GT START-UP PROCEDURE

3 Fuel GAS/HSD/Naphta.
PRESTART CHECKS :
1.
Ensure all valve positions and spades / blinds are ok after water wash.
2.
Ensure spade provided on water wash inlet line.
3.
Check all instruments and lines are fitted with proper support/clamps.
4.
Checking of GCV, SRV and Liquid Fuel Control valve strokes.
5.
IGV angle stroke check.
6.
Check the operation of Purge air three-way valve (VA19).
7.
Check False Start drain line and Telltale leak off line for any choking.
8.
Check Load gear and turbine compartment vent fans auto changes over.
9.
Check free rotation of Liquid fuel Flow Divider.
10. Check lube oil level (should be more than 75%)
11. Line up cooling water to lube oil cooler and atomising air cooler .
12. Keep the atomising air cooler inlet and outlet drain (isolation) valves open up to
FSNL.
13. Check the position of compressor bleed valves and confirm that these valves are
open.
14. Ensure bearing sealing air isolation isolation valve is open.
15. Ensure that guillotine damper is open and diverter damper is closed.
16. Check the position of IGV and also check for any leaks in the hydraulic oil
system.
17. Drain BHAG KOD and BHAG line near GT for any condensate / water.
18. Check that the control interlock and protection DC circuit is free of any ground
fault.
19. Check for any alarm existing at MARK V.
20. Put portable fire extinguisher near fuel forwarding skid and also near GT.
21. Check the quality of spark from spark plugs before installing .
22. Check all flame detectors are healthy.
ACTIVITIES :
1.
Check the lube oil circuit physically. Connect electrically AOP (88QA) and
ratchet pump (88HR) and start Ratcheting from the panel. Check the following :
AOP discharge pressure and lube oil header pressure
Individual bearing i/l header pressure
proper flow of lube oil through all return line sight glasses
Any leakage in the circuit.
2.
check lube oil mist eliminator fan (88QV) is running with ratchet selection and
set the vacuum pressure at - 50 mmwc.
3.
Following motors are to be electrically connected , kept on auto and manual
STOP PB s are to be kept in unlock position.

Load Gear vent fans 88VG1 / 2

Turbine compartment vent fans 88BT1 / 2

Accessory compartment vent fans 88BA1 / 2

Gas compartment vent fan 88VF

Auxiliary hydraulic oil pump 88HQ

Frame blowers 88 TK1 & 88 TK2

WARREN pump lube oil motor 88QA2 & 88QE2

Naphtha scavenging fan 88NS.

4.
Check the following in Diesel Engine
i.
DM water level (> 80%)
ii.
Lube oil level (F)
iii.
Diesel tank level ( > 80% )

iv.
Diesel engine cooling water inlet and outlet valves are open .
v.
Fuel cut off lever position ( pulled out )
5.
HSD lining up :

Check the HSD line up in filter skid and keep the isolation valve u/s of 3 way
c/o valve closed. Confirm the long recirculation valve is full open.

Confirm the vents and drains of the filters which are in line are fully closed.

Line up HSD to HSD pump from the standby Day tank .

Prime both the filters and pumps.

Confirm both the pumps are on MAN on panel.

Keep the PCV KPIC656 on MAN and give 10% MV.

Connect both the pumps electrically.

Start one pump and slowly open the discharge valve . Check the discharge
pressure and also filter DP.

Open the discharge valve of the other pump and put it on auto. Confirm its
STOP PB is released.

Prime the 25 micron & 5 micron filters which are in line. Also, charge the stand
by filters , prime and keep ready for change-over.

Start drain tank sump pumps and empty out so that any leakage in the system
can be indicated by the increasing level of the drain tank.

Prime the HSD line d/s of 3 way c/o valve (88FT) upto the liquid fuel stop
valve ( VS1 ).

Open the topmost vent inside acc. compartment

Crack open the isolation valve u/s of 3 way c/o valve

Once full bore HSD comes from the vent , close the vent valve fully.

Open the isolation valve fully.

