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Operation Instruction
SEPCOIII
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Approved by:
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CONTENTS
TURBINE OPERATION RULES
PART 1 Overview
Chapter 1 Specification of Main Equipment ………………………………………………
5
Chapter 2 Specification of Auxiliary Equipment …………………………………………
14
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Chapter 15 Generator parallels off, while turbine does not trip ……………..….……77
Chapter 16 Generator parallels off, and turbine trips …………………………………77
Chapter 17 Turbine trips, while the generator does not parallel off …………………78
Chapter 18 Failure of Thermodynamic Power Supply …………………………………78
Chapter 19 High Bearing Temperature of Turbine-generator Unit ……………………
79
Chapter 20 Burning out of Turbine-generator Bearing Bush ……………………….…79
Chapter 21 Steam Turbine Shaft Bending ………………………………………………80
Chapter 22 Steam turbine Overspeed ………………………………………………..…82
Chapter 23 Feed water pump set outlet check valve is untight and rotates
reversely.83
Chapter 24 Turbine-generator unit operates at abnormal frequency …………………
83
Chapter 25 Boiler Fire Extinction …………………………………………………………
84
Chapter 26 Treatment of Accidents & Abnormity of the Motor ………………………..85
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Appendix 1: Comparison Table of the Temperature & Pressure of Saturated Water &
Steam ………………………………………………………………………………….......147
PART 1: Overview
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47 >60 >60
46 >2 >2
1.3.6 The peak to peak vibration amplitude measured near the bearing journal of turbine shall be
≤ 0.075mm during normal operation, which shall not exceed 0.25mm as critical speed passing in
speed rise;
1.3.7 The power load of the unit is permitted to reach 135MW when the HP heaters are cleared;
1.3.8 The unit is permitted to run continuously with low load when the exhaust pressure of turbine
increases to 0.0146Mpa (a). The alarm back pressure of turbine is 16.9kPa (a) and trip back
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Generator End
Upper
Half
Lower Half
MainStopValve(L) MainStopValve(R)
Governing
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The turbine unit is 14 meters long in total and arranged on the 9m operation floor, with a
combination of HP initial steam stop valve and HP governing valve mounted on both sides in the
front which is supported on the holder of main stop valve, 4 flexible HP steam inlet pipes
connected with the 4 governing valves and the HP cylinder’s upper and lower steam inlets
respectively, and governing valve controlled by oil servo-motor.
The high pressure nozzle section consists of four groups of nozzle segments, The unit can reach
rated power by 3 valves opening fully and the fourth group provides guarantee for the availability
of rated power in summer and at low parameters.
HP & MP cylinder is double-floor cylinder with 1 governing stage and 8 pressure stages in the HP
part. There is a section of steam extraction led to HP heater #1 after stage 7, and steam
exhausted by HP flows through lower cylinder’s exhaust port and HP exhaust check valve to the
reheater, a portion of which is led to HP heater #2 as regenerative extraction.
The reheated steam flows to MP part via MP combined valve through two rigid steam inlet pipes.
There are 10 pressure stages in MP part with a third stage extraction to deaerator after stage6
and a fourth extraction led to LP heater #4 after stage 8.
For MP exhaust part, the upper half is designed to exhaust steam upwards that flows into LP
cylinder through 2 flexible cross over pipes with compensation capacity; the lower half has a fifth
extraction led to LP heater #5.
The LP cylinder is double flow and has 2×6 stages, there are a 6th and 7th extraction openings set
in LP cylinder that lead extraction to LP heater #6 and LP heater #7 (built-in type) inside the
condenser respectively and led out after the stage 3 and stage 6 respectively.
This steam turbine has three bearing pedestals in all, in which 3 turbine journal bearings, 1
generator front bearing and 1 thrust bearing are mounted. All bearing pedestals are floor
mounted. Besides journal bearing in bearing pedestal #1, there are also main governing set,
including main oil pump and emergency governor etc.
Two MP combined valves are arranged on the left and right side in the middle of the unit
respectively, which may move freely on its bearing surface with expansion of the turbine, the MP
governing valve only operates for regulation at below 30% load and opens fully not to take part in
regulation in the case where the load is more than 30%.
The rotary equipment of steam turbine rotor is mounted on the back bearing pedestal and driven
by motor after speed reduction, rotor turning gear speed rotation is 7~8r/min, each bearing is
equipped with HP jacking oil system in order to lower the start-up power of rotary equipment and
protect all bearings from damage.
LP cylinder is equipped with atomizing nozzle type low-load spray regulator inside that may
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operate to spray automatically in the case where the LP cylinder exhaust temperature is higher
than 80℃ so as to ensure normal operation of the unit.
1.4.1.2 Sliding key system
The sliding key system is the supporting and locating system of stator part, the steam turbine
proper supporting and locating mode is: front frame, middle frame and rear frame and exhaust
hood frame are fastened on the foundation by means of foundation bolts and back grouting and
are equipped with front bearing pedestal, middle bearing pedestal, rear bearing pedestal and LP
outer cylinder thereon respectively. Longitudinal keys are arranged on the front frame along the
center axis, the front bearing pedestal can move on its frame along the axis. HP & MP outer
cylinder upper claws are supported on the front and middle bearing pedestal, the lower claw’s
transverse keys connect with the front and middle bearing pedestal, besides longitudinal keys,
there are also transverse keys on some position of the middle frame, and the cross point of
longitudinal and transverse key is the dead point of HP & MP stator part, the front bearing
pedestal HP and MP cylinder and middle bearing pedestal take this as the dead point to perform
axial expansion and contraction. There is a vertical key mounted on both upside and downside of
both ends of HP & MP outer cylinder with key way plate fixed on the neighboring bearing pedestal
for the purpose of smooth expansion and contraction and keeping cylinder center aligning.
1.4.1.3 Thrust bearing
The unit adopts the Michell thrust bearing. The thrust collar integrates with steam turbine, and
both its front and back sides are mounted with positive and negative thrust bearing pads with 12
pieces laid on the whole circle of each. And each pad is equipped with a RTD temperature
measuring device for measuring its metal temperature. The back of thrust bearing pad rests on
erection loop, and erection loop leans against the spheric seating, which gives self alignment
effect. Positive or negative thrust of steam turbine bearing operates on the operating pad or non-
operating pad separately, and the bearing displacement on thrust pad shall not be more than
0.4mm. The lubricating oil enters between thrust collar and thrust pad via oil inlets on both sides
for lubricating, and then flows out from thrust collar outer side, the return oil escapes from the top,
and there are two return oil adjusting screws mounted on return oil outlet, which can adjust the oil
return quantity to control return oil temperature.
1.4.1.4 Journal bearing
This unit adopts elliptic type journal bearing, which consists of a bearing bush cast with Babbitt
metal, bearing shell and spheric seating. The bearing is made into upper and lower, two halves
that are fixed and positioned by screws and taper pins, the bearing case matches with spheric
seating on spherical surface, which gives self alignment effect, and there are four set pieces on
the spheric seating for the use of adjustment. Lubricating oil flows into bearing through a hole at
lower part of bearing and then flows into bearing pedestal via the bearing end. There is a
platinum resistor mounted on the bearing bush that can measure the bearing metal temperature,
there is oil from return chute in the bore of locating pin in upper bearing half, which temperature
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can be measured as that of bearing return oil, and there is HP jacking oil hold at the bottom of
bearing bush.
1.4.1.5 Shafting
The steam turbine proper shafting consists of HP & MP rotor and LP rotor. Connection between
HP & MP rotor and LP rotor relies on the rigid coupling integrated with main shaft forging, and the
shims in between two halves of coupling are connected with screws. As configured for the
purpose of meeting the requirement of rotor center aligning in assembly, in such a case, the
center on both ends of coupling must keep correct and concordant in assembly so as to allow the
rotor center line to become smooth and continuous curve in operation. The rigid coupling is very
sensitive to the bearing load distribution because of high rigidity, thus its requirements for the
assembly technology and shafting aligning are much higher, but it has such advantages as high
strength, short rotor length, easy processing and reliable operation.
Semiflexible coupling is used in between LP rotor and generator rotor, such coupling has a
corrugated pipe joint on the end coupling connecting with generator rotor, which has certain
flexibility, and connects with an minor axis on the other end coupling, and the minor axis covers
the generator rotor to transmit the torque by means of interference and key, such semiflexible
coupling may allow the unit safety operation not to be affected by slight change in the steam
turbine and generator center in installation and operation.
1.4.2 Technical specifications of governing system
1.4.2.1 The governing system is able to keep idle running of steam turbine at rated steam inlet
condition, rated vacuum and full open main stop valve, with speed oscillation value >≯ 6r/min.
1.4.2.2 The governing system is able to guarantee stable parallel operation of steam turbine and
other units.
1.4.2.3 The governing system is able to control and guarantee the need of steam turbine
incorporating into network and adaptation to changes in speed and load.
1.4.2.4 For this unit operating at rated steam conditions and rated speed, the governing system is
able to control the turbine speed not to result in the trip of emergency governor as the unit rejects
load.
1.4.3 Technical specifications of steam turbine control system
1.4.3.1 This unit has three sets of governors:
Emergency governor handle to be tripped by operator manually for emergency;
Mechanical emergency governor to trip at overspeed;
Four governor solenoid valves controlled by ETS, which receive the governing signal of
important parameters of steam turbine.
1.4.3.2 System function:
1.4.3.2.1 Governing function:
The governor valve will trip to shut down the turbine for emergency trip as the following
parameter exceeds the specified value.
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Jiangsu Yihaun
Manufactured by Manufactured by
Group Co., Ltd.
2.4 Shaft seal system
2.4.1 Shaft seal
HP & MP seal ring are high & low-tooth labyrinth structure and LP seal ring is flat tooth structure;
HP & MP cylinder diaphragm seal is embedded seal, the sealing strip is riveted into the
diaphragm with fillet; the seal ring of LP diaphragm seal is mounted in the septalium and fixed
with spring leaf.
2.4.2 Shaft seal heater
Item Unit Specification
Model JQ-50-1
Heating surface area m2 50
Design flow of main
m3/h Total flow, 300 minimum
condensate flow
Design pressure MPa Tube side 3.1, shell side 0.1
Working pressure MPa Tube side 2.00
Test pressure MPa Tube side 3.9, shell side 0.125
Design temperature ℃ Tube side 100, shell side 100
Working temperature ℃ Tube side 60, shell side 100
Net weight t 2.23
2.4.3 Shaft seal fan:
Specification of shaft seal fan Specification of the motor
Model AZY-09.32-020.0-01 Model 132S
Full pressure 9.32kPa Power 7.5kW
Speed 2,900r/min Speed 2,900r/min
Flow 20m3/min Voltage 415V
Zhejiang Yuyao Blower Wannan Electric
Manufactured by Manufactured by
Plant Machine Co., Ltd.
2.5 Condensate and steam extraction system
2.5.1 Specification of condenser
Cooling water
Model N-9000 32.5℃
temperature
Single shell, bisection, double
Type Number of pass 2
passes and surface type
Total active cooling Velocity in cooling
9,000 m2 2m/s
surface area water pipe
Design pressure of tube Outer diameter of
0.25MPa φ25mm
side cooling water pipe
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The two-stage series connection bypass system is adopted, in which, the flow capacity of HP
pass is considered as 70% of steam flow under VWO condition and the flow capacity of LP
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bypass is considered as the sum of HP bypass flow plus HP bypass attemperating water flow.
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pressure switch of control system, metal temperature of main cylinders and etc.).
9) Any safety protection or system fails or unit protection operating values are not in accordance
with stipulation.
10) Any one of the following equipment has fault or the corresponding interlock protection test is
unqualified: starting oil pump, AC (DC) lubricating oil pump, jacking oil pump, turning gear, EH oil
pump.
11) The oil level of main oil tank and EH oil tank is lower than the limit value or the oil quality and
cleanliness are unqualified. Lubricating oil inlet temperature is abnormal and return oil
temperature is overhigh.
12) Water seeps through the turbine.
13) Quality of water and steam are not in accordance with requirements.
14) Heat preservation of the unit is imperfect.
15) Other auxiliary equipment or system fails in operation.
