500 MW Simhadri O&M Manual

STEAM TURBINE
OPERATION & MAINTENANCE

INSTRUCTIONS
SIMHADRI 2X 500 MW
NTPC
BHARAT HEAVY ELECTRICALS LTD.

HARIDWAR
Steam Turbine Preface
General
This manual contains information on the operation and maintenance of steam turbine. The informa-
tion has been prepared on the assumption that the operating and maintenance personnel have basic
knowledge of power plant engineering and operation.
It is an essential prerequisite for satisfactory operation and maintenance of the steam turbine that the
operating and maintenance personnel are fully familiar with the design of the steam turbine plant and
receive thorough training in operating and maintaining the unit.
Extensive operation beyond rated design values will eventually result in increased maintenance ex-
penses or a corresponding reduction in the useful life of the steam turbine. Bharat Heavy Electricals
Limited can not be responsible for any malfunction occuring as a result of operation beyond rated
limits and such operation, if undertaken by utilities, must be at their own risk.
The part numbers of components, indicated in the Description section of the manual should not be
used for ordering spare parts, always give the details specified in the drawings supplied separately.
Effort has been made to include adequate information in this manual. For any further information or
clarification please contact: Field Engineering Se/Vices, Steam Turbine Engineering, BHEL, Hardwar,
India -249403.
BHEL, Hardwar 5.0-0001-04

Steam Turbine Contents
Description
GENERAL Rear bearing pedestal 5.1-0340-01

Preface 5.0-0001-04 Journal bearing IP rear 5.1-0345-01/2
Contents 5.0-0002-04/3 Casing supports and guides 5.1-0350-01/2
DESCRIPTION LP Turbine
Casing 5.1-0410-01/4
Brief Description Atmospheric relief diaphragm 5.1-0420-01
Sectional arrangement 5.1-0001-03 Blading, drum stages 5.1.,0430-01
General description 5.1-0002-04/2 Blading, low pressure stages 5.1-0440-01/2
Fixed points 5.1-0003-01 Shaft seals 5.1-0450-01
Rear bearing pedestal 5.1-0460-01
Technical Data Journal bearing 5.1-0470-01/2

Construction, speed & steam
pressures 5.1-0100-04/3 Turning Gear
Steam and casing Hydraulic turning gear 5.1-0510-01
temperatures, feed water Manual turning gear 5.1-0520-01
heaters out of service 5.1-0101-04/2 Hydraulic lifting device 5.1-0530-01
Bearing metal temperatures,
vibration, weights 5.1-0102-04 Control System
Oil supply, oil pumps 5.1-0103-04/2 General description 5.1-0600-01
Control fluid supply and Start-up procedure 5.1-0610-01/2
control fluid pumps 5.1-0104-03/2 Speed control 5.1-0620-01/2
Limit curves, HP stop & Electrical speed measuring 5.1-0621-01
control valve 5.1-0110-01 Protective devices 5.1-0630-01/2
Limit curves, HP casing 5.1-0111-01/2 Overspeed trip test 5.1-0631-01
Limit curves, HP shaft 5.1-0112-01/2 Testing of stop valves 5.1-0632-01
Limit curves, IP shaft 5.1-0113-01 Electrohydraulic LP bypass
Steam purity required values control system(general) 5.1-0640
for main steamcpndensate 5.1-0120-01 Electrohydraulic bypass
Oil specification standard 5.1-0130-02 control (electrical system) 5.1-0641/2
Fire resistant fluid for Electrohydraulic LP bypass
turbine control system 5.1-0140-02/2 control (hydraulic system) 5.1-0642/2
Extraction check valve 5.1-0650-01
HP Turbine Swing check valve 5.1-0651-01

Valve arrangement 5.1-0205 Testing of check valves in
Casing 5.1-0210-01/3 cold reheat line 5.1-0652-01
Blading 5.1-0220-01 Automatic turbine tester
Shaft seals and balance piston 5.1-0230-0112 general 5.1-0660
Front bearing pedestal 5.1-0240-01/2 Automatic turbine tester
Rear bearing pedestal 5.1-0250-01/2 for protective devices 5.1-0661/6
Combined journal and thrust Automatic turbine tester
bearing 5.1-0260-01/2 stop and control valves 5.1-0662-01/2
Journal bearing, HP front 5.1-0270-01/2 HP actuator 5.1-0665
Casing supports and guides 5.1-0280-01/2 Electrohydraulic seal steam
pressure control 5.1-0670-01/3
IP Turbine Governing scheme 5.1-0680-01

Casing 5.1-0310-01/3 Control system diaphragm
Blading 5.1-0320-01 legend 5.1-0681-01/5
Shaft seals 5.1-0330-01/2 Lubrication chart 5.1-0690-01/3
BHEL, Hardwar 5.0-0002-04/1

Control System Parts Emergency trip valve for
Hydraulic speed governor with manual trip out 5.1-0911
starting and load limiting device 5.1-0710 Solenoid valve for remote
Adjusting gear 5.1-0720 trip out 5.1-0912
Electrohydraulic converter Overspeed trip 5.1-0920
for turbine control system 5.1-0730-02/3 Overspeed trip releasing
Hydraulic amplifier for device 5.1-0921
turbine control system 5.1-0740-02/3 Overspeed trip test device 5.1-0922/2
Damping device 5-1-0750.01 Low vaccum trip 5.1-0935
Electrical speed pick-up 5.1-0760 Condenser safety device 5.1-0940
Pressure converter 5.1-0761 Solenoid valve for temperature
Converter for electrohydraulic controlled interlock 5.1-0950
bypass governor 5.1-0770 Vacuum breaker 5.1-0960/2
Bypass limiting regulator 5.1-0780 Pressure switch for injection
Transformer for LP bypass water 5.1-0970
control system 5.1-0790/2 Changeover valve for
testing device 5.1-0980
Steam Valves and Accessories
Combined main stop and Oil Supply
control valve 5.1-0810-01/2 Oil supply system 5.1-1000-01
Servomotor for main stop Main oil tank 5.1-1010-01/2
valves & reheat stop valves 5.1-0811 Main oil pump with hydraulic
Hydraulic servomotor for speed transmitter 5.1-1020-01/2
main & reheat control valves 5.1-0812 Auxiliary oil pump 5.1-1030-01
Test valve for emergency DC emergency oil pump 5.1-1040-01
stop valve 5.1-0813 Jacking oil pump 5.1-1050/2
Combined reheat stop & Oil throttle 5.1-1080
control valves 5.1-0814 Oilthrottle 5.1-1081
Hangers for reheat stop & Three way control valve for
control valves 5.1-0815-01 lubricating oil temp. control 5.1-1090-01
Steam strainer 5.1-0816
Bypass stop & control valve 5.1-0820-01 Control Fluid Supply
Actuator for bypass HP control fluid pump with LP
control valve 5.1-0821 extraction 5.1-1110
Servomotor for bypass Plate-type filter 5.1-1120
control valve 5.1-0822 Duplex filter for pilot control
Water injection valve 5.1-0830 of control valves 5.1-1130/3
Pilot valve of injection Regenerating plant 5.1-1140/3
water valve 5.1-0831
Changeover valve for OPERATION
bleeder check valve 5.1-0840 Introduction 5.2-0001-01
Auxiliary valve of Specification of steam, oil &
extraction check valve 5.1-0841/2 control fluid 5.2-0002
Rotary vane actuator for Testing of turbine
reheat swing check valve 5.1-0853-01 components, General 5.2-0020
Pilot valve for rotary vane Turbine systems testing
actuator of swing check valve 5.1-0854 testing intervals
Auxiliary pilot valve for rotary Controllers 5.2-0021-01
vane actuator of reheat swing Automatic turbine tester 5.2-0022-01
check valve 5.1-0855-00 Automatic turbine tester 5.2-0023
Gland steam control valve 5.1-0860-01 Protective devices 5.2-0024-01
Leakage steam control valve 5.1-0870-01 Safety devices 5.2-0025
Valves 5.2-0026
5.0-0002-04/2
Protective Devices Monitoring devices 5.2-0027
Main trip valve 5.1-0910/2 Operating parameters 5.2-0028
Startup Protective devices 5.2-0450/4
Starting the turbine 5.2-0110-01 Automatic turbine tester 5.2-0455/6
Startup & shutdown Oil system 5.2-0460/4
diagrams, symbols 5.2-0111 Control fluid EHS-system 5.2-0470/2
Startup diagram Gland steam system 5.2-0480-01
General 5.2-0112/2 Bypass system 5.2-0490/2
Preparation for startup 5.2-0113
Oil System & Turning Gear 5.2-0130-01/5 MAINTENANCE
Control Fluid System 5.2-0135-01/4 Introduction 5.3-0001
Condensing Plant 5.2-0140-01/4 Inspection schedule 5.3-0010-01/2
Bypass System 5.2-0150/3 Maintenance schedule
Warm-up & startup of Introduction 5.3-0020-01
turbine 5.2-0160~01/5 Turbine 5.3-0021-01
Temperature criteria 5.2-0170-01/4 Oil system, seal steam
Controllers 5.2-0180/4 system, drains 5.3-0022-01/3
FRF system 5.3-0023-01/2
On-load Running Testing during start-up 5.3-0030-01/6
Load operation, Introduction 5.2-0200 Testing during power operation 5.3-0035-01/4
Synchronisation and loading 5.2-0210/5 Operating records 5.3-0036-01
Power operation, controllers 5.2-0220/9 Acquisition & archiving of
Actions to prevent unallowable operating data 5.3-0037-01/3
heat-up through blade windage 5.2-0230/4 Remedial actions for off-normal
operating conditions 5.3-0040-01/6
Shutdown Measurement of internal
Introduction 5.2-0300 efficiency 5.3-0050-01
Shutdown diagram Testing during shut down 5.3-0060-01/4
General 5.2-0310-01 Testing during standstill 5.3-0061-01/5
Turbine-generator 5.2-0320-01/5 Testing of safety valves 5.3-0062-01
Condensing plant 5.2-0330-01/2 Testing of signalling devices 5.3-0063
Oil system 5.2-0340-01/2 Testing of TSE / TSC 5.3-0064/3
Fast cooling down of turbine 5.2-0350-01 Steam washing of turbine 5.3-0070-01/2
Preventing corrosion in Oil care 5.3-0080-01
idle turbine 5.2-0360/2 Grease & oil lubrication 5.3-0081
Care of control fluid 5.3-0082/7
Fault Tracing Determination of FRF purity 5.3-0083-01
Introduction 5.2-0400 Vibration dampers 5.3-0100
Serious faults 5.2-0410/5 Instructions for overhaul 5.3-0200-01/7
Vibration 5.2-0420/4 Turbine restart after
Bearing temperatures 5.2-0421 boiler repairs 5.3-0210
Expansions 5.2-0422-01/2 Turbine restart after major
Casing temperatures 5.2-0423 inspection or repairs 5.3-0220/2
Turbine stress evaluator, Environmental protection 5.3-0250
measures to av9id Fluorelastomer products
impermissible operation 5.2-0430/4 safety notice 5.3-0251
Stop & control valves 5.2-0440 Ordering of spares 5.3-0300
5.0-0002-04/2 5.0-0002-04/3
Steam Turbine General Description
Description
Construction, Steam Flow lower pressure and temperature effective at the

The turbine is a tandem compound machine with exhaust from the inner casing.
separate HP. IP and LP sections. the HP section
being a single-flow cylinder and the IP and LP sections LP Turbine
double-flow cylinders. The turbine rotors and the The casing of the double-flow LP cylinder is of three-
generator rotor are connected by rigid couplings. shell design. The shells are horizontally split and are
of rigid welded construction. The innermost shell,
The HP turbine is throttle controlled. The initial steam which carries the first rows of stationary blades, is
is admitted ahead of the blading via two main stop supported so as to allow thermal expansion within
and control valve combinations. A swing check valve the intermediate shell. The intermediate shell rests
is installed in the line leading from HP turbine exhaust at four points on longitudinal girders, independent of
to the Reheater to prevent hot steam from the reheater the outer shell. Guide blade carriers, carrying the last
flowing back into the HP turbine. stationary blade rows are also attached to the
intermediate shell.
The steam coming from the Reheater is passed to
the IP turbine via two reheat stop and control valve Blading
combinations. Cross around pipes connect the IP and
LP cylinders. Connections are provided at several The entire turbine is provided with reaction blading.
points of the turbine for feedwater extraction The stationary and moving blades of the HP and IP
purposes. sections and the front rows of the LP turbine are
designed with integrally milled inverted T -roots and
HP Turbine, Barrel Type Casing shrouds. The last stags of the LP turbine are fitted
with twisted drop -forged moving blades with fir-tree
The outer casing of the HP turbine is of the barrel roots engaging in grooves in the shaft with last stage
type and has neither an axial nor a radial flange. This stationary blades made from sheet steel.
prevents mass concentrations which would have
caused high thermal stresses. The almost perfect Bearings
asymmetric design of the casing permits moderate
and nearly uniform wall thickness at all sections. The The HP rotor is supported on two bearings, a journal
inner casing is axially split and supported so as to be bearing at Its front end, and a combined journal and
free to move in response to thermal expansion. As thrust bearing immediately next to the coupling to the
only slight pressure differences are effective, the IP rotor. The IP and LP rotors have a journal bearing
horizontal flange and joint bolts of the inner casing each at rear end. The combined journal and thrust
can be kept small. The barrel type casing permits bearing incorporates a journal bearing and a thrust
flexibility of operation in the form of short start-up times bearing which takes up residual thrust from both
and a high rate of change of load even at high initial directions. The bearing metal temperatures are
steam conditions. measured by thermocouples directly under the babbit
lining. The temperature of the thrust bearing is
IP Turbine measured in two opposite thrust pads.
The IP trbine section is of double-flow construction The bearing pedestals are anchored to the foundation
with horizontally split casings. Allowance is made for by means of anchor bolts and are fixed in position.
thermal movement of the inner casing within the outer
casing. The inner casing carries the stationary The HP and IP turbines rest with their lateral support
blading. The reheated steam enters the inner casing horns on the bearing pedestals at the turbine
at the mid-section top and bottom. The provision of centerline level. The HP and IP casings are connected
an inner casing confines high steam inlet conditions with the bearing pedestals by
to the admission section of this casing, while the joint
flange of the outer casing is subjected only to the

in front of the turbine-generator unit. All valves are
casing guides, which establish the centerline
actuated by individual hydraulic servomotors.
alignment of the turbine casing. The axial position of
the HP and IP casings is fixed at the support brackets
Turbine Control System
on HP-IP bearing pedestal. The fixed point for the LP
The turbine has an electrohydraulic control system.
casing is at the front point of support on the
An electric system measures speed and output and
longitudinal girder. Thermal expansion of the casings
controls them by operating the control valves
originates from the fixed points.
hydraulically via an electrohydraulic converter. The
electrohydraulic controller ensures controlled
Shaft Seal and Blade Tip Sealing
acceleration of the turbine-generator up to rated
All shaft seals, which seal the steam in the casings
speed and limits speed overshoot in the event of
against atmosphere, are axial-flow labyrinth-type
sudden load rejection. The linear power frequency
seals. They consist of a large number of thin seal
droopcharacteristic can be adjusted in fine steps even
strips which, in the HP and IP turbines are caulked
when the turbine is running.
alternately into grooves in the shafts and the
surrounding seal rings. In the LP turbine, the seal
Turbine Monitoring System
strips are caulked only into the seal rings. Seal strips
of similar design are also used to seal the radial blade
In addition to measuring and display instruments for
tip clearances.
pressure, temperatures, valve lifts and speed, the
monitoring system also includes instruments for
Valves
measuring and indicating the following parameters:
The HP turbine is fitted with two main stop and control Rotor expansion measured at the rear-bearing
valves. One main stop valve and one control valve pedestal of the LP turbine
with stems arranged at right angles to each other are Axial shift measured at the HP-IP pedestal
combined in a common body. The main stop valves Bearing pedestal vibration, measured at all turbine
are spring-action single-seat valves; the control bearings
valves, also of single-seat design, have diffusers to Shaft vibration measured at all turbine bearings
reduce pressure losses.
Oil and Control Fluid Supply System
These valve combinations are located at both sides
of the turbine with their stems horizontal. The HP A common oil supply system lubricates and cools the
valves are connected to the turbine by ‘easily bearings and drives the hydraulic turning gear. The
separable collar couplings, which contain self-sealing main oil pump is driven by the turbine shaft and draws
U-rings as sealing elements. oil from the main oil tank. Auxiliary oil pumps maintain
the oil supply on start-up and shutdown, during turning
The IP turbine has two reheat stop and control valves. gear operation and when the main oil pump is faulted.
The reheat stop valves are spring-action single-seat When the turning gear is started, a jacking oil pump
valves. The control valves, also spring-loaded, have forces high-pressure oil under the shaft journals to
diff~sers. The’control valves operate in parallel and prevent boundary lubrication. The lubricating and
are fully open:fn the upper load range. In the lower cooling oil is passed through oil coolers before
load range, they control the steam flow to the IP entering the bearings.
turbine and ensure stable operation even when the
turbine- generator unit is supplying only the station The control fluid pumps situated on a control fluid
load. tank supply the hydraulic turbine and bypass control
system and the protective devices and valve
The reheat stop and control valves are supported free actuators’with HP and LP control fluid.
to move in response to thermal expansion on the
foundation cover plate below the operating floor and
5.1-0002-04/2
Steam Turbine Fixed Points
Description
Design Of the supports for the turbine on the foundation expan~ion. Centering of these casings is provided by
has to allow for the expansion of the turbine during thermal guides which run in recesses in the found~tjon cross beam.
cycling. Axial movement of the casings is unrestrained.
Constrained thermal expansion would cause Hence, when there is a temperature rise, the outer
overstressing of the components. The method of casings of the lP turbine expand from their fixed points
attachment of the turbine components is also critical to towards the generator. Differences in expansion between
the magnitude of the differential axial expansion between the outer casings and the fixed bearing pedestals, to which
the rotor systen, and turbine casings. which must be given the shaft seal casings are attached, are taken up by bel-
careful attentior, in the determination of int’ernal lows expansion joints.
clearances.
The following components form the fixed points for the Rotor ExpansIon
turbine: The thru’st bearing is housed in the rear bearing
pedestal of the HP turbine. The HP turbine rotor expands
The HP. IP and LP tlirbine bearing pedestals from the thrust bearing towards the front bearillg pedestal
The horn supports of the HP and IP turbine of the HP turbine and the IP turbine rotor from the thrust
The longitudinal beams of the LP turbine bearing towards the generator.
The thrust bearing in the HP turbine rear bearing The lP turbine’rotor is displaced towards the generator
pedestal by the expansion of the shaft assembly, originating from
the thrust bearing.
Casing Exp.ansion
The bearing pedestals are anchored to the toundation Differential Expansion
by means of anchor bolts and are fixed in position. The Differential expansion between the rotors and casings
HP and IP turbines rest with their lateral support horns on results from the difference between the’ expansion
the bearing pedestals at”the turbine centerline level; The originating from the bearing pedestal behind the HP turbine
HP and IP casings are connected with the bearing and that from the thrust bearing. The largest differential
pedestals by casing guides whic’h establish the centerline expansions of the HP and IP turbines thus occur at the
alignment of the turbine casings. The axial position of HP ends farthest from the thrust bearing.
and IP casings is fixed at the HP-IP pedestal. Thermal Differential expansion between the rotor and casing of
expansion of the casings originates from the fixed points. the lP turbine results from the difference between the
The LP Turbine casings are held in place axially by means expansion of the shaft assembly, originating from the thrust
of keys on base plates fitted at the front support points on bearing, and the casing expansion, which originates from
the longitudinal beams. thus allowing free lateral he fixed points on the lP turbine longitudinal beams.

Steam Turbine Technical Data
Construction, Speed
Description
& Steam Pressures
Load
Rated Load 500 MW
Maximum Load under valve wide open (VWO) condition 524.9 MW
Construction
Three cylinder reheat condensing turbine
Single flow HP Turbine with 17 reaction stages Type : H30-100-2
Double flow IP Turbine with 12 reaction stages per flow Type : M30-63
Double flow LP Turbine with 6 reaction stages per flow Type : N30-2x10
2 Main Stop and Control Valves Type : EV320-1
2 Reheat Stop and Control Valves Type : IV560
1 Swing Check Valve in cold reheat line DN-800
Make BHEL Tiruchy
2 Bypass Stop and Control Valves DN-400
Extraction Swing Check Valves
Extraction 1 : No valve
Extraction 2 : 1 Swing Check Valve with actuator and DN 800
1 Swing Check Valve without actuator Make BHEL Tiruchy
Extraction 4.1 : 2 Swing Check Valves with actuator DN 500
Make BHEL Tiruchy
EXtraction 4.2 : 2 SwIng Check Valves with actuator DN 500
Make BHEL Tiruchy
Extraction 5 : 1 Swing Check Valve with actuator and 1 Swing DN 400
Check Valve without actuator Make BHEL Tiruchy

Speed
Rated speed 50.0 cIs
Speed limitation in load and station operation

Max. Speed, no time limitation 51.5 cIs
Min. Speed, no time limitation 47.5 cIs
Permissible for a maximum 2 hours during the life of LP blading
Speed below 47.5 cIs
Speed above 51.5 to 60 cIs
Speed exclusion range at operation without load * 7 to 47.5 cIs
Standard over speed trip setting Max. 55.5 cIs
* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance ‘
Steam Pressures
♦ ♣ ♥
Rated Long time operation Short time operation
Initial Steam 166.7 166.7 200 bar
Before 1st HP drum stage 154.4 169.8 169.8 bar
♠
HP cylinder exhaust 44.0 50.6 51.3 bar
♠
IP cylinder stop valve inlet 39.6 45.9 48.44 bar
Extraction 6 44.0 50.6 57.4 bar
LP cylinder exhaust 0.1026 0.3 0.3 bar
♦ These values correspond to 500 MW load with 3 % make-up and 0.1026 bar back pressure
with all heaters in service and rated steam conditions.
♠ The safety valves must be set so that short time values are not exceeded.
♣ Long time operation : Upper limit value, permissible without time limit.
♥ Short time operation : Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in anyone year
All pressures are absolute pressures
5.1-0100-04/2
Speed
Rated speed 50.0 cIs
Speed limitation in load and station operation

Max. Speed, no time limitation 51.5 cIs
Min. Speed, no time limitation 47.5 cIs
Permissible for a maximum 2 hours during the life of LP blading
Speed below 47.5 cIs
Speed above 51.5 to 60 cIs
Speed exclusion range at operation without load * 7 to 47.5 cIs
Standard over speed trip setting Max. 55.5 cIs
* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance ‘
Steam Pressures
♦ ♣ ♥
Rated Long time operation Short time operation
Initial Steam 166.7 166.7 200 bar
Before 1st HP drum stage 154.4 169.8 169.8 bar
♠
HP cylinder exhaust 44.0 50.6 51.3 bar
♠
IP cylinder stop valve inlet 39.6 45.9 48.44 bar
LP cylinder exhaust 0.1026 0.3 0.3 bar
♦ These values correspond to 500 MW load with 3 % make-up and 0.1026 bar back pressure
with all heaters in service and rated steam conditions.
♠ The safety valves must be set so that short time values are not exceeded.
♣ Long time operation : Upper limit value, permissible without time limit.
♥ Short time operation : Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in anyone year
All pressures are absolute pressures
5.1-0100-04/2
Construction, Speed
Description
& Steam Pressures
Load
Rated Load 500 MW
Maximum Load under valve wide open (VWO) condition 524.9 MW
Construction
Three cylinder reheat condensing turbine
Single flow HP Turbine with 17 reaction stages Type : H30-100-2
Double flow IP Turbine with 12 reaction stages per flow Type : M30-63
Double flow LP Turbine with 6 reaction stages per flow Type : N30-2x10
2 Main Stop and Control Valves Type : EV320-1
2 Reheat Stop and Control Valves Type : IV560
1 Swing Check Valve in cold reheat line DN-800
Make BHEL Tiruchy
2 Bypass Stop and Control Valves DN-400
Extraction Swing Check Valves
Extraction 4.1 : 2 Swing Check Valves with actuator DN 500
Make BHEL Tiruchy
EXtraction 4.2 : 2 SwIng Check Valves with actuator DN 500
Make BHEL Tiruchy
Extraction 5 : 1 Swing Check Valve with actuator and 1 Swing DN 400
Check Valve without actuator Make BHEL Tiruchy

Low vacuum trip, standard setting
Hydraulic low vacuum trip 0.3 bar

Electrical low vacuum trip 0.3 bar
Hydraulic low vacuum trip bypass operation 0.6 bar
Seal steam Supply system

Pressure in seal steam header (above atmospheric) 35 mbar
Axial shift
Alarm ± 0.5
Trip ± 1 mm
Direction of rotation
Anti clock wise when viewed from Front Pedestal towards the Generator
5.1-0100-04/3
Steam & Casing Temperatures
Description
Feed water Heaters out of service
Steam Temperatures
Rated value Long-term 400 hrs. per year 80 hrs. per year
Annual value subject to Max. 15 min. in
average annual average individual case
Main steam at HP 537.0 545.3 551.0 565.0 C
0
stop valve inlet

HRH steam at IP 537.0 545.3 551.0 565.0 C
0
Stop valve inlet
♦
Rated value Long term 80 hrs. per year In special
operation Max. 15 min. in cases at no
individual case load
♥
HP turbine 336.4 353.4 436.4 500.0 C
0
exhaust
♥
Extraction 6 336.4 353.4 436.4 500.0 C
0
Extraction 5 412.8 417.8 452.8 C

0
Extraction 4 290.8 300.8 340.8 C

0
Extraction 3 185.2 196.2 240.2 C

0
Extraction 2 126.0 146.0 186.0 C

0
Extraction 1 65.4 85.4 130.4 C

0
LP turbine 46.4 70.0 70.0 C

0
exhaust
Long-term operation: upper limit value permissible without time limit.

♦ These values co”espond to 500 MW Load with 3% makeup and O. 1026 bar back pressure
with all heaters in service and rated/steam conditions.
♥ Only valid for the no ioad perioq with high reheat pressure after trip-out from full load operation.
For individual case apprdx. 15 minutes.
The turbine is immediately re-/oaded or the boiler immediately reduced to minimum load if no load
operation is maintained. -
Casing Metal Temperatures

Wall Temperatures Alarm at Machine must be shut down at
HP turbine casing exhaust 485 500 0
C
Outer casing of LP cylinder 90 110 0
C
Spray water to LP turbine must be switched on at 90°C

Casing Metal Temperature Differences
Temperature Difference Alarm at Machine must be tripped at
Between upper & lower casing ± 90 ± 100 C

0
halves of HP turbine, middle

0
halves of IP turbine, front

0
halves of IP turbine, rear
Permissible differential temperature between parallel steam supply lines

No time limitation 17 C
0
Short time period (15 min) 28 C

0
In the hottest line the limitations indicated for main and reheat steam temperature must not be exceeded
Feedwater Heater out of service

Operation with feedwater heater out of serivce Main steam flow, Km/s Load,
(indicative) MW
Extraction A6=0 395 500
Extraction A5 =0 421 500
Extraction A 1 =0 423 500
Extraction A6,A5.0 400 526.6
Output Limit during Testing with Automatic Turbine Tester

Testing of main steam stop and control valves 400 MW
Testing of HRH steam stop and control valves 200 to 500 MW
Motoring
Motoring is the condition in which the turbine is driven by the generator at rated speed with the stop
and control valves closed. In this operating mode, certain turbine components are heated up by
windage power of the blading.
To prevent heat-up beyond permissible temperatures, motoring must not be allowed to continue for
longer than one minute. If the condenser low vacuum limit of 0.3 bar 15 exceeded, motoring must
not be allowed to continue for more than 4 seconds.
5.1-0101-04/2
Bearing Metal Temperatures
Description
Vibration, Weights
Bearing babbit metal temperatures
Alarm at Machine must be shut down at

Operation temperature below 75 0C 90 0C 130 0C
Operation temperature 75 to 85 0C 100 0C 130 0C
Operation temperature 85 to 90 0C 110 0C 130 0C
Operation temperature above 90 0C 115 0C 130 0C
Vibration
Absolute bearing housing vibration Absolute shaft vibration
Standard alarm setting 25 µm above normal level
Maximum alarm setting 42 µm 1 00 µm
Limit value for tripping 53 µm 160 µm
The normal level is the reproducible vibrational behaviour typical for the machine & dependent
on the operating conditions.
Vibration readings indicated in control room are half peak. The above values are also given
in half peak.
Weights
HP turbine, completely asembled 94.6 T
IP turbine, top half outer casing 25.7 T
IP turbine, top half inner casing, complete with blading 15.5 T
LP turbine, top half outer casing complete 42.6 T
LP turbine, top half inner outer casing, complete with blading, guide blade carriers & 37.0 T
diffusers
HP turbine rotor, complete with blading 16.3 T
IP turbine rotor, complete with blading 23.1 T
LP turbine rotor, complete with blading 90.0 T
Main stop and control valve, complete with servo motors, without bend & pipe section 22 T
Reheat stop and control valve, complete with servo motors, without bend & pipe section 32 T
All weights have been calculated with safety allowances. Slings chosen must provide sufficient
security.

Oil Supply, Oil Pumps
Description
OIL SUPPlY
Main oil tank, rated capacity 25/40 M3
First oil filling (estimated) 47.5 M3
Flushing oil quantity (estimated) 28.5 M3
Oil cooler for operation, number 1 No.
Oil cooler for reserve, number 1 No.
Min. 38 °C
Oil temperature at cooler outlet, unit in operation Normal 45
Max. 47
Oil temperature at cooler outlet, unit shut down Max. 75 °C
Temperature rise of oil in bearings Normal 20 °C
Max. 25
Estimated oil requirement for Bearing 1 0.8 dm3/s
Estimated oil requirement for Generator front bearing 7.92 dm3/s
Estimated oil requirement for Generator rear bearing 7.92 dm3/s
Estimated oil requirement for Exciter bearing 0.70 dm3/s
Estimated oil requirement for Hydraulic Barring at 4.5 -5.0 bar 57.4 dm3/s
Duplex oil filter- full flow, Type: 2.68.2, size 355/750, Nb 150 1 No.
Make: Boll & kirch, Germany
Filtration particle size of duplex filter element 37 µm
Filtration particle size of main oil tank filter element 250 µm
Safety valve in jacking oil system, setting 200 bar
Pressure limiting valve in jacking oil system, setting 180 bar

Duplex oil filter for jacking oil, Type: 400 D 140, Nb 25 1 No
Make: K&H Eppensteiner, Germany
Filtration particle size of jacking oil filter 37 µm
Jacking. oil pump, cut-in and cut-out speeds

Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid damage
to bearings.
Jacking oil pump should be cut-out at speeds above approx. 540 rpm.
Oil pumps
Main Oil Auxiliary oil DC emergency Jacking oil pump
pump pump oil pump
Quantity 1 2 1 AC:2 DC:1
Make BHEL KSB KSB Tushako
Type 350 m3/hr ETA-150-50VL ETA-100-33VL T3SA 38/46
Rated eapacity 87.48 48 30 1.84 dm3/s
Discharge 8.4 6.7 2.3 178 bar
pressure
gauge
Speed 50 24.75 23.75 48.3 c/s
Drive turbine AC motor DC motor AC motor DC motor
5.1-0103-04/2
Control Fluid System &
Description
Control Fluid Pumps
Control fluid system

A Fire Resistant Fluid (FRF) is used for the control system
Control fluid tank, rated capacity 10/16 M3
First fill quantity (estimated) 15 M3
Flushing fluid quantity (estimated) 10 M3
Control fluid cooler for operation 1 No.
Control fluid cooler for reserve 1 No.
Control fluid regeneration system

Gear pump Make : Steimel, Type : BGK 2-24R
Fluid flow 0.28 dm3/s
Gauge pressure 3.06 ata
speed 25 /s
Motor power 0.75 KW
1 Control fluid purification system Make: Rotring, Type: PR 100.1
1 Drying filter Make: EPE 1"
2 Fueller’s earth filter Make: Rotring, Type: PYG-5-350
1 Fine filter Make: Rotrina, Type: S-1801-14-TUY

Control Fluid Pumps
Control pumps 2 Nos.

I Manufacturer KSB. Type: WKVM80/1 +3
Speed 2975 rpm
Drive A.C. electric motor, Manufacturer- Siemens, Type: 1LA6316-2AC 94/2
Enclosure IP 55
Voltage 415 V
Frequency 50 Hz
Motor rating 160 KW
Rated current 256 A
Starting current 1792 A
Control fluid pumps operating characteristics Fluid flow Discharge

(dm3/s) Pressure (bar)
Operating point I (normal operation)
Low pressure leakage fluid 12.1 11.5
High pressure leakage fluid 9.33 38.5
Operating point II (during start & opening of stop valve servomotor)
Low pressure leakage fluid & low pressure control fluid 25.1 10.8
High pressure leakage fluid 9.33 37.8
IOperating point III (during opening of CV servomotor/LP Bypass operation after load throw off)
Low pressure leakage fluid 12.1 10.6
High pressure leakage fluid & high pressure control fluid 24.36 31.6
All pressures are gauge pressures.
5.1-0104-03/2
∆θ [K]

Limit Curves
Description
Permissible temperature difference ∆θ in the wall of the HP casing

dring Sliding Pressure Operation Mode
∆θ [K]

Permissible temperature difference ∆θ in the wall of the HP casing
∆θ [K]
5.1-0104-03/2
Limit Curves
Description
Permissible temperature difference ∆θ in the wall of the HP turbine shaft

∆θ [K]
∆θ [K]

Permissible temperature difference ∆θ in the wall of the HP turbine Shaft
∆θ [K]
∆θ [K]
5.1-0104-03/2
Limit Curves
Description
Permissible temperature difference ∆θ in the wall of the HP turbine shaft

∆θ [K]
∆θ [K]

Steam Turbine Steam Purity Required values
for main steam condensate
Description
The deposits which occur in turbines due to every effort should be made to achieve the values in
impurities in the steam can lead to thermodynamic the normal operation column.
and mechanical inefficiencies and, with the presence
of salts, especially chlorides, and sodium hydroxide A recording instrument may be used to continuously
also cause damage to turbine parts. The corrosion monitor the electrical conductivity of the main steam
stressing caused by active deposits, for example, has and turbine condensate following a strongly acid
an adverse effect on the fatigue strenght of the blade cation- exchange unit. In order to determine slight
material when the steam is in the transition zone impurities, the sodium concentration should be
between the superheated and the saturated state. measured in addition to this. Should saline
contamination occur, the turbine is to be immediately
Compliance with the target values is mandatory washed with saturated steam to remove salt deposits.
in continuous operation, with the values in the normal
operation column preferable. With the commissioning Whether an alkaline, neutral or combined method is
of a new plant and starting-up operation, however, used for conditioning, the water steam circulation is for
these values can not be attained with an economical the customer to decide. If an alkaline method is used,
outlay. The values listed in the column “starting-up the oxygen content in the main steam condensate can
operation “are then valid. be max. 0.02 mgikg and the pH value in the turbine
condensate max.9.3 with brass condenser piping. When
It should be pointed out that adherence to the the condenser piping is of copper-nickel alloys, the pH
target values does not rule out deposition in the value must not exceed 9.5. There is no limitation for the
turbine with absolute certainity. Wherever possible pH value with non- corroding steel or titanium.
QUANTITY TARGET VALUE NORMAL OPERATION START UP

**
Conductivity at 25°C, down stream
of highly acidic sampling cation µS/cm < 0.2 0.1 < 0.50
exchanger, continuous measurement
at sampling point
Silica (SiO2) mg/kg < 0.020 0.005 < 0.050
Total iron (Fe) mg/kg < 0.020 0.005 < 0.050
Total copper (Cu) mg/kg < 0.003 0.001 < 0.010
Sodium (Na) mg/kg < 0.010 0.002 < 0.020
• To avoid any drop in efficiency, it is recommended that values be kept below the target values and into
the range of the values for normal operation.
•• The target values must show a noticeable downward trend. On initial start-up of new plants the values
given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours for other start
ups.
Recommended values for main steam condensate

Steam Turbine Oil Specification
Standard
Description
Introduction Flash point min. 200°C IS:1448 P-59

(Cleveland open cup)
This standard specifies the turbine oil recommended
Copper strip corrosion not worse IS:1448 P-15
for use in governing and lubrication systems of the test at 100 0C for 3 hrs. than No.1
turboset.
Pour ooint -60C max. IS:1448 P-10
Description Rust preventing 0-B max. DIN: 51585
Oil of viscosity class ISO VG 46 shall be used. The characteristics
oil shall be a petroleum product with or without Emulsion 40-40-0 (20 DIN: 51599
additives to meet the requirement of this standard. characteristics minutes)
The finished oil shall be clear and free from water, Total acidity after 1000 max. 2.0 mg. DIN: 51587
suspended matter, dirt, sediment and other impurities. hrs. oxidation of KOH per
gm. of oil
The turbine oil shall not contain additives having any Foaming
negative effects on the materials of the oil system. characteristics at 25°C ASTM: D892
The turbine oil must be capable of withstanding Foaming tendency max. 400 cm3
bearing temperature of max. 130 °C and oil tank Foaming stability max. 450 s
temperature of max. 80 °C without physical and Deaeration capacity at 4 minutes DIN: 51381
chemical degradation. 500C max.
Ash (% by weight) max. 0.01 IS:1448 P-4
The properties of the oil shall not be affected by
Water content by max.0.01% ISO: 3733
centrifuging, water washing or filtering. weight
Compatibility Content of solid 0.05% max. DIN 51592
particles by weight
For topping up of the oil system, it is preferable if the Particle distribution min.17/14 ISO:4406
oil used is of the same brand and quality as that code
already in the system. However, if the same brand of Water release 300 s max. DIN: 51589
oil is not available and where it is intended to mix in
different products that individually conform to this Properties of turbine oil in use shall be limited to as
standard, a compatibility test should be conducted follows:
before actually mixing the oils. Samples of both the
oils in equal volume should be mixed and centrifuged Properties Value Test
for about 40 hrs. and then mixture must comply fully Method
with the requirements of this standard. NeuraIisation No. max.0.5 mg. IS:1012 P-58
(Total acidity) KOH per gm.
Properties Foamlng
characteristics at 250C ASTM: D892
The oil should comply with the requirements given in Foaming tendency max. 600 cm3
table below when tested according to the test methods Foaming stabilit max. 600 s
given in the respective standards mentioned against Water content (by wt.) max. 0.1% ISO: 3733
each. For obvious reasons, we don’t give any special
recommendation to a particular brand of oil to be used All other properties shall be limited to the same values
in the oil system of our turbosets. Any brand of the oil as for fresh oil.
complying with the above standards may be used.
Following oils are acceptable
Properties of new batches of turbine oil shall be
Brand Supplier
as follows:
Servoprime 46 lOC
Properties Value Test Turbol 46 Bharat Petroleum
Method
Shell Turbo oil T 46 Bharat Shell Ltd.
Kinematic Viscosity IS:1448 P-25
Mobil DTE Medium/DTE798 Indo Mobil Ltd.
at 40 0C 41.4 -50.6 cst
at 50 0C 28 cst Daohne SuDer Turbine oil 46 Savita Chemicals
Viscosity Index min. 98 IS:1448 P-56 ReQal R & 0 46 Caltex
Neutralisation No. max.O.2 mg. IS:1012 P-58 Turbinol 46 HPCL
(Total acidity) of KOH per Gulf Crest 46 Gulf Oil India Ltd.
gm. of oil Castrol Perfecto T -46 Castrollndia Ltd.
Colour max. 2 IS:1448 P-12 (Super clean)
Spacific gravity at 50 0C 0.85 IS:1448 P-32 Power Turbo-46 APAR Ltd.

Steam Turbine Fire Resistant Fluid (FRF)
for Turbine Control System
Description
Introduction The FRF must be free of ortho-cresol

compounds.
This specification is valid for Fire Resistant
Fluids (FRF) recommended for BHEL make The FRF must not pose a safety or health
steam turbine control system. According to hazard to the persons working with it,
ISO 6743/4, FRF is a fluid based on provided that the requisite hygiene
triarylphosphate ester marked ISO-L-HFDR. regulations are observed.
General Requirements Limit values
The FRF shall not. cause corrosion to The following limit values are not to
Steel, Copper and its alloys, Zinc, Tin or beexce~ded during the life time :
Aluminium.
Kinematic viscosity - maximum variation
The FRF must provide sufficient corrosion
± 5% with reference to delivery condition.
protection to the materials used in the FRF
system.
Neutralisation number - maximum increase
The FRF shall be continuously regenerated 0.20 mg KOH/g with reference to delivery
with Fuller’s earth or. an equivalent condition.
regeneration agent.
Air release -maximum 12 minutes.
Note : Before using regeneration agents other
than Fuller’s earth (e.g. ion exchangers) BHEL Foaming at 25 °C -Tendency maximum
and FRF manufacturer or supplier shalf’ be 200 ml, Stability maximum 450 sec.
contacted.
DisPosal
The FRF must not cause any erosion or
Supplier to be,qontacted for ‘Buy Back’ of
corrosion on the edges of the control
used fire resistant fluid.
elements.
The FRF must be shear-stable. It should In consultation with supplier, liquid material
not contain any viscosity index improver. should be incinerated and material
absorbed on sand should be disposed off
FRF leaking from the system must not as hazardous solid waste.
ignite or burn in contact with hot surfaces
(up to 550 C).
The FRF must be capable of w.ithstanding
continuous operating temperatures of 75 Following fire Resistant F1uids are
°C without physical or chemical approved:
degradation.
The FRF must be miscible with traces Brand Supplier
(max. 3 Vol. %) of triarylphosphate esters
of another kind but of the same base, 1. Reolube Turbo- FMC, UK
natural or synthetic. There should be no fluid 46XC
deterioration of the FRF in presence of
2. Fyrquel EHC 46 PCAS/AKZO, France
such trace quantities.
3. Gulf Turbofluid Gulf Oil India Ltd.
The air release of the FRF should not
46XC
deteriorate in presence of fluoroelastomer
seals and packings used in the FRF 4. Anvol PE 46XC Castrol lndia Ltd.
system.

Recommended Properties of FRF
Property Numerical Unit Test method

Value DIN/ISO ASTM
Kinematic Viscosity at 40 °C (ISO VG 46) 41.4 .50.6 mm2/s DIN 51 562-1 D 445
Air release at 50 °C ≤3 minutes DIN 51 381 D 3427
Neutralisation number ≤ 0.1 mg KOH/g DIN 51 558-1 D 974
Water content ≤ 1000 mg/kg DIN 51 777-3 D 1744
Foaming at 25 °C : Tendency ≤ 100 ml D 892

Stability ≤ 450 sec (Seq. 1)
Water separability ≤ 300 sec DIN 51 589-1
Demulsification ≤ 20 minutes DIN 51 599 D 1401
Density at 15 °C ≤ 1250 kg/m3 DIN 51 757 D 1298
Flash point (Cleveland open cup) > 235 °C DIN/ISO 2592 D 92
Ignition temperature > 550 °C DIN 51 794
Wick flame persistance time ≤5 sec DIN/ISO 14935
Pour point ≤.18 °C DIN/ISO 3016 D 97
Particle distribution * ≤ 15/12 Code ISO 4406
Chlorine content ≤ 50 mg/kg DIN 51 577-3
Oxidation stability ≤ 2.0 mg KOH/g DIN 51 373
Hydrolytic stabilty
Change of neutralisation number ≤ 2.0 mg KOH/g DIN 51 348 -
Electrical resistivity > 50 MΩm IEC 247
* The required system cleanliness is dependent upon the system design. Suitable measures
(e.g. filtration, separation) have to be taken to achieve this cleanliness level.
5.1-0140-02/2
Steam Turbine HP Turbine
Description Valve Arrangement
General Arrangement length of the admission section between the control

valves and the casing results in a very low steam
The HP turbine has 2 main stop valves and 2 volume in this section, which has a beneficial effect
control valves located symmetrically to the right and on the shutdown characteristics of the turbine-
left of the casing. The valves are arranged in pairs generator unit.
with one main stop valve and one control valve in a
common body.
Valve Actuation
Steam flow Each main stop valve and control valve has a
dedicated hydraulic servomotor(3;5). The servo-otors
The main steam is admitted through the main are mounted above floor level so that they are easily
steam inlet passing first the main stop valves and accessible and can be simply maintained.
then the control valves. From the control valves the
steam passes to the turbine casing(1). The short
BHEL, Hardwar 5.1-0205

Casing
Description
Barrel type Casing are relieved by the high pressure acting from the
outside, and can thus be kept small. For this reason,
The HP outer casing is designed as a barrel-type turbines with barrel-type casing are especially suitable
casing without axial joint. An axially split inner casing for quick start-up and loading.
(4) is arranged in the barrel-type casing(3)
Seals
Because of its symmetrical construction, the The pretensioned U-shaped seal ring(12) , that is
barrel - type casing retains its cylindrical shape and forced against the axial sealing surfaces by the steam
remains leakproof during quick changes in pressure and the I shaped seal ring (16),that allows
temperature (e.g. on start-up and shut down, on load axial displacement of the inner casing(4) and the
changes and under high pressures). The inner casing, barrel-type outer casing (3) from tha adjacent spaces.
too, is almost cylindrical in shape as the joint flanges

valves are connected to the inlet connections of the
outer casing by Breech Nuts(8) (Fig.2) through
buttrers threading. Sealing is achieved by U-seal
rings(6) which is forced against the outer sealing
surface by inlet steam pressure. The annular space
around the sealing ring is connected to the condenser
Connection to Main Stop and Control Valves through a steam leak-off line. Cylindrical pins(7)
located at the joint flange prevent rotation of the inlet
The steam lines form the main stop and control pipe with respect to the outer casing
5.1-0210-01/2
Attachment of Inner Casing
The inner casing (4) is attached in the horizontal

and vertical planes in the barrel-type casing(3) so that
it can freely expand radially in all directions and axially
from a fixed point when heating up while maintaining
concentricity relative to the turbine rotor.
On the admission side, four projections of the inner

casing (4) and on the exhaust side three projections
fit into corresponding grooves in the barrel-type casing
(3). In the horizontal plane these projections rest on
fitted keys (10) and in the vertiical plane they are
guided by the fitted keys(Fig.3&4). Radial expansion
is therefore not restricted by this suspension.
As shown in fig.6 the axial fixed point of the inner

casing is provided by a shoulder in the barrel-type
casing (3) against which a collar of the inner casing(4)
rests. The axial thrust to which the inner casing is
subjected is transmitted to and absorbed by the thrust
ring (14) , via thrust pads(13). The thrust ring is held
in position by support ring (15).
Outlet Connections
The exhaust end of HPT has single outlet
connection from bottom. At the flange connection a
U-seal ring (19) is provided to prevent any leakage
(Fig.1)

Blading
Description
Moving and Stationary Blades
The HP turbine blading consists of 17 drum stages.

All stages are reaction stages with 50% reaction.
The stationary and moving blades of all stages
(Fig.1) are provided with inverted T-roots which
also determine the distance between the blades.

The shrouds are machined integral with the blades
and forms a continuous shrouding after insertion.
The moving and stationary blades are inserted into

corresponding grooves in the shaft( 4) and inner
casing (1) and are caulked at bottom with caulking
aterial (5) .The insertion slot in the shaft is closed
by a locking blade which is fixed by grub screws.
Special end blades whiich are locked with the joint
plane by grub screws are used for the inner casing.
Gap sealing
Sealing strips(6) are caulked into the inner

casing(1) and the shaft (4) to reduce leakage
losses at the blade tips. Cylindrically machined
surface on the blade hrouds are opposite the
sealing strips. The surfaces have stepped
diameters in order to increase the turbulence of
the steam and thus the sealing effect. Should an
operational disturbance cause the sealing strips
to come into contact with opposite surfaces, they
are rubbed away without any considerable amount
of heat being generated. They can easily be
renewed at a later date to provide the specified
clearance.

Shaft Seals and Balance Piston
Description
Function Gap Seals
The HP Turbine has shaft seals in front and rear. Sealing betweer1 the rotating and stationary
The fornt shaft seal is labyrinth type, while the rear parts of the turbine is a:Ghieved by means of seal
shaft seals is to seal the interior of the casing form strip’(6) caulked into seal rings (2,7,9) and into the
the atmosphere at the ends of the shaft on the rotor (3) (details D andE). The pressure gr/tdient
admission and exhaust sides. The difference in across the seal is reduced by conversion of
pressure before and after the raised part of the shaft pressure. energy into veiocity energy which is then
seal on ‘the admission side serves to counteract dissipated as turbulence as the steam passes
the axial thrust caused by steam forces. The through the numerous compartments according to
effective seal diameter is suited to the reuirements the labyrinth principle.
for balancing the axial thrust.
Seal Rings
The seal rings (2), the number of which depends
on the pressure gradient to be sealed are divided
into several segments as shown in Sectiqn§ A-A,

B-B and C-C and mounted in T -shapedOl;lnular
grQoves in the inner casing (1 ) and shaft seal cover
(4) such that they are free to move radially. Each
segment is held in position against a shoulder by
helical springs
(1 1). This provides the proper clearance for the seal
ga~5. Should rubbing occur, the segment concerned
can retreat. The heat developed by light rubbing of
the thin seal s.trips (6) is so slight that it cannot cause

deformation of the rotor (3). VVhen the turbine is caulked into the shaft and into seal rings centered
started from the cold or warm state, the seal rings in the outer casing (Detail E).
naturally heat up faster than the CCising. However, The outer seal rings can be removed for
lht!Y can expand freely In the radial direction against inspection and if necessary, seal strips can be
the centering force of the helical spring (11). rAplaced during short turbine shut down keeping
The shaft seal are axial-steam flow non- module in place,
contacting seals.
In the region subJected to the low relative Steam Spaces
expanSion in tM vicinity of the r:ombinfld journal and Steam spaces are provided within the shaft seals.
thrust bearing, the seal strips are caulked alternately From spaces ‘Q’ and ‘A’, leakage is drawn off to
into the shaft and into spring-supported scgmented another part of the turbine for further use, The steam
seal ri.ng$ in the casing, forming a labyrinth to seal header is connected to space’S’, The slight
impede the outflow of steain (Detail D). amount of leakage steam which are still able to pass
In the region subject to greater relative expansion the seal ring are cor1ducted from the space ‘T’ into
at the exhalJst end, see through seals are used. in the seal steam condenser.
which the seal strips are located opposite each other,
5.1-0230-01/2
Front Bearing Pedestal
Description
Arrangement Details of casing supports and casing guides are

given in description 5.1-0280.
The front bearing pedestal is located at the turbine-
side end of the turbine generator unit. Its function is Connection of Bearing Pedestal and Foundation
to support the -turbine casing and bear the turbine
rotor. It houses the following components and The bearing pedestal (1) is aligned to the foundation
instruments. by means of hexagon head screws that are screwed
into it at several points. On completion of alignment,
Journal bearing [1] the space beneath the bearing pedestal is filled in
Hydraulic turning gear [2] with special non-shrinking grount. The bearing
Main oil pump with hydraulic speed transducer [3] pedestal is anchored to the foundation by means of
Electric speed transducer [4] anchor bolts (13). The anchor bolt holes are filled with
Overspeed trip [5] gravel, which gives a considerable vibration damping
Shaft vibration pick-up effect.
Bearing pedestal vibration pick-up
1 Bearing pedestal 7 Hydraulic turning gear

2 Main oil pump 8 Bearing pedestal vibration pick-up
3 Hydraulic speed transducer 9 Shaft vibration pick-up
4 Electric speed transducer 10 Journal bearing
5 Gear coupling 11 HP turbine rotor
6 Over speed trip 12 Foundation
Fig.1 Axial Section through HPTurbine Front Bearing Pedestal

The defined position of the bearing pedestal on the the Foundation. Ori completion of alignment, the
foundation is established by a projection in the middle remaining space in this recess is likewise filled with
of the bearing pedestal base engaging in a recess in grout.
10 Journal bearing Also refer to the following information

12 Foundation
13 Anchor bolts [1] 5.1-0270 Journal Bearing
14 Hex head screw [2] 5.1-0510 Hydraulic Turning Gear
[3] 5.1-1020 MainOilPump with Hydraulic Speed Transducer
Fig- 3 Cross Section of Jounal Bearing [4] 5.1-0760 Electric Speed Transducer
[5] 5.1-0920 Overspeed trip
5.1-0240-01/2
Rear Bearing Pedestal
Description
Arrangement
The bearing pedestal is located between the HP
and IP turbines. Its function is to support the turbine
casing and bear the HP and IP turbine rotors.
The bearing pedestal houses the following turbine

components:
Combined journal and thrust bearing [1]

Shaft vibration pick-up
Thrust bearing trip (electrical)
Details of casing supports and casing guides are
given in descriptions 5.1-0280 and 5.1-0350.
Connection of Bearing Pedestal and Foundation
The bearing pedestal is aligned on the foundation

by means of hexagon head screws that are screwed
Into it. On completion of alignment, the space beneath
the bearing pedestal is filled in with special non-
shrinking grout. The bearing pedestal is anchored to
the foundation by means of anchor bolts (10). The
anchor bolt holes are filled with gravel, which gives a
considerable vibration damping effect. The defined
position of the bearing pedestal on the foundation is
established by a projection in the middle of the bearing
pedestal base engaging a recess in the foundation.
On completion of alignment, the remaining space in
the recess is likewise filled with grout.
1 HP turbine rotor
2 Combined journal and thrust bearing
3 Bearing pedestal vibration pick-up
4 Shaft vibration pick-up
5 Thrust bearing trip (electrical)
6 Coupling bolts
7 IP turbine rotor
8 Foundation
Fig. 1 Axial Section through the HPTurb!ne Rear Bearing

Pedestal

2 Combined journal and thrust bearing
8 Foundation
9 Hex head screw
Fig. 2 Cross Section through Combined Journal

and Thrust Bearing
10 Straight pin
11 Anchor bolt
12 Plate
13 Round nut
14 Hex nut
15 Guard cap
Fig. 3 Connection between Bearing Pedestal and

Foundation
Also refer to the following information
[1] 5.1-0260 Combined Journal and Thrust Bearing
5.1-0250-02/2
19 Thermocouple
integralily machined shaft collars run. These collars 20 Thermocouple
and thrust pads permit equal loading of the thrust
bearing in either direction. As shown in section N-N, Oil Supply
the thrust pads are of the tilting type, secured in place Lubricating oil is admitted to the bearing shells
by pins (23) and flexible mounted on split spring from one side via oil line (11) from where it flows to
element (21). the oil spaces milled into the upper and lower bearing
shells at the horizontal joint.
Temperature Measurement
Metal temperature of the journal bearing and thrust
pads is monitored by the thermocouples (19,20)
(Section E-E and G-G).
7 Bearing liner
24 Sealing ring
Oil leaving the journal bearing flows to the two annular
grooves adjac,ent 10 the bearing surface and then to
the thrust pads (6). Through the two oil return cowlings
(5), oil is discharge into the drain area in the pedestal
(9)
JackingOil
Pressages are located at the lowest point In the lower

bearing shell through which high pressure jacking oil
is supplied .under the journal atlow~eed:ofthe turbine
rotor (on start up or shutdown). Thus dry friction IS
prevented and the .breakaway torque on start-up with
turning gear is reduced.
High pressure oil “a” flows under the journals via

the oil line and via openings in the lower bear\ng shell
(12). O-rings (24)locat~d between the bearing liner
(7) and the lower bearing shell (12) prevents any oil
from penetrating between the two elements
(Details“C”).
Any leakage passing the sear will drain off to the
4 Bearing shell upper 21 Spring element bearing pedestal through a groove in th~lower bearing
6 Thrust pad 22 Key shell. This arrangement ensures thatno oil penetrates
12 Bearing shell, lower 23 Dowel pin between the bearing liner and the bearing shell.
5.1-0260-01/2
Steam Turbine Combined Journal and Thrust Bearing
Description
Function The journal bearing is constructed as elliptical

sleeve bearing. The bearing liners are provided with
The function of the combined journal and thrust
a machined babbit face; additional scraping is neither
bearing is to support the turbine rotor and to take the
necessary nor allowable.
residual axial thrust. The magnitude and direction of
In order to prevent the bearing from exerting a
axial thrust to be carried by ,the bearing depends on
bending moment on the shaft, it is pivot-mounted on
the load conditions of the turbine. This bearing is
spherical seat (16). The spherical block (14) with
located in the bearing pedestal between HPT & I PT.
shims (13,15), is bolted to the lower bearing shell (12).
The thrust bearing maintains desired axial clearances
A transverse projection in the upper part of the cap
for the combined turbine generator shaft system.
(2) and the fitted key (3) prevent the bearing shells
from rising.
Construction and Mode of Operation The bearing shells are located laterally by keys
The combined journal and thrust bearing consists (10). The bearing is supported axillay against the
of the upper and lower bearing shells (4, 12), thrust pads bearing pedestal (1,9) by means of keys (17, 18)
(6), cap (2), spherical blocks (14, 16) and keys (1O, (Section H-H). This fixing is of great importance for
17). The upper and lower haives (4, 12) of the bearing axial clearance in the whole turbine.
shell are bolted and doweled at the horizontal joint by Located at each end of the bearing shell, babbitted
means of 4 taper pins and 4 stocket-head screws. thrust pads (6) from two annular surfaces on which
the
Section A-A Section B-B
1 Bearing pedestal, upper 7 Bearing liner 13 Shim

2 Cap 8 Turbine shaft 14 Spherical block
3 Key 9 Bearing pedestal,lower 15 Shim
4 Bearing shell, upper 10 Key 16 Spherical seat
5 Cowling with oil baffle 11 Oil line 25 Key
6 Thrust pad 12 Bearing shell, lower a Shaft Jacking Oil

Jacking oil
As shown in Detail B, a threaded nozzle( 17) is

arranged at the lowest point of the lower bearing shell
(6) through which high pressure lift oil is supplied to
the space below the journals when the rotor is turning
at low speed (on start-up and shutdown).This high
pressure oil floats the shaft to prevent dry friction and
overcome breakway torque during start-up on the
hydraulic turning gear.
A seal (18) prevent high pressure oil from

penetrating the space between threaded nozzle and
ring (16) and thus from lifting the babbit. Any leakage
oil can drain through passages in the bearing shell
below the ring.
Removal of Bearing Shells

16 Ring
Not only the upper shell(3) but also the lower 17 Threaded nozzle
bearing shell(6) can be removed without the removal 18 Sealing ring
of rotor (5). To enable this to be done. the shaft is 19 Thermocouple
lifted slightly by means of jacking device but within
the clearance of the shaft seals. The lower bearing
shell can then be turned upwards to the top position
and removed.
5.1-0270-01/2
Steam Turbine Journal Bearing
HP Front
Description
Construction bearing shells. Centering of the bearing shells in the

vertical plane is achieved by means of key (8) fitted
The function of the journal bearing is to support on both sides of the projection.
the turbine rotor. Essentially. the journal bearing The bearing shells are fixed laterally by key (11) which
consists of the upper and lower shells (3,6), bearing are bolted to each other. Each key is held in position
cap (1), spherical block (7), spherical seat (14) and in the bearing pedestal (10) by two lateral collars.
the key (11) .The bearing shells are provided with a The temperature of the bearing bodies is monitored
babbit face. The sliding surfaces of this bearing are by thermocouples (19) as shown in section c-c.
machined and additional scraping is neither
necessary nor permissible. Both bearing shells are Oil Supply
fixed by means of taper pins and bolted together.
In order to prevent the bearing from exerting a Lubricating oil is admitted to the bearing shells from
bending moment on the roter (5), it is pivot-mounted one side and flows to oil spaces that are milled into
in the spherical seat (14). For this purpose. the the upper shell at the horizontal joint and are open to
spherical block (7) with shims (12,13) is bolted to the the rotor. The rotor (5) picks up oil from oil pocket
bearing shell (6) .A projection in cap (1) with shims machined into the babbitting .The oil emerges from
(9) fits into a corresponding groove in the bearing the bearing shell where it is collected in the oil return
shell (3) and prevents vertical movement of the cowling (4) and drained into the bearing pedestal(10).
1 Cap 6 Lower bearing shell 11 Key

2 Tab washer 7 Spherical block 12 Shim
3 Upper bearing shell 8 Key 13 Shim
4 Oil return Cowling 9 Shim 14 Spherical seat
5 Turbine Rotor 10 Bearing pedestal 15 Shim

Casing Supports ad Guides
Description
Supports The turbine casing (2) is supported with its two

front and two rear support horns on the horn supports
The turbine casing is supported on the support of the bearing pedestal (1,3) at the turbine centerline
horns such as to make allowance for the thermal level. This arrangement determines the height of the
expansion. It is essential for the casing to retain casing and also allows thermal expansion to take
concentric alignment with the rotot, which is supported place in the horizontal plane by the support horns
independently.
1 2 3
1 Front bearing pedestal

2 HP turbine
3 Rear bearing pedestal
Fig.1 Connection between Turbine Casing and Bearing Pedestals

sliding on the sliding pieces (6) of the bearing allow the turbine casing to expand freely.
pedestals (1 ;3) To prevent lift-off of the turbine casing
(2), holders (4) hold down projections of the support Fixed Point
horns which engage in mating recesses in the bearing
pedestal. The fixed point for the turbine casing (2) is located at
the rear horn support on HP-IP pedestal at the turbine
When the turbine is being erected, a clearance’s’ is centerline level and is formed by the parrallel keys
maintained between the thrust bar(5) and the turbine (16). Axial expansion of the turbine casing (2)
casing support horn projection. originates from this point.
Guides
The central location of the turbine casing at right

angles to the turbine centerline is provided by the
guides shown in section B-B and E-E. These guides
Section C-C
5.1-0280-01/2
Steam Turbine IP Turbine
Casing
Description
Double Shell Construction The provision of an inner casing confines the

steam inlet conditions to the admission section of this
The casing of the IP turbine is split horizontally casing. While the joint flange of the outer casing is
and is of double shell construction. A double-flow inner subjected only to the lower pressure and temprature
casing (3,4) is supported in the outer casing (2,5) effective at the exhaust from the inner casing. This
(Fig.1) Steam from the HP turbine after reheating means that the joint flange can be kept small and
enters the inner casing from top and bottom through material concentrations in the area of the flange re-
two admission branches which are integral with the duced to a minimum. In this way, difficulties arising
mid section of the outer casing. This arrangement from deformation of a casing with flange joint due to
provides opposed double flow in the two blade non uniform temperature rise ,e.g. on start-up and
sections and compensates axial thrust. The centre shut down, are avoided. The joint of the inner casing
flow prevents the steam inlet temperature from is relieved by the pressure in the outer casing so that
affecting the support horns and bearing sections. this joint has to be sealed only against the resulting
differential
pressure.
A

Aamlsslon ana Extraction Brancnes The tolerances of the annular grooves in the inner
The angle ring (9) from the connection of casing are dimensioned to allow the long legs of the
admission and extraction branches with the inner angle ring (9) to slide in the groove. The angle rings
casing (3,4) (Detail 0, Fig. 2,3). One leg of the angle are flexibly expanded by the pressure on the inside
ring (9) at such a connection bears against the back and their outer areas forced against the annular
of the collar of the threaded ring (7) in the outer casing, grooves to provide the desired sealing effect.
while the other fits into an annular groove in the inner
While providing a tight seal, this arrangement
casing. The threaded ring (7) is fitted in such a way
permits the inner casing to move freely in all
that the short leg of the angle ring can slide freely
directions.
between the collar of the threaded ring and the outer
casing. The steam pressure prevailing on the inside,
Attachment of Inner Casing
forces the angle ring against the face of the outer
Due to the different temperatures of the inner
casing.
casing relative to the outer casing, the inner casing
is attached to the outer casing in such a manner as
to be free to expand axially from a fixed point and
radially in all directions, while maintaining the
concentricity fo the inner casing relative to the shaft.
The steam admission connections and the extraction
connections are designed to avoid any restrictions
due to thermal expansion. The inner casing is
attached to the outer casing in the horizontal and
vertical plane.
5.1-0310-01/2
In the horizontal plane, as shown in details E and Shoulders on the bottom half outer casing (51
F (Figs. 4, 51, the four support horns of the top half project into corresponding recesses in the bottom half
inner casing (31 rest on plat~s (13) which are inner casing 141 and, together with the fitted keys
supported by the joint surface of the bo~tom half outer (141, provide a centering system for the inner casing
casing (5). The shoulder screws (12) are provided 13, 4) in the transverse plane This arrangement allows
with sufficientclearance to permit the inner casing-to axial and radi_al ~xpansion of the inner casing relative
expand freely in all/directions in the horizontal plane. to the outer casing while the fitted keys 1141 maintain
Thermal expansion in the vertical direction originates transverse alignment.
from the point of support at the joint. This ensures
concentricity of the inner casing relative to the rotor
(1) I in this plane.
The support horns provided at the bottom half
inner casing (4), project into the recesses in bottom
half outer casing (5) with clearance on all sides.
Located on top of each SUl>port horn is a spacer
disc (1 1 I. whose upper surface has a clearance’s’
to the flange face o’f the top half outer casing. (21.
This clearance thus determines the lift of the inner
casing.
As shown in details E, the inner casing iSllocated
axially by the fitted keys (101 arranged on both sides
of the support horns of the bottom half inn.er casing
(4). Thernlal expansion in the axIal direction
originatesfrDm these points. Radial ex. I pansion is
not,pre,’4ented by these fitted keys, as they are free
to slide i~\t~e recesses of the bottom half outer casing.