6.
Check EOP cut-in with ratcheting by stopping AOP by logic forcing .
7.
Connect diesel engine starter motor 88DS and give START command to
GT.

CHECKS AFTER START COMMAND:

1.
Check diesel engine fuel pressure (5 kg./cm2)
2.
Check diesel engine cooling water o/l temperature ( max. 85 degree C)
3.
Cross check the diesel engine local tachometer reading with the panel reading
at different stages.
4.
Check the condition of diesel engine exhaust.
5.
Check the FSD outlet for any liquid as soon as diesel engine starts
accelerating. In case of any liquid coming, cranking to be continued till dry air
comes.
6.
Check the auto cut-in of warren pump AOP ( 88QA2 )
7.
Check the condition of booster air compressor.
8.
Check the general condition of the compartments at cranking speed for any
noise or abnormal sounds.
9.
Check the liquid pressure at selector valve assembly while firing and control
HSD pressure this time.
10. Check the auto cut-in of turbine compartment vent fan after firing takes place.
11. Check the auto cut-in of accessory and load gear compartment vent fan .
12. Continuously monitor flow divider pressure and leaks from ferrule joints of
liquid fuel lines.
13. Check that the diesel engine is disengaged at around 60% speed .
14. Check for stopping of diesel engine automatically after cool down. If not, diesel
engine to be stopped manually by pushing the fuel cut-off lever in .

15. Monitor the following on panel continuously :

exhaust temperature plot
spread
flame detector readings
bearing vibration
bearing metal and drain temperatures
lube oil and atomising air temperature
opening of IGV
CHECKS TO BE CARRIED OUT AT FSNL:
1.
Check the bleed valves are closed.
2.
Check the auto cut in of frame blowers one by one with a time delay of 1 min.
3.
After removing water contents start self cleaning of air inlet filters.
4.
Check the auto cut in of AOP, EOP & AHOP by isolating the pressure switches
( 63QA, 63QL & 63HQ ) on the local gauge panel.
5.
Check the mist eliminator suction pressure. Maintain it at 50 mmwc by
adjusting the bypass valve.
6.
Check the following readings
Flow divider pressures
MOP discharge pressure, Lube oil header pressure, Hydraulic oil pressure, Trip oil
pressure, all filter DPs , CPD , Atomising air pressure, all bearing lube oil inlet
pressures, warren pump lube i/l and return pressures & filter DP, HP filter DP etc.
7.
Check the position of IGV (57-degree angle).
8.
Check any hydraulic oil or HSD leaks. Also, monitor the drain tanks level .
9.
Commission CO2 fire fighting system.
10. Check all parameters in MARK-V <I> STATION.
11. Check for any flue gas leakage from. the exhaust duct manway or bellows.
SYNCHRONIZING:
1.
After ensuring all parameters are Normal GT can be synchronise .
2.
As soon as GT breaker is closed, Machine will take spinning reserve load of 4
MW.
3.
Machine can loaded as per requirement.
4.
Due to sudden increase in HSD flow, pressure might come down drastically.
So, during this period continuously monitor HSD pressure and control if necessary.
DIESL ENGINE TRIAL ON TEST MODE
GT Staring Diesel Engine can be tried on test mode by disengaging the starting
clutch. Following procedure is followed for this test
1.
Ensure diesel engine for cooling water, engine oil, and diesel tank levels.
2.
Disengaging the clutch
i.
Isolate 88DE and 88HR motors modules
ii.
Open the guard on the clutch assembly.
iii.
Connect 88HR and start ratcheting
iv.
Before the forward stroke put the clutch disengagement manual 4 way
valve VM2-1 lever on Disengage position.
This will disengage the clutch during reverse stroke. Check it physically also at
MARK-V from L33HR-1 position.
3.
Once the clutch is disengaged put off the ratcheting immediately otherwise the
ratchet mechanism will remain ON continuously.
4.
Isolate 88HR motor module.
5.
Connect 88DE motor
6.
Select Diesel Engine test mode on MARK -V panel.