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1.2.2 Tests prior to turbine start-up (after overhaul and minor repair of unit)
1) Static test of turbine governing system;
2) ETS test of turbine;
3) Major interlock test of the unit;
4) Interlock test of starting oil pump, AC lubricating oil pump and DC lubricating oil pump of
turbine, and interlock test of jacking oil pump and exhaust fan of main oil tank;
5) Interlock test of feed water pump;
6) Interlock test of circulating water pump;
7) Interlock test of vacuum pump;
8) Interlock test of condensate water pump;
9) Interlock test of EH oil pump;
10) Protection test of HP& LP heater and deaerator;
11) ON/OFF tests of all motor-operated valves, and pneumatical valves and hydraulic valves;
12) Interlock test of HP & LP bypass devices;
13) Interlock test of circulating water booster pump;
14) Interlock test of inner cooling water pump;
15) Interlock test of LP heater drain water pump;
16) Interlock test of shaft seal fan;
17) Interlock protection test of steam extraction check valves.
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after the jacking oil pressure of all bearings is normal through checking. The unit shall be put into
continuous turning operation for at least more than 4 hours prior to the turbine start-up.
1.3.10 Check the Air cooler system is ok.
1.3.11 Put the generator’s air cooling system into operation.
1.3.12 Start the vacuum pump to build up vacuum of condenser to 30kPa.
1.3.13 After warming up of shaft seal pipe by water drain is normal, start the shaft seal fan to put
the shaft seal system of turbine into operation. The LP cylinder shaft seal steam temperature
shall be within the range of 121~177℃. Inform the boiler staff to ignite the boiler when the
vacuum of condenser reaches 70kPa.
1.3.14 Ignite the boiler to increase temperature and pressure.
1.3.15 Put the bypass system (first the LP bypass and then HP bypass) into operation after
warming up the piping. Put the bypass automatic control into operation.
1.3.16 Start the feed water pump according to the water level of steam drum. The water goes via
bypass valve of the HP heaters. Adjust the water flow with feed water bypass (or conduct water
filling with condensate water-filling pipe). Close the recirculation valve of economizer in water
filling.
1.3.17 Timely open the water filling valve of HP heater after feed water pump start to ensure the
HP heater has the condition of put-in of water side.
1.3.18 The up rate of temperature and pressure shall be as per the requirement of boiler cold
start.
1.3.19 When the initial steam pressure reaches 0.1Mpa, check and confirm the drain valve before
the main stop valve is in open position, check the tightness of HP & MP main stop valves and HP
exhaust check valves to prevent cold water and steam from going into the turbine;
1.3.20 When the pressure rises to 0.5~1.0Mpa, advise the chemical staff to test the steam quality
to decide whether to put continuous blowdown flash tank into operation according to chemical
treatment requirement.
1.3.21 The turbine can be impulsed when the steam pressure rises to 1.5~1.6Mpa, initial steam
temperature to 360℃, reheat steam temperature to 300℃, the temperature difference between
initial steam side and reheat steam side is not more than 17℃, the steam quality is qualified
through test grade and all parts of boiler are normal.
1.4 Impulsing of turbine
1.4.1 Check if the turbine protection ETS system is put into operation normally.
1.4.2 Check if the display of DEH panel is normal.
1.4.3 Condition and preparation for unit impulsing
1.4.3.1 Steam conditions of turbine cold impulsing:
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1.6 Load up
1.6.1 After warming up with initial load ends, check if the turbine cylinder expansion is normal
without jamming;
1.6.2 Put the governing stage pressure circuit into operation as the case may require in the
process of load up;
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1.6.3 Make the load up to 13.5MW (10% of rated load) by means of valve position at a load up
rate of 0.6MW/min.
1.6.4 Check if the auto operation of bypass system is normal, bypass valves close gradually with
rise of unit parameters.
1.6.5 When the load is up to 13.5MW (10% of rated load), steam pressure to 2.0~3.5 Mpa, initial
steam temperature to 450℃, reheat steam temperature to 400℃ and the temperature of HP
stator lower carrier to 390℃, check if the drain valve at upstream of MP combined valve closed
automatically, if not, close it manually.
1.6.6 When the load reaches 27MW (20% of rated load), check if the water spray device closed
automatically according to LP cylinder exhaust temperature, if not, close it manually. It may put
the unit power control circuit into operation at this time.
1.6.7 When the load reaches 27MW (20% rated load):
A. Check if the initial steam pressure is 4~5 Mpa, temperature is 470℃ and reheat steam
temperature is 430℃;
B. Check if the drain valve at downstream of MP combined valve closed automatically, if not,
close it manually;
1.6.8 When the feed water pump flow is >280t/h, confirm the recirculation motor-operated valve
of feed water pump closed by interlocking;
1.6.9 Open the sub-picture controlling set value on DEH control picture to set the target load at
60MW and load up rate at 1.3MW/min, press the button GO to make load of unit continue to go
up.
1.6.10 When the pressure of extraction #3 is > 0.25Mpa, open the extraction #3 to the motor-
operated valve of deaerator; and close gradually the auxiliary steam header to deaerator, here
the deaerator operates in sliding pressure mode;
1.6.11 When the steam side pressure of No.2 HP heater is 0.3 MPa higher than that of deaerator,
change the water drain of HP heater into the deaerator; close the water drain of HP heater valve
to condenser valve, slightly open the HP heater No.1 and No.2 to the air valve of deaerator.
When the pressure of steam extraction #3 is > 0.3 Mpa, change the steam supply of the auxiliary
header into the steam extraction #3 of this unit.
1.6.12 As the load reaches 54MW (40% rated load), initial steam pressure to 7Mpa and
temperature to 470℃ and reheat steam temperature to 450℃, start one LP drain water pump
according to the water level of LP heater, close water drain of LP heater to drain valve of
condenser, and put the auto control of drain into operation when the water level is adjusted to be
normal.
1.6.13 When the load reaches 121.5MW (90% of rated load), steam conditions shall be up to
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nominal parameters in which initial steam pressure is 13.24Mpa, initial and reheat steam
temperature are 535℃:
1.6.13.1 From warming up with initial load to 90% of rated load, the time of steam conditions
reaching the ratings shall be controlled at 120 min;
1.6.13.2 Put the “Initial Steam Pressure Control” into operation on the DEH panel as the case
may require after initial steam pressure reaches the rating;
1.6.14 Change the control mode of valves from “Single Valve Control” to “Sequence Valve
Control” after the unit load reaches over 50MW, and pay attention to the change in load in
changeover.
1.6.15 Continue to make load up until 135MW, perform an overall check and report the check
results to the unit supervisor.
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shall be regarded as qualified if pad vibration ≯0.03mm, it is necessary to trip to shut down the
turbine in excess of 0.03mm. It is necessary to trip to shut down the turbine as the pad vibration
exceeds 0.1mm over critical speed (or vibration increases suddenly with abnormal noise if not up
to 0.05mm).
1.7.10 Differential expansion:
Positive differential expansion of HP & MP cylinder must not exceed +8mm, and it is necessary to
shut down the unit immediately if so; negative differential expansion of HP & MP cylinder must
not be less than -3mm and it is necessary to shut down the turbine immediately if up to -3mm; in
the process of speed up, closely monitor the differential expansion, hold the speed if discovering
differential expansion alarm, and shut down the turbine as up to the shutdown value.
1.7.11 Absolute expansion of cylinder:
In start-up, pay attention to monitoring the absolute expansion of cylinder and compare with the
same in the first start-up to prevent cylinder expansion from being obstructed, cylinder shall
expands continuously with jamming, if expansion is abnormal, it is required to reinforce warming
up, find out and remove the cause.
1.7.12 Differential temperature between upper and lower part of the cylinder: must not be more
than 50℃.
1.7.13 Axial displacement: must not exceed ±1mm. Shut down the turbine as up to ±1.2mm.
1.7.14 LP cylinder exhaust temperature: must not exceed 80℃ (alarm value), shut down the
turbine as up to 121℃.
1.7.15 Metal temperature and return oil temperature of all bearings:
(1) Normally return oil temperature of all bearings shall be below 75℃; shut down the turbine as
up to 80℃;
(2) Outlet oil temperature of oil cooler is within 38℃~42℃;
(3) Metal temperature of journal bearing #1~3 shall be below 107℃; shut down the turbine as up
to 113℃; the metal temperature of journal bearing # 4~5 shall be below 75℃, shut down the
turbine as up to 80℃;
(4) Metal temperature of thrust bearing shall not be higher than 99℃; shut down the turbine
immediately as up to 107℃;
(5) Lubricating oil pressure is within 0.09~0.15Mpa.
1.7.16 Before the unit impulsing, adjust the initial and reheat steam parameters to meet the start-
up requirements by bypass, generally these is no need to adjust the parameters in the process of
unit speed up so as not to affect the rotating speed. After the unit paralleling in, check if the
automatic control of bypass is normal and pay attention to that the tracking of attemperating
water shall be normal; the adjustment of the opening extent of HP & LP bypass shall be based on
the need of boiler to prevent too acute oscillation of MP governing valve as a result of too high
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steam pressure of boil side and too large opening of bypass, at the same time pay attention to
the pressure difference before and after HP exhaust steam check valve to prevent it from being
closed and causing chocking.
1.7.17 Strictly monitor the water level of HP & LP heater, deaerator and condenser in the process
of start-up.
1.7.18 Temperature rise & decrease rate
Temperature
Name Temperature rise rate
decrease rate
Temperature of initial steam <2~2.5℃/min <1.5℃/min
Temperature of reheat steam <3~3.5℃/min <2.5℃/min
Outer wall of initial and reheat steam pipe 8℃/min
Outer wall of steam valve 4~6℃/min
Flange wall of cylinder 2~2.5℃/min
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2.3.2 Fix impulsing parameters as per the following table according to cylinder temperature:
Item Warm state Hot state Remarks
upperr half metal
temperature of HP 150~300 300~400
inner cylinder (℃)
At least 50℃ higher than At least 50℃ higher With 50℃ superheat
Initial steam the lower half metal than the lower half degree under
temperature (℃) temperature of HP stator metal temperature of corresponding
carrier HP stator carrier pressure
At least 30℃ higher With 50℃ superheat
At least 30℃ higher than
Reheat steam than the lower flange degree under
the lower flange metal
temperature (℃) metal temperature of corresponding
temperature of MP cylinder
MP cylinder pressure
Time from
impulsing to full 50 10
speed (min)
450
Max speed in
100 Must not be more
speed up (r/min)
than 500
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2.3.3.1 Checking and tripping operation of DEH panel are the same with that of Cold Start;
2.3.3.2 Fix the impulsing time and speed up rate according to cylinder temperature;
2.3.3.3 Other operations and checking in the process of turbine speed up are the same with that
of Cold Start.
2.3.3.4 Because HP automatic main stop valve, speed governing valve, MP combined valve and
steam lead pipe, etc. parts can cool quickly after shutdown, pay attention to the temperature rise
rate of them in start-up to prevent excessive heating and pay attention to the vibration of unit.
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the rated speed. If necessary, open wider the low pressure bypass to lower the reheat steam
pressure and control the HP cylinder exhaust temperature to be lower than 360℃.
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temperature
LP cylinder exhaust
kPa 8.83 20.3
pressure
LP cylinder exhaust Alarm at 80℃ , shut down at
℃ <65 120
temperature 121℃
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value
Normal value 2,550
High value I 2,750 Alarm
Interlock open the motor-operated overflow
High value II 2,850
valve of deaerator
Interlock close the steam extraction No.3
Water level motor-operated valve and check valve
mm
of deaerator interlocking, interlock close the motor-
High value III 2,950
operated overflow valve of the deaerator
when the water level decreases to below
2,750mm;
Low value I 2,350 Alarm
Low value II 680 Feed water pump trip
Normal 0.68 Operate at sliding pressure
Pressure of
MPa Low pressure 0.3 Alarm for low pressure
deaerator
High pressure 0.85 Safety valve operate
1.7 Oil system of steam turbine
Name Unit Normal Max Mini Remarks
Alarm at 0.08Mpa;
AC lubricating oil pump puts in at
0.07Mpa;
Lubricating oil
MPa 0.078~0.147 DC lubricating oil pump put in at
pressure
0.06Mpa;
Shut down at 0.06Mpa;
Turning stop at 0.03MPa
Inlet oil pressure of
MPa 0.098~0.11
main oil pump
Alarm at 0.9Mpa;
Outlet oil pressure of
MPa 1.1~1.18 Interlock start oil pump at
main oil pump
0.883Mpa
Outlet oil temperature
℃ 38~42 45 38 Alarm at 35℃
of oil cooler
Return oil temperature
℃ <65 <75 Alarm at 65℃
of bearing #1-#5
Metal temperature of Alarm at 107℃, shut down at
℃ <85
journal bearing #1-3 113℃
Metal temperature of
℃ <70 Alarm at 75℃, shut down at 80℃
journal bearing #4-5
Metal temperature of
℃ <85 Alarm at 99℃, shut down at 107℃
thrust bearing
Oil level of main oil
mm 1808 2,616 1,245 Shut down at 1,245 mm
tank
Inlet oil pressure of MPa Refuse to start at below 0.039MPa
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2.1 BASE
In this mode, both the power and pressure control circuit have been cut off, the main controller of
turbine-boiler is controlled by operators manually. On the boiler side, change the boiler load
demand manually to adjust the initial steam pressure. ON the turbine side, change the turbine
load demand to control the unit’s power through DEH.