Blading
Description
Moving and Stationary Blades The moving and stationary blades are inserted into
The IP turbine bfading consists of 1 2 drum stages appropriately shaped grooves in the rotor 14) and in
in each steam flow direction. All stages are reaction the inner casing 11) and are bottom caulked with
stages with 50% re~ctil)n. The stationary and moving caulking material IS). The insertion slot in the rotor is
blades of all stages are provided with inverted T - sealed by a locking blade which is fix{!d by grub
roots which also determine the distance between the screws. Special end blades, which lock with the
blades. All these blades are provided with integral horizontal joint, are used at the horizontal joint of the
shrouds, which after insta;J,iation form a continuous inner casing 11). Grub screws which are inserted from
shroud. the joint, secure the stationary blades i” the grooves.
Gap SealIng
Sealing strips 17) are caulked into the inner casing
11) and the rotor 14) to reduce leakage losses at the
blade tips. Cylindrically machined surfaces on the
blade shrouds are opposite the sealing strips. These
surfaces have stepped diameters in order to increase
the turbulence of the steam and thus the sealing
effect. Should an operation disturbance calIse the
sealing strips to come into contact with opposite
surfaces, they are rubbed away without any
considerable amount of heat being generated. They
can then easily be renewed at a later date to provide
the specified clearances.

Shaft Seals
Description
Function caulked into the shaft and into seal rings centered ill
The function of the shaf~ seals is to seal the interior the outer casing.
of the turb.ine casi,ng against the atmosphere at the The outer seal rings can be removed for inspection
front (thrust beari,ng end) and rear shaft penetrations and, if necessary. seal strips can be replaced du!.ing
of the IP turbine. sort turbine shut down keeping module in place.
The shaft seals are axial-steam-flow non-
contacting seals. Gap Sealing
In the region subject to low relative expansion in Sealing between the rotating and stationary
the vicinity of the eombined journal and thru~t bearing, elements of the turbine is achieved by means of seal
the seal strips are caulked alternatively into the shaft strip (91 ,caulked into seal rings (3;5) and into the
and into spring-supported segmented rings jn the rotor (4) (details A and CI. The pressure gradient
casing, forming a labyrinth to impecje the outflow of across the seal is reduced by conversion of pressure
steam. energy into velocity energy which is then dissipated
In the region subject to greater relative expansion as turbulence as the steam passes through the
at the exhaust end, see-through seals are used, in numerous compartments according to the labyrinth
which the seal strips are located opposite each other, principle.

Seal Rings When the turbine is started from the cold or warm
state, the seal rings naturally heat up faster than the
The seal rings (3), the number of which depends mounting rings. However. they can expand freely in
on the pressure gradient to be sealed are divided into the raldal direction against the centering force of the
several segments as sho’Nn in Section B.B and helical springs (6).
mounted in grooves in the mounting -ings such that
they are free to move radially. Each segment is held Steam Spaces
in position against a shoulder by helical springs (6) Steam spaces are provided within the shaft seals.
and by the steam pressure above the seal rings (3). From space ‘P’, leakage is drawn off to the steam
This provides the proper clearance for the seal gaps. seal header. The slight amount of leakage steam
Should rubbing occur. the segments concerned can which are still able to pass the seal ring are conducted
retreat. The heat developed by light rubbing of the from the space ‘R’ into the seal steam condenser.
thin seal strips (9) is so s’ight that it cannot cause
deformation of the rotor (4),
5.1-330-01/2
Description Rear Bearing Pedestal
Arrangement
The bearing pedestal is located between the IP

and LP turbines. Its function is to support the turbine
casing and bear the weight of IP and LP rotors.
The bearing pedestal houses the following turbine

components:
• Journal bearing (1)

• Shaft vibration pick-up
• Bearing pedestal vibration pick-up
• Hand barring arrangement
The bearing pedestal (1) is aligned on the

foundation by means of hexagon head screws that
are screwed into it at several points. On completion
of alignment ,the space beneath the bearing pedestal
is filled in with special non shrinking grout. The bearing
pedestal is anchored to the foundation by means of
anchor bolts. The anchor bolt holes are filled with
gravel, which gives a considerable vibration damping
effect.

Jacking Oil
As shown in section B-8, two threaded nozzles

(17) are arranged at the lowest point of the lower
bearing shell (6) through which high pressure oil is
supplied to the space below the journal when the rotor
is turning at low speed (on start-up and shutdo~n).
This high pressure oil floats the shaft to prevent dry
friction and overcome breakaway torque during
startup, thus reducing torque requirements of the
hydraulic turning gear [1].
A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzal and
oil can drain through passagaes in the bearing shell
below the ring.
Removal of Beering Shells

Not only the upper shell (3) but also the lower
bearing shell (6) can be removed without the removal
of rotor (5). To enable this to be done, the shaft is
lifted slightly by means of jacking device but with in
the clearance of the shaft seals. The lower bearing
shell can th~n be turned upwards to the top position
and removed.
[1] 5.1-0510 Hydraulic Turning Gear
5.1-0345-01/2
Description IP Rear
Construction vertical plane is achieved by means of shims (8).

The bearing shells are fixed laterally by spacers
The function of the journal bearing is to support (10) which are bolted to each other. Each spacer is
the turbine rotor. Essentially, the journal bearing held in position in the bearing pedestal (11) by two
consists of the upper and lower shells (3, 6), bearing laterall collars. The temperature of the bearing bodies
cap (1), torus piece (7), cylindrical support (14) and is monitored by thermocouples (15) as shown in
the keys (10). The bearing shells are provided with a section C-C.
babbit face. The sliding surfaces of this bearing are
machined and additional scraping is neither Oil Supply
necessary nor permissible. Both bearing shells are
fixed by means of taper pins and bolted together. Lubricating oil is admitted to the bearing shells
from both sides, from where it flows to oil spaces
In order to prevent the bearing from exerting a milled into the upper and lower shells at the horizontal
bending moment on the rotor (5), it is pivot-mounted joint that are open to the rotor end. Oil from the oil
in the cylindrical support (14). For this purpose, the space machined in the babbitting is carried through
torus piece (7) with shims (12, 13) is bolted to the the rotor (5) and emerges from the bearing shell from
bearing shell (6). A projection in cap (1) with shims where it is collected in the oil return cowling (4) and
(9) fits into a corresponding groove in the bearing drained into the bearing pedestal (11).
shell (3) and prevents vertical movement of the
bearing shells. Centering of the bearing shells in the

Description Casing Supports and Guides

The turbine casing (2) is supported with its two
front and two rear support horns on the horns supports
of the bearing pedestals(1,3) at the turbine centerline
level. This arrangement determines the height of the
casing and also allows thermal expansion to take
place in the horizontal plane by the support horns
sliding on the sliding pieces (6;16) of the bearing
pedestals (1 ;3). To prevent lift. off the turbine casing
(2), holders (4;15) hold down projections of the
support horns which engage in mating recesses in
the bearing pedestal.
When the turbine is being erected, a clearance’s’
is established between the thrust bars(5;14) and the
turbine casing (2) support horn projection.
Guides
The central location of the turbine casing at right

angles to the turbine centerline is provided by the Fixed Point
guides shown in section B.B .These guides allow the
turbine casing to expand freely. The fixed point for the turbine casing (2) is located at
the front horn support at the turbine centerline level
and is formed by the parallel keys ((7;10). Axial
expansion of turbine casing (2) originates from this
point
5.1-0350-01/2
Steam Turbine LP Turbine
Description Casing
Construction Inlet Connections

Steam admitted to the LP turbine from the IP
The LP turbine casing consists of a double flow turbine flows into the inner casing (4,5) from both sides
unit and has a tripl~ shell welded casing. The outer through steam inlet nozzles before the LP blading
casing consists of the front and rear walls, the two Expansion joints are instC\lIed in the steam piping to
lateral longitudinal support beams and the upper part. prevent any undesirable deformation of the casings
The front and rear walls as well as the connection due to thermal expansion of the steam piping.
areas of the upper part are reinforced by means of
circular box beam. The outer casing is supported by
the ends of the longitudinal beams on the base plates
of the foundation.

Arrangement of Inner Casing in Outer Casing the plates allow extract alignment of the casing in the
The LP casing has a double-flow inner casing. centre plane and expansion transverse to the axis of
This inner casing is a double shell construction and the machine.
consists of the outer part(3,6) and the inner part(4,5).
The inner shell is suspended in the outer shell to allow Support and Guiding of Inner Casing in Outer Casing
thermal movement and carries the front guide blade
rows. The complete assembled inner casing rests in the
The rear guide blade rows of the LP stage are horizontal plane with 4 brakets on the sliding piece(15,
bolted to the outer shell of the inner casing. The 18) placed in the plates bolted to the longitudinal
complete inner casing is supported in the LP outer support beam of the casing. The two brackets (detail
casing (1,8) in a manner permitting free radial C Fig.5) on the turbine side are fixed in the axial
expansion ,concentric with the shaft,and axial direction by fitted keys (16) as oppesed to the
expansion from a fixed point(Fig.2). brackets on the generator side (detail 0 Fig.6) which
are not fixed. Any thermal expansion in the axial
Support and Guiding of Outer Casing dircetion thus originates from here.
The spacer bolts( 17) prevent lifting of the inner
The outer casing rests with the brackets at the casing. The clearance of these spacer bolts in the
end of the longitudinal beam on the base plates fixed holes of the brackets is dimensioned to permit the
to the foundation crossbar. The outer casing of the inner casing to expand horizontally on sliding piece
LP turbine is axially fixed at the respective front (15) of the fixed support transverse to the axis of the
brackets(Fig.2). machine, and on sliding piece (18) of the non-fixed
In the lower area of the circular beams which support transverse and parallel to the machine axis.
reinforce the front and rear walls of the outer casing, As thermal expansion in the vertical direction
the casing is guided in the vertical centre plane (Fig.1, originates at approximately the level of the horizontal
3) which takes the radial and axial expansion into joint, the concentricity of the inner casing with the
account. shaft is ensured in this plane.
Two guide plates are welded vertically to the lower As shown in detail E (Fig.2,4) two casing guides
inner bend of each of the beams. The guiding piece are located at the lower half (6) of the outer shell to
(12) which is rigidly connected to the foundation prevent any transverse displacement of the inner
crossbar, fits between these plates. Fitted pieces(11) casing from the centerline of the turbine. Radial and
inserted between the square guiding piece(12) and axial expansions is not prevented by fitted keys(14)
in these casing guides.
5.1-0410/2
Fig. Guiding of the Outer Casing
Suspension of the Inner Shell
The inner shell (4,5) is suspended in the outer

shell (3,6) in the horizontal plane and is guided axially
in the vertical plane (Fig.7and 8). In the horizontal
plane, the upper half (4) of the inner shell is supported
by four brackets resting on the support plates (21,22)
located at Land M of the joint face of the lower half of
the outer shell (Fig.9 & 10). The brackets of the upper
part(3) of the outer shell which project over the cover
plates (20) , prevent lifting of the inner shell. The slight
clearance between these cover plates and the suspension as shown in detail A Fig. 11. The lower
brackets permits free horizontal expansion of the inner ends of the centering prins are fitted into keys (27)
shell in all directions at the support points. Thermal which slide in axial grooves in the inner shell. This
expansion in the vertical plane originates at the joint arrangement permits axial displacement of the inner
face. This ensures concentricity of the inner shell with shell relative to the keys (27) and vertical
the shaft in this plane. displacement along the axis of the centering pins(26)
The brackets of the inner shell, lower half (5) while
project into recesses of the outer shell, lower half (6)
.These brackets are provided with clearance on all
sides and serve to align the inner shell, lower half (5)
in the outer shell, lower half (6) by the use of jacking
bolts during erection. On the I P turbine side, 2 fitted
keys (19) are inserted between each bracket are
recess. As shown in detail L, these fitted keys fix the
inner shell in the axial direction and thermal expansion
thus originates from here.
In the vertical plane 4 centering pins (26) which
are guided in bushings (25) are provided for the
5.1-0410/3
3 Outer shell, upper half
4 Inner shell, upper half
5 Inner shell, lower half
6 Outer shell, lower half
Fig. 7 Inner Casing, Longitudinal Section
displacement transverse to the axis of the unit

prevented by the keys. Thermal expansion transverse
to the axis of the unit originates from these keys so
that concentricity of the inner shell with the shaft is
also maintained in this plane. The bushings(25) have
an eccentric bore and by turning them during
alignment of the inner casing, the inner shell
5.1-0410/4
Steam Turbine Atmospheric Relief Diaphragm
Description
Function and operation for the steam. The diaphragm consists of a thin rolled
lead plate. To insure that the remnants of the
Atmospheric relief diaphragms are provided in the diaphragm and rupturing disc are not carried along
upper half of each exhaust end section to protect the by the blow-off steam, brackets (4) are provided. As
tubine against excessive pressure. In the event of long as there is a vacuum in the condenser the
failure of the low vacuum trips the pressure in the atmospherric pressure forces the blow-out diaphragm
condenser rises to an exessively high level until the and the rupturing disc against the supporting flange
force acting on the rupturing disc(1) ruptures the (3),
breakable diaphragm. thus providing a discharge path
1 Rupturing disc
2 Breakable diaphragm
3 Supporting flange
4 Brackets

Description Blading, Drum Stages
Arrangement
The drum blading stages 1 to 3 of the double flow LP

turbine are of reaction type with 50% reaction. They
are Located in the inner-Inner casing and form the
initial stages of the LP blading. The LP stages
following these drum stages are described in detail
in a separate section [1].
Guide and moving blades
All guide and moving blades of drum stages have

integral shrouds, which after installation form a
continuous shrouding. The moving blades (7) of the
last drum stage are tapered and twisted. All stationary
and moving blades have T -roots which also
determine the distance between the blades. They are
inserted into the matching grooves in the turbine shaft
(5) and inner casing (1) and are caulked in place with
caulking material (6). The insertion slot in the rotor is
closed by means of a locking blade which is secured
in its position by means of grub screws between shaft
and lock bl~de .In casing, blades at joint planes are
fixed by means of grub screws.
Inter stage Sealing
In order to reduce blade tip losses, tip to tip sea lings

are provided in these stages. Thin sealing strips (9)
are caulked in inner casing (1) and turbine rotor(5).
The sealing fins are machined on the shrouds of
moving and stationary blades opposite to the sealing
strips in inner casing or rotor (Detail A). This design

Description Blading, Low Pressure Stages
Guide and Moving Blades are made from steel sheets to form hollow blades.
The last three stages of the LP turbine are also Suction slits are provided in the blades of row (7).
reaction stages. Each stage is made up of guide and Through these slits water particles on the surface of
moving blades. these last stage guide blades are drawn away to the
condenser.
1 - Inner casing
2 - Stationery blade row
3 - Moving blade
4 - Turbine shaft
6 - Moving blade
8 - Moving blade
The stationary blade rows (2, 5, 7) are made by The moving blades (3) of first LP stage are tapered.
welding inner ring, blades and outer ring together to twisted and have integral shrouds with T -root. The
form Guide Blade Carriers in two halves, that are last two stages of moving blades (6,8) have curved
bolted to inner casing (1). The blades of rows 2 & 5 fir-tree roots (View-X) which are inserted in axial
are of precision cast steels and the blades of row 7

grooves in the turbine ,shaft (4) and secured by Inter stage sealing
means of clamping pieces (11). Axial movement of
In order to reduce blade tip losses at the stationary
the blades is prevented by segments of locking plate
blade rows (2,5.7). sealing strips (9) are caulked into
segments (12) and the end segments are spot welded
turbine shaft. Opposite to this, sealing strips are also
at joint. The difference in circumferential speed at the
caulked on the inner ring of stationary blade rows as
root and tip of the moving blades is taken into
shown in Detail A. This arrangement permits
consideration by the twisted design of the blades.
favourable radial clearances to be attained. In case
of rubbing, the thin seal strips are worn away without
generating much heat. They can be easily replaced
at a later date to restore the required clearances.
Detail B
9 - Seal strip
10 - Caulking wire
11 - Clamping piece
12 - Locking plate
VIEW X
5.1-0440-01/2
Description Shaft seals
Function
The function of the shaft seals, arranged between

the bearing pedestals and the LP turbine, is to seal
tne interior of the LP turbine casing against
atmosphere at both ends of the rotor shaft.
When the turbine is started from cold or warm state,

the seal rings naturally heat up faster than the shaft
seal housing. However, they can expand freely in the
radial direction against the centering force of the
helical springs.
Gap Sealing
Sealing between the rotating and stationary

components of the turbine is achieved by means of
seal strip (5), caulked into the seal rings (2). The
ressure gradient across the seal is reduced by
conversion of pressure energy into velocity. which is
then dissipated as turbulence as the steam passes
through the numerous compartments.
Seal Rings
The seal rings (2) are divided into several segments
Steam spaces
as shown in Section 8-8. and mounted in grooves in Steam spaces are provided within the shaft seals.
the shaft seal housing (1) such that they are free to During start-up and on-line turbine operation. seal
move radially. Each segment is held in position steam is fed into space-Q to prevent air ingress into
against a shoulder by 3 helical springs (p). This the vacuum region of the system. The slight amounts
provides the proper clearance for the seal gaps. of leakage steam, which are still able to pass the
Should rubbing occur. the segments concerned can middle seal rings. are sucked from space-R into the
retreat. The heat developed by light rubbing of the thin seal steam condenser.

Description Rear Bearing Pedestal
Arrangement
The bearing ~t:destal is situated between the LP
turbine and generator. Its f unction is to bear the LP
rotor.
The bearing pedestal contains the following turbine
components:
Journal bearirlg [1)

Shaft vibration pick-up

The bearing pedestal is aligned to the foundation
by means of hexagon head screws that are screwed
into it at several points. On completion of alignment,
the space beneath the bearing pedestal is filled in
with special non-shrinking grout. The bearing pedestal
is anchored to the foundation by means of anchor
bolts. The anchor bolt holes are filled with gravel,
which gives a considerable vibration damping effect.
1 LP turbine rotor
2 Bearing pedestal vibration pick-up
3 Shaft vibration pick-up
4 Journal bearing
5 Couplil\g bolts
6 Generator rotor

Description
Construction The bearing shells are fixed laterally by the keys

(10) which are bolted to each other. Each key is held
The function of the journal bearing is to support in position in the bearing pedestal (11) by two laterall
the turbine rotor. Essentially, the journal bearing collars. The temperature of the bearing bodies is
consists of the upper and lower shells (3, 6), bearing monitored by thermocouples (15) as shown in section
cap (1), spherical block (7), cylindrical shells (14) and C-C.
the keys (10). The bearing shells are provided with a
babit face. The sliding surfaces of this bearing are Oil Supply
machined and additional scraping is neither
necessary nor permissible. Both bearing shells are Lubricating oil is admitted to the bearing shells
fixed by means of taper pins and bolted together. from both sides, from where it flows to oil spaces
milled into the upper and lower shells at the horizontal
In order to prevent the bearing from exerting a joint that are open to the rotor end. Oil from the oil
bending moment on the rotor (5), it is pivot-mounted space machined in the babbitting is carried through
in the cylindrical shell (14). For this purpose, the the rotor (5) and emerges from the bearing shell from
spherical block (7) with shims (12, 13) is firmly bolted where is collected in the oil return cowling (4) and
to the bearing shell (6). A projection in cap (1) with drained into the bearing pedestal (11).
shims (9) fits into a corresponding groove in the
bearing shell (3) and prevents vertical movement of Lift Oil
the bearing shells.. Centering of the bearing shells in As shown in section 8-8, 2 threaded nozzles (17)
the vertical plane is achieved by means of shims (8).
BHEL, Hardwar 5.1-0470/1

are arranged at the lowest point of the lower bearing
shell (6) through which high pressure oil is supplied
during start-up. This high pressure oil relieves the
bearing to overcome breakaway torque and
prevent.:dry friction, thus reducing the torque
requirements of the hydraulic turning gear [1].
The lift oil flows into the above mentioned threaded
nozzles (17) through passages in the lower bearing
shell (6). A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzle and
oil can drain through passages in the bearing shell
below the ring.
Removal of bearing shells

Not only the upper (3) but also the lower bearing
shell (6) can be removed without the removal of the
shaft (5). To enable this to be done, the shaft is lifted
slightly by means of the jacking device but within the
clearance of the shaft seals. The lower bearing shell
can then be rotated to the top position and removed.
15 Termocouple
16 Ring
17 Threaded nozzle
18 Sealing ring
Also refer to tne following sections
5.1-0470/2
Steam Turbine Hydraulic Turing Gear
Description
Arrangement Function
The function of the hydraulic turning gear is to
The hydraulic turning gear is situated between the rotate the shaft system at sufficient speed before start-
main oil pump and the journal bearing in the HP up and after shut-down in order to avoid irregular
turbine front bearing pedestal. heating up or. cooling down and thus avoid any
distortion of the turbine rotors. The air flow set up by
the blaQes along the inner wall of the casing during
turning operation provides good heat transfer
conducive to temperature equalization between upper
and lower casing halves.
Operation
During turning gear operation, the shaft system is
rotated by a blade wheel which is driven by oil supplied
by the auxiliary oil pump. This oil passes via a check
valve into the nozzle box (1) and from there into the
nozzles (2) which direct the oil jet in front of the
blading.
Return Oil Flow

After passing the blading, the oil drains into the
bearing pedestal and flows with the bearing oil into
the return flow line.
Manual Turning Gear

A manual turning gear is provided in addition to
the hydraulic turning gear to enable the combined
shaft system to be rotated manually 11 J.
Lifting of Shaft
To overcome the initial break-away torque on start-
up and to prevent dry friction, the bearings are relieved
during turning gear operation by lifting oil supplied
from below, i.e. the shafts are lifted slightly.

Steam Turbine Manual Turning Gear
Description
Function Operation
A manual turning gear is provided in addition to The following steps are required to make the
the hydraulic turning gear [1] to enable the combined turning gear ready for operation. Remove cover (2),
shaft system to be rotated manually. It can be used open the latch (7) and attach a bar to lever (1). .
both to start the turbine-generator unit rolling and to On completion of manual.wrning gear operation,
turn the shaft system through a given angle. return lever (1) and pawl (6) to the position shown,
remove the bar, secure the lever (1) and latch (7!
Construction and replace the cover (2).
The manual turning gear consists essentially of a Manual operation of the turning gear may be done
gear machined into the IP turbine rotor rear half only after the shaft system has been lifted with high
coupling (10) and pawl (6). The pawl engages the pressure lift oil. If manual rotation of the shaft is
gearing to turn the shaft system when operated by difficult, this may be due to incorrec’t adjustment of
means of a bar attached to the lever (1). The pawl (6) the shaft lift oil system or to a rubbing shaft. In thi$
is shown disengaged and the lever (1) resting against case, corrective action must be taken before steam
the stop. The lever is held in this position by the latch is admitted to the turbine.
(7) when not in use.
Section A-A
1 Lever 6 Pawl
2 Cover 7 Latch
3 Gasket 8 Pin
4 Flange 9 Pin
5 Bearing pedestal 10 IP turbine rotor
Also refer to tne following information


Steam Turbine Hydraulic Lifting Device
Description
Function driven emergency lifting oil pump (12) ensures the

lifting oil supply if the lifting oil pumps 13 & 14 fail.
When the turbine is started up or shut down, the The pressure oil piping of the lifting oil pump that is
hydraulic lif.tinQ device is used to increase or maintain not in operation is closed by the check valve (19). In
the oil film between rotor and bearings. The necessary order to protect the lifting oil system from damage
torque from the hydraulic turning device or from the due to improper switching on of the lifting oil pump
manual turning device is reduced in this way. when the check valve (19) is closed, spring-loaded
safety valve (18) are situated in the piping between
Mode of Operation the lifting oil pumps and the check valve (19). The
The bearings are relieved by high pressure oil that necessary pressure in the system is kept constant
is forced under the individual rotor journals, thus by means of the pressure limiting valve (8). The
raising the rotor. pressure limiting valve can be relieved by the bypass
valve (9). The superfluous flow from the pump is
Speed limit Values conducted into the main oil tank.
In order to avoid damage to the bearings, the lifting The necessary lifting oil pressures are set for each
oil pump must be switched on below a certain speed. bearing by the fine control valves (7) in the oil pipes.
The exact speeds for switching on and off can be Check valves (6) in the lifting oil pipes prevent oil
seen in the Technical Data 5.1-01 00 ~nd Operational from flowing out of the bearings into the header during
Value Report. turbine operation when the lifting device is naturally
switched off.
Lifting Oil Pump, Oil Supply
The lifting oil pumps (13), which are jack-screw Valve Arrangement
immersion pumps situated on the tank (10), supply The fine control valves (7) of the turbine bearings,
the high pressure oil for the lifting device. The oil is the check valves (6) and the pressure gauges are
drawn off directly by one of the two three phase a.c. arranged in boxes which are connected laterally to
motor driven 100% pumps (13,14). The d.c. motor the bearing pedestals.
1 HI’ turDlne I2 Elec\ncallY anven emergency IITtlng all pump

2 IP turbine 13 Electrically driven standby lifting oil pump
3 LP turbine 14 Electrically driven lifting oil pump
4 Generator 15 Electrically driven emergancy oil pump
5 Exciter 16 Electrically driven full load auxiliary oil pump
6 Check valve 17 Electrically driven standby full load auxiliary oil pump
7 Fine control valve 18 Spring loaded safety valve
8 Prassura limiting valve 19 Che.ck valva
9 Bypass valva 20 Duplex filter
10 Main oil tank c Drain
11 Motor

Steam Turbine General Description
Description
The turbine i:ontrol system descriptIon for 500 MW The special operating conditions existing in reheat
steam turbine comprises the following: con. densing turbines necessitate additional control
elements. On start-up of the high-pressure boiler it is
General Description necessary to start up the turbine straight away with a
Start-up Procedure considerable steam rate and, due to the high
Speed Control temperature in the reheater, to admit steam to the
Electrical Speed Measurirlg reheater immediately.
Protective Devices As long as the HP section of the turbine is unable
Overspeed Trip Test to accommodate all the steam supplied by the boiler,
Testing of Stop Valves the rejected steam is routed directly to the reheater
Bypass Control System (General) via HP bypass valve. The steam from the reheater
Electrohydraulic Bypass Control (Electrical System) which cannot be accommodated by the IP section
Electrohydraulic Bypass Control (Hydraulic System) with its control valves MAB 10 + 20AA002 and reheat
Extraction Check Valve stop valves MAB 10 + 20AA001 is routed into
Swing Check Valve condenser MAG 10 BC001 by way of LP bypass
Testing of Swing Check Valves in the Cold Reheat valves MAN 11 + 1 2AA001 and MAN 11 + 12AA002.
Lines
Automatic Turbine Tester. General The IP turbine must be fitted with its own control
Automatic Turbine Tester. Protective Devices valves to prevent steam remaining in the reheater
from entering the turbine via the IP and LP section
Automatic Turb;ne Tester. Stop Valves
and causing further acceleration of the turbine after
HP Actuator
the main steam control valves have been closed in
Electrohydraulic Gland Steam Pressure Control
the event of load rejection. In addition, the steam
Control System Diagram
pressure in the main steam line would increase after
List of Parts
sudden closure of the main steam control valves, thus
Lubrication Chart causing the HP by pass valve to open, with the result
Lubrication Chart. Index that even more steam would flow into the IP section
Turbine generator unit MAA50 HA00,. MAB50 of the turbine.

HA00 and MAC10 HA00 1 comprises three-cylinder
reheat condensing turbine with condenser MAG 1 0 It is the function of main oil pump MA V21 AP001,
driven directly by the turbine shaft, to supply oil for
BC001 and a direct-driven three-phase a.c. generator.
bearing lubrication, for the oil circuit for the overspeed
The turbine has a hydraulic speed governor trip test, and for the primary oil circuit, pressure in
MAX46 BY001 and an electric turbine controller. The which is generated by hydraulic speed transmitter
hydraulic speed governor adjusts control valves MAA MAX44 APOO 1. Two Electrically driven auxiliary oil
10 + 20 AA002 and MAB 10 + 20 AA002 by way of pumps are provided for auxiliary oil supply. The LP
hydraulic amplifier MAX 45 BY011 , whilst the electric control fluid circuit (8 bar), the HP actuators of the
turbine controller acts on these control valves by way main steam control valves, reheat control valves and
of electrohydraulic converter MAX 45 BY001. the LP bypass stop and control valves (32bar) are
supplied by 2 HP full-load control fluid pumps installed
Hydraulic amplifier MAX45 BY011 and
in the control fluid tank.
electrohydraulic converter MAX45 BY001 are
switched in parallel to form a minimum gate. The The turbine is equipped with an electrohydraulic
system not exercising control is in its maximum seal steam control system, an electrohydraulic bypass
position. control system, an automatic turbine tester for the
protective devices, main stop valves and reheat ‘Stop
valves, and an automatic functional group control.

Steam Turbine Start-up Procedure
Description
Mode of Operation in the system is subject to no significant change during

start-up. It is not possible to supply the hydraulic fluid
The turbine is started up and brought up to speed
connection of solenoid valve MAX48AA202 from this
with the assistance of the control valves MAA 1
system ,as this would have an inadimissible effect
0+20AA002 and MAB10+ 20 AA002. If the hydraulic
on the trip fluid system while the latching operation
controller is to govern start-up,the reference speed
with the solenoid valves MAX48AA201 and
setter MAX46BY001 must be set to minimum speed
MAX48AA202 during testing is taking place.
during this process. In this case,the speed reference
from the electric controller is at maximum .If After latching in, the trip fluid circuit is closed .The
,conversely ,start-up is to be governed by the electric trip fluid now flows to the space above piston KA01
controller,reference speed setter MAX46 BY001 is of stop valves MAA10+20AA001 and MAB10+20
set to maximum and the speed reference from the AA001 forcing it down against piston discs
electric controller to minimum. The combined stop KA002.0peration of the start-up and load limiting
and control valves are closed because the trip fluid device is continued until their lower limit position is
circuit is not yet pressurized .Turning handwheel reached.
KA01 clockwise or operating motor MAX47 BY001
When handwheel KA01 is turned back or motor
MM of start-up and load limiting device MAX47BY001
MAX47BY001 M of start-up and load limiting device
in the close direction relaxes spring KA06 in auxiliary
MAX47BY001 is operated in the open direction, the
follow up piston KA08 via the linkage ,thereby
control fluid is allowed to drain first from the auxiliary
preventing a buildup of auxiliary secondary fluid
start-up fluid circuit and then from the start-up fluid
pressure. The hydraulic amplifier MAX45 BY011 with
circuit. The piston of test valves MAX47AA011+012
follow-up pistons KA01 and KA02 is now the control
and MAX 47 AA021+022 are forced upwards by the
valves closed position so that a buildup of secndary
springs ,whereupon the trip fluid above piston KA01
fluid pressure is prevented when main trip valves
slowly drains off. The pressure difference thus created
MAX51 AA005 and MAX51 M006 are latched in.
lifts both postons together into their upper limit position
Further turning of handwheel KA01 moves valve ,thus causing stop valve MAA 10+20 AA001 and
KA02 of start-up and load limiting device MAB10+20 AA001 to open .Main trip valves MAX51
MAX47BY001 further downwards,admitting control AA005 and MAX51 AA006 are now held in their
fluid first into the start-up fluid circuit and then into operating position by the fluid pressure beneath the
the auxilliary start up fluid circuit.The start-up fluid differential piston.
flows to the space above the pistons of test valves
Once the stop valves are open ,further turning of
MAX47AA01+012 and MAX 47AA021 + 022, forcing
handwheel KA01 or operation of motor MAX 47
them down against the action of the springs. The
BY001 M of the start -up and load limiting device in
auxiliary start-up fluid raises the pistons of main trip
the open direction will,after passing through a certain
valves MAX51AA006 and MAX51 AA006, thereby
dead range ,cause lever KA03 and sleeve KA04 to
moving them into their normal operating and
move further downwards ,as a result of which the
permitting trip fluid to flow to test valves
auxiliary secondary fluid pressure begins to increase
MAX47AA011+012 and MAX47AA021+022 of the
and acts via hydraulic amplifier MAX45 BY011 and
main stop valves and intercept position stop valves.
follow up pistons KA01 and KA02 to gradually open
At the same time ,overspeed trips MAY10AA001 and
control valves MAA 1 0+20AA002 and MAB10+20
002 are latched in if they have been tripped. The
AA002 .This brings the turbine up to about 85 to 90%
function of stop valve MAX42AA011 is to interrupt
rated speed. Speed controller MAX46BY001 now cuts
transiently the fluid supply to solenoid valve
in to maintain turbine speed .Start-up and load limiting
MAX48AA202 from the connection downstream of
device MAX47 BY001 is then brought into the fully
filters MAX42 BT001 and MAXAA005 MAX42 BT 002
open position .A presure gauge MAX44 CP501 and
during latching info maintrip. Valves MAX51 AA005
electric speed transduucer MYA001 CS011-013 are
and MAX51 AA006 by means of start-up and load
used to measure speed.
limiting device MAX47BY001 ,because the pressure
drops in this line considerably for a short time as a Reference speed setter MAX46 BY001 is used
result of the high flow of fluid required to fill the drained for further speed run-up for connecting the turbine-
trip fluid system during this latching -in-period ,The generator unit in parallel and for bringing it on load.
pressure upstream of soleniod valve MAX48AA202 Turning handwheel KA 01 of the reference speed
is maintained via orifice MAX42BP022 during this setter or operation of motor MAX46 BY001 M increase
period. This ensures that the solenoid valve remains the tension of speed setting spring KA02 to increase
in the position shown.The auxiliary start-up fluid circuit speed. Since in interconnected operation speed is
at the start-up and load limiting device MAX47BY001 determined by grid conditions,actuation of the
is fed from the system down stream of filterMAX42 reference speed setter has the effect of changing
BT003(fluid supply during testing), since the pressure turbine output.

Load Limitation turbine -generator unit from turning speed .Start-up
and load limiting device MAX47 BYOO1 is brought
Start-up device MAX47 BYO01 engages into its open position once the stop valves have been
mechanically in controller bellow KAO9 of speed opened .Slowly raising the speed refercnce from the
controller MAX46 BYOO1 so that it can serve electric controller cuts in the electric speed control
simultaneously as a load limiting device; this means system ,and the turbine generator unit is brought up
that opening of the control valves MAA 10+20 AAO02 to rated speed and synchronized.
and MAB 10+20 AAO02 is limited to an adjustable
setting. This setting is made manually or form the Further loading is governed by the electric power
control room via motor MAX47 BYOO1 M. controller by increasing the load reference within the
admissible rate of load change.
Electrohydraulic Turbine Controller
If the turbine is to be started up with the

electrohydraulic turbine controller, the reference
signal from the electric speed controller must first be
set to minimum so that this takes over running up the
5.1-0610-01/2
Steam Turbine Speed Control
Description
Speed control may be exercised either trip medium circuit by way of orifices.
hydraulically or electrohydraulically
The varying secondary medium pressure in the
Hydraulic Control follow-up pistons of the hydraulic converter in
turn effects changes in the positions of their
Main oil pump MAV21 AP001 supplies the associated control valves or other control
bearing and primary oil circuits with control oil devices.
whilst hydraulic speed transmitter MAX44AP001
Electrohydraulic Control
acts as a pulse generator for the control circuit,
providing a primary oil pressure proportional to The speed of the turbine is measured digitally.
the speed. This oil pressure can also be read For this purpose electrical speed transducers
directly from speed Indicator pressure gauge MYA01 CS011 to 013 are mounted on the
MAX44CP501. This primary oil pressure acts highpressure end of the turbine shaft.
on diaphragm KA09 of hydraulic speed governor
MAX46BY001 against the force of speed setting The electrohydraulic converter constitutes the
spring KA02 which is tensioned by reference link between the electrical and hydraulic parts
speed setter MAX46 BY001. The travel of of the governing system. The electrohydraulic
diaphragm KA09, which can be limited by converter consists of the speed control converter
starting and load limit device MAX47 BY001, is MAX45 BY001 and a plunger coil system CG001
transmitted by linkage KA03 to sleeves KA04 of T. The signal from the electrohydraulic controller
auxiliary follow-up pistons KA08, the pistons actuates the control sleeve via the plunger coil
KA05 of which are held against the medium system. The control sleeve determines the
pressure by spring KA06. Medium drains off position of pilot valve KA07 in the manner of a
according to the amount of port overlap between follow-up piston. The further mode of action is
piston and sleeve and a medium pressure the same as that of the hydraulic speed
corresponding to the tension of spring KA06 is governor. Two differential transmitters -CG001A
built up. This auxiliary secondary medium and -CG001K are locate at piston KA08 of speed
pressure acts as a pulse signal via pilot valve control converter MAX45 BYO01 as feedback
KA07 of hydraulic converter MAX45 BY011. transmitters to the electrohydraulic controller.
This stabilizes the control process.
Piston KA08 of this hydraulic converter assumes
Change-over from Hydraulic to
a position corresponding to the auxiliary
secondary medium pressure and operates the
Electrohydraulic Control
sleeves of follow-up piston KA01 andKA02 via As already mentioned, Change-over from one
a linkage system. A feedback system stabilizes control system to the other is possible even
the position of pilot valve KA07 and piston KA08 during operation as the two controllers are
of hydraulic converter MAX45 BY011. As already connected in parallel downstream of the
described for auxiliary follow-up piston KA08, a associated follow up piston batteries, which form
secondary medium pressure corresponding to a minimum value gate. This means that it is
the position of the sleeves and to the related always the controller with the lower set point
spring tension builds up in the follow up pistons which leads.
of hydraulic converter MAX45 BY011. Any
If the turbine is operated with the hydraulic
change in the position of linkage KA03 results
governor, the speed set point of the
in a proportional change of the secondary
electrohydraulic controller is set at “max speed”
medium pressures in the follow-up pistons of
which prevents the electrohydraulic control
the hydraulic converter.
system from coming into action. To bring in the
The secondary medium circuits and the auxiliary electrohydraulic control system, the speed set
secondary medium circuits are supplied from the point of the electrohydraulic controller must be

reduced slowly until the secondary medium their upper end positions against the force of
pressures drop slightly. When this occurs, the the spring and, via a linkage, tension the,
electrohydraulic controller has taken over. Then spring,s of follow-up pistons KA02 of the control
the reference speed setter of hydraulic governor valves in such a way that this produces the
speed Max46 BYOO1 is set to “max. Speed”. desired setting response of the IP control valves
The electrohydraulic controller is then fully in relation to the HP control valves.
effective and can operate over the entire load
If the condition “Turbine load less than set
range. The hydraulic speed governor also acts
minimum load and the ratio of HP exhaust steam
as a speed limiter in the event of failure of the
pressure to main steam pressure greater than
electrohydraulic controller. In this case,
a set value is fulfilled”, e.g. after a load rejection,
operation of the turbine may immediately be
solenoid valve MAX42 MO51 is de energised,
continued by means of the hydraulic speed
thereby cutting off the flow of control medium to
governor.
the regulating cylinders and allowing the control
medium under the pistons to drain off. The
Change-over from Electrohydraullc to pistons are moved into their lower end position
Hydraulic Control by the restoring springs and the springs of follow-
up pistons KAO2 are adjusted so that the IP
Change-over is performed in the reverse control valves do not begin to open until the HP
sequence. First reduce the setpoint at reference control valves have opened to a greater extent,
speed setter MAX46 BYOO1 until the secondary with the result that the HP exhaust steam
medium pressures drop slightly. This indicates temperature is lowered.
that the hydraulic speed governor has taken
For operation of the plant without the HP and
over. Then set the setpoint of the
LP bypass stations, a manual adjusting
electrohydraulic controller to maximum. The
mechanism KA 11 is also provided for adjusting
hydraulic speed governor is then completely
the relationship between the valves such that
effective and can operate over the entire load
the reheat valves open before the main steam
range.
valves. Under these operating conditions,
solenoid valve MAX42MO51 is energised and
Adjusting Device for Valves an interlock is provided to prevent de
energisation.
An adjusting device, which makes it possible to
change the setting response of the HP and IP This adjustment may only be performed
control valves, is provided for limiting the HP manually and must always be performed on both
exhaust steam temperature. follow-up piston batteries MAX45BYOO1 and
MAX45 BYO11, to ensure that change-over from
In normal operation, control medium is admitted hydraulic to electrohydraulic control and vice
to the space below the pistons of regulating versa Is possible at all times. This manual
cylinders MAX45 BY001 KA10 and MAX45 adjustment must always be reversed before the
BY011 KA 10 by way of energised solenoid valve HP or LP bypass station is brought into
MAX42 M051, whereby the pistons move into operation.
5.1-0620-01/2
Steam Turbine Control System
Description Electrical Speed Measuring
The electrical speed signals originate from the in the pulse converter and then fed to tM speed
electrical speed transducers which consist of four Hall measuring unit, electro-hydraulic controller and speed
generators, MAYO 1 CSO 1 1 to 014 (one as spare) target unit.
and an aluminum disc with 120 permanEmt magnets The speed measuring unit incorporates two speed
arranged around its circumference located on the ranges. The lower range covers 0-360 rpm and the
main oil pump shaft. upper range.9-3600 rpm. The change-over from one
The permanent magnets of the aluminum disc act range to the other is completely automatic.
upon the four stationary Hall generators, three of A speed indicator mounted on the hydraulic control
which supply a voltage pulse to the pulse converters equipment rack provides local speed readings.
each time a magnet passes. The fourth is a spare. Indicating lights located near the speed indicator show
For safe(y reasons, the actual speed is sensed and which range is engaged.
processed in three separate channels. In the event From the speed measuring unit, speed signals are
of failure of one channel, the other two channels con- also provided to the turbine stress evaluator/
tinue to function and the faulty channel is alarmed. controller, automatic turbine tester and recorders.
The voltage pulses are amplified and converted to a Output signals are available for the remote speed
measurable DC voltage which is proportional to speed indicators, the turning gear oil supply valve, shaft lift
oil pump and other uses.

Steam Turbine Protective Devices
Description
Overspeed Trip room that turbine trip has been initiated by the low-
Two overspeed trips MAY10 AA001 and 002 are vacuum trip.
provided to shut down the turbine in the event of To make it possible to latch-in the trip devices and
overspeed. Each trip device consists of an eccentric thus to build up trip fluid pressure for adjusting and
bolt fitted it! the turbine shaft with its centre of gravity testing the control loop or similar purposes when the
displaced from the axis of rotation and held In position turbine is shut down and no vacuum exists, the low-
against centrifugal force by a spring up to an vacuum trip has an auxiliary piston which is loaded
adjustable preset speed of 10 to 12 % above the with primary oil pressure above the adjustable
normal turbine operating speed. At the pfeset compression spring. When the turbine is shut down
overspeed, centrifugal force overcomes the spring there is no primary oil pressure and so the auxiliary
force and the eccentric bolt flies outwards into its piston is unable to tension the ddjustable compression
extended position. In doing so it strikes the pawl which spring arranged above the diaphragm system. The
releases the pistOn of the releasing device KA01. spring below the diaphragm system lifts the valve,
Through combined spring force and fluid pressure, closing the auxiliary trip fluid circuit so that the trip
the piston opens the auxiliary trip fluid circuit to the devices can be latched in.
main trip valves MAX51 AA005 and MAX5 1 AA006.
As soon as the turbine is started up and brought
Thrust-Bearing Trip up to speed, primary oil enters the space above the
Thrust-bearing trips MAD 12 CY011/0 12/0 13 are auxiliary piston, forcing in into its lower end position
tripped electrically in the event of excessive axial at a turbine speed far below rated speed. Thus the
displacement of the turbine shaft. low-vacuum trip is rest for initiation of turbine trip
before the turbine has reached rated speed.
Pressure Switch
Installed in the trip fluid circuit are two pressure Solenoid Valves for Load Shedding Relay
switches MAX51 CP011 and MAX51 CP012 which Solenoid valves MAX45 AA001 and MAX46 AA01
bridge the longtime delayed relays of the reverse- 1 are provided to prevent the turbine from reaching
power protection system in such a way that the trip-out speed in the event of a sudden load rejection.
generator is shut down by response of the short-time These valves are actuated by the load shedding relay
delayed relays as soon as it begins to motor. The if the rate of load drop relative to time exceeds a
annunciation Turbine trip initi8ted is transmitted predetermined value. Solenoid valve MAX45 AA001
simultaneously to the control room. opens the reheat control valve secondary fluid circuit
directly. Solenoid valve MAX46 AA011 opens the
Remote Solenoid Trip
auxiliary secondary fluid circuit. Pilot valve KA07 of
Remote solenoid trip is activated via solerwid
hydraulic converter MAX45 BY01 1 moves upward
valves MAX52 AA001 and r..1AX52 AA002. The
and allows the control fluid to flow to the area below
remote solenoid trip may be initiated manually from
piston KA08 of the converter. Piston KA08 moves to
the control room by push button, by the electrical low-
its upper end position, thereby depressurizing all
vacuum trip or the thrust bearing trip or other
secondary fluid circuits.
protective devices.
Since the reheat control valve secondary fluid
Low-Vocuum Trip for Turbine Protection
circuit opens directly, the reheat control valves (which
An increase of pressure in the condenser causes
control the major portion of the power output) close
the valve of low-vacuum trip MAG01 AA011 to move
without any appreciable delay. A small delay is
downwards from its upper position und~r the force of
involved in closing all other control valves by
the pre-tensioned spring. This action depre~surizes
depressurizing the auxiliary secondary fluid circuit,
the space below the right-hand valve. The right-hand
but his action is still performed before an incre<1se
valve is moved into its lower position by a spring and
in turbine speed causes the speed controller to
thus opens the auxiliary trip fluid circuit. Opening the
respond. At the same time, the extraction check
auxiliary trip fluid circuit depressurizes the fluid below
valves, which are dependent on secondary fluid via
the differential pistons of main trip valves MAX51
extraction valve relay MAX51 AAO 1 1 , close.
AA005 and MAX51 AA006 and the differential pistons
are activated by a spring. This closes the control fluid After an adjustable interval, the solenoid valves
inlet to the trip fluid system and at the same time are reclosed, permitting secondary fluid pressures
opens the main trip fluid circuit to drain, causing the corresponding to the reduced load to bui.ld up again.
trip fluid pressure to drop and all stop and control
Turbine Trip Gear
valves in the turbine to close. Limit switch MAG01
The trip fluid is taken from tne control fluid circuit
CG011 B signals to the control room that the low-
via main trip valves MAX51 AAO05 and MAX51
vacuum trip is not in its normal operational position.
AAO06 and flows both to the secondary fluid circuits
Limit switch MAG01 CG011 C indicates in the control
and to the stop valves MAA10+ 20 AAO01 and

MAB10+20AAO01. The main trip valves serve to At the same time, the control valves and extraction
rapidly reduce the fluid pressure in the trip fluid circuit. check valves also close, as the secondary fluid
If the pressure below the differential piston of main circuits are fed from the trip fluid circuit. Thus on trip
trip valves MAX51 AAO05 and MAX51 AAO06 drops initiation, all turbine stop and control valves close.
below a preset adjustable value, the piston in each
valve is forced downwards by the spring, opening the Manual local Trip Method of
drain passage for the trip fluid and closing the control Initiating Turbine Trip
fluid inlet. Manual local initiation of turbine trip is performed
by way of local trip valve MAX52 AAOO5. The valve
If the pressure in the trip fluid circuit drops below must be pressed downwards manually, thus opening
a predetermined value, spring loading separates the the drain passage for the auxiliary trip fluid. The two
upper and lower pistons of main stop valves MAA 10 limit switches MAX52 CGOOSC and MAXS2
+ 20 AAO01 and reheat stop valves MAB 1 0 + 20 CGOOSE indicate in the control room that trip has
AAOO 1, and all the stop valves close very rapidly. been initiated locally by hand.
5.1-0630-01/2
Steam Turbine Overspeed Trip Test
Description
Testing with Turbine under Load Condition to their original position.When this happened, valve
Overspeed trips MAY 1 0 AAOO 1 and 002 can KA02 must be depressed to admit control medium
be tested using test device MAX62 AAOO1 with the into the auxiliary start-up medium circuit to the
turbine running under load or no-load conditions. To differential piston of the overs peed trip valve. The
operate the test device, valve KA03 is first depressed valve moves towards the right and latches the
and held in this position. This isolates the auxiliary overspeed trip valve in again.
trip medium circuit from the overspeed trips and The buildup of pressure in the auxiliary start-up
prevents the main trip being initiated by the overspeed medium circuit between the overs peed trip test device
trips. Subsequent operation of handwheel KAO 1 and the overspeed trip can be followed at pressure
moves the centre valve downwards. This action gauge MAX48 CP501. When valve KA02 is then
blocks the drain and allows the control oil to flow released, the auxiliary start-up medium pressure
through the centre bore of the pump shaft into overs returns to O. The auxiliary trip medium pressure must
peed trips. The control oil pressure thus builds up then remain at its full value (readable at pressure
and moves the eccentric bolts outwards against the gauge MAX52 CP501 ).If this is the case, valve KAO3
spring force, releasing the pawls of the overspeed may be released. The test is completed. If, when valve
trip releasing device, as a results of which the piston KA02 is released, the auxiliary trip medium pressure
moves rapidly inwards. The pressure in the auxiliary collapses, valve KA02 must be depressed again and
rip medium circuit, up to the over speed trip test must be held in this position a little longer. It is
device, then collapses. Operation is followed by essential that the auxiliary trip medium pressure must
observing the reading at press4re gauge MAX52 remain steady before valve KAO3 is released.
CP501.
The trip pressure is read off at pressure gauge Testing with Turbine under No-Load Condition
MAX62 CP501. If during operation at rated speed, Overspeed trips MAY10 AAOO1 and 002 must
this pressure should deviate from the baselin~ value be tested at regular intervals by running the unloaded
as recorded in the test report, a defect in the turbine up to trip speed. This is done by operating
overspeed trip may be assumed. It the trip pressure lever KAO7 of hydraulic speed governor MAX46
is too high, the bolt may be made to move freely by BYOO 1, which depresses linkage KA03, thus
rapidly operating the valve by means of handwheel increasing the secondary medium pressures. This
KA01 several times in succession. If this measure causes the control valves to open and the turbine
does not have the desired result, the turbine must be starts to overspeed. The actual speed at which trip
shut down and the uverspeed trips checked. occurs can be read off at pressure gauge MAX44
As soon as the auxiliary trip medium pressure CP501.
drops to 0 at pressure gauge MAX52 CP501, the Limit switches MAY10 CGO01 and 002C of
centre valve must overspeed trips MAY10 AAO01 and 002 indicate in
be returned to it original position using handwheel the control room that main trip valves MAX51 AAO05
KA01. The pressure in the test line should then return and MAX51 AAOO6 have been actuated by overs
to 0, as can be read off at pressure gauge MAX62 peed protective device.
CPSO1. The bolts of the overspeed trips should return

Steam Turbine Testing of Stop Valves
Description
Main Steam Stop Valves immediately. The main control valves may be closed
for testing purposes for riot longer than 4 to 5 minutes
The stop valves can be tested for freedom of so that the unbalanced steam flow is only present for
movement independently of each other even during a short period to avoid significant effects on the HP
operation with the aid of the test valves MAX47 AA011 turbif’le casing.
to 012 attached to each of them. The main stop valves It is also a precondition for testing the stop valves
MAA 10 and 20 AAO01 may only be tested at a load that there should be a mixing header in the steam
that is less than 80% of the maximum output. leads between the boiler and stop valves.
If the test is conducted with the initial pressure
controller out of operation, the main stop valves may
only travel out of the Open position to about 50% Reheat Stop Valves
closed at the most and are to be reopened Testing of a reheat stop valve must be conducted
immediately. If the initial pressure controller is in at a power output at which the reheat intercept valves
operation complete closure of a main stop valve may MAB10 and 20 AAO02 are fully open. First the
be performed. This, however, is conditional upon the associated reheat intercept valve is to be closed by
response time of the initiai pressure controller being pressing of push button in the supply unit. Then the
high enough to keep the initial pressure constant even reheat stop valve MAB 1 0 or 20 AAO01 is closed by
during the testing procedure. actuating test valve MAX47 AA021 and 022 and
First the main stop valve concerned MAA 10 or reopened. On completion of the test the reheat
20 AAO02, is to be closed by pressing of push button intercept valve is to be reopened.
in the supply unit. If in operation, the initial pressure As for the main steam stop valves,’ It is a
controller opens the other main control valve precondition for testing the reheat stop valves that
accordingly. Once the control valve has been shut there should be a mixing header in the steam leads
the stop valve can be closed. It is to be reopened between the boiler and the stop valves.

Steam Turbine Electrophydraulic LP Bypass
Description Control System
General
Function dependent, is used as the reference input for the

The function of the I.p. bypass control system is electric controller. This variable reference value is
to monitor the pressure in the reheat system and to replaced by a fixed refer~nce value for certain
control it under certain operating conditions. During operating sequences, such as start-up and shutdown.
start-up and shutdown, and at operation below The controlled variable is the reheat pressure after
minimum boiler load, the volume of steam not utilized the boiler outlet.
by the i.p and I.p. cylinders of the turbine must be The electric controller has a characteristic tailored
passed to the condenser via the I.p. bypass valves. to the pressure distribution within the turbine and
This requires the bypass control system to maintain monitors the reheat prcssure. Monitoring is either a
the pressure in the reheater constant in accordance function of the reference input “Pressure before h.p.
with the preset reference value. In the event of reaction blading” or a function of the fixed reference
disturbances, e.g. load shedding or trip out, the value under certain operating conditions. If the reheat
amount of excess reheat steam passed to the pressure exceeds the reference value, the electric
condenser depends on the capacity of the condenser. controller will act on the plunger coil of the
electrohydraulic converter and nitiate oypass
Mode of operation operation.
In the electrohydraulic I.p. bypass control system, The bypass control system operates the combined
the electric controller governs a number of hydraulic bypass emergency stop and control valves via various
actuators. The link between the electric controller and intermediate elements. This double shut-off
the hydraulic part of the control system is provided arrangement separates the condenser from the
by the electrohydraulic converter in the form of a jet reheater both during normal operation and when it
pipe amplifier controlled by a plunger coil. can not accept any more bypass steam.
In order to monitor the flow-dependent reheat The hydraulic part of the control system includes
pressure, irrespective of whether fixed-pressure or the necessary protective and safety devices for the
variable-pressure operation is used, the pressure condenser as well as the interlocks for the water side.
before the h.p. drum blading, which is also flow See section: I.p. bypass control (hydraulic).

Steam Turbine Electrophydraulic Bypass Control
(Electrical System)
Description
Measured Valve Acquisition actuator travel. The condenser protection device

Pressure transducers with bourdon tube continues to be operative via the hydraulic LP bypass
movements measure ttle relleat pressure (controlled governor.
variable) and the pressure upstream of the HP balding
Tracking Control
(to form the reference variable).
In order to facilitate switching 0’1 and off of the
Setpoint Formation automatic controller during operation, the control
Two setpoints, the fixed setpoint and the reference variable not taking effect inthe controller (manual
variable, are formed for the LP bypass controller, the control voltage, or automatic controller output voltage,
effective setpoint under any set of operating depending on the operating mode) is made to
conditions being the greater of the two, as selected continuously follow up that effective in the controller.
by an auctioneer. This function is performed by the tracking controller.
When the automatic controiler is effective, the manual
The fixed setpoint car) be set in the control room
controller is automatically made to follow up the
to any point between 0 and approximately 120% of
automatic controller output voltage, the manual
the maximum LP bypass pressure with the aid of a
controller itself being inoperative. This permits the
motorized set point adjuster. It is normally used to
automatic controller to be switched off and the manual
set the lower limit for the pressure setpoint.
controller to take over operation at any time. When,
The pressure upstream of the HP blading, required on the other hand, the system is under manual control,
for reference variable formation, is measured by the the output voltage of the inoperative automatic
dedicated pressure transducer and transmitted to a controller is made to automatically follow up the
matching amplifier which sets the characteristic for manual control voltage. As long as the actual pressure
the reference variable as a function of the pressure value and the effective setpoint are identical, the
upstream of the HP blading. change-over will be bumpless; if setpoint and actual
value are not identical, the automatic controller will
When both setpoints. fixed setpoint and refererlce
match the actual value to the setpoint on being
variable, have been applied, they are compared in
switched on.
the auctioneer, the greater of the two beirlg selected
and taking effect in the controller. Monitoring
The electrical section of the electrohydraulic LP
Provision is also made for limiting the reference
bypass control is monitored for the following faults,
variable to an adjustable level below the set pressure
which are annunciated at the control desk by means
of the reheat safety valves. The actual value for reheat
of the group alarms Fault in controller, Fault in
pressure is supplied by the pressure transducer as a
automatic interface, Fault inrtlheat safety valve
proportion (between 0 and 120%) of the maximum
actuation circuit and Fault in condenser
LP bypass pressure.
temperature protection system 1:
Pressure Controller
Fault in controller
The continuously-acting electronic pressure
1 Fault in power supply to controller
controller consists of a DC amplifier and a power
2 Insertion fault
amplifier.
3 Fault in power supply to pressure transducer for
The deviation is formed at the input to the DC measuring pressure upstream of HP blading
amplifier by comparing the effective setpoint with the 4 Fault in power supply to pressure transducer for
actual value. The pressure controller has a measuring reheat pressure
proportional integral (PI) characteristic. The power 5 Fault in power supply to Collins transmitters
amplifier actuates the moving coil of the 6 Fault in power supply to binary signal conditioning
electrohydraulic converter directly and through this, section for solenoid valve for 2nd spray water
the LP bypass valves. There is a constant relationship stage.
between controller output voltage and valve position.
Fault in automatic interface
If there is no voltage applied to the plurlger coil, all
1 Fault in power supply to automatic interfacG
LP bypass valves close.
2 Insertion fault
The LP bypass controller can be changed over to
Fault in reheat safety valve actuation circuit
the manual mode from the automatic control mode
1 Fault in power supply to reheat safety valve
using the Controller ON/OFF push-button. It is then
actuator
possible to actuate the valves directly using the open
2 Module fault
and close push buttons at the manual controller. This
may be necessary in the event of defects in parts of Fault in condenser temperature protection system 1
the automatic system and is essential for testing valve 1 Module fault
Automatic Change-over from Automatic to

Manual Mode of Operation control desk. All command and alarm voltage signals
To increase operating reliability, automatic are completely decoupled from other controller
change-over to manual operation is performed in the voltages.
event of any of the faults listed under the group alarm
Fault in controller, Items to 6 above. Reheat Safety Valve Actuation Circuit.
This automatic charlge-over to manual operation The auxiliary control circuit for the reheat safety
ensures, thanks to the tracking fe~ture, that the valve valves serves to prevent overheating of the reheater
position at the moment at V\’hich the abcve faul~s tubes by opening the safety valves, regardless of the
occur is retained. This prevents spurious automatic reheat pressure, when there is insufficient flow
control actions and provides the operating personnel through the reheater. The conditions atthe reheater
with sufficient time to intervene manually to avert are reflected in the control deviation while the reheat
operating disturbances. flow is determined by the actual valve lift. Should the
control deviation rise above a preset limit value without
Automatic Interface dll stop valves being opened and before all control
The electro hydraulic LP bypass controller valves have attained a preset minimum lift, the reheat
incorporates an automatic interface f3ature. In case safety valves will be actuated to open after a short
of a cold or warm start-up, when reheat pressure is dead time of adjustable duration. The reheat safety
low, the fixed setpoint value is to be brought down to valves can also be opened directly from the control
enable sufficient flow through reheater. This is done desk. The limit switches on the stop and control valves
by switching on the auto control interface from the are interrogated via input modules.
5.1-0641/2
Steam Turbine Electrophydraulic LP Bypass Control
Description (Hydraulic System)
Operation bypass rate is exceeded, thus limiting the bypass rate.