7.
Start diesel engine by pressing 43DE-1 (diesel engine test switch) locally.
Diesel engine will run till this switch is kept in press condition.
8.
After satisfactory run and checking engine parameters release the switch.
9.
Isolate the 88DE motor.
10. Come out of Diesel Engine test mode on MARK-V panel
11. Normalising Clutch: i.
Put back the clutch disengagement manual 4 way valve VM2-1
lever on Engage position.
ii.
Connect 88 HR motor and start ratcheting.
iii.
The clutch will get engaged in the forward stroke.
iv.
Check the clutch physically and from L33HR-1 position in MARK -V
12. Stop ratcheting and put back the guard on the clutch assembly.
13. Re-Start ratcheting.
GT INTERLOCKS
AUXILARY SYSTEMS:
SL NO
DESCRIPTION
1
2
3
4
5
6
7
2

SETTING

Diesel engine lube oil pressure switch 63QD-1

Lube oil header temperature high alarm 26 QA-1
Lube oil header temperature high trip 26 QT-1A,1B
Lube oil pressure low alarm 63QA-1 AOP start
Lube oil pressure low EOP start 63 QL-1. Refer MCC drawing.
Lube oil filter differential pressure high alarm 63QQ-1
Lube oil mist eliminator pressure switch 63QV-1
L63QTX low lube oil pressure trip L63QT 2A, L63QT 2B, & L63QA

0.28 Kg/Cm2
740C
790C
1.1 Kg/Cm2
0.4 Kg/Cm2
0.75 Kg/Cm2
0.7 Kg/Cm2
0.55, 0.55, and
1.1 Kg/Cm2

8
9
10
11
12

(2/3logic )
High lube oil level 77QH-1
Low Lube oil Level 77 QL-1
Turbine exhaust frame cooling air pressure low 63TK-1,2
Hydraulic trip pressure low gas stop valve 63HG-1,2,3 (2/3 logic)
Hydraulic trip pressure low Liquid Fuel stop valve 63HL-1,2,3 (2/3

13
14
15
16
17

logic)
Hydraulic filter differential pressure alarm 63HF-1
Low Hydraulic oil supply press. AHOP start 63HQ-1
Gas fuel pressure low alarm 63 FG-3
Liquid fuel pressure low trip 63 FL-2 with tome delay of 60 sec.
Warren LO header temperature high trip (26QT-3) with TD of

3.4 Kg/Cm2
72 Kg/Cm2
11.6 Kg/Cm2
1 Kg/Cm2
760C

18

sec
Warren LO pressure low EOP (88QE-2) start 63QA-4 (2 sec time

6 Kg/Cm2

19

delay)
Warren LO pressure low Turbine trip L63 QT: 63 QA-3 and 63QA-4.

4.5 & 6 Kg/Cm2

Time Delay of 8 sec (2/2 logic).

respectively

Warren LO tank level low and high alarms 71QL-2, 71QH-2

Main AA compr. Diff. Pressure alarm 63AD-1A

0.4 Kg/Cm2

20
21
22
23

CW temperature high alarm DE 26DW

Turb. Comp., Acc Comp., Scavn fan, Gas Valve Comp fan & Load
Gear Comp. Pressure low alarms 63AT-1,2, 63AT-3,4, 63SN, 63VF-1,

52.3 MBar
1.4 Kg/Cm2
1.4 Kg/Cm2

1000C

SL NO

SETTING

DESCRIPTION
63VG-1,2
Turbine inlet air filter differential press. High alarm 63TF-1.