Unit shall be switched to Base mode if any condition as follows is met:
MFT operating;
Operator selected the Base mode;
Both boiler main controller and turbine main controller are operated manually at the same time.
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the dead-band of module, the output and unit power demand are summed up and sent to the
turbine side to limit the initial steam pressure to change further. At the same time, the combustion
rate on boiler side changes quickly to make the initial steam pressure return to the range of
specified value. This control mode is commonly used by general unit plant that takes advantage
of thermal storage capacity of boiler and ensures the stability of steam pressure.
Cooperative control system requires both boiler main controller and turbine main controller are on
Auto position, otherwise it is unavailable.
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1.2.5 Decrease the parameter and load according to the normal shutdown curve at the rate of
initial steam temperature of 1.5℃/min, reheat steam temperature of >≯2.5℃/min and initial steam
pressure of 0.05Mpa/min.
1.2.6 Open the sub-picture of set value control on the main control picture of DEH to set target
load at 75MW and load down rate at 1.13MW/min, then press “RATE” and “ENTER” button; press
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to decrease to zero.
1.2.20 Start AC lubricating oil pump, advise electrical personnel that the generator can be
paralleled off, at this time the steam turbine and boiler shall interlock trip (press the button “OFF”
to trip them in special case). Check HP & MP main stop valve, governing valve, extraction check
valve and exhaust check valves of HP cylinder A & B that shall close all; unit speed decreases.
1.2.20 Works to done during unit idle time
1.2.20.1 Check the condition of unit idling, listen to its internal sound and record the idle time;
1.2.20.2 When the rotating speed is 2,500r/min, close the air valve of condenser; when the
rotating speed is 1,500r/min, check if the jacking oil pump opened automatically, if not, open it
manually;
1.2.20.3 When the rotating speed is 300~400r/min, open the vacuum breaker valve to decrease
vacuum degree, control the rotating speed to “0” and vacuum to “0”; stop the shaft seal motor,
stop the shaft seal steam supply and close isolating valve; stop the vacuum pump.
1.2.20.4 When the unit comes to rest, put the continuous turning into operation and record the
shaft bending and turning gear current.
1.2.21 Operation after shutdown
1.2.21.1 Check HP & LP bypass that shall stop and exit.
1.2.21.2 Close the cooling water valve of oil cooler and air cooler, close the attemperating water
valve of feed water pump and open the oxygen exhaust valve of deaerator to decrease the
pressure to zero.
1.2.21.3 When boiler is filled with water, stop the feed water pump, stop the deaerator heating
and close the isolating valve.
1.2.21.4 Open the recirculation of condensate pump and adjust the water level of deaerator and
condenser.
1.2.21.5 When the exhaust hood temperature is <50℃, stop the circulating water pump with
approval of unit supervisor.
1.2.21.6 When the exhaust hood temperature <50℃, stop the condensate pump with approval of
unit supervisor.
1.2.21.7 When the HP carrier lower half metal temperature is <150℃, stop continuous turning.
1.2.21.8 When the rotor comes to rest; release the interlocking of oil pump and stop the jacking
oil pump and AC lubricating oil pump.
1.2.22 Precautions in normal shutdown
1.2.22.1 In the process of shutdown, keep the initial and reheat temperature within normal range
as much as possible that shall not be lower than 450℃minimally.
1.2.22.2 In the process of load down, pay attention to the change in differential expansion of HP
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& MP cylinder, when the differential expansion reaches -1mm, stop load down, if such negative
value continues to increase, take measures to reduce the load quickly to zero for shutdown.
1.2.22.3 When the vibration at unit idling increases, reduce the vacuum degree to make the unit
speed lower quickly.
1.2.22.4 After the unit shuts down and before the boiler, deaerator and auxiliary steam header
release pressure completely, closely monitor the metal temperature of steam turbine to prevent
steam & water from escaping into the steam water.
1.2.22.5 If discover exhaust cylinder temperature increases after shutdown, find out the cause
and cut off steam source, or else start the condensate pump and put the LP cylinder spray into
operation to reduce the exhaust cylinder temperature. After shutdown, pay attention to monitoring
the water level of condenser and deaerator to prevent overfeed of water.
1.3 Sliding pressure shutdown
1.3.1 After receiving “Sliding pressure Shutdown” command from shift engineer, make
preparations for shutdown and get done with division of work and conduct referring to normal
shutdown.
1.3.2 Decrease the load to 100MW according to normal shutdown requirement, and then take
advantage of sliding decreasing initial steam pressure and temperature to decrease the load.
1.3.3 Change the steam source of auxiliary steam header to be supplied by neighboring turbine
or starting boiler and check if the steam pressure and temperature of auxiliary header is normal.
1.3.4 Principle of sliding pressure shutdown
1.3.4.1 Contact the boiler operator to decrease the initial steam pressure first according to sliding
parameter shutdown curve, hold the load demand and pay attention to the opening of governing
valve, governing stage temperature and lower cylinder temperature drop.
1.3.4.2 After initial steam pressure decrease, lower the LOAD DEMAND gradually according to
the load sliding down to cooperate in controlling the initial steam pressure, at this time, keep the
initial steam temperature stable as much as possible.
1.3.4.3 Contact the boiler operator to stabilize pressure and hold load, and decrease the initial
steam temperature according to the governing stage temperature and the upper-lower cylinder
temperature as per sliding pressure shutdown curve.
1.3.4.4 Every time load decreases by 10MW, keep the steam pressure, temperature and load
stable for 5 minutes.
1.3.4.5 Pay attention to the opening of governing valve, governing stage temperature and upper
cylinder temperature drop, monitor the section pressure that shall not exceed the rated value, and
keep the reheat steam temperature catch up with the initial steam temperature decreasing rate.
1.3.5 Operation of sliding pressure shutdown
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1.3.5.1 The main controller operator on duty shall reduce the pressure and temperature at the
rate of 0.04~0.049MPa/min and 1.5℃/min for initial steam and 2.5℃/min for reheat steam; pay
attention to controlling the load down rate at 0.4MW/min.
1.3.5.2 Reduce the initial steam temperature to 500℃ and pressure to 10.79MPa slowly, open
wide the speed governing valve gradually and reduce the load to 100MW and keep stable
operation for 20 minutes.
1.3.5.3 Reduce the initial steam pressure and temperature at the rate of 0.03~0.04MPa/min and
1.5℃/min, unit load continues to decrease and pay attention to controlling the load down rate at
0.4MW/min.
1.3.5.4 When the load decreases to 40MW, keep stable operation for 40 minutes.
1.3.5.5 When the initial steam flow is ≤ 30%, put HP & LP bypass and three-stage attemperating
water into operation, continue to reduce the initial steam pressure and temperature at the rate of
0.03~0.04Mpa/min and 1.5℃/min, unit load continues to decrease and pay attention to controlling
the load down rate at 0.4MW/min.
1.3.5.6 When the load decreases to 10MW, initial steam pressure to 1.6~2.0MPa and initial
steam temperature to 370℃~380℃, the sliding pressure shutdown is over and prepare to shut
down. Open the sub-picture of set value control on the main control picture of DEH to set the
target load at 0MW and load down rate at 5MW/min, and the unit load continues to decrease.
1.3.5.7 Report to the shift engineer when the load decreases to zero and trip to shut down the
unit.
1.3.5.8 Other operations refer to normal shutdown.
1.3.6 Precautions in the sliding pressure shutdown
1.3.6.1 Strictly follow the principle of reducing pressure first and reducing temperature second in
sliding pressure shutdown, and assign special person to monitor the reduction of steam
temperature and pressure and read meter once every 10 minutes, within which the pressure drop
must not exceed 0.4 MPa and temperature drop must not exceed 15℃, if not, stop reducing
pressure and temperature immediately and continue after stabilizing for a period.
1.3.6.2 Keep an identity between the initial steam and reheat steam which temperature difference
must not be more than 40℃, and degree of superheat must be higher 50℃ so as to prevent
water hammer accident.
1.3.6.3 If discover the negative value of differential pressure increases too fast in sliding pressure
shutdown, lower the load down rate. When HP differential expansion reaches -0.1m, stop
reducing load and continue after differential expansion rises again, if the measures take no effect
and the differential expansion continues to increase, reduce the load to zero quickly and trip to
shut down the unit. Start AC lubricating oil pump, and record the idle time and listen to the sound
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deaerator water level and HP & LP heater water level to prevent valves of steam, extraction and
drain system from untightness and resulting in cold steam and water entering the turbine;
1.4.6 In turning, pay attention to monitoring lubricating oil inlet temperature of all bearings that
shall be higher than 21℃, as well as indications of metal temperature of all bearings, turning gear
current and turbine cylinder temperature that shall be normal and record them once every hour;
1.4.7 Keep the turning gear and oil circulating system running for not less than 48 hours after
normal shutdown;
1.4.8 After turbine shutdown, it is prohibited to fill the condenser and heater to test leak when the
cylinder temperature is higher than 200℃, If it must be conducted, work out reliable preventive
measures against sharp cooling of cylinder resulting in shaft bending that shall be approved by
the shift engineer;
1.4.9 After bypass system is stopped, check to make sure attemperating water valve is closed
tightly;
1.4.10 If there is clear friction sound inside the cylinder during turning, stop turning, but change to
15 minutes interval and turn the rotor by180°, and forced turning is not permitted;
1.4.11 When the first stage metal temperature of HP cylinder is higher than 150℃, the turning
can only be stopped with approval of unit supervisor, get done with marking clearly, record the
stop time, and turn by 180° manually every 5~15 minutes according to the state of cylinder.
Turning time is required to be at least 10 times larger than the stop time prior to restart;
1.4.12 After shutdown, if the bearing or other parts require maintenance, both the turning gear
and oil circulation shall operate for more than 24 hours to keep the outlet oil temperature of oil
cooler at about 35℃, and it can stop the turning gear and cut off oil circulation after which, but it
is necessary to prolong the turning time prior to unit start;
1.4.13 For the shutdown for emergency maintenance, keep the turning gear and bearing oil
system circulation for at least more than 3 hours, after which it can stop turning and oil circulation
for 15 minutes and do not stop the oil circulation as much as possible. 15 minutes after stop, start
the turning gear to operate for 2 hours or until the eccentricity becomes stable. After which, it can
stop the turning gear and oil circulation, but the offtime shall not exceed 30 minutes, among
which, 15 minutes after stop, start the oil circulation to turn rotor by 180°. After 30 minutes
mentioned above, start the turning gear and oil circulation, and run the steam turbine over again
for 2 hours or until the eccentricity becomes stable. As long as turn the rotor by 180° every 30
minutes within the following six hours, the system will be able to be off for long. Start the oil
circulation to lubricate all bearings during the 180° turning.
1.4.14 If it is required to stop the turning gear for emergency due to unit fault, which may make
the rotor suffer from serious bending, so it must keep oil circulation for at least over 24 hours after
shutdown to prevent bearing from overheating, and keep the outlet oil temperature of oil cooler
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supervisor.
1.10 The operator shall not leave the post in the process of treatment of fault and accident, If the
fault occurs during work shift, it postpone the time of shift, the staff to hand over shall go on
working and eliminate the accident with assistance by the staff to take over until the unit recovers
normal operation or receiving the order about shift from the unit supervisor.
1.11 People irrelevant to the accident shall not stay at the spot.
1.12 After treatment of fault and accident, the staff on duty shall report the time, phenomenon,
reason, development and the treatment process to the shift engineer and keep detailed records,
and the meeting it after work shift shall analyze the fault.
1.13 First make every effort to eliminate the danger to personal and equipment safety in case of
accident.
1.14 Strive to keep normal running of non-faulted equipment.
1.15 Prevent wrong judgment or treatment caused by bad contact, uncertain condition and
inaccurate report.