This ensures that the volume limitation has a clear
Electrical LP bypass controller MAN01 DPO01
control behaviour (Proportional control action). This
activites the plunger coil arranged on the left-hand
feedback is only effective in volume limitation. It is
side of transducer MAX53 BYO01. In the event of
not necessary for the other two limit pressures.
voltage increases, jet pipe KA01 is swung to the right
and piston KA08 of transducer MAX53 BYO01 is To protect the reheater from the thermal damage
moved in the downward direction. This takes up a as a result of heat accumulation, it must always have
position proportional to the downward direction. This a minimum amount flowing through it. For this reason
takes up a position proporitional to the voltage change the reheater safety valves are actuated by the electro
due to the rigid feedback. Sleeves KA04 of follow-up hydraulic LP bypass controller at a preset deviation.
piston KA02 and KA03 connected to the piston are
In normal bypass operation this signal is
move in the downward direction and the fluid pressure
interlocked via limit switches MAN11 and 12 CGO01
in the follow’up pistons rises.
0 and MAN11 and 12 CGO02B unless quick-closing
At the beginning of the control process, injection LP bypass valves MAN11 and 12 AAO01 are
valves MAN 11 and 12AAO03 and 004 are opened completely open and LP bypass control valves MAN
by way of spool valve MAX53 AA031 and the 11 and 12 AAO02 are approx. 60% open. If qnly one
actuators to injection valve KA01 are opened due to valve fails to meet these conditions, the signal goes
at first to the rising pressure in follow-up piston KA03. through and the safety valyes open {thus they open
The injection water reaches the pressure-reducing at precisely the existing reheater pressure (below
orifice and is available for cooling down the bypass design pressure).
steam flowing into the condenser, with a slight delay
So that the safety valves do not respond
compared to the injection valves, emergency valves
unnecessarily as a result of delays present in the
MAN 11 and 12 AAO01 are fully opened as the fluid
hydraulic control elements, the signal to them is
pressue in follow-up piston KA02 rises (assuming that
passed via two parallel time delay relays which delay
the piston of the actuator to bypass limit controller
contact by approx. 5 sec.
KA07 is in the upper limit position) and following this,
LP bypass control valves MAN 1 and 12 AAO02 are Second Low-Vacuum Trip
opened taking up a defined position due to the A low-vacuum trip MAG01 AA016 is installed in
feedback caused by the respective fluid pressure the signal line from follow-up piston KA02 to spool
(proportional control action). valves KA02 and KA05 of the LP Bypass valves for
the double protection of condencer MAG10 BCO01
LP bypass limit controller MAX53 BY011 has
during bypass operation. If the vacuum sinks below
priority over transducer MAX53 BYO01. As soon as
a preset valve during a fault in LP bypass limit
injection water is available at the required pressure
controller MAX53 By011, the spool valve of low-
at there is also a sufficiently high vacuum in condenser
vacuum trip MAG01 AA016 is moved in the downward
MAG1 0 BCO01, the jet pipe is swung to the right
direction from its upper limit position by the loaded
and the piston of the actuator to bypass limit controller
spring. The spool valve thus cuts off the signal line
KA07 moves into the upper limit position. As a result
and simultaneoulsy opens the drains so that signal
the pressure in follow-up pistion KA02 in increased
fluid in the line between low-vacuum trip MAG01
so that LP bypass valves MAN11 and 12 AAO01 and
AA016 and spool valves KA02 and KA05 is
MAN 11 and 12 AAO02 are released for opening.
depressurized and the LP bypass valves close. As
If the vacuum in condenser MAG10 BCO01 drops the vacuum increases again, bypass operation is
or the pressure downstream of the LP bypass valves released in the reverse sequence on attainment of
rises above the permissible value,. or the pressure the set limit value.
of the injection water is too low, the jet pipe of LP
Pressure Switch
bypass limit controller MAX53 BYO01 is moved to
A pressure switch MAN01 AA011 in installed in
the left and the piston of the actuator to bypass limit
the signal line from follow-up piston KAO2 to spool
controller KA07 moves downwards. In the bottom
valves KA02 and KA05 of the LP bypass valves to
position of piston KA07, the spring is follow up piston
protect condenser MAG10 BCO01 in the event that
KA02 is expanded to such an extent that the LP
wate injection fails. If the injection pressure drops
bypass valves are unable to open. By means of
below and adjustable value during a malfunction in
feebback to the measuring system “Pressure
LP bypass limit controller MAX53 BY011, the spool
downstream of LP bypass valves” a certain piston
valve of the pressure switch MAN01 AA011 is moved
setting and thus a certain setting of the LP bypass
from the upper limit position downwards. The spool
valves is allocated the each pressure deviation if the
valve then cuts off the signal line and simultaneously
pressure allocated to the maximum permissible

opens the drains so that s!gnal fluid in the line between when the temperature falls short of the limit value
pressure switch MAN01 AA011 and spool valves again.
KAO2 and KA05 is depressurized and the LP bypass Staggered Water Injection
valves close. As the injection pressure increases
aga1n.lP bypass operation is released in the reverse In the present case, the entire maximum boiler
sequence when the preset limit value is reached. steam flow is routed to the condenser. The injection
water rate is staggered in two stages so that under
Solenoid Spool Valves
normal start-up and shutdown conditiC’ns the
Thermocouprls which transmit a switching pulse
condensate pumps do not have to supply the entire
to associated solenoid spool valves MAX53 AA021
amount of injection water required for the full boiler
and 022 when a specified temperature is exceeded
flow and so that the excess water flow does not
are fitted in the steam dome opposite the bypass
become too high. In this additional device, solenoid
steam inlet to protect condenser MAG 10 BCO01,
valve MAX53 AAO41 is opened by way of pressure
The ~olenoid valves shut off the signal fluid and at
switch MANO1 CPOO1 and injection valves MAN11
the same time open the drain so that the signal fluid
and 12 AAOO4 via directional control valve MAX53
in the rille between solenoid spool valves MAX53
AAOO41 when the steam pressure upstream of the
AA021 and 022 and spool valves KA02 and KA05 of
pressure-reducing orifices exceeds a value allocated
the LP bypass valves valves i$ depressurized and
to an amount approx. 45% of the maximum bypass
the LP bypass valves close. The LP bypass valves
flow. This divides the injection water volume into two
may only be opened manually from the control room
approximately equal quantities.
5.1-0642/2
Steam Turbine Extraction Check Valve
Description
Steam Turbine Description In the event of major output drops above the
opening point 0 the swing check valves, there is a
The function of extraction check valve LBQ50,
danger that the contents of the feedwater heaters will
LBS21 , LBS31 , LBS4 and LBS42 AAO. is to prevent
flash into steam. In this case ,clouser of the swing
the backflow of steam into the turbine from the
check valvess is assisted for a short time by means
extraction lines and the feedwater heaters.
of pistons KA01 of auxiliary slide valve MAX51 AA011
Two free-swinging check valves are installed in .In normal operation ,piston KA01 passes trip oil to
each extraction lines A2,A3,A4 and A5. In the event piston KA02. In event of an abropt output drop, the
of flow reversal in the extraction lines,the valves close pressure on the top side of piston KA01
automatically ,whereby actuator KAO1 assists the drops,whereas depressurization beneath the piston
closing movement of the disk. is delayed by a check valve and the pressure in fluid
The machinical design if the swing check valves accumulator MAX45 88001. the resulting differential
is such that they are brought into the free -swinging pressure moves the piston upwad to interrupt the trip
position by means of trip fluid pressure via actuator fluid supply to the swing check valves ,whose closing
KAO1 and the disk is moved into the steam flow by movement is assisted by the spring force of actuator
means of spring force acting via the lever ,shaft and via a flow restrictor .The piston moves back into its
dask lever and closes if differential pressure is either original position to open the way for the trip fluid to
lowered or reversed. release the swing check valves.
Turning the handwheel on the change-over valves
The trip supply to actuator KAO1 is controlled by
MAX51 AA048,MAX51 AA051 etc. close the
extraction valve relay MAX51 AAO11 ,change-over
assocoated swing check valves within the bounds of
valves MAX51 AAO28,MAXAAO31 etc.
the effectiveness of the spring.
Extraction valve relay MAX51 AAO11 actuates the
swing check valves in accordance with the secondary The swing check valve in extraction lines A4 can
fluid pressure ,suitable adjustment of the spring in also be triggered by differential pressure switch
relation to piston KAO2 sets the turbine load at which L8S42CPO02. This differential pressure switches
the swing check valves are released for opening or energizes solenoid valves MAX51 AA 028 and MAX
asisted in closing .The release setting for opening AA031 if the steam flow drops below a preset rate
cannot be arbitrarily adjusted towards higher turbine (differential pressure ),thereby further assisting the
output ,as the swing check valve will open even closing action of the swing check valve.
without the release action if the steam pressure The position of all swing check valves is indicated
difference experts a greater force than the closing via position transmitters-CGO01A and CGO02A.
spring.

Steam Turbine Swing Check Valve
Description
In order that the turbine may be completely line from returinig to the turbine .By removing the valve
separated from the steam mains when it is stationary from the steam flow during operation above 5to 10%
,an additional check valve LBC10 AAO01 is fitted in of maximum power ,additional pressure losses during
the line between the h.p.cylender and the reheater normal operation are avoided .If ,during start-up ,the
and operating through the auxiliary valve MAX42 steam pressure on the inlet side of the valve and at
AAO01 and the ratory actualator KA01 depending on the same time the secondary medium pressure is
the pressure in the associated secondary medium not yet sufficient to open the valve,the steam pressure
circuit. The swing check valve opens fully when the will open the swing check valve against the medium
control valves reached approx.5to 10% of their full- pressure in the manner of a safety valve.
power travel. Only when the control valves reach this
point again as they are being closed is the swing The Open and Control position of the swing check
check valve brought into steam flow in the norma valve are inducated in the control room via the limit
direction ceases the check valve is closed by the switches.
acuator KA01 and prevent the steam in the cold reheat

Steam Turbine Testing of Check Valves
Description in Cold Reheat Lines
The check valve LBC10 AAOO1 in cold reheat limited ,the check vaves can not be closed completely
line is wide open during normal operation by its .They can be brought only in an intermediate position.
associated rotary servomotor KAO1.For testing the
movability ,the cheek valve can be moved in closing When the check valve starts moving ,the closing
direction by interreputing the connectioin between limit switch will change position which is indicated in
change-over valve MAX42 AAOO1 and HP the control room.With this indicator the regular
secondary fluid line with closing of shut-off valve movement of the check valve can be checked after
MAX45 AA566 (change-over valve and shut-off valve closing shut-off valve MAX45 AA566 nearby this
are installed in the turbine hydraulic control rack). value. After this check the shut-off valve has to be
reopened. The check valve is moved then in tis wide
By closing the shut-off valve the change-over valve open position. At the position indicator in the control
MAX42 AAOO1 is reversing and rotary servomotors room it can be checked if the check valve has reached
are moving the check valves in closing again its wide open position.
direction.Because the torque of these servomotor is

Steam Turbine Automatic Turbine Tester
Description General
Function The automatic turbine tester is divided into the

lollowing 2 subgroups:
Healthiness of the protective devices and the stop
valves and control valves is vitally important for the 1. Protective devices
operational reliability and availability of the turbine Description: “Automatic Turbine
.Hence,it is essential that these equipments are Tester,Protective device”.
always kept in a fully serviceable condition .Economy 2. Main stop and control valves
has dictated longer intervals between turbine Description: “Automatic Turbine tester, stop
overhauls,wih the result that testing of the equipments and controI valves”.
and devices is now necessary at ragular intervals
during normal operation. The complete testing of all components which
There are manually -operated devices for testing must operate when an automatic trip becomes
the free operation of the stop valves and control valves necessary is assured ,despite the subdivision into two
.However ,these tests do not cover all components testing groups ( protective devices, stop and control
involved in an automatic trip with the result that the valves), because the main trip valves which store the
conditions only party corrsepond to those prevailing trip signal by mechanical hydraulic means are
during a real trip. operated together with each protective device and
subsequent satisfactory reduction of the trip oil
The system pressure after the valves are monitored.
Any possible mal-operation assiociated with Nature of the description

manually operated devices are avoided with fully-
automatic tests by means of the automatic turbine The descriptions mentioned above contain the
tester.Full protection for the turbine during testing is practical sequance of the tests on the individual
also assured by suitable circuit arrangements. This devices and gives details of possible irregularities.
increases the operational reliability and availability of Thedescription of equipment contained in the
the plant. automatic control cubicle (stepping switches ,interlock
The automatic turbiune tester is realised in digital modules,etc),the control panel in the control room and
technology. schematic circuit diagrams are contained in the
separate electrical section of the Operating Manual
System adaptation for the automatic turbine tester.
For the understanding of the automatic turbine

The system is subdivided into functional groups
tester from these descriptions it is assumed that the
for each device.Each group contains the device itself
reader is fully conversant with the functioning of the
and all necessary transmission elements for initiation
individual protective devices and valves within the
of a normal trip.
overall turbine governing and protection system.

Description for Protective Devices
Scope of Testing is thus also tested.

Features of the Automatic Turbine Tester
The Automatic turbine tester(ATT) subgroup for
the protective devices is divided into a preliminary The automatic turbine tester is distinguished by
test and the following four individual testing systems. the following features:
1 Remote trip solenoid MAX 52 AAO01 1 Individual testing of each turbine protective device.
2 Remote Trip solenoid MAX 52 AAO02 2 Automatic testing, upon selection of a test ,of the
3 Overspeed trips MAY 10 AAO01/MAY AA 002 devices that protect the turbine during that test.
4 Low vacuum trip MAG01 AA011 Testing of the protective devices for normal
One or more systems can be selected for testing turbine operation can only be performed if the
at the control panel and the selection .is stored. The preliminary test has run without fault and the
start of the test program automatically causes a protection of the turbine during testing is assured.
preliminary test to be carried out on the protective 3 Monitoring of all program steps for execution within
channels which are to be effective during actual a certain time.
testing and then establishes the test circuit .Once the 4 Interruption if the running time of any program step
first test selected has been completed and the is exceeded or if trip is initiated.
protective device has latched in again, the test circuit 5 Automatic reset of the test program after a fault.
is restored to its normal operational configuration. 6 Protection of the turbine during testing provided
Further selected tests must be started individually by by special test protective devices.
pressing the Test push-button to start the program.
Setting Data
General
The setting data for the pressure switches are
During normal operation, the protective devices listed in the setting record Measuring Point List. The
act via main trip valves MAX51 AAO05 and MAX 51 actually set values are logged in the Commissioning
AAO06 on the stop and control valves and extraction
Test Record .The test running times ,etc. are entered
swing check valves. The remote trip solenoids MAX
in the functional diagrams.
52 AAO01 and MAX 52 AAO02, overspeed trips
MAY10 AAO01/MAY 10 AAO02 and low vaccum trip Test Sequence
MAG01 AA011 actuate main trip valves MAX 51
Start of Testing
AAO05 and MAX 51 AAO06 by opening Ithe auxiliary
trip fluid circuit. The test begins with the selection of the protective
For the duration of testing of the protective devices, devices subgroup .This is performed by pressing the
a test circuit is established .In orderto keep the trip subgroup On/Off push.button.
fluid circuit effective ,it is isolated from main trip valves The subgroup remains On until switched off when
MAX 51 AAO05 and MAX 51 AA 006 by means of the program has been completed. While the protective
change-over valve MAX 51 AA 211 and supplied with devIces subgroup program is running ,the other
Fluid via solenoid valves MAX51 AA201 and MAX subgroups are blocked.
51 AA202 (remote trip during testing). The On/Off push-button is also used to
Trip Initiation During Testing acknowledge alarms.
To provide normal protection for the turbine during Selection
testing ,any trip intiation signals from the protective
After the subgroup has been switched on, the
devices will de-energize the solenoid valves for
remote trip during testing and the same time initiate protective device to be tested is selected by pressing
the reset program. This also applies to all normal the selection push.button for the individual device.
electrical remote trips such as generator A separate selection push-button is to provided
protection,etc. For the duration of testing ,two for each protective device. Only one selection may
electrical speed signals are formed to provide be made at a time .Selection of a fur1her test is
protection against turbine overspeed. possible only once all other programs have ended.
During all electrical testing of the protective Test Push-Button
devices,the electric trip action is prevented ;however The automatic test program is star1ed by pressing
,all annuniciations are activated as for actual trip. The the Test push-button
appropriate section of the alarm annuniciation system

Cancel Push-Button over valve MAX 51 AA 211. Subsequently ,solenoid
valve MAX 51 AA202 is deenergized via the second
This push-button can be used to terminate the test
channel of its Schmitt trigger ,thereby depressurizing
program running at any time and to initiate the reset
program. The reset program has priority over the test the control fluid still present between solenoid valves
program. MAX 51 A201 and MAX51 AA202. This process is
mol)itored by pressure switch MAX 51 CP205 .On
LampTest Push-Buttton successful completion of the preliminary test ,the test
All the signal lamps on the control panel can be circuit is automatically estabilished ,which permits
tested by pressing the Lamp Test Push-button. realistic testing of the protective devices without
initating turbine trip.
Individual Tests
Solenoid valves MAX51 AA201 and MAX51 AA
The individual tests is performed after completion 202 (for remote trip during testing) are again
of the preliminary test after the test circuit has been energized whereupon control fluid is supplied to
estabilished . change over valve MAX51 AA211 .Then solenoid
Successful completion of each ivdividual test is valve MAX 61 AA201 is energized ,effecting change-
annunciated by the limit switches on main trip valves over from trip fluid to control fluid. The control fluid in
MAX51 AAO05 and MAX51 AAO06 ,pressure switch this line drains off,and the pressure difference drives
MAX 52 CP2t1 in the auxiliary trip fluid circuit and change-over valve MAX51 AA211 into its test position
pressure switch MAX 51 CP209 in the trip fluid circuit (lower end position),thereby actuating limit switch
between change-over valve MAX 51 AA211 and the MAX 51 CG 211 C which annunciates this status.
main trip valve MAX51 AAO06. The associated limit
switch also annunciates when a protective device Deactivating the Test Circuit
(except for the remote trip solenoids) has been The test circuit is deactivatied in the reverse order
activated .On completion of each individual test, all on completion of the selected test and after automatic
activated protective devices are returned to their latching of the protective device concerned in its
normal operating position by reset solenoid valves normal operating position.
MAX 48 AA201 and MAX 48 AA202 and the test
circuit is deactivated. Hydraulic Test Signal Transmitters
Whenever several of the same type of protective The functuion of the hydraulic test signal
device are provided ,only one will be described in the transmitters is to activate the related protective device
following, as the test procedure is the same for all. (with the exception of the remote trip solenoids ).Each
Preliminary Test proctective device has an associated test signal
transmitter. For testing the overspeed trip device,the
Pressing the Test push-button automatically associated test signal transmitter builds up a test
initiates a test of the protective circuits to be effective pressure relatively slowly and passes it to the
during testing. overspeed trips; for testing the low vacuum trip,an
Function
The function of the preliminary is to detect any
faults in 1I1e protective Circuits to be used during
testing,and,if any are detected ,to inhibit testing of
the protective device,as this would leave the turbine
without protection.
Test Sequence
In the course of the preliminary test, solenoid
valves MAX 51 AA201 and MAX 51 AA 202 (remote
trip during testing) are automatically tested before the
test circuit is estabilished .These valves (MAX 51
AA201 and MAX 51 AA 202) are first energized
,resulting in a buildup of control fluid up steam of
change-over valve MAX 51 AA 211.lnitiation of
Schmitt triggers (in the speed measuring unit) de-
energizes solenoid valve MAX51 AA201 and the
control fluid up stream of change-over valve MAX51
AA211 is drained .Successful completion of testing
is annunciated by pressure switch MAX 51 CP 207
between solenoid valve MAX 51 AA201 and change-
5.1-0661/2
air pressure signal is introduced to the device via an Attention : The level for manual actuation of the
orifice.The testing signals to rem6te trip solenoids main trip valve must not be tested-operated
MAX 52 AAOO1 and MAX52 AAOO2 are formed during burbine operation, as the electrical trip
within the automatic turbine tester itself and not by a action is always initiated via the manual trip-out
test signal transmitter. limit switch.
Main Trip Valves Remote Trip Solenoids

MAX 51 AAOO5 and MAX 51 AAOO6 MAX52 AAO1 and MAX 52 AAOO2
Only one of the two main trip valves is described The twin electrical remote trip feature consists of
in the following, as they are constructionally and the two remote trip solenoid valves MAX 52 AAOO1
functionally identical. and MAX 52 AAOO2.0ne trip channel is described
here ,as the test procedure is the same for both.
Function
Function
The function of the main trip valve is to amplify
and store the hydraulic or mechanical (manually The function of the remote trip solenoids is to
initiated local) trip signal .It must respond in the course depressurize the auxiliary trip fluid circuit in the sortest
of every successful protective device test. possible time ,thereby bringing main trip valves
MAX51 AAOO5 and MAX 51 AAOO6 into their trip
Operation
positions,in the event of a malfunction requiring
Each main trip valve is kept in its position by electriclal trip initiation.
auxiliary trip fluid pressure .If a protective device is
During normal operation ,the remote trip solenoid
actuat~d ,the auxiliary trip fluid circuit is depressurized
isolates the auxiliary trip fluid circuit from the drain.
and the main trip valve is activated. This connects
For testing ,the automatic turbine tester switches over
the trip fluid and auxiliary trip circuits to drain and
the solenoid valve so that the auxiliary trip fluid circuiit
shuts off the control fluid supply to the turbine valves.
is connected to drain .Trip initiation is monitored
At the same time ,limit switch 1 is actuated.
downstream of the main trip valves by pressure
Auxuliary start-up fluid pressure forces differcntial
switches MAX 51 CP209 and MAX 52 CP 211 in the
piston (3) into its normal operating position .Control
auxiliary trip fluid circuit .In addition ,the limit switch
fluid IV is then free to pass through to buildup the
of each main trip valve must annuciate successful
pressure in the trip fluid and fluid and auxiliary trip
completion of the test.
fluid circuits.Pressure switches MAX48 CP201
andMAX48 CP202 monitor the orderly pressure Latching -in
collapse of auxiliary start-up fluid circuit after latching On successful completion of testing ,remote trip
-in-of main trip valves. solenoids MAX 52 AAO1 and MAX 52 AAOO2 are
deenergized .The reset program is then started.

.The connects the auxiliary trip fluid circuit to drain
,thereby depressurizing it. The loss of auxiliary trip
fluid pressure cause the main trip valve to drop ,which
in turn causes the trip fluid pressure to collapse.
To activate the overspeed trip at rated speed ,as
the test routine performed by the automatic turbine
tester requires,a specific force,equivalent to the
increase in centrifugal force between rated speed and
preset trip overspeed ,is needed .For testing ,this force
is exer1ed by the test oil pressure ,acting on the bolt
(2) .On the basic of the existing defined geometry
the reproducible measure for the trip speed ,and can
therefore be used to check whether the overspeed
trip responds at the desired setting.
Test Sequence
The test oil pressure is produced using the
hydraulic test signal transmitter which is also used
for manual testing .First the command is given to the
actuator motor to go into the trip position (down) .After
a cer1ain idling time ,the test oil pressure builds up to
act on the two overspeed trip bolts (2) .
Function If the two bolts are functioning correctly ,they will
fly outwards into the trip position when the defined
The two overspeed trips are provided to protect pressure is reached ,thereby activating the main trip
the turbine against overspeeding in the event of load valve via pawl (4) ,piston (5) and the auxiliary trip
rejection coincident with failure of the speed controller fluid circuit.The two overspeed trips are monitored
,As theyare particularly important to the protection of for activation at the given test oil pressure by the two
the turbine, they can also be locally tested by hand pressure switches MAX 62 CP211 and MAX 62
CP212 in the test oil line ,and the limit switch (6)
with the aid of the overspeed trip device MAY62
.Pressure switches MAX 62 CP211 and MAX 62 CP
AAOO1 (hydraulic test signal transmitter) during 212 are preset to respond at a cer1ain level
turbine operation at rated speed .(For description see (approx.O.15 bar) below and above the test oil
Overspeed Trip Test). referance pressure is determined during
commissioning and entered in the commissioning test
Operation record .Limit switch (6) must respond within the
When the preset overspeed is reached ,the pressure range between the settings of pressure
eccentric flybolt (2) of each overspeed trip activates switches MAX 62 CP211 and MAX 62 CP212. A slow
piston(5) and limit switch annunciator (6) via pawl (4) buildup of pressure is required for this operation, that
5.1-0661/4
is why a relatively long monitoring period equivalent
to the running time of the actuator, has to be selected
Premature response of the overspeed trips is
annunciated.
Latching-in
Once the trip has been initiated, the actuator of
the hydraulic test signal transmitter is driven back
untill the limit switch annunciates that normal position
has been reached. Monitoring must be continued until
the test oil pressure at pressure switch MAX62 CP213
is less than 0.1 bar.
This double check-back of the hydraulic test signal
transmitter having returned to normal position ensures
that, after completion of testing, the overspeed at which
the turbine will trip is not reduced due to test oil pressure
remaining effective and that the overspeed trip will not
be set off prematurely in the event of load reduction.
While test oil pressure is decreased, the two overspeed
bolts spring back into their normal positions at a
pressure well above 0.5 bar.
Subsequently, piston (5) is brought back into its
normal position by the pressure of auxiliary start-up
fluid II and latched in with pawl (4). At the same time,
piston (5) shuts off drain channel IV, so auxiliary trip
fluid III can build up pressure. Once this has been
done, the auxiliary start-up fluid can be depressurized.
Low Vacuum Trip Latching-in
MAGO1 AAO11 When test signal transmitter (solenoid valve)
MAGO1 AA201 has been deenergized and the
Function connection between low vacuum trip and the
The function of the low vacuum trip is to operate
condenser reestablished, condenser pressure builds
the main trip valve if, during normal operation, the
pressure in the turbine condenser exceed a preset up again above diaphragm (4). Piston (6) moves into
valve. its upper end position thereby opening the passage
for the control fluid flow to piston (7). When piston (7)
Operation is in its upper end position, the auxiliary trip fluid circuit
When the condenser pressure exceeds the is closed again. Restoration of normal operating
adjusted limit, the piston (6) is moved downwards by
configuration is annuciated by the limit switch of the
this pressure, which acts against diaphragm {4), and
the spring force (3). Thereby pressure below piston low vacuum trip and by pressure switch MAGO1
(7) drops and this piston moves in its lower end CP201.
position by spring force connecting the auxiliary trip Reset Solenoids
fluid circuit to the drain. The resultant depressurization MAX48 AA201 and MAX48 AA202
of the auxiliary trip fluid circuit actuatbs main trip
valves MAX51 AAO05 and MAX51 AAO06, thereby Function
closing all turbine valves. The function of the reset solenoids is to restore
Test sequence the tripped protective devices to their normal operating
After energizing of test signal transmitter (solenoid positions during the ATT reset program.
valve) MAGO1 AA201, fitted in the signal line to the
condenser, this signal line is blocked off and Operation
simultaneously the space above diapragm (4) is The reset solenoids are two 2/3 way solenoid
connected to atmosphere. The air flow via an orifice valves, fitted in the auxiliary start-up fluid line. Both
causes a slow increase of pressure by which the solenoid valves are energized in the course of the
pistons (6) and (7) move to their trip position reset program conducted after each subtest, so that
connecting the auxiliary trip fluid qircuit to the drain. auxiliary start-up fluid II is supplied with control fluid
The low vacuum trip is monitored for operation III. The control fluid pressure forces all protective
within the specified vacuum range by observing devices back into their normal operating positions.
pressure switches MAGO1 CP202 and MAG01 and the trip fluid and auxiliary trip fluid pressure can
CP204. build up again.

When the protective devices have latched in again,
reset solenoid MAX48 AAO21 is deenergized first to
shut oft the control fluid supply through this value.
Dispersion of the auxiliary start-up fluid pressure is
monitored by pressure switch MAX48 CP201.
The second reset soleniod MAX48 AA202 is then
deenergized to disperse the pressure between the
two solenoid valves. This is monitored by pressure
switch MAX48 CP~O2. The use of two reset solenoids
ensures that main trip valve MAX51 AAOO5 and
MAX51 AAOO6 and overspeed trip will always be
sl,lre to be actuated if either one of the two reset
soleniods is deenergized.
5.1-0661/6
Description Stop and Control Valves
The following description refers to a standard stop trip, as the pressure downstream of the stop valve
and control valve assembly. The same text applies cannot drop off during closure because the control
analogoysly to both the main stop and control valves valve is closed. This means that the steam pressure
and the reheat stop and control valves. The valve acting against the spring closure force (stem lift) is
assembly descriebed is drawn in the closed position greater than in the event of normal trip.
(ready for start-up).
The automatic turbine tester intervenes only in the
General fluid circuits normally used to control the valves and
The stop and control valves of the turbine are the uses only trip fluid to actuate the test valves (MAX47
final control elements actuated by the protective AA011 and 012) and to reset and open the stop
devices arid it is, therefore, equally important that valves. Thus closure of the valves cannot be impeded
these, as well as the protective devices, should in the event of a genuine trip during testing, regardless
function reliably: The testing of these valves in of the stage which the test has reached. This also
conjuction with testing of the protective devices, as applies to the control valves, as the ATT does not
already described in Automatic Turbine Tester, interrupt the secondary fluid circuit and secondary
General ensures that all elements which must fluid can thus be depressurized in the normal manner
respond on turbine trip are tested for their ability to in the event of a trip.
function reliably.
Features of Automatic Turbine Tester
Each stop valve is tested together with its The ATT has the following features:
associated control valve. The automatic turbine tester
1 Separate part-testing of each valve assembly.
is designed so that only one valve assembly may be
2 Time-related monitoring of all program steps, and
selected and tested at any time.
their implementation.
Test Requirements 3 Interruption due to running time exceeded or
turbine trip.
To avoid turbine output changes and initial
4 Automatic reset of test program after a fault..
pressure variations due to the closing of the tested
5 Protection of the turbine during testing provided
control valve during testing, the electro hydraulic
by special test protective circuits.
turbine controller must be in operation prior to testing.
To facilitate compensation by the controller, the Setting Data
closing time of the control valves is relatively long, The setting data for the pressure switches used
and to enable initial pressure to be maintained to monitor the individual valve movements are listed
constant, testing is only permissible when the turbine in the setting record Pressure Switch settings. The
output is below a certain value. actual set values are logged in the Commissioning
Special Conditions during Testing Test Record. The test running times, etc., are entered
in the functional diagram.
The main stop and control valves may only be
tested if no other ATT subgroup is running. Test Selection Units
There are combined main steam and control
During testing the selected control valve (MAA 10
valves” and 2 combined reheat stop and control
and 20AAOO2) is closed completely by means of a
valves, each of which is tested as a separate unit
motoroperated actuator (-AAOO2M) acting on pilot
and has a separate selection pu~h-button on the ATT
piston (KAO6) parrallel to pilot value (KAO5). This
control panel. They are
result in a closing movement simulating that which
occurs when the associated secondary fluid pressure Selection1 : Main ‘stop and control valve, left
drops. The resultant, constant slow closing movement Selection 2 : Main stop and control valve, right
is necessary in order to keep the output constant. Selection 3 : Reheat stop and control valve, left
Thus the conditions for actuation of the valve are the Selection 4 : Reheat stop and control valve, right
same during testing as during normal actuation by
Test Procedure
the controller.
Start of Test
The stop valves, which are held in the open
position by trip fluid pressure during normal operation, The test starts with the selection of subgroups by
are subjected to exactly the same hydraulic conditions pressing the On/Off push-button.
during testing as would be the case in the event of The subgroup remains On until it is switched off
actual turbine trip, as the action of the protective after the program is concluded. When one subgroup
devices is simulated by the soleniod valve (MAX61 program is running, the other subgroup are blocked.
AA211 and 212). The steam side conditions during The On/Off push button also acknowledges
testing are somewhat more severe than during actual signals:

Selection piston KA01 of the stop valve. This piston is forced
If the test. requirements have been fulfilled, the downwards by pressure of the medium, thereby
valve, assembly (e.g. main stop and control valve, ten$ioning the spring between piston KA01 and piston
left) to be tested is selected by switching in the disc KA02 and finally pressing against piston disc
subgroup by pressing ttle selection push-button. KA02. Up to this point the medium pressure above
piston KA01 is relatively low, being equal to the spring
A separate selection push-button is provided for force acting against it. The spontaneous pressure rise
eadh valve assembly. Only one selection may be when piston KA01 has made contact with piston disc
made at a time. Selection of a further test is not KA02, and thus on completion of the spring tensioning
possible until the prograh1 already selected has action, is detected by pressure switch MAX51 CP222,
ended. 227. If all conditions are fulfilled within this relatively
Operation Push-button long monitoring period, soleniod valve MAX61 AA211
and 212 is deenergi?ed (operating position), so that
The test run is started by pressing the Operation trip medium is once again able to flow to test valve
push- button in the Stop and Control valves tile. MAX47 AA011 and 012 and the drain is blocked off
Shutdown Push-button again. The buildup of trip medium pressure is
monitored by pressure switch MAX51 CP221, 226.
This push-button can abort the current unit test
and introduce the reset program, which has priority When the pressure is sufficiently high, the stop
over the test program. valve is opened by de-energizing solenoid valve
MAX47 AA211 and 212 (operating position). Test
Lamp Test Push-button valve MAX47 AA011 and 012 switches over, admitting
All lamp on the panel are tested by pressing the trip medium to the underside of the piston disc KA02
Test push-button. and after a certain amount of further travel, slowly
connects the space above piston KA01 with the drain.
Closure of Control Valve The resultant pressure difference causes the
If all the test requirements have been fulfilled and tensioned piston relay to open the stop valve. As soon
the selection and operation push-buttons pressed, as the open position is reached, the full trip medium
the control valve (MAA 10 and 20AAOO2) is closed pressure builds up. This is monitored by pr~ssure
by means of the associated actuator (test motor - switch MAX51 CP221, 228 and by limit switch -
AAOO2M). Operation of the actuator (KA01) is CGO01 D. Testing of the stop valve is now completed.
continued until limit switch (-CGO02C) and limit switch Re-Opening of Control Valve
(-AAO02M S72, S73) on the actuator is tripped to
If the conditions are fulfilled within the specified
annunciate that the control valve being tested is in monitoring period, the control valve is reopened. The
closed position. motor of positioner -AAO02M is operated in the
During this time, the turbine output controller opening direction. Positioner -AAO02M moves the
compensates for the effects of closure of the valve control valve into its original position in the reverse
being tested on the turbine output by opening the sequence to the closing action. Again the initail
remaining control valves. pressure and output are kept constant by the
The running time for closure of the control valve appropriate controller. Operation of positioner
is monitored. If the control valve is functioning AAO02M is continued until, after a certain amount of
properly, it will close within the preset running time. overtravel, it has positively ceased to influence the
controller. This position is detected by limit switch -
Closure of Stop Valve AAO02 MS61 or -AAO02 MS62. If the control valve
Then the soleniod valve (MAX61 AA211 and 212) is functioning properly, it will open within the preset
energized. This allows trip fluid to flow to the space running time.
below change-over slide valve (MAX61 AAO11 and Cancellation of Selection
012), which moves into its upper end position and
connects the space below piston disc (KA02) ,!:,!’h On conclusion of testing of each valve assembly,
the selection is automatically cancelled and the
the drain. The pressure irl this space’drops rapidly
program is shut down.
and is monitored by pressure switch (MAX51 CP223,
228). When the pressure at this pressure switch has Interruption due to Running Time Exceeded
dropped slightly below the break-away pressure of The reset program is automatically initiated if the
piston disc (KA02), monitoring of the stop valve runnig time for any step in the test program is
closure time starts. The associated limit switch (- exceeded. If any running time is exceeded during the
CGO01 E) annunicates entry of the valve into its reset program, the program halts. In either case, the
closed position, thus making it possible to monitor alarms Fails signal and Time overrun are
the valve closing action for completion within the generated. If the Faults in ATT alarm is displayed,
maximum permissible running time. the fault lies in the automatic tester itself.
Opening of Stop Valve Interruption due to Turbine Trip
Next, soleniod valve MAX47 AA211 and 212 is If electrical turbine trip is initiated during testing,
energized (test position) and trip medium is admitted all solenoid valves are deenergized and posltioner -
to the control surface of the piston in the test valve AAO02M is returned to its extreme position and the
MAX47 AA011 and 012. The piston moves into its program cancelled. All equipment associated with the
lower end position against the spring force, thus automatic turbine tester are automatically returned
permitting trip medium to flow to the space above to their normal position.
5.1-0662-01/2
Steam Turbine HP Actuator
Description
The actuator is of the two-stage amplification type, When the signal fluid pressure changes, spool valve
i.e. it irlcorpqrates pilot and main control mechanisms. KAO5 is displaced which results in movement of
The actuating forces for movement of the HP corltrol auxiliary pilot piston KAO6. The movement of piston
valve are generated, in the opening direction, by main KAO6 is transmitted via the resetting linkage of the
actuator piston KAO2 under the force of the control pilot mechanism to the resetting spring, causing spool
fluid and, in the ciosing direction, by the disc spring valve KAO5 to return to the central position which
colur1Jn. During actuation. main pilot valve KAO7 establishes proportionality between the signal fluid
acts as a 3-way valve to allow the control fluid to flow pressure and the travel of auxiliary pilot piston KAO6.
to the space behind main actuator piston KAO2. Main At the same time, main pilot valve KAO7,
pilot valve KAO7 is actuated via the resetting linkage displaceci via the resetting linkage system by auxiliary
by means of auxiliary pilot piston KAO6 which is pilot piston KAO6, effects displacement of main
subject to control fluid pressure on both sides. actuator piston KAO2 whose movement returns main
The actuating signal -given by the signal fluid pilot valve KAO7 to the central position via the
pressure acts on the fact of spool valve KAO5 resetting mechanism. Consequently the position of
pressing it against the resetting spring on the opposite the pilot and main actuator pistons are proportional
side. Acting as a 4-way valve, the spool valve allows to the secondary fluid pressure in the steady state
fluid to flow to both sides of auxiliary pilot piston KAO6. (on completion of the control action).

Steam Turbine Electrohydraulic Seal
Description Steam Preassure Control
Function variable at a preset valve by adjusting the final

With all shaft seals subject to a positive pressure controlling elements. The actual valve of the control
difference. the escaping steam is throttled to a low system is acquired continuously by the transducer
pressure and fed into a header 1 .1 which is common 1.6 and compared against the set value in the electric
to all shaft seals. Those seals which arc under controller 1.9. If the actual value deviates from the
vacuum must be supplied with seal steam to prevent set value, one of the final controlling elements (either
the ingress of air. The supply of steam is taken from the leak-off or steam supply control valve) is adjusted
the header 1.1. The amount of leakage steam and until the actual value again agrees with the set value.
seal steam required depends on the pressure at the Only if there is a large control deviation, e.g. during a
seals, which, in turn, is primarily dependent on the full-load trip, are all valves operated simultaneously.
turbine load. The electric controller is realised in digital technology.
The function of the control system is to maintain Mode of Operation
the pressure at the bleed-oft points of all seals at the The input signal coming from the controller «ows
same present pressure. This is effected by exhausting through the solenoid (3 ~). The magnetic field of the
steam from the header (e.g. to the condenser) or solenoid together with the magnetic fjeld of the
supplying extra steam to the header 1.1, according permanent magnet system (42) exercises a force on
to operating conditions. the freely pjvoted armature (30). This force ‘reacts
against the force generated by rt1e tension of the
Arrangement
return spring. If the input signal is changed, the
Leak-off control valve 1.3 is used for discharging
equilibrium will be disturbed and, therefore, there will
surplus steam from the header 1.1 and seal steam
be a deflection of the armature retained by the spring
supply control valve 1.4 for admitting extra steam to
(32) and return spring (36). The baffle plate (29) then
it. All valves are actuated by type HSA-1-K
covers the two rebound nozzle tips (15) to an unequal
electrohydraulic actuators. The actuators 1 .11 are
extent. In the oil flow that flows through two choke
under the continuous control of an electric controller
valves (21) to the rebound nozzles (161, a pressure
1.9 each via an electrohydraulic converter. The
differential is created. The oil pressure existing in the
electrohydraulic converter comprises a control coil
rebound nozzles is applied to the face of the slide
which adjusts the position of the impingement plate
gate (1 al. The slide gate is deflected and releases
of the hydraulic preamplifier.
the oil flow to or from the hydraulic cylinder (5.11)
Controller The deflection of the slide gate is dependent upon
The function of the electric controller 1.9 in the magnitude of an input signal change. The greatest
conjunction with the transd\Jcer 1.6 and the actuating amount of deflection and, therefore, the fastest
elements (control valves) is to maintain a controlled change in the

hydraulic cylinder’s position is already achieved with piston moves and in so doing changes the position
an input signal change of delta I ~ 3 mA. of the coupled actuator. At the same time, the tension
Following smaller changes in signal, the hydraulic in the return spring 1361 changes via the return rod
cylinder operation is correspondingly slower. The 144) and the adjustment level 139), until the tension
servo-valve enables an extremely sensitive control of the springs and magnetic forces reach a state of
by virtue of its special construction. The main cylinder equilibrium. The armature returns to its mid position,
5.1-0670-01/2
the pressure on the faces of the slide gates (1a) are Electric manual control
of equal magnitude. The slide gate moves to its mid The controller can be switched off by the push
position, the oil flow to the cylinder is initially reduced button “Controller on/off”. Then the valves can be
and, when the slide gate (1 a) reaches its middle controlled directly by hand by means of the push-
setting it is completely shut off, and the main pistqn button “Higher/Lower” below the valve position display
of the hydraulic cylinder is in its set position. The with the aid of the remote-control msnual control setter
poSition of the main piston or rather the actuator IS of the electrical equipment. The inscription “Higher/
directly proportional to the input signal on the servo Lower” refers to the change in pressure when the
valve. push-button is operated, e.g. “Higher” means
Double Blocking Valve increasing the pressure (the leak-off steam control
valve closes or the seal steam control valve opensl.
A double blocking valve is connected to the outlet Manual control is disconnected during automatic
ide of the servo-valve. The pump pressure opens the control, the manual control setter is then automatically
hydraulically operated check valve (8). the tracked to the controller output voltage by the
connections to the hydraulic cylinder (5. 1) are free. equalizing controller so that when changing over from
If the oil supply fails, both hydraulically operated check automatic control to manual control the manual control
valve close. The hydraulic cylinder’s piston will be setter is already in the correct position. Under manual
retained in its last position. control the equalizing controller automatically tracks
Display of control deviation /Adjusting the set value the output voltage of the disconnected controller 1.9
The control deviation is displayed on each of the to the manual control voltage. If the control deviation
two desk tiles for the valves. The two instruments has been reduced to zero by positioning the valves
are connected in parallel. before the controller is switched on, the change-over
from manual control to automatic control will be
The set value for steam pressure in the header bumpless; otherwise the controUer regulates the
can be adjlJsted between 0 and 22 mbar at the pressure to the preset value after it has been switched
controller by means of the set value push-button. on. Thus, it is quite easy to switch the controller on
the off during operation.
5.1-0670-01/3
Steam Turbine Control System
Description Diagram Legend
Power Plent iden- Title Coor- Power Plent iden- Title Coor-
tificetion System dinete tificetion System dinete
LBB01 CP511 Pressure Geuge, Steam before KAO6 Relay Piston for Prll Control Pilot Valve C7
BvPilss Valve E8 KA07 Main Pilot VoJlve C7
KA09 Handwhoel for Tosting Device B7
LBC10 AAO01 Swing Check Valve Cold Rehflater E7 M Eletrical Motor for Testing Devica B7
KAO1 Rotary Servomotor E7 MS61 Torque limit Switch,
LBC10 CGO01 B Limit Switch, Open Position E7 Teeting Device 100% ATT B7
C Limit Switch, Closed Position E7 MS62 Travel Limit Switch,
D Limit Switch, Open Position E7 Testing Device 100% ATT B7
E Limit Switch, Closed Position E7 MS72 Torque Limit Switch,
Testing Dev!ce 0% A TT B7
LBS21 AAO01 Extraction Check Valve A2 E12,13 MS73 Travel Limit Switch, B7
KA01 Servomotor E12, 13 Testing Device 0% ATT
LBS21 CGOO1 A Remote Position Indicator E12,13
MAA10 + 20
LBS31 AAO01 Extraction Check Valve A3 E13 CGO02 A Remote Position Indicutor C7
KAO 1 Servomotor E 13 C Limit Swit ch,Closed Valve Position ATT C7
LBS31 CGOO 1 A Remote Position Indicator E13
MAB10 +20
LBS31 AAO02 Extraction Ch~k Valve A3 E13 AAO01 Reheat Stop Valve ABC9
LBS31 CGO02 A Remote Position lndicetor E1 3 KAO1 Piston A9
KA02 Piston Disc A9
LBS41 AAOO1 Extraction Check Valve A4 C10
KA01 Servomotor C10 MAB10 + 20
LBS41 CGOO 1 A Remote Position Indicator C10 CGO01 B,F,H, Limit Switch, Open Vilive Position A9
C,G,J Limit Switch, Closed Valve Position A9
LBS41 AAOO2 Extraction Check Valve A4 C10 D Limit Switch, Open Valve Position ATT A9
KAO1 Servomotor C10 E Unlit Swit ch,Closed Valve Position ATT A9
lBS41 CGO02 A Remote Position Indicator C10
MAB10+ 20
LBS42 AAOO 1 Extraction Check Valve A4 AB11 AAO02
KAO 1 Servomotor A 11 Main Control Valve BC9,10
LBS41 CGOO 1 A Remote Position Indicetor B 11 KA01 Servomotor C10
KA02 Piston C10
LBS42 AAO02 Extraction Check Valve A4 AB1 1,12 KA05 Pre Control Pilot Valve C10
KAO1 Servomotor A12 KA06 Relay Piston for Precontrol Pilot Valve C10
LBS41 CGO02 A Remote Position Indicator B12 KAO7 Main Pilot Valve C10
KA09 Handwheel for Testing Device B10
LBOSOAAOO1 Extraction Check Valve AS E9 M Electrical Motor for Testing Device B10
KAO 1 Servomotor E9 MS61 Torque Limit Switch,
LBOSO CGOO1 A Remote Position Indicator E9 Testing Device 100% ATT B10
MS62 Travel Limit Switch,
LBOSOAAOO2 Extrection Check Valve AS E9 Testing Device 100% ATT B10
LBOSO CGO02 A Remote Position Indicator E9 MS72 Torque Limit Switch,
Testing Device 0% ATT B10
MAA10 + 20 MS73 Travel Limit Switch, B10
AAOO1 Mein Stop Valve ABC7 Testing Device 0% ATT
KA01 Piston AB7
KAO2 Piston Disc B7 MAB10 + 20 .
CGO02 A Remote Position Indicator C10
MAA10 + 20 C Limit Switch, Closed Valve Position C10
CGO01 B,F,H Limit Switch, Open Valve Position B7 ATT
C,G,J Limit Switch, Closed Valve Position B7 MAD12
D Limit Switch,Open Valve Position ATT B7 CY1 1,12,13 Electrical Thrust Bearing Trip D8
E Limit Switch,Closed Valve Position ATTB7
MAG01 AA01 1 Low VecuumTrip. B5
MAA10+ 20 MAG01i011 B Limit Switch, Not Reset B5
AAOO2 Main Control Valve BC7,8 C Limit Switch, Alarm B5
KAO 1 Servomotor C7,8 E Limit Switch, Alarm ATT B5
KA02 Piston C7 MAGO 1 AAO 16 Condenser Safety Device
KAOS Pre Control Pilot Valve C7 (Bypass Controll) G 12. 1 3

MANO 1 AAO01 Twin Check Velve G8,9 MAX32BTO21 Fluid Filter for Pre Control,
MANO1 AA01 Hydraulic Pressure Switch EF10 Rehollt Control Valves A10
MAN01 CP511 Pressure Gauge. Water Injection F10
MANO1 DPO01 Electro-HydraulicLP Bypass Governor F6,7 MAX32BTO81 Fluid Filter for Pre Control,
KAO1 Hand Adjustment F7
Bypass Control Valves C11
MAN11 + 12
AAOO1 LP Bypass Stop Valve EF12 MAX41 CPSOl Pressure Gauge. Control Fluid
KAO1 Actuator F11.12 (Hydraulic Control Equipment Rack) C2
KA02 Pilot Valve F12
MAX42AAOO1 Slide Valve for S\’/ing Check ‘./aJve
MAN11 +12 Cold Reheat D7.8
CGO01 B, D Limit Switch, Open Valve Position F11
C, E Limit Switch, Closed Valve Position F11 MAX42AAOO2 Slide Valve for Swing Check Valve
Cold Reheat D8
MAN11 +12
AAO02 MAX42AAO N11n-Return Valve B1
LB Bypass Control Valve D1 1, 12
KA01 Servomotor D11
MAX42BTOO1 Fluid Filter
KA02 Piston D11
(Hydraulic CCintrol Equipment Rack) C1
KAO5 Pre Control Pilot Valvo D11
KA06 Relay Piston for Precontrol Pilot Valve D11
KAQ7 Main Pilot Valve D11 MAX42BTOO2 Fluid Filter
(Hydraulic Control Equipment Rack) C2
MAN 11 + 1 2
CGOO2 A Remote Position Indicfltor D11 MAX42BTOO3 Fluid Filter
B Limit Switch, Interlocking Rahea,er (Hydraulic Control Equipment Rack) B4
Safety Valves D11
MAX42BTO21 Fluid Fi!ter (Hydraulic .
MAN11 +12 Bypass Control Equipment Rack) G6
AAO03 Water Injection Valve AB13
KA01 Servomotor A 13 MAX42BTO22 Fluid Filter for Water Injection Valves
(Hydraulic Bypass Control
MAN11 + 12
Equipment Rack) A 12
CGO03 B Limit Switch, Open Position A 13
C Limit Switch, Closed Position A 13
MAX42CP501 Pressure Gauge, Control Fluid
MAN11 + 12 (Hydraulic B’ .pass Control
AAO04 Water Injection Valve for Sequential Equipment Rack) FG6
Water Injection AB 14
KAO 1 Servomotor A 14 MAX42CP511 Pressure Gauge, Control Fillid Water
Injection Valve Open B12
MAN11 + 12
CGO04 B Limit Switch. Open Position MAX42CP512 Pressure Gauge. Control Fluid Water
C Limit S witch, Closed Position A 14 Injection Valve for Sequential Water
Injection Open B13
MAN11 + 12
CP501 pre.sute Gauge. Steam behind MAX44APOO1 Hydraulic Speed Transmitter E1
Bypass Valve G9
MAX44CP501 Pressure Gauge, Primary Oil A5
MAV21 APOO Main Oil Pump DE1
MAV21BTOO1 Oil Filter MAX45BBOO1 Accumulator for Extraction Valve

(Hydraulic Control Equipment Rack) D4 Relay E4,5
MAX31 MAX45BVOO1 Electro-Hydraulic Converter FG4,5

88011 + 016 Accumuletor for HP Servomotor, KAO1 Follow-Up Piston for Main
Main Cor.trol Valvos BC7 Control Valves FG4,5
KA02 Follow Up Piston for Reheat
MAX31 8B021 Accumulator for HP Servomotor, Control Valv8S FG5
026 Rehoat Control Valves BC10 KAO4 Sleeve G4
KAO5 Piston FG4
MAX31 BB021 Accumulator for HP Servomotor, KA06 Helicel Spring F4
BB041 049 Bypess Control Velves CD11
KAO7 Pilot Valve FG4
KA08 Piston F4
MAX32
8T011 +012 Fluid Filter for Pre Control. KA 10 Adjusting Device Control Valves F5
Main Control Valves AB7 KA 11 Manual Adjusting Davice F5
5.1-0681-01/2
MAX45 F Umit Swiitch, 56% G1

CGO01 A Remote Position Indicator F4 MAX47CP501 Pressure Gauge ,Start-up Fluid G1
K Remote Position Indicator F4 MAX48 CP501 Pressure Gauge,
T Moving Coil F4 Auxiliary start-up fluid E3
B Limit Switch Operating Without Bypass
Valves and Adjusting Device Blocked F5
C Limit Switch, Displacment of tv MAX51
Control Valves F5 5 AAO05 +006 Main Trip Valve B2
MAX 45BY011 Hydraulic Converter FG2,3 MAX 51

KA01 Follow-up Piston for Main Control Valves FG3 CGO05+006C Umit Switch, Alarm B2
KA02 Follow-Up Piston for ReheatControl FG3 E Umit Switch, Alarm,ATT B2
valve
KA04 Sleeve G3 MAX51 AA011 Extraction Valve Relay DE5
KA05 Piston FG3 KA01 Valve D5
KA06 Helical Spring F3 KAO2 Valve DE5
KAO7 Pilot Valve FG2
KA08 Piston F2 N MAX51AA041 Slide Valve for Extraction
KA09 Proportional Band Adjusbnent G2 Check Valve A2 E12
KA10 Aadjusting Device Control Valves F3,4
KA11 Manual Adjusting Device F4 N MAX51 AAO44 Slide Valve for Extraction
MAX45CGO11 B Umit Switch , Operation Without Bypass Check Valve A3 E13
Valves and Ajusting Device Blocked F3,4 MAX51 AA047 Slide Valve for Extraction
C Umit SWitch , Displacement of control Check Valve A4 C12
valves F4
MAX51 AA048 Slide Valve for Extraction
MAX45CP501 Pressure Gauge.Secondary Fluid Check Valve A4 A 11
Main Control valves F2
MAX 51 AA 050 Slide Valve for E:xtraction
MAX45CP511 Pressure Gauge ,Secondary Fluid Check Valve A4 C12
Reheat Control Valves E2
MAX 51 AAO51 Slide Valve for Extraction
MAX46BYOO1 Hydraulic Speed Governor FG 1,2 Check Valve A4 A11
KA01 Handwheel F1
KA02 Speed Setting Spring F1 MAX 51 AA056 Slide Valve for Extraction
KA03 Link G 1,2 Check Valve A5 E9
KAO4 Sleeve G2
KA05 Piston FG2 MAX51 AA211 Changeover Valve 83
KA06 Helical Spring F2
MAX51 CG2118 Umit Switch,up Normal PositionATT B3
KA07 Trip Tester Level F2
C Umit Switch,Down- Test Position ATT B3
KA08 Auxiliary Follow-up Piston FG2
KA09 Governor Bellows G1
MAX51CP501 Pressure Gauge,Trip Fluid AB3
M Electrical Motor F1
MAX51 CP522 Pressure Gauge ,Trip Fluid above piston
MAX46CG001 A Remote Positon Indicator F1,2
527 Main Stop Valve A6
B Limit Switch 100%
(Start-Up Automatic) F1,2
MAX 51 CP523 Pressure Gauge ,Trip Fluid below piston
528 Disc Main Stop Valve B6
MAX46CP 501 Pressure Gauge.
Auxiliary Secondary Fluid F2
MAX51 CP542 Pressure Gauge, Trip Fluid above Piston
547 Reheat Stop Valve A9
MAX47
AA011 +012 Test Valve for Main Stop Valves B6
MAX51 CP543 Pressure Gauge ,Trip Fluid below Piston
548 Disc Reheat Stop valve B6
MAX47
AA021 +022 Test Valve for Reheat Stop Valves AB9 MAX52AAO05 Local Trip Valve B2
MAX52 CG005 C Umit Swltch,Alarm B2
MAX47BY001 Starting and Load Limit Device FG 1 E Umit Swtich Alarm ATT B2
KAO1 Handwheel F1
KAO2 Valve FG 1 MAX 52 CP501 Pressure Gauge ,Aux, Trip Fluid D3
M Electrical Motor F1
MAX53 AA021 Solenoid Valve Temprature
MAX47CG001 A Remote Position Indicator F1 Dependent Interlocking EF11
B Limit Swiitch, 1 00% G1 A Magnet Coil Open EF11
C Limit Switch, 0% G1 B Magnet Coil Closs EF11
D Limit Switch, 42% G1
5.1-0681-01/3
Power Plant Iden- Title Coor- Power Plant Iden- Title Coor-
tification System dinate tification System dinate
MAX 53 CG 021 B Limit Switch 100% F11 MAYO 1

C Limit Switch 0% F11 CS011 +013 Electrical Speed Transmitter E1
MAX53 AA022 Solenoid Valve Temperature MAGO1 AA201 Solenoid Valve for Testing
Depending Interlocking EF11 Low Vacuum Trip B4
A Magnet Coil Open EF11
B Magnet Coil Closed EF11 MAX42AAO01 Solenoid Valve,Adjustment of
Control Valves FG5
MAX53 022 B Limit Switch 100% F11
C Limit Switch 0% F11 MAX45AAO01 Soleniod Valve for Load Shedding Relay
in Secondary Fluid to Reheat
MAX53 AA031 Slide Valve for Water Injection Valve A12 Control Valves DE5
MAX53 AA041 Slide Valve for Water Injection Valve MAX46AAO11 Solenoid Valve for Load Shedding Relay
(Sequential Water Injection) A 13 in Auxiliary Secondary Fluid G2
MAX 53BYO01 Converter for Electro-Hydraulic MAX47

LPBypass Governor FG6,7 AA211 +212 Solenoid Valve for start -up Fluid,
KA01 Jet Pipe FG6 Main Stop Valve B5,6
KA02 Follow -up Piston for LP BYPass
Control Valves G7 MAX 47
KA03 Follow -up Piston for Water AA221 +222 Solenoid Valve for Start-up Fluid,
Injection Valves G7 Reheat Stop Valves AB8
KA04 Sleeve G7
KA05 Piston G7 MAX48
KA06 Helical Spring G7 AA201 +202 Solenoid Valve for Auxiliary
KA07 Limit Pressure Amplifier Piston G7 Start-Up Fluid BC1
KA08 Differential Pressure Amplifier Piston G7
KA09 Setting Device for Differential Pressure G7 MAX51AA021 Solenoid Valve for Extraction
Amplifier Piston G7 Check Valve A2 E12
MAX53CGOO1AA Remote Piston Indicator F7 MAX51AA024 Solenoid Valve for Extraction

T Moving Coil G6 Check Valve A3 E13
MAX53 BY 011 LP Bypass limiting Regulator FG8 MAX51AA027 Solenoid Valve for Extraction
KAO1 Jet Pipe F8 Check Valve A4.1 C 12
MAX53 MAX51 AA028 Solenoid Valve for Extraction

CP501 +502 Pressure Gauge ,Signal Fluid Check Valve A4.2 A10
LP Bypass Valve F11
MAX51 AAO30 Solenoid Valve for Extraction
MAX 53CP511 Pressure Gauge , Signal Fluid Check Valve A4.1 C12
Water Injection Valve C12
MAX51AA031 Solenoid Valve For Extraction
MAX61 Check Valve A4.2 A11
AA01 +012 Test Valve for Main Stop Valves B6
MAX51 AA036 Solenoid Valve for Extraction —
MAX61 Check Valve A5 E9
AA021 +022 Test Valve for Reheat Stop Valves AB8
MAX51 AA201 Solenoid Valve for Control Fluid
MAX62AAO01 Overs peed Trip Test Device CD4 Supply During Test B3
KA01 Valve for Test oil CD4
KA02 Valve for Auxiliary Start-up Fluid CD4 MAX51AA202 Solenoid Valve for Control Fluid
KA03 Valve For Auxiliary Trip Fluid CD4 Supply During Test B4
M Electrical Motor C4
MAX52AAO01 Remote Trip Solenoid C2
MAX62CGO01 B Limit Switch ,up-Normal position ATT C4
C Limit Switch ,Down- Test Position ATT C4 MAX52AAO02 Remote Trip Solenoid C2
MAX62CP501 Pressure Gauge, Test Oil Overs peed D1 MAX53AA051 Sioenoid Valve for Sequential
Trip Water Injection C13
MAY10
AAO01 +002 Overs peed Trip E2,3 MAX61AA201 Solenoid Valve for Changeover from
KA01 Releasing Device E2,3 Trip Fluid to Control Fluid C3
MAY10
CGO01 +002 C Limit Switch,Alarm E3
E Umit Switch Alarm ATT E3
5.1-0681-01/2
5.1-0681-01/4
MAX61 MAX48 CP202 Pressure Switch for Auxiliary

AA211 +212 Solenid Valve for Testing fo Start-up Fluid Between Solenoid
Main Stop Valves C5,6 Valves MAX48AA201 and202 B1
MAX61 MAX51
AA221 +222 Solenoid Valve for Testing of CP011 +012 Pressure Switch for Trip Alarm A1
Reheat Stop Valves C8
MAX51
LBBO1 CP11 Pressure Transducor Hot Reheat CP013 Pressure Switch for Trip Fluid
HP Right E6 (Automatic Start-up) A1
lBS42 CPOO2 Differential Pressure Monitor for MAX51

Extraction Check Valve A4 CP205 +206 Pressure Switch for Trip Fluid Between
(Batron -Cell) B11 Solenoid Valves MAX51 AA201
and202 B3
MAA50CPOO6 Pressure Transducer 1st State Pressure
(By Pass Control) E7 MAX51
CP207 +208 Pressure Switch for Trip Fluid Ahead of
MAGO1CP2O1 Pressure Switch ,low-Vacuum Trip, Changeover Valve MAX51 A211 B3
Vacuum min. B4
MAX51
MAGO1CP2O2 Pressure Switch ,low-Vacuum Trip, CP209 +210 Pressure Switch for Trip Fluid Ahead of
Vacuum max. B4 Changevoer Valve MAX51 AA211 B2,3
MAGO1CP2O3 Pressure Switch,low-Vacuum Trip, MAX51CP 221 Pressure Switch for TRip Fluid ahead of
Vacuum min. B5 226 Main Stop Valve, Test Valve B6
MAGO1CP2O4 Pressure Swltch.Low-Vacuum Trip MAX51CP222 Pressure Switch for Pressure above
Vacuum max. B5 227 Piston of Main Stop Vale B7
MAG10CPO11 Pressure Switch, Electrical Low MAX51 CP223 Pressure Swich for Pressure below
Vacuum Trip. 246 Piston Disc of Main Stop Vale A68
Signal .Pressure to high E13
MAX51CP242 Pressure Swiitich for Trip Fluid above
MAG 10CPO12 Pressure Switch ,Electrical low 247 Piston of Reheat Stop Valve A9
Vacuum Trip,Alarm E13
MAX51 CP243 Pressure Switch for Trip Fluid Below
MAG10CPO13 Pressure Switch Electrical low Vacuum 248 Piston Disc of Reheat Stop Valve B9
Trip Interlocking MAG10CPO12 E14
MAX52CP211 Pressure Switch forAuxilairy
MAG10CPO16 Pressure Switch for Engergislng of Trip Fluid BC3
Vacuum Breaker E13
MAX62 CP 211 Pressure Switch for Test oil of
MANO1CPOO1 Pressure Switch for Sequential overspeed Trip max D1
Water Injection
MAX62 Cp 212 Pressure Switch for Test oil of
MAX45 CP211 Pressure Switch For Reheat Control overs peed Trip max. D1
Valves Secondary Fluid
MAX62 CP 213 Pressure Switch for Test oil of
MAX48 CP2O1 Pressure Switch For Auxiliary overspeed Trip Pressure Collapsed D2
Start-up Fluid
MAX45 AAO21 Presssure Convertor For EHC E4
5.1-0681-01/5
5.1-0681-01/3
Steam Turbine Lubrication Chart
Description
No. Lubrication Point Filling Lubricant Lubrication Top-up Remarks

Quantity Interval Quantity
1 Overspeed test device Turbine oil” Every 1 to 2
months
2 Reduction gear of overspeed 200g Grease Every 1 to 2 ~ 10g
trip test device Servogem-2 months
3 Bearing at low vacuum trip Turbine oil” Every 1 to 2
months
4 Main control valve stem Molykote U After every Use no oil or
disassembly grease
5 Main stop valve stem Molykote U After every Use no oil or
disassembly grease
6 Limit Switch attachment on Molykote M30 Every 1 to 2 Use no oil or
main stop valve months grease
7 Limit switch attachment on Molykote M30 Every 1 to 2 Use no oil or
main control valve months grease
8 Hinge of main control valve Molykote M30 Every 1 to 2 Use no oil or
shaft position indicator months grease
9 LAWA actuator VR 16 of 0.4 kg Calypsol SF7-026 Every 104 0.4 kg
main control valve Operating hours
10 Reheat control valve stem Molykote U After every use no oil or
disassembly grease
11 Reheat stop valve stem Molykote U After every Use no oil or
disassembly grease
reheat stop valve months grease
13 LEWA actuator VR 16 of 0.4 Kg Calypsol SF7-026 Every 104 0.4 kg
reheat control valve operating hours
14 Hinge of reheat control valye Molykote M30 Every 1 to 2 Use no oil or
shaft position indicator months grease
reheat control valve months grease
16 Hinge of extraction swing Molykote U After every Use no oil or
check valves disassembly grease
17 Adjusting gear of starting 200 9 Grease Every 1 to 2 ~ 10 g
and load limit device Servogem-2 months
18 Journal for hydraulic Turbine oil * Every 1 t02
speed governor months
19 Adjusting gear of reference 200 g Grease Every 1 to 2 ~ 10 g
speed setter Servogem-2 months
20 Bearing trimming device Turbine oil* Every 1 to 2
months
21 Hinge of cold rehdat leg Molykote U After every Use no oil or
swing check valve disassembly grease
22 Journal for Converter for Turbine oil* Every 1 to 2
bypass governor months
23 Bearing of condenser safety Turbine oil* Every 1 to 2
device for bypass operation months

No. Lubrication Point Filling Lubricant Lubrication Top-up Remarks
Quantity Interval Quantity
24 Hinge of bypass control valve Molykote M30 Every 1 to 2 Use no oil or

Shaft position indicator’ months grease

bypass control valve months grease
26 Bypass control valve stem Molykote U After every Use no oil or

disassembly grease
27 Limit switch attachment on Molykots M30 Every 1 to 2 Use no oil or

bypass stop valve months grease
28 Bypass stop valve stem Molykote U After every Use no oil or

disassembly grease
29 Shaft seal steam valve Molykote U After every Use no oil or

stem guides disassembly grease
Lubrication point
not marked
30 Shaft seal stem valve 7 to 9 kg Hydraulic oil to 1 st oil change 7 to 9 kg Lubrication point
actuators DIN 51517 and after 6 months, not marked
VDMA 24 318 thereafter every.
H-LP oils** 12 months
* Turbine oil 46/Servoprime 46 of 10C, Turbinal 47 of HPCL or ~quivalent

** HLP 46 (VG) ISO of IOC
5.1-0690-01/2
Steam Turbine Hydraulic Speed Governor
Description with Starting and Load Limiting Device
Function If the primary oil pressure falls (as a result of

increasing load and the resulting drop in speed), the
The function of the hydraulic speed governor is to link (11) and the sleeve (5) sliding on the follow-up
operate the control valves to give the appropriate piston (4) are move downwards by the speed setting
turbine steam throughput for the particular load spring (13) so that the overlap of the pons in the sleeve
condition. The arrangement and functioning of the and the follow-up piston is reduced. This causes the
governor within the overall governing system is pressure in the Auxiluary secondary fluid circuit to
described in the section on governing. rise and the follow-up piston follows the movement
of the sleeve against the increasing force of the
Construction tension spring (3) until normal overlap of the ports
The principal components of the speed governor and equilibrium are restored. The lift of the control
are the bellows (8), the link (11). the speed setting valves is increased in this manner by the increased
spring (13), the sleeve (5) and the follow-up piston secondary fluid pressure.
(4). The primary oil supply from the hydraulic speed Conversely, a rise in primary oil pressure causes
transmitter is available at connection ‘a 1 ‘. A fire the lift of the control valves to be reduced.
resistant fluid is used as the hydraulic fluid in the When the pre-compression of the speed setting
governing system. An additional bellows (9) prevents spring (13) is varied with the reference speed setter
primary oil getting into the control fluid circuit should it changes the relationship between the primary oil
ther~ be a leakage in the governor bellows (8). In pressure and the secondary fluid pressure and hence
this case, the leakage oil can be drained off via the relationship between speed and power output.
connection ‘c1 ‘. Should a leak in the bellows (9) occur, Lever (12) allows the link (11) to be depressed by
the control fluid that has leaked in will also be drained hand to give a lift. signal to the governor, e.g. to
off via connection ‘c1’. provide a second means of overspeeding the machine
for testing the overspeed trips in addition to the
The primary oil pressure (con nection ‘a 1 ‘) is overspeed trip tester.
dependent on the speed and determines the position
of the tank (11) via the bellows (8) and the push rod Starting and load limiting device
(10). The speed setting spring (13) opposes the Before stan-up the pilot valve (21) is brought to its
primary oil pressure. Its pre-compression can be bottom limit position either by hand or remotely by
varied either by hand or remotely by the motor (16). the motor (20). This causes the bellows to be
The sleeve (5) which can slide on the bottom end of compressed via the lever (6) and the pin (7) until the
the follow-up piston (4) is attached to the link (11). governor assumes the piston Control valves closed.
The follow-up piston is held against the auxiliary With the valve (21) in the bottom limit position control
secondary fluid pressure (connection ‘b’) by the fluid from connection ‘a’ can flow simuiltaneously to
tension spring (3). The follow-up piston and the sleeve the auxiliary staning fluid circuit (connection ‘u1 ‘) and
have ports which at normal overlap allow sufficient as staning fluid via connection ‘u’ to the stop valve to
fluid to escape to produce equilibrium between the prepare these for opening. When the valve (21) is
auxiliary secondary fluid pressure and the force of moved back the auxiliary staning fluid circuit is
the tension spring (3). depressurized and subsequently the starting fluid
Each steady-state position of the line (11) and connection ‘u’ is opened to the return ‘c’. This opens
hence of the sleeve (5) corresponds to a specific force the stop valves. Further upward movement of the
from the tension spring (3) and hence to a specific valve (21) causes the pin (7) to -release the bellows
secondary fluid pressure which in turn determines as with falling primary oil pressure and the control
the position of the control valves. valves are opened. The releasaof the bellows can be
limited by the pin (7) so that the cor1trol valves do
Mode of Operation not open any further despite a further reduction in
primary oil pressure.