24
25
26
27
28

152.4 mm Or 6

Turbine inlet air filter differential pressure. High trip 63TF-2A,2B

Inches of WC
203 mm Or 8

Turbine exhaust Duct pressure high alarm 63EA-1

Turbine exhaust Duct pressure high trip 63ET-1, 2 (2/2)
CW valves operation at set values VTR-1, VTR-2

Inches of WC
406 MMWC
508 MMWC
54, 1070C

GT TRIP LOGICS: L4PST: SL. NO

DESCRIPTION AND SETTING

1
2

L45FTX fir indication trip

L63QTX low lube oil pressure trip L63QT 2A, L63QT 2B, & L63QA (2/3logic settings

3
4
5

0.55, 055, and 1.1 Kg/Cm2 respectively))

L86TGT generator Lockout trip
L4 RLYT relay circuit feedback trip (external Trip)
L63ETH exhaust pressure high trip L63EAH, L63ET1H, L63ET2H (2/3 Logic settings

6
7

406, 508 & 508 mmWC)

L39VT GT trip on high vibration (see the separate sheet)
L2SFT Startup fuel excess trip--- L60FFLH liquid fuel flow high FQL1> 9.4%. (in gas

8
9
10
11

GRV_POS>10 %)
L12H_FLT loss of protective HP speed inputs (L14_ZE TCEA HP zero speed.
L4CT customer trip input
L12HF control speed signal loss (TNH<TNKHF---5%)
L12HFD_C control speed signal trouble (TNH_OS-TNH> 6.5%)

12

L12HFD_P protection speed signal trouble (TNH-TNH_OS > 6.5%)

13
14
15

L12H_P HP overspeed trip

L12H_ACC HP excessive acceleration trip
L3SFLT control system fault trip
i.

L3COMM_IO common I/O status (1=OK, 0= Lost communication)

ii.

L14HS and L4

iii.
iv.

L14HSX & L94X & L4

L1stop command PBstop turbine

16

L86GCVT gas control valve not following reference trip (!FSR2-FSG! > 5% with TD 5
sec.

(set and Latch)

L4PRET: SL. NO
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION
L3GRVFB pos feed back trbl (FSGR < -6.67% TD 2SEC Set & Latch
L3GRVO GRV Open trbl. (FSGR > 6.67% TD 2SEC)
L3GRVSC GRV current trbl (FAGR < 30% TD 2 SEC)
L3GFIVP fuel intervalve pressure trbl. ( FPG2 < -5.0 PSI)
L3GCVFB GCV Pos feed back Fault ( FSG < -30% TD 2sec)
L3GCVO GCV Open trbl alarm logic (FSG > 5% TD 2sec)
L3GCVSC GCV servo current Fault (FAG < 30 % TD 2sec)
L3LFBSQ liquid Fl B/P valve flow detect. Trbl alarm (FQL1 > 3% TD 2 SEC)
L3LFBSC liquid Fl B/P valve servo current Trbl alarm ( FAL < 30 %) TD 2sec)
L62TT2 multiple start counter (No of Auto start >= K62TT2---- 2 counts)
L2DWZ2 diesel failure to brake turbine Shaft ( after diesel warm-up timer L2DWX if
L14HR not coming within 3 minutes)

L4POST
SL. NO

DESCRIPTION

1
2
3
4
5

L63HLL liqd fuel hudr. trip press. Low (L63HL1L, L63HL2L, L63HL3L 2/3)
If L3COM_B is not OK one L63HL1L will trip M/C
L63HGL guel gas Hydr. trip press low
L26QT L26QT1A, L26QT1B and L26QA 2/3
If L3COM_B is not OK one L26QT1A will trip M/C

6
7
8

L12H electr. Overspeed trip (TNH > TNKHOS 110%)

LCPRERR comp oper limit control at max error
L28FD Flame detection goes off (28FDA, B, C, D . 3 out of 4 going blank with TD 1

SEC)
L30SPT high exhaust temp spread trip
L86TXT exhaust over temp trip (if TTXM > (TTRXB+TTKOT2)

TTKOT2= 400F TTXM >

TTRXB+220C
OR ISO TRIP
10

TTXM > (TTKOT1) isothermal trip 11100F (6380C)

L86TFB Exh thermocouple open trip (TTXM < TTKXM4

11
12

i.e. TTXM < 1210C

L86CBT compressor Bleed Valve position trouble trip
L3SMT starting device trip

2500F).