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3.2 In the case where the initial and reheat steam temperature on turbine side increases to above
545℃ and cannot recover after running for 30 minutes; where the temperature continues to rise
to 555℃ and cannot recover within more than 15 minutes; or where the temperature exceeds
565℃;
3.3 The initial steam pressure increases to above 14.71Mpa;
3.4 The back pressure of conderser reaches 20.3KPa or circulating water interrupts;
3.5 The steam turbine rejects load to 0 to run for more than 15 minutes;
3.6 The change in frequency is lower than 46HZ;
3.7 The initial and reheat steam and feed water pipe or valve breaks to endanger the equipment
safety;
3.8 The MFT operates, but the major interlock of turbine-boiler refuses to operate;
3.9 The main stop valve, governing valve and MP combined valve are jammed and cannot
recover;
3.10 LP cylinder exhaust temperature reaches 121℃;
3.11 The steam turbine motor operates for more than 1 minute;
3.12 When an important monitoring meter displays inaccurately or fails, it must stop running in
the condition that there is not any effective monitoring means;
3.13 The copper tube of condenser breaks resulting a great deal of circulating water entering the
steam side.
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hand to check if the if the HP & MP main stop valve, speed governing valve, extraction check
valve and HP exhaust check valve are closed and if the rotating speed of unit decreases;
6.3 Release the starting oil pump interlocking and start the lubricating oil pump;
6.4 If boiler MFT operates, treat it according to MFT operation emergency shutdown;
6.5 Adjust the steam supply pressure of deaerator and shaft seal, and switch to the standby
steam source in time;
6.6 Check thoroughly, listen to the sound of unit and record the idle time;
6.7 Other operations as per normal shutdown procedure.
7. Decreasing of Vacuum
7.1 Phenomenon
7.1.1 The condenser vacuum indication decreases, local vacuum gauge, DEH or DCS displays
vacuum decreasing;
7.1.2 The exhaust temperature of steam turbine rises;
7.1.3 “Conderser Vacuum Low “sound & light alarms.
7.2 Cause
7.2.1 The circulating water pump works abnormally and the system valve is operated by mistake,
which result in interruption or lack of circulating water;
7.2.2 The steam supply of shaft seal is not enough or shaft seal carry-over;
7.2.3 The water level of condenser is too high;
7.2.4 The vacuum pump works abnormally;
7.2.5 The vacuum system leaks or the system valve is operated by mistake;
7.2.6 The condenser piping is dirty;
7.2.7 The water temperature of vacuum pump is high;
7.2.8 No level or overfeed of water of the shaft seal heater.
7.3 Treatment
7.3.1 If discover the condenser vacuum decreasing, check the exhaust temperature immediately
to ascertain vacuum down;
7.3.2 If the condenser vacuum decreases, it shall start the standby vacuum pump rapidly to
observe the change in vacuum;
7.3.3 If the vacuum keeps on decreasing, it shall reduce the unit load appropriately until alarm off,
find out the cause and give treatment;
7.3.4 Check the operation of circulating water pump:
a. Check if the circulating water pump operates normally, otherwise switch to the standby
circulating pump or start another pump, when there are two pumps operating, if one pump stops
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for fault to result in decreasing of condenser vacuum, it shall close the outlet valve of faulted
pump quickly;
b. Check the outlet valve of circulating water pump, and open it in time if it is closed by mistake;
c. Check if the circulating water pressure is normal, if it is low, check if the circulating water
system leaks or is blocked;
d. Check the differential pressure between the circulating water outlet and inlet of condenser is
normal, if it is high, then clean a half of condenser;
e. Check if the disc valve of condenser inlet & outlet is closed by mistake; if so, open it
immediately;
7.3.5 Check the shaft seal system:
a. If the shaft seal header pressure is low, then check if the shaft seal steam source and overflow
valve are normal to adjust the shaft seal header pressure to normal;
b. If the steam pressure of LP shaft seal is low, then turn down the shaft seal attemperator spray
isolating valve and adjust the LP shaft seal steam temperature at 149℃;
c. If the shaft seal heater pressure is high, then start the standby shaft seal heater blower to
check if the multi-stage water seal of shaft seal heater is broken and water level is normal.
7.3.6 Check if the water level of condenser condensation sump is high, if so, it shall find out the
cause and give treatment;
7.3.7 Check if the LP extraction flange and junction plane of LP cylinder leak, if the vacuum
system is tight, in the case where the vacuum system leaks, seal it off and contact with
maintenance personnel to treat;
7.3.8 Check if the vacuum breaker valve is opened by mistake
7.3.9 Check if any vacuum valve and flange leaks;
7.3.10 Check if the water level of vacuum pump steam-water separator is normal and if the
vacuum pump water temperature is normal;
7.3.11 When the back pressure of condenser reaches 20.3KPa, the steam turbine shall trip
automatically and trip it manually, and give treatment according to the procedure of fault
shutdown.
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8.1.4 The initial steam and reheat steam pipe or the extraction pipe vibrate, shaft seal has water
hammer sound, and there is white steam belching from the main stop valve and speed governing
valve lever, as well as the flange of extraction pipe;
8.1.5 Temperature of initial and reheat steam decreases sharply;
8.1.6 Temperature of LP shaft seal header decreases sharply.
8.2 Cause
8.2.1 The boiler drum is overfed with water;
8.2.2 The steam drum pressure drops sharply, which result in the carry-over;
8.2.3 Adjustment of the boiler steam temperature is inappropriate;
8.2.4 When the unit is started, the drainage of turbine proper, shaft seal system and all relevant
steam pipes are not smooth;
8.2.5 The heater leaks or drainage is not smooth and deaerator is overfed water;
8.2.6 The unit load changes abruptly;
8.2.7 Boiler water is unqualified or carry-over (priming);
8.2.8 The attemperating water valve of bypass system is not closed tightly;
8.2.9 When the superheat degree of initial steam and reheat steam is low, the speed governing
valve swings severely.
8.3 Treatment
8.3.1 Open the drain valves of steam turbine proper and the relevant steam pipes to intensify
proper drainage;
8.3.2 If water flowing into the steam turbine is caused by water overfeed of heater, it shall stop
the overfed heater and isolate it to drain water;
8.3.3 In case of white steam belching from the main and reheat steam pipe flange, and main stop
valve and governing valve lever, treat according to fault shutdown;
8.3.4 Record the idle time of turbine and listen to the sound of inside of turbine in idling carefully;
8.3.5 Put the turning gear into operation after the turbine come to rest, it shall execute the
stipulations for turning gear operation in shutdown strictly, and intensify proper drainage;
8.3.6 After turbine shutdown caused by water emergency, it can only restart the turbine after the
unit is normal through check, temperature difference between upper and lower cylinder is<50℃,
and rotor eccentricity <0.076mm with approval of the chief engineer;
8.3.7 In the process of the start, it shall pay attention to monitoring the axial displacement,
vibration and bearing temperature, etc. parameters and drainage of relevant stem pipes of the
turbine proper, if any abnormal sound or stator-rotor friction in the process of restart, it shall break
the vacuum to shut down immediately;
8.3.8 In case of water flowing into the turbine, if the axial displacement, differential expansion and
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bearing temperature reach the tripping value, idle time shortens obviously, or there is any
abnormal sound inside the turbine, it shall shut down to check.
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10.1 Phenomenon
10.1.1 The fire monitor control raises the alarm;
10.1.2 Flare or smoke is discovered locally;
10.1.3 When the turbine oil pipe leaks, the oil level of main oil tank decreases;
10.1.4 When the lubricating oil system leaks, lubricating oil pressure decreases, signal
“Lubricating Oil Pressure Low” may be raised and AC & DC lubricating oil pump may interlock
start.
10.2 Cause
10.2.1 Oil system leaks;
10.2.2 Oil leaks to high temperature hot body or faulted electrical equipment;
10.2.3 Oil pipe is broken due to external causes and oil leaks to the hot body.
10.3 Treatment:
10.3.1 If any abnormal change in the oil level of main oil tank and all oil pressure, it shall find out
the cause, if due to oil leak of oil system, it shall ascertain the leaking point and try to isolate it
from surrounding hot body pat and operating equipment to prevent the oil system from catching
fire, meanwhile, contact the maintenance personnel to treat the leaking point temporarily;
10.3.2 If the equipment and pipe of unit oil system is damaged to leak, in any case where the
equipment or pipe cannot be isolated from system to be treated or oil has seeped into the heat
distribution pipe, it shall shut down to treat immediately;
10.3.3 After the system catches fire, it shall cut of the equipment power supply endangered by
the fire, and then extinguish the fire and advise the fire fighter immediately;
10.3.4 If the fire cannot be extinguished quickly and endangers the personal and equipment
safety, it shall break the vacuum to shut down for emergency immediately. Release the
interlocking of starting oil pump, not start the starting oil pump to shut down the lubricating oil
pump; if the lubricating oil system catches fire that cannot be extinguished, resulting in shutdown,
it may reduce the lubricating oil pressure to decrease oil leak in the precondition of ensuring
normal lubrication of bearing.
10.3.5 When the fire endangers the main oil tank or top platform, plant building and neighboring
turbine, after tripping to shut down, it shall open the emergency oil drain valve of main oil tank,
keep mini permitted oil level prior to the rotor coming to rest and drain out the remaining oil after
rotor coming to rest.
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become abnormal.
11.1.1 Phenomenon
a. Initial steam and reheat steam pressure gauge change;
b. DEH and DCS display the initial steam and reheat steam pressure alarm;
c. When the unit operating in coordinated control mode, its load changes correspondingly.
11.1.2 Cause
a. Fault in control system;
b. Unit’s load changes abruptly.
11.1.3 Treatment
a. If it is the fault in control system that caused abnormality of initial and reheat steam
pressure, it shall adjust the charge of fuel to restore the initial and reheat steam pressure;
b. If it is the too quick change of unit’s load that caused abnormality of initial and reheat
steam pressure, it shall try to stabilize the load and change it after the initial and reheat
steam pressure recovering;
c. If the initial and reheat steam pressure are high, it may increase the unit’s load to make
the pressure recover;
d. When the initial steam pressure rises up to 14.71Mpa, it shall trip to shut down the turbine;
e. When the initial and reheat steam pressure change, it shall pay attention to the unit’s
vibration, sound, differential expansion and axial displacement, as well as temperature
difference between upper and lower cylinder of turbine;
f. When the steam pressure drops, it shall control each monitored section pressure not
exceeding the max permitted value with initial steam flow rate>≯440t/h;
g. If the steam pressure keeps on dropping to below 4Mpa and cannot recover, treat
according to fault shutdown.
11.2 Steam pressure does not change, but the initial steam and reheat steam temperature
become abnormal.
11.2.1 Phenomenon
a. Initial steam and reheat steam temperature gauge change;
b. DEH and DCS display the initial steam and reheat steam temperature alarm.
11.2.2 Cause
a. Governing of attemperator to the initial steam and reheat steam fails;
b. Boiler steam drum is overfed with water;
c. Boiler combustion is unstable and combustion condition changes;
d. Unit’s load changes greatly;
e. Coking or soot deposit of furnace;
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valve, shaft seal and junction plane of cylinder, if any water hammer, it shall shut down the
turbine for emergency. Closely monitor the change in metal temperature and differential
expansion;
11.3.4 Pay attention to the change in shaft seal pressure and water level of condenser and all
heaters, switch over the steam source of deaerator in time;
11.3.5 When the initial steam temperature and pressure decrease at same time, although not to
the shutdown temperature, the initial steam temperature is over 50℃ lower than the first stage
metal temperature, it shall report to the unit supervisor and request for fault shutdown.
12. DEH Failure
12.1 Phenomenon
12.1.1 “DEH Power Failure” light and sound alarm is raised;
12.1.2 DEH displays “Main Power Supply Failure” and “Standby Power Supply Failure”;
12.1.3 DEH displays “DEH failure” and the indicator lamp lights;
12.1.4 The indicator lamp of “Operator Auto” on DEH operating panel goes out;
12.1.5 The indicator lamp of “Manual” on DEH operating panel lights;
12.1.6 DEH displays “Speed Failure”.
12.2 Cause
12.2.1 Computer’s AC power off;
12.2.2 Fault in computer or VCC card;
12.2.3 Two of DEH speed feedback channels get fault in increasing and decreasing the speed of
turbine (extensive speed control).
12.3 Treatment
12.3.1 If it is required to change the load or rotating speed, operate the "GV UP” and “GV Down"
manually and observe the change in speed or load via the "Speed" or "Power" window.
12.3.2 Pay attention to monitor if the changes in turbine lubricating oil temperature, bearing return
oil temperature, axial displacement, differential expansion and vibration are within normal range.
12.3.3 If DEH power off, turbine should trip automatically, and otherwise it shall trip it manually;
12.3.4 If DEH failure caused main stop valve or HP governing valve on one side closing, it shall
shut down the turbine immediately.