Steam Turbine Adjusting Gear
Description
Function as to permit the spindle to slide axially in the bushing

The adjusting gear is used for manual or motor (4) which can rotate in cover (19). Spring (6) forces
operation of the reference speed setter and the the thrust rings (18) against bushing (4) which
starting and load limiting device. prevents bushing (4) and spindle (16) from turning.
Spindle (16) however, can be moved axially by turning
Mode of Operation the wormwheel (15).
The speed/load adjusting gear is operated either Spindle (16) can be moved up or down depending
manually or by means of motor (28). The rotary on which direction wormwheel (15) turns. The limit of
movement of the motor shaft is transmitted to travel is set by limit rings (14 and 17). If either stop
wormwheel (15) via wormwheel and the worm (9) has been reached the thrust rings operates as a slip
attached to it. Wormwheel (15) is located axially on coupling. The thrust rings also protect the motor (28)
the threaded portion of the handwheel spindle (16) from overload in the event of restrictive movement
by insert (5) and the gear casing (11). The spindle within the adjusting gear.
(16) is connected with bushing (4) by a featherkey so
Section C-C Section A-A

Steam Turbine Electrohydraulic Converter
Description for Turbine Control System
Function
The electrohydraulic converter is the connecting
element between the electrical and hydraulic
parts of the turbine control system. It converts
the signals from the electric controller into the
hydraulic signals and amplifies them before
transmitting them to the actuating devices.
Construction
The principal components of the converter are
moving coil system (12), sleeve (10), pilot valve
(6), amplifier piston (3), follow-up pistons (21),
differential transformer (1) and actuator (17).
Bushings and follow-up pistons ‘A’ are
connected to each other via the adjusting screws
(24), spring end pieces and the springs (22).
The control signals from the electrohydraulic
converter operate the sleeve (10) via the moving
coil system (12). This sleeve slides up and down
on the top end of the pilot valve (6) and
determines the position of the valve in the
manner of a follow-up piston. The pilot valve and
sleeve have ports which depending on the
overlap, control the amount of trip fluid flowing
from connection ‘x’. In the
steady-state condition, the pilot valve is in its
center position and the trip fluid pressure acting
on the face of the pilot valve is in equilibrium
with the force of me compression spring (9). The
pilot valve is kept in rotation by control fluid
flowing from tangential holes in an integral collar
to give greater freedom of reciprocal motion and
counterbalance the fluid pressure acting on the
achieve high response sensitivity.
follow-up pistons. Each follow-up piston and
sleeve (20) has ports, which control the
When the pilot valve is deflected from its center
secondary fluid flow according to the overlap.
position, control fluid from connection ‘a’ is
When the throttling area is changed by the
admitted to the space above or below the
movement of the sleeve (20) it also changes
amplifier piston (3) with the opposite side of the
the pressure in the follow-up piston causing it to
piston opened to the fluid drain. The resulting
follow the movement of the sleeve. This varies
motion of the amplifier piston is transmitted via
the tension of springs (22) until equilibrium is
lever (13) to the sleeves (20) which in turn can
regained between the spring force and the new
slide on the following-up pistons (21). The
secondary fluid pressure. Each position of the
secondary fluid circuits, which are fed from the
amplifier’ piston (3) corresponds to a specific
trip fluid circuit via throttles and supply the
position of the sleeves (20) and, therefore, the
various actuating devices, are connected at point
follow-up pistons (21). The position of the follow-
‘b’. The secondary fluid pressures are
determined by the tension of springs (22) which

up piston is the determining factor for the a simultaneous feedback action on the pilot valve
secondary fluid pressure at point ‘b’. (6) via the differential transformers (1). The
sleeve (10) is moved back until the new position
of the amplifier piston causes the pilot valve (6)
Section D-D
to assume its center position and equilibrium is
restored between the fluid pressure below the
pilot valve and the compression spring force (9).
When a command is given to close the control

valves, the controlling action is similar but in the
reverse manner.
Adjusting Device for Valves

The follow-up pistons ‘B’ and the lever (14) of
the rotary shaft (15) situated above it are
connected by the springs (22) of follow-up
pistons ‘B’, the guide bolts (16) and the adjusting
screws (30). During normal operation an
energized solenoid valve allows control fluid ‘a1’
to flow under the piston (25) of the actuator (17).
The piston (25) is moved upwards against the
forces of the spring (26) [Stop (31) locked in
The initial tension of the follow-up piston springs

can be varied by means of the adjusting screws
(24).
Controlling Action with the EI,ctrohydraulic

Converter
When the electric controller gives a command
to open the control valves, the sleeve (10) is
moved upwards by the moving coil system (12),
thus decreasing the fluid drain area. This causes
the pressure below the pilot valve (6) to increase
and the valve moves upwards and opens the
way for control fluid from connection ‘a’ to flow
to the space below the amplifier piston (3). The
following movement of the amplifier piston then
slides the sleeves (20) downwards over the
levers (13, ~9) reducing the drain area between
the sleeves and the follow-up pistons, causing
the pressure in the follow-up pistons and
secondary fluid circuits to rise.
The motion of the amplifier piston (3) produces
5.1-0730-02/2
normal position by pin] and the initial tension of for example after load shedding, the solenoid
the tension springs (22) of the follow-up pistons valve will be de-energised. This blocks the flow
‘B’ is adjusted by means of the lever (28. 14) of control fluid to the actuator (17) and allows
which results in the IP control valves opening in control fluid under the piston (25) to flow into
relation to the HP control valves as intended for the return pipe. The force of the spring (26)
this operation. moves the piston into the lower end position and
the tension springs (22) of the follow-up pistons
If the condition turbine load less than a set ‘B’ are adjusted so that the IP control valves do
minimum load and the ratio of HP exhaust not begin to open until the HP control valves
steam pressure to main steam pressure are
greater than the set pressure ratio is fulfilled, wider open. The lever (28) then rests on the
precisely set stop (31). Limit switch (29)
indicates: Setting device engaged.
Setting Device for start-up without

BypassValves
If the plant is started up without bypass system,
the reheat stop and control valves must open
before the main steam stop and control valves.
For this purpose, the handwheel (32) is set in
the upper end position. Signal from limit switch
(33): Setting device In operation -without -
bypass-system position.
15 - Rotary shaft
17 - Actuator
25 - Piston
26 - Compression spring
27 - Piston rod
28 - Lever
29 - Limit switch
30 - Adjusting screw
31 - Setting device
32 - Hand wheel
a1 - Control fluid
b - Secondary fluid
c - Return fluid
5.1-0730-02/3
Steam Turbine Hydraulic Amplifier
Description for Turbine Control System
Function its centre position and the pressure in the

The function of the hydraulic amplifier is to auxiliary secondary circuit and the force of spring
amplify the signals from the hydraulic speed (8) are in equilibrium. The pilot valve is kept in
governor (connection. ‘b1’) so that they are rotation by control fluid flowing from tangential
sufficient for the actuating devices. holes in an integral collar to give greater freedom
of reciprocal motion and high response
Construction sensitivity.
The principal components ‘of the amplifier are
amplifier piston (1), Pilot valve (7), follow-up When the pilot valve is deflected from its center
piston (2) with sleeves (3), mechanical feedback position control fluid from connection ‘a’ is,
system (6) and actuator (21). Bushings and admitted to the space above or below the
follow-up pistons ‘A’ are connected to each other amplifier piston (1) with the opposite side of the
via the adjusting screws (10), spring end pieces piston opened to the fluid drain. The resulting
and springs (11). Auxiliary secondary fluid flows motion of the amplifier piston is transmitted via
over the pilot valve (7) via connection ‘b1’. In lever (5) to the sleeves (3) which in turn, slide
the steady-state condition, the pilot valve is in on the follow-up piston (2). The secondary fluid

circuits, which are fed from the trip fluid circuit to a speqific position of the sleeve (3) and the
via throttles and supply the various aCtuating follow-up piston (2). The position of the follow-
devices, are connected at point ‘b’, The up piston is the determining factor for the
secondary fluid pressures are determined by the secondary fluid pressure at point ‘b’.
tension of springs (11), which counterbalance
the fluid pressures acting upon the fOllow-up The initial tension of the follow-up piston springs
pistons. Each follow-up piston (2) and sleeve can be varied by means of the adjusting screws
(3) has ports, which control the secondsry fluid (10, 14), and the levers (15, 16).
flow according to the overlap, When the throttling
area is changed by movement of the sleeve (3), Controlling Action with the Hydraulic
it also changes the pressure in the follow-up Amplifier
piston causing it to follow the movement of the The pressure above the pilot valve (7) is varied
sleeve, This varies the tension of spring until by the hydraulic governor varying the auxiliary
equilibrium is regained between the spring force secondary fluid pressure connection ‘b1’. An
and the new secondary fluid pressure. Each increasing auxiliary secondary fluid pressure
position of the amplifier piston (1) corresponds
5.1-0740-02/2
causes the secondary fluid pressure at the If the condition Turbine load less than a set
connection ‘b’ to rise and open the actuating minimum load and the ratio of HP exhaust
devices; a reduction in the secondary fluid steam pressure to main steam pressure
pressure causes the actuating device to close. greater than the set pressure ratio is fulfilled,
The motion of the amplifier piston produces a for example after load shedding, the solenoid
simultaneous feedback via lever (6) and causes valve will be de energised. This blocks the flow
the pilot valve to assume its center position when of control fluid to the actuator (21) and allows
the new position of the amplifier piston is control fluid under the piston (20) to flow into
reached. Each auxiliary secondary fluid pressure the return pipe. The force of the spring (19)
corresponds to a certain position of the piston moves the piston into the lower end position and
(1) which, in turn, results in a certain the tension springs (11) of the follow-up pistons
secondaryfluid pressure at connection ‘b’ with ‘B’ are adjusted so that the IP control valves do
each auxiliary fluid pressure. The degree of not begin to open until the HP control valves
proportionality of the hydraulic governor can be are wider open.
adjusted by varying the position of lever pivot
(6) with the adjusting screw (9). The lever (16) then rests on the precisely set
stop (25). Limit switch (17) indicates: Setting
The follow-up piston ‘B’ and the lever (15) of device engaged.
the rotary shaft (12) situated above it are
connected by the springs (11) of follow-up Setting Device for Start-up without
pistons ‘B’, the guide bolts (13) and the adjusting bypass valves
screws (14). During normal operation, an If the plant is started up without bypass system,
energised solenoid valve allows control fluid ‘a1’ the reheat stop and control valves must open
to flow under the piston (20) of the actuator (21). before the main steam stop and control valves.
The piston (20) is moved upwards against the For this purpose, the hand wheel (24) is set in
force of the spring (19) [stop (24) locked in the upper end position.
normal position by pin and the initial tension of
the tension spring (11) of the follow-up piston Signal from limit switch (23): Setting device in
‘B’ is adjusted by means of the lever (15, 16) operation without bypass system position.
which result in the IP control valves opening in
relation to the HP control valves as intended for
this operation.
5.1-0740-02/3
Steam Turbine Damping Device
Description
Function
The damping device is located in the bypass
control injection water line and serves to damp out
any pressure surges and pulsations.
Mode of Operation
When the pressure at the Inlet ‘a’ increases, the
ball (6) is held firmly against the lower seat and the
rising pressure can be propagated to the outlet ‘b’
only slowly through the throttling passage in grub
screw (2).
Conversely, if the pressure in inlet ‘a’ falls
suddenly, the higher pressure in outlet ‘b’ lifts the ball
(6) from the lower seat, closing the throttling passage.

Steam Turbine Electrical Speed Pick-Up
Description
Construction and Mode of Operation circumference. This disc is mounted on the shaft (7)
The electrical speed pick-up located in the front of the main oil pump by means of the hub ring (g, 11).
bearing pedestal indicates the exact speed through The magnets (6) are associated with the Hall probes
all speed ranges of the turbine. The measuring mounted in a holder (4). On rotation of the disc (10)
procedure functions as follows: electrical impulses are developed as a result of the
alternating effect between the mrgnets {6)and the Hall
A non-magnetic disk (10) is fitted with small probes. This output frequency is conducted to the
magnet (6) of alternating polarity around its speed measuring unit.

Steam Turbine Pressure Converter
Description
Function
The pressure converter is installed in the IP
secondary oil circ:.uit. It does not permit to raise the
IP secondary oil pressure beyond certain value.
Construction
The pressure converter is provided with a follow
up piston (3) which slides in the bushing (6) at the
top and in the sleeve (2) at the bottom. The bushing
and follow up piston are connected to each other via
the adjusting screws (9, 10) and the spring (4). There
are drainage slots in the follow up piston (3) and
sleeve (2), through which a larger or smaller amount
of oil can flow into the oil return line ‘c’ depending on
how much they overlap. The oil pressure prevailing
in the follow up piston 13) is connected to the reheat
control valves for speed control via connection ‘x’.
Mode of Operation
When the setscrew (9) of the pressure converter
has been appropriately set, IP secondary oil pressure
is permitted to increase to certain value.
1 Ring
2 Sleeve 8 Cap
3 Follow up piston 9 Set screw
4 Spring 10 Set screw
5 Cesing
6 Bushing c Return flow
7 Cover x Trip oil

Steam Turbine Converter for Electrohydraulic
Description Bypass Governor
Function
The Converter which is a jet pipe hydraulic
regulator, has a plunger coil system (2) that detects
a direct current from the electric LP bypass governor.
This electrical measured varible is converted into a
force and transferred to the jet pipe (3)
Mode of Operation
The control fluid supplied to the jet pipe (3) via
connection ‘a’ leaves at high speed and travels to
the nozzles of the pressure distributor.
The energy due to the velocity of the jet is
converted into compression energy in the pressure
distributor which is connected to both sides of the
associated control piston by two pipes.
The position of the jet pipe (3) depends on the
voltage of the direct current to which the plunger coil
system is subjected and on the adjusteing springs
(4). If the variable to be controlled is at its nominal
value, the forces of the plunger coil system (2) and
the adjusting system (springs 4) are in equilibrium.
The jet pipe is then in the center position, the pressure
on both sides of the associated control cylinder is
equal and the piston is at rest. By using the adjusting
screws (5), the initial stress of the adjusting spring
(4) can be changed and thus the required nominal
value set according to the design data.
If the variable to be controlled deviates from its
nominal value, the jet pipe moves away from its center
position via the plunger coil system and conducts fluid
above or below the associated control piston which
is thus moved upwards or downwards [1].

Steam Turbine Transformer
Description for l.p. Bypass Control System
Function the follow-up pistons (7) ,and are moved into the
follow-up pistons by the lever system (16,17,24) when
The transformer converts the signals emitted from control fluid is admitted to the piston (22). The follow-
the bypass governor or bypass limiting regulator into up pistons and sleeves have por1s through which
appropriate signal fluid pressure(1) . more or less fluid escapes depending on the amount
of overlap. If the piston (22) pulls the sleeves
Design downwards, the amount of por1 overlap decreases
and the pressure in the follow-up pistons increa$e
The transformer consists of the follow-up .The follow-up pistons are then forced further
pistonsA,B,C,D,(Fig.1) and of the actuators forthe downwards while the tension, of the springs (4)
bypass goverhor (Fig.3) and bypass limiting regulator increases, until a new state of equilibrium is
(Fig.4) .The follow-up pistons(7) are guided in the established at increased fluid pressures and normal
bushes (5 and 13). The bushes and follow-up pistons port overlap. If the sleeves are moved upwards, the
A,B,are connected to one another via the setscrews processes described take place conversely, so that
(2). spring-end pieces, (3) and the spring (4), The the fluid pressures in the follow-up pistons drop.
springs of the follow-up pistons C,D with the guide
pins(12) and setscrews represent the connection
between the follow-up pistons C,D and the levers(14)
of the rotary shaft(15) above (Fig.2 and 3 ). All fluid
spaces of the follow-up pistons mentioned are fed
with control fluid via throttle each.The fluid spaces in
the follow-up pistons A,B are connected to the
change-over valve of the injection water valve via
connections’ b1'. Connections ‘b2’ of the follow-up
pistons C;D lead to the change-over valves of the
emergency stop and control valves of the bypass
system. The sleeves (8) slide on the lower ends of

Owing to the floating arrangemet of the follow-up its upper end position, the sleeves of the follow-up
pistons and their suspension from springs, It is pistons are pulled downwards via the lever system
possible to achieve a linear relationship between the (16,17,24) and the fluid pressure of these follow-up
fluid pressure and the spring travel in accordance with ~istons are increased, as a result of which first the
the spring characteristics. injection water valves and then the emergency stop
and control valves of the bypass system are opened.
The initial tension of the spring (4) in the follow-up
pistons C;D maybe changed by means of the piston Only after the bypass limiting regulator has come
(28) of the bypass limiting regulator via the levers into action as a result of a disturbance, and the control
(14) which are fitted to the rotary shaft(15). fluid ‘a3’ moves the piston (28) downwards, will the
fluid pressure in the follow-up pistons C;D drop, with
Control Sequences the bypass valves closing.
If control fluid ‘a l’ is admitted to the space above proper setting of the transforlJ’ler may be checked
the .piston (22) by the electrohydraulic transformer by means of the manual setting device (19,20).
with the piston (28) of the bypass limiting regulator at
5.1-0790/2
Steam Turbine Bypass Limiting Regulator
Description
Function to the velocity of the jet is converted into compression

energy in the pressure distributor which is connected
The function of the bypass limiting regulator. which
to both sides of the associated control piston by two
is a jet pipe hydraulic regulator, is to prevent steam
pipes.
being blown into the condenser when the limit values
The position of the jet pipe (1) depends on the
Condenser pressure too high; Bypass flow too
force of the corrugated tube measuring system acting
much and injection water pressure too low are
on both sides of the jet pipe and on the forces of the
exceeded. This is done either by closing or not
adjusting system ,which also act on both sides. The
releasing the bypass stop and control valves(1 ).
adjusting system consists of adjusting springs and
The jet pipe regulator (2) has an adjusting and a adjusting screws for setting the nominal value. If the
measuring system. The adjusting system allows the variable to be controlled is at its nominal value, the
nominal value of the controlled variable to be achieved forces of the measuring system and the adjusting
by effecting a force which counteracts the force of system are in equilibrium. The jet pipe is then in the
the measuring system. This counterforce of the centre position, the pressure on both sides of the
adjusting system is produced by a spring loading associated control cylinder is equal and the control
which can be manually set within the required limits cylinder piston is at rest. By using the adjusting screws
by means of an adjusting screw. The measured (4), the pretension of the adjusting springs(3;9) can
variable is transformed into a force and transferred be changed and thus the required nominal value set
to the jet pipe(1). according to the design data.
If the variable to be controlled deviates from its
Mode of Operation nominal value, the jet pipe (1) moves away from its
The control fluid supplied to the jet pipe (1) via centre position via the corrugated tube measuring
connection a leaves at high speed and travels to the system and conducts fluid above and below the
nozzles of the pressure distributor. The energy due associated control piston which is thus moved upward
and downwards.

Steam Turbine Combined Main Stop Valve
Description and Control Valve
Function and Arrangement Stop Valve
One stop and one control valve are combined in a The steam enters the valve casing (13) via the Inlet
common body. The main stop valve provides a means connection and remains above the stop disc (1). The
of Isolating the turbine froin the main steam line and main valve disc incorporates a pilot disc formed from
can rapidly interrupt the supply of steam to the turbine. the end of the valve steam (3). The valve stem is
The function of the control valve is to regulate the sealed by packing rings (6). On the back of the valve
flow of steam to the turbine according to the prevailing disc is a raised seat which comes into contact with a
load. neck bush (4) when the valve is fully open and so

provides extra sealing at this point for the stem. Both Control Valves
stem and disc are secured against torsion. The valve
body cover (2) is held in the valve casing (13) by a The stem and disc (16) of the control valve are in
threaded ring (8). There is a U-shaped gasket (5) one piece. Balancing holes in the valve disc reduce
between cover and casing. The two legs of the gasket the operating force required. The valve stem and disc
are pressed agianst the sealing face to give a tight (16) are guided in the cover (17) and the stem is
joint .The stop valve is opened hydraulically and sealed by packing rings (20). When the valve is fully
closed by spring force. opened, the raised seat of the valve disc rests against
the neck bushing (18) and provides additional sealing.
Testing Main Stop Valve As with the stop valve, the valve body cover (17) is
held in the casing by a threaded ring (21) and is sealed
Each stop valve must be tested at regular intervals by U-shaped gasket (19). The control valve is
to ensure proper functioning. A testing valve is actuated by the piston of the servomotor (26) that is
provided for this purpose. operated by a cup spring in the closing direction and
hydraulically in the opening direction.
5.1-0810-01/2
Steam Turbine Servomotor for Main Stop Valves
Description and Reheat Stop Valves
The operative part of the servomotor consists of is reduced. This arrangement restricts the flow of fluid
a two-part piston, the lower disc-shaped part of which past the piston disc and so produces a braking action
is connected via piston rod,to the valve stem. The which causes the valve disc to seat gently.
other par1: of the piston is bell-shaped and moves
All fluid connections are routed through a test
within the housirlg which is in the form of a cylinder.
valve. All operations can be contrOtTed by means of
Two spiral springs are placed between the two halves
the test valve and the starting and main trip valve.
of the piston; at the lower end a spring plate is
interposed between the springs and the piston disc.
When trip fluid is admitted to the space above the
bell-shaped part of the piston, it moves this half of
the piston downwards, compressing the springs, until
it seats against the piston disc.
After the main stop valves have been opened, the
turbine is started by the control valves. Before the
main stop valves can be opened, however, they must
be “pressurized”, i.e. prepared for opening, by
admitting trip fluid from the trip fluid circuit to the space
above the piston to press it down against the piston
disc after overcoming the resistance of the springs.
The edge of the bell-shaped half of the piston is
designed to produce an fluid-,tight seal with the piston
disc.
To open the valve, fluid from the trip circuit is
admitted to the space below the piston disc and,
simultaneously, the space above the bell-shaped half
of the piston is opened to drain. This causes both
halves of the piston to move together in the direction
which opens the valve. In order to reduce fluid leakage
past the bell-shaped part of the piston when the valve
is open, a back seat is provided in the housing against
which the collar of the piston can seat.
When the valve is tripped, the pressure in the trip
fluid circuit, and hence in the space below the piston
disc, falls, with the result that the springs separate
the two halves of the piston and the piston disc
connected to the valve stem moves to close the valve.
Just before the valve disc seats, the piston disc enters
a part of the cylinder where the diametralclearance

Steam Turbine Hydraulic Servomotor
Description for Main and Reheat Control Valves
High-pressure type
The flow of steam to the turbine is regulated by Main Control System

varying the lift of the control vale by means of its The movement of the pilot piston (4) deflects the
servomotor. main pilot valve (3) from its centre position by means
The control valve is actually moved by the piston of lever (5) so that either, control fluid from connection
(9) which is loaded on one side by the disc springs ‘a’ is directed to the underside of piston (9) and the
(10) and on the other side by hydraulic pressure. The control valve opens, or the underside of piston is
position of the valve is determined by the secondary opened to drain so that the disc springs can close
fluid pressure which is controlled by the governor. the control vale. Shortly before the main valve disc
Since large operating forces are required, the actually comes into contact with the seat, the
servomotor is of the high-pressure type (approx. 32 servomotor piston (9) enters a recess turned in the
bar) and has a pilot control system. The supply of body and thrr+tles the flow of fluid draining from the
secondary fluid (connection ‘b’) controls the auxiliary unders,lde of the piston. This slows down the valve
pilot valve (14) which directs control fluid from closing m~{ion and the disc seats gently. The spring
connection ‘a1’ to the appropriate side of the ~ilot (1) pre-loads the:linkage and prevents any slackness
piston (4). The pilot piston operates the main pilot or lost motion at th’e pivots. The straight feedback
valve (3) through lever (51 so that when the valve is cam (7) mounted on the end of the servomotor piston
being opened, control fluid from connection ‘a’ is rod (8) returns the main pilot vale (3) to its centre
directed to the underside of piston (9). When the valve position by means of a lever system. The slope of
is being closed, fluid drains through the main pilot the feedback cam is in two stagJs to give two degrees
valve. of proportionality, which produce good linearity of the
steam flow characteristics.
Pilot Control System
When the turbine is running and the valve is steady Testing Device
at any particular value of lift, the auxiliary pilot valve The control valve can be operated either by hand
(14) VJi!1 be in the centre position shown in the or under power independently of the governor by
drawing. In this position the force exerted by the spring means of the testing device (1 1) in order to check
(13) and the secondary fluid pressure acting on the the free movement of the valve. The testing device
auxiliary pilot valve are in equilibrium. When the acts on the lever (5) in the ~ame manner as the pilo~
governor varies the secondary fluid pressure to open piston (4); the system demanding the smaller valve
or close the control varve, the auxiliary pilot valve is lift being in control,
deflected from this centre position. This allows control
fluid (connection’ a 1 ‘) to flow to one side of the pilot Damping Device
piston (4) while the other side of the piston is opened Fig.2 illustrates the auxiliary pilot valve (14) and
to drain. The movement of the pilot piston returns the the damping device in the secondary fluid circuit. Any
auxiliary pilot valve to its centre position by means of sign~ls in the secondary fluid circuit are damped out
the feedback linkage (12) thus giving proportionality by passing the secondary fluid through capillary tube
between secondary fluid pressure and pilot piston (16) before it enters the auxiliary pilot vale (14).
travel. The degree of proportionality of the pilot control
system can be adjusted by varying the position of Any air carried by th’e secondary fluid is conducted
th~ feedback lever pivot (12). The auxiliary pilot valve to the ,:ree space in the actuator via the screw plug
is continuously rotated by the action of fluid issuir]g (18) and holes in the casing of the dampirlg device
from tangential drillirlgs in a disc mounted on its and pilot valve.
spindle in order to ensure that the valve moves freely
at all times.

Steam Turbine Test Valve
Description for Emergency Stop Valve
Function pressure in the start-up fluid circuit or by manually

The function of the test valve is to open and close turning the handwheel (3). The trip fluid can now flow
the emergency .stop valve, either by start-up fluid from connection ‘x’ to connection ‘x2’ via the auxiliary
circuit or manual operation, especially when the valve (5) and ducts in the casing, and thus under the
emergency stop valve is being checked for easy piston disc.
movement [1).
Testing the Emergency Stop Valves
Arrangement For testing the emergency stop valve, the valve
Each test vale (6) and auxiliary valve (5) is (6) is moved slowly downwards by means of the hand
arranged in series behind a solenoid valve (1 ;2). wheel (3). In this way, trip fluid is admitted
Each emergency stop valve is served by one test {bic9,nnection ‘x, , and then connection ‘x2’Iinked to
valve, whereby a test valve (6) is combined with arl drain c, which closes the emergency stop valve. After
auxiliary valve (5) in a common casing. These blocks this, the handwheel (3) is slowly turned back and the
of test valves are arranged in frames immediately next emergency stop valve op,ens again. This procedure
to. the relative emergency valve groups. is accordingly the reverse of the closing procedure.
Opening of the Emergency Stop Valve Closing the Emergency Stop Valve by Automatic
In order to open the emergency stop valve, the Testing Device
valve (6) must first be forced downwards against the When trip fluid is admitted under the auxiliary valve
force of the spring (7). This can either be done by (5) via connection ‘v’, this will be forced (Jpwards
start-up fluid (connection ‘u’) or manually with the hand against the pressure of the spring (4). This links
wheel (3). Trip fluid (connection ‘x’) can then flow to connection ‘x2’ with drain ‘c’ via valve (5). Fluid thus
connection ‘x1’ and on over the piston in the drains under the piston disc in the emergency stop
emergency stop valve. The valve must then be valve and the valve closes suddenly.
returned to the upper position, either by lowering the

Steam Turbine Combine Reheat Stop
Description and Control Valves
Function and Construction base bushing (5) and provides additional sealing at
One stop and one control valve are combined in a this point. Metal packing rings (3) seal the valve stem.
common body with their stems arranged at right The stop valve is opened hydraulically and closed by
angles to each other. The stop valve can interrupt spring force.
the supply of steam from the reheater to the i.p.and
Ip turbines extremely quickly. The control valve Testing Stop Valves
controls the steam flow to the i,p. and h.p.turbines on Each stop valve must be checked for correct
load rejection, start-up and shutdown and remains operation at regular intervals. A test valve is provided
fully open in the upper load range to eliminate any for this purpose The checking procedure is described
throttling losses. Further details of the arrangement in section “Test valve”
of the valve combination in the control system can
be seen under section “Governing system”. Control Valve
The control valve has a pipe-shaped valve disc
Reheat Stop Valve (14) that is bolted to the valve stem (13) and slides in
The stop valve is a single seat valve with integral the bushing in the valve cover (11) The valve disc is
pilot valve. Steam enters via the inlet of the valve provided with relieving holes to reduce the necessary
body (2) and remains above the valve disc(7) when controlling force. A ring fixed in the bushing of the
the stop valve is closed. A pilot valve, integral with valve cover prevents the valve disc from rotating. This
the valve stem(6) is provided for relieving, thereby valve disc also has a back sealing that operates when
reducing the force necessary for opening. The valve the valve is fully open. Asbestos/graphite packing
disc (7) slides in the bushing of the valve cover (4) rings (10) seal the valve stem (13) in the valve cover
and has a bead on the back which lies against the (11). The control valve is operated by the piston of
the servomotor (9) i.e. is opened hydraulically and
closed by cup springs.
In the event of a disturbance in the system or on
trip-out, both stop valve and control valve close
rapidly.

Steam Turbine Hangers for Reheat Stop
Description and Control Valves
The reheat stop and control valves arranged are taken up via the disk spring (8) and tie rod (6) by
beneath the turbine operating floor in front of the girders (1) that rest horizontally on shims in a recess
turbine-generator unit are suspended at three points in the foundation and are connected to the foundation
from girders in the upper foundation plate in such a via clamping plates.
way that they can follow thermal expansion of the Tie rod (6) is screwed into rod cap (5) and when
steam lines. the correct elevation of the reheat stop and control
The ball-and-socket design of the tie rod ends (5) valve(3) has been established, is secured to prevent
and spring body (9) and the disk spring stack (8) turning.
arrangement permit free movement of the reheat stop
and control valve(3) in all directions. Tensile forces

Steam Turbine Steam Strainer
Description
Function tacked to the T -section intermediate rings (3). The

Steam Strainers are installed in the main steam maximum mesh size of the strainer, which id
lines and in the hot reheat lines from the boiler. They determined by the height of the corrugations, is 1.6
protect the admission e1ements of the HP and IP mm. The effective area is made at-least three times
turbines from foreign objects which could be picked the cross-sectional area of the pipe. The strainer is
up in the boiler or associated piping. used for both initial commissioning of the turbine and
for regular operation.
Construction
The strainer screen (2) is made of corrugated strip
wound on a frame. This design offers a high degree
of resistance, even to particles impinging at high
velocity. The frame consist of two rings (1, 6) and a
number of rods (5) welded between the rings. The
rods are additionally held by reinforcing rings (4)
welded i!’1side them. The strainer is designed for a
single direction of flow from the outside inwards. For
longer strainers, the screen is made up of several
parts. The end turns of the corrugated strip are then

Steam Turbine Bypass Stop and Control valve
Description
Function body via the admission branch and encounters the

One stop and one control valve are combined in a valve disk (11). An internal pilot valve in this disk
common casing. On a signal from the bypass relieves the pressure on the disk to reduce the force
governor and the bypass limiting regulator, this valve required to open it. The internal pilot valve is integral
combination conducts the steam from the reheater with the valve stem (8). A bead on the back of the
circuit into the condenser by bypassing the turbine valve disk against the stellited bushing (7), when the
[1]. valve is open, provides additional sealing at this point.
The valve disk is guided in the bushing (9) of the
Bypass Stop Valve valve cover. Metal seal rings and graphite rings behind
The bypass stop valve, which is either closed or the stem leak-off steam extraction seal the stem to
fully opened, is situated in the admission part of the the outside. The stop valve is opened hydraulically
valve body (13). The bypass steam enters the valve and closed by spring force [2].
Bypass Control Valve

The bypass control valve is situated in the exhaust
part of the valve body (13). It controls the flow of
bypass steam according to signals received from the
bypass controller. The control valve is operated by
the piston of the actuator which closes under spring
force and opens under the control fluid pressure, the
amount of the opening being determinde by the fluid
under the piton, controlled by a pilot valve [3]. The
disk of the control valve is integral with the stem. The
valve stem is sealed and guided in the valve cover in
the same way as for the stop valve.
Any leakage steam still arising behind the seal
bushings (6,17) is drawn off which guarantees
effective sealing of the steams.

Steam Turbine Actuator
Description for Bypass Stop Valve
Function the pilot valve is lifted and control fluid a can flow
under the piston (12) and the bypass stop valve is
The function of the actuator is to operate the opened. The upper end of the actuator rod enters a
bypass stop valve according to the signals from the passage in the hoodiilled with fluid so that the bypass
LP bypass governor [1]. stop valve can open softly.
When the pressure of the signal fluid ‘b’ under the
Mode of Operation
pilot valve (8) is reduced, the space under the piston
(12) becomes depressurized due to the alternation
The bypass stop valve is controlled by the piston
in pilot valve position and thus the bypass stop valve
(12) and actuator rod (11) according to the positon of
is closed by the force of the cup springs (13). Just
the pilot valve (8). The piston is loaded on the one
before the valve cone seats, the piston enters a
side by the disc springs (13) and on the other by the
recess in the casing bushing and throttles the return
control fluid ‘a’. When the bypass fluid ‘b’ is not
flow of the control fluid under the piston. The closing
pressurized, the pilot valve (8) remains in the end
movement is slowed so that the valve cone seats
position shown due to the spring (5) force. This means
softly.
that control fluid a cannot flow under piston (12) and
the bypass stop valve is closed by force of the disc The pre-tensioning of the spring (5) and thus the
spring. signal fluid response pressure can be adjusted by
means of the threaded bolt (3).
When bypass signal fluid is fed to connection ‘b’,

Steam Turbine Water Injection Valve
Description
Function
By Injecting colldensate. the water InJec.tion valve
de-superheats. steam not accepted by the turbine
and dumped into the condenser [1].
Operation
The water Injection valve consists of valve spindle
(16), piston (3), cylinder (1) and valve body parts (13,
17). Pressure fluid is admitted via connection ‘a l’ or
‘a2’ to open or close the valve. A pilot valve controls
the admission of fluid to the space above or below
the piston (3). The condensate supplied by the
condensate pump flows into the water injection valve
via inlet ‘h’ and when the valve opens, to the injection
nozzles via the outlet ‘j’. In the valve body part (17),
valve spindle (16) is sealed by grooved packing rings
(6,8) arranged between neck bushing (11) and gland
nut (4). When the valve is open, the rim of the valve
cone presses against the neck bushing (11) to form
a tight seal.
The position of the valve is signalled to the control
room by limit switch (15).
Any leakage fluid or water is collected in chamber
bushings 15, 7) and drained off through connections
‘c’ and ‘k’.
1 Cylinder
2 Threeded bushing
3 Piston
4 Gland nut
5 Chamber bushing
6 Grooved ring
7 Chamber bushing
8 Grooved ring
9 Pecking support ring
10 Base ring
11 Neck bushing
12 Threaded ring
13 Valve body
14 Valve seat
15 limit switch
16 Valve spindle with cone
17 Valve body top
a1 Pressure fluid above piston
a2 Pressure fluid below piston
c Leekage fluid
h Condensate inlet Cc
i Condensate outlet
k Leakage water

Steam Turbine Pilot Valve
Description of Injection Water Valve
Function
The pilot valve operates the injection water when

bypass operation begins [1].
Mode of Operation
If the bypass controller transmits an opening signal
to the bypass valves, control fluid is fed to connection
‘b’ and lifts the valve (10) against the force of the
spring (5). As soon as the valve has left the centre
position shown, control fluid ‘a’ passes through
connection ‘a2’ to the space belbw the piston of the
injection water valve, opening it. At the same time,
connection ‘a1’ communicates with connection ‘c’
through which the fluid in the space above the piston
flows off.
Conversely the fluid pressure ‘b’ drops, and with
it the valve (10) below the centre position shown, the
control fluid will then be admitted to the piston to cause
the injection water valve to close. The initial tension
of the spring (5) and thus the point at which the
injection water valve opens can be adjusted by means
of a setscrew (3). All signals from the secondary fluid
circuit are dampened by the throttle capillaries (1)
before they reach the valve. To prevent the valve (10)
from seizing in its sleeve (9) during operation, control
fluid is passed through the centre bore and out
through tangential bores in the wheel disc (8) to make
the valve (10) rotate. A thrust ball bearing (7) as well
as the ball (13) is fitted for this purpose.
1 Throttle capillary tube 12 Slotted nut

2 Cap nut 13 Ball
3 Setscrew
4 Hood
5 Compression spring a Control fluid
6 Spring disc a1 Control fluid
7 Thrust ball bearing (closes injection water valve)
8 Wheel disc a2 Control fluid
9 Valve bush (opens injection water valve)
10 Valve b Signal fluid
11 Bush c Return

Steam Turbine Changeover Valve
Description for Bleeder Check Valve
Function
The function of the changeover valve is to
manually operate the actuator of the bleeder check
valve ‘1).
Mode of Operation
The trip fluid (connection x) holQs the valve (10)
in the upper end position (illustrated) a~ainst the force
of the spring (8). The trip fluid flows via the holes in
the valve to connection x 1 and then on to the actuator
of the bleeder check valve. The valve can be moved
downwards by means of handwheel (1). In this way
connection x1 is connected to the fluid drain ‘c’ and
the fluid drains away from the actuator of the bleeder
check valve. The spring of the actuator can then
initiate the closing of the check valve. If the pressure
drops at the trip fluiQ connection x, the spring (8)
pushes the valve (10) downwards. In this way the
fluid drain of the actuator is not freed.
1 Handwheel
2 Spindle
3 Cap nut
4 Bush
5 Lip ring
6 Coyftr
7 Bush
8 Spring
9 Ball
10 Valve
11 Cover
c Drain fluid
x Trip fluid
x1 Trip fluid to eotuetor

Steam Turbine Auxillary Valve
Description of Extraction Check Valve
Function in the lowest position by the force of the spring (7).

The auxiliary valve c9ntrols the fluid supply to the With this position of the valve, the trip oil ‘x’ can flow
extraction check valve actuators and its function is to to the other valves and -as soon as these valves have
give the check valves a signal to close in the case of been switched to the upper position by secondary
a drop in load or trip-out so that steam cannot flow fluid from follow-up piston of reheat control valves-
out of bleeder lines back to the turbine. The auxiliary on to the change-over valves of the extraction check
valve serves several check valves[1]. valves(conncetion ‘x1‘). The check valves are then
free to open. On a reduction in load, as mentioned
Mode of Operation above, the pressure above the valve (11) is reduced
Trip fluid is admitted through connection ‘x’ on the accordingly while the Pressure below the valve is
body (10) (section A-B). Secondary fluid from follow- retained for a while. This is made possible by the fact
up pistons of main control valves is admitted to the that the pressure reduction below the valve is retarded
spaces above and below the valve (11) through by the ball (15) and the pressure in the accumulator
connection ‘b2’ As the pressure above the valve (11) (connection ‘b’) until the equaliburium is reestabilished
are equal under normal conditions, the valve is held

between the pressure in the accumulator and the new adjusting the springs, these valves are forced
pulse fluid Pressure (connection ‘b2’) via the upwards against the action of the springs and op$n
equalizing passage in the cover (12). Owing to the the path for the trip fluid to the change-over valves of
brief differential surge, the valve (11) is forced the extraction check valves. The lift of the valves is
upwards against the action of the spring (7), thus limited by a collar at their lower end. By appropriately
cutting off the trip fluid supply to the check valves setting the springs (14) to the valves, it can be
and opening the fluid return. As a result of this, the ascertained at which secondary fluid pressure i,e,at
check valves receive a closing impulse and close at which turbine load, the check valves open or receive
reduced or reversed differential steam an impulse to close.
pressure. If the pressure in the secondary fluid circuit drops,
The valves (16), (sectionC-D) are acted upon from the valves are pushed downwards by the force of the
below (connection ‘b1’) by the load -dependent springs and the inlet ports from the trip fluid circuit
secondary fluid pressure of the control valves. If the are cut off, the bleed valves thus receiving an impulse
secondary fluid pressure exceeds the value set by to close.The fluid in the line to the change-over valves
can drain off through the opened fluid return ‘c’.
5.1-0841/2
Steam Turbine Rotary Vane Actuator
Description for Reheat Swing-Check Valve
Function segments 11). This rotary movement, transmitted by

The function of the rotary vane actuator flanged actuator shaft 18) tu shaft 13) of the swing-check valve
to the swing-check valve is to open or close the swing- via coupling 15;6) closes the swing-check valve.
check valve fitted in the cold reheat line (1). Conversely, the swing-check valve is opened when
control fluid is admitted through connections ‘d1’
Operation
When the pilot valve operated by the transformer Seals, Fixing
of the speed controller passes control fluid via Actuator shaft 18) is guided in bushings 11 1) at
connections ‘d’ to the interior of the actuator, the both endt of the segments 11) and is sealed o.ff by
adj9cent connection ‘d l’ is depressurized. The control seal ring I’ 0). The segments 11! are fixed in body
fluid then flows through bores in the body into the 112) and in cover 113) by means of fitted pins.
two diametrically opposite chambers turning rotary Leaking fluid ‘c’ is drained to the header.
vane (2) on actuator shaft (8) into contact with the

Steam Turbine Pilot Valve for Rotary Vane Actuator
Description of Swing-Check Valve
Function
The function of the pilot valve is tu control the

admission of cuntrol fluid to the moving vane actuator
in such a way that the swing-check valve is operated
in accordance with the pressure in the secondary fluid
circuit [1].
Mode of operation
The swing-check valve is kept open as long as
the pressure in the secondary fluid circuit does not
drop below a definite limit value. If signal fluid enters
the body i13) via connection ‘b’, the valve (s) is lifted
against the action of the spring (3). The initial tension
of this spring and thus the point at which the swing-
check valve opens can be adjusted. If the valve (8) is
lifted beyond the centre position illustrated, the control
fluid entering at connection ‘a’ flows on to a chamber
of the actuator via connection ‘a2’ to open the swing-
check valve. Connection ‘a1’ then communicates with
the fluid return ‘c’ via passages in the body (13),
permitting the fluid to drain away from the actuator
chambers not supplied with control fluid. If the valve
(8) drops below the centre position illustrated, the
control fluid will then be conversely admitted to
the.actuator chambers in such a way that the swing-
check valve closes.
To prevent the valve (8) from seizing in its sleeve

(7) during operation control fluid is passed through
the centre bore and out through the tangential bores
at the wheel disc (6) to impart rotary movement to
the valve (8). For this reason, a deep-groove bali
bearing (15) is fitted between the valve (8) and the
spring disc (5).
1 Cap nut
2 Adjusting screw
3 Helicel compression spring
4 Spring dilc
5 SprinG disc
6 Wheel disc
7 Sleeve
8 Valve
9 Slotted nut
10 Bush
11 Ball
12 Throttle

Steam Turbine Auxiliary Pilot Valve
Description for Rotary Vane Actuator
for Reheat Swing-Check Valve
Function
The function of the auxiliary pilot valve for the pilot
valve for the reheat check valve actuator is to control
the admission of control fluid to the pilot valve in such
a way that the swing-check valve is actuated in
accordance with the pressure in the secondary fluid
circuit 11).
Operation
The swing-check valve is kept open as long as
the pressure in the secondary fluid circuit does not
drop below a definite limit. Secondary fluid entering
body (9) via connection ‘b’ lifts spool (7) against the
action of the spring (3). The initial tension of this spring
and thus the point at which the swing-check valve
opens can be adjusted. If spool (7) is lifted beyond its
central pOSition as illustrated, the control fluid
entering at connection ‘a’ flows on via connection ‘a”
to connection ‘b’ of the pilot valve to open the swing-
check valve via the rotary actuator. If spool (7) drops
below its central position as illustrated, control fluid
is admitted to the opposite chambers of the rotary
actuator, so that the swing-check valve closes.
To prevent spool (7) from seizing in its sleeve (6)
control fluid is passed through the centre bore in the
spool during turbine operation and out through
tangential bores in the upper part of spool (7) to impart
rotary motion to the spool. A deep-groove ball bearing
(6) between spool (7) and spring retainer (4) reduces
friction from the rotary motion.

Steam Turbine Gland Steam Control Valve
Description
Function
One function of the gland steam control valve,

which is situated in the grand steam pipe of the seal
steam system, is to supply the shaft seals with seal
steam during start-up and in the lower load range. A
further function is to keep the set pressure in the
header constant in order to prevent air penetrating
the vacuum of the shaft seals [1].
Construction and Mode of Operation

The control valve is operated by the piston of the
electrohydraulic actuator which is moved in the open
and closed direction by the pressure of the control
fluid. The piston rod (2) is connected to the valve stem
(7) via the coupling (4), the threaded cap (5) and cover
(6).
The steam flow is regulated by the irlternal pilot
valve, which is integral with the valve stem, and the
main cone (13). The position of the valve is shown
on the lift scale (3). The valve stem (7) and valve
cone (1 3) are guided in the bushing (11).
Any leakage steam arising in the upper part of the
bushing (1 1 ) is conducted to the header.
1 Electrohydraulic actuator
2 Piston rod
3 lift scale
4 Coupling
5 Threaded cap
6 Cover
7 Valve stem with pilot valve
8 Packed stuffing box
9 Valve yoke
10 Base ring with pltcking rings
11 Bushing
12 Valve cover
13 Valve cone
14 Valve casing
c Leakage steam

Steam Turbine Leakage Steam Control Valve
Description
Function
The function of the leakage steam control valve,
which is situated in the leakage steam pipe of the
seal steam system, is to drain excessive steam from
the header [1].
Construction and Mode of Operation

The control valve is operated by the piston of the
electrohydraulic actuator which is moved in the open
and close direction by the pressure of the control fluid.
The piston rod (3) is connected to the valve stem
(8) via the coupling (4). The packing rings (10) and
the bushing (12) seal the passage of the rod to the
outside and guide the valve stem (8) during the
opening and closing movement.
1 Electrohydraulic actuator
2 Valve yoke
3 Piston rod
4 Coupling
5 Threaded piece
6 Cover
7 Lift indicator
8 Valve stem
9 Stuffing box
10 Base ring with packing rings
11 Valve cover
12 Bushing
13 Valve casing
Also refer to the following sections

[1] 5.1-0670 Electrohydraulic Seal Steam Pressure
Control

Steam Turbine Main Trip Valve
Description
Function different pistons being forced tightly against the body

The Function of the main trip valve is to open the assemblies (10) by the rising pressure of the fluid.
trip fluid circuit in the event of abnormal conditions, Control fluid flows into the casing (11) via connection
thereby closing the valves and thus shutting off ‘a’ and with a tripping device lateced in (in the position
admission of steam to ttle turbine[1]. shown), into the trip fluid circuit via connection ‘x’.
The trip fluid circuit leads to the stop valves and the
Construction secondary fluid circuits. Via passage drilled in the
The main trip vaive consists of mainly two valves body (11) (Section A-A) fluid flows to the auxiliary
(12) that slide in the casing (11) and are loaded by trip fluid circuit which leads to the hydraulic protection
the springs (5,6). The valves (12) are designed as devices

Operation valves (12) move downwards due to the spring force
When starting the unit, the valves (12) are lifted and their own weight, thus connecting connections
by the start up fluid (connection ‘u1 ‘) against the force ‘x’ and ‘x1’ with the fluid back flow ‘c’. This
of the springs (5,6) and forced tightly against the depressurizes the trip fluid circuit which causes the
assemblies (10). In this way pressure is build up in main and reheat stop valves to close. The fluid supply
the trip fluid circuit (x) and the auxiliary trip fluid circuit to the secondary fluid circuits is also shut off, thus
keeps the valve in the position shown while the start causing the control valves to close.
up fluid drains through the start up device. The two valves (12) work independently of each
Should the fluid in the pressure in the auxiliary other so that even if one valve fails the function if the
trip fluid circuit drop below a specific value for any tripping device in not impaired. The limit switches (1)
reason (e.g. by tripping of a pi’otection device) the transmit electrical signals to the control room.

[1] 5.1-0630 Protective Device
[2] 5.1-0680 Govering Scheme
[3] 5.1-0681 Govering Scheme Legend
5.1-0910/2
Steam Turbine Emergency Trip Valve
Description for Manual Trip Out
The emergency trip valve enables the machine to

be manually tripped out.
The valve consists of the valve cone (8), which
slides in the bushing (9) and is loaded by the spring
(7), and the ball head (,.) with the spinqle (4).
During normal operation the valve (8) is forced
tightly against the bushinQ (6) by the pressuie of the
auxiliary trip fluid arising at connection ‘x1 ‘. To actuate
the trip, the ball head (1) is pushed downwards. This
opens the valve and connects the auxiliary trip fluid
circuit (connection ‘x1 ‘) with the fluid back flow ‘c’,
The drop in pressure in the auxiliary trip fluid circuit
actuates the emergency tripping device. The limit
switch 12) shows. the tripping of the valve.
On start-up, before the auxiliary trip fluid is
pressurized, the valve (8) is forced upwards against
the bushing by the auxiliary start-up fluid (connection
‘u1‘).
1 Ballhead
2 Limit switch
3 Cover
4 Spindle
5 spring
6 Bushing
7 Spring
8 Valve cone
9 Bushing
10 Casing
11 Cover
x1 Auxiliary trip fluid

u1 Auxiliary start-up fluid
c Return fluid


Steam Turbine Solenoid Valve for
Description Remote Trip-out
Function
The solenoid valve is installed in the auxiliary trip
fluid line to the automatic trip gear and, when
operated, causes the auxiliary (‘rip fluir1 circuit to be
opened and the turbine !;topped, The solenoid valve
is remote-controlled electrically, e.g. from the control
room or from a protective device [1].
Construction
The directions of flow are indicated by arrows on
the body. The solenoid sleeve (4) is bolted to the
casing (6) and is inserted in the m~gnet casing (11
with the armature 13). The complete valve element
is placed in tht! body (6) and held by the plug 111).
The two valve discs 181 s3al the valve seats 191.
The solenoid valve and the line to the automatic trip
gear are ventilated by means of the screw [12].
Mode of Operation
When the solenoid (1) is not energized, the
armature (31 is “,oved downwards by the spring (2)
so that the valve disc (8) is pressed against the valves
seats 19) to provide sealing. The solenoid valve is
operated by energizing the solenoid 11 I. The
armature and the valve discs are drawn upwards
against the force of the spring (2) so that the auxiliary
trip fluid ‘a’ is linked with the drain ‘c’ and the pressure
in the line to the automatic trip gear collapses 12).
1 Magnet casing
2 Spring
3 Armature
4 Solenoid sleeve
5 Hexagonal nut
6 Casing
7 Ring
8 Stem with two valve dilci
9 Valve leat
10 O-ring
11 Plug
12 Ventilation screw
a Auxiliory trip fluid to 8utometic trip gear

c Drain
[2] 5.1-0910 Main Trip Valve

Steam Turbine Overspeed Trip
Description
Function and Construction

The function of the overspeed trip is to stop the
turbine when the permissible speed is exceeded. It
is fitted ir) the turbine rotor (7) and consists of the
eccentric bolt (4), adjusting screw (6), spring (51 and
the screw plug (1).
Mode of Operation
The overs peed trip mech~nism is set by the
adjusting screw (6). By appropriate adjustment of the
screw, the centre of gravity of bolt (4) is positioned
eccentrically to the turbine shaft so that below the
tripping speed the bolt is held in the position shown
by the spring (5) against the centrifugal force. In this
position, the bolt bears against the screw plug (1 ). If
the turbine rotational speed exceeds the overspeed
setting, the centrifugal force overcomes the force of
the spring (5) and forces the bolt (4) out of the turbine
rotor (7). This activates the turbine automatic stop
mechanism.
1 Screw plug 5 Spring

2 Guido bushing 6 Adjusting screw
3 Guiding foil 7 Turbine rotor
4 Bolt 8 Guic,le bushing
Fig. 1 Arrangement of overspeed trip in turbine rotor

Steam Turbine Overspeed Trip Releasing Device
Description
Function the shaft 113) due to the force of spring-loaded valve

The function of the overspeed trip releasing device 131 and the auxiliary trip fluid ‘x l’ against the rod.
is to open the auxiliary trip oil circuit and thereby shut This movemer\t opens fluid drain ‘c’ to the auxiliary
down the turbine when an overspeed is reached which trip fluid and the resulting loss in pressure trips the
would subject the rotor to high centrifugal force [1 ]. turbine f31. The electrical trip signal is transmitted to
the contro’ room by the limit switches (1).
Construction
The overs peed trip releasing device located in Testing the Overspeed Trips for Free Movement
the bearing pedestal consists of valve bodies (4, 10), Proper functioning of the overspeed trips is
valve and rods (3, 5,7,81, pawls (12) and limit switch important since severe damage may result from
(1). The bellows 16) on the valves and rods prevent excessive over. speeds. The overspeed trip test
hydraulic control fluid from entering bearing pedestals device makes it possible to check the bolts as well
and lubrication system. When the turbine i$ started as valves and rods (3, 5, 7, 8) without interrupting
up, tl,e valve, rods and pawls are latched by auxiliary operation of the turbine (4).
start-up fluid ‘u1 ‘.
Start-up
Turbine Trip by Overspeed Trip Device Before restarting the turbine following a trip, latch
When the overspeed trip operates, the eccentric in the overspeed trip. This is done by admitting
bolts fly out radially and strike pawls (121. The impact auxiliary startup fluid ‘u1’ into valve body (41 and
of the bolt rotates. the pawls outwards against the forcing the respective valve (3) outwards until rod (8)
force of torsion springs (1 1) [2). The latches of the engages the latch of the pawl. The auxiliary start-up
pawls release rod 181 which, in turn, moves towards fluid flow is interrupted and auxiliary start-up fluid flows
via a hole to fluid drain ‘c’.

Steam Turbine Overspeed Trip Test Device
Description
Function Construction
The function of the overspecd trip test device is The overs peed trip test device consists of three
to test and exercise the overspeed trip. The valves (4,10, 11) combined in valve block (12). Valve
overspeed trip consists of bolts which protrude (11) is held in the position by spring (9) which bears
against the force of a spring under the effect of against guide piece (15) and rod (7). In this position
centrifugal force during an overspeed condition. The auxiliary trip fluid can pass to the overs peed trip
bolt strikes a pawl and thus opens the trip fluid circuit release valve via connection ‘x’ and ‘x1 ‘. If the valve
sp that the stop and control valves immediately (11) is pushed inwards and held by means .of the
interrupt the admission of steam to the turbine. know (6), the auxiliary trip fluid circuit (connection
Perfect functioning of the overs peed trip is of the
utmost importance [1].

‘x’ and ‘x1’) is separated from the overs peed trip (5), the valve (1 Q) can be moved inwards so that the
release apart from a small quantity of fluid v/hich is passage from connection ‘a2’ is blocked from drain
permitted to pass to fill up the empty pipe after the ‘c1’. Control oil can now flow from connection ‘a1’ via
test operation.-This prevents the emergency stop the bushing (13) and the valve (10) to connection
from being actuated by the overspeed trip. ‘a2’ and the bolts of the overspeed trip.
Valve (19) performs the function of admitting test Valve (41 is used for resettIng the overspeed trip
oil to the eccentric bolts of the overspeed trips, re1ease valve after the test operation.., When valve
causing them to protrude from the turbine shaft during (4. is pushed” inwards against the force of spring (31,
the overspeed trip t,est operation. Valve (10) is guided control fluid can trow from connection ‘a’ to ‘u”, thus
in guide bushings (13,14). A tentre bore with radial latchi’ng in the overspeed trip valve, During start-up,
openings is provided in the valve. An annular chamber connoctions ‘u’ and ‘u’ i provide a passage for a~xiliarv
in the bushing (13) is connected to test oil connection start-up fluid for latching in the overspeed trip release
‘a 1’. In the position shown oil is prevented from valve. After the test operation, the valves (4, 11) are
entering the bore of the valve. By means of handwheel blocked by means of the bolts (17).

[1] 5.1-0920 Overspeed Trip
[1] 5.1-0921 Overspeed Trip Releasing Device
5.1-0922/2
Steam Turbine Low Vacuum Trip
Description
Function below the diaphragm is at atmospheric pressure.

Upon failure of the condenser to maintain proper
The purpose of the low vacuum trip is to operate vacuum, diaphragm (8) is forced downwards by the
the main trip valve when a failure of vacuum occurs increase in pressure and the force of. the spring (7)
in the condenser, thus tripping out the main and reheat against the force of spring (10), thus moving valve
stop and control valves and shutting off the supply of (9) downwards. This establishes a connection
steam to the turbine within the shortest possible time between ‘x l’ (control fluid) and drain ‘c’ so that the
[1]. auxiliary trip fluid circuit is depressurized and the main
trip valve operates. Concurrently, valve (11) actuates
Operetion the limit switches (15), which initiates an alarm
The condenser vacuum is connected via I contact.
(connection to condenser) to the top side of the The range in which the vacuum safety device
diaphragm (8). The space operates can be varied by adjusting the initial tension
of the spring (7) by means of the adjusting screw (5).
In order to isolate the auxiliary trip fluid circuit
during starting, auxiliary pilot valve (9) is lifted by
means of the spring (10) so that drain ‘c’ is shut off,
thereby establishing pressure in the auxiliary trip fluid
circuit when no vacuum exists.
As primary oil pressure builds up with the increase
in turbine speed, piston (2). In forced into the lower
position. This lower position is rea:.hed when the
speed is still far below the rated valve at which time
the low vacuum trip safety device is ready to operate.
1 Casing
2 Piston
3 Guide
4 Limit switch
(condenser protection ready for operation)
5 Adjusting screw
6 Stem
7 Compression spring
8 Diephregm
9 Auxiliary pilot valve
1 1 Velve
12 Cesing
14 Diaphragm
15 Limit switch
(maih trip)
a Controf fluid
c Drain (fluidt
c1 Drain (oill
d Primary oil
x1 Auxiliary trip fluid
I Connection to condenser


Steam Turbine Condenser Safety Device
Description
Function
The function of the condenser safety device

situated in the control fluid circuit of the bypass control
system is to protect the condenser, when there is an
excessive increase in pr6ssure in the condenser, by
opening the control fluid lines so that the resLllting
drop in pressure causes the bypass valves to close
[1].
Mode of Operation
The steam space in the condenser is connected
with the spring space above the diaphragm (5) via
connection ‘I’. the space below the diaphragm is at
atmospheric pressure. If the pressure in the
condenser increases excessively, the diaphragm (51,
and thus the valve (6), is forced downwards out of
the upper end position by the increasing pressure
and the force of the spring (41. This shuts off the
connection ‘a” to the bypass valve from connection.
‘a’ from the converter and connects it to. drain’ c’.
The pressure range in which the vacuum safety

device operates can be varied by adjusting the initial
tension of the spring (41 by means of the adjusting
screw (2).
During commissioning the valve (61 is

automatically moved into the upper end position,
where it keeps the control fluid circuit closed, as soon
as the negative pressure in the condenser falls below
the preset value. In order to be able to close the control
fluid circuit when there is still insufficient vacuum in
the condenser, the vai’Je is lifted via the lever (101
and cam (91 but is not yet brought into its upper end
position. As already mentioned, this end position is
not reached until there is sufficient vacuum.
After this, the lever (101 and cam (91 drop down
and do not impair the functioning of the vacuum safety
device. Any leakage fluid can drain off through
passages in the valve sleeve (71 and the casing (8).

