressure trip.

2) Hydraulic oil pressure low trip.
3) HP exhaust temp high trip.
4) L-1 stage steam temperature trip.
5) High exhaust temp trip.
6) Exhaust vacuum trip.
7) Off line ETD test trip.
8) Shutdown trip.

AUXILLARY TRIP 2:

9) Zero speed trip

10) Turbine trip on Bypass Error.
11) HP turbine speed trip.
12) HP zero speed.

68
STEAM TURBINE PROTECTION
AUXILLARY TRIP 3:

1) HP Accel / Deaccel rate too high.

2) Manual emergency trip circuit enabled.
3) Process trip from BOP DCS.
4) Unit trip via 86G 1A lockout relay.
5) GSU transformer lock out trip.
6) Gen breaker failure lockout relay trip.
7) Unit trip via 86G1B lockout relay.
8) Speed deviation above the limit trip.

AUXILLARY TRIP 4:

9) Axial position trip.

10) Axial probes failed trip.
11) Axial probes failed or position trip.
12) Differential expansion trip.
13) Vibration trip.
14) Rotor expansion trip.

69
 STEAM TURBINE PROTECTION
SIX MAGNETIC PROBES TO
SENSE SPEED OF ST

VIBRATION

SPEED

THRUST

VIBRATION

SPEED

70
S.T NORMAL PARAMETERS
SECTIONS PRESSURE (BAR) TEMPERATURE (°C) FLOW
(KG/HR)
MSV INLET 123.4 565 279940
MSV OUTLET 122.4 565 279940
TURBINE MAIN 121.58 564.4 559879.4
STEAM INLET
CRV INLET 33.63 565 318919
TURBINE HRH INLET A/B 33.3 563.67 318919
RH BOWL 33.3 563.6 -

CROSS OVER 4.76 301 -

ASV INLET 5.32 255 90040.11

ASV OUTLET 5.32 255 90040.11

ACV INLET 5.32 255 90040.11

ACV OUTLET 5.11 259 90040.11

HP EXHAUST CRHA 38.15 392 271405

HP EXHAUAT CRH B 38.15 392 271405

71
S.T NORMAL PARAMETERS
SECTIONS PRESSURE (BAR) TEMP (°C) FLOW (KG/HR)

RHCV INLET 63.31 462 -

RHCV OUTLET 41.39 462 -

CSBV INLET 63.31 462 3524

CSBV OUTLET 41.39 462 3524

1st RH COOLING 63.31 462 3524

STEAM AT STAGE 6
N1 PACKING LEAK OFF 4.76 365 3055

SSFV INLET 14.98 260 2485

SSFV OUTLET 0.276 316 2485

SSDV –U INLET 0.276 316 1437

SSDV-U OUTLET 0.276 316 1437

SSDV –D INLET -0.32 316 1437

SSDV- D OUTLET -0.32 315 1437

EXHAUST CASING -0.9 47.11 -

72
THE END
THANKS TO ALL

73