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unqualified;
14.2.12 The generator rotor is not heated equally.
14.2.13 The running components in the front bearing case fall off.
14.2.14 Center of the turbine-generator is abnormal, or the rotor bending is relatively large and
exceeds the specified value as starting.
14.2.15 Condenser vacuum is low;
14.2.16 The generator exciter caused the vibration;
14.2.17 Anchor bolts of all bearing bushes of the turbine-generator unit become loose;
14.2.18 Oil contains foreign matters that wear the bearing bush tungsten-base alloy or water mix
in oil and oil is emulsified.
14.3 Treatment
14.3.1 The unit vibrates sharply suddenly, or metal sound inside the unit can be heard clearly, it
shall break the vacuum for emergency shutdown quickly.
14.3.2 Abnormal vibration occurs during operation:
a. When discovering the bearing vibration increases gradually, if the rotor vibration exceeds
0.08mm or bearing vibration exceeds 0.03mm, it shall report to the unit supervisor to try to
eliminate the vibration, if the rotor vibration exceeds 0.254mm, it shall shut down
immediately;
b. If the unit sends out impulsive sound from the inside in operation or the conductivity of
condensate increases suddenly, the monitored section pressure at same load rises and
vibration increases obviously, it shall immediately break the vacuum for emergency
shutdown;
c. When the shaft vibration changes by 0.05mm or bush vibration changes ±0.03mm, it shall
find out and try to eliminate the cause, when the bearing vibration change increases to
0.015mm suddenly, it shall trip and shut down the unit immediately;
d. When the load changes, it shall reduce the load until vibration disappears;
e. If it fails in ascertaining the vibration cause directly, it shall take measures to reduce the
load, If the vibration or abnormal sound remains, report to the unit supervisor and relative
leaders for settlement.
14.3.3 Abnormal vibration occurs during start-up and shutdown:
a. In the case where rotor eccentricity at a speed of below 600r/min or bearing vibration
exceeds 0.03mm at a speed of below 1200r/min in the process of start-up speed rise, it shall
trip and shut down the unit immediately. When the unit operates at critical speed, if the
bearing vibration exceeds 0.10mm or shaft vibration exceeds 0.25mm, it shall trip and shut
down the unit immediately. It is prohibited to warm up with critical speed or reduction of
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speed forcedly. It can only restart the unit after ascertaining and removing the cause;
b. It shall cease the start-up when there is friction at end shaft seal or through-flow parts,
report to the unit supervisor and relative leaders, it can only restart the unit after finding out
the cause;
c. In the process of shutdown, if friction sound inside the end shaft seal or cylinder can be
heard clearly, it shall break the vacuum for emergency shutdown;
d. In the case of shutdown due to abnormal vibration, it shall pay attention to the idle time
and listen to the inner sound of the unit carefully and increase the time of continuous turning.
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16.2.1 When the speed decreases to 3,000r/min, release the interlocking of starting oil pump and
start the lubricating oil pump;
16.2.2 Pay attention to adjusting the water level of condenser and HP & LP heater, put the LP
cylinder spray into operation;
16.2.3 Maintain the water level of deaerator and switch into standby steam source of deaerator;
16.2.4 Check the unit completely and switch the steam supply of shaft seal to the standby;
16.2.5 Record the idle time when the speed decreases to zero, and stop the steam supply of
shaft seal when the vacuum decreases to zero and put the turning gear into operation in time;
16.2.6 After shutdown, check the unit thoroughly, find out the causes of speed governing system
operating abnormally and generator paralleling off, it can only restart the unit after eliminate the
causes and unit being normal through test.
17. Turbine trips, while the generator does not parallel off
17.1 Phenomenon
17.1.1 Some protection operates and makes signals, power reaches zero or displayed in
negative;
17.1.2 HP & MP Main stop valve, speed governing valve, extraction check valve and HP exhaust
check valves closed;
17.1.3 The generator does not parallel off and speed does not change.
17.2 Treatment
17.2.1 After the protection operating, it shall cut off the outlet switch of generator-transformer unit
to parallel off and shut down, and the operating time of unit without steam shall not exceed 1
minute;
17.2.2 Check and ascertain the cause steam turbine protection operating, treat according to
emergency shutdown or fault shutdown;
17.2.3 If the protection of steam turbine operates by mistake, it shall advise the thermodynamic
engineer to find out and remove the cause quickly. If it fails within 15 minutes, it shall shut down
the unit for fault;
17.2.4 Advise the electric staff to find out and remove the non-tripping cause of generator-
transformer unit quickly;
17.2.5 After removing the fault, it can only restart the unit after it is normal through test.
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18.1.3 Power failure of motor-operated valves and governing valves, and malfunction of all
automatic governing;
18.1.4 Partial protections and interlocks of the unit can not operate.
18.2 Treatment
18.2.1 Immediately contact heat engineer to recover the power supply, check and monitor primary
meters locally, and switch the automatic into manual governing;
18.2.2 Report to the unit supervisor and keep the unit load stably as much as possible;
18.2.3 Avoid adjusting as much as possible, monitor the operation of equipment according to the
indication of local meters and ammeter of each auxiliary equipment, etc., and make necessary
adjustment locally;
18.2.4 When the system or equipment becomes abnormal, and the unit loses operating and
monitoring means, which affect the safety of main equipment, report to the unit lead and conduct
fault shutdown;
18.2.5 If the heat control power supply can not recover within 30 minutes, make fault shutdown.
18.2.6 If the heat control power supply of turbine and boiler fail at the same time, it shall conduct
fault shutdown.
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inside the bearing and observe the condition of return oil, and lower the unit load at high
temperature alarm;
19.3.4 If the shaft seal pressure is high and the steam leak of shaft seal is serious, it shall check
the steam source governing valve of shaft seal and adjust the shaft seal pressure to normal;
19.3.5 When the temperature of journal bearing #1-3 of turbine reaches 112℃, the temperature
of journal bearing #4-5 of generator reaches 80℃ and the temperature of thrust bearing reaches
107℃, the steam turbine should trip automatically; if bearing return oil reaches 80℃, it shall treat
according to emergency shutdown for fault;
19.3.6 Pay attention to adjusting the unit load and vacuum of condenser.
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and parallel the unit in, if fails, it shall conduct fault shutdown;
22.3.2 When the unit speed rises up to 3,300r/min, check that the mechanical and
electromagnetic overspeed protection shall operate. Otherwise it shall trip and shut down the unit
manually, verify that the HP & MP main stop valve and all extraction check valve shall be closed,
cut off all possible steam access to turbine and immediately open the vacuum breaker valve for
emergency shutdown;
22.3.3 If the overspeed is caused by HP & MP main stop valve being jammed, it shall
immediately start the overheater or reheater atmospheric exhaust valve, and etc. to reduce the
pressure;
22.3.4 Eliminate the cause of overspeed after the turbine is shut down for overspeed, and it can
be restarted after it is qualified through calibration, it shall intensify overall check of the unit in
restart, if any abnormality, it shall find out and eliminate the cause immediately.
23. Feed water pump set outlet check valve is untight and rotates reversely
23.1 Phenomenon:
23.1.1 Feed water pump reverses;
23.1.2 The pressure of the outlet header pipe decreases and the current of the parallel running
pump increases;
23.1.3 Sound of the reversing pump is abnormal and accompanied by increased vibration;
23.1.4 Water level of deaerator rises;
23.1.5 Water level of steam drum decreases and feed water flow decreases;
23.1.6 The oil inlet temperature of working oil cooler rises.
23.2 Treatment
23.2.1 Once discovering pump reversing, it shall close the outlet motor-operated valve and center
tap motor-operated valve of this pump immediately;
23.2.2 If the reversing feed water pump outlet motor-operated valve and center tap valve loss
power or jammed and cannot be closed, it shall stop the working feed water pump, close the
forced handwheel of HP heater outlet check valve, close the main feed water motor-operated
valve of boiler and feed water bypass motor-operated valve, press MFT to shut down the boiler
and shut down the turbine without vacuum broken;
23.2.3 In any case, the feed water pump can only be stopped after all outlet motor-operated
valves have been closed. Assign person to monitor locally if the pump reverses in the process of
stopping the pump;
23.2.4 When the feed water pump restores standby, it shall open the outlet motor-operated valve
with hand, and verify the outlet check valve have returned prior to electric opening.
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25.1.3 Furnace inner is dark, flame of the monitor disappears, alarm window of no fire in the
upper, middle and lower layer raised an alarm;
25.1.4 Steam’s pressure and temperature decrease sharply, the water level of steam drum first
decreases and then rises;
25.1.5 Boiler fire extinguishing, MFT operates, steam turbine trips, generator-transformer unit
parallels off the system;
25.2 Cause
25.2.1 Conditions of the MFT operation are met;
25.2.2 Auxiliary power interrupts;
25.2.3 Boiler load is too low, operation and adjustment are improper, disproportion between air
and pulverized coal, primary air speed is too high or proportioning of primary and secondary air is
improper;
25.2.4 Jet burner operates with seriously unfilled corner, coal feeder gets fault, pulverized coal
chute is blocked, level of pulverized coal is too low, which make combustion unstable that is not
adjusted and treated in time;
25.2.5 Water-cold wall pipe, economizer, superheater and reheater burst seriously;
25.2.6 Boiler has serious fouling and coke residue fall off by a large area;
25.2.7 Coal quality is too poor, volatile content is too low or coal type changes suddenly;
25.2.8 When ash is being removed, large amount of cold air enter the furnace;
25.2.9 When the combustion is unstable, fail in put oil into supporting the combustion in time;
25.2.10 During startup, oil gun gets fault and oil quality is poor;
25.2.11 Induced and forced draft blower trip;
25.2.12 Both flame monitor and cooling fan get fault.
25.3 Treatment
25.3.1 Extinguish the boiler fire and treat the unit as emergency shutdown;
25.3.2 Report to the unit supervisor, extinguish the boiler fire, if the turbine does not trip, reduce
the load to 5~20MW according to the steam pressure, keep turbine at full speed, but if the
operating time at no load exceeds 15 min, it shall trip to shut down the turbine immediately;
25.3.3 Close the attemperating water valve, change the auto control of feed water to manual
control and control the water supply well, prevent the boiler from being overfed with and lack of
water; monitor and adjust the water level of the deaerator and condenser, as well as shaft seal
pressure.
25.3.4 In the process of fire extinction, pay attention to control no cooling of cylinder, strictly
prevent water hammer accident, closely monitor the differential expansion and temperature
change of all metals.
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25.3.5 For boiler fire extinction, if it is to maintain low power operation, it shall keep initial steam
pressure and temperature down rate not exceed the permitted value and fulfill the operations or
checks as specified in section 25.3.2~25.3.4.
25.3.6 In the process of treatment, closely monitor we various differential expansion, axial
displacement, temperature, vibration and sound, etc. of thrust bearing pad.
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temp. temp. rise temp. temp. rise temp. temp. rise d temp. temp. rise
Stator and
rotor 95℃ 55℃ 105℃ 65℃ 110℃ 70℃ 125℃ 85℃
winding
Stator core 100℃ 60℃ 115℃ 75℃ 140℃ 80℃ 140℃ 100℃
Sliding
100℃ 60℃ 110℃ 70℃ 140℃ 80℃ 130℃ 90℃
ring
Sliding
80℃ 40℃ 80℃ 40℃ 80℃ 40℃ 80℃ 40℃
bearing
Rolling
100℃ 60℃ 100℃ 60℃ 100℃ 60℃ 100℃ 60℃
bearing
The temperature of bearing in normal operation shall be stable, generally the sliding bearing
temperature shall not exceed 65℃ and the rolling bearing temperature shall not exceed 80℃.
The enclosure temperature of the motor with grade A insulation must not exceed 75℃;
The enclosure temperature of the motor with grade E insulation must not exceed 80℃;
The enclosure temperature of the motor with grade b insulation must not exceed 85℃;
If excess, it shall lower the output or take measures to lower the temperature.
1.3.2 Vibration shall accord with specification:
Rated rotating speed (r/min) 750 1000 1500 above 1500
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it is subordinate.
1.4 Ceasing of rotating equipment
1.4.1 If there is reversal after the equipment stops, separate it immediately, find out and eliminate
the cause.
1.4.2 It shall be in standby state after the equipment stops, it shall keep the cooling water smooth,
if considering saving water, it can turn down the cooling water valve, but keep a record.
1.4.3 The rotating equipment is divided into “Run”, “Standby” and “Service”, three states. Any
person must not break the standby into service without approval.