Steam Turbine Solenoid Valve for Temperature
Description Controlled Interlock
Function
Wherl there is an unallowable rise in condenser
temperature due to lack of injection ‘Nater a
temperature sensor situated in the condenser dome
sends electric sigoals to the solenoid valve which
open the signal fluid circuit of the bypass valve
actuators, thereby closing the bypass valves so that
the steam flow to the condenser is interrupted [1].
Mode of Operation
During normal operation, the control fluid” a’ holds
the main control valve (7) against the force of the
compression spring (8) in toe center position as
shown here, This provides the connection between
the signal fluid from pressure switch for injection water
‘b’ and the stop and control valve operator of the
bypass stop valve ‘b “, If the temperature in the
conde!!iser rises to an unallowable value, the solenoid
valve (3) is moved downwards against the force of
the compression spring (4) so that the control fluid ‘a’
Drising before the main control valve (7) is connected
with the drain ‘c’.
Simultaneously, the control fiuid ‘a’ can fiow behind
the main valve (7) so that the main valve moves
forwards Doainst the force of the comprcssionspring
(6) and the sionai fluid circuit ‘b l’ is opened and
connected to the drain ‘c’ and the bypass stop and
control valve closed’.


Steam Turbine Vacuum Breaker for
Description Reducing the Running Down
Time of the Turbine
Function
With normal shut down or tripping of the machine,

the function of the vacuum breakers is to cause an
increase in condenser pressure by conducting
atmospheric air into the condenser together with
bypass steam flowing into the condenser from the
bypass station. When the pressure in the condenser
increases, the ventilation of the turbine blading is
increased, which causes the turbo set to slow down
so that the running down time of the turbo set and
the time needed for passing through critical speeds
are shortened.
Total Vacuum Breakers

In special cases requiring a rapid shut dclNn of
the turbo set, the total vacuum breaker is employed.
Electrical Control of Total Vacuum Breaker

So that the vacuum can also be broken without
limitation due to condenser pressure, a manual key
is provided. This key opens the vacuum breaker
valve. However, it can not go into the closing position
until the close key provided for closing is used. This
control enables a complete equalization of condenser
and ambient pressure.
Autometic Control
The vacuum breaker is also actuated automatically
by the turbine fire protection system to shut the turbo
set down more quickly. It is switched back manually
using the close key in this case.
Mode of Operation of Vacuum Breaker

When the magnet is not excited, the solenoid valve
is switched to open. The control medium arising holds
the vacuum breaker valve in the closed position by
means of the power piston. When the pressure drops
the vacuum breaker is opened by spring force.
Opening Process
When the magnet is excited the control medium
is without pressure so that the control medium in front
of the solenoid’valve is connected with the drain ‘c’.
The piston (3) and thus the valve disc (19) are moved
upwards by the force of the spring (5) (Fig. 2).

Closing Process
When the magnet is not excited the valve is £Iosed
by. the control medium arising. The pressure of the
control medium ‘a’ via the piston (3) presses seal ring
(17) arranged in the valve disc (19) on to the valve
seat (20) against the force of the compression spring
(5).
1 Piston cover
2 Stop
3 Piston
4 Velve stem
5 Compresaion spring
6 Platon bottom
7 Limit switch
8 Specer column
9 Cep nut
10 Glend leal
11 Pecking
12 Velve cover
13 Bushing
14 Valve calling
15 Screw coupling
16 Divided ring
17 Seal ring
18 Disc guide
19 Velve disc
20 Velve teet
e Control medium
1 Inlet for etmospheric air
11 Atmospheric eir flowing into condenser
Fig. 2 Drewlng Showing Function of Vecuum Breeker
5.1-0960/2
Steam Turbine Pressure Switch for Injection Water
Description
Function tension of which is set to the appropriate rated value,

The pressure switch monitors the injection water. is provided as a counter force.
When the injection water pressure drops below the
set rated value, the control fluid is interrupted and Mode of Operation
thus the LP bypass valve closed [1]. The lever (4) diverts the fluid jet leaving the nozzle
(11) so that there is no fluid pressure above the piston
Construction surface of the slide valve (12), If the pressure drops
The pressure switch consists of a casing in which below the rated value. however. the lever allows the
a measuring system, a counter-c:onnected system jet of fluid to enter the bushing (13) which subjects
for adjusting the rated value, a knife-edged lever (4), the piston surface of the slide valve (12) to fluid
a nozzle (11) and a slide valve (12) are installed. pressure, The slide valve is thus pushed downwards
The measUfing system consists of bellows (2) against the force of the spring (14) into the shut-off
upon which the injection water pressure ‘I’ acts and position in which control fluid ‘a2’ is Gonnected to the
these influence the knife-edged lever (4) via a pushrod return flow ‘c’, This process causes the signal fluid to
(3). The cylindrical pin (101 is the pivot point of knife- be cut off and thus the bypass valves to be closed.
edge lever (4). The compression spring (6). the If necessary, the knife-edged lever (4) can be fixed
in its end position by means of the lever (17).

Steam Turbine Changeover Valve
Description for Testing Device
Function
The function of the change-over valve is to shut
off the flow of trip fluid into the trip fluid circuit while
the protective devices are’ being tested for proper
operation by means of the automatic turbine tester
and to allow control fluid tat to flow in so that the stop
valves do not close when the safety devices respond
[1].
Mode of Operation
During normal operation, the control fluid ta l’ in
the space under the piston (8) of the change-over
valve keeps the valve in the upper end position shown
here. In this way, connection:tx’ is connected with
connection ‘x l’ and trip fluid can flow into the trip fluid
circuit. The space above the piston (6) Iconnection
‘at) remains depressurized during normal operation.
When safety devices are checked for proper

operation, the space below the lower piston (8) is
depressurized by means of asolenoid valve and
control fluid ‘at enters the space above the upper
piston, which moves the valve into the lower position.
Due to the connection now made between
connections ‘a’ and tx1 t, control fluid tat can flow
freely into the trip fluid circuit, which keeps the stop
valves open for the duration of the test. Two limit
switches (1) transmit the position of the valve to the
control room.
1 Limit switch 9 Body

2 Piston rod 10 COVef
3 Seal
4 Bushing a Contfol fluid
5 Inset a1 Control fluid
6 Upper piston c Fluid drain
7 Sliding bushing x Trip fluid from tripping device
8 Lowef piston x1 Trip fluid to trip fluid circuit

[1] 5.1-0660 Automatic Turbine Tester-General

1 Main oil pump 12 Generator bearing 23 Standby auxiliary oil pump
2 Hydraulic turning gear 13 Exciter 24 Check valvs
3 Journal bearing 14 Threttle valve 25 Injector
4 HP turbine 15 Throttle 26 Main oil tank
5 Combined journal and thrust bearing 16 Seal oil reserve tank 27 Butterfly volve
6 IP turbine 17 Dupex filter 28 Extractor for oil vapour suction
7 Journal bearing 18 Oil temperature control valve 29 Check volve
8 LP turbine 19 Oil cooler 30 Oil separater
9 Journal bearing 20 Jacking oil pump 31 Throttle
10 Generator bearing 21 D.C Emergency oil pump 32 Throttle
11 Generator 22 Auxiliery oil pump 33 Hydrailic turning gear shut-off valve
Steam Turbine Oil Supply System
Description
The following oil system is shown in a simplified The full-load submersible auxiliary oil pumps are
form. The complete connection diagram of the system situated on the main oil tank (26) and draw in oil
can be seen in the contract drawings. directly. Check valves behind the auxiliary pumps and
in the suction line of the main oil pump prevent oil
The oil system fulfils the following functions: from flowing back via pumps that are not in operation.
a Lubricating and cooling the bearings.
b Driving the hydraulic turning gear during Emergency Oil Pump
interruptions to operation, on start-up and shut-
down [1]. When main and full-load auxiliary oil pumps fail,
c Jacking up the shaft at low speeds (turning gear the lubrication oil supply is maintained by a d.c. driven
operation, start-up and shut-down) [1.2]. emergency oil pump (21). This pump supplies oil
directly to the lubricating oil line, bypassing the oil
Oil System cooler and thus preventing damage to the bearings.
Under normal operating conditions, the main oil Partial Control of the Auxiliary Oil Pumps
pump (1) situated in the bearing pedestal and coupled
directly to the turbine shaft draws oil from the main The full-load auxiliary oil pumps and the
oil tank (26) and conveys it to the pressure oil system. emergency oil pump are automatically started by sub
loop control as soon as the pressure switch limit has
The suction of the main oil pump is aided by the been reached. The pressure switches are set in
injector. The injector produces pressure at the suction sequence so that the pumps can be started in
connection to the main oil pump sufficient for all types succession if necessary.
of operation. This guarantees that the main oil pump
takes over the safe supply of oil and cavitations that Oil Return System
could occur due to greater suction heads are avoided.
The amount of oil required for driving is extracted from The lubricating oil from the bearings is returned to
the pressure oil circuit and adjusted by means of the the main oil tank via a header.
throttle (31).
A loop in the returned oil piping behind the seal oil
The oil for the turning gear (2) is also extracted reserve tank (16) prevents H2 gas reaching the main
from the pressure oil system. Oil is admitted to the oil tank (26) when there is a disturbance in the seal
nozzles by opening the shut-off Valve (33). oil system.
The pressure oil is cooled in the oil cooler (19) Extraction of oil Vapour
and reduced to lubricating oil pressure in the throttle
(32). The throttle is adjusted on initial start-up, The main oil tank is designed to be air tight. The
extractors (28) produce a slight vaccum in the main
The amount of oil required for each bearing is oil tank and the bearing pedestals to draw off any oil
adjusted on start-up by means of the oil throttles (15). vapour.
Full-load Auxiliary Oil Pumps Duplex Filters

During turning gear operation, start-up and run- Oil for the bearings is passed through the duplex
down operation, one of the two three-phase a.c., full- oil filter (17) which can be switched over and cleaned
load auxiliary oil pumps (22,23) supplies the pressure during operation.
oil system and takes over the function of the main oil
pump when this is not in operation because the turbine
is running too slowly.

[2] 5.1-0530 Hydraulic Lifting Device

Steam Turbine Main Oil Tank
Description
Function The capacity of the tank is such that the full

quantity of oil is circulated not more than 8 times per
The main oil tank contains the oil necessary for hour. This resl!lts in a retention time of approx. 7 to 8
the lubrication and cooling of the bearings, for the minutes from entry into the tank to suction by the
jacking system and for the hydraulic turning gear. It pumps. This time allows sedimentation and
not only serves as a storage tank also for deaerating detrainment of the oil.
the oil.
1 Sunction pipe (injector) 8 Oil inlet

2 A.C. auxiliary oil pump 9 Riser section inlet
3 D.C emergency oil pump 10 Inspection port
4 Jacking oil pump 11 Oil vapour exhauster
5 Oil level indicator 12 Level switch
6 Riser section drain 13 Oil strainer
7 Main section drain .

Oil Flow in Tank air as possible. The driving elements of the pumps
are fixed to the base plates of the tank covet.
Oil returning to the tank from the oil supply system
first flows through a submerged inlet (8) into the riser Oil Strainer
section “of the tank where the first stage of deaeration
takes place as the oil rises to the top of the tank. Oil The basket type oil strainers (13) are mounted in
overflows from the riser section through the oil strainer the tank. They are of brass wire mesh of 0.25 mm
(13) into the adjacent section of the tank where it is filtration particle size and can be exchanged by
then drawn off on the opposite side by the suction opening the tank cover.
pipe or the oil pumps.
Oil Vapour Exhaust
Oil pumps
The whole tank is made as airtight as possible.
The main oil pumps draws the oil through a suction Oil vapour exhausters (11) produce a slight negative
pipe (1) situated at the flow end of the tank (1). This pressure in the tank, in the return drain lines and in
suction pipe is constructed as an injector to aid the the spaces in the bearing pedestals so that oil vapour
suction of the main oil pump which has to overcome arising is drawn off.
a certain suction head. Power oil is conducted to the
injector via an injection pipe. This injection pipe also Oil Level Indicator
fills the suction pipe of the main oil pump when the
plant is being started up. The main oil tank has a direct reading oil level
indicator and a fluid limitswitch. This permits signals
The auxiliary oil pumps (2,3) arranged on the tank to be transmitted when maximum and minimum levels
are electrically driven rotary oil pumps(2). The jacking have been reached. Extra tank volume is provided
oil pumps(4) also situated on the tank, are electrically between the normal operating level and the tank cover
driven jack-screw immersion pumps (3). All pumps to accept oil from the entire oil supply system when
immerse in the oil contained in the tank and draw oil the turbine is shut down, The tank is constructed with
from the deepest point in order to obtain oil as free of a sloping bottom with drain connections at the lowest
point (6,7).

(1) 5.1-1020 Main oil Pump
(2) 5.1-1030 Auxiliary oil Pump
(3) 5.1-1040 D.C Emergency oil pump
(4) 5.1-1050 Jacking oil pump
5.1-1010-01/2
Steam Turbine Main Oil Pump with
Description Hydraulic Speed Transmitter
Function the double flow impeller (5) is an integral part of

The main oil pump is situated in the font bearing the pump shaft. The pressure and suction chambers
pedestal and supplies the entire turbine with oil that are sealed off from each other by seal rings (4) which
is used for bearing lubrication, cooling the shaft are split and secured against turning at the joint. The
journals and as primary and test oil. The main oil pump pump shaft (5) runs in the journal bearing (1) and the
is driven direct from the turbine shaft via the coupling combined journal and thrust bearing (7). Both
(11). If the turboset is out of. operation or the main oil bearings are lubricated with filtered 011. If the
pump fails, auxiliary oil pumps take over the overspeed trip test device, which is described
necessary oil supply. These pumps also convey oil separately [2] is actuated, overspeed trip test oil ‘a’
into the suction branch of the main oil pump until the flows to the overspeed trip devices via the oil tube
main oil pump has started to draw from the main oil (16) built into the pump shaft (5).
tank which is situated at a lower level [1].
Construction

Hydraulic Speed Transmitter
The pump shaft (5) also carries the hydraulic
speed transmitter (14) which runs in the bearing (7)
and in rings (13). The hydraulic speed transmitter
operates on the same principle as a centrifugal pump
impeller. Any change in speed gives rise to a pressure
change in primary oil circuit ‘a1’ which serves as a
control impulse for the hydraulic speed controller. The
hydraulic speed transmitter (14) is supplied with
control oil from the hydraulic control equipment rack
via the oil supply reservoir (9). ! \n annular bead in
the speed transmitter ensures that its interior is atways
covered with a thin layer of oil to maintain a uniform
initial pressure. Excess oil drains into the bearing
pedestal.
Electrical Speed Plck-up

The pick-up for the electrical speed transmitter
(12) is a nonmagnetic disc into which small magnets
are inser1ed around the circumference. When the
disc rotates as the pump runs, ~h8 alternating effect
between the magnets and the Hall generators, not
shown here, gives rise to a voltage signal which is
forwarded to the electrical speed display [3].
Fig. 2 Hydraulic Speed Transmitter, Cross Section
5.1-1020-01/2
Steam Turbine Auxiliary Oil Pump
Description
Description removed from the tank as a complete unit. After the

The auxiliary oil pump is a vertical one-stage rotary suction casing (14) has been removed ahd the shaft
pump with a radial impeller and spiral casing. It is nut (16) loosened. the impeller can be extracted. It is
fixed to the cover of. the oil tank and submerges into advisable to renew the split rings (17) when
the oil with the pump body. It is driven by an electric exchanging the impeller. The now clearance between
motor that is bolted to the cover plate (1). The oil split ring and impeller neck is 0.3 mm in oiameter.
enters the suction connection from underneath and
is supplied to the oil system via the pressure pipe Exchanging the Bearings
(18). The pump shaft has: a sleeve bearing (12) in When dismentaling. the pump must be removed
the pump casing and a grooved ball bearing (7) in as above. Loosen the pump casing from the pressure
the bearing yoke. The bearings are lubricated from line and suspension pipe from cover plate. Remove
the pressure chamber of the pump; the sleeve bearing coupling halves from the shaft by means of an
via a bore in the casing; the grooved ball bearing ‘,ia appropriate device. Remove retaining ring (6), loosen
a lube line. bearing nut (6) and detach grooved ball bearing.
Extract pump shaft after the unscrewed impeller.’The
Assembly pump is reassembled in reverse order.
The pump is assembled before despat ch and can
be mounted on and bolted to the oil tank as a complete Adjusting Pump Rotor
unit. When connecting, care must be taken th~t the During assembly, the rotor rests on the sealing
piping is not stressed when bolted. ring of the suction casing. Lift the rotor by means of
the bearing nut (5) until the rotor sits firmly with the
Dismounting shoulder of the shaft and the distance ring (8) at the
Exchanging the Impeller inner ring of the grooved ball bearing. Secure the
After the motor has been disassembled and the bearing nut with threaded pin.
pressure pipe disconnected. the pump must be

Steam Turbine D.C. Emergency Oil Pump
Description
Function discharge pipe (18) to the oil supply system.

The emergency oil pump is of the vertical, The vertical pump shaft (9) is connected to the
centrifugal, submerged type and serves for lubrication motor shaft by a flexible coupling equipped with rubber
and cooling of the bearings during emergency -sleeved coupling studs. The radial ball bearing (7)
conditions. carries the downward thrust load of the pump and
with the lower babbited sleeve bearing 112) guides
Location the shaft. The lower sleeve bearing is mounted in
The unit is located on top of the main oil tank and volute 113). Pressure lubrication is provided to both
driven by a D.C. motor. The complete pump -motor bearings. The lower bearing is supplied with oil
assembly is attached to m.ounting plate (1) which is through a drilled oil passage from the discharge side
bo!ted to the top of the main oil tank. of the pump. The upper bearing is oil fed by pipe (10)
which connects to the pump discharge. Seal rings
Construction (17) form a seal between the impeller suction and
Oil is delivered by impeller (15) via the intake (141 the pump discharge.
to volute (13) from where the oil flows through

Steam Turbine Jecking Oil Pump
Description
Function to the cover plate (2). The oil nows into the suction
The jacking oil pump is a self-priming screw- branch of the suction casing (15) from underneath
spindle pump with three spindles and internal bear- and is supplied to the lifting oil system by the pump
ings The pump supplies the jacking oil that is needed via the pressure pipe (3).
for lifting the shafting at low speeds [1]. The driving spindle (16) and the two moving
spindles (20) run in the inner casing (13). The fluid
Construction, Mode of Operation pressure to which the spindle thread is subjected on
The screw-spindle pump is connected vertically the pressure side is compensated by the driving
to the cover plate (2) of the main oil tank via a sup- spindle by means of the balancing piston (shrunk-on
port (5) and immerses with the suction casing (15) sleeve) running irl the throttle bushing (11). With the
into the oil, The drive is an electric motor that is bolted

hollow moving spindles, the axial thrust is
compensated by the balancing pistons arranged on tank. The grooved ball bearing is lubricated with this
the suction side which run in the balancing bushings oil. The driving spindle is fixed by means of the
(21). grooved ball bearing in the bearing carrier (9) that is
The throttle bushing (11) and the driving spindle bolted to the pressure casing (12) of the pump.
(16) form a throttling gap that separates the pressure Due to the special profile given by the sides of the
area from the following area. The oil that leaves the threads the three spindles form sealed chambers, the
throttle gap. flows via the grooved ball bearing (7) contents of which are continuously being moved
into the support and from there back into the main oil axially from the suction side to the pressure side of
the pump as the spindles rotate.

[1] 5.1-0100 Technical Data
[1] 5.1-0530 Hydraulic Lifting Device
5.1-1050/2
Steam Turbine Oil Throttle
Description
Arrangement
The oil throttles arranged immediately before the
bearing in the lubricating lines serve for adjusting the
necessary amount of oil for the bearings. While the
left half of the sectional view represents the oil throttle
during oil flushing, the right half shows the oil throttle
in normal operation.
Construction
The main parts of the oil throttle are the body (8),
in which either the oil strainer (7) which is held in
place by the screw plug (6), for the flushing process
or the adjustable throttle piece (5) with parts (1, 2, 3)
for normal operation are inserted.
Operation
The flushing process is carried out before the
turbine is taken into service. After the flushing, the oil
strainer (7) as well as the screw plug (6) are to be
exchanged with the throttle piece (5) and the screw
plug (3) with the capped nut (11. By Ineans of the
adjustable throttle piece, the cross section of the
passage is then adjusted for normal operation,
according to the necessary amount of the lubricating
oil and consequently the lubricating oil flow adapted
to the required oil exit temperature of the bearing.

Steam Turbine Oil Throttle
Description
Arrangement Operation
The oil throttles arranged immediately before the The flushing process is carried out before the
bearings in the lubricating lines inside the bearing turbine is taken into service. The strainer (7) is
pedestals serve for adiUsting the necessary amount installed in final stage of flushing. The oil strainer (7)
of oil for the bearings. While the Fig. 1 represents the as well as the blind cover (6) are to be exchanged
oil throttle during normal operation, Fig. 2 shows the with the throttle spindle (1), cap nut (2), nut (3) and
oil throttle during final stage of oil flushing. cover (4). By means of adjustable throttle, the cross
section of the oil passage is then adjusted for normal
operation. according to the necessary amount of the
lubricating oil and consequently the lubricating oil flow
adapted to the required oil exit temperature of the
bearing.

Steam Turbine Three-way Control Valve
Description For Lubricating Oil Temp, Control
Description
The three way temperature control valve has the

function of regulating the lubricating oil temperature
at 45 °C. Possible oil flow paths for regulating the oil
temperature are:
All lubricating oil flows through oil cooler.

Lubricating oil flows through oil cooler and bypass
piping.
All lubricating oil flows through bypass piping.
Valve Type
Three way Angle Valve with Electric Actuator.

Steam Turbine H.P. Control Fluid Pump
Description With LP Extraction
Description
The extraction or dual pressure pump is a vertical
rotary pump in multiple stages. It is attached to the
cover of the fluid tank and submerges in the
control1luid. Drive is provided by an electric motcr
located on the cover plats (1). Control fluid enters
the suction casing (10) from below and is conducted
into the LP control fluid circuit via the pressure pipe
(1 9) and into the HP control fluid circuit via pressure
pipe (23). The pump shaft is guided by a sleeve
bearing 111) in the suction casing and by bait bearings
(25) in the bearing support (4). The bearings and the
bevel gear coupling are lubricated from thp 1 st stage
pressure chamber, the sleeve bearing via a passage
in the casing, the bait bearings and the bevel gear
coupling via the lubricating pipe (22).
Assembly
The pump is delivered in assembled state and can
be placed as a unit on the tank and bolted to it. When
connecting the pressure pipe care must be taken that
the piping is not stressed when bolted.
Exchanging the Rotors

When the motor has been dismantled and the
pressure piping removed. the pump must be extracted
as a unit from the tank. After the suction casing has
been removed and the rotating wheel nut loosened,
the 1 st stage rotating wheel can be extracted. In order
to dismantle the other stages, the baffle ring and then
the stage casing are removed. It is expedient to renew
the seal rings when exchanging the rotating wheels.
The new clearance between seal ring and the neck
of the rotating wheel is 0.3 mm in diameter. The pump
is assembled in the reversed sequence.
Exchanging the Bearings 111 and 25)

The pump is first taken apart: loosen pump casing
from pressure piping and bearing support from the
cover plate; remove coupling half from the shaft by
means of special device; remove bearing securing
device; loosen bearing cap (2) and bait bearings. The
pump is assembled in the reversed sequence.
Adjusting Pump Rotor

During assembly the shaft is supported by the
sealing ring of the suction casing. The shaft is lifted
by means of the nut (2) until the rotor with shaft
shoulder and distance ring (24) sits firmly on the inner
ring of the bait bearing. Bearing nut is then secured
with threaded pin.

Steam Turbine Plate-type Filter
Description
Function
The plate type filter cleans the oil or fluid used in
the governing system.
Construction
The plate type filters are installed in Governing
and LP Bypass racks. Single stage plate type filters
are used in Lp Bypass racks while in Governing rack
the filter has three stages. The filtering elements are
arranged in parallel inside the casing. The main
components of the filter are: handwheel (1). filter top
(2), filter element (3), body (4) and sludge drain plug
(5).
Mode of Operation
The control fluid enters the body at the right hand
arrow and passes through the filter element (3). the
sludge being arrested on the surface ot the cartridges.
The clean fluid flows out to the machine.
Operation and Maintenance

To clean tpe plate type filter, use the handwheel
(1) to turn the filter cartridges. The sludge and dirt
removed collect at the bottom of the body (4) in the
sludge collection chamber. The handwheel (1) should
be turned 2 or 3 revolutions daily. Accumulated sludge
is to be removed at fairly long intervals when the plaht
is shut down by removing the screw plug (5). The
filter cartridges need not be removed.
Disturbance
If the filter is not given due attention and the
handwheel not turned regularly. it may happen that
the cartridges become so clogged that it is impossible
to turn the main spindle, and there is only a very slight
flow of fluid through the filter. In such cases. no force Do not take the cartridges apart, After the filter
should be applied under any circumstances. It is element, has been cleaned, place it back in the
relatively easy to correct this kind of trouble when position. It is possible that the gland in the filter top
the machine is shutdown: Remove the element from may become loose or sticky, In such cases tighten
the body carefully. The cartridges can now be cleaned the gland nut or replace the packing. Be sure not to
thoroughly by using a noncorrosive cleaning fluid. tighten the nut too m,uch so as to prevent the
perhaps with the aid of a brush. cartridges from being turned.

Steam Turbine Duplex Filter
Description for Pilot Control of Control Valves
Function Mode of Operation of Differential pressure Gauge

Duplex filters permit the dirty fiter elements to be
regenerated during operation. The casing is divided into two pressure ch:ambers
by a diaphragm se:aled piston. The first ch~mber is
Construction connected with the filter enterance and the other with
The puplex filter consists of two filter bodies and the exit. In the normal case ( P=O ), the piston IS
is fitted with a change-over device which enables the held in the zero position by a tension spring. On an
filter to be switched as desired. The filter bodies are increase in the differential pressure, the piston is
designed according to the pressure stage and the pushed against the tension spring. Each alteration in
relevant codes and the filter itself is designed to pressure corresponds to a certain piston setting. This
p.rovide safety,taking into account the differential position is transferred magnetically,i.e. with low
pressures.
Fig. 1 Duplex Fitter and Valve Changeover Device friction, to the indicating disc and the two contacts
outside the pressurized area. A certain red portion of
Installation of Duplex Filters the which occurs,for example,when filter
When the filter is being bolted to the foundation, contamination increases two viewing windows of the
the casing must not be subjected to any external indicating disc,and at specified switching points a
stresses. This also applies when the piping is being particular contact, thus correspond to the prevailing
connected .Care must be taken that the fluid flows differential pressure.
through in the correct direction. The directin of flow is
normally marked on the flanges of the filter bodies. Valve Changeover Device
The changeover device consists of two
Differential Pressure Gauge changeover valves arranged one above the other.
The function of the device is to measure and give Valve discs (4) that control the path of flow in the
a visual indication of’the variation in the differential valve casing are moved by means of a star-wheel
pressure via spindle that has a left and right hand thread. This
construction guarantees synchronized movement of
the two valves discs whereby one filter chamber is
switched on before the other chamber is switched
off, Without causing the flow to be interrupted .A visual
indicatqr on the upper valve casing shows the
prevailing direction of flow and switching.
Fig.2 Cylendrical Fitter Fig.3 Differential Pressure Gauge

Operating the Changeover Valve
The large arrow on the switching gauge (1) gives,

the direction of flow and the small arrow the switching
direction. Before operating the changeover device,the
pressure equalizing coak (2) must be open.
The duplex filter is switched to the other filter
chamber by turning the star-wheel (3) in the given
direction. By means of a turning lever,the valve discs
can be easily loosened, The star-wheel (3) is also
tightened to the end position by means of this turning
lever. The valve discs (4) open in the appropriate
direction of flow and the change-over process is then
completed. The cock of the pressure equalizing pipe
must then be closed so that one filter chamber is
hermetically sealed.
Start-up and Cleaning
Change-over device in intermediate position; both

filter chambers in operation
Open vents in both chambers
Start-up plant slowly
Close vents when air has escaped and fluid begins
to come out
Block one filter chamber by opening changeover
device. While the first filter chamber is filtering ,the
shut off chamber is in reserse until the permissible
differential pressure has been reached due to
contamination. When the permissible differential
pressure has been reached ,one must switch over
to the clean filter chamber .as follows:
Open pressure equalizing cock and check whether
the reserve chamber is full by opening the vents
for a short time
Change over
Close pressure equalizing cock.
Open vent in shut-off half; this relieves the control
,fluid and gives the possibility of checking whether
the changeover device has blocked the flow to
the filter chamber.
Disassemble the casing cover of the shutoff filter 1 Switching position indicator
chamber. 2 Pressure equalizing cock
Remove filter elements vertically in an upwards 3 Star-wheel
direction, 4 Valve disc
Clean mesh of filter element with appropriate
cleahing material and by blowing through the mesh
from the clean side (see filter cleaning Fig.4 Fuller’s Earth Filter
instructions). be taken that the fluid in the casings is not under
Re-insert cleaned filter element. pressure.
Close casing through cover; vent is still open. Unscrew switching gauge.
Before replacing cover,take care that condition Loosen valve discs by turning star-wheel
and position of seal are perfect. If necessary Disassemble upper cover.
change seal.
Unscrew valve stem with valve disc(4).
Open pressure equalizing cock until filter half is
deaerated. Check sealing rings and renew if necessary.
Close vent filter half is reserve again. This process Screw valve stem with valve disc(4) back again.
is to be repeated from point 6, as necessary Close casing with cover.
Assemble switching gauge.
Removal and Installation of Changeover Valve Disassemble lower cover.
Belore removing the changeover valve, care must Unscrew Valve stem with valve disc.
5.1-1130/2
Clearing the Filters
1. Normal Cleaning
1.1 With multi-part filters, each element is cleaned
in dividually.
1.2 Brush the individual elements with a not too hard
brush and suitable cleaning agent over a bath
or container and rinse.
1.3 Blow compressed air from the clean side
through the filter that has been cleaned in this
vo/ay in order to remove any dirt particles
caught in the filter mesh. The cleaning process
can be carried out with filter cleaning apparatus
(Fig. 5).
Application according to Item 2.3
2. Cleaning Obstinate Dirt

2.1 Place complete filter in a container with a
cleaning agent for several hburs or spray
repeatedly at short intervals.
2.2 ‘treat filtur elements as described under 1.2 and
1.3.
2.3 Using filter cleaning apparatus (Fig.5! and
suitable agent, blow through filter thoroughly
from clean side.
3. Cleaning Disassembled Filter Elements

(Only with bolted construction)
Only when absolutely necessary to be
performed with great care.
3.1 loosen all nuts (a) on respective filter element Fig. 5 CIeaning device for filter element.
and remove.
3.2 Dotach lower filter plate (b)
3.3 Detach filter casing (c) 4. Cleaning Agents
3.4 Remove support pipe (d) Suitable cleaning agents are e.g. air, water,
3.5 Clean strainer basket (c) as in Item 2 steam, Tri-Perchlorethylene, petrol, benzene,
3.6 Clean all parts. also upper filter plate (g) and diesel oil, etc.
stay rod (e)
3.7 Check all seals (f) and strainer basket (c) for The application depends on their cleaning
damage and renew if necessary capacity and their compatibility with the media
3.8 Assemble filter elements and bolt firmly. Care to be filtered.
must be taken here that strainer basket and
seals sit properly.
5.1-1130/3
Steam Turbine Regenerating Plant
Description
General The Fuller’s earth needed for regenerating the fire

Of the various types of fire resistant fluid, the only resistant fluid must be dry (at 10SoC the amount of
ones suitable for use with our turbines are phosphoric expellable water must only be 1% of the weight).
esters of the group HS-D which have a low water The US strainer number 30/60 mesh is the
and chlorine content. granular size to be used (or this must correspond to
Their chemical composition and structure the details from the fluid manufacturer). The dust
necessitate certain measures and alterations proportion of the, granulate must not be used. The
compared with an oil system. amount of earth must not be too little and must be
Fire resistant fluid systems for our turbines are stamped or shaken to avoid the formation ‘of’ gaps
provided with a bypass regenerating plant. The design and channels which would reduce the effectiveness
of this plant is made to the specifications of the fluid of the Fuller’s earth.
manufacturer. Any acids and ageing products are The efficiency of the regenerating plant is to be
removed during operation by the continuous filtering controlled by an exact record of the neutralization
through Fuller’s-earth and mechanical filters. value and the degree of purity.
The mode of operation of this natural earth
treatment is based on a ion-exchange reaction. In Construction of Regenerating Plant
addition to the precautions against acidifying of the The filter group consists of 2 Fuller’s earth filters
fluid, continuous care is taken that any solid particles (6) and a mechanical Filter (7). The cleaning and
are separated by the fine filter so that they can not deacidifying takes place in a separate circuit. A pump
speed up the reaction. The fine filter of this plant (4) conducts a constart amount of fluid through the
retains particles of Fuller’s earth as well as providing filter group into the tank (1). When the filter is
the essential cleanliness of the whole system and contaminated there is an
increasing the life of the filters.

increase in the fluid pressure. A spring safety valve
(3) is installed to protect the system against an
excessively high increase in pressure.
Fuller’s earth Filter (Fig. 2)

The Fuller’s earth filter contains three sections with
a special granulate which binds the acid present. Two
filters work in parallel and. can not be switched over.
Mechanical Fine Filter (Fig. 3)

Following the Fuller’s earth filters is a fine filter
with textile inserts of finest mesh. These inserts retain
the finest particles of dirt, both metallic and
nonmetallic impurities. In this way the fine filter also
serves the safety of the control fluid system by
trapping any particles of granulate that may be
circulating. The fine filter also separates water
particles and other ageing materials which would
make it necessary so renew the control fluid too soon.
Commissioning and Maintenance of the Filter

Plants
The filters are to be continuously deaerated by
slightly opening the vent valve.
Observe pressure increase on pressure gauge
The acid content must be checked by examining
the fluid in the laboratory at certain intervals.
If there is a constant increase in the acid value.
the granulate is exhausted and must be replaced
earlier than originally intended.
The increasing contamination of the filter can be
measured by the constant increase in pressure.
The differential pressure indicators installed in the
system show optically the degree’ of
contamination. When the white-red segments are
only showing red, the filter material must be
changed.
1 Connection for pressure gauge
Exchanging the Earth Filling (Fig. 2) 2 Connection for air exhaust
3 Connection for safety valve
4 Control fluid Inlet
Switch off pump
5 Contrul fluid outlet
Open filter drain (6). Drain Filter (Flg.2)
6 Connection to drain tank
Loosen cover bolts 7 Filter basket with gauge
Lift cover -do not damage seal
Loosen .drain pipe screws and lift basket cover Fig. 2 Fuller’s Earth Filter
Extract filter basket (7) carefully and centrally
Clean inside of filter casing
Clean filter basket (7)
After cleaning care must be taken that the parts
are completely dry Insert clean basket cover and tighten well with
Fill filter basket and Insert. The earth must be screw so that no Fuller’s earth can escape
carefully pressed down-without force -so that the Close drain (6).
sections are filled compactly in order to prevent Replace cover carefully and tighten uniformly by
later setting of the earth and the possible formation means of screws (pay attention to seal)
of channels Switch on pump (4).
5.1-1140/2
Instructions for Installation of Filter Cartridges
of Fine Filter (Fig.3)
The filter cartridges (8) are to be immersed in the
control fluid before the first commissioning and
installed in the filter. The cartridges must be placed
above the drain pipe so that the large opening of the
filter cartridge faces downwards. By inserting the
rubber and metal discs and the clamping springs in
this sequence, the filter cartridges are stressed by
means of the clamping screws to equalize an
alteration in the length of the filter cartridge column.
Means of Cleaning
The following are to be used for cleaning:
Textile and paper cloths without threads, benzine,
white spirit, trichloroethylene, perchloroethylene and
compressed air.
When using these, the respective accident
prevention rules are to be observed.
Remains of cleaning materials are to be Carefully
removed (when chlorinated hydrocarbon is used there
must be no increase in the chlorine content of the-
FRF).
Each newly cleaned surface is $usceptibJe to
corrosion. In order to protect the surfaces, therefore,
they must be moistened With FRF or a corrosion
protection medium compatible with FRF immediately
after cleaning.
1 Connection for pressure gauge

2 Connection for air exhaust
3 Connection for safety valve
4 Control fluid inlet
5 Connection for thermometer
6 Control fluid outlet with flow gauge
7 Connection for sludge outlet and drainage
8 Filter cartridges
Fig. 3 Mechanical Fine Filter
5.1-1140/3
Steam Turbine Operation of the Turbine
Operation Introduction
In the Operation section of the manual the steps state thermal stresses affecting the steam admission
of startup, power operation and shutdown of the area, and the turbine dedicated computing channels
turbine are given. perform on going calculations of material fatigue. This
allows turbine operation within aset envelope against
Also, the activities that must be performed during various permitted stress types or loading
shutdown to maintain operability are described. combinations. Temperature margins are indicated on
CRT during all operating conditions.
Basic knowledge of operation and monitoring of The turbine can be operated in line with three
turbines are taken for granted. Further knowledge different stress limits or operating modes viz. ~ast,
gained during the commissioning period gives the Normal and Slow, which are selected by operator
operating staff a more complete understanding of action. To safeguard shaft material, switch over from
turbine generator operation. slow to normal or fast mode is not permitted until the
temperature in shaft center line exceeds 100 °C.
Role of Turbine Stress Controller (TSC) Beyond this point, it is possible to switch over from S
The function of TSC is to continuously monitor (slow) to N (normal) mode or from N to F (fast) mode
and evaluate the main components of turbine viz. at any time. However. before the TSC enables switch
Main steam stop and control valve, HP rotor, HP over from F mode to back to N mode or from N to S
casing and IP rotor in respect of their material limits mode, it automatically checks whether there will still
and fatigue life. It monitors the operational non steady be a positive temperature margin of 15 °C in the new
mode once this change over has been affected.

Steam Turbine Specification of Steam, Oil and
Operation Control Fluid
The efficiency of turbine and functioning of its Turbine Oil

components depend, among other things, on whether Oil Specifications guideline (3) lists the
the steam quality and the properties of the operating requirements for the operating fluid. Also maintenance
fluids fulfil the requirements listed in the Description instruction on Oil Care (4) should be followed. Regular
section of this manual. Particular care should always sampling and laboratory checks. will indicate that .the
be takeh during startup that the purity and the physical turbine oil complies with the specifications.
1\ chemical properties comply with the turbine The purity (freedom from liquid and solid
manufacturer’s guidelines. impurities), air-release properties and foaming
characteristics of the oil are important to the
Steem Purity functioning of the turbine generator unit’s
The steam purity must comply with the guideline components.
on ‘Steam Purity’ (1) before startup and power
operation is begun. Control Fluid
Blade deposits reduce the efficiency. Deposits can The guideline ‘Control Fluid’(5) has the
only be removed by time-consuming processes 12) requirements for this operating fluid. The maintenance
and occur during power operation when normal instruction ‘Cafe of Control Fluid’ (6) should also be
values are exceeded. followed. Regular sampling and laboratory checks,
Immediate corrective action must be taken to will indicate that the control fluid complies with the
restore the required steam Quality specified in the specifications.
guideline (1). The purity (freedom from liquid and solid
impurities). neutralisation coefficient as a
characteristic for ageing. air-release properties and
foaming characteristics of the fluid are important to
the functioning of the turbine generator unit’s
components.

[1] 5.1-0120 Steam Purity Required Values
[2] 5.3-0070 Steam Washing of Turbine
[3] 5.1-0310 Oil Specification
[4] 5.3-0080 Oil Care
[5] 5.1-0140 Fire Resistent Fluid
[6] 5.3-0082 Care of Control Fluid

Steam Turbine Testing of Turbine Components
Operation General
Introduction Countermeasures for Off-normal Conditions

The operational reliability and a,’ailability of a
turbine is assured only if all the vital components and It is recommended that all off-normal conditions
monitoring equipment for operation are inthe specified detected in the course of testing be eliminated by the
condition at all times. countermeasures specified in the remedial action and
This applies particularly to : maintenance instructions in the turbine manual.
controllers In some cases the desired condition may be
protective devices restored sooner or prevented from deteriorating if the
safety devices testing intervals are shortened. Use of this opportunity
stop and control valves and other important turbine is recommended. Shorter testing intervals also make
valves it easier to detect and monitor any progressive
monitoring equipment deterioration in the condition of component.
On this basis, the optimum timing for the
The unit’s operating parameters can provide necessary remedial actions may be determined in in
important information on the condition and reliability the light of other factor, requiring consideration.
of the turbine unit and its systems,
Performance of Tests
Testing Intervals Tests are generally performed by the operator’s
The following recommendations for time properly qualified plant personnel.
Intervals between tests have been compiled on the As a rule the performance testing should be
basis of experience gained by the turbine executed immediately after mauntenance or overhaul
m,nufecturer end the operators. activities, such as major insprection, in the presence
of qualified personnel concerned form BHEL.

Steam Turbine Turbine System-Testing
Operation Testing Intervals-Controllers
Component Test Cycle Plant

- Type of test After start -Up Status
after shutdown>1 month
during of after overhaul
shutdown
monthly
running
Weekly
yearly
Turbine Governor
- function 1 x x x
- setting x x
Loed Shedding Relay

- function x x
- setting x x
Bypes Controller
- function 3 x x x
- setting x x
Seel Steam Controller

- function x x
Fluid Temperature Controller

- function x x
Oil Tempereture Controller
- function x x

Operation Testing Intervals
Automatic Turbine Tester

shutdown
monthly
running
Weekly
yearly
Automatic Turbine Tester for Protective Devices
- functioning of remote trip solenoid 2 x x x
- functioning and setting of overspeed trips
- functioning and setting of hydraulic low vacuum trip

Operation Testing Intervals -
Automatic Turbine Tester

shutdown
monthly
running
Weekly
yearly
Automatic Turbine Tester for Stop and Control Valves 1 x x x
- free movement of stop valves
- free movement of control valves

Steam Turbine Turbine System Testing
Operation Testing Intervals - Protective Devices

shutdown
monthly
running
Weekly
yearly
Main Trip Valves
- functioning and breakaway pressure x x x
Overspeed Trips
- functioning and setting during testing with x x x
hydraulic test signal transmitter
- functioning and setting during testing by overs peed 1 x x
Thrust Bearing Trips

- functioning x x
Hydraulic Low Vacuum Trip

- functioning and setting x x
Electrical Low Vacuum Trip

- functioning and setting 6 x x
Bypass Mode Low Vacuum Trip

Reverse Power Protection

- functioning at each shutdown 1 x x x
Oil Starvation Trip

- functioning and setting 1 x x
Turbine Fire Control System

- functioning 1 x x x
- alarms 1 x x x
Alarms from Protective Devices

.functioning and setting of binary signal transmitters 3 x x

Operation Testing Intervals - Safety Devices

shutdown
monthly
running
Weekly
yearly
Safoty Valves
- functioning and set pressure x
Rotary Pump Relief Valves .

- functioning and set pressure x x
Subloop Control for Auxiliary and Emergency Oil Pumps

- functioning 3 x’ x x
- setting of pressure switches x x
Automatic Changeover Units for Control Fluid Pumps

- functioning 3 x’ x x
- setting of pressure switches x x
ExtractIon NRV Checks

- functioning 1 x x
- setting of differential pressure switches x x x
At each shut-down and startup

Operation Testing Intervals - Valves

shutdown
monthly
running
Weekly
yearly
Stop Valve
- free movement x x x
using starting and load limiting device.
test valve or trip actuation
- breakaway pressure x x
- leak tightness at each startup x x x
Control Valve
- free movement x x
using starting and load limiting device.
test gear or trip actuation
- leak tightness 1 x x
(in conjunction with test of reverse power protection at
each shutdown)
- free movement x x
(observe control valves lift at each load change) 1 x
Extraction Valva
- free movement 2-4 x x x
by observation of position indicators
Vacuum Breaker
- functiorting at each shutdown 1 x x x
CRH NRV
- free movement 2 x x x
by operating pushbutton on desk

Operation Testing Intervals - Monitoring Devices

shutdown
monthly
running
Weekly
yearly
Alarms
- functioning x x
Binary Signal Transmitters

Speed Indicators
Temperature Gauges
Expansion Measuring Devices
Vibration Me8suring Devices
liquid Level Measuring Devices
Valve lift Transducers
- accuracy of indication 3 x x x

Operation Testing Intervals - Operating Parameters

shutdown
monthly
running
Weekly
yearly
Steam Pressures
Steam Temperatures
Steam Mass Flow Rates
Casing Temperatures
Be8!lng Metal Temperatures
Expansion
Vibration
liquid Levels
Oil Pressures
Oil Temperatures
Control Fluid Pressures
Control Fluid Temperatures
- recording of operating values for long term monitoring 3 x x
purposes

Steam Turbine Starting the Turbine
Operation
Introduction compiled so that with their help the turbine generator

Startup of the turbine and auxiliary systems must unit can be started up from the control room by
always be pe~ormed to ensure operational reliability operating the control devices by watching the analog
and economy. displays.
Startup is a phase where almost all operating The schematics have added instructions that must
values are subject to change, monitoring of these be followed during startup or operation of the system.
transient operating state by the monitoring Instrumentation and control functions are given in A
instrumentation demands close attention. TAS functional schematics. To maintain operational
It is very important that all control operations are reliabiiity and economy, certain tests must be
always performed in the recommended sequence. performed during all phases of turbine operation. This
To fulfill these requirements, startup schematics furnishes information on the condition of turbine
are prepared to show all control operations and generator components.
monitoring criteria for the turbine and its auxiliary Since some tests must be carried out before or
systems. during the startup phase, a list of the tests and their
The startup schematics of the turbine manual are intervals (1) is given at the beginning of the system-
startup schematics.
Also refer of the following sections

[1] 5.2-0020 Testing of Turbine Components

Steam Turbine Startup and Shutdown Diagrams
Operation Symbols
The symbols commonly used in other operating schematics are nominal values and may deviate from
documents are used for the startup and shutdown the actual values recorded in the logs and from the
schematics. actual settings of the binary signal transmitters.
Insofar as symbols with indices are used instead
Normally, the checkback from the execution of a of values, only the values recorded in the logs shall
switching or control operation also constitutes the be used.
enabling criterion for the following switching or
operating step. Symbols used:
If there are other criteria to be fulfilled before a + interrogation from the control room
step can be enabled, these criteria are listed prior to = interrogation from the local control station
the first or next step, as the case may be. – interrogation at equipment
(N) + manual switching operation from control
Unless otherwise stipulated. the criteria are and room
gated, i.e. all criteria must be fulfilled. (N) = manuacl switching operation from local
control station
An or gate between two or more criteria indicates (N) - manual svvitching operation at equipment
that one of several criteria must be fulfilled. ** switching operation triggered automatically
(can, however, also be performed manually
The symbols and rules apply to all schematic
from control room)
representations of control operations contained in the
* switching operation triggered automatically
turbine manual.
(can, however. also be performed manually
References to further explanations are identified from local control station)
in the schematics by the number of the instruction * switching operation triggered automatically
concerned. The operating values given in the (manual actuation not possible)

Steam Turbine Startup of Turbine / Generator
Operation Startup Diagram (General)
(01) + TURBINE/GENERATOR START UP PREPARE REF. TO 5.2-0133

+ PREPARATION FOR START UP COMPLETED
(02) + EXTERNAL SYSTEMS READY FOR OPERATION CHECK
CIRCULATING WATER FOR CONDENSER AVAILABLE
COOLING WATER FOR COOLERS AVAILABLE
AUXILIARY STEAM AVAILABLE
DEMINERALIZED WATER SUPPLY AVAILABLE
CONDENSATE SYSTEM READY FOR OPRN.
VACUUM PUMP READY FOR OPRN.
THE EXTERNAL SYSTEMS DO NOr BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAMS OF SYSTEMS.
INSTRUCTIONS OF EXTERNAL SYSTEMS MUST
AGREE WITH TURBINE OPERATION.
+ EXTERNAL SYSTEMS READY FOR OPRN.
(03) + OIL SYSTEM AND TURNING GEAR START REF. TO 5.2-0130
START OF OIL SYSTEM APPROX.6 HOURS
PRIOR TO TURBINE START.EXTEND
TIME IN ADVANCE OF TURBINE START IF
OIL TEMPERATURES ARE EXTREMELY LOW.
WITH FGA (OIL SUPPLY)
OR
MANUAL OPER. AT OPER. CONSOLE
FGA=FUNCTIONAL GROUP AUTOMATIC
+ SHAFT TURNS
– CF-RECONDITIONING-PLANT AND HEATERS IN OPERATION
PRIOR TO CONTROL PUMP OPERATION THE
CONTROL FLUID TEMPERATURE SHOULD BE > 20°C
TEMP. RATE DURING HEATER OPERATION 1-2 K/H
START OF OPERATION OF RECONDITIONING
AND HEATERS IN ACCORDANCE WITH INITIAL
TEMPERATURE AND HEATING RATE.
OPERATE RECONDITIONING PLANT CONTINUOUSLY
IF NEUTRALISATION NUMBER TENDS TO INCREASE
+ TEMPERATURE IN CONTROL FLUID TANK > 20°C
(04) + CONTROL FLUID SYSTEM START REF. TO 5.2-0135
WITH FGA (CONTROL FLUID SYSTEM)
OR
MANUAL OPER.AT OPER.CONSQLE
+ CONTROL FLUID SYSTEM IN OPERATION
(05) + CONDENSING PLANT START REF.TO 5.2-0140
TIMING OF CONDESING-PLANT START MUST
AGREE WITH TIMING OF FIRST STEAM ENTERING
THE CONDENSING PLANT
THE CONDENSING PLANT DOES NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAM OF SYSTEMS.
INSTRUCTIONS OF THE MANUFACTURER OF THE
CONDENSING PLANT MUST AGREE WITH TURBINE
OPERATION.
+ CONDENSATE PUMPS ON
WITH FGA (CONDENSING PLANT)
OR
MANUAL OPER.AT OPER.CONSOLE

+ VACUUM PUMPS ON
WITH FGA (CONDENSING PLANT) :
OR
WITH SLC(AIR REMOVAL)
OR
MANUAL OPER, AT OPER, CONSOLE
+ SEAL SYSTEM SUPPLY ON

WITH SLC (SEAL STEAM)
OR
MANUAL OPER, AT OPER,CONSOLE
+ VACUUM < P AMB
+ SEAL STEAM PRESSURE > P AMB
(06) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION
+ CRITERIA FOR BYPASS OPERATION FULFILLED

(07) + START OF BYPASS OPERATION OBSERVE REF. TO 5.2-0150
(08) + MAIN STEAM (MS) LINE WARM UP REF. TO 5.2-0160

WITH FGA (TURBINE CONTROL)
OR
+ MAIN STEAM (MS) LINE WARMED UP
(09) + CRITERIA FOR WARMING UP TURBINE CHECK
(10) + TURBINE WARM UP REF. TO 5.2-0160

OR
+ TURBINE WARMED UP
+ CRITERIA FOR SPEEDING UP TURBINE/ FULFILLED
GENERATOR
(11) + TURBINE/GENERATOR TO RATED SPEED SPEED UP REF. TO 5.2-0160

OR
+ TURBINE/GENERATOR SPEED 3000 RPM
+ CRITERIA FOR SYNCHRONISING FULFILLED
(12) + GENERATOR BREAKER ON REF. TO 5.2-0210

OR
AUTOMATIC SYNCHRONISER
+ GENARATOR SYNCHRONISED
+ LOADING CRITERIA FULFILLED
(13) + TURBINE/GENERATOR LOAD REF. TO 5.2-0210
5.2-0112/2
Steam Turbine Preparation for Startup
Operation Startup Diagram
(01) - PRESERVATION DEVICES REMOVE

- AIR DRYER REMOVED
- CONNECTING FLANGES CLOSED
- AIR OUTLET SOCKETS CLOSED
(02) - INSPECTION OPENINGS CLOSE

MAN-OR HANDHOLES IN
- LP TURBINE
- CROSS AROUND PIPES
- CONDENSER
(03) + VOLTAGE SUPPLY SWITCH ON

+ DRIVES ENERGISED
+ REMOTE CONTROLS ENERGISED
+ CONTROLS ENERGISED
+ MEASURING DEVICES ENERGISED
+ ALARM DEVICES ENERGISED
+ SUPERVISORY EQUIPMENT ENERGISED
+ PROTECTIVE DEVICES ENERGISED
+ TESTING DEVICES ENERGISED
(04) + LIGHT BULBS FOR PANEL AND ALARMS CHECK

+ DEFECTIVE LIGHT BULBS REPLACED
(05) + MEASURING EQUIPMENT READY FOR OPERATION CHECK

+ CHECK OF O-SETTING CARRIED OUT
+ RECORDERS SWITCHED ON
+ RECORDERS TIME APJUSTED
(06) + LIQUIP LEVELS CHECK

+ LEVEL OF CONDENSER NORMAL
+ LEVEL. IN U-LOOPS NORMAL
+ LEVEL OF OIL TANK NORMAL
+ LEVEL OF CONTROL FIUID TANK NORMAL
(07) - FILTERS CLEAN
(08) + TEST PROGRAM (STANDSTILL) CARRY OUT REFER TO 5.3-0061

TESTING INTERVALS OBSERVE REFER TO 5.2-0020
(09) + TEST PROGRAM (STARTUP) CARRY OUT REFER TO 5.3-0030

TESTING INTERVALS OBSERVE REFER TO 5.2-0020
(10) + GENERATOR READY FOR OPERATION CHECK

+ GENERATOR HYDROGEN FILLED
+ SEAL OIL SYSTEM IN OPERATION
+ PRIMARY WATER SYSTEM IN OPERATION
+ OIL VAPOUN EXTRACTION IN OPERATION
+ SUBLOOP CONTROL OIL PL/MPS AND FANS ON
+ IMPORTANT OPER. VALUES GENERATOR NO ALARM
+ LIQUID IN GENERATOR NO ALARM

Steam Turbine Operating position of
Operation Manually Operated Valves
Introduction Symbols and definations

Most of the manually operated valves in a turbine • Measures for the setting of valves
generator unit have to be in a defined position prior - manually on location
to startup,and this position must be checked before = manually on the local control console”
the unit goes into operation. + manually in the control room”
*
Lead Sealing of Valves for remote controlled valves only
It is recommended that all valves, the position of
which remains unchanged during operation be se- • Operating positions
cured In position with lead seals. All that need then
be checked is that the seals are undemaged. Open
Closed
The valves which are secured with lead seals must Mode-Dep. = Mode-dependent (position
be indentlfied in the check list. varies with mode of operation,
cannot be classed as Open or
Closed) .
Permset = permanently set
Operational = ready to opetate(i,g, control
valves)
/FG = Position cannot be cQntrolled
manually (controlled by
automatic functional group
controls or by medium carried)

Steam Turbine Oil System and Turning Gear
(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES fGE!~ERAL) CHECKED
AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRAzNSMITTERS OPEN
VALVES BEFORE/AFTER PUMPS OPEN
PERMANENT VENTS’ OPEN
VENTS OF COOLERS OPEN
VALVES If-I FILLING LINES (PERMANENT) OPEN
VALVES BEFORE/AFTER FANS IN SERVICE OPEN
VALVES BEFORE/AFTER STAND BY FANS CLOSED
DRAIN VALVES OF COOLERS CLOSED
DRAIN V ALVES OF TANKS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN TEMPORARY V~NTS CLOSED
VENTS OF COOLERS (WATER SIDE) CLOSED
VENTS OF FILTERS CLOSED
VALVES IN TEr..1PORARY FILLING LINES CLOSED
V ALVES OF PRESSURE TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE PIPES FOR TESTING CLOSED
MULTI WAY VALVES OF COOLERS IN SERVICE
MULTI WAY VALVES OF FilTERS IN SERVICE
THROTTLE VALVES IN VAPOUR LINES ADJUSTED
SPEC. MAN. OPER. VALVES OF SYSTEM CHECKED
AND IN POSITION
THROTTLE VALVES IN JACKING Oil LINES ADJUSTED
RELIEF VALVE OF JACKING Oil SYSTEM ADJUSTED
COOLING WATER VALVES OF STANDBY CLOSED
OIL COLER
DRAIN OF OIL COOLER WATER SIDE OPEN
FILLING LINE OF STANDBY Oil COOLER CJIL SIDE OPEN
VALVE POSITION OIL PURIFYING PL!ANT ADJUSTED
+ OIL PUMPS READY FOR OPRN MAV22 APOO1
MAV23 APOO1
MAV24 APOO1
MAV31 APO01
MAV32 APOO1
MAV33 APOO1
OIL PUMPS ON MANUAL CONTROL SWITCH ON
OR
OIL PUMPS ON SUBlOOP CONTROL SWITCH ON
OIL PRESSURES NORMAL
+ OIL VAPOUR FAN (TURBINE) ON MAV82 ANOO1
OR MAV82 AN002
OR READY FOR OPRN MAV82 ANOO2
OR MAV82AN-OO1
+ OIL VAPOUR FAN (GENERATOR) ON MKO31 ANOO1
OR MKO32 ANOO1
OR READY FOR OPRN MKO32 ANOO1
OR MKO31 ANOO1
+ SUBLOOP CONTROL OIL VAPOUR FAN GEN. ON -----------------------
ONE our OF TWO VAPOUR FANS OF THE
TURBINE OIL TANK AND THE GENERATOR
MUST BE IN OPERATION AS LONG AS THE
GENERATOR IS FILLED WITH HYDROGEN.

ONE OIL COOLER OIL SIDE IN SERVCE MAV41 BCOO
OR MAV41 BCOO2
CHECK OIL COOLER(S)IN SERVICE AT THE

INDICATOR AT THE CHANGE-OVER VALVE(S)
DO NOT ADJUST ANY INTERMEDIATE POSITION
OF CHANGE-OVERVALVE
- COOLING WATER”’FOR OIL:COOLER(S) AVAILABLE
OPERATION OF THE COOLING WATER SYSTEM
ACCORDING TO SEPARATE INSTRUCTIONS NOT
INCLUDED IN THE TURBINE MANUAL
- SERVICE O!L COOLER (WATER SIDE) FILLED MAV41 BCOO1
AND VENTED OR MAV41 BCOO2
- COOLING WATER PIPE
- STAND BY OIL COOLER WATER SIDE DRAINED MAV41 BCOO1
IF THE OIL COOLER IN STANDBY CAN NOT BE AND QRIED OR MAV41 BCOO2
DRIED BY OIL FLOWING VIA THE FILLING
AND THE VENT LINE, THE OIL COOLER IN ST AND
BY MUST BE EXPOSED TO THE FULL FLOW OF
THE COOLING WATER ONCE WEEKLY TO
PREVENT DEPOSITS CAUSING CORROSIVE
ATTACKS TO THE MATERIAL
+ SLC OIL TEMPERATURE CONTROL
THE OIL TEMPERATURE CONTROLLFCAN!BE
SWITCHEDDN10fi)= MANUALLY. IT ALSO GETS
ON/OFF COMMANDS FROM FGA ON FULFiLLMENT
OF CERTAINCRlA
- OIL LEVEL IN TANK ‘1’ ‘j:1 NORMAL MAV10 CL521
COMPARE ACTUAL VALUES WITH ST AND~
STILL CONDITION VALUES OF OIL PUMPS.
- OIL FILTERS INCLUDING STANDBY FILTERS READY FOR OPEN
FILTER ELEMENTS CLEANED OR REPLACED
- OIL PROPERTIES NORMAL
OIL CLEAR.
NO COLLECTION OF WATER AT THE BOTTOM
OF THE OIL TANK.

+ MANUAL OPERATED VALVES GENERATOR ADJUSTED
REFER TO GENERATOR MANUAL
, + GENERATOR HYDROGEN FILLED
+ HYDROGEN PURITY > 97% MKG25 CQO01
+ SEALL OIL PUMP AIR SIDE ON MKW11 APOOl

OR MKW21 APOO 1
+ STANDBY SEAL OIL PUMP AIRSIDE OFF MKW21 APOO 1
OR MKW11APOO1
AND MKW31 APOO1
+ SEAL OIL PUMP GAS SIDE 0N MKW13 APOO 1
THE DC SEAL OtL PUMP WILL ONLY BE
OPERA TED ‘iF’T~E AC POWER SUPPlY
IS FAULTY
+ SUBLOOP CONTRSCOF SEAL OIL PPS. ON

THE SEAL OIL PLANT MUST ALSO BE IN AND
OPERATION IF THE TURNING GEAR
WILL BE OPERATED EVEN THE GENERATOR
IS NOT FILLED WITH HYDROGEN.
+ SEAL OIL SYSTEM NO ALARM
+ LIQUID IN GENERATOR NO ALARM AND MKA22 CLOO1

ANDMKA23 CLOO1
AND MKA23 CL011
5.2-0130-01/2
(O3) + CRITERIA FOR BEGIN OF START UP CHECK
IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE STARTED UP FROM
STANDSTILL
+ AUXILIARY OIL PUMP OFF MAV22 APOO1
AND MAV23 APOO1
+ EMERGENCY OIL PUMP OFF MAV24 APOO1
THE DC EMERGENCY OIL PUMP WILL OPERATE
IF AC POWER SUPPLY FAILS
+ TURNING GEAR OIL VALVE CLOSED MAV51 AAO01
AND
+ SUBLOOP CONTROL TURNING GEAR OFF MAV51 EEO01
+
SUBLOOP CONTROL OF AUX OIL PUMPS OFF MAV.. EEOO1

AND
+ SUBLOOP CONTROL EMERGENCY OIL PUMPS OFF MAV24 EEO01
+ JACKING OIL PUMPS OFF MAV31APOO1
AND MAV32 APOO1
AND MAV33 APO01
i AND
+ SBULOOP CONTROL JACKING OIL PUMPS OFF MA V30 EEOO 1
` AND MAV33 EEO01
(04) + FGA OIL SYSTEM START

FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THE FGA
OR
+ OIL SYSTEM MANUAL OPERATED START
.
(05) + AUXILIARY OIL PUMP SWITCH ON MAV22 APO01
OR MAV23 APO01
+ AUXILIARY OIL PUMP ON MAV22 APO01
OR MAV23 APO01
OR WITH FGA OIL SUPPLY
(05/S) + AUXILIARY OIL PUMP 1 ON MAV22 APO01

OR AUXILIARY OIL PUMP 1 FAULTED MAV22 APO01
+ AUXILIARY OIL PUMP 2 MANUAL OPERATION ON MAV23 APO01
+ OIL PRESSURE > 5 KG/CM2 MAV21 CPO01
+ LUB OIL PRESSURE > 1.2 KG/CM2 MAV42 CPO01
+ OIL LEVEL IN TANK NOALARM MAV1O CLOO1
’ + FILTER LUB OIL SYSTEM NO ALARM
DIFERENTIAL PRESSURE ACROSS FILTER NOT HIGH MAV42 CP013
PRESSURE BEHIND FILTER NOT LOW MAV42 CPO14
LOCAL INDICATOR NOT INITIATED MAV42 B1001
CHECK STAND BY FILTER BY LOCAL
CHANGE OVER
(06) + TURNING GEAR OIL VALVE OPEN MAV51 AAO01

+ TURNING GEAR OIL VALVE OPEN MAV51 AAOOl
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL TURNING GEAR SWITCH ON MA V51 EEOO 1
+ SUBLOOP CONTROL TURNING GEAR ON MAV51 EEO01
+ OR WITH FGA (OIL SUPPLY)
(06/5) + SUBLOOP CONTROL TURNING GEAR ON MAV51 EEO01
SUBLOOP CONTROl OPENS AND CLOSES THE
TURNING GEAR OIL VALVE DEPENDING ON
TURBINE/GENERATOR SPEED.
TURNING GEAR OIL VALVE (OPEN) < 210 RPM
TURNING GEAR OIL VALVE (CLOSED) > 240 RPM
TURNING GEAR OIL VALVECLOSES DURING
STARTUP AND OPENS WHEN THE TURBINE
IS COASTING DOWN .AFTER SHUTDOWN.
,
DO NOT SWITCH OFF SUBLOOP CONTROL
AS LONG AS TURBINE IS IN OPERATION TO
MAKE SURE TURNING GEAR CUTS IN IF
TURBINE WILL BE SHUTDOWN.