13

L4IGVT IGV control trbl trip (before FSNL CSGV-CSRGV >

7.5 DEG A
After FSNL CSGV < 50 DEG A
VIBRATION MONITORING OF GT AND INTERLOCKS
There are total 10 vibration sensors provided for monitoring bearing and Load Gear
vibrations of GT.
GROUP 1 (Turbine): BB1 & BB2 on bearing No. 1 (Turbine Front bearing)
BB4 & BB5 on bearing No. 2 (Turbine Rare bearing)
GROUP 2 (load Gear):
BB7 & BB8 on Load Gear
GROUP 3 (Generator): BB9 & BB10 on Generator front bearing
BB11 & BB12 on Generator rare bearing
GT trip will be initiated in any one of the following conditions
1.
In a group of four sensors of turbine one sensor going up to alarm level (12.5
mm/sec) and other going to trip level (25 mm/sec) will initiate trip.
2.
In a group of four sensors of generator one sensor going up to alarm level
(12.5 mm/sec) and other going to trip level (25 mm/sec) will initiate trip.
3.
To ensure reliability of the machine two sensors (BB7 & BB8) are provided on
the load gear instead of one recommended by the manufacturer. Any one of these
two sensors going up to trip level or going faulty will not cause tripping of the
machine. If one goes to alarm level and other goes up to trip level will trip the
machine.
4.
If one of the sensors is disabled (considering it is showing a faulty indication),
the remaining three sensors will be considered as active and unit trip will take place
if out of these three sensors one goes to alarm and other goes to trip level of
vibrations.
5.
If one of the sensors in load gear is disabled (considering it is showing a faulty
indication) then unit trip will take place if the active sensor goes to trip level of
vibrations.
6.
If majority (two) of the sensors are disabled then only one sensor going to trip
level (25 mm/sec) is sufficient to trip the machine.
7.
If all the sensors in a group (4 in turbine or 4 in generator or 2 in load gear)
are disabled or identified as faulted then turbine Auto Fired Shut Down command
will be initiated by MARK V.

Adjacent sensor differential alarm will come if paired or adjacent sensors

(defined by J39R_g) signals are differed by a constant LK39DIFF= 3.8 mm/sec after
a time delay of 0.5 sec.
Each sensor channel that is defined as being utilised by KJ39U_g mask is monitored
for open circuit sensor faults. If a vibration sensor channel is determined to be faulty
an alarm is annunciated to operator. This sensor can be disabled so that an additional
transducer fault will not trip machine
COMBUSTION MONITORING SYSTEM
All the exhaust temperature thermocouples used for the TTXM calculation are sorted
from highest to lowest.

Allowable spread is calculated based on maximum CTDA and system exhaust

temperature TTXM
TTXSPL = [0.145*TTXM 0.08*CTDA + 30]0C
The median of the three 160C, 690C and calculated TTXSPL is taken as allowable
spread limit.
Three highest spreads are calculated as below
Sprd1= Highest TC Lowest TC reading
Sprd2 = Highest TC Second Lowest TC reading
Sprd3 = Highest TC Third Lowest TC reading
Combustion monitoring trip is enabled at 14HS speed (with Master Protection is not
tripped L4 & NORMAL shut down is not selected L94X). This logic L83SPM is through
at 14HS with 60 sec time delay.
Based on the three highest spread, calculated above, following six logics are
generated in the spread algorithm.

L60SP1: - If
Sprd1 > TTXSPL

L60SP2: - If
Sprd1 > 5*TTXSPL

L60SP3: - If
Sprd2 > 0.8*TTXSPL

L60SP4: - If
Sprd3 > TTXSPL

L60SP5: - If the lowest and the second lowest temperature readings are of
adjacent thermocouples.

L60SP6: - If the second lowest and the third lowest temperature readings are
of adjacent thermocouples.
Based on above logics following alarms are generated:

If sprd1 > TTXSPL (Logic L60SP1) COMBUSTION TROUBLE alarm (only) will
be generated after time delay of 3 sec.