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2.1 General
Industrial water pump house holds 3 industrial water pumps, 1 is vacuum pump and 2 water
filtering pumps. In normal condition, 1 or 2 industrial water pumps operate and others for standby;
for number of operating sets may be determined according to variation of season and water
consumption in the precondition of guaranteeing header pressure. There are interlocking devices
in between #1~3 industrial water pumps, if operating pump trips, the standby pump will start
automatically. One industrial pump house contains 2 blowdown pumps, which can realize
automatic start-up and shutdown in case foul water level is high.
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3.3.3 Close inlet valve and outlet valve of oil purification device;
3.3.4 Turn the power switch to OFF position.
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3.4.8 Low water level control and alarm: After opening water discharge valve, water level will
decrease promptly, as decreasing to the set water level, water discharge valve will close, water
level will no longer decrease thereupon. In case water level keeps on decreasing to the set ultra
low level, equipment will shut down, meanwhile low level alarm lamp (LP07) will flash.
3.4.9 Alarm of water discharge time being over long: if water level is lower than the high water
level as a result of water discharge valve opening, and if the discharge time is over long that
exceeds 5min, the water discharge valve can not close, equipment will shut down, and
meanwhile alarm lamps of low water level and high water level will flash synchronously.
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metallic friction sound inside steam turbine. And stop one jacking oil pump.
4.2.10 Measure the eccentricity of shaft that shall be < 0.076mm and less than the original value
by 0.03mm.
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prevent fullness of oil cooler water side from being little, and deposit corrosion from accelerating.
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4.5.11 Remarks
4.5.11.1 When unit starts and stop, the main oil pump operating at above 2,700r/min ( 90% rated
Rev) can meet all the oil demand of speed governing and lubrication;
4.5.11.2 The capacity of single oil cooler is 100%, and only one set is enough in normal
operation;
4.5.11.3 The brand of lubricating oil is 32# steam turbine oil with cleanness up to grade NAS7.
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5.1.8 Open slowly the strainer inlet valve of circulating water to the generator air cooler manually,
fill the cooling water pipeline of turbine oil cooler slowly with water, and thereafter put it into
operation.
5.2 Normal shutdown of circulating water system
5.2.1 When the exhaust temperature of LP cylinder is lower than 50℃ and circulating water has
no user, it can contact the relative staff to stop the running of the circulating water pump;
5.2.2 Check if the circulating pump and outlet disc valve are on the “auto” position, assign special
staff to monitor locally before pump shutdown;
5.2.3 Contact the local staff to close the outlet disc valve of circulating water pump, when closing
to the extent of 75%, it shall interlock stop the circulating pump and check that the pump should
not reverse.
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5.4.1.4 Close slowly the air valve of condenser on stopped side and circulating water inlet motor-
operated disc valve, pay attention to that the back pressure of condenser shall not be lower than
16.9Kpa, start another vacuum pump if necessary to intensify monitoring of the vibration,
differential expansion and axial displacement;
5.4.1.5 Close the circulating water inlet and outlet motor-operateddisc valve of condenser on the
stopped side, open the circulating water discharge valve on the stopped side, pay attention to the
change in vacuum. If there is serious leakage in the condenser’s pipe, here pay attention to
vacuum decreasing, it shall close the circulating water discharge valve immediately, report to the
unit supervisor to restore the original running mode immediately and make decisions after
reporting;
5.4.1.6 After circulating water on the stopped side drain away, the vacuum shall keep within the
permitted range, power off the motor-operated inlet disc valve of condenser on the stopped side,
motor-operated outlet disc valve and rubber ball pump motor, then it may permit the maintenance
personnel to open the manhole to work;
5.4.1.7 In the whole process of cleaning and leak stoppage, it shall monitor strictly the change in
the condenser vacuum and exhaust temperature, if any abnormality and vacuum decreases
sharply, stop working immediately and load on as per vacuum.
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5.7.2.1 Once circulating water interruption is ascertained, unit load shall be decreased to zero
immediately, inlet & outlet disc valves of steam condenser or outlet valve of circulating water
pump shall be checked for mis-close, if any, it shall be opened at once. The auxiliary water pump
shall be started for recovering water supply as soon as possible, if fails, shutdown shall be
performed promptly;
5.7.2.2 After shutdown for fault, if water supply for steam condenser can not be recovered
temporarily, condensate pump recirculation valve shall be opened in time.
5.7.2.3 In case of circulating water interruption, the interconnection valve between industrial water
and circulating water shall be opened in time, and attention shall be paid to the metal temperature
of all the auxiliary equipment, outlet temperature of oil cooler and air cooler that must not exceed
the specified value;
5.7.2.4 In case of circulating water interruption, pay attention to if the steam condenser rupture
disk operates, if any, perform shutdown immediately.
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6.2.2.1 Open the motor-operated valve of overflow valve and auxiliary steam inlet governing
valve;
6.2.2.2 Regulate the pressure of seal steam supply header to that of governing valve setting
point;
6.2.2.3 Start a shaft seal heater blower, and the other for standby, regulate the water level of shaft
seal heater;
6.2.2.4 Close drain valves of steam seal return steam pipes of HP & MP cylinder, and close the
drain pipe of steam seal return steam header.
6.2.2.5 Regulate pressure of steam seal header to 0.02~0.03MPa, LP steam seal temperature to
121ºC~176ºC, and difference between rotor metal temperature of high & MP steam turbine shaft
seal and steam pressure of shaft seal to >≯111ºC;
6.2.2.6 Check if the continuous drain operation of steam seal header between steam
attemperating section and LP steam seal is normal.
6.2.2.7 Close drain valve on steam seal piping after steam supply of steam seal being normal;
6.2.2.8 Precaution:
① In cold start-up, it shall pump vacuum first, and then supply steam to steam seal;
② In warm-hot start-up, it shall supply steam to steam seal first, and then pump vacuum.
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interlocking switch of auxiliary condensate pump first. Start the standby pump first in switching
condensate pumps.
7.3.2 Adjust the condensate recirculation valve to maintain the pressure of condensate water
within the normal range.
7.3.3 Close the outlet motor-operated valve of condensate pump, pay attention to the variation of
condensate header pressure and the water level of steam condenser and deaerator.
7.3.4 Shut down the condensate pump.
7.3.5 When the condensate pump acts as standby after shutdown, put it on the “auto” position
and open the outlet motor-operated valve.
Check the motor-operated outlet valve and pay attention to the pressure change of the
condensed water main pump and water level of the Condenser and deaerator;
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7.5.2.4 When the pump shuts down for servicing, close all cooling system valves, sealing water
valves, air extraction valves and the pump outlet & inlet valves.
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shall be opened;
d. When the water level of LP Heater is III, the protection operates, it shall close the extraction
check valve and steam inlet valve of LP Heater, parallel off and isolate the LP Heater;
e. When discovering the copper pipeline leaks, it shall be isolate and service it in time.
Chapter 8 Feed Water & Deaerating System
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8.2.2.4 The oil level of the oil tank is on the upper-limit the oil quality is qualified, when the
auxiliary oil pump operating, the oil tank temperature of hydraulic coupling is ≥ 15°C, oil pressure
within 0.17~025Mpa or so and 018Mpa minimally;
8.2.2.5 Drain out the gas in the oil and water pipeline of cooler and feed oil to circulate. When the
filter’s differential pressure is > 0.06Mpa, switch it to the cleaning side. The lubricating oil shall
keep on circulating until the strainer of filter is clean;
8.2.2.6 Check if the water level of the deaerator is normal, the temperature is > 50°C, the feed
water pump has a temperature difference between its upper and bottom pump body is lower than
20°C;
8.2.2.7 The sealing water system works normally and loop is smooth; Check if the pressure after
the sealing water governing valve is the ring is 0.05~0.1Mpa higher than the unloading water
pressure;
8.2.2.8 Check if all transmission contacts of hydraulic coupling speed governing mechanism are
firm transmitting reliably, and the handle is flexible, after it is normal through hand operation, set
the scoop tube at 0 position;
8.2.2.9 Power on the feed water pump motor after it is qualified through insulation test and it is
permitted to close the switch;
8.2.2.10 Close the water discharge valve of the feed water pump body;
8.2.2.11 Check if the recirculation valve is opened wide and set it on “AUTO” position.
8.2.3 Check and preparation prior to HP heater operation:
8.2.3.1 Ensure the check work is finished, the work site is clean the equipment pipeline heat
preservation is good, meters are all complete, report to the heat engineer to power on the meters
and protections;
8.2.3.2 Measure the motor insulation of all motor-operated valves that shall be good, qualified
and powered on;
8.2.3.3 Check if the system valves are on correct position;
8.2.3.4 Put the HP heater protective water source into operation and the pressure is normal;
8.2.3.5 Companying with the heat engineer to conduct relevant test and interlock tests to HP
heater that is good: extraction check valve #1 & 2 are normal through test, HP heater water level
protection is normal through test, and the HP steam inlet motor-operated valve and emergency
drain motor-operated valve are normal through opening/closing and interlock test;
8.2.3.6 Check and test that the HP heater drain auto-control valve’s opening and closing are
flexible, direction is correct, and automatic control is normal.
8.2.3.7 Check if the HP heater four-way valve is on the bypass position.
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8.3.14.2 When the auxiliary oil pump is operating, the lubricating oil pressure is >0.17Mpa;
8.3.14.3 Open the booster pump inlet valve, feed water pump outlet valve and the recirculation
valve;
8.3.14.4 The temperature difference between the pump body and feed water pump inlet is <
20°C;
8.3.14.5 The differential pressure of the sealing water of feed water pump is > 0.1Mpa;
8.3.14.6 The interlocking switch of feed water pump in on AUTO position, and the scoop tube’s
opening is on 60% position.
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to that the feed water temperature decreasing rate must not be more than 1.83℃/min;
8.6.3 When the differential pressure between the steam side of HP heater and deaerator is less
than 0.3MPa, switch the drain to the condenser, close the #2 HP heater drain and lead it to the
hand-operated valve of deaerator; close the continuous exhaust valve of HP heater;
8.6.4 Close the air inlet motor-operated valve of HP heater #1, close the extraction 1 check valve
fully, close the air inlet motor-operated valve of HP heater #2 and the extraction 2 check valve.
When closing the all, verify the inlet valve is closed tightly, then stop the water side of HP heater,
close the inlet & outlet four-way valve of HP heater with the feed water running along the bypass.
Check if the feed water pressure is normal;
8.6.5 Open the pipe of steam extraction 1 and 2 to drain water appropriately;
8.6.6 When there is a short time maintenance work on HP heater steam side, it is permitted to
operate with only the steam side stopped, but it shall verify there is no leak in the HP heater, and
open the water discharge valve on the steam side to discharge water until the steam side
pressure decreases to 0 prior to operation. It is forbidden strictly for HP heater to operate with
only steam side.
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“Auto” position;
8.8.5 Start the auxiliary oil pump;
8.8.6 Reduce the rotating speed to minimal, set the scoop tube at zero point, and click the button
“Stop” of feed water pump to stop the feed water pump. Record the idle time;
8.8.7 Adjust the sealing water pressure to normal in time;
8.8.8 When the lubricating oil inlet temperature the decreases to 40 ℃, turn down the cooling
water value of lubricating oil cooler. When oil temperature of the service oil cooler is 50℃, turn
down the cooling water valve of the service oil cooler;
8.8.9 If it is to put the feed water pump into standby, open its outlet valve and check the check
valve that shall be closed tight and feed water pump is on “Auto” position;
8.8.10 If the feed water pump requires a maintenance, it shall ensure the auxiliary oil pimp to
operate for half 30min after pump stop and supply oil to cool the feed water pump.
8.10 Check and maintenance of the feed water & deaerating system
8.10.1 Check and maintenance of deaerator
a. It shall monitor the changes in pressure, temperature and water level from time to time when
the deaerator is normal operation. If any abnormality, adjust it/them back to the normal range;
b. When the condensate pump stopped because of fault, it shall start the standby condensate
pump instantly. If the inlet water of deaerator interrupts, it shall close the air inlet valve
immediately in order to prevent the deaerator from overtemperature;
c. It shall open the deaerating valve wider if there is not qualified oxygen content in the water of
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deaerator. It may open the heating & steam inlet at the bottom if necessary to adjust the oxygen
content to qualified;
d. Check the indication of the pressure gauge, thermometer and water level gauge of deaerator
on schedule, if any abnormality, it shall report for treatment in time;
e. If the water level decreases because of improper adjustment of water level or the condensate
pump’s insufficient output, it shall take some measures to make up water timely. But pay attention
to that: Don’t hurry, it may affect the pressure of deaerator and cause vibration. It may lower the
unit load if necessary;
f. If the water level still keeps on decreasing measures, it report to the unit supervisor. If
emergency water level occurs to affect normal operation of feed water pump and cause fault
hereof, it shall lower the load to shut down the unit;
g. Check the running condition of the safety valve of deaerator in operation regularly, when
deaerator is overpressed, pop the safety valve in order to ensure normal operation of deaerator.