+ TURNING GEAR OIL VAlVE OPEN MAVs1 AAO01
+ OIL LEVEL IN TANK NO ALARM MA.V10 ClO01
(71) + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ` SWITCH ON

AND
+ SUBlOOP CONTROL OF Et”,ERGENCY Oil PUMPS SWITCH ON
+ SUBLOOP CONTROL OF AUXILIARY Oil PUMPS ON
AND
+ SUBlOOP CONTROL OF EMERGENCY Oil PUMPS ON
OR WITH FGA (OIL SUPPLY)(02)
(07/S) *+ SUBLOOP CONTROL OF AUXILIARY Oil PUMPS ON

AND
+ SUBLOOP CONTROL OF EMERGENCY Oil PUMPS ON

THE SUBlOOP CONTROLS START THE AUXILIARY
OIL PUMPS AND THE DC EMERGENCY OIL PUMPS
DEPENDING ON PRESSURE.
AUXILIARY Oil PUMP 1 < 4.8 KG/CM2 MAV21 CPO11
AUXILIARY Oil PUMP 2 < 4.5 KG/CM2 MAV21 CP012
AC EMERGENCY Oil PUMP < 1.1 KG/CM2 MAV42 CP011
DC EMERGENCY O.lL PUMP < 1.1 KG/CM2 OR MAV42 CPO 12
SIMULTANEOUSLY ALARMS WILL BE ACTUATED.
UBRICATING OIL PPESSURE MAv21 CP011
AND/OR
LUBRICATING OIL MAV42 CP011
THE SUBLOOP CONTROLS OF EMERGENCY OIL PUMPS
AND JACKING Oil PUMPS MUST NOT BE SWITCHED
OFF UNTil THE SHAFT STOPS COMPLETELY.
(08) + SEAL OIL PREs.SURE GENERATOR END CHECK
+ SEAL OIL PRESSURE AIR SIDE TURBINE END > P MIN MKW71 CP511
+ SEAL OIL PRESSURE AIR SIDE EXCITER END > P MIN MKW71 CP521
+ SEAL OIL PRESSURE GAS SIDE TURBINE END > P MIN MKW73 CP511
+ SEAL OIL PRESSURE GAS SIDE EXCITER END < P MIN MKW73 CP521
= SUBLOOP CONTROL OF SEAL OIL PUMPS ON
THE SUBlOOP CONTROL OF THE SEAL Oil PUMPS
START THE PUMPS DEPENDING ON SEL OIL PRESSURE.

P MIN ACCORD.lNcG,.TO ACTUAL H2 PRESSURE.
(09) +. JACKING OIL PUMP SWITCH ON MAV31 APO01,

OR MAV32 APO01
+ JACKING OIL PUMP ON MAV31 APOOl
OR MAV32 APO01
+ SUBLOOP CONTROL OF JACK1NG OILlPUMP SWITCH ON MA V30 EEOO 1
AND MAV33 EEOOl
+ SUBLOOP CONTROL OF JACKING OIL PUMP ON MAV30 EEOOl
AND MAV33 EEOOl
OR WITH FGA(OIL SUPPLY)

(09/S) + SUBLOOP CO~TROL OF JACKING OIL PUMP ON MAV30 EEO01
AND MAV33EEOO1
+ JACKING OIL PUMP ON MAV31 APOOr ‘

OR JACKING OIL MP FAULTED MAV31 APO01
+ JACKING Oil PUMP MANUAL OPERATlON ON MAV32 APO01
OR MAV33 APO01
SUBLOOP CONTROL STARTS AND STOPS THE
JACKING Oil PUMP 1 DEPENDING ON
TURBINE/GENERATOR SPEED CRITERIA.

JACKING OIL PUMP 1 ON < 510 RPM
JACKING OIL PUMP 1 OFF > 540 RPM
AND
SUBlOOP CONTROL STARTS THE JACKING OIL

PUMP 2 DEPENDING ON JACKING OIL PRESSURE
5.2-0130-01/4
Steam Turbine Control Fluid System
(01) + SYSTEM READY FOR OPERATfON CHECK
- MANUAL OPERATED VALVES (GENERAL) CHECKED CHECKED

AND IN POSITION
ROOT VALVES IN IMPULES-PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
PERMANENT VENTS OPEN
ISOLATING VALVES BEF/BEH CON- OPEN
TROL VALVES
ISOLATING VALVE IN CONTROL FLUID LINES OPEN
VALVES AHEAD OF HYDRAULIC ACCUMULARTORS OPEN
VENTS OF COOLERS OPEN
DRAIN VALVES OF COOLERS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN DRAINS OF PIPING CLOSED
VALVES OF PRESSURE-TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VENTS OF COOLERS (WATERSIDE) CLOSED
VENTS OF FILTERS CLOSED
MULTI-WAY VALVES OF COOLERS ADJUSTED
MULTI-WAY VALVES OF FILTERS ADJUSTED
- SPEC.MAN.OPER. .OF SYSTEM CHECKED

AND IN POSITION
COOLlNG- WATER VALVES OF CLOSED
STANDBY CONTROL.FLUID COOLER
DRAIN OF STANDBY CF- COOLER OPEN
WATERSIDE
VALVES IN RECONDITIONING PLANT ADJUSTED
+ CF-RECIRCULATION PUMP READY F OPE RAT MAX91APOO1
CF-PUMPS MANUALLY SWITCH ON

OR CF-PUMPS WITH SUBLOOP CONTROL SWITCH ON
CONTROL FLUID PRESSURESS NORMAL
CF-COOLER CF-SIDE IN SERVICE MAX41 BCOO1

OR MAX41 BCOO2
CHECK CF-COOLER IN OPERATION
AT LOCAL INDICATOR OF CHANGE
OVER VALVE.
DO NOT ADJUST ANY INTERMEDIATE
POSITION OF CHANGE OVER VALVE
- COOLING WATER FOR CF-COOLER AVAILABLE
- COOLER IN OPER. WATERSIDE FILLED MAX4i bt:~(;OI

AND VENTED ORMAX41 BCOO2
- COOLING -WATER PIPE VENTED
STANDBY CF-COOLER WATER SIDE DRAIND MAX41 BCO01

AND DRIED ORMAX41 BCO02
IF THE CF-COOLER IN STANDBY
CANNOT BE DRIED BY WARM
CONTROL FLUID FLOWING VIA
THE FILLING AND VENT-LINES
THE CONTROL-FLUID COOLER

IN STANDBY MUST BE FLUSHED
BY FULL WATER FLOW ONCE
WEEKLY TO WASH OUT-DEPOSITS
TO AVOID CORROSION ATTACK
OFTHETUBES.
+ CF- TEMPERATURE -CONTROL ON MAX01 DTO01

THE CF- TEMPERATURE CONTROL
CAN ALWAYS BE SWITCHED ON.
IF THE FUNCTIONAL GROUP
AUTOMATIC WILL RECHECK THE
MODE OF OPERATION OFTHE
CONTROLLER OR THE COMMAND
<ON> WILL BE GIVEN THE
CRITERIUM IS FULFILLLED AND
THE PROGRAM CONTINUES.
+ SETPOINT CF- TEMPERATURE CONTROL 55+5.5 CEL MAX11 CTO02

FIX SETPO1NT
+ CF-TEMPERATURE CONTROL VALVE CLOSED AX41AAO01

CF- TEMPERATURE IN TANK <55 CEL
+ LEVEL IN CONTROL FLUID TANK NORMAL MAX11 CL521

COMPARE ACTUAL VALUES WITH
TEST REPORT VALVES DURING
STAND STILL OF CF-PUMPS
+ CF-FILTERS IN SERV.AND STANDBY

FILTER-INSERT CEANED READY F OPE RAT
OR
FILTER REPLACED .
FILTER CODE NO REFER TO
SINGLE LINE DIAGRAM.
- CF-RECONDITIONING PLANT READY F OPE RAT

FILTER EARTH NOT EXHAUSTED.
SAMPLES OF THE CONTROL FLUID
MUST BE TAKEN AND ANALYSED
FOR PROPERTIES OF FLUID.
THE FILTER EARTH MUST BE
REPLACED IN REGULAR INTERVALVES
GIVEN IN INSTRUCTION
5.3-0082 OR IN SPECIFICATION.
MECHANICAL FINE MESH FILTER
NOT EXHAUSED OBSERVE DIFFERENTIAL
PRESSURE WHEN OPERATING
RECONDITIONING PUMP,
EARTH-AND MECHANICAL FILTER
FILLED AND VENTED
-START RECONDITIONING PUMP
-VENT FILTERS
-SHUT-DOWN RECONDITIONING PP
- DEAERATION OF CF- TANK READY F OPE RAT

AIR-FILTER: NO CHANGE IN
COLOUR.
EXHAUSTER FAN <ON>
5.2-0135-01/2
- CONTROL FLUID PROPERTIES NORMAL
REFER TO 6.3-0082
- CONTROL FLUID HEATER READY F OPERA T
(02) + CRITERIA FOR BEGIN OF STARTUP CHECK

IF THE FOLLOWING CRITERIA
ARE FULFILLED THE SYSTEM
WILL BE STARTED-UP FROM
< STANDSTILL> .
+ CONTROL FLUID PUMPS (CF-PUMPS) OFF MAX16APOO1
AND MAX16APOO2
+ SUBLOOP CONTROL OF CF-PUMPS OFF MAX16EEOO1
+ SUBLOOP CONTROL CF-HEATERS OFF MAX91EEOO1
+ CF-RECONDITIONING PUMP OFF MAX91 APO01
+ CF-TEMPERATURE IN TANK < 20 CEL MAX11CTO01
(03) + SUBLOOP CONTROL CF-HEATERS SWITCH ON MAX91EEO01

AND
+ CF-RECONDITIONING PUMP SWITCH ON MAX91APO01
+ CONTROL FLUID HEATER ON MAX91AHOO1

AND
+ CF-RECONDITIONING PUMP ON MAX91 APOO 1

THIS STEP HAS TO BE CARRIED
OUT IN DEVIATION FROM THE
FGA-PROGRAM TO SATISFY THE
CRITERION
CF-TEMPERATURE IN TANK > 20 CEL
TO START CF. PUMPS
(04) + CF-PUMP. FOR OPERATION PRESELECT MAX16APO01

OR MAX 16APO02
+ CF-PUMP. FOR OPERATION PRESElECTED MAX16APOO1
OR MAX16APO02
(05) + CONTROL. FLUID SYSTEM MANUAL START
OR WITH FGA < CONTROL. FLUID SYSTEM>
+ FGA < CONTROL-FLUID SYSTEM> START
OPERATION OF PUSH BUTTONS

REFER TO MANUAL FOR THE FGA-
FGA = FUNCTIONAL GROUP AUTOMATIC
+ CF-TEMPERATURE IN TANK > 20 CEL MAX11CTO01
(06) + ONE CONTROL FLUID PUMP SWITCH ON MAX16APOO1

OR MAX 16APO02
+ ONE CONTROL FLUID PUMP ON MAX 1 6APOO 1

OR MAX16APOO2
OR WITH FGA < CONTROL FLUID SYSTEM>

(06/S) + ONE CONTROL FLUID PUMP ON MAX16APOO 1
OR MAX16APO02
+ CONTROL FLUID PRESSURE > 28 BAR MAX31CPOO1
+ CONTROL FLUID PRESSURE > 5 BAR MAX41 CPOO 1
+ FILTER SUPERVISORY EQUIPMEt)iT NO ALARM
+ LEAKAGE SUPERVISORY EQUIPMENT NO ALARM
- LEVEL IN CONTROL FLUID TANK NORMAL MAX 11 CL621
(07) + SUBLOOP CONTROL OF CF-PUMPS SWITCH ON MAX16EEO01
+ SUBLOOP CONTROL OF CF-PUMPS ON MAX16EEOO1

SUB LOOP CONTROL OF CF-PUMPS
STARTS THE STANDBY PUMP IF
THE CF-PRESSURE BEHIND PUMP
DROPS TO < 28 BAR
(08) + SUBLOOP CONTROL CF-HEATER SWITCH ON MAX91AHO01

+ SUBLOOP CONTROL CF-HEATERS ON MAX91AHOO1
THE SUBLOOP,CONTROL OPERATES
THE HEATER DEPENDENT ON THE
FOLLOWING CRITERIA:
<ON> AT CF-TEMP. IN TANK < 55 CEL MAX1 1CTOO1
<OFF> AT CF-TEMP. IN TANK > 57 CEL MAX1 1CTO01
OR
< ON> AT THE HEATER < 50 CEL MAX91 CTOO 1
<OFF> AT THE HEATER > 65 CEL MAX91CTOO1
THE HEA TER- TEMPERA TURE-PRO-
TECTION WILL BE INITIATED
AT A TEMPERATURE AT HEATER > 75 CEL MAX91CTO02
THE SUBLOOP CONTROL INTER-
LOCKS THE HEATER, IF THE
CF- TEMPERATURE CONTROL VALVE
IS NOT CLOSED.
(08/5) + SUBLOOP CONTROL CF-HEA TERS ON MAX91 AHOO 1
(09) + CF-RECONDITIONING PUMP SWITCH ON MAX91 APO01
+ CF-RECONDITIONINGPUMP ON MAX91 APOO 1
(09/5) + CF-RECONDITIONING PUMP ON MAX91APOO1
(10) - FILTER OF RECONDITIONING PLANT VENT
THE STEPS (08) AND (09) MUST NOT

BE CARRIED OUT IF THE CF-
HEATER AND/OR THE RECONDITIONING
PLANT OPERATES PRIOR TO CONTROL
FLUID PUMP OPERATION.
5.2-0135-01/4
(04) + DRAIN OF SEAL STEAM HEADER OPEN MALe-1AA011
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
+ SUBLOOP CONTROL DRAINS SWITCH ON MALOOEEO01
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
POSITION OF DRAIN VALVE(S)
DEPENDING ON TEMPERATURE
CRITERIA IN HEADER
VALVE(S) <OPEN> STEAM-TEMP. < 120 CEL
VALVE(S) <CLOSEQ> STEAM-TEMP. >150 CEL
(05) + AIR SUCTION EQUIPMENT START

AND
+ SHAFT SEAL STEAM SUPPLY START
OR WITH FGA <CONDENSING PLANT>
+ FGA <CONDENSING PLANT> START
REFER TO MANUAL FOR THE FGA.
FGA=FUNCTIONAL GROUP AUTOMATIC
(06) + SEAL STEAM EXHAUST FAN SWITCH ON MA80ANO01

OR MAW80AN001
+ SEAL STEAM EXHAUST FAN ON MAW80ANO01
OR MAW80ANO02
AND
+ SEAL-STEAM CONTROL SWITCH ON ..........................
+ SEAL-STEAM CONTROL ON ..........................
AND
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP CONTR. <SEAL-STEAM> SWITCH ON ..........................
+ WARM-UP CONTR. <SEAL-STEAM> ON ..........................
OR WITH SLC <SEAL-STEAM
SLC=SUBLOOP CONTROL
(06/S)* + SEAL STEAM EXHAUST FAN ON MAW80ANO01
OR MAW80ANO02
AND
(06/S)* + SEAL-STEAM CONTROL ON ..........................

AND
(06/S)* + WARM-UP CONTR. <SEAL-STEAM> ON ..........................

BY STEAM FLOW THROUGH THE
WARM-UP VALVE THE STEAM-
TEMPERATURE UPSTREAM OFTHE
SEAL-STEAM SUPPLY VALVE
WILL BE INCREASED UNTIL THE
REQUIRED TEMPERATURE WILL
BE REACHED.
THE SEAL STEAM SUPPLY VALVE
MUST NOT BE OPENED UNTIL
THE TEMPERATURE CRITERIA
IS FULFILLED AND A MINIMUM
VACUUM IS REACHED IN THE
CONDENSER.
CRITERIA FOR OPENING THE
SEAL STEAM SUPPLY VALVE
STEAM-TEMPERATURE > 220 CEL
VACUUM < 0.7 BAR

(07) + VACUUM-PUMPS SWITCH ON
THE VACUUM PUMPS DO NOT BELONG
TO THE SCOPE OF SUPPLY OF THE
<TURBINE/GENERA TOR>.
OPERATION OF PUMPS AND VALVES ‘.
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION ,\CCORDING
TO SPECIAL INSTRUCTIONS. .
IOPERATION OF PUMPS AND VALVES
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION REFER
TO PLANT-MANUAL
+ VACUUM-PUMPS ON MAJ60ANO01
AND MAJ70ANO01
(08) + AIR-SUCT -VALVE VACUUM PUMP OPEN
+ AIR-SUCT-VALVE VACUUM PUMP OPEN
(08/S)*+ VACUUM PUMP ON MAJ60ANO01

AND MAJ70ANO01
+ VACUUM < 0.7 BAR MAG10CPO01
+ TEMP. AHEAD OF SEAL-ST. SUPPLY VLV > 220 CEL MAW10CTO01
(09) * + OPENINGOFSEAL-STEAMSUPPLYVLV OBSERVE MAW11AAO01
+ SEAL STEAM PRESSURE >P AMB MAW20CPO01
+ VACUUM < 0.15 BAR
(10) + VACUUM PUMP OPERATION CHANGEOVER

CHANGE IN OPERATION OF VACUUM-
PUMPS SERVES THE PURPOSE TO
HAVE ALL VACUUM PUMPS IN OPER-
ATION WHICH ARE NECESSARY
TO REMOVE AIR AND GAS FROM
THE CONDENSER DURINGOPER-
ATION. OBSERVE ALL CRITERIA -
INVOLVING VACUUM PUMP-OPER-
ATION.
GENERAL OUTLINE:
+ SERVICE VACUUM PUMP ON

AND
+ STARTUP A. STANDBY VACUUM PUMPS CFF
5.2-0140-01/4
Steam Turbine Bypass -System
Operation Start of Operation
(01) + SYSTEM READY FOR OPERATION CHECK
- MANUAL OPERATED VALVES CHECKED

ACCORD. TO LIST OF
VALVE-POSITION
AND IN POSITION
+ BYPASS-CONTROLLER ON
+ BYPASS-CONTROLLER NOT FAULTED
+ FIXPRESSUREREFERENCEVALUE KG/CM2
THE SErnNG OF THE FIX
PRESSURE REFERENCE VALUE
DEPENDS ON THE REQUIREMENTS
OF THE STEAM-GENERATOR
F.E. THE SYSTEM FLOW THROUGH
THEREHEATER.
THE SETPOINT HAS TO BE
RAISED DURING STARTUP TO
MEETTHE DESIGN-VALUE FOR
MINIMUM LOAD OF THE STEAM-
GENERATOR.
FIX PRESSURE REFERENCE
VALUE AS DESIGNED. ...KG/CM2
+ HYDRAULIC PRESSURE SWITCH DELOCKED

THE H’(DRAULIC PRESSURE
SWITCH MUST ONLY BE
BLOCKED FOR THE PURPOSE
OF TESTING.
(02) + EXT. SYSTEM READY F. OPERATION CHECK

EXTERNAL SYSTEMS = SYSTEMS
BEYOND THE SCOPE OF SUPPLY
OF THE TURBINE/GENERATOR
+ CIRCULATING WATER OF CONDENSER AVAILABLE
+ CONDENSATE PUMPS IN OPERATION
+ VACUUM-PUMPS IN OPERATION
+ VACUUM < 0,6 KG/CM2
(03) + INT. SYSTEM READY FOR OPERATION CHECK

INTERNAL SYSTEMS = SYSTEMS
WITHIN THE SCOPE OF SUPPLY
OFTHETUR8JNE/GENERATOR.

+ Oil SYSTEM IN OPERATION
+ TURNING GEAR IN OPERATION
+ CONTROL FLUID SYSTEM IN OPERATION
+ VACUUM-PUMPS IN OPERATION
+ VACUUM < 0,6 KG/CM2
(04) + STATE OF OPERAT. STEAM- CHECK

GENERATOR
+ STEAM-GENERATOR IN OPERATION
+ REHEAT PRESSURE/FIX PRESS. RELATION < 1

REF. VALUE
(05) + CRITERIA FOR BEGIN OF STARTUP CHECK
+ BYPASS STOP VALVE CLOSED MAN11AAO01

AND MAN12AAO01
+ BYPASS CONTROL VALVE CLOSED MAN11AAO02

AND MAN12AAO02
+ HYDR. SIGNAL OF BYPASS CONTROL < 1.0. KG/CM2
+ SP RAY WATER PRESSURE < 1.0 KG/CM2
+ REHEATPRESSURE/FIXPRESS. RELATION = 1
REF. VALUE
(06) + START OF BYPASS-OPERATION OBSERVE

BYPASS OPERATION STARTS IF
THE STEAM PRESSURE UPSTREAM
OF THE BYPASS VALVE MEETS
THE PRESS-REFERENCE VAlUE.
* + BYPASS STOP VALVE OPENS MAN11AAO01

AND MAN12AAO01
* + SPRAY WATER VALVES (STAGE 1) OPEN

DESIGNATLON OF THE SPRAY.
WATER VAlVES ACCORDING TO
SINGLE LINE DIAGRAM.
* + BYPASS CONTROL VALVE OPENS MAN11AAO02

AND MAN12AAO02
+ INTERLOCKS OF BYPASS-CONTROLS NOT INITIATED

THE BYPASS-CONTROL AND
STOP VALVES CLOSE IF THE
FOllOWING CRITERIAARE
FULFILLED:
VACUUM > 0.6 KG/CM2
SPRAYWATERPRESSURE < 9,5 KG/CM2
5.2-0150/2
+ LIMIT VALUE OF STEAM FLOW NOT INITIATED
THE LIFT OF THE BYPASS-
CONTROL VALVES WILL BE
LIMITED. IF THE LIMIT
PRESSURE IS REACHED
THE BYPASS-CONTROL VALVE
CLOSE. .
+ LIFT OF BYPASS-CONTROl-VAlVES 100%
(07) + FIXPRESSUREREFERENCEVAlUE SETHIGHER
+ FIXPRESSUREREFERENCEVALVE HIGHER
+ LIFT OF BYPASS-CONTROL-VALVES < 100%

THIS CASE CAN OCCUR IF
THE FIXPRESSURE REFERENCE
VALUE HAS BEEN REDUCED
BELOW THE DESIGN VALUE
DURING STARTUP.

Steam Turbine Warmup and Startup of Turbine
(01) + TURBINE READY FOR STARTUP CHECK

AND
+ MAIN STEAM LINES READY FOR WARMUP CHECK
+ MANUAL OPERATED VALVES OPEN.
(POSITION ACCORDING TO LINE DIAGRAM)
TEST VALVES OF STOP VALVES OPEN
HYDRAULIC VALVES OF EXTRACTION NRV OPEN
+ ELECTROHYDRAULIC TURBINE CONTROL ON
+ ELECTROHYDRAULIC TURBINE CONTROL NOT FAULTED
+ SPEED REFERENCE VALUE < N TURN GEAR
NORMALLY THE TURBINE WILL BE CONTROLLED
BY THE ELECTROHYDRAULIC CONTROLLER.
REFER TO 5.2-0180 FOR CHANGE OVER TO AND
OPERATION OF HYDRAULIC GOVERNOR
+ STARTING AND LOAD LIMIT DEVICE 0% MAX47 BYOO1
+ SPEED SETTER HYDRAULIC GOVERNOR 100 % MAX46 BYOO1
+ TURBINE STRESS EVALUATOR/CONTROLLER (TSE/TSC) ON
+ TSE/TSC NOT FAULTED
TSE/TSC TEST POSITIVE
NO ALARM
.NO FAULT INDICATOR ILLUMINATED
NO UNREASONABLE POSITION OF DISCS
+ TSE/TSC INFLUENCE ALWAYS ON
EXEMPTION: TSE/TSC FAULTY
CHANGE OVER WHEN DISTURBED. REFER TO 5.2-0430
IF THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURE AT THE MEASURING POINTS
WHICH REPRESENT THE THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED. REFER TO 5.1-011.
REF 5.2-0430 IF TSE/TSC ALLOWANCE IS REDUCED.
APPLIES TO ALL MODES OF OPERATION
+ TRIPPING DEVICE TURBINE PROTECTION NO ALARM
OVERSPEED TRIP MAY10 AAO01
AND MAY10 AAO02
IF STARTING AND LOAD LIMIT DEVICE > 20 %
+ ELECTRICAL TRIP NO ALARM
+ CASING DIFFERENTIAL TEMPERATURES NO ALARM
HP TURBINE CENTER TOP/BOTTOM < 90°C MAA50 CT051
AND MAA50 CT052
OR IP TURBINE FRONT TOP/BOTTOM < 30°C MAA50 CT043
AND MAA50 CT044
OR IP TURBINE REAR TOP/BOTTOM < 30°C MAA50 CT061
AND MAA50 CT062
CASING DIFFERENTIAL TEMPERATURES DETERMINE
THE DISTORTION OF THE TURBINE CASINGS

ALL REQUIREMENTS AS PER GENERATOR MANUAL
FULFILLED BEFORE STARTUP
+ GENERATOR BREAKER OFF
+ EXCITATION BREAKER OFF
+ SEAL OIL PLANT IN OPERATION
+ H2 PRESSURE P DESIGN MKG25 CPO03
+ HYDROGEN PURITY > 97% MKG25 CQO01
+ H2 TEMPEARTURE CONTROL ON
+ H2 TEMPERATURE CONTROL NOT FAULTED
+ PRIMARY WATER PUMP ON MKF12 APO01
OR MKF22 APO01
+ STANDBY PRIMARY WATER PUMP OFF MKF22 APO01
OR MKF12 APO01

+ PRIMARY WATER PRESSURE > P MIN MKF12 CPOOl
+ SUBLOOP CONTROL PRIMARY WATER PUMPS ON
+ PRIMARY WATER CONDUCTIVITY < 1,5 MYS/CM MKF35 COOOl
+ PRIMARY WATER TEMPERATATUREV CONTROL ON
+ PRIMARY WATER TEMPERATURE CONTROL NOT FAULTED
THE CRITERIA FOR THE GENERATOR HAVE TO
BE FULFILLED FOR ALL MODES OF OPERATION
WHICH CAN OCCURR,
+ DRAIN UPSTREAM OF MCV OPEN MAL11AA011

AND MAL AA011
+ DRAIN HP OUTER CASING OPEN MAL22 AAOll
CRITERION: TEMPERATURE HP TURBINE < 300 °C
OR
+ DRAIN HP OUTER CASING CLOSED MAL22 AAOll
CRITERION: TEMPERATURE HP TURBINE > 320 °C
+ DRAIN AHEAD OF SWING CHECK CRH NRV OPEN MAL65 AAOll
CRITERION: CRH NRV CLOSED
+ DRAIN BEFORE IP CONTROL VALVE OPEN MAL26 AAOll
AND MAL27 AAOll
+ DRAIN DOWN STREAM IP CONTROL VALVE OPEN MAL31 AAOll
AND MAL32 AAOll
CRITERION: VALVE CASING TEMPERATURE
MINUS SATURATION TEMPERATURE OF STEAM <-20 °C
OR
+ DRAIN BEFORE IP CONTROL VALVE CLOSED MAL26 AA011
AND MAL27 AAOll
+ DRAIN DOWN STREAM IP CONTROL VALVE CLOSED MAL31 AAO 11
AND MAL32 AAOll
CRITERION: VALVE CASING TEMPERATURE
MINUS SATURATION TEMPERATURE OF STEAM > 50 °C ‘
CRITERION: EXTRACTION VALVE CLOSED
(05) + CRITERIA FOR BEGIN OF START UP CHECK

IF ALL CRITERIA AS LISTED BELOW ARE
FULFILLED THE TURBINE/GENERATOR WILL
BE STARTED FROM
-TURNING GEAR IN OPERATION
-STOP VALVES CLOSED
+ MAIN STEAM STOP VALVES CLOSED MAA10 AAOOl
ANDMAA20 AAOO 1
+ REHEAT STOP VALVES CLOSED MAB10 AAOOl
AND MAB20 AAOOl
+ HP CONTROL VALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
+ IP CONTROL VALVES CLOSED MAB 10 AAO02
AND MAB20 AAO02
+ SWING CHECK VALVE COLD REHEAT L4NE CLOSED LBC10 AAOOl
+ EXTRACTION VALVE CLOSED
(06) + DRAINS AHEAD OF MS/RH STOP VALVES CHECK
(07.) + PREWARMING OF TURBINE START

OR WITH FGA (TURBINE CONTROL)
PROGRAMME (STARTUP) START
REFER TO MANUAL FOR THE FGA
(08) + SLC WARM-UP CONTROL SWITCH OFF.

+ SLC WARM-UP CONTROL OFF
5.2-0160-01/2
(08/S) + WARM-UP CONTROL OFF
(09) + DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL11 AA011

AND MAL AA011
+ DRAIN AHEAD OF HP CCNTROL VALVES CLOSED MAL11 AA011
AND MAL12 AA01 1
OR WITH FGA (TURBINE CONTROl)
(09/S)*+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL11 AA011
ANDMAL12 AA01 1.
(10) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 5.2-0170
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 5.2.0170
OR
+ MAIN STEAM VALVE TEMPERATURE < 100 °C
RELEASE OF STEP(05) OF THE FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PROGRAMME
HA VE BEEN FULFILLED
(11) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION
(12) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BYO01
OR WITH OF FGA (TURBINE CONTROl)
(12/S) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BYO01
STARTING AND LOAD LIMIT DEVICE > 42% MAX47 BYO01
+ MAIN STEAM STOP VALVES OPEN MAA10 AAO01
MAA20 AAO01

+ STEAM TEMPERATURE CRITERIA FULFILLED
FOR CRITERIA REFER STEP (10)
(14) + SLC WARM.UP CONTROL SWITCH ON.

(14/S) + SLC WARMUP CONTROL SWITCHED ON
TRACKING DEVICE SWITCHED ,ON
(15) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX4B.YO01

(15/S)+ STARTING AND LOAD LIMIT DEVICE RAISE MAX47 BYO01
+ STARTING AND LOAQ. LIMIT DEVICE > 56 % MAX47 BYOO 1
+ REHEAT STOP VALVES OPEN MAB10 AAO01
MAB20AAO01
(16) + WAIT
WARM UP PROCEDURE WILL BE GUlPED BY THE
WARM.UP CONTROL. LEADING PARAMETER IS THE
TEMPERATURE ALLOWANCE OF THE TSEfTSC CHANNEL
(ADMISSION). THE DRAINS OF THE CONTROL
VAL VES WILL BE OPENED AND CLOSED DEPENDING
ON THE MAGNITUDE OF TSC ALLOWANCE. IF THE
WARM.UP CONTROL IS DISTURBED OR NOT IN
OPERATION OPERATE DRAIN VALVES OF THE HP
CONTROL VALVES MANUALLY. CLOSE ON DECREASING
TSEfTSC ALLOWANCE. OPEN ON INCREASING TSEfTSC
ALLOWANCE. IF THE TSEfTSC IS FAULTY OPERATE
DRAIN V ALVES ACCORDING TO WALL TEMP
AT THE TSEfTSC RECORDER. REFER TO TECHNICAL
DATA FOR LIMITS OF DIFFERENTIAL
TEMPERATURES OF THE TSEfTSC.
5.2-0160-01/3
(17) + DRAINS MAIN STEAM LINE CLOSE
+ DRAINS MAII’J’STEAM LINE CLOSED
THE DRAINS OF MS LINE DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR)
CRITERION: STEAM IN MS LINE SUPER HEATED

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REF. 5.2-0170 FIG.1,4
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REF. 5.2-0170 FIG.L.5
THE RELEASE OF STEP (12) OF FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PRO(1RAMME
HAVE BEEN FULFILLED
(19) + LOAD REFERENCE VALUE CHECK MYA01 DUO01

+ LOAD REFERENCE VALUE > 10 % MYAOL DUOOL
(20) + SPEED REFERENCE VALUE SET HIGHER

+ SPEED REFERENCE VALUE > 650 RPM
THE WARMUP SPEED’MUST NOT EXCEED THE
MINIMUM SPEED OF THE BARRED SPEED RANGE
IN ORDER TO AVOID OPERATION IN RANGES
WHERE NATURAL FREQUENCY OF FREE STANDING
LP BLADES IS TO BE EXPECTED,
OR WITH FGA (TURBINE)
(20/S)*+ SPEED REFERENCE VALUE SET HIGHER
THE PREWARMING PROCEDURE IS GUIDED BY THE
TSE/TSC INFLUENCE TO THE ELECTRO HYDRAULIC
CONTROL, THE SPEED WILL BE REDUCED IF THE
TSE/TSC ALLOWANCE IS REDUCED TO ZERO, IF
THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE THERMAL STRESSES OF CASING
AND ROTOR MUST BE EVALUATED. REFER 5,2-0430
IF TSE/TSC ALLOWANCE IS REDUCED
+ SPEED OF TURBINE/GENERATOR > 240 APM

(21) + TURNING GEAR OIL VALVE CLOSE MAV51 AAOOL
(21/S)*+ TURNING GEAR OIL VALVE CLOSED MAV51 AAOOL
+ SPEED OF TURBINE/GENERATOR > 540 RPM

22) + JACKING OIL PUMP SWITCH OFF MAV31 APOOL
OR MAV32 APO01
+ JACKING OIL PUMP OFF MAV31 APOOL
AND MAV32 APOOL
(22/S)*+ JACKING OIL PUMP OFF MAV31 APO01
AND MAV32 APOOL

AND
+ OPERATIONAL VALUES OF TURBINE C-HECK
+ STEAM TEMPERATURE CRITERIA FUT.FIL.LED REF. 5.2-0170 FIG,6
+ TURBINE STRESS MARGIN > 30 OK
+ BEARING VIBRATION,., NORMAL
+ SHAFT VIBRATION NORMAL
DEFINITION OF NORMAL VALUES OF VIBRATION:
VIBRATION PREVIOUSLY OBSERVED WHEN OPERATING
WITH SAME SPEED AND OTHER PARAMETERS
5.2-0160-01/4
(24) + WARM-UP CONTROL SWITCH OFF
WARM-UP CONTROL OFF
OR WITH FGA (TURBINE CONTROLI
(24) + WARM-UP CONTROL OFF
(25) + SPEED REFERENCE VALUE SET HIGHER MYAO1 DUO01

+ SPEED REFERENCE VALUE > 3000 RPM MYA01 DUOO1
(25/S)+ SPEED REFERENCE VALUE > 3000 RPM
(26) + WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITICAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCUR. THE TSE/TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC .
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSERRSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED REFER TO 5.1-011..
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.
+ SPEED REFERENCE VALUE 3000 RPM

(27) + OPERATIONAL VALUES OF TURBINE CHECK
+ BEARING VIBRATION NORMAL
+ BEARING TEMPERATURES NORMAL
(28) + DRAIN AHEAD OF HP CONTROL VALVES CLOSE MAL 11 AAO11

AND MAL 12 AA011
+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL 11 AA011
AND MAL 12 AA011
OR WITH FGA (TURBINE CONTROLI
(28/S) + DRAIN AHEAD OF HP CONTROLVALVES CLOSED MAL 11 AA011
AND MAL 12 AAO1 1
(29) + AUXILIARY OIL PUMP SWITCH OFF MAV22 APO01

AND MAV23 APO01
+ STEAM TEMPERATURE CRITERIA CHECK

+ GENERATOR SYNCHRONIZE REFER TO 5.2-0210
5.2-0160-01/5
Steam Turbine Warming-up and Starting the Turbine
Description Temperature Criteria
The admission steam temperature should meet

the metal temperature as shown in the diagram below
in order to start and load the turbine in shortest
possible time.
Note : The following criteria represent approximate

values, which can be optimized by operational
experience.
Turbines with Automatic Turbine Aunup System

(ATAS) should under go optimising.
Criteria for the opening of stop valves
When opening the main stop valves the main

steam parameters’should meet the following
recommended values.
Minimum main steam temperature
θms>θs Fig.1
θms = Main steam temperature at steam

generator outlet
θs = Temperature of saturated steam

(depending on main steam pressure)
and
θms>f(θmcv50%) Fig.2
θms = Main steam temperature at steam

generator outlet
θmcv50% = Middle wall temperature of main

control valve casing

Maximum main steam saturation temperature
ahead of the turbine
θs>f(θmcv 50%) Fig.3
θs = Maximum main steam saturation

temperature ahead of the turbines
θmcv 50% = Middle wall temperature of main

control valve
Starting Cretaria
When the main control valves are opened the main
steam and reheat steam temperatures should fulfill
the following criteria:
Minimum main steam temperature
θms>θs Fig.1
θms = Main steam temperature ahead of

the turbine
θs = Temperature of saturated steam

(depending on main steam pressure)
and
θms>f(θHT50%) Fig.4
θms = Main steam temperature ahead of

turbine
θHT 50% = Middle wall temperature of HP-

casing or simulated middle phase
shaft temperature
5.2-0170-01/2
Minimum reheat temperature
9Reh > f (9IT 50%) Fig. 5
9Roh = Steam temperature in the hot reheat

line
9IT 50% = Simulated midwall temperature of the

IP-shaft
Speeding up criteria
Before the turbine is brought to rated speed the

main steam temperature 9MS ahead of the turbine
should fulfill the following criteria:
9MS < f ( 9HT 50% ) Fig. 6(a) & (b)
9MS = Main steam temperature ahead of

the turbine
9HT 50% = Middle wall temperature of the HP-

turbine casing or simulated midwall
temperature of HP shaft
5.2-0170-01/3
LoedIng criteria
Before the turbine is loaded the reheat

temperature, ahead of the turbine s,hould fultill the
following criteria
9Reh > f (9IT 50%) Fig. 7
9Reh = Steam temperature in the hot reheat

line
9IT 50% = Simulated midwall temperature of the

IP-turbine shaft
5.2-0170-01/4
Steam Turbine Warming-up and Starting the Turbine
Operation Controllers
1 Operating modes of the control systems and

of the starting and load limit device
Electrical speed Control
- Warmup operation the turbine generator Unit is accelerated and
maintained at constant warmup speed
- Running up the turbine I generator unit accelerate unit to rated speed
- Rated speed operation maintain unit at rated speed
Hydraulic governour
The turbine generator unit is accelerated and
- Warm-up operation
maintained at constant warm-up speed by manual
actuation of the starting and load limit device
When the reference speed setter is in the 0%
- Running up the turbine generator unit
position, the hydraulic governer takes over speed
control at approx.BO% rated speed
so, run -up of the turbine generator unit from
approx. BO to 100% rated speed is controlled by
- Rated speed Operation the hydraulic speed governer.
overspeed trip test :, maintain unit at rated speed
Acceleration to 107% of rated speed by the governor;
speed is increased to trip speed using acceleration
lever on casing of hydraulic goevrnor;
During overspeed trip test ,the electrical speed
controller must be disengaged and switched off.
Starting and load limit device The main trip valves are brought into operating
- setting operating configuration of main trip position when the starting ~nd load limit device is
valve in the 0% position.
- Opening the stop valves When the starting and load limit device is in
approx 40% open position, the stop valves should
be open;
the test valves of the stop valves must be in the
- Warm up operation operating position for the opening procedure.
see Hydraulic speed governor
0-107% (limitation by hydraulic speed governor)

2 Electrical speed control
Control range in % rated speed the actual setpoint follows the target setpoint
Setpoint control along preset gardients.
- Target setpoinVactual setpoint The preset gradient is reduced according to a
predeterminaned characterstic to confirm to the
- Limitation of setpoint by turbine, stress margin generated by the TSE
evaluator (TSE) The TSE signal must always be present if the TSE
is not faulted.
- Application of the TSE signal The actual setpoint no longer follows the target
setpoint iif the TSE is defaulted
- Oparation with TSE faulted the actual and target setpoint must be matched up
before the TSE signal can be switched off. When the
signal from TSE is not present, the therrnal
stress in the turbine components must be figured
out by comparing. The actual temperature and their
differences with the curves for permissibe
temperature margins as given in Technical Data 5.1-011

Limitation by higher-level or alternative
controllers or other devices
- Minumum value selection Effecive controller = controller with the lowest
setpoint setting at any time (also applies to other
devices influencing the opening characterstic)
- Hydraulic speed governor Limit setpoint by hydraulic minimum
(speed setting device approx.80%) value selection;
- Starting and load limit device Limit setpoint by hydraulic minimum
valve selection;
excessive control valve opening can be prevented
by using the starting and load limit device to
limit valve travel.
Operation
- Operating elements and monitoring see arrangement of control desk as described in
instruments controller manual. Pay attention to notes on operation
of release pushbuttons!
- Operating logic sequences for changing See Appendix (for changing the operating mode durfng
the operating mode no-load operation see
Power Operation, Controller 5.2-0180
3 Hydraulic Speed Governor
Setpoint control
- Target setpointfactual setpoint The actual setpoint immediately follows the target
setpoint (no influence from turbine stress evaluator),
During operation with the hydraulic speed governor,
the thermal stresses in the turbine components must
be figured out on the basis of the TSE display or,
if the TSE is faulted, by comparing the actual
temperatures and their differences with the curves
for permissible temperature margins as given in
Technical Data 5.1-011.
Limitation by higher-level or
alternative controllers or other device
- Minimum Value selection Effective controller = controller with lowest
setpoint setting at any time (also applies to other
devices influencing the control characterstic)
- Electrohydraulic controller Limits setpoint by hydraulic minimum
<100% value selection
- starting and IQad limit device Limits setpoint by hydraulic minimum
value selection
Operation
- Operating elements and monitoring See arrangement of control desk as described in
instruments in controller manual
- Operating logic sequences for See next page
changing operating mode
5.2-0180/2
+ Turbine generator unit speed = Turning gear speed
+ Stop valve pos,ition = 0%
+ Control Valve position = 0%
+ Main trip valves = depressurized
+ Starting and load limit device = 40% open
+ Reference speed setter = 0%
+ Electrical speed reference = 0%
(1) + Electrical speed reference raise

(2) + Plunger coil deenergize

+ Plunger coil deenergized
(3) + Starting and load limit device lower

+ Starting and load limit device =0%
+ Main trip valves in operating configuration
(4) + Starting and load limit device raise

+ Starting and load limit device >40%
+ Stop valve position = 100%
+ Warm-up criteria for main steam lines fulfilled
(A) + Main Steam lines warm-Up

+ Critaria for admission of steam into turbine fulfilled
+ Steam generation adequate

+ Control valves open
+ Turbine generator unit speed = warm-up speed
(6) + Using Starting and load limit device maintain constant speed
(B) + Turbine Warm-up

+ Run-up criteria fullfilied
+ Steam generator output adequate

+ Control Valve open
+ Turbine generator unit speed > warm-up speed
+ Turbine generator unit speed = 75% rated speed

+ Starting and load limit device = 100% open
(9) + Reference speed setter raise

+ Turbine generator unit speed = rated speed
Operating logic sequence 1: Starting up the turbine generator unit with the
srarting and load limit device and the hydraulic
speed governor
A see Warming up the Main Steam Line
B see Warming up Starting up the Turbine
5.2-0180/3
+ Turbine generator unit speed > turning gear speed and
< 75% rated speed
+ Electrical speed reference = turbine generator unit speed
+ Starting and load limit device = 56 to 100%

+ Starting and load limit device effective
(2) + Electrical speed reference raise

+ Electrical reference = 100%
(3) + Plunger coil deenergize

+ Plunger coil deenergized
(4) + Using starting and load limit device maintain constant speed
(5) + Reference speed setter lower

Operating logic sequence 2: Transition from operating with electrical speed controller to
operating with starting and load limit device
(Speed approx, 80% rated speed)
+ Turbine generator unit speed > Turning gear speed and

75% rated speed
+ plunger coil deenergized
+ Starting and load limit device effective
(1) + Plunger coil energize

+ Plunger coil energized
(2) + Electrical speed reference lower

+ Turbine generator unit speed = electrical speed reference

+ Starting and load limit device 56 to 100 %
(4) + Reference speed setter raise

Operating logic sequence 3 : Transition from operating with starting and load limit
device to operation with electrical speed controller
(Speed approx ,80% rated speed)
5.2-0180/4
Steam Turbine Load Operation
Power operation begins by synchronizing of the availability and reliability.

generator. The turbine generator load may then be
raised or lowered according to the commands from The operating staff must detect all operating
the monitoring/controlting equipment, in particular the conditions that is a danger to tile turbine generator
load margins from the turbine stress evaluator (TSE)/ and must immediately correct them.
turbine stress controller (TSC), to meet the grid power
requirement. Regular checking of protection equipment, long-
term monitoring of operating variables and operational
During power operation. monitoring is essential maintenance are very important for early detectioil
for the economic operation of the turbine generator. and elimination of system faults.
Neglecting this principle runs the risk of reductions in

Steam Turbine Synchronization and Loading
(01) + GENERATR READY TO BE CHECK
SYNCHRONIZED
+ SPEED OF TURBINE/GENERATOR 3000 RPM
+ DRAIN OF SEAL STEAM HEADER NORMAL
+ H2-SUPPL Y SYSTEM NO ALARM
+ SEAL-OIL PLANT NO ALARM
+ PRIMARY WATER SYSTEM NO ALARM
+ LIQUID IN GENERATOR NO ALARM
+ STEAM TEMPERATURE CRITERIA FULFILLED
(02) + EXCITATION BREAKER SWITCH ON
+ EXCIT ATION BREAKER SWITCHED ON
(02/S)* + EXCITATION BREAKER SWITCHED ON
(03) + GENERATOR VOLTAGE SET HIGHER
+ GENERATOR VOLTAGE HIGHER
(03/S)* + AUTOMATIC SYNCHRONIZER ON
(04) + GENERATOR VOLTAGE CONTROL CLOSED
+ GENERATOR VOLTAGE CONTROL SWITCHED ON
OR WITH (AUTOMATIC SYNCHRONIZER)
(04/S)* + GENERATOR VOLTAGE CONTROL SWITCHED ON
(05) + SYNCHRONOSCOPE SWITCHED ON
+ SYNCHRONOSCOPE SWITCHED ON

(07) + GENERATOR VOATAGE ADJUSTED
BY MEANS OF REFERENCE
VALUE OF VOLTAGE CONTROL
+ GENERATOR/LINE-VOLTAGE MET
(07/5)* + GENERATOR/LINE-VOLTAGE MET
(08) + GENERATOR FREQUENCY ADJUSTED

BY MEANS OF REFERENCE
VALUE OF SPEED CONTROL
+ GENERATOR/LINE-FREQUENCY MET
(08/5)* + GENERATOR/LINE-FREQUENCY MET

GENERATOR FREQUENCY MUST
BE ADJUSTED IN SUCH A WAY
THAT THE NJEEDLE OF THE
SYNCHRONOSCOPETURNS
SLOWLY IN THE DIRECTION
GENERATOR FREQUENCY HIGHER
THAN LINE FREQUENCY =
FAST SYNCHRONIZING.
FAST SYNCHRONIZING ENSURES
THAT THE GENERATOR Will
BE LOADED IMMEDIATELY
AFTER SYNCHRONIZING
THUS PREVENTING REVERSE
POWER RELAY TO BE ACTUATED.
(09) + SYNCHRONIZING DEVICE START
+ GENERATOR BREAKER SWITCHED ON

IF THE BREAKER WILL BE
SWITCHED ON MANUAllY
ADJUSTED PHASE ANGLE TO
NEEDLE OF SYNCHRONOSCOPE
MUST MEff THE ZERO-ANGLE
MARK ON THE SCALE WHEN
SWITCHING IN BREAKER.
(09/5)* + GENERATOR BREAKER SWITCHED ON
(10) + SPEED REFERENCE VALUE SET HIGHER MYA01DU001
+ GENERATOR LOAD > 10%
5.2-0210/2
(11) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47BYO01
+ STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01
OR WITH FGA (TURSINE CONTROL)
(11/S)* + STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01
+ TURBINE STRESS EVALUATOR (TSE) CHECK
+ TURBINE STRESS EVALUATOR (TSE) CHANGED OVER

AT A PRESENT MINIMUM LOAD
THE TSE CHANGES OVER FROM
TEMPERATURE-TO LOAD SCALE
+ GENERATOR LOAD > 10%
LOAD CONTROLLER SWITCHED ON

THE LOAD CONTROL WILL BE
SWITCHED ON AT A PRESET
MINIMUM LOAD.
(12) + LOAD REFERENCE VALUE SET HIGHER MYA01 DUO01
+ LOAD REFERENCE VALUE TARGET LOAD MYA01 DUO01
(13) + WAIT
(13/S)* + LIMITED LOAD REFERENCE VALUE HIGHER MYA01DUO01

THE LIMITED LOAD REFERENCE ‘C
VALUE FOLLOWS THE TARGET
LOAD REFERENCE VALUE
WITH THE ADJUSTED
LOAD GRADIENT.
THE LOAD GRADIENT WILL
BE REDUCED, IF REDUCTION
OF THE TSE ALLOWANCE OCCUR.
THE TSE INFLUENCE WILL BE
EFFECTIVE VIA THE REFERENCE
LIMITER.
IF THE TSE IS FAULTED THE

DIFFERENTIAL- TEMPERATURES
AT THE MEASURING POINTS
WHICH REPRESENT THE
ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST
BE EVALUATED.
REFER TO 5.2-0430 IF
TSE-ALLOWANCE IS
REDUCED.
5.2-0210/3
(14) + RAIN DOWNSTREAM RCV CLOSE ‘.
OR WITH SUBl,.OOP CONTROL (DRAINS)

POSITION OF DRAINS CHECK
+ DRAIN DOWNSTREAM OF HP-CONTR. CLOSED MAL 15AAO01

VLV AND MAL 16AAO01
CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATVRATION
TEMPERATURE OF STEAM
+ DRAIN OUTER CASING CLOSED MAL 22AA011
CRETERIUM:
TEMP.HP-CASING TOP >320 CEL
+ DRAIN AHEAD OF SWING-CHECK CRH CLOSED MAL65AA011
CRITERIUM: LBC10AAO01
NON RET.CHECK VLV COLD REH. OPEN
+ DRAIN UPSTREAM RCV CLOSED MAL26AA011

ANDMAL27 AA 11
CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATURATION
+ DRAIN DOWNSTREAM RCV CLOSED MAL31AA011

AND MAL32AA011
CRITERIUM:
VALVE CASING TEMPERATURE > 50 CEL
MINUS SATURATION
(15) + HEATER OPERATION CHECK

+ HEATERS IN OPERATION
+ EXTRACTION VALVE > 0% LBO50AAO01
AND LBS41AAO01
AND LBS42AAO01
AND LBS31.A.AO01
AND LBS21 AAO01
(16) + DRAINS OF EXTRACTIONS CLOSE MAL47AA011

ANDMAL51AA011
AND MAL54AA015
AND MAL55AA011
5.2-0210/4
+ DRAINS OF EXTRACTIONS CLOSED MAL47 AAO11
AND MAL51AAO11
AND MAL54AAO15
AND MAL 55AAO11
IF THE EXTRACTION STEAM

FLOW WILL BE REDUCED,
CAUSING THE EXTRACTION
VALVE TO CLOSE THE
RESPECTIVE DRAIN MUST
BE OPEN.
+ BOILER/TURBINE LOAD RELATION 1
(17) + BYPASS CONTROL VALVE CHECK
+ BYPASS CONTROL VALVE CLOSED MAN11AAOO2

AND MAN12AAOO2
+ BYPASS STOP VALVE CLOSED MAN11AAOO1

AND MAN12AAOO1
5.2-0210/5
Steam Turbine Power Operation
Operation Controllers
1 Control System Operating Modes

Electrical speed control
- During synchronization of generator Setting and maintenance of constant synchronization
speed.
- After synchronization of generator Run-up to approx. 2x unit auxiliary power requirement
(normal operating mode) before changeover to load control.
- After synchronization of generator Power operation up to Pmax or until control.
(operating mode if load controller defective) valves full open.
- Load shedding Interception of turbine generator before it reaches
(disconnection of generator from power grid) trip speed;
Maintenance of constant speed at residual load
(auxiliary power requirement);
Hydraulic control
(operation if electrical control system defective)
- During synchronization of generator Setting and maintenance of constant synchronization
speed.
- After synchronization of generator Power operation up to Pmax or until control valves full
- Load shedding open.
(disconnection of generator from power grid) Interception of turbine generator before it reaches trip
speed;
Back up by overspeed anticipatory relay.
Maintenance of constant speed at residual load
(auxiliary power requirement);
Electrical load control of turbine generator

- Constant pressure operation without Maintenance of constant load up to Pmax by
frequency influence positioning control valves.
- Constarlt pressure operation with As above, turbine gere,r,~tor assists in grid freQuepcy
frequency influence as given by the stabilization when frequency changes.
proportional setting of the frequency
control and by the thermal storage
capacity of the steam generator
- Variable pressure operation without Maintenance of constant load;{steam generator con-
frequency influence trol system takes over control when max. control
valve lift reached).
Maintenance of constant load;
- Variable pressure operation with frequency Turbine generator assists in grid frequency stabil-
influence as given by the proportional ization when frequency changes.
setting of the frequency control unit
and the thermal storage capacity of the
steam generator by controlled throttling of
the control valves
Initial pressure control by the electrical

load controller (alternative to limit initial
pressure control)
- Constant pressure operation Maintenance of constant pressure in steam gene~tor
(with or without frequency influence) as given by proportional settings characteristics of”
pressure reference value.
limit initial pressure control by the electricalload
controller
(alternative to initial pressure control)
- Operation of load controller with or
without frequency influence for stabilization Maintenance of constant pressure in steam generator
of steam generator operation as given by proportional setting characteristic of
in the event to pressure drops pressure referencb value incorporating response
reference value.

2 Electrical Speed Control
Control range
- Speed (as % 9f rated speed) 0-170%
(limited by hydraulic governor)
- Valve lift 100%

- load at design pressure. 100%
Reference limiter
- Target reference value/actual The actual reference value tracks the target
reference value reference along a preset gradient.
- Limitation of reference limiter by TSE The present gradient Is reduced in accordance with
(turbine stress evaluator) component a predetermined characteristic to conform to the
load margin generated by the TSE.
- Application of TSE signal The TSE signal must always be present unless the
TSE is faulted. .
- Operation with TSE faulted The actual reference value no longer tracks the
target reference value if the TSE is faulled;
Actual and target reference value must be matched
up before the TSE signal can be switched off.
The thermal stresses In the turbine components
must be assessed by comparison of the actual tem-
peratures and their differences with the curves for
permissible temperature margins given in
TechnicaI Date 5.1-011.
limitation’by priority or alternative
controllers or other equipment
- Minimum value selection Controller in effect = controller with lowest
setpoint;
(also applicable to other equipment that affects
the controller output signall.
- Hydraulic governor < 100% limits reference value by means of hydraulic minimum
value selection.
- Starting and load limit device < 100% limits reference value by means of hydraulic minimum
value selection.
Control valve lift overshot can be prevented by
means of starting and load limit device
Operation
- Control and monitoring devices See desk allocation diagram in controller man~l.
Note instructions on use of reJease pushbuttons I
- Control logic for cnanging operating See appendix
mode
Instructions for control and operational
monitoring
- speed reference value after changeover After changeover to load control the speed
to load control reference value is to be set such that speed will
revert to approx. 0.6% above rated speed in the
event of load shedding.
3 Hydraulic Governor
Control range
- Speed 80-107%
- Valve travel at rated speed 100%
- load at design pressure 100%
Reference limiter
- Target reference value/actuaf Actual reference value tracks target reference
reference value value directly (nQ TSE component).
During operation with the hydraulic governor in
control, the thermal stresses in the turbine com-
ponents must be assessed by referring to the TSE
display or, if the TSE is faulted, by comparing
the actual temperatures and their differences with
the curves for permrssible temperature margills as
give in Technical Data 5.1-011.
5.2-0220/2
Limitation by priority or alternative
- Minimum value selection Controller in effect == controller with lowest
reference value;
the controller output signal).
- Electrohydraulic controller < 100% Limits reference value by means of hydraulic
minimum value selection.
- Starting and load limit device < 100% Limits reference value by means of hydraulic
minimum value selection.
Operation
- Control and monitoring devices See desk allocation diagram in controller manual.
- Control logic for changing operating See appendix
mode
monitoring
- Actual speed after load shedding As dictated by setting of speed reference val~e
before load sheddjng with allowance for droop,
After shedding, the actual speed must revert to
rated speed.
- Starting and load limit device During operation with the hydraulic governor in
control, the turbine generator assists in grid
frequency stabilization as governed by thge droop
of the controller;
The influence of the frequency component on the
load reference value tending to raise power can
be eliminated by switching in starting and load
limit device
4 Load Control by the Electrical Controller
Control range
- Valve travel 100%
- Load at design pressure 100%
Reference limiter
- Target reference value/actual The actual reference value tracks the target
reference value reference value along a preset gradient.
- Limitation of reference limiter by TSE The present gradient is reduced in accordance with
a predetermined characteristic to conform to the
load margin generated by the TSE.
- Application of TSE signal The TSE signal must always be present unless the
TSE is faulted.
- Operation with TSE faulted The actual reference value no longer tracks the
target reference value if the TSE if faulted;
Actual and target reference value must be matched
before the TSE signal can be switched off.
The thermal stresses in the turbine components
must than be assessed by comparison of the actual
temperatures and their differences with the curves
for permissible temperature margins given in
Technical Data 5.1-011.
Limitation by priority or alternative
- Minimum value selection Controller in effect = controller with lowest
reference value;
the controller output signal).
Absolute limit load reference value Limit reference values by means of electric minimum
selection;
Active in the event of unit malfunctions.
5.2-0220/3
- Hydraulic speed governor < 100% Limits reference value by means of hydraulic
minimum value selection
- Starting and load limit device < 100% See above
Operation
- Control and monitoring devices See desk allocation diagram in controller manual.
Note instructions on use of release pushbuttonsl
- Control logics for changing operating See appendix
mode
monitoring
- Changeover from speed to load and from Valve lift reference value must be matched up prior
load to speed control To changeover..
- Switching off load controller in the Changeover from load to speed control is effected
event of load shedding When the load falls below a preset value;
Changeover back to load control is effected if the
actual load rises above the lower limit within
approx. 2s.
- Cutin of initial pressure controller The pressure control deviation must be 0 before
the initial pressure can cut in.
5.2-0220/4
APPENDIX
+ Turbine generator speed = rated speed

+ Turbine generator load = Zero MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = rated speed
+ Speed changer = 100%
+ Starting and load limit device = 100%
(1) + Speed changer lower

+ Speed changer reference value < electrical speed reference value
(2) + Electrical speed reference value raise

+ Electrical speed reference value = max. speed
+ Valve position controller reference value > 100%
(3) + Plunger coil switch off

+ Plunger coil off
+ Required speed reference value higher or lower
(4) + Speed changer raise or lower
Control logics 1: Changeover from electrical to hydraulic speed control in idling mode, e.g. for exercising overspeed trips.
+ Turbine generator speed =rated speed

+ Turbine generator load = ZeroMW
+ Plunger Coil off
+ Electrical speed controller not in operation
+ Speed Changer = % position for rated speed
(1) + Plunger coil Switch on

+ Plunger coil on
(2) + Electrical speed reference value lower

+ Electrical speed reference value < speed setter reference value
(3) + Speed changer raise

+ Required speed higher or lower
(4) + Electrical speed reference raise or lower
Contrllogics 2: Changeover from hydraulic speed control in idling mode,e.g. after excercising overspeed trips.
5.2-0220/5
+ Turbine generator load >0MW
+ Individual valve controller in operation
+ Plunger coil on
+ Electrical load controller in operation
+ Electrical speed reference value = rated speed + load component
+ Speed Changer = 100%

+ Speed changer reference valve < electrical speed reference value
(2) + Electrical speed reference value raise

+ Valve position controller reference value > 100%

+ Plunger coil off
+ Load reference value higher or lower

+ Hydraulic frequency control not required

+ Starting and load limit device in effect

+ Speed changer = 1 00%
+ Load higher or lower
(7) + Starting and load limit device raise or lower
Control logic 3: Changeover from electrical to hydraulic speed control during speed controlle~’PP~er operation
(procedure (5) onwards: Switching off hydraulic frequency influence)
5.2-0220/6
+ Turbine generator load > OMW
+ Plunger coil off
+ Electrical speed controller not in operation
+ Starting and load limit device = in effect

+ Speed changer in effect

+ starting and load limit device = 100%
(3) + Plunger coil switch on

+ Plunger coil on
(4) + Electrical speed reference value < speed changer reference value

+ Load reference value higher or lower
(6) + Electrical speed reference value raise or lower
Control logics 4: Changeover from hydraulic to electrical speed control in power operation
(up to procedure (2): switching on hydraulic frequency component)
5.2-0220/7
+ Turbine generator load > a MW
+ Plunger coil on
+ Pressure component on
+ Pressure controller in operation
+ Electrical load reference value = actual # pressure component
+ Electrical speed reference value = appprox. 1.005 xrated speed
(1) + Electrical initial pressure controller switch off

+ Initial pressure controller off
+ Limit initial pressure controller on
(2) + Initial pressure component switch off

+ Initial pressure component off

+ Speed changer reference valve < electrical load reference value
(4) + Electrical speed and load reference values raise

+ Electrical load reference value = max. load

+ Plunger coil off
+ Turbine generator load reference value higher or lower

+ Hydraulic frequency control off

+ Starting and load device in effect

+ Turbine generator load reference value higher or lower
(9) + Starting and load limit device raise or lower
Control logics 5: Changeover from electrical load control to hydraulic speed control
procedure (5) + (6) switch off hydraulic frequency influence
5.2-0220/8
+ Turbine generator load > 0 MW
+ Plunger coil A off
+ Electrical load reference value = max. load
+ Speed Changer = 100%
+ Starting and load limit device in effect

+ Speed changer in effect

(3) + Plunger coil switch on

+ Plunger coil on
(4) + Electrical load controller switch on

+ Electrical load controller on
(5) + Electrical reference value lower

+ Electrical reference value = approx. 1.005 x rated speed
(6) + Electrical load reference value lower

+ Electrical load reference.value < speed setter reference value

(8) + Electrical load reference value raise or lower

+ Load actual load higher or lower
+ Initial pressure controller reference value on
+ Limit initial pressure required
(9) + Initial pressure component switch on
(10) + Initial pressure controller control balance

+ deviation
+ Initial pressure controller control balanced
deviation
(11) + Initial pressure controller switch on

+ Initial pressure controlleron
(12) + Steam generator output reference value raise or lower
Control logics 6: Changeover from hydraulic to electrical load control in power operation
Procedure (1) + (2) Switch off hydraulic frequency conball
Procedure (9) + (10) Switching on pressure controner
5.2-0220/9
Steam Turbine Actions to Prevent Unallowable Heatup
Operation Through Blade Windage
Procedural Instruction
Introduction General actions to prevent unallowable heatup

During startup and shut-downs, there can be iong of the steam turbine due to windage
period during which Steam turbines are operated at Limitation of the period of ‘motoring’ operation
very low volumetic flows. This operating mode can Blade windage can occur in expansion sections
result in blade windage in individual stages of multi-
of a steam turbine if volumetric flow drops to zero,
stage turbines.
resulting in the turbine being driven by the
The direction of the energy conversion cycle at generator which acts as a motor driven by the
the affected blade stages is reversed. The mechanical public power system.
energy transmitted by the turbine shaft is converted - Activation of short-time reverse power
to thermal energy, which in turn result in an increase protection following turbine trips
in the temperature of both the steam and the turbine
After turbine trip, which can be initiated during
components.
any operating mode of the turbine generator
Unallowably high temperatures can occur as a unit. the generator must be isolated from the
result of blade windage, leading to loosening of the public power system after no more than four
blade assembly of drum stages through plastic seconds through activation of the short-time
deformatipn.
reverse power protection.
Turbine casings can undergo deformation due to in order to prevent motoring of the generator
the effects of high temperatures. at high speed beyond this time period owing
During steam turbine operation, the operating to the interruption in volumetric flow and high
mode and limiters and protective devices must be steam pressure in one expansion section.
used to keep heatup due to blade windage within the Activation of long-time reverse power
prescribed Imits. protection during a (schedule) turbine
generator shut-down, the control valves of the
Thermodynamic and operating factors affecting turbine generator unit are closed, to allow the
blade windage generator to be isolated from the public power
The following factors can lead to blade windage: system through activation of the long-time
Volumetric flow Blade windage can occur as a reverse power protection.
result of insufficient volumetric flow through a The maximum time delay for activation of the
multistage expantion section of the steam turbine. long-time reverse power protection specfied in
The lower the volumetric flow through a blade the Technical Data must not be exceeded. The
stage, the lower the turbine efficiency will be in long-time reverse power protection must be
the case of very low volumetric flows, steam flow functionally tested in conjunction with leak
through the stage is not directed and the steam testing of the control valves each time the
has to be accelerated up to the average speed of turbine generator unit is shut down.
the rotating blades, which creates a deceleratin Turbine trip after limit values have been reached
effect. Blade windage causes temperature increases at
As the volumetric flow decreases, and the turbine certain exhaust-steam or casing -temperature
starts to operates at zero load, blade windage measuring points. The limit values of the
result in transition from power transfer from the
temperature at which turbine trip is to be initiated
blades to power transfer to the blades.
are specified in the Technical Data. if, under
Blade windage starts in the final blade stages of
an expansion section, and extends towards the particularly unfavorable conditions, these
first stages as flow decreases. temperatures are reached, turbine trip must be
initiated, either manually from the control room,
Steam density, steam pressure and turbine or automatically by tripping of a protective device.
generator speed.
The degree of windage-induced heatup Which
occurs as a result of low volumetric flow through Blade windage in the HP expansion section of a
an expansion section of the steam turbine steam turbine with reheat
depends on the windage power. At low volumetric flows, blade windage can
The higher the steam density and the turbine occur towards the exhaust end of the HP expansion
speed to the third power, the greater will be section if the steam pressure in or downstream otthe
windage power, and therefore the heatup, in one HP turbine section is high.
blade stage. Blade windage can occur during the following
Owing to the proportional relationship between modes of operation:
steam density and steam pressure, the steam No-load or low-load operation during startup of
pressures in expansion sections undergoing the tubine generator unit.
windage can be used to determine the degree of No-load or a auxilary-power operation following
heatup due to windage. load rejection.