If Sprd1 > 5*TTXSPL (Logic L60SP2) EXHAUST THERMOCOUPLE TROUBLE

alarm will be generated after time delay of 4 sec.
Even though the Sprd1 becomes normal after reaching to alarm level the alarm will
reset (logic normalize) only after giving MASTER RESET
Combustion monitoring trips
1)
If
Sprd1 > TTXSPL
AND
Sprd2 > 0.8*TTXSPL
AND
The lowest and the 2nd lowest TCs are adjacent.
Then trip the M/C after 9 Sec Time Delay
(I.e. if L60SP1 AND L60SP3 AND L60SP5 are coming simultaneously then
trip after 9 seconds)
2)
If
Sprd1 > 5*TTXSPL
AND
Sprd2 > 0.8*TTXSPL
AND
The 2nd & 3rd lowest TCs are adjacent
Then trip the M/C after 9 Sec Time Delay
(I.e. if L60SP2 AND L60SP3 AND L60SP6 are coming simultaneously then
trip after 9 seconds)
3)
If
Sprd3 > TTXSPL
Then trip the M/C after 9 Sec Time Delay
(I.e. if L60SP4 comes then trip after 9 seconds)

2000F (930C) as and when FSR is increased or lowered with LOAD RAISE, LOWER
commands bias the allowable spread TTXSPL. The bias remains for 60 second
and becomes normal with a defined ramp rate.

CO2 FIRE FIGHTING SYSTEM FOR GT

Fire detectors are provided in various compartments as follows

Accessory compartment 6 numbers setting 3150C

Turbine compartment 6 numbers setting 3150C.

Turbine Compartment Exhaust 2 numbers setting 3830C.

Load Gear Compartment 2 numbers setting 3150C.

Load tunnels 2 numbers 3830C

Generator compartment 12 numbers setting for 6 detectors 100 0C and for

remaining 6 detectors 800C.
The CO2 fire fighting cylinders are grouped in to two parts.
1.
For Accessory and Turbine Compartments. (Total 23 cylinders each of 45 Kg
weight. 8 for initial discharge and 15 for extended discharge)
2.
For load gear and Generator compartments. (Total 8 cylinders each of 45 Kg
weight. 4 main 4 stand by)
As the fire is detected by any two of sensors in the group CO 2 will be released in the
respective compartments of the group through initial discharge header and extended
discharge header. Initial discharge will be at high pressure and will last for 1 minute
for extinguishing the flame. The extended discharge, which will start along with initial
discharge, will continue for some time with low pressure.
In the group of 4 cylinders provided for load gear and Generator compartments a
diversion valve assembly is given which will divert the released CO 2 to either load
gear compartment or the generator compartment depending upon where the fire is
detected.
The compartments ventilation fans will be put off as soon as the fire is detected. The
CO2 pressure, with the detection of fire will close also all the dampers in the
ventilation system.
One bell will ring in the GT hall to alert the operator who is taking round inside the
GT compartments before release of the CO2.
The pressure switches (45CP-1A, 2A, 3, 4) mounted on the headers on fire
protection system are set at 4.1 Kg/Cm2.On detection of fire MARK V will initiate fire
indication trip L45FTX.

HRSG(Unfired) Data
of Frame-9 size GT

TECTROMBAY

GIPCL
BAROD

NTPC
KAYANKUL

NTPC

RPPL
PATHALGAGA

AM

GT MODEL

SIEMENSV94.2

GEFR#9E

GE-FR#9E

SIEMEN
S-V94.2

GE-FR#9E

HP STEAM FLOW Tph

227.6

176.15

188.4

231.13

181.4

80

80

80

80

80

525

520

520

520

520

167.8

121

151.3

153.6

131.4

LP STEAM FLOW tph

46.1

45.5

39.5

46.38

33.5

PRESUURE Kg/sqcm

7.0

6.0

6.0

5.7

6.7

TEMPERATURE Deg
celsius
FW TEMPERATURE
Deg celsius

200

200

200

200

200

167.8

120

150.2

152

130.1

PRESSURE
kg/sqcm(a)
TEMPERATURE Deg
celsius
FW TEMPERATURE
Deg celsius