8.10.2 Check & maintenance of feed water pump
a. Check if the feed water pump set has any friction and leak, vibration is normal and no
abnormal sound.
b. The oil level of oil tank and bearing is normal and the auxiliary oil pump is in good and standby
state;
c. All the protections have been put into operation, the automatic equipment works normally;
d. The sealing and cooling water system operate normally and the return water is unimpeded; the
sealing water governing valve can adjust automatically to make the pressure after valve have
always been 0.05~0.1MPa higher than the pressure before the booster pump inlet valve. At the
same time, maintain the return water temperature of sealing water within 70-80℃;
e. The coupling works soundly, and the speed governing mechanism is not jammed.
8.10.3 Check and maintenance of HP heater
a. HP heater water level is normal, and operation of automatic drain governing device is normal;
b. No water hammer and vibration;
c. Inlet and outlet temperature of water side is normal;
d. Temperature and pressure of steam side are normal;
e. No leak in the system through check;
8.11 Abnormal operation & treatment of the feed water & deaerating system
8.11.1 Abnormal operation & treatment of HP heater
8.11.1.1 Conditions of emergency stop of HP heater
a. Pipes and valves, etc. on the steam side burst, which endangered the personal and equipment
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safety;
b. Water lever of HP heater rises, treatment takes no effect and water level gauge is on the
utmost;
c. When water level gauge burst and can not keep on working;
d. The HP heater proper leaks seriously and cannot keep on working.
8.11.1.2 Treatment of t HP heater overfeed with water
Phenomenon:
a. Alarm for high water level of HP heater;
b. Protection may operate;
c. The HP heater outlet water temperature is low, and the heater vibrates.
Treatment:
a. When HP heater water level is high, check if the HP heater drain system operates normally,
when the drain governing valve is jammed, it shall open the emergency drain valve to lower the
water level, and contact with the maintenance personnel for treatment;
b. The running HP heater leaks and the water level rises to 850mm/1,125mm (HP heater#1/ HP
heater#2) sharply, the water level high value I alarm is raised;
c. If the HP heater water level rises to 1,000mm /1,275mm (HP heater #1/ HP heater #2), the
water level high value II alarm is raised to open emergency drain valve automatically;
d. If the Hp water level keeps on rising up to 1,200mm/1,475mm (HP heater#1/ HP heater#2),
the water level high value III alarm is raised, HP heater protection operates to close the feed
water inlet & outlet four-way valve of HP heater, as well as the extraction motor-operated valve
and check valve, open the water discharge valves on the steam side and water side and the air
release valve;
e. If the automatic paralleling off system of HP heater protection malfunctions and refuses to
operate, it shall parallel off the HP heater by hand immediately, if still no effect, it shall operate all
valves by hand locally immediately to parallel off HP heater;
f. When the HP protection operates to parallel off automatically, it shall pay attention to adjusting
the boiler combustion to prevent the initial steam from overtemperature or unit from overload.
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e. Record the idle time and vibration value of the faulted pump;
f. Complete other operations of pump stop, and take necessary safety measures as the fault may
be;
g. Report to the unit supervisor if there is no standby pump to shut down the unit for emergency.
8.11.3.4 Tripping off of feed water pump
Phenomenon:
a. The service pump’s current reaches “0”, the pump stops, emergency alarm is raised and feed
water pressure swings or decreases;
b. The standby pump interlock starts.
Cause:
a. Fault in the 6.6 KV busbar;
b. Protections of feed water pump and motor operate or are operated by mistake;
c. Misoperation made by man;
d. The emergency button is pressed by mistake.
Treatment:
a. Check and close the outlet motor-operated valve and center tap valve of the tripped-off pump,
check the auxiliary oil pump of the tripped-off pump that shall interlock to stop automatically;
b. If the standby pump doesn’t start, start it immediately, if no standby pump, or the standby
pump cannot be started by hand, it may recluse the tripped-off pump once more (when it doesn’t
reverse);
c. Adjust the interlocked pump’s rotating speed, put the feed water automation into operation, and
check if every part operating normally;
d. Check the recirculation valve of the tripped-off pump that shall be opened, and the recirculation
valve of interlocked pump shall be closed, otherwise operate by hand;
e. If no standby pump is available in the system, and the faulted pump can not start either, report
to the unit supervisor as soon as possible to conduct fault shutdown.
8.11.3.5 Vaporization in feed water pump
Phenomenon:
a. Abnormal noise occurs to the feed water pump’s inlet pipe or the inner of pump body;
b. Current and pressure of the inlet and outlet swing greatly;
c. Feed water pressure decreases.
Cause:
a. Deaerator pressure and water level decrease suddenly;
b. The inlet strainer is blocked;
c. When the flow decreases to the opening value of the automatic recirculation valve, but it fails in
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operating, for which the operation and treatment are not timely;
d. The inlet valve of booster pump is closed by mistake in operation.
Treatment:
a. Treat as per the requirements of emergency stop of pump;
b. Find out the causes for vaporization in feed water pump, and eliminate the abnormity;
c. If the vaporization is caused by inlet strainers of booster pump and feed water pump being
blocked, it shall start the standby pump immediately;
d. Only when the inlet pressure and deaerator pressure and water level become normal can it
restart the pump or put the standby into operation.
8.11.3.6 Feed water pressure decrease
Cause:
a. Fault in the hydraulic coupling or the scoop tube is jammed;
b. Water quantity used by the boiler increases greatly suddenly;
c. Water pipe breaks or HP heater leaks seriously;
d. The outlet check valve of standby pump is not closed tightly and the pump reverses;
e. The system valve is operated by mistake;
f. The service feed water pump is vaporized;
g. When the feed water flow is 280t/h, the recirculation valve of service feed water pump is not
closed.
Treatment:
The fead water flow exceeds 200t\h.The recirculation valve of the working feed water pump
hasn’t been closed.
a. If the feed water pressure decreases, it shall ascertain the cause quickly and report to the unit
supervisor at the same time;
b. If the feed water pump gets fault, start the standby pump quickly;
c. If the standby pump reverses, close the outlet motor-operated valve;
d. Stabilize the water quantity used by the boiler if the cause is sudden increase of water quantity,
adjust the speed of feed water pump and start the standby pump if necessary;
e. If the standby pump has interlocked, it shall adjust the rotating speed timely to prevent the feed
water from overpressure, after everything is normal, stop one feed water pump;
f. If the recirculation valve of feed water pump operates abnormally, contact the maintenance
personnel to treat.
8.11.3.7 Hydraulic coupling scoop tube being jammed
Phenomenon:
a. Adjustment to the scoop tube takes no effect;
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b. The feed water pump operates at a certain speed, which can’t satisfy the requirement of the
boiler or the rotating speed decreases.
Treatment:
a. Move the scoop tube locally to make it return to normal;
b. If moving the scoop tube locally is useless, it shall stop the faulted pump and start the standby
pump in time;
c. Contact the maintenance personnel, it must not restart or put the standby into operation until
eliminating the defect.
Chapter 9 DEH System
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Then DEH will rise or decrease pulse according to the command received from electric aspect,
turbine set value will change thereupon. Each pulse can rise or decrease the turbine set value by
1r/min, and with internal PID regulator, DEH can control turbine rotating speed to change
thereupon, thus makes turbine rotating speed be synchronous with network.
After synchronization, DEH will let turbine load on 5% initial load automatically. In the meanwhile,
AS mode will disengage automatically and transfer back to OA mode.
9.5.3 Put-in and trip of power loop (MW IN, MW OUT)
In on load operation, operator can select to put power loop feedback into operation: operator can
click the button “Feedback state” on lower left of main control panel to pop up the sub picture,
then click button “power loop”, afterwards click “put-in” button within 3S, then control will enter the
power loop put-in mode, meanwhile the main panel displays device has entered to “Power loop
IN” mode,
After power loop feedback put-in, load signal will enter controller as feedback signal to control
load to be identical with set value (undisturbed switch). Prior to power feedback put-in, DEH is in
open-loop control, and there is certain difference between load set value and load, which is
decided by the current main steam pressure, if main steam pressure is the rated value, load set
value will be close to the load value.
Generally, operator shall select the power loop clearing mode in order to ensure the initial steam
pressure stable and boiler combustion adjustment stable. That is because after power feedback
put-in, when main steam pressure fluctuates, valve opening will vary thereupon to guarantee
developed power being identical with the load set value, and that vibration will accelerate
vibration of boiler outlet pressure, but in order to guarantee load steady, power loop put-in is
necessary.
9.5. 4 Remote control mode (ADS)
In on load OA operation, and the “set value” is close to the “remote control set value”, operator
can select to enter remote control mode: operator shall send out DEH remote control request,
then press the button “Control mode” on top left of main control panel to pop up the sub picture,
click button “Remote control”, afterwards click button “Put-in” within 3S, and then control will enter
the ADS mode, meanwhile the main panel displays device has entered to “ADS” mode. At that
time, load set value is under the control of CCS (Coordination control) system.
Attention: as entering OA mode, ADS mode will disengage automatically.
9.5.5 Initial steam pressure limit (TPL)
In on load OA operation, and initial steam pressure is higher than 90% rated pressure, operator
can select the TPL (initial steam pressure limit) mode: operator can pressure the “Limit value” on
lower left of main control panel to pop up the sub picture, then click button “Initial steam pressure
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limit”, afterwards click button “Put-in” within 3S, and then control will enter to TPL mode,
meanwhile the main panel will display the main steam pressure limit is “IN”
In the case of TPL mode, as initial steam pressure being lower than 90% rated pressure, load set
value will decrease at a fixed rate. Shut down the control valve hydraulic servomotor can
compensate the decrease of main steam, thus avoid initial steam pressure decrease being to
large.
TPL mode also can be cleared on limit at sub picture: click the button “initial steam pressure
restriction”, afterwards click button “Clear” within 3S, and then control will disengage from TPL
mode.
9.5.6 Remote control initial steam pressure limit (RTPL)
In OA operation, and the initial steam pressure is larger than 90% rated pressure, operator can
select the RTPL (Remote control initial steam pressure limit) mode: operator shall press the “limit
value” on lower left of the main control panel to pop up the sub picture, then click button “Remote
control initial steam pressure limit”, afterwards click button “Put-in” within 3S, and then control will
enter the RTPL mode, meanwhile, the main panel will display the Remote control initial steam
pressure limit being “IN”
In RTPL mode, and the initial steam pressure is lower than 90% rated pressure, load set value
will decrease at a fixed rate. Shut down the control valve hydraulic servomotor can compensate
the decrease of initial steam, thus avoid initial steam pressure decrease being to large.
RTPL mode also can be cleared on limit sub picture: click button “Initial steam pressure
restriction”, afterwards click “Clear” button within 3S, and then control will disengage from TPL
mode.
9.5.7 Load limit (HLL) mode
In on-load OA operation, operator also can select high load limit mode: operator can press the
button “limit value” on lower left of main control panel to pop up the sub picture, then input the
load set value in high load limit mode area, afterwards click button “High load limit”, and click
button “Put-in” within 3S, control will enter the high load limit mode thereupon, meanwhile the
main panel will display “IN”. In case of high load limit mode, set value will not exceed the load
limit value.
High load limit mode also can be tripped on limit value sub picture: click button “High load limit”,
and then click button “Clear”, control will disengage from the high load limit mode thereupon.
9.5.8 Valve position limit mode (VPL)
In OA operation, operator also can select the valve position limit mode: operator can click the
button “limit value” on lower left of main control panel to pop up the sub picture, click “valve
position limit”, then input valve position limit value in valve position limit mode area, afterwards
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click button “GO”, here valve limit value will enter the DEH control logic. In case of valve position
limit mode, valve command will not exceed the valve position limit value.
9.5.9 Single valve/ sequence valve (SIG/SEQ) mode
In case of OA operation, operator also can select SIGLE (single valve) or SEQ (sequence valve)
operation mode: click the button “valve mode” on milled lower part of main control panel to pop
up he side picture, click single valve (or sequence valve) and the two switching buttons (press
switching button within 3S after clicking single valve button, and it will be effective if the two
buttons being red synchronously.
In SIGLE mode, command of all the control valves is the same and all the control valves take part
in control synchronously; in SEQ mode, four control valves will operate one after another
according to a certain sequence. The switching time between two modes is about 3S so as to
guarantee no disturbance of load in the whole switching process.