The risk of unallowable heatup due to windage ,is of the drains compared to the volume of the space
particuarly high following load rejection, since this constituted qy the HP turbine and the HP exhaust
may coincide with a high reheat steam pressure, steam lines upto the non return valve (s) is not a
meaning that turbine generator speed temporarily large enough to ensure sufficiently fast drainage,
exceeds rated speed. the plant operator can arrange with the turbine
Motoring operation prior to activation of the long- supplier for an HP turbine a dump valve to be
time reverse power protection during shut-down beckfitted (e.g. to reduce the time required for
pressure reduction).
of the turbine generator unit Actions to be taken in the event of fault-induced
At overspeed during overspeed trip testing closure of the main steam stop and/or control
valves
Actions to be taken to prevent unallowable heatup One particular fault which can arise occure during
of the HP turbine due to windage power operation when the volumetric flow through
Optimization of the volumetric flow through the HP the HP turbine approaches zero as a result of fault-
turbine by staggered operation of the main steam and induced closure of the main steam stop and/or
reheat control valves. control valves, but the turbine generator unit
By Specifying a staggered control valve operating continues to operate because the reheat control
sequence in which the main steam control valve valves are still open. In the event of such a fault,
open before the reheat control valves, the further operation of the turbine generator unit is
volumetric flow through the HP turbine during no- not allowed, and must be stopped through remote
manual initiation of a turbine trip.
load or low-load operation is optimized so that The occurence of this type of fault is indicated by
unallowable heatup due to windage can only occur a load surge, opening of the HP bypass station
under the most unfavourable conditions e.g. if the and an increase in the HP exhaust steam
pressure downstream of the HP section is too high. temperature.
Optimization of the volumetric flow through the HP Actions to be taken in the event of backflow of
turbine by means of trimming device steam through the check valve(s) downstream of
During turbine operation at low volumatric flow, the HP turbine. Blade windage can occure as a
the trimming device adjusts the staggered result of non- leaktightness or faulted operation
operating sequence of the main steam and reheat of the check valve (s) down stream of the HP
control valves on the basis of HP turbine exhaust turbine if pressure in the reheater is high.
steam temperature, thus ensuring that the largest Non-leaktightness or faullted ‘operation’of1he
possible volume of steam flows through the HP check valve(s) occurs if the steam pressure
downsteam of the HP turbine cannot be reduced
turbine. to less than the reheat steam pressure downsteam
Proper observance of limit conditions for reheat of the check valve (s) must be subjected to regular
steam pressure checks for freedom of movement and leaktigtness,
The steam pressure ration P MS I PAs as a in order to prevent adverse effects in terms of
function of power ratio must not drop below that blade windage.
specified in Data Sheet. Actions to te taken in the event of a high steam
If the turbine generator unit at a volumetric flow temperature downstream of the HP turbine
approaching zero e,g. during turbine generator If blade windage occurs in the HP turbine, there
shut-down prior to activation of the long-time will be an increase in steam temperature at1he
reverse power protection or during operation at measuring point downsteam of the HP turbine.
overspeed for overspeed trip testing, the The limit value of maximum allowable exhaust
maximum reheat steam pressure PAs MAN steam temperature specified In the TechnicaL
Data must not be exceeded.
specified in Data Sheet [1] must not be exceeded. After the alarm “HP exhaust temperature high” has
The limit conditions for reheat steam pressure been issued the following actions must be
cal)be estabilished on the basis of setpoint values implemented immmediately to prevent
fqr1he main steam and IP/LP bypass controllers. unallowable heatup due to windage:
Draining the HP turbine by opening the drain stablish a steam pressure ratio P MJP AS which lies
valves in the case of low volumetric flow combined above the characterstic curve specified in Data
with high reheat steam pressure,the HP turbine Sheet (1)
must be drained by opening the valves in the drain - reduce steam pressure in the HP turbine by
lines located downstream of the HP control valves, lowering the constant-pressure setpoint for the
at the turbine outer casing and upstream of the IP/ LP bypass control system
non return valve(s) downstream of the HP turbine. - reduce the main steam temperature
These drain valves are actuated on the basis of a - if the generator is connected to the public
power system, increase the turbine load
load signal (p<approx. 5%) or the opening signal
of the HP turbine dump valve, which can be Blade windage in IP turbines
installed as an additional limiter. Causes
If necessary, the drains subloop control must be In t he case of IP turbines, blade windage (which
switched immediately the MANUAL mode and the can result in allowable heatup of the blading )has
drain valves must be opened using a remote a number of casiJes, including excessively low.
manual command. volumetric flow across the balding.
Backfitting an HP turbine dump valve Actions
If under unfavorable conditions the cross sections in the annunciation “IP exhaust steam temperature
high” is issued, or if the limit value forthe
temperature
5.2-0230/2
(24) + WARM-UP CONTROL SWITCH OFF
WARM-UP CONTROL OFF
(24) + WARM-UP CONTROL OFF
(25) + SPEED REFERENCE VALUE SET HIGHER MYAO1 DUO01

+ SPEED REFERENCE VALUE > 3000 RPM MYA01 DUOO1
(25/S)* + SPEED REFERENCE VALUE > 3000 RPM
(26) + WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITiCAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCUR. THE TSE/TSC INFLUENCE WILL
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC .
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSErrSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED REFER TO 5.1-011..
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.
+ SPEED REFERENCE VALUE 3000 RPM
(27) + OPERATIONAL VALUES OF TURBINE CHECK
+ BEARING VIBRATION NORMAL
+ BEARING TEMPERATURES NORMAL
(28) + DRAIN AHEAD OF HP CONTROL VALVES CLOSE MAL 11 AAO11

AND MAL 12 AA011
+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL 11 AA011

AND MAL 12 AA011
(28/S)* + DRAIN AHEAD OF HP CONTROLVALVES CLOSED MAL 11 AA011
AND MAL 12 AAO1 1
(29) + AUXILIARY OIL PUMP SWITCH OFF MAV22 APO01

AND MAV23 APO01
+ STEAM TEMPERATURE CRITERIA CHECK

+ GENERATOR SYNCHRONIZE REFER TO 5.2-0210
5.2-0160-01/5
Steam Turbine Shutdown of the Turbine
The turbine-generator should be shutdown cooling (2) must be followed.

according to operating instruction shown in the We recommend accelerated cooling to reduce
shutdown diagrams. cooldown time when shutting down the turbine-
If an emergency occurs, the turbine generator unit generator unit for preventive maintenance or repairs.
may be rapidly unloaded and/or be shutdown by Short shutdowns should be used to perform minor
operating the trip pustl-button or trip valve from any maintenance unless large-scale preventive
operating condition. maintenance programs or repairs are to be
During shutdown, all tests (1) for this must be performed. It is a good idea to have a list ready of
performed. In particular test the over3peed protection those jobs that can be done during short shutdowns.
by overspeeding after the recommended interval has Operational readiness should be maintained
elapsed. This test may be performed when the turbine during maintenance and testing programs and/or
is at operating temperature, particular attention is should be established after their completion to enable
drawn to this test in this context. speedy restart of the turbine-generator unit.
If work has to be performed immediately after During long periodS of shutdown the turbine and
shutdown of the turbine on hot parts or if the turning other components may be e>tposed to corrosive
gear is to be shutdown, instruction for accelerated attacks. So care must be taken to ensure all
components are protected against corrosion as
described in the specific instructions.

Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram (General)
(01) + TURBINE/GENERATOR UNLOAD REF. TO 5.2-0320

OR
+ FGA (TURBINE -CONTROL STANDSTILl) START
(02) + START OF BYPASS OPERATION OBSERVE REF. TO 5.2-0320
(03) + GENERATOR BREAKER TO BE OPENED OBSERVE REF. TO 5.2-0320

REVERSE POWER PROTECTION INITIATED
(04) + TEST PROGRAM (SHUTDOWN) CARRY OUT REF. TO 5.3.0060
(05) + TURBINE TRIP INITIATE REF. TO 5.2-0320

OR WITH FGA (TURBINE-CONTROl)
+ TURBINE TRIP INITIATED REF. TO 5.2-0320
(06) + START OF AUXILIARY OIL PUMP OBSERVE REF. TO 5.2-0320
(07) + TURNING GEAR OPERATION START REF. TO 5.2-0320

+ SHAFT LIFT OIL SUPPLY SYSTEM IN OPERATION
+ TURNING GEAR OIL SYSTEM IN OPERATION
*+ SHAFT LIFT OIL PUMP ON
*+ TURNING GEAR OIL VALVE OPEN
(08) + STEAM -GENERATOR NOT IN SERVICE

+ BYPASS -OPERATION COMPLETED
+ CONDENSING PLANT SHUT DOWN REF. TO 5.2-0330
+ VACUUM PUMPS OFF
+ SEAL -STEAM SUPPLY SHUT -DOWN
+ CONDENSATE PUMPS OFF
+ CIRCULATION WATER SUPPLY NOT IN SERVICE
OBSERVE
(09) + CONTROL FLUID PUMPS SHUT -DOWN REF. TO 5.2-0320
(10) + OIL SYSTEM WITH FGA (OIL SUPPLY) SHUT -DOWN REF. TO 5.2-0340
OR
MANUAL OPERATION AT OPER. CONSOLE
+ SHAFT STANDSTILL
+ OIL SYSTEM NOT IN SERVICE

Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram
(01) + OPERATIONAL CONDITIONS CHECK

+ LOAD CONTROLLER ON
+ LOAD GRADIENT ADJUSTED
ADJUSTMENT ACCORDING TO
- REQUIREMENT OF LOAD DESPATCHER
- STEAM GENERATOR CONTROL
- THERMAL INFLUENCE ON TURBINE
+ BYPASS CONTROL ON
+ FIXED PRESSURE SET POINT BYPASS CONTROL ...KG/CM2
ADJUSTMENT IN AGREEMENT WITH
PRESSURE REQUIREMENTS -
- REHEAT PRESSURE DURING START-UP
AND SHUTDOWN
+ ELECTRO HYDRAULIC TURBINE CONTROL NOT FAULTED
+ BYPASS CONTROL NOT FAULTED
+ TSC -INFLUENCE ON
+ TURBINE STRESS CONTROLLER (TSC) NOT FAULTED
IF THE TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED.
REFER 5.2-0430 IF TSC ALLOWANCE IS REDUCED
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
+ SUBLOOP CONTROL TURNING GEAR OIL VALVE ON
+ SUBLOOP CONTROL DRAINS ON
THE SUBLOOP CONTROLS MUST ALWAYS BE
SWITCHED ON DURING OPERATION
+ TURBINE/GENERATOR LOAD > 0 MW
IT IS ASSUMED THAT THE TURBINE/GENERATOR
WILL BE UNLOADED FROM ANY LOAD TO 0 LOAD
WITHOUT DELAY
(02) + LOAD REFERENCE VALUE LOWER

+ LOAD TARGET VALUE 0 MW
OR WITH FGA (TURBINE -CONTROl)
+ FGA (TURBINE -CONTROL STANDSTILl) START
(02/S) * + LOAD TARGET VALUE 0 MW
(031 + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
THE LIMITED LOAD REFERENCE VALUE FOLLOWS
THE TARGET LOAD REFERENCE VALUE WITH THE
ADJUSTED LOAD GRADIENT. THE LOAD GRADIENT
WILl. BE REDUCED IF REDUCTION OF TSC
ALLOWANCE OCCUR. THE TSC INFLUENCE WILL
+ TURBINE/GENERATOR LOAD: STEAM GENERATOR LOAD <1
(04) * + START OF BYPASS OPERATION OBSERVE

BYPASS VALVES OPEN IF LOAD OF STEAM
GENERATOR IS GREATER THAN
TURBINE/GENERATOR LOAD
*+ BYPASS STOP VALVES OPEN MAN11 AAO01
AND MAN12 AAO01
*+ BYPASS CONTROL VALVES OPEN MAN11 AAOO2
AND MAN 12 AAOO2

(50) + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
+ AUXILIARY POWER SUPPLY SECURED
CRITERION:
AFTER THE GENERATOR CIRCUIT BREAKER IS OPEN
THE UNIT AUX. POWER SUPPLY IS SECURED
OPERATION OF SWITCH GEARS MUST AGREE
WITH AUXILIARY POWER SUPPLY FACILITIES
*+ TURBINE LOAD CONTROLLER OFF
*+ TURBINE SPEED CONTROLLER ON
AFTER A FIX SET MINIMUM LOAD IS REACHED
THE TURBINE CONTROLLER CHANGES OVER FROM
LOAD TO SPEED CONTROL
(06) + SPEED REFERENCE VALUE LOWER

OR WITH FGA (TURBINE -CONTROL)
(06/S1 *+ SPEED REFERENCE VALUE LOWER
+ SPEED REFERENCE VALUE < RATED SPEED
*+ MAIN STEAM CONTROL VALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 10 AAOO2
AND MAB20 AAO02
*+ REVERSE POWER PROTECTION INITIATED
*+ GENERATOR CIRCUIT BREAKER OPEN
MEASURES TO BE TAKEN ON FAILURE.
OF REVERSE POWER PROTECTION REF. TO 5.2-0410
(07) + TEST PROGRAM (SHUT DOWN I CARRY OUT REF, TO 5.3-0060

TESTING INTERVALS OBSERVE REF. TO 5.2-0020
FGA PROGRAM INTERRUPT
(08) + TURBINE TRIP INITIATE

OR WITH FGA
(08/S) *+ TURBINE TRIP INITIATED
+ BEGIN OF COASTING DOWN TIME NOTE
*+ TRIP FLUID PRESSURE 0 KG/CM2 MAX51 CPO 13
*+ MAIN STEAM STOP VALVES CLOSED MAA10 AAO01
AND MAA20 AAO01
*+ REHEAT STOP VALVES CLOSED MAB10 AAOO1
AND MAB20 AAO01
*+ MAIN STEAM CONTROL V ALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 1 0 AAO02
AND MAB20 AAO02
*+ SWING CHECK VALVE COLD REHEAT CLOSED LBC10 AAO01
*+ EXTRACTION NON RETURN VALVES CLOSED
CODE NO. OF EXTRACTION NON RETURN VALVES
REFER TO SINGLE LINE DIAGRAMS
*+ VACUUM BREAKER OPEN MAG10 AAO01
VACUUM BREAKER BRINGS VACUUM DOWN TO O.2KG/CM2
VACUUM BREAKER CLOSED AT VACUUM > 0.2 KG/CM2
IN CASE OF DANGER TO THE TURBINE/GENERATOR
THE VACUUM CAN BE REDUCED SO THAT COAST P AMB
DOWN TIME WILL BE REDUCED ACCORDINGLY.
*+ SPEED OF TURBINE/GENERATOR < 3000 RPM
(09) + STARTING AND LOAD LIMIT DEVICE LOWER MAX47BYO01

+ STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01
OR WITH FGA (TURBINE -CONTROL)
(09/5) + STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01
5.2-0230-01/2
(10) + DE-EXCITATION BREAKER OPEN
+ DE-EXCIT A TION BREAKER OPEN
(11) + VACUUM BREAKER CHECK

+ VACUUM > 0.2 KG/CM2
+ VACUUM BREAKER CLOSED
(12) + SPEED REFERENCE VALUE LOWER

+ SPEED REFERENCE VALUE 0%
(13) + WARM-UP CONTROL (SEAL STEAM) SWITCH CONTROL

+ WARM-UP CONTROL (SEAL STEAM) OFF
(14) + DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPEN MAL11 AA011
OR WITH FGA AND MAL12 AAO 11
+ DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPEN MAL 11 AA011
AND MAL12 AA011
(15) + START OF AUXILIARY OIL PUMP OBSERVE MAV22 APO01

OR
+ START OF EMERGENCY OIL PUMP OBSERVE MAV24 APO01
+ OIL PRESSURE < 4.8 KG/CM2 MAV21 CPO01
+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV22 APO01
OR
+ OIL PRESSURE < 4.5 KG/CM2 MAV21 CPO01
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
*+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV23 APO01
OR
+ LUBE OIL PRESSURE < 1.2 KG/CM2 MA V42 CPO 14
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
AND MAV23 APO01
*+ EMERGENCY OIL PUMP BY SUBLOOP CONTROL ON MAV24 APO01
+ OIL TEMPERATURE CONTROL VALVE CLOSE MAV41 AAO01
+ OIL TEMPERATURE CONTROL VALVE CLOSED MAV41 AAO01
+ SPEED OF TURBINE/GENERATOR < 510 RPM

(16) + JACKING OIL PUMP SWITCH ON MAV31 APO01
OR MAV32 APO01
+ JACKING OIL PUMP ON MA V31 APOO 1
OR MAV32 APO01
OR BY SURLOOP CONTROL JACKING OIL PUMP
*+ JACKING OIL PUMP ON MAV31 APO01
MAV32 APO01
+ JACKING OIL PRESSURE IN HEADER > 100 KG/CM2 MAV35 CP012
OR
JACKING OIL PRESSURE IN HEADER < 100 KG/CM2 MA V35 CPO 12
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON MAV32 APO01
OR
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON MAV33 APO01
ON FAILURE OF AC POWER
+ END OF COASTING DOWN TIME NOTE
THE MEASUREMENT OF COASTING DOWN TIME
WILL GIVE VALUABLE INFORMATION ABOUT
INTERNAL CONDITIONS OF THE TURBINE, ESPECIALLY
WHEN SHUTDOWN OCCURS DUE TO DANGER
5.2-0320-01/3
+ SPEED OF TURBINE/GENERATOR < 210 RPM
(17) + TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
+ TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
OR BY SUBLOOP CONTROL TURNING GEAR
*+ TURNING GEAR OIL VALVE OPEN MAV51 AAO01
(18) + DRAIN VALVES OPEN

+ DRAIN HP OUTER CASING OPEN MAL22 AA011
CRITERION:
TEMPERATURE HP OUTER CASING MIDDLE TOP < 300 °C
OR TURBINE LOAD <2%
+ DRAIN AHEAD OF CRH SWING CHECK VALVE OPEN MAL65 AA011
CRITERION: CRH NRV CLOSED
+ DRAIN UPSTREAM OF EXTRACTION VALVES OPEN
DESIGNATION OF DRAIN VALVES ACCORDING
TO SINGLE LINE DIAGRAM.
CRITERION: EXTRACTION CHECK VALVES CLOSED
+ DRAIN SEAL STEAM HEADER OPEN MAL81 AA011
CRITERION: TEMPERATURE IN SEAL STEAM HEADER < 120 °C
+ SUBLOOP CONTROL OF DRAINS NOT FAULTED
*+ DRAIN VALVES BY SUBLOOP CONTROL OPEN
CRJTERION : REFER TO MANUAL OPERATION
(19) + MODE OF OPERATION STEAM GENERATOR CHECK

AND
+ MODE OF OPERATION BYPASS CONTROLS CHECK
AND
+ MODE OF OPERATION CONDENSING PLANT CHECK
+ STEAM GENERATOR NOT IN SERVICE
+ BYPASS OPERATION COMPLETED
CRITERION:
BYPASS STOP VALVES CLOSED
BYPASS CONTROL VALVES CLOSED
THE BYPASS OPERATION IS COMPLETED IF THE
REHEATER OF THE STEAM GENERATOR IS
DEPRESSURIZED. THE REHEATER WILL BE
DEPRESSURIZED BY LEADING THE STEAM INTO
THE CONDENSER OR BY OPENING THE EXTERNAL
REHEATER DRAIN VALVES. THE BYPASS VALVE
WILL BE USED TO LEAD THE STEAM TO THE
CONDENSER. THE FIXED PRESSURE SET POINT
HAS TO BE LOWERED.
+ CONDENSING PLANT NOT IN SERVICE REF. TO 5.2-0330
VACUUM PUMPS OFF
CONDENSATE PUMP OFF
NOTE
IF THE CONTROL FLUID SYSTEM WILL BE SHUT
DOWN WITHOUT SHUTTING DOWN THE
CONDENSATE PUMP THE BYPASS SPRAY
WATER VALVES WILL OPEN. ON REF. TO 5.2-0330
OR OFF
+ SEAL STEAM PRESSURE P AMB
SEAL STEAM CONTROLLER OFF
SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
FAN OF SEAL STEAM CONDENSER OFF MAW80 ANOO1
AND MA W80 ANOO2
5.2-0230-01/4
+ TEST PROGRAM (STANDSTILL) COMPLETED
+ CONTROL FLUID SUPPLIED DEVICES NOT IN SERVICE
(20) + CONTROL FLUID SYSTEM MANUAL OPERATION SHUTDOWN
OR WITH FGA (CONTROL FLUID SYSTEM)
+ FGA (CONTROL FLUID SYSTEM STANDSTILD START
REFER TO THE MANUAL FOR FGA.
(21) + SUBLOOP CONTROL HP .CONTROL FLUID PUMP SWITCH OFF

+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
+ HP -CONTROL FLUID PUMP OFF MAX16 ArOO1
OR MAX 16 APO02
(21/S) *+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
(21/5) *+ HP -CONTROL FLUID PUMP OFF MAX 16 APOO 1
AND MAX 16 APOO2
NEUTRALIZATION NO. NORMAL

NEUTRALIZATION NO. DOES NOT
TEND TO INCREASE
(22) + CF -RECONDITIONING PUMP SWITCH OFF MAX91 APOO1
+ CF -RECONDITIONING PUMP OFF MAX 91 APOO1
(22/S) *+ CF -RECONDITIONING PUMP OFF MAX91 APOO1
+ TEMPERATURE IN CONTROL FLUID TANK < 50 °C MAX11 CTO01

(23) + SUBLOOP CONTROL OF CONTROL FLUID HEATER SWITCH OFF
FLUID HEATER
SWITCH OFF SUBLOOP CONTROL OF CONTROL
FLUID HEA TEA ONLY IF THE CONTROL FLUID SYSTEM
MUST NOT BE OPERATED FOR AN EXTENDED PERIOD ~
OF TIME AND/OR THERE IS SUFFICIENT TIME TO C
HEAT-UP THE CONTROL FLUID IN THE TANK PRIOR
TO RESTART.
5.2-0320-01/5
Steam Turbine Condensing Plant
Operation Shutdown Diagram
(1) CRITERIA FOR SHUT DOWN CHECK

+ STEAM GENERATOR NOT IN SERVICE
+ BY PASS OPERATION COMPLETED
+ HP BYPASS VALVES CLOSED
+ EXTERNAL DRAINS OF STEAM LINES OPEN
BEFORE THE CONDENSING PLANT Will BE SHUT
DOWN ALL. ADMISSION STEAM SYSTEM HAVE
TO BE DEPRESSURIZED.
(2) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOllOWING CRITERIA ARE FillED
THE SYSTEM Will BE SHUT DOWN FROM OPERATION
+ AIR SUCTION VALVE OF VACUUM PUMPS OPEN
+ SERVICE VACUUM PUMP ON
+ VACUUM BREAKER CLOSED
+ SEAL STEAM CONTROL ON
AND
+ SEAL STEAM SUPPLY VALVE OPEN
+ SEAL STEAM EXHAUST FAN ON MAW11 AAO01
MAW80 ANO01
ORMAW80 AN02
+ CONDENSATE SYSTEM IN OPERATION
+ CIRCULATING WATER OF CONDENSER AVALABLE
+ VACUUM BREAKER OPEN
+ WARM-UP CONTROL (SEAL STEAM) ON
(3) + CONSENSING PLANT MANUAL OPERATION SHUT DOWN

OR WITH FGA (CONDENSING PLANT)
+ FGA (CONDENSING PLANT STANDSTill) START
FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAlFORTHEFGA
(4) + AIR SUCTION VALVE VACUUM PUMP CLOSE

+ AIR SUCTION VALVE VACUUM PUMP CLOSED
(5) + VACUUM PUMPS SWITCH OFF

+ VACUUM PUMPS OFF
THE VACUUM PUMPS DO NOT BELONG TO THE
SCOPE OF SUPPLY OF THE TURBINE/GENERATOR
OPERATION OF VACUUM PUMPS AND VALVES
ACCORDING TO SPECIAL INSTRUCTION.
(6) + VACUUM BREAKER OPEN MAG10 AAO01

+ VACUUM BREAKER OPEN MAG10 AAO01
OR WITH FGA, SUBGROUPS (SEAL STEAM SUPPLY
STANDSTILL)
(06/S) *+ VACUUM BREAKER OPEN MAG10 AAO01

+ VACUUM > 0.8KG/CM2
+ SEAL STEAM CONTROL SWITCH OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSE MAW11AAO01
+ SEAL STEAM CONTROL OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
OR WITH FGA,SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(07/S) *+ SEAL STEAM CONTROL OFF
AND
(07/S) *+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
(08) + SEAL STEAM EXHAUST FAN SWITCH OFF MAW80 ANO01

ORMAW80 AN02
+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(08/S) *+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2
()9) + CONDENSATE SYSTEM SHUT DOWN

+ CONDENSTATE SYSTEM NOT IN SERVICE
THE CONDENSATE SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE-
GENERATOR). SPECIAL INSTRUCTIONS FOR
-CONDENSATE PUMPS
-CONDENSER lEVEL CONROl
-MINIMUM FlQW CONTROL
-HEATERS
MUST AGR~E WITH TURBINE OPERATION AND
HAVE TO BE FOllOWED.
THE CONDENSATE SYSTEM CAN ALSO BE
SHUT DOWN AFTER STEP (12) IS CARRIED OUT.
(10) + CIRCULATING WATER SYSTEM SHUT DOWN

+ CIRCULATING WATER SYSTEM NOT IN SERVICE
C.iRCUlATING WATER SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE
GENERATOR).
THE CIRCULATING WATER SYSTEM SHOULD STAY
IN OPERATION DURING SHORT DOWNS TO
AVOID CORROSION OF THE CONDENSER TUBES,
THE CIRCULATING WATER’SYSTEM CAN£E SHUT
DOWN AFTER STEP (12) IS CARRIED OUi.
(11) + VACUUM BREAKER CLOSE MAG10 AAOO1

+ VACUUM BREAKER CLOSED MAG10 AAO01
OR WITH FGA (SEAL STEAM SUPPLY STANDSTill)
(11/S) *+ VACUUM BREAKER CLOSED MAG10 AAO01
(12) + WARM-UP CONTROL (SEAL STEAM) SWITCH OFF

+ WARM-UP CONTr10l (SEAL STEAM) OFF
OR WITH FGA (SEAL STEAM)
(12/S) +* WARM-UP CONTROL (SEAL STEAM) OFF
5.2-0330-01/2
Steam Turbine Oil System
Operation Shutdown Diagram
(01) + CRITERIA FOR STANDSTILL CHECK

+ CASING TEMPERATURE < 100 °C MAA50 CT053A
BEFORE THE TURBINE GEAR IS STOPPED, SHAFTS AND MAA50 CT054A
AND CASING MUST COQL DOWN TO 100 °C TO
PREVENT SHAfT DISTORTION DURING STANDSTILL
PERIOD FOLLOWING TURNING GEAR OPERATION.
THE TURNING GEAR MUST BE STOPPED IF ABOVE
TEMPERATURES ARE REACHED, EXCEPT IN CASES
WHERE EXTENDED TURNING GEAR OPERATION IS
REQUIRED e.g. IF THE TURBINE IS TO BE STARTED
IN SHORT TIME.
(02) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOLLOWING CRITERiA ARE FULFILLED
THE SYSTEM WILL BE SHUT DOWN FROM
TURNING GEAR OPERATION.
+ SUBLOOP CONTROL TURNING GEAR ON
AND
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
AND
+ AVXILIARY OIL PUMP ON MAV22 APOOl
OR MAV23 APOOl
+ WAITING TIME FOR COOLING DOWN (K4) EXPIRED
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
AND
+ JACKING OIL PUMP ON MAV31 APOOl
OR MAV32 APO01
(03) + FGA (OIL SUPPLY STANDSTILl)

FOR OPERATION OF PUSH BUTTONS REFER
TO MANUAL FOR FGA.
OR
+ TURNING GEAR MANUALLY OPERATED SHUTDOWN
(04) + SUBLOOP CONTROL TURNING GEAR SWITCH OFF

AND
+ TURNING GEAR OIL VALVE CLOSE MAV51 AAO01
+ SUBLOOP CONTROL TURNING GEAR OFF
AND
+ TURNING GEAR OIL VALVE CLOSED MA V5 1 AAOO 1
OR WITH FGA (OIL SUPPLY)
(04/S) *+ SUBLOOP CONTROL TURNING GEAR OFF MAV51AA012
(05) + WAIT
THE WAITING TIME IS EXPIRED WHEN THE
SHAFT COMES TO A COMPLETE STOP.
+ SHAFT STAND STILL

06) + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS SWITCH OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH OFF
AND
+ AUXILIARY OIL PUMP SWITCH OFF MAV22 APO01
OR MAV23 APOOl
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
+ AUXILIARY OIL. PUMP OFF MAV22 APO01
AND MAV23 APO01
AND
+ EMERGENCY OIL PUMPS OFF MAV24 APO01
OR WITH FGA (OIL SUPPLY)
(06/S) *+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
*+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
*+ AUXILIARY OIL PUMP OFF MAV22 APOOl
AND MAV23 APO01
AND
*+ EMERCJENCY OIL PUMP OFF MAV24 APO01
(07) + WAIT
WAIT FOR SHUTDOWN OF JACKING OIL PUMP UNTIL
THE RELATIVE EXPANSIONS ARE REDUCED AND NO
FURTHER MAJOR AXIAL SHIFTING OF THE JOURNALS
IN THE BEARINGS IS EXPECTED.
(08) + SUBLOOP CONTROL OF JACKING OIL PUMP SWITCH OFF

AND
+ JACKING OIL PUMP SWITCH OFF MAV31 APOOl
OR MAV32 APO01
+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
+ JACKING OIL PUMP OFF MAV31 APO01
OR WITH FGA (OIl. SUPPLY) AND MAV32 APO01
(08/S) *+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
*+ JACKING OIL PUMP OFF MAV31 APO01
AND MAV32 APO01
5.2-0340-01/2
Steam Turbine Fast Cooling Down of the Turbine
Operation
Introduction Shutdown the turbine in accordance with the

respective instructions after cooling down during
If service activities or repairs have to be carried bypass operation has been completed.
out very soon or immediately after shut down of the
turbine, it is advisable to reduce the cooling down
time. Fast coolinQ down is necessary especially if Fast cooling down during stand still
activities are to be executed at turbine parts which
are exposed to high operational temperatures. During stand still air will be sucked through the
turbine by the vacuum pumps resulting in fast cooling
Cooling down of the turbine during operation of casing and rotor.
The cooling down of the turbine Is to be started Arrangement of the elr Inlet sockets
during load operation as follows:
HP turbine: Between main steam stop valves and
Reduce unit power output to the boiler minimum control valves.
load.
Slowly reduce admission temperatures to values IP turbine: At the admission pipes between control
which can be maintained steady by boiler control. valves and IP turbine,
The HP exhaust temperature may not be reduced During normal operation the air inlet sockets are
to the saturation point corresponding to the HP closed by blank flanges.
exhaust pressure.
Procedure
Observe the TSErrSC lower margin.
Open air inlet sockets
NOTE: Do not reduce load and temperature at
the same time because of the danger to Set test valve of all stop valves in the position stop
excettdthepermissible relatIve expansion and the valve closed.
lower margin of the TSE/TSC
Operate vacuum pumps
Load or temperature reduction have to be stopped
or the rate of ‘change to be reduced depending l’pon Observe TSErrSC lower margin and stop vacuum
the limiting values of relative expansion and the lower pumps if limit values are exceeded.
margins of the TSE/TSC.
Operate the turbine with reduced load and steam The fast cooling down of turbine has to be
temperatures until the lower margin of TSE/TSC limited to those cases where this measure is
do not change significantly any more. unavoidable with respect to the availability of the
turbine.

Steam Turbine Preventing Corrosion
Maintenance in Idle Turbines
Introduction Fig.1 shows the effect of relative humidity on rusting

If a turbine stands idle for a long period it is liable loss (VA) for a sample of carbon steel.
to corrosiorl attack which if not prevented by The rusting loss increase sharply when the relative
appropriate means, will cause deterioration of the humidity is high therefore, to inhabit corrosion attack
componants. in an idle turbine, the ralative himidity of the enclosed
air should be maintaine below 50% as far as possible.
During long idle periods when the turbine has
cooled to the ambient temperatures, all components
which come into contact with steam vapour, water or
damp air are liable to corrision attack.
The Effect of Corrosion
Seizure of sliding components due to increased

volume of the products of corrosion,
Heavier wear of corrosion-damaged surfaces,
erosion of material.reducing sections and

producing notch effects which weaken the
components.
Leaks at valve and fittings,
fouling of the systems which spreads the corrosion

to other areas.
Factors Contributing to Corrosion
Chamically corrosive gases and vapours are

seldom encountered in normal power stations in
sufficiently high concentrations to cause damage.
However, if a turbine is installed in or near a chemical FIg. 1 Enect of Relative HumIdIty on Hustlng Loss Vr
plant it wolJld be possible for such gases and vapours
to increase the amount of corrosion. Preventing Corrision During Idle Periods
On the other hand, water-which is responsible for If complete effectiveness of the following method
a high proprotion of all corrosion -is found in all of corrosion prevention is to be achieved, it is essential
turbines which have cooled down and been idle for for no steam at all to enter the turbine while it is idle.
some time.
Any auxiliary steam lines which will remain under
The water originates from: steam pressure during a complete unit shut-down
must be isolated in a manner which ensures that no
Residual water in inadequately drained spaces steam can enter the turbine.
steam leaking into the turbine and condensing
the condensation produced when the temperature

within the turbine falls below point ( this is the
principal source of the water).

The turbine itself and its connecting pipe work
must be well drained through out the idle period. It is
also advisable to drain the condensate from the
condenser.
There are basically two possible methods of
preventing corrision attack caused by condensation
from the air inside the turbine:
The turbine components can be heated by means
of a hot air blower to a temperature above that of
the outside air.
The high relative humidity air inside the turbine
can be exchanged for dry air.
For large turbines, therefore, a method of

prevention is recommended employing an Air dryer
1 Heater
2 Fan
3 Filter
Fig. 3 Dry air preservation system for a HMN-turbine
Fig.2 Principle of the Air Dryer
to exchange the high relative humidity air in the turbine
for dry air.
Filtered air from the atmosphere is drawn into the The wet air escapes at the drains behind HP
Air dryerby a fan and moisture is removed from it In a Turbine at flanges between IP.valves and IP casing
rotating drying wheel before it is delivered to the and the lowest point of the condensers.
turbine. The dying wheel which has absorbed the
moisture is dried by a reverse flow of hot air in the Main steam control valves have to be opened and
regenerating sector which is separate from absorption blocked in this position.
sector.
There will an obevious drop in the relative humidity Operation of the air -dryer must be exccuted in
only a few hours after switiching on the Air dryer. It aqcordance with the instructions of the dryer-
must be operated continously while the turbine is idle. manufacturer.
The dryer’s relatively low power consumption does
not involve any great cost. The air dryer does not belong to the scope of
supply of BHEL.
The filter of the Air dryer must be clean from time
to time depending on the dust content in the air supply.
It is inadvisable to operate the air dryer without the Preservatlt!lnof the Oil System
filter because of the danger of blockage in the fine
tubular ducts of the absorption wheel. Two air dryers The turbine oil contains corrosion inhibitors
are needed. therefore it is unnecessary to adopt any special
measures to preserve oilcarrying components except
Figure 3 shows the interconnection between air- to operate one of the auxiliary oil pumps for an hour
dryers and turbine. at intervals of two to three weeks.
5.2-0360/2
Steam Turbine Fault Tracing
The scope and content of the trouble shooting In the instruction “Special Faults” (1), measures
instructions are limited to criteria or mearure that can are complied that must be taken when faults occurs
be performed by the control panel operator or the that could have servere consequences.
turbine operator without specialised help and averting The operating staff must be trained to take proper
events determental to the operation and availability actoin should these faults occur.
of the turbine generator unit.
Also refer to tne following information

[1] 5.2-0410 Serious Faults

Steam Turbine Serious Fault
Operation Fault Tracing
Introduction Many of the criteria refer not only to extreme

Many operating faults require the monitoring staff conditions requiring immediate action but also to the
to take immediate appropriate action if serious trends of the process transients, which must also be
reductions in the availability, operating reliability and taken into consideration.
service life of the turbine are to be averted. The turbine is in danger not only when the
The following criteria and instructions must be specified limits of a process parameter are reached
included in the intensive schooling and training but also when the process parameter deviates
program for the monitoring staff. markedly or rapidly from the normal values otherwise
observed.
Fault
Other symptoms Cause Remedy
Load Rejection
Turbine generator remains in opera- Breaker opens as a result of an Control valves and extraction valves
tion after short-time rise in speed internal or external fault closed by the turbine governor to
stop the steam flow through the
turbine;
manual intervention is not possible
as automatic shut-down is too fast;
Excess steam from steam generator Normal procedure Reduce steam generator to minimum
is dumped to the condenser through output immediately if this is not
the bypass valves done automatically by the unit
control;
Prolonged operation at rated speed operation may continue indefinitely;
with or without residual load Limits specified in 5.1-0101 must
not be exceeded;
set reference speed setter to rated
speed;
Reduce main steam temperature
or load
turbine if HP turbine exhaust
steam temperature approaches to limits;
General rule:
determine cause of shut-down
synchronize generator if permitted
by results of fault tracing.
Load rejection with turbine trip
Turbine speed reaches trip speed Beaker opens as a result of See also Turbine Trip and 5.2- 0450
of overspeed trip internal or external fault;
Adverse condition during load investigate conditions;
rejection; e.g. load and speed prior to load
rejection
Control malfunction check control ana remedy malfunction;
Turbine Trip
Turbine trip by protective Stop and control valves and extraction
devices valves close;
generator disconnected from steam
by reverse power protection relay;
speed drops;
auxiliary oil pump cuts in due to
loss of pressure as speed drops;
turning gear operation commences;
Turbine -generator unit in reduce condenser vacuum to shorten
imminent danger coast down;
-open vacuum beaker;
-stop air extraction;

Fault
-allow air to enter condenser plant.

Excess .;team from steam generator Reduce steam generator to minimum
is dumped to the condenser through output immediately if this is not done
the bypass valves automatically by the unit control;
General rule:
Overs peed after load rejection Determine cause of trip see also
Shaft displacement in thrust 5.2- 0450
bearing due to damage to bearing; see load rejection with turbine trip;
Condenser vacuum reduce due to inspect thrust bearing and, if necessary,
fault in condenser plant; repair, see also 5.2-0421 refer to fault
Remote trip by protective devices tracing instruction and eliminate fault;
in steam supply system, turbine Refer to relevant fault tracing
or generator instruction and eliminate fault
Reverse power protection relay
fails to open generator breaker
turbine control valves closed by Suspected that steam is still Attention: do not open generator
control as load removed entering the turbine breaker manually (danger of imper-
missible overspeed );
check positions of control and
extraction valves.
(Desired position: 0%);
trip turbine;
observe closing of stop valves;
check steam pressure in turbine;
check output display;
reduce condenser vacuum;
--open vacuum breaker;
--stop air extraction from
--condenser plant;
--allow air to enter condenser plant;
open turbine drains;
open drains between stop and control
valves;
shut down steam generator;
reduce steam pressure in steam
supply lines;
Fault in reverse power protection if reverse power protection relay is not
relay actuated by all or some of the above
mentioned measures, it is very probable
that there is a fault in the reverse
power protection relay;
in this case; disconnect the generator
from the supply sY$tem by opening
the breaker;
The following parameters exceed
the permissible limits even though
remedial measures have been taken
as prescriPed in the relevant fault
tracing instructions
Vibration high see 5.2--0420 Use load limiting device to reduce load
or on turbine -generator unit from any
causing differential temperatures see 5.2-0423 operating mode to no -load and! or
high shut down unit by actuating main trip
or valve;
bearing metal temperatures high see 5.2-0421 reduce condenser vacuum to shorten
coastdown;
or
5.2-0410/2
Fault
differential expansion high see 5.2-0422 Note: The decision whether the load
or limiting device should be used to
temperature differences between further reduce load before the main trip
parallel steam supply lines high valve is actuated will depend both on
or the seriousness of the danger and on
rapid, large drop in inlet stream the amount by which the limits are
temperature exceeded.
or
condensate level in condenser
very high
The following parameters exceed the
permissible limits
Inlet steam pressure high; pressures Steam generator output too high Reduce steam generator output
and duration of exposure to or
excessive pressures limited as increase turbine load
specified in 5.1-0100
Inlet steam temperatures high; Fault in steam generator Change steam generator operation;
Temperatures and duration of eliminate fault if necessary;
exposure to excessive tempera-
tures limited is specified in .
5.1-0101
Steam pressures upstream of Load too high Reduce turbine load;
blading and/or extraction steam
pressure high;
Pressures and duration of exposure
to excessive pressures limited as
specified in 5.1-0100
Irregularities in the turbine e.g. blade Measure stage pressures and compare
fouling with normal values under identical
operating conditions;
measure efficiency;
HP exhaust temperature high during Reduce main steam temperature or
no-load or low-load operation increase turbine load;
if these measures do not reduce the
temperature ,initiate turbine trip;
LP turbine exhaust temperature high Ventilation through blading Start injection into LP turbine or
during no load or low-load operation increase load;
Bypass stream temperature high Condenser vacuum low
during bypass operation Injection water pressure too low Check condensate pumps;
Bypass steam flow rate too high Reduce steam generator output
Control valve or stop valve fails to
open again after testing with automa-
tic turbine tester
all measures as prescribed in Fault in valve or turbine tester The turbine plant may be operated
5.2-0455 fail with defective valve for max. 1 week;
If necessary ,the output must be
reduced so that the limits as
prescribed in 5.1 -0100 are not
exceeded;
Drain line upstream and down stream
of defective valve thoroughly;
Observe limits for temperature
difference between parallel steam
supply lines;
5.2-0410/3
Fault
Shaft assembly runs down without

lubricating oil
Fault in auxiliary and emergency oil Check bearing metal temperatures; if
pumps, shaft lift oil pump in operation impermissibly high ,inspect bearings
Fault in shaft lift oil pump(s) Danger of bearing Whipping .Check
bearing metal temperatures;Cfieck
bearings
Fire or fire hazard during operation Set off fire alarm; follow fire protection
rules;if necessary ,initiate fire-fighting
measures;
at the same time:
Escape of Control fluid Leakage in piping or other turbine Press fire.protection pushbutton 1 or
components Switch off subloop control for the
control fluid pumps immediately and
shut down (operating) pump (result:
turbine generator unit trips)
Escape of oil from the lubricating Leakage in piping or other turbine Press fire.protection pushbutton 2
oil system components (Pressing fire-protection pushbutton 2
automatically initiates fire-protection 1
measures); result: turbine generator unit
trips; or, shut down turbine generator
unit. Oepressurize control fluid systems
(measures as above): Switch off sub
loop control for Shaft lift oil pumps;
Start up shaft lift oil pumps; Switch off
subloop control for auxiliary oil pump;
if necessary, shut down auxiliary oil
pump(s); check to ensure that subloop
control cuts in emergency oil pump as
oil pressure drops; Close turning gear oil
valve; reduce condenser vacuum to
shorten coast down;
-open vacuum breaker
-stop air extraction from condenser plant
allow air to enter condenser plant
Shaft comes to a standstill when Shut down DC bearing oil pump; Keep
fire-protection measures are shaft lift oil pump in operation if no
initiated leakagefrom the shaft lift oil
system; Turn shaft though 180
degrees at intervals of approx. 10
minutes; For treatment of turbine
after complete standstill shaft see
5.2-0460.
Eliminate leak and perform
hydrostatic pressure test;
Acknowledge initiation of fire
protection measures; Restart
lubricating and control fluid system;
Commence turning gear operation;
Reserve and replace insulating
materials soaked with escaped fluid;
Clean structural and mechanical
components contaminated with
escaped fluid; Start up turbine
generator unit
Note: if the above instructions are
observed ,it is unimportant what the
degree of automation of the fire
protection devices- with regard to
trip initiation and shortening of the
coast down time is;
5.2-0410/4
Fault
Fire or fire hazard during

turning gear operation
Set off fire alarm;
Follow fire protection rules;
If necessary ,Initiate fire-fighting
measures;
Escape of control fluid leakage in piping or other turbine Measures as for: Fire or fire hazard
components during operation
Escape of oil from the lubricating oil leakage in piping or other turbine Shaft lift oil pump stays in operation;
system components Close turning gear oil valve; Switch of
subloop control for auxiliary oil pumps;
Shut down auxiliary oil pumps;
Check to ensure that ,sub loop control
cuts in the bearing oil pump as oil
pressure drops; For further measures,
see
Fire or fire hazard during operation
Escape of oil from the shaft lift oil leakage in piping or other turbine Shut down shaft lift oil pump (risk of
system components bearing damage is minor if turning gear
stays in operation);
Isolate and eliminate leak, Start up
shaft lift oil pump;
Lubricating or control fluid loss
annunciated by level monito,ring
circuit
Separate control fluid system
Alarm: fluid level low or very low
(2-out-of-3) The system must be checked
immediately for leakage if this alarm
is generated in rapid succession,
a leak must be assumed and
appropriate fire-protection measures
taken;
Oil system The system must. be checked
Alarm: oil level low immediately. Check for leakage if this
alarm is generated;
Oil system
Turbine trip due to oil level very low
(2-out-of-3) Fire protection measures initiated
automatically;
Note: The trip system is inoperative
during turning gear operation;
Escape of steam
Leakage in piping or other turbine Localize steam leakage immediately
components and depressurize system concerned,
if possible; if there is a rupture hazard
(pre-rupture leak), shut down turbine
generator unit immediately Carefully
consider risk of erosion at sealing
surfaces and decide on time of shut
down;
Earthquake Unload and shut down turbine genera-
tor unit rapidly;
Check bearings and alignment;
Check valve supports;
Check pipe hangers and tank supports.
5.2-0410/5
Steam Turbine Vibration
Despite all design, manufacturing and erecti9n So, it is difficult to give a complete list of possible
measures to prevent it, excessive vibratioin can occur causes and ‘power corrective action to be taken in
and because the various kinds of vibrations are this procedure.
intermingled, the reasons for it are difficult to isolate.
The following data refers to the characteristics,
If excessive vibration occurs, it is necessary to causes and remedial actions pertaining to some
carryout extensive tests together with the typical type of vibration
manufacturerto determine its cause and effective
measures to be taken to combat it.
Fault
Rapid or instantaneous increase

in vibration over the permissible
limits or the range of the
measuring system
(alarm or instrument display)
Loud noises and/or the following Suspected damage,e.g. broken Caution: Stop turbine immediately
operating parameters exceed blades or metalto metal rubbing even when accuracy of reading is
their limits, doubtful;
Wall temperature because of Clearances eliminated by casing check whether increased vibration
rapid temperature changes distrortion is maintained after load is reduced
and when running down.
Casing differential temperatures. Clearance eliminated by casing measure the time taken to run
distortion. down; listen for noises during 1his
period.
Low-frequency vibration. Unatable running due to self- Reduce turbine load immediately
vibration frequency less than excited vibration until vibration decreases;
rotational frequency. examine vibration;
Irregular point trace from recording load turbine slowly to stability
instrument. limit.
Vibration increases above normal

values for specific power outputs
and operating conditions
Vibration values less than Many possible causes. Carryout the following tests to find
permissible limits out the causes;
Determine main frequency of vibration;
measure vibration at all bearings in
three planes
h horizental
v vertical
a axial
measure shaft vibration in two
directions at right angles if possible;
measure the phase relationship of
the bearing and shaft vibration;
measure the foundation vibration;
measure the vibration in relation to
all principal operating parameters
and their variations.

Fault
Increased vibration at rated speed

Increased vibration over entire Changes in shaft system balance Examine magnitude and direction
load range under steady-state due to: of vibrations;
opera1ion. Rotor condtion induced by eccentric
check the coupling for;
Vibration increased above previous coupling. Firm and proper fit of coupling
values, including when passing bolts;
through critical speed ranges fit of centring spoigot and re
cess; redial runout of couplings
axial runout of coupling faces;
alignment;
initial corrective action:
Dynamically re-balance the rotors
(except if coupling bolts are not
tight and alignment unsatisfactory);
correct any discrepancies
found during the checks;
Permanent shaft distortion due to Measure redial runout of shaft;
metal to metal rubbing Dynamic re-belancing of rotors.
final corrective action.
Stress relieving thermal
stabilisation and balancing at
manufacture’s works if
runout is more.
Blade damage Inspect blading;
it blades in the finallP stages are
damaged, a temperory corrective
measures is to shorten the blade
in the 1800 opposite position to
damaged blade or to attach a
balancing weight in the plane of
damage to compensate for the
missing piece (consult
manufacturer).
If the blade damage is suspected
elsewhere the appropriate turbine
casing must be opened; .
Modifications or repair on the Dynamic re-balance of rotors.
blades during an overhaul,
Temporary increase in vibration Temporary shaft distortion due to Reduce speed,load and/or tempera-
during non-steady operating temporary non-uniform temperature ture rates of change;
conditions (startup, loading distribution during temperature wait until vibration improves when
and unloading, main steam changes. steady-state conditions are reached;
temperature changes,etc.)
Temporary distortion of shaft Reduce load and/or temperature
resulting from metal to metal rubbing rates of changes;
at the seal rings caused by misalign-
ment due to temperature changes.
Alignment changes due to restricted Remove restriction to expansion
expansion at turbine cassssing and by improving sliding of bearing
bearing housings. housings and casing guides.
5.2-0420/2
Fault
Constait relationship between Many possible causes. Determine relationships by measuring

vibration and specific operating magnitude and direction of
conditions and changes vibration under varied operating conditions.
If possible, vary only one operating
parameter at a time;
after. each variation there must be a
delay for steady-state conditions;
check the following operating
parameters and conditions.
Speed
Active load
Reactive load
Valve lift
Steam temperatures
Casing temperatures
Steam pressure
( all temperatures
Bearing metal temperatures
Casing expansion
Thrust bearing position
Shaft eccentricity.
Check turbine casing and bearing
housing for:
freedom of spacing washers;
seating and freedom of expansion
of casing paws;
freedom of movement for bearing
housings;
freedom of movement for pipe
work.
Note: Changes in vibration
characteristics due to changes
in temperature usually occur
slowly and at a constant rate.
Increased vibration during warm-up. Warm-up speed near a critical. Change the warm-up speed within
permissible ranges.
Increased vibration during turbine Increased vibration passing Pass through critical speed ranges
accelearation. Vibration is normal critical speeds. rapidly.
at rated speed.
Increased vibration during turbine Distortion remaining from an inter- Reduce turbine speed to less than
acceleration. No improvement in ruption of turning gear operation 400 rpm. and eliminate shaft distortion
vibration at rated speed before start-up. before increased speed.
Increased vibration in LP turbine Balancing pressure of generator Adjust seal ring balancing pressure.
and generator area. axial seal ring not correctly set.
5.2-0420/3
Fault
Sudden sharp increase in vibration

with accentuated low-frequency
components
Vibratioin frequency less than
rotational frequency
Irregular point trace from recording Many possible causes. After finding out the stability limits.
instrument. determine operating parameters
affecting vibration to aid in determining
cause:
Oil temperature
Load
Control valve lift
Expansion
Shaft displacement
Bearing metal temperatures.
Vibration is related to load Bearing loading to low. Increase bearing loading by changing
and valve lift. Bearing clearance excessive the ailignment.
Vibration related to lubricating Changing in damping properties due Change oil temperature.
oil temperature changes. changes in viscosity
5.2-0420/4
Steam Turbine Bearing Temperatures
Fault
Bearing Temperatures High

Rapid rise of one or more bearing If a fault in the temperature Shut down turbine immediately to
metal temperatures to the preset measuring equipment can be prevent consequental damage;
alarm level; similar temperature rise ruled out, the bearing is damaged
not observed before under Check bearing, clarfy and remedy
comparable conditions cause of bearing damage;
Inadequate oil supply Check oil pressure upstream of
damaged bearing;
Check flow restrictor setting;
Check filters or contamination;
Dirt Check bearings for signs of wear;
take oil samples;
Tilting of bearing Check bearing installation;
(including thrust bearings)
Excessive thrust Clarify cause of excessive thurst.
(in thrust bearings)
Rapid rise of bearing metal Fault in oil temperature control Check oil temperature downstream
temperatures system of cooler;
Switch off controller.
establish normal oil temperature:
Fault in oil controller Estabilish oil temperature manually
Fault in cooling water supply Check water flow through cooler:
shut-down turbine generator unit
if temperatures reach the permissi
ble limits in the event of cooling
water supply failture;
Cooling water temperature high Startup stand-by oil cooler;
Oil cooler fouled Change over to stand by oil cooler
* Slow rise of one or more bearing Misaliignment Check alignment;
metal temperatures

Steam Turbine Expansions
Fault
Alarm or display:
Differential expansion high
Positive (+) differential expansion Rotor longer than casing Check the annunciation to if posi-
or tive (+) or negative I-I expansion is
Negative (-) differential expansion Rotor shorter than casing high;
determine transient of expansion;
start measures to stop further
differential expansion;
shut down turbine generator unit if
permissible differential expansion ‘is
reached and wait for expansion to
recede;
Differential expansion of HP turbine
at front end high
Positive (+) differential expansion During non-steady-state operation, Wait for temperature equalisation
rotor heats up sooner than casing between rotor and casing or for differ-
ential expansion to recede before
performing speed or load changes;
Main steam temperature too Reduce main steam temperature;
high
Poor sliding of HP turbine during Improve sliding of HP casing during
warm-up of turbine casing next inspection;
NegativeH differential expansion During non-steady state operation, Wait for temperature equalisation bet
rotor cools down sooner than casing ween rotor and cBsing or for differen-
tial expansion to recede before
performing load changes;
Main steam temperature Raise main steam temperature;
during start-up too low.
Poor sliding of HP turbine casing improve sliding of HP casing during
during cool-down. next inspection
Differential Expansion of IP turbIne,
at rear end hIgh
Positive (+) differential expansion During non steady state operation, In many cases, better steam flow
rotor heats up sooner than casing through the IP turbine casing will brin
a reduction in differential expansion;
increase speed and load within
permissib.le limits and notice effects;
if this does not causes the differentia
expansion to recede. wait for temper-
ature equalisatiorl’ before performing
further speed or load changes;
Rehea temperature too high Reduce reheat temperature.
Poor sliding of IP turbine casing Improve sliding of IP casing during
next inspection

Fault
Negative(-) differential expansion Negative differential expansion at

this measuring occurs only
under extremely un favourable op-
erating conditions, as positive (+)
different!al expansion is to be
expected due to the mean temperatures
of rotor and casing during operation
Pronounced drop in reheat stop reheat temperature drop
temperature immediately;
Severe restriction in expansion of Irnprove sliding of turbine casing.
turbine casing during cool-down.
High rate of expansion change Reduce air or steam flow;
due to forced cooldown of IP
turbine by means of air or steam
Differential expansion of LP turbine
at rear end high
Positive (+) differential expansion The maximum differential expansion Check differential expansion at rear
usually depends on the mean rotor end of IP turbine and start proper
temperature and the differential measures to reduce differential
expansion of the IP turbine expansion;
Increase in mean LP turbine rotor Load the set and normalize rotor
temperature as a result of prolonged temperature;
no -load operation Note: When shutting down the turbine
due to impermissible expansl’on, it must
be remembered that the LP tlKbine rotor
becomes shorter during rated speed
operation as a result of transverse
contraction;
So an increase in differential
expansion is to be expected during
shut-down;
Negative (-) differential expansion Negative differential expansion
occurs only if the differential
expansion at the rear end of the
IP turbine becomes negative.
This effect is to be expected
only if expansion of IP turbine
is severely restricted
Reading of shaft position in thrust
bearing differs from previous readings
under otherwise identical conditions
Check positive Qhanges in Higher residual thrust on thrust Check stage pressures;
positive( +) direction (thrust bearing;
towards the rear) or negative wear in thrust bearing Check bearing metal tempel ature at
(-) direction (thrust towards the thrust bearing
the front.
5.2-0422-01/2
Steam Turbine Casing Temperatures
Fault
Annunciation: Casing temperature

differentials top/bottom high
+ (positive) = higher temperature in

top half casing
- (negative) = lower temperature in
top half casing
during start-up Uneven heat dissipation due to not If possible, increase steam flow
∆ 9 + or - enough steam flow ,through casing through turbine to obtain uniform
warm-up;
after load reductions, during low as above as above
power operation
∆ 9 + or -
after load reductions Steam back-flow or entry of water Open drain valves in extraction lines;
∆9+ into turbine through extraction test functioning and leak-tightness
lines of extraction valves;
take measures at the feed-water
heaters to prevent back-flow;
during power operation Casing temperatures affected by Check condition and measure
∆ 9 + or leaks in sealing elements inside the clearances at sealing elements during
turbine overhaul and refit or replace leaky
elements as necessary;
notify manufacturer and ask to
calculate if turbine can be operated at
higher temperature differentials for.
the time being; .
during start-up Casing or steam lines not properly Check position of drain valves,
∆9- drained open any closed drain valves;
during start-up Drain valves still open too wide, Close drain valves further or comple-
∆9+ causing uneven steam flow through tely;
turbine
during standstill or turning Uneven cooling due to air currents Start turbine very carefully;
gear operation within the foundation or inside wait until the steam admitted begins
the turbine to reduce temperature differentials
before running up to rated speed;
during standstill or power Uneven heat dissipation due to Repair lagging;
operation imperfect lagging
Casing temperature differentials

excessive
in any operation mode (additional Run down turbine immediately by
turbine protection not operative) tripping; observe rundown;
record rundown time;
turbine generator comes to stand- Carefully try to turn shaft system
still after rundown (in turning using manual shaft turning device;
gear operation) Warning I Do not rotate the shaft
system forcibly;
wait until temperature differential
has fallen to permissible level;
set turning device in operation;

Fault
Limitation by TSE turbine monito- Increase in steam flow during The influence of the TSE on,the
ring channel during turbine runup accelaration of turbine diminishes set-point controller reduces the speed
to rated speed margin gradient or,at a certain margin,
caused the speed gradient to tend
towards O;
a certain TSE margin (determined
empirically) must be avialable
before the turbine generator unit is
I run up to rated speed;
operation of the turbine generator
unit at constant speed within the
critical speed range is inadmissible;
the control valves must therefore be
closed and the turbine generator
unit must be warmed up at a
speed below the lower boundary of
the critical speed range specified
in the Technical Data
5.1-011.. until an appropriate
TSE margin is available;
Ithe turbine generator unit is auto-
matically run down to the set warmup
speed by means of the gradient
monitor as soon as a certain
permanently set minimum speed
gadient is not attained.
Turbine run-up causes an increase in Automatic and/or manual measures
the supply steam temperature so ures as above;
that the margin is reduced The TSE display and the recorder
make it possible to recognize
which turbine section has the
smallest margin; it is therefore
possible to widen the margin by
reducing the temperature of the
supply steam to that specific
section within the limits permitted
by the steam generator;
if the supply steam temperature
cannot be reduced, further run-up
will have to be delayed until the
trailing turbine has warmed up
sufficiently.
Margin for IP turbine reduced; Warmup operation does not warm Automatic and/or manual meas
temperature of IP turbine low; up the IP turbine sufficiently to ures as above;
reheat temperature high prevent reduction of the margin prephylactic adjustment of the
reheat temperatur within the limits
permitted by the steam generator
is recommended;
If the turbine generator unit can be
run up to rated speed, wait for IP
turbine to warm up sufficiently at
rated speed before synchronizing
the generator, since further margin
reductions are to be expected
when the unit goes on load if the
IP turbine has not been warmed up ;
sufficiently.
5.2-0430/2
Fault
Limitation by TSE turbine monito- Steam flow too high in relation The influence of the TSE on the
ring channel during power oper- to turbine temperature conditions setpoint controller reduces the
ation speed gradient and/or the turbine
load is reduced and the generator
possibly disconnected from the grid
by the reverse power protection
realy;
Lower margin of turbine stress evalu-
ator restricted during non-steady-
state operation
(Lower red screen at 0 mark)
Limitation by TSE admission moni- Main steam temperature too low in Do not open main steam stop v:alves
toring channel during warm-up relation to main steam line and valve until temperature has been adjusted
of the main steam line and the temperature accordingly.
main steam stop and control
valves.
Limitation by TSE turbine monito- Main steam temperature too low in Check steam conditions upstream of
ring channel during warm-up relation to turbine temperature the turbine; raise steam tempera-
and/or start-up of the turbine turebefore warning and or start-
ing up the turbine.
Limitation by TSE turbine monito- Load change leads to a reduction of Reduce load gradient and/or hold
ring channel during unloading throttle temperature downstream of load constant until non-steady-
of the turbine main steam control valves state condition has passed.
Note: Turbine shut-down by trip
Bctuation is permitted from Bny
load condition.
Limitation by TSE admission and Rapid. pronounced temperature Immediately adjust turbine out-
turbine monitoring channels reduction due to fault in steam put to changed steam generater
during disturbances in steam gen- generator conditions by means of load set.
erator operation point limiter so as to signifi-
cantly reduce the steam flow; if
the additional influence due to
throttling prevails and/or if
there is no end to the steam gen-
erator malfunction in sight. the
turbine must be tripped.
Limitation by TSE after load Normal occurrence as a consequenc No particular measures required
rejection with or without residual of the reduction; in throttle tem- in the event of isolated load
load, or TSE margin becomes perature; will reduce turbine life rejections.
negative only if repeated frequently
5.2-0430/3
Fault
Fault in turbina stress evaluator

Alarm Electrical fault in turbine stress In the event of a fault in the turbine
evaluator stress evaluator during speed and
Red fault annunciator on the load operation, the TSE influence
display instrument lights up on the turbine controller is immedia-
tely cut out, the delayed setpoint;
Turbine stress evaluator illumi- match target setpoint and delayed
nation failed setpoint and acknowledge alarm;
cut out TSE influence;
Alarm evidently spurious continue monitoring of the turbine
generator unit for thermal stress
by comparing recorded temperatures
with the permissible temperature
curves shown in Technical Data
5.1-011..
Locate and eliminate fault in turbine
stress evaluator as described in
the TSE manual.
TSE display deviates from pre-

programmed test readings during
testing.
Test program not locked in, e.g. Fault in turbine stress evaluator Locate and eliminate fault in
in the case of deviations bet- turbine stress evaluator as des-
ween limited setpoints cribed in the TSE manual
5.2-0430/3
Steam Turbine Stop and Control Valves
Fault
Stop valve fails to open

Stop valve system ready for operation Verify opening of stop valves locally;
Start-up pressure < valve opening Test valve closed Open test valve;
Stop valve system is made ready Pressure above piston has not built Wait until star1lng and load linlit
for operation by driving the starting up sufficiently when test valve is device is in 0% position and pressure
and load limit device towards 0% changed over above piston of stop valve has built up;
Stop valve closes when internal Pressure difference preventing main Close drain downstream of stop valve;
pilot valve has reached the end of valve from opening
its travel;
drains downstream of stop valve
Iopen
Pressure above piston drops Internal pilot valve jammed inside Overhaul stop valve and free internal
immediately when pressure builds main valve pilot valve;
up below piston (steam pressure
present)
Control valve fails to open
Secondary pressure present Cutoff valve in secondary line Open cutoff valve in secondary line;
closed
Gear of test valves not in Bring gear of test valves into
operating position operating position;
Control valve opens and closes
erratically
Slight changes in secondary Defect in feedback system of Check feedback system for blockages;
pressure actuator
Control valve fail to respond to

control signals
Starting and load limit device Starting and load limit device Bring starting and loac1limit device
not in 100% position limiting hydraulic governor into 100% position.
Reference speed setter not in 100% Reference speed setter limiting Bring reference speed setter into
position during operation with hydraulic governor 100% position;
electro-hydraulic turbine controller
Change in relationship between
secondary pressure and control valves
Steady-state operation Many causes possible Check hydraulic governor, converter
and actuators:
Record control characteristics;
travel of start-up and load
limit device;
travel of converter;
secondary auxiliary pressure;
secondary pressure;
travel of control valves;
and have control setting corrected
by manufacturer
Change in mutual relationship of
Control valve travels
Steady-state operation Many causes possible As above
Restrictioh in movement of valve Less clearance between valve cone Maintain required clearance between
stem & bush valve cone & bush by machining ID
of bush
Excessive tightening of glands of Slightly reduce the tightening of the
the valve glands of the valves

Steam Turbine Protective Devices
Fault
Turbine trip
manual trip-out Main trip valve actuated lecally Check condition that was the reason
or from control room for tripping turbine locally or from
the control desk and find out if tur-
bine generator unit can be restarted,
automatic trip-out Protective device operated. Find out cause of turbine trip from
Many causes possible recorder plots or annunciations;
if trip is started due to protection
criteria within turbine, check for
damage or irregularities that
would preclude further operation
of the unit;
it trip started due to faults out-
side the turbine, check whether
turbine trip operation was called
for in accordance with the protection
concept;
the cause of trip must be identified
and must be rectified before the
unit is started up again.
Automatic turbine trip’
Main trip valves operated The main trip valves operate Check annunciations to find out if
whenever trip is started. both main trip valves operated;
if only one main trip valve has opera-
ted, test signalling circuit
(limit switche$, wiring, lamps) and
repair any mechanical fault affecting
the defective valve;
Overspeed trips operated The overspeed trips operate when Operation of the overspeed trip is
the preset speed limit is reached. normally prevented by the tuibine
governor if load rejection occurs, i.e.,
whenthe generator breaker is opened;
check if trip was caused by these:
Overspeed trips operate too Perform oil pressure test on
early overs peed trips.
-Find out oil pressure where trips
operate and compare with pressure
previously set
-Perform overspeed test with turbine
at operating temperature.
-adjust overs peed trips
-checking if spring fatigued.
Turbine control malfunction Check free movement of hydraulic
control elements
-Control valves
-converter;
remove blockages or other
malfunctions;
check electrical turbine controller

Fault
Load rejection relay failed to Check solenoid valves;

respond actuate contactor and notice
effect on secondary pressures of
solenoid valves opening;
if secondary pressures do not
collapse, test coils of solenoid
valves for operation;
if actuation of load rejection
relay is not annunciated, check
measuring circuit.
Leak in turbine control valves Check for leaks in turbine control
valves:
notice operation of reverse power
protection if turbine control
valves are closed during synchro-
nized generator operation
Failure of reheat control valves Exercise reheat control valves
Extraction check valves fail to Check position of extraction
close or leaking check valves; .
check temperature in extraction
lines; .
rapid temperature drops after load
rejection are probably due to
extraction check valves leaking.
Thrust bearing trip responded Excessive play in thrust bearing Check bearing metal temperatures;
check thrust bearing;
find out cause of high thrust
bearing wear (axial thrust, damage,
lack of oil)
False response of thrust bearing Check thrust bearing trip, parti-
trip cularly the latching edges.
Electrical low vacuum trip Loss of condenser vacuum Identify the causes of condenser
responded vacuum loss.
Fault in circulating water supply Check circulating water pumps;
check flow of circulating water
through condenser.
Fault in gland seal steam supply Check positions of control valves;
check controller;
if fault in controller or if control
valves malfunction, switch off
controller and maintain gland seal
stearm pressure manually or by
local operation of valves.
Fault in vacuum pumps Check operation of vacuum pump.
Air entry into condenser Test for leaks;
shut down vacuum pumps and
measure pressure rise;
locate and repair leaks;
examine rupture disks for cracks.
Hydraulic low vacuum trip Loss of condenser vacuum as stated earlier
responded
Turbine trip started via electrical Temperature differentials high Check recording instruments;
signal from additional turbine identify causes as described in
protection system because casing instruction 5,2-0423
temperature differential(s) high
5.2-0450/2
Fault
Turbine trip .c;tarted via electri- Cooling steam flow too low Check valve settings.
cal signal because temperature
of exhaust steam from HP turbine Pressure of exhaust steam from Reduce pressure by suitable
high HP turbine too high measures.
Main steam temperature in HP Reduce main steam temperature.
turbine too high.
Turbine trip started via electri- Trip by fire protection system see 5.2-0410
cal signal from the fire
protection system
Faults in protective devices

Main trip valves fails Jammed Turbine generator unit must not be
to operate operated if main trip valves are
not functionIng perfectly;
locate and repair fault immediately.
Trip solenoids Fault in solenoids Do not operate turbine generator
unit if trip solenoids are not
functioning perfectly;
locate and repair fault
Both overs peed trips fail to Overs peed trip jammed or fouled Repeat testing by test oil pressure
operate during overspeed several times until turbine trip
testing starts at normal test oil pressure
Attention: Normal trip speed must values;
not be exceeded by more than 2% if the defective overspeed trip
still does not operate satisfac-
torily, operation of the turbine
generator unit must not be continued.
Trip devices jammed locate and repair fault immediately.
Incorrect speed reading Check speed indicator;
(compare frequency of excited gene-
rator with system frequency by means
of synchronizing device);
adjust speed indicator.
One overspeed trip fails to Jammed or fouled Perform testing by test oil
operate during overspeed pressure;
testing
Staggering of overs peed trip If testing by test oil pressure
settings reveals that the two overs peed trips
respond at slightly staggered
settings no further action is
necessary.
Overspeed trip operates at too Turbine generator unit speed Check speed indicator;
high a test oil pressure when too low when generator not (compare frequency of excited gene-
tested by test oil pressure synchronized rator with system frequency by
means of synchronizillg device);
correct speed;
adjust speed indicator,
Movement of overs peed trip mecha- Repeat testing by ~est oil pressure
nism impaired several times until turbine trip
operates at the test oil pressure
values previously measured.
Leak in test-oil line inside Check test oil line at next oppor-
the bearing pedestal tunity.
Overspeed trip fails to operate Cause of maloperation may be too Adjust test oil pressure.
when tested by test oil pressure high a test oil pressure
Movement of overspeed trip Increase speed with generator
mechanism impaired unsynchronized and perform test;
if the defective overspeed trip
still does not operate satisfacto-
rily, operation of. the turbine
5.2-0450/3
Fault
generator unit must not be conti-

nued until fault has been corrected.
Overspeed trip operates at too Turbine generator unit speed too Check speed indicator (as fl)r
low a test oil pressure when high when generator not at too high a trip speed)
tested by test oil pressure synchronized
Drift of trip !speed Test overspeed trip by overspeeding
(e.g. spring fatigue) at next opportunity;
adjust overspeed trip settings if
necessary;
turbine generator unit my continue
in operation but may be liable to
premature tripping.
One overspeed trip fails to Movement of one overspeed trip Test intact overs peed trip daily
operate when tested by test oil mechanism impaired by test oil pres~ure until fault
pressure, can be corrected at next oppor-
test oil pressure maximum, tunity.
second trip responds normally
Thrust bearing trip fails to Malfunction of test device Check test device and control
operate during testing using medium pressure.
the automatic turbine tester
Hydraulic low vacuum trip operates Malfunction due to jamming or There is a danger of the {:ondenser
too late (at too Iowa condenser drift in setting and last-stage blades in the lP
vacuum) turbine being damaged;
therefore correCt malfunctions as
quickly as possible or adjust
trip setting;
until 1his can be don,e. test intact
low vacuum trrp at frequent inter-
vals.
Speed-dependent release for See above for consequences;
operation faulted by jamming of overhaul piston. for speed dependent
piston release for operation;
see above for rnterim measures
pending correction Qf fault.
Hydraulic low vacuum trip Danger of outage of turbine gene-
operates too early at too high rator uflit dye to premature trip;
a condenser vacuum find out causes of premature trip.
Drift insetting Correct setting.
Diaphragm damaged Check diaphragm and replace.
Protection system operating Fault in signal transmitter Check srgnal transmitter.
largely with electricalsignal or
formation fail to operate or fault in signal path Check signal path.
operate at too high or too low or
limit levels faun in protective devices Check protective devices.
In the fire protection system Fault in signal path Check signal path and devices;
test, one or more tire control or correct fault ornCJtify and in-
protective devices do not device malfunction struct shift personnel that fire
operate automatically. protective devices must
be manually operated if a fire occurs.
5.2-0450/4
Fault
Fault After Selecting and.

Starting Program
Group and individual alarms Electrical or mechanical faults Find out and record program
on outomatic turbine tester status preliminary test (PT), test
control panel program (TP), reset program (RP)
and program step where fault occurs;
record and decode group and indivi
dual alarms;
locate falt as stated in the
description section of the turbine
manual and the Automatic Turbine
Tester (ATT)-manula;
if reset program (RP) runs without
fault (program status after RP=
status as before starting Automatic
Turbine Tester), repeat the test to
get further information on the
nature of the fault.
contine to perform non-faulted
test programs as normal;
Program connot be started
Alarm No starting condition Operating condition of the turbine Check starting conditions from the
generator unit does not correspond functional diagrams and compare
to the interlock release criteria with actual operating conditions
for the Automatic Turbine Tester of turbine and restart test program;
Note: During turbine shut down the
starting conditions for various
programs will not be fulfilled if
testing is to be performed while the
turbine is shut down the missing
starting conditions must be simulated;
Fail signal during
Protective Devices Test Program
Alarm Fail signal and possibly Electrical or mechanical fault in Reset program started automatically
also Time overrun a protective or test device or check running of program in the
monitoring element control room and, if necessary, locally
on the basis of the program status
and the positions of the protective
and test devices;
if possible return protective and
test devices to normal operating
position mechanically;
if reset program runs without fault;
repeat individual test to obtain
further information about cause of
fault or to stop jamming of protective
and test devices;

Fault
Fail signal during valve

test program
Alarm Fail signal and possibly Electrical or mechanic81 fault in Reset program started automatically;
also Time overrun a protective device, valve or check running of program in the
monitoring element (pressure control room and, if necessary.
switch, position transmitter etc.) locally also, on the basis of the
program status and the positions of
the valves and test devices;
restore to normal operating
condition if possible;
Main stop valve fails to open -Close all downstream valves
by remote control
(also drain valves)
-open faulty stop valve using test
valve
-open downstream valves by
remote control.
Turbine trip due to operating ,
criteria while test program
is running .
Alarm Fail signal and Normal occurrence, since the turbine Reset program started automatically;
annunciation from general alarm generator unit will be shut-down observe running of reset program;
system by the protective devices even check criteria that caused trip to
during testing if the criteria for make sure trip conforms to protection i
turbine trip are fulfilled. concept;
locate and remove fault in Automatic
Turbine Tester if trip was caused
by wrong test procedures;
Running of protective devices test
program interrupted, program
stopped in faulted program step
Several annunciations show fault Fault in electronic circuitry of Test circuit remains in force;
in electronic circuitry of Automatic Turbine Tester protection of the turbine is
Automatic Turbine Tester ensured for the duration of this
fault by the protective equipment
operative during testing;
call in maintenance personnel for
the electronic equipment of the
Automatic Turbine Tester to repair
faults as described in the automatic
turbine tester manual;
Running of valve test program
interrupted. program stopped in
faulted program step -
Several annunciations shows fault Fault in electronic circuitry of Return valves tested to normal
in electronic circuitry of Automatic Turbine Tester operating position; .
Automatic Turbine Tester -Check control valve and other
downstream valves, and close
valves by remote control it
necessary.
-open stop valve using test valve
-open control valve and down-
stream valves.
5.2-0455/2
Fault
Fault in power supply to automatic

turbine tester for protective devices
Several annunciations show fault Fault in power supply Redundant design of the power supply
in power supply ensures best security against outage
of the turbine generator unit;
Circuit breaker of test motor, if a circuit breaker has tripped,
solenoid valve, or other elec- actuate test equipment or valves
trical equipment tripped; locally to restore normal operating
condition;
clarify and remove cause of fault
in power supply as described in the
Automatic Turbine Tester manual;
Fault during reset progrom after
testing of protective devices
Program stopped, change-over Position of protective and test Check position of test or protec-
valve in test position devices incorrect due to electri- tive device locally and return to
cal or mechanical faults operating position by h~nd if
necessary;
- test signal transmitter for Move test signal transmitter for
overs peed trip not in operating overspebd trip into normal operating
position, e.g. because minia- position by hand:
ture circuit breaker tripped
- main trip valve or trip, device Actuate contactor for approxi-
not in operating position mately 10s to return main trip
valve or trip device to normal
operating position;
if normal operating position cannot
be restored, there is a meGhanic,,1
or hydraulic fault (e,g, jamming of
solenoid valves, worn latching
edges, oil press~re t()O low for
latch-in that must be corrected,
False electrical signals due to Check monitoring equipment and
faults in monitoring elements signal paths;
(pressure switches, position check valves of pressure switches
transmitter, etc.), This type (desired status: open);
of fault is present if devices check circuitry of position tral1s-
are in operatinw position but no mitter;. correct setting if
checkback signal is generated. necessary;
Incorrect operation of protective
device during testing
Trip solenoid valves for protect- Fault in electrical operation Testing of protective devices is
ing the turbine during testing. or mechanical fault in solenoid not permissible if this fault occurs,
are not actuated, valves; the test will be prevented by the
incorrect operation of monitring electronic circuitry;
equipment
- operating fault check trip signal;
- fault in solenoid valves check operation;
check power supply;
- fault in monitoring equipment check valves of pressure switches
(desired status: open)
vent pressure switch;
check signal path of checkback
signal;
check functioning of faulted
pressure switch;
replace pressure switch (first
switch off Automatic Turbine Tester).
5.2-0455/3
Fault
Failure of remote trip solenoids Fault in operation of electrical The protection of the turbine
or mechanical fault in solenoid generator unit is not fully
valves: guaranteed;
incorrect operation of monitoring the turbine must be shut down unless
equipment the fault can be cleared during
operation (e.g. by switching on the
power supply)
- fault in operation check signal path for formation of
trip signal;
- fault in solenoid valves check operation;
check power supply;
check freedom of movement of villve;
- fault in monitoring equipment check valves of pressure switches
(desired status: open):
vent pressure switch;
check signal path of checkback
signal;
check functioning of. faulty pressure
switch;
if necessary replace pressure switch
(first switch off Automatic Turbine
Tester);
Main trip valve fails to operate Fault in protective device See troubleshooting instructions for
protective devices;
main trip valve jammed turbine generator unit must not
remaIn In operation;
fault must be corrected immediately.
Fault in monitoring equipment Check valves of pressure switches
(desired status: open);
check position transmitter
reset if necessary;
Overs peed trips fail to Operate Actuation fault in test device Take action if incorrect operation
(running time exceeded) or incorrect operation of over- of the overspeed trips occurs see
speed trip instruction Protective devices.
Troubleshooting 5.2-0450
.Actuation fault in test signal Check if the test signal. transmitter
transmitter operates during test;
Fault in power supply if test signal transmitter does not
operate, check power supply and
motor;
check actuation;
Overspeed trips operate at too Mechanical blockage of over- Repeat test several times;
high a test oil pressure speed trips determine test oil pressures where
trips responds;
if this does not clear fault, take
action described in 5.2-0450 e.g.
set overspeed trips during over-
speed tests,
Overspeed trips operate at normal Limit switch of test signal Correct setting of limit switch;
test oil pressure, but after test transmitter incorrectly set,
signal transmitter has reached its
limit position.
5.2-0455/4
Fault
Overs peed trips operate at too low Functioning of overspeed trip Danger of premature turbine trip;
a test oil pressure (annunciation impaired
only, no interruption) check overs peed, trip setting by
precise oil pressure testing or
overs peed test;
correct setting;
Overs peed trips operate at test Fault in functioning, circuitry Check functioning of pressure
oil pressures previously observed or setting or pressure switches switches;
for monitoring response check circuitry and setting;
locate fault and repair;
correct setting if necessary;
Trip mechanism of overspeed trips Latch-in pressure too low Check auxiliary start-up pressure;
fails to latch-in.
latch-in edges or trip mechanism repair trip mechanism;
worn
Low vacuum trip fails to operate Fault in operation of test Check solenoid;
valve
air inlet duct obstructed, clear air inlet duct using probe;
primary circuit piston not in repair low vacuum trip device;
normal operating position
Low vacuum trip operates too late incorrect operation of low vacuurn For consequences and steps to be
(at too Iowa vacuum) trip device taken, see instruction 5.2-0450
check condenser vacuum where trip
device operates;
repair mechanical fault or correct
setting
Low vacuum trip operates too early incorrect operation of vacuum Availability of turbine g’enerator
(at too high a vacuum) annuncia- trip device unit may be reduced due to premature
tion only, no interruption tripping;
check condenser vacuum where trip
device operates;
repair mechanical fault or correct
setting.
Incorrect operation of valves
during testing
Stop valve fails to close Control valve not closed
- Fault in valve test positioner Check power supply and motor of
or its actuation valve test positione
Check actuation circuitry;
- Checkback Control valve Check functioning limit switch,
closed missing signal path and setting or limit switch;
repair fault in signal path;
correct setting of limit switch;
replace limit switch;
- Fault in actuation of stop Check operation of trip
valve solenoid;
test solenoid;
check freedom of movement of valve;
Stop valve closed too slowly Incorrect mechanical operation of Repeat test;
stop valve measure time taken for valve to close;
repair valve if no other cause}
malfunction of monitoring equip- Check monitoring equipment;
ment check valves for pressure switches;
(pressure switches, position check functioning and setting of’
transmitters etc. pressure switches;
check functioning and setting of limit
switches;
.
5.2-0455/5
Fault
Stop valve fails to open Fault in operation of solenoid Check operation of solenoid valves;
open stop valve with test valve;
locate fault in operation;
check power supply and solenoid as
soon as downstream valves are
closed;
Stop valve opens abruptly Jamming of valve positioner locate fault immediately and repair
valve;
Control valve or other valve down- Close .valve downstream of stop valve
stream of stop valve open clarify why control valve was open
(step sequence, step criteria);
locate fault and repair.
5.2-0455/6
Steam Turbine Oil System
Fault
Oil characteristics insufficient
Air release property Oil contamination Examine oil samples; remove impuri-
> limit value acc. to Speci- ties through centrifuge, remove water.
fication Water content high Remove water;
Improper sealants Check sealants used. do not use any
sealants containing silicon;
Oil mixed with too much antifoam Consult oil supplier;
additive
Foaming on oil surface of oil Foaming during startup due to simul- Introduce waiting period between
tank taneous release of air trapped in the closure of turning gear oil valve
oil and air entrained in the and run-up of the turbine;
system as a result of temperature Check oil level and correct by
increase in the oil tank, topping up or draining;
Water content Entry of steam vapour into oil Remove water from oil system by
system separation or draining;
Check pressure in bearing housings;
locate cause of excessive leak;oH
steam from shaft seals and repair;
Oil level in oil tank low

during rated speed operation Normal oil loss (oil level drops Top up with oil of the same make and
slowly) type;
high oil loss Examine system .for leaks, if a large
leak occurs, unload turbine generator
immediately and/or initiate fire-
protection measures; Examine oil
coolers for punctured tubes,
Plug leaky tubes
during turning gear operation Measures as for oil level changes
during rated speed operation;
On topping up make allowance for oil
level recorded during turning gear
operation,
Attention I 2-out-of-3 fire protection
ineffective during turning gear
operation!
during rates speed or turning Oil builds up in return com part- Open oil tank cover;
gear operation ment due to fouled strainer Check strainer and if heavily fouled
Change strainer and clean;
Examine residues in strainer;
Oil pressure Low

in pressure oil system during Normal procedure Observe startup of auxiliary oil
shut-down of turbine generator pump;
unit If subloop control fails: start
auxiliary oil pump manually from
control desk;

Fault
in pressure oil system immediately Main oil pump is not taking over oil See incorrect operation of Main oil
after rated speed has been delivery pump.
reached Check valve downstream of auxiliary Check pressures downstream of
oil pump leaking auxiliary oil pumps and pumps for
reverse rotation;
Start up and shut down auxiliary
oil pumps with defective valve once
more;
Shut down turbihe generator and
ensure freedom of check valve move-
ment by alternating auxiliary oil
pumps;
Overhaul check valve
Turning gear oil valve still open Close turning gear oil valve from
control desk or locallY by hand;
in pressure oil system during Oil level too low Check oil level in oil tank;
rated speed operation Top up if necessary;
Main oil pump faulty Check main oil pump;
Air content of oil too high Examine air release capability
(ARC) {common investigations by
operator, oil supplier and turbine
manufacturer); .
in lubricating oil system Examine as for oil pressure drops
in pressure oil sY$tem;
With heavy pressure loss observe
whether turbine trip is initiated;
in lubricating oil system on Filter not filled and vented before Check bearing metal temperatures;
filter changeover changeover Check bearing after temperature
increase’
in lubricating oil system on oil Standby oil coofer not filled and Measures as for preS$ure loss on
cooler changeover vented before changeover filter changeover
Warning: Danger of bearing damage
Is considerably greater than with
Improper filter changeover
Differential pressure across Filter fouled Changeover filter properly;
filter high Clean filter inserts;
Main oil pump does not take over
oil supply on startup
Oil level in tank low See faults
Oil level low
Air content of oil too high See faults
Oil properties insufficient;
Main oil pump faulty Check main oil pump;
Turbine speed may be temporarily
raised to force main oil pump
to take over;
Oil temperature high
during rate speed operation No flow of cooling water through Check positions of cooling water
after startup oil cooler in service (malfunction isolating valves for oil.
can also occur on oil cooler cooler in service;
changeovers) Open if closed or throttled;
Oil temperature not yet set Set selector valve;
5.2-0460/2
Fault
during startup and power Oil cooler not vented on oil side Check vents;
operation or cooling water side
Cooling water inlet temperature Look for cause of cooling water
too high temperature increase and correct
Oil cooler fouled on cooling Changeover of oil cooler
water side Note: follow changeover Instruc-
tions;
Clean fouled oil cooler
Oil temperature low
during shut-down of’ turbine Oil temperature control valve Close oil temperature control
generator unit not closed valve
during rated speed operation after Oil temperature controller faulty Close oil temp control valve manually
startup
Turning gear does not startup

automatically
Turning gear oil valve OPEN Compare actual shaft lift oil pressures
Shaft lift oil pump ON with set pressures
Correct pressure if necessary
Check oil temperature, if too high
1> 45°C) reduce
Check using manual turning gear
whether shaft turns easily
Warning: Do not rotate the
Shaft system forcibly
Turning gear oil valve OPEN Radial clearance bridged by casing Let turbine cool down;
Shaft lift oil pump ON or rotor distortion’ Shaft lift oil pump must be operating
Differential temperature on one
casing> limit temperature
Warning: Do not rotate the
Shaft system forcibly
or
Turbine generator unit shut Rubbing of rotor due to destruc- Check bearing and replace
down due to high bearing metal tion of bearing or shaft journal in
temperature bearing not jacked
Turning gear oil valve does not close
during startup Turning gear oil valve faulty Close turning gear oil valve manually-
(acceleration to warm-up or rated drive
speed) control or
AC-power supply
after initiation of fire-protection Turning gear oil valve interlocked Acknowledge fire-protection
system measures;
When shutting down turning Closure of turning gear oil valve Allow turbine generator unit to
gear interlocked via casing temperature cool down further or make interlock
ineffective;
Note: Record release and cancel if
turblne Is to be rsstarted;
5.2-0460/3
Fault
Turning gear oil valve does not

open
on startup ‘Turning gear oil valve faulty Open turning gear oil valve manu.
or drive ally in place
control
on shut-down of the turbine
generator
Main Oil Pump
Bearing Failura
Test oil pressure built up Failure due to electro-erosion; Replace damaged MOP
during, normal operation Rotor earthing arrangement not components. Attend rotor
and Turning gear operation healthy earthing arrangement.
Poor insulation at Generator Improve insulation.

rear pedestal
Oil vapour coming from
bearing pedestal
Vapour fan running Vapour fan faulty; Start standby vapour fan
Wire cloth in the oil stripper is Clean or replace the wire cloth.
chocked
Vapour suction Flap valve Readjust the flap valve.
at the bearing pedestal closed
Seal steam leaking from glands:

Seal steam pressure normal Seal steam exhauster fan not Startup one seal steam exhauster
operating fan; check position of valves up-
stream of exhauster fan and correct.
(valves of standby exhauster fan
must be closed).
Mechanical ur electrical fault in Discharge seal steam to atmosphere.
seal steam exhauster fan
Seal steam pressure high, no seal steam pressure set point Lower set point
fault in valve or controller functions too high
Seal steam pressure low:

Both control valve operating in Mechanical or electrical fault Open bypass valve and maintain
a sequence faulted constant pressure manually
Mechanical fault in seal steam

control valve:
Valve fails to follow control Pressurizer valve faulty or set check pressurc, reset pressurizer
signals too low valve
Filter fouled (annunciation) Clean/replace filter and change oil
of the actuator as specified
ElectricaI fault:
Valves Many causes possible Determine problem on the basis of
valve description and correct;
control system Many causes possible Determine causes on the basis of
instrumentation and control manual
5.2-0460/4
Steam Turbine Gland Steam System
Fault
Seal steam escaping from glands
Seal steam pressure normal Seal steam exhauster fan not Start one seal steam exhauster fan;
operating check position of valves upstream of
exhauster fan and correct (valves of
standby exhauster fan must be
closed);
Mechanical or electrical fault in seal Discharge seal steam to atmosphere;

steam exhauster fan
Seal steam pressure high; no fault Seal steam pressure setpoint too lower setpoint;
in valve or controller functions high
Seal steam pressure low
Both control valves operating in Mechanical or electrical fault Open bypass valve and maintain
sequence faulted oconstant pressure manually;
Machanical fault In 8eal steam control

valve
Valve fails to follow control Pressurizer valve faulty or set too Check pressure. reset pressurizer
signals low valve;
Filter fouled (annunciation) Clean/replace filter and change oil of

the actuator as specified
Electrical fault
Valves Many causes possible Determine problem on the basis of

valve description and correct;
Control system Many causes possible Determine cause on the basis of

instrumentation and control manual
and correct.

Steam Turbine Control Fluid EHS- System
Fault
Control fluid properties inadequate Examine control fluid samples

Rise in neutralization number (NN) Impure control fluid Start up bypass regeneration unit
(Observed on the basis of constant immediately or
values measured continuously check its operational status
under the same conditions) (as-switched status);
Examine control fluid for water ‘
content, (take sample from surface);
Change over to other control fluid
cooler;
Fuller’s earth filter exhausted Replace Fuller’s earth filter, even
if replacement not yet scheduled;
Clean fine mesh filter;
High water content Water entering via cooler Change over to other control fluid
cooler; determine cause of wDter entry.
Air-release property diminished Take measures as for rise in neutraliza
lion number INN)
Level in control fluid tank low

Slowly sinking level in fluid tank normal fluid loss not replaced Top up With colltrol fluid of same
make; take sample of topping-up fluid
Level sinking rapidly (2-out-of-3 excessive loss Caution: Stop turbine generator
level very low monitor responds) immediately. Stop control fluid pumps
and initiate fire protection measures
Control fluid pressure low Pump faulty Check control fluid pumps; change
over to standby pump or
observe startup of standby pump
Control fluid differential pressure Filter fouled Change over to other filter, clean
across interchangeable filter high filter element or insert new filter
element
Control fluid temperature low Excessive cQOling of system piping Check temperature controller; if
or fault in closed-loop control control valve is open, switch off
temperature regulator and close
control valve; switch on heater when,
control valve is closed
Control fluid temperature high inadequate cooling Check temperature controller; check
cooling water temperature, check
cooling water adequately vel1ted;
change over to other control
fluid cooler; .
Heater switched on Switch off heater
(fault in open-loop control)
Temperature at heater protective Control fluid heater overheated Switch off control fluid heater
tube high

Fault
Leak in hydraulic devices

Control fluid/oil leakage monitor Check carefully which medium is
responds escaping: oil, control fluid or both
- Leakage of control fluid at the Operation of the t\Jrbine generator
hydraulic governor may be continued provided that the
escape of fluid is continuously
monitored
- Leakage of oil or control fluid Diaphragm damaged: Repair leak
- Iand oil at the hydraulic governor Difficulties in regulating during
operation using hydraulic governcr;
in the event of both media escaping,
danger of oil mixing with control
fluid
- Leakage of oil at the trip Operation of the turbine gerlerator
mechanisms of the overspeed unit may be continued provided that
governor or the shaft position the escape of fluid is continuously
monitor monitored
- leakage of oil or oil and control Diaphragm damaged on the control Repl}ir leak
fluid at the trip mechanisms of fluid side, danger of turbine trip, if
the overspeed governor or the both oils are leaking danger of
shaft positioh monitor control fluid mixing with oil
Alarm: Control fluid/water leakage
monitor responds
- Leakage of control fluid at Operation of turbine generator may
hydraulic pressure alarm be continued
- Leakage of water at hydraulic Danger of water mixing with Repair leak
pressure alarm conttof fluid
5.2-0470/2
Steam Turbine Bypass System
Fault
Bypass stop and control

valves fail to open
Reheat pressure> constant or Check condensate pressure,
variable pressure setpoint condenser vacuum arId bypass steam
temperature;
Injection water pressure downstream
of injection water control valves
< interlock pressure
Condensate pump(s) failed Check operating conditions of conden-
sate pump of condensate system
Pressure downstream of Establish normal conditions;
condensate pump(s) too low
Fault in injectionwater colltrol Check actuators of injection water
valves or their actuators. control valves, e,g. slide valves
for valve operation;
Condenser vacuum low See fault tracing i!:lstructions for
condenser plant;
Bypass steam temperature high See fault tracing instructions for
condenser plant;
Reheat pressure < constant Constarlt pressure setpoint too high Lower constant pressure setpoint;
pressure setpoint but> .
variable pressure setpoint
Reheat pressure> constant Fault in control Check fault annunciations in control
or variable pressure setpoint; cabinet;
Interlocks ineffective remedy faults as described in bypass
control manual;
shut down control until fault is
remedied and control reheat pressure
manually;
Bypass stop and control valves
close during bypass operation
Reheat pressure > constant Injection ‘Nater interlock effective
pressure set point ,
Injection ,water pressure < Check operating conditions of con-
interlock pressure densate pumps or condensate system;
establish normal operating condi\ions;
Condenser vacuum interlock See fault tracing instructions for
effective condenser plant;
Bypass steam temperature inter- Injection water flow rate too low,
lock effective check 2nd stage water injection if
bypass steam flow rate is high
Bypass control valves close
Reheat pressure> constant Steam flow rate limitation effective Reduce steam generator output;
pressure setpoint

Fault
Bypass stop and control valves

close or fail to open
Reheat pressure> constant Fault in injfction w!!ter control valves Check signal pressure and pressure
pressure setpoint or their actuators beneath pistons of injection water
control valves;
Condensate pressure upstream
of injection water control l’
valves normal;
Condensate pressure downstream Signal pressure not present: Locate fault in regulator or hydraulic
of injection water control valves fault in regulator or hydraulic control gear and remedy;
< interlock pressure control gear
Signal pressure present, pressure Remedy fault in changeover valve for
beneath pistons of CIne or:more injection water control valves;
injection water control valves
not present: changeover valve
defective Open bypass val...es until fault is
remedied;
Signal pressure present, pressure Remove blockage in injection water
beneath pistons of injection control valve
water pilot valve present:
Injection water control valve Open bypass valves;”
jammed
Reheat pressure> constant Fault in interlock elements Check limit pressure control .Clear
pressure setpoint ‘
Condensate pressure upstream Limit pressure control gear
and downstream of injection water fails to open;
control valve> interlock pressure fault in limit pressure control Locate and remedy fault in limit
pressure control gear;
Limit pressure control gear
opens:
fault in pressure switch Locate and remedy fault in pressure
switch;
if only one on the hydraulic
condensate pressure monitoring
channels is faulted. the faulted
channel may be blocked and bypass
operation continued.
Attentionl No redundant pressure
monitoring effective: use other criteria.
e.g. bypass steam temperature, to
assess injection water flow rate;
remedy fault as soon as possible;
Reheat pressure> constant Fault in interlock elements for
pressure setpoint loss of condenser vacuum
Condenser pressure normal
Diaphragm of limit pressure Replace diaphragm;
control gear damaged
Diaphragm of bypass condenser Replace diaphragm;
safety device damaged close cutoff valve upstream of
measuring element;
insert lever and lock;
replace diaphragm;
in this case bypass operation may be
continued for the duration of the
repair;
Reheat pressure> constant Fault in interlock elements for high Check temperature measuring circuit,
pressure setpoint bypass steam temperature actuators of solenoid valves and
Bypass steam temperature normal remedy fault;
5.2-0490/2
Steam Turbine In-Service Maintenance
Maintenance Introduction
The availability, reliability and economy of a turbine Inspection Schedule

generator depend on the proper condition of all The inspection schedule 11) includes all essential
components. testing and operating data recording activities as well
as procedures to identify the condition of components.
This goal can only be achieved through a The inspection schedule is supplemented by
comprehensive maintenance program. tables specifying the’ testing intervals, instructions and
test records for comparison of the desired/actual
This maintenance program specifies activities to conditions.
be performed with the unit in service to establish the
actual condition at regular intervals (inspection = tests Maintenance Schedule
and recording of operating data) and to maintain the The maintenance schedule 12) contains all
desired condition (maintenance). maintenance activities and intervals. It is
supplemented by maintenance instructions that
describe particular maintenance procedures.

[1] 5.3-0010 Inspection Schedule
[2] 5.3-0020 Maintenance Schedule

Steam Turbine Inspection Schedule
Maintenance
Inspection Schedule Turbine
Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
1.0 Testing of Test according to
1.1 Controllers Functioning Ref. 5.2-0021 5.3-0030 (Start up)
and setting 5.3-0035 (Power oprn.)
5.3-0060 (Shut down)
1.2 Automatic Turbine Tester Functioning Ref. 5:2-0022 5.3-0061 (Stand still)
and 5.2-0023
1.3 Protective devices Functioning Ref. 5.2-0024
and setting
1.4 Safety devices Functioning Ref. 5,2-0025
and setting
1.5 Valves Functioning Ref. 5.2-0026
Free movement
leak tightness
1.6 Monitoring devices Functioning Ref. 5.2-0021
Setting and
Accuracy
2.0 Recording and documentation of Comparison Ref 5.2-0028 Also Ref. 5.3-0037
operational parameter and conditions of specified for long term
and actual data monitoring
2.1 steady-state operation h
2.2 non-steady-state operation every start-up
2.3 faults every occurrence
2.4 Analysis of steam purity d
2.5 Measurement of internal efficiency Internal 3m Ref. 5.3-0050
condition of
turbine
3.0 Check lP turbine last stage blading during. minor.
intermediate
and major
inspections
3.1 Visual Inspection erosion
3.2 Sllrface crack examination crack
4.0 Examine accessible expansion Mechanical During minor during shut down
joints in cross-around and damage intermediate
extraction lines and major
Inspections
4.1 Visual inspection
4.2 Surface crack examination
5.0 Visual inspection of casing supports
5.1 Seating of casing on support elements w
5.2 Cleanliness w

Frequency
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
6.0 visual inspection of steam-tightness leakage d

6.1 Casing joints
6.2 Flanges
6.3 Shaft seals
6.4 Valve stems
6.5 Instrumentation connections
7.0 Drains
7.1 Check internalleak-tightness w
7.2 Check external leak-tightness w
8.0 heck pumps, motors and other

drives in continuous operation
8.1 vibration behaviour d
8.2 Head d
8.3 Bearing temperatures d
8.4 Thrust d
8.5 leak-tightness d
9.0 visual inspection of piping .

9.1 leak-tightness d
9.2 Vibration d
9.3 Hangers w
9.4 Expansion w
9.5 Vibration dampers 3m
10.0 Hydraulic accumulator

10.1 Check charge pressure 2w
1 1.0 Oil tank

1 1 .1 Level check d
1 1.2 Foaming characteristics of oil w
11.3 Water collection on bottom of 2w
oil tank
1 1.4 level check in bucket filter to
assess filter chocking w
11.5 Water content of oil d
11.6 Solid particle content of oil d
11.7 Analysis of oil properties Ref.5.1-0130 Ref.5.3.0080
12.0 FRF tank d

12.1 level check d
12.2 level check in bucket filter to access
filter chocking w
12.3 Foaming charateristics of FRF w
12.4 Analysis of fluid poperties Ref.5.1-0140 Ref. 5.3-0082
13.0 Oil/FRF filter

13.1 Check differential pressure reading d
13.2 Check venting d
5.3-0010-01/2
Steam Turbine Maintenance Schedule
Maintenance Introduction
The following maintenance schedules describe all The maintenance schedules are subdivided as
important activities to be performed during turbine follows:
operation or outages.
Special instructions will be given for maintenance 5.3-0021 Turbine
work to be performed during prolonged outages. e.g. 5.3TP022 Oil System. Seal Steam System. Drains
for overhauls,only. 5.3-0023 FRF System

Maintenance Trbine
Frequency
Activity Work to be performed or tested d = daily Remarks
No. Criteria w = weekly
m = monthly
y = yearly
1 Cleaning of sliding surfaces Visual inspection1 m

- casing supports
- spacer bolts and discs for
bearing pedestals and
turbine casings
2 Cleaning of turbine blading by measurement of ηi as indicated by criteria The criteria indicating

flushing through with saturated stage pressure when saturated steam
steam as prescribed in flushing is necessary
5.3-0070 are the internal
efficiency Tl and the
stage pressures
3 Preservation of turbine using relative humidity continuous during shut-downs

air drying equipment as in turbine < 50% lasting longer than
prescribed in 5.2-0360 1 week
4 Lubrication of components of the as prescribed in

turbine control and turbine 6.1-0690
protection systems as prescribed
in 5.1-0690
5 lubrication of components of the as prescribed in

bypass control and bypass 5.1-0690
protection systems as prescribed
in 5.1-0690
6 Tightening of turbine 1m
control valve packings
7 Tightening of valve stem seals 3m or in the event

of leakages
8 Lubrication of valve stems as prescribed

as prescribed in 5.1-0690 in 5.1-0690

Maintenance Oil System, Seal Steam System, Drains
OIL SYSTEM
Frequency
m = monthly
y = yearly
1 Cleaning of filters
and strainers
- Switch over duplex filters ∆ p across filter as indicated by
and clean fouled filter cartridges criteria, max 6m
as prescribed in 5.1-1130
- turn plate-type filters through d
two three revolutions as
prescribed in 5.1-1 120
- clean plate-type filters 6m -1 y during appropriate
shut-downs and
overhauls
- replace filter papers ∆ p across filter as indicated by
in fine mesh filter criteria, max 6 m
- change oil tank strainers, oil level in bucket as indicated by during appropriate
clean fouled strainers as strainers criteria, max 6m- y shut-downs and
prescribed in 5. 1-1 010 overhauls
- clean wiremesh of oil stripper 6m
2 Cleaning of oil using centrifuge solid or liquid continuous, as
foreign matter in oil indicated by criteria
3 Cleaning of centrifuge as deposits in 1m
specified by the manufacturer centrifuge as indicated by criteria
4 Cleaning of oil tank after draining oil deposits in oil tank 3 -4 y during overhauls
5 Maintain oil tank level at service level in oil tank 1 d (check), topping
level; top up with oil of same up as indicated by
make and properties criteria
6 Draining of water from the oil tank water collecting as indicated by establish cause of
on oil tank bottom criteria water accumulation
7 Oil or grease change as specified by
in valve actuators actuator
- motive oil valve manufacturer
- Oil temperature control valve
8 Lubrication of pump and fan motors as specified by motor
- auxiliary oil pumps manufacturer.
- emergency oil pump
- jacking oil pumps
- oil vapour exhauster fans
9 Lubrication of oil vapour exhauster as prescribed by fan
fan bearings manufacturer

Frequency
Parameter measured h = hourly
m = monthly
y = yearly
10 lubrication of valve stem at the

lubrication points provided as
prescribed in 5.3-0081
11 Tightening of valve ,steam seals 3m or in the event of

leakages
12 Elimination of oil leakages by oil leakages continuous

tightening of flanges and bolted joints
13 Check vibration dampers as 1y

14 Charging of hydrqulic charge pressure 1m

accumulators
SEAL STEAM SYSTEM
Frequency
m = monthly
y = yearly
1 Change of control fluid for seal 1y

steam control valve actuators as
2 Filter change for seat steam control 1y

valve actuators as prescribed in its
manual
3 lubrication of vapour condenser as specified by motor

fan motors manufacturer
4 Lubrication of vapour condenser as prescribed by

fan bearings fan manufacturer
5 Lubrication of valve stems at the 3m

lubrication points as prescribed .
in 5.3-0081
6 Tightening of valve stem seals 3m or in the event

leakages
5.3-0022-01/2
DRAINS
Frequency
m = monthly
y = yearly
1 Oil or grease change in drain valve as specified by

actuators actuator manufacturer
2 Lubrication of drain valve stems 3m
at the lubrication points provided.
as prescribed in 5.3-QO81
3 Tightening of drain valve stem seals 3m or in the event of
leakages
4 Check on drain line sludge traps 1 -2y

Maintenance FRF System
OIL SYSTEM
Frequency
m = monthly
y = yearly
1 Cleaning of filters
and strainers
- Switch over duplex filters; ∆ p across filter
clean and replace fouled filter
cartridges as per 5.1-1130
- Turn plate-type filters through
two three revolutions d
- Clean plate-type filters 6m -1 y during appropriate
shut-downs and
overhauls
- Replace filter papers ∆ p across filter as indicated by
in fine-mesb filter as criteria, max 6 m
- Replace fuller’s earth Neutralization 6m or as
filling in regenerating number indicated by criterion
filter as prescribed in
5.3-0082
- Change FRF tank FRF level in as indicated by appropriate
strainers; clean strainers criteria shut-downs and
fouled strainers overhauls
- Regenerate air filters or Discoloration of 3m, or as
exchange filter filling filter filling indicated by criterion
2 Cleaning of FRF tank after deposits 3-4y during overhauls
draining FRF in FRF tank
3 Keeping the FRF in Level in FRF tank 1 d check
FRF tank at operating level Top up as indicated
by criterion
Top up using FRF of the Some
brand and with the same properties
4 Lubrication of motors as specified by the
for pumps and fans motor manufacturer
- FRF pumps.
- FRF circulating pump
- FRF vapour extraction fan
5 Lubrication of the bearings of the as specified by fan
FRF vapour extraction fan manufacturer
6 Lubrication of the valve stems at 3m
the lubricating points provided
7 Retightening of the valve 3m of if
stem packing leakage detected

Frequency
m = monthly
y = yearly
8 Elimination of leaks by retightening leakage continuously, as

flanges and unions indicated by criterion
9 Checking of damping fluid in 1 -2 Y

vibration dampers as prescribed
in 5.3-0100
10 Charging of hydraulic Filling pressure 1m

accumulators
5.3-0022-01/2
Steam Turbine Testing During Start-up
Maintenance
Introduction A number of tests require that certain components

Tests demonstrate the readiness for operation and be in a definite position (e.g. main trip valves in
the proper functioning of important components: They operating position, stop valves closed, etc.)
must be. performed before and during start-up of the The operation sequence establishing certain
turbine generator unit, irrespective of the time of the operating conditions is given in the form of general
preceding shutdown. instructions to avoid constant repetition in the tables
If all prerequisites for performance of the complete of test sequences.
test program are not fulfilled, reduced testing to show
the readiness of the auxiliary, emergency and jacking Test Performance
oil pumps for operation must be performed. Take care to avoid any risks to people or machines
The scope of the test program for start-up of the while performing tests.
turbine is to rrlake sure that all tests required to be Any simulated conditions necessary for the tests
performed before start-up after a shutdown period of must be cancelled after completion of tests.
approx. 4 weeks [1, 2] have been completed. Steam inlet valves may only be opened for test
purposes if the piping systems upstream of the valves
Test Procedures are not under pressure and the systems concerned
Tests, prerequisites, test activities and criteria in have been expressly cleared for testing.
table form is intended to simplify testing. The symbols Test performance must be recorded.
at the head of the columns in the tables are an aid to If incorrect operation of the equipment being tested
understanding the concise test instructions. occurs, take action establishing full .operational
The tables are also suited to use as checklists. reliability of the turbine generator unit immediately.
Whenever no specific test instructions are prescribed Pay attention to fault tracing instructions.
for any test, the test sequences shown in the table
must be followed. Also refer to the following sections
[1] 5.3-0061 Testing During Standstill
[2] 5.2-002.. Testing of Turbine Components
Equipment tested Preconditions Date

Type of test () Test Step Result
• Result Tested by
Main trip valves in operating

position
Stop valves closed Starting and load limit device not in
0% position .
Test valves of stop valves in left-hand
end position (=stop valves open)
(1) Move test valve pilot into right-hand
end position using handwheel (=stop
valves closed)
(2) Bring starting and load limit device into
0% position
• Main trip valve in operating position
40% position
• Main trip valve in operating position
and ready to trip
• Stop valves closed

Stop valves open Starting and load limit device not in

0% position
Test valve of stop valve in left-hand
end position
0% position
• Main tOp Yllv. in o~r.ting position
(2) Bring mrtinog end \o8d timrt ~ mto
40% potitron
• Main trip Vllvt in operating position and
ready to trip
• Stop valves open
Auxiliary oil pumps

Pressure dependent on command Shaft at standstill
from subloop control before Oil system depresswrised
Starting turning gear operation Auxiliary and emerg.ncy oil pumps off
Subloop controls on Manual
(1) Switch auxiliary oil pump 1 5ubIoop control
to Auto
• AuKitiary oil pump 1 on
• System oil pressure present
(2) Switch auxilary oil pump 2 subloop control
to Auto
(3) Switch auxilary oil pump 1 subloop control
to Auto
(4) Switch auxilary oil pump 1 off
• Auxilary od pump 2 on
• System oil pressure present
D.C Emergency oil pump

Pr..ute.dependant III commend (1) Switch D.C. emergency oil pump subloop control on
from subIoop control befort
starting turning gear operatian (2) Switth auxiliary oil pump 2 subloop control
to Manual
(3) Switch auxiliary oil pump 2 off
• DC .mergency oil pump on
• Lubricating oil pressure present
(4) Switch DC em.rgency oil pump subloop
control to Manual
(5) SwitCh DC emergency oil pump off
• Oil system depressurised
• Auxiliary ana emergency oil pumps off
5.3-0030-01/2
Auxiliary and Emergency oil pumps

Operational readiness before Shaft at standstill
Starting turning gear operation Oil system depressurised
(Testing n,ot required if subloop Auxiliary and emergency oil pumps off
controls have already been Subloop controls on Manual
successfully tested)
(1) Switch auxiliary and emergency oil pumps
in turn to Manual on .
• System oil pressure pre’sent
Auxiliary and Emergency oil pumps

Operational readiness after starting Turning gear in operation
turning gear operation One auxiliary oil pump operating
(1) Switch stand-by auxiliary oil pump
to Manual on
• Pressure buildup in system

(2) Switch stand-by auxiliary oil pump to Manual off
(3) Switch emergency oil pump to Manual on
• Pressure buildup in system
(4) Switch emergency oil pump to Manual off
Auxiliaryoil pumps
Speed-dependent cutout when Turbine generator unit speed = rated speed
rated speed is reached .
(1) Verify cut out of auxiliary oil pump
Jacking oil pumps

Speed-dependent on commapd Shaft at standstill
of AC Jacking oil pump 1 from Jacking oil pumps off
subloop control before starting Subloop controls on Manual
turning gear operation .
(1) Switch AC jacking oil pumps subloop

control to Auto
• AC jacking oil pump 1 on
• Jacking oil pressure present
(2) Switch AC jacking oil pumps subloop

control to Manual
(3) Switch AC jacking oil pump 1 off

• AC jacking oil pumps off
• Jacking oil system depressurised

Manual on before starting Shaft at standstill

(1) Switch stand-by AC jacking oil pump 2
to Manual on
• Stand-by AC jacking oil pump 2 on
• System oil preS$ure present
(2) Switch stand-by AC jacking oil pump 2
to Manual off
• AC jacking oil pumps off
• System depressurised
Speed-dependent on command Shaft at standstill

of DC Jacking oil pump from Jacking oil pumps off r”
subloop control before Subloop control on Manual
(1) Switch DC jacking oil pump subloop
control to Autq
• DC jacking oil pump on
• Jacking oil pressure present
(2) Switch DC jacking oH pump subloop
control to Manual
(3) Switch DC jacil;ing oil pump off
DC jecking oil pump off
Jacking oil system depressurised
Operational readiness of Shaft at standstill

Jacking oil pumps Jacking oil pumps off
Subloop Gontrols on Manual
(1) Switch jacking oil pumps in turn to
Manual Off
• Jacking oil pressure presertt
Control Fluid pumps

Pressure-dependent on command Control fluid system depressurised
from subloop control Control fluid pumps off
Subloop crorltrol on Manual
(1) Select one control fluiq pump (e.g. pump 1)
(2) Switch subloop cCintrol to Auto
• Control fluid pump 1 on
• Control fluid system pressure present
(3) Select controjfluid pump 2
5.3-0030-01/4
(4) Switch control fluid pump 1 off

• Control fluid pump 2 on
(5) Switch subloop control to Manual
(6) Switch control fluid pump 2 off
• Control fluid system depressurised
• Control fluid pumps off
0 Operational readiness of control Control fluid system depressurised

fluid pumps Control fluid pumps off
(Testing not required if subloop Subloop control on Manual
controls have already been
successfully tested) (1) Switch control fluid pumps in turn to
Manual on
Remote trip initiation

Push button operation Main trip valve in operating position
Stop valves closed
(1) Press trip push button
• Trip annunciated
Stop valves
Lleak test Main steam pressure present upstream
of stop valves
Stop valves closed using test valves
(1) Open control valves
• No speed increase
(2) Bring back test valves to operating position
Control valves
Leak test Control valves closed using motorised
actuator
Main steam pressure present upstream
of turbine
(1) Open stop valves
• No abnormal speed increase
(2) Bring back motorised actuator to open
position

Overspeed trip
OiI injection test Generator synchronised
Unit in low-load operation
(1) Release testing device for operation
(2) Press and hold down test valve for
inhibiting trip (left-hand valve)
(3) Turn handwheel of hydraulic test signal
transmitter to right until test oil circuit
is pressurised
(4) Observe oil pressu res wh er,g overspeed trip
device operates
• Auxiliary trip circuit depressurised
(5) Turn handwheel of hydraulic test signal
transmitter to left until test oil circuit
is depressurised
(6) Bring trip device of overs peed trip into
operating position using right-hand valve
Auxiliary trip pressure built up
(7) Repeat test until overspeed trip operates
at the same test oil pressure in successive
tests
5.3-0030-01/6
Steam Turbine Testing During Power Operation
Maintenance
Tests that demonstrate the readiness for operation Test Performance

and the proper functioning of important components Test performance must be recorded. If incorrect
must be performed during power operation of the operation of the ‘equipment tested occurs, take action
turbine generator unit. The time intervals between establishing full operational reliability of the turbine
tests are given in a separate instruction [1]. generator unit immediately.
Pay attention to fault tracing instructions. [2)
Test Procedures
Tests, prerequisites, test activities and criteria in
table form is intended to simplify testing. The tables
can be used as checklists. When no specific
instructions are prescribed for any test, the test Also refer to the following sections
sequences shown in the table must be followed. [1] 5.2-002.. Testing of turbine components
[2] 5.2-0400 Fault Tracing

Turbine controllers
Functional test Control valve opening < 100%
(1) Change setpoint of effective controller
• Change in control valve. opening corresponding
to setpoint change
Functional test Load approx. 50%
Bypass control
(1) Open HP bypass station slowly by
operating pushbutton on control panel
• Reheat pressure increases
• Injection wate: pressure present
• Bypass stop valves open
• Bypass control valves begin to open
(2) CloseHP bypass station , ..
• Reheilt pressure drops
• Bypass control valves close
• Bypass stop valves close
• Injection water pressure reduced
Seal steam controller
Functional test Seal steam controller on
(1) Seal steam controller off
(2) Induce control deviation by operating control
valves (Pushbutton on control panel)
(3) Seal steam controller on
(4) Verify correction of seal steam pressure

Oil temperature controller

FunctiOrlal test Oil temperatu~e controller on
(1) Oil temperature controller off
(2) Induce control deviation by operating
temperatllre coiitrol valve (Pushbutton on
control panel)
(3) Oil temperature controller on
(4) Verify correction of oil temperature
Auxiliary and emergency oil pumps

Operational readmess test Auxiliary and emergency oil pumps off
(1) Auxiliary pumps subloop control off
(2) Auxiliary oil pump 1 Manl.ial on
• Pressure buildup downstream of Pl1mp
(3) Auxiliary oil pump 1 Manual off
(4) Auxiliary oil pump 2 Manual on
• Pressure buildup downstr~am of pump
(5) Auxiliary oil pumps 2 Manual off
(6) Auxiliary oil pumps. subloop control on
(7) Emergency oil pump Manual on
• Pressure buildup cjlownstre~m of pump
(8) Emergency oil pump Manual off
Control fluid pumps

Operational readiness test Service control fluid pump ()n
(1) Stand-by control fluid pump Manual on
• Pressure buildup do...nstream of tes~ed pump I
(2) One control fluid pump MantJal off
Main trip valves

Ease of movement test Automatic turbine tester available
(1) Select arid start test program for one
protective device
• Main trip valves respond
• No fault annunciations on automatic
turbine tester
5.3-0035-01/2
Remote trip solenoids

Functional test Automatic turbine tester available
(2) Select and start” Remote trip solenoids
test program
• Main trip valves respond
turbine tester
Overspeed trips
Functional test and testing of setting Automatic turbine tester avaHabie
(1) Select and start Remote trip test program
• Overspeed trips respond
(2) If ATT annunciates fault, repeat overspeed
trip test
Overspeed trips
Manual functional test and testing (1) Release hydraulic test signal transmitter
of setting
(2) Depress left-hand piston of hydraulic test
signal transmitter to limit and h01d down
(3) Increase test pressure using handwheel of
Overspeed trip(s) respond(s)
(4) Ascertain pressure at which trip(s) respond(s)
and record
(5) Reduce test pressure using handwheel of
(6) Depress right-hand piston of hydraulic test

signal transmitter to limit
• Auxiliary trip pressure builds up
(7) Release right-’hand piston of hydraulic test
signal transmitter
(8) Release left-hand piston of hydraulic test
signal transmitter
(9) Repeat test as often as necessary, until trip
Operates at the same test pressure as set
during commissioning

Hydraulic low-vacuum trip

Functional test and testing of setting Automatic turbine tester available
(1) Select and start Low-vacuum trip
test program
• low-vacuum trip operates
turbine tester
Differential pressure switch in extraction

lines
Functional test Extraction system in operation
E.xtraction swing check valve open
Hydraulic release present
(1) Reduce differential pressure across
differential pressure switch
• Extraction swing check valve closes slightly
Stop and control valves .

Exercising Automatic turbine tester available
(1) Apply test load
(2) Select and start test program for stop
and control valve unit to be tested
• Control valve closes
• Stop valve closes
• Stop valve opens
• Control.valve opens
• No fault annunciation on automatic’turbine
tester
Extraction swing check valves

Exercising Extraction system in operation
change load or extraction flow
• EXtraction swing check’ units perform
movements
Alarms
Functional test 5.3-0063 Alarms generated
(1) Record alarms generated
Speed indicator (1) Compere with grid frequency
Important operating values

Recording 5.3-0036
Drains
Leak test (1) Test temperature condition of drain valves
5.3-0035-01/4
Steam Turbine Operating Records
Maintenance
Introduction Documentation of Operating Data During

The documentation of the operating data forms Non-steady-State Operation
part of the inspection program that is intended to To assess the desired factual value deviations
identify the actual condition of the turbine-generator occurring during steady state operation, it may
and its components. sometimes be useful to include in the analysis also
operating data recorded during, non-steady-state
Documentation of Operating Data operation. For this reason, it is advisable to compile
(Ind file all operational logs relating to startup and
All operating data must be logged and evaluated shut..down procedures, i.e.:
at regular intervals and under comparable steady
Charts of recording instruments;
state conditions. Chronological reports of swit ching and operational
The desired/actual value comparison serves to : procedures;
detect inadmissible operating conditions and to Failure or alarm reports.
change the mode of operation; For each nonsteady-state condition, these records
gather information for any should be reviewe;d for:
- non-scheduled maintenance and repair work; limits reached ,or exceeded;
- repair work to be planned on a long-term basis faults indicative of malfunction.
(e.g. during overhaul, for preventive maintenance); By comparing the records with earlier startup
procedures, check to see if the startup was performed
verify the success of measures implemented
according to the operating manual and the
during overhauls; requirements of the most economical mode of
verify the reliability of measuring devices. operation.
The opera\ing data must always be read at the Documentation of Failures
same monitoring instruments, and should be Irrespective of whether a failure is due to external
compared for identical operating conditions (load, or internal influences, it is recommended that a
steam parameters). During reading, there should be thorough analysis and follow up measures should be
no variation in the operating data required to remain undertaken to prevent a repetition with detrimental
effect on availability and reliability of the turbine-
constant during steady-state operation. If necessary, generator.
the turbine-generator may be operated at constant
The following information may be useful in
load for a longer period of time until steadystate connection with the failure analysis:
conditions are obtained.
Chronological failure report or fault alarm record;
After recording, the operating values should be Chronological report of switching and operational
compared with the data recorded during initial procedures (including total duration of outage);
commissioning or following earlier overhauls. Recorder charts or printouts of all operating data
reflecting the sequence of operations before,
If the actual values deviate from the desired during and after the failure;
values, the following measures should be performed, Immediate operator action to correct the fault.
depending on the kind of deviation: unless it is evident from the chronological report
of the switching ancf operational conditions;
Correction of operating variables and conditions; Information on external influences preventing the
Execution of maintenance work; restoration of normal operating conditions;
Execution of repair work; Information on consequential failures.
Scheduling of repair work on a long term basis. Availability Record
If the deviations of the operating data cannot be The availability is of essential importarlce for tr,e
corrected by changing the operating variables and economy of steam turbine generator operation and
forms a part of the document required for the overall
conditions or by performing maintenance work, a assessment of plant components. The results of this
detailed analysis should be carriad out in consultation assessment art significant for the improvement of
with the manufacturer in order to : existing plant components and their reliability. The
data compiled for determination lof availability is an
establish the relationship between the desired/ important tool when making any predictions.
actual value deviations and other events,
observations and test results; AIso refer to the following section.
determine the possible cause of the deviation;
5.2-0028 Testing Intervels -Operating Parameters
assess the risk; 5.3-0037 Acquisition & Archiving of Operational Data
perform or plan the repair work. 5.3-0040 Ramedial Actions for Off-normal Operating
Conditions
5.3-0050 Measurement of Internal Efficiency

Steam Turbine Acquisition and Archiving
Maintenance of Operation Data
Procedural Instruction
Introduction In order