9.5.10 OPC mode (OPC MODE)
Moreover, there is OPC (overspeed protection control) function set in DEH, in case load of steam
turbine is over 30%, and main oil switch of motor trips, at that time, with the function of solenoid
valve, all the hydraulic servomotors of control valve will control oil pressure to unload, thereby
closing all hydraulic servomotors of governing steams. With the quick close of hydraulic
servomotor, rotating speed acceleration will be restrained, and if steam turbine rotating speed is
lower than 103% rated speed, and it is already 7.5S after OPC operation, then solenoid valve will
lose excitation and hydraulic servomotor will start to maintain normal operation for waiting for
synchronization. If steam turbine rotating speed still is larger than 103% after 7.5S, the valve will
not open until steam turbine speed is lower than 103%.
9.5.11 Manual (TM) mode
It also can enter the manual control mode in steam turbine operation. Pay attention that in
manual operation, operator can change the set value (GVSPT/TVSPT) of control valve and main
steam valve directly without the participation of DEH, and this is belonging to open loop
operation, which is inappropriate to be used except rotating speed path fault, etc. special
situation. The method for entering manual (TM) is as follows: press the manual button on manual
control panel, if red lamp lights, that indicates device being in manual operation state, here
operator can click the control mode button on top left of main panel to pop up the sub picture, and
the manual state bar will display “IN”, meanwhile main panel will display device being in “TM”
mode.
In manual operation, operator can realize the control of steam turbine by controlling control valve
set value directly with operating the “GVUP” “GVDN” buttons on manual operation panel, thereby
change rotating speed and actual load.
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In TM mode, OPC function remains, once OPC operate, it still will close all steam governing
valves.
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10.2.5 During bypass put-in, put HP bypass in first, then the HP bypass, regulate pressure after
governing valve and steam temperature to meet the requirement of start-up till outlet parameter
being steady and normal;
10.2.6 In unit shutdown, the temperature and pressure releasing valve, pressure reducing valve
and water spray control valve need to be open step by step according to operation parameter,
after unit shutdown, the above shall be closed in time.
10.2.7 Bypass device operating time is less than 8S at constant speed;
10.2.8 The max designed through flow of bypass system is 70%B MCR
Notes: six hydrodynamically-operated valves (including HP bypass pressure release valve, HP
bypass attemperating water isolating valve, HP attemperating water governing valve, LP pressure
release valve, LP bypass attemperating water isolating valve and LP attemperating water
governing valve), shall open automatically in case of unit fault (all are on the interlocking
position).
10.3 Shutdown of 70% bypass system
10.3.1 After unit loads on, bypass system shall be tripped according to the regulating requirement
of boiler parameter.
10.3.2 In bypass trip, HP bypass shall be tripped first, and then the LP bypass, the attemperating
water valve shall be closed first and then the pressure relief valve.
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11.1 In order not to let the drain flow inversely, all drains are connected and arranged on the drain
header by pressure grade in order, the drain heater connects with the proper drain flash tank that
drains water to the condenser sump via pipeline at the bottom and connects with the throat part
of condenser via pipeline on the top.
11.2 In order to avoid accidents of water escaping into the ST and to reduce the loss of accidents,
all turbine proper drains and other drain valves related to the safety of turbine shall be operated
as follows:
11.2.1 Turbine proper drain shall follow the principle of starting by stages;
11.2.2 The drain on the upstream of turbine MP combined valve shall be kept open prior to the
unit is loaded up to 10% of rated load;
11.2.3 The drain on the downstream of turbine MP combined valve shall be kept open prior to the
unit is loaded up to 20% of rated load;
11.2.4 The drain on the upstream of turbine MP combined valve shall be kept open prior to the
unit is loaded down to10% of rated load;
11.2.5 The drain on the downstream of turbine MP combined valve shall be kept open prior to the
unit is loaded down to 20% of rated load;
11.2.6 Before opening the main drain valves, avoid breaking the vacuum, but this term is not
applicable to the emergency case requiring breaking vacuum.
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12.1.9 Verify the air compressor and service air system are put into operation and operating
normally.
12.1.10 The manhole on the steam side of condenser steam side is opened. Check if the drain
valve before HP exhaust check valve is opened.
12.1.11 Only when the cylinder temperature decreases to below 350℃, it can put the quick
cooling equipment into operation.
12.2 Monitoring of parameters in quick cooling process:
In order to ensure the mental temperature inside the turbine can decrease evenly in the process
of quick-cooling after turbine shutdown so as to prevent overstress due to excessive cooling,
rotor from bending and cylinder and welded junction from deforming, it must strictly monitor the
changes in each point temperature, temperature difference between cylinder inner and outer wall,
temperature difference between upper and lower cylinder, absolute expansion, differential
expansion, axial deflection, rotor eccentricity, turning gear current, compressed air temperature
and flow and electric heater current in the process of putting the quick cooling equipment of
turbine into operation. The monitor control index of main parameters includes:
12.2.1 First stage metal temperature decreasing rate of HP cylinder is<5℃/h.
12.2.2 Carrier temperature decreasing rate of MP cylinder is<5℃/h.
12.2.3 Temperature difference between upper and lower cylinder of HP & MP cylinder is <42℃.
12.2.4 Indication of HP cylinder differential expansion is -2~+7.0 mm.
12.2.5 Indication of LP cylinder differential expansion is +6.5mm.
12.2.6 Rotor eccentricity is <0.076mm.
12.2.7 Turning gear current is normal.
12.2.8 Lubricating oil pressure is 0.12Mpa.
12.2.9 Cylinder expansion and contraction are smooth without sudden change
12.2.10 Control the compressed air flow within 25~80t/h.
12.2.11 After putt the quick cooling equipment of turbine into operation, , try to adopt no
temperature difference and little flow mode as much as possible in the early stage of air supply,
then slowly reduce the air temperature to keep the little temperature differences and increase the
flow to observe the change in the cylinder’s temperature. Strictly control the cylinder’s air inlet
temperature and ventilation quantity. In principle, keep stable for 30min every time of adjustment,
if there is no change or great change, make readjustment. The outlet temperature of air heater
shall decrease steadily without sudden change. When the air duct wall temperature of HP & MP
cylinder is about 100℃ and the first stage metal temperature of HP cylinder decreases by less
than 200 ℃, it may increase the ventilation quantity. When the first stage metal temperature of
HP cylinder and No.1 stator carrier temperature of MP cylinder reach below 140 ℃ and do not
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rise again obviously, it may end the forced ventilation. Close the air inlet valve and keep on
turning for 30min to see if the temperature of all points rises again, if not, it may stop turning to
start servicing.
12.3 Put-in of quick cooling equipment of turbine:
12.3.1 Put the LP cylinder spray of main machine into operation normally.
12.3.2 Slightly open the blowdown valve of oil-water separator and the drain valve of the gas
collection tank.
12.3.3 Open the total valve of compressed air.
12.3.4 Put the heater into operation.
12.3.5 Open wide the primary valve and adjust the air inlet flow of secondary valve as putting the
quick cooling equipment into operation. Slowly open the hand-operated air inlet valve of
compressed air to HP & LP drain pipe.
12.3.6 Open gradually the air inlet valve wider and set the outlet temperature of air heater
according to the decreasing of cylinder’s temperature, and control the temperature decreasing
rate not exceed 5℃/h.
12.3.7 Check if the exhaust temperature that shall not exceed 80℃.
12.3.8 In the process of put-in, check if the temperature difference between upper and lower
cylinder that shall not be more than 41℃.
12.3. In the process of put-in, pay attention to the change in cylinder expansion, differential
expansion and deflection.
12.3.10 Pay attention to the turning gear operating that is normal.
12.3.11 Keep various records.
12.3.12 If any abnormality, it shall stop air inlet of cylinder and report to the shift engineer.
12.4 Precautions in quick cooling operation:
12.4.1 Prior to forced cooling, purge the forced cooling system first up to standard and drain out
the water depositing in the system pipe.
12.4.2 In the case where turning gear of turbine is not put into operation, it is absolutely
prohibited to put the quick cooling equipment into operation; if so, stop the quick cooling system
immediately after the turning gear tripping.
12.4.3 Put the electric heater into adjusting the outlet steam temperature to warm up the system
pipe.
12.4.4 In the process of cooling, control the air inlet flow and outlet steam temperature strictly in
accordance with the specified decreasing rate, intensify monitoring, make adjustment from time
to time, control various parameters within permitted range and ensure safety of the unit.
12.4.5 In the process of forced cooling, it shall monitor and ensure normal operation of lubricating
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oil system, jacking oil system, turning gear, LP cylinder spray system and circulating water
system, if any system above stops, it shall stop forced cooling of turbine until the system
recovers.
12.4.6 In the process of forced cooling, intensify the monitoring of the operation of service
compressed air system at the same time.
12.4.7 In the process of cooling, if the decreasing rate difference between HP & MP cylinder
temperature is high, it may adjust and control with each branch valve.
12.4.8 It must not interrupt the compressed air as putting the quick cooling equipment into
operation so as to avoid dry heating of heater.
12.4.9 When the quick cooling equipment heater is in operation, pay attention to the operation of
heater, if air compressor stops or compressed air interrupts, it shall stop inlet of compressed air
and stop the quick cooling equipment.
12.4.10 When the quick cooling equipment is in operation, keep record of the turning gear
current, exhaust cylinder temperature, governing stage metal temperature of turbine, MP carrier
temperature, cylinder expansion, differential expansion, deflection and cylinder temperature, etc.
proper parameters once every half a hour.
12.4.11 In the process of quick cooling, it shall drain the water of steam-water separator, steam
bleeding box and gas container of air compressor and clean the filter periodically to prevent oil
and water dirty from entering the cylinder. Only in condition that the compressed air and flow are
normal, can the heater be put in to operation and can air be supplied to the turbine after the air
heater temperature becoming in accordance with the index. If discovering the air heater fails to
control temperature, it shall close the air source to prevent cold water supplied to turbine.
Precautions and parameter requirements:
a. When the governing stage mental temperature is 350-300℃, the temperature decreasing rate
shall be less than 3℃/h and the temperature difference between hot air and mental shall be less
than 40℃.
b. When the governing stage mental temperature is 300-250℃, the temperature decreasing rate
shall be less than 4℃/h and the temperature difference between hot air and mental shall be less
than 60℃.
c. When the governing stage mental temperature is 250-200℃, the temperature decreasing rate
shall be less than 5℃/h and the temperature difference between hot air and mental shall be less
than 90℃.
d. When the governing stage mental temperature is 200-150℃, the temperature decreasing rate
shall be less than 5℃/h and the temperature difference between hot air and mental shall be less
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than 130℃.
12.4.12 When air temperature exceeds the deviation or the electric heater loses power, it shall
raise the alarm and interlock close the inlet valve to prevent cold air from entering and cooling the
cylinder excessively, meanwhile cut off the power supply of heater to prevent the heater from dry
heating.
12.5 Stop of quick cooling system
After finishing quick cooling, adjust the potentiometer to 0 point manually, stop the heater, open
the power supply switch and continue to ventilate for 5~10 minutes, then close all valves. Slightly
open of the blowdown valve to prevent air leak of air inlet valve from resulting in water entering
the equipment.
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Appendix Part
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Appendix 1: Comparison Table of the Pressure [P] & Temperature [th] of Saturated Water & Steam
P th P th P th P th P th
0.0015 13.036 0.07 89.595 0.31 134.66 1.4 195.04 4.6 258.75
0.002 17.513 0.08 93.512 0.32 135.75 1.5 198.29 4.8 261.37
0.0025 21.096 0.09 96.713 0.33 136.82 1.6 201.37 5.0 263.91
0.003 24.1 0.1 99.683 0.34 137.87 1.7 204.31 5.5 269.93
0.0035 26.694 0.11 102.32 0.35 138.87 1.8 207.11 6.0 275.55
0.004 28.963 0.12 104.8 0.36 139.86 1.9 209.80 6.5 280.82
0.0045 31.035 0.13 107.13 0.37 140.78 2.0 212.37 7.0 285.79
0.005 32.898 0.14 109.32 0.38 141.71 2.1 214.85 7.5 290.50
0.006 36.183 0.15 111.37 0.39 142.62 2.2 217.24 8.0 294.97
0.007 39.025 0.16 113.32 0.40 143.62 2.3 219.55 8.5 299.23
0.008 41.534 0.17 115.17 0.41 144.52 2.4 221.78 9.0 303.21
0.009 43.787 0.18 116.93 0.42 145.39 2.5 223.94 9.5 307.21
0.01 45.833 0.19 118.62 0.43 146.25 2.6 226.04 10.0 310.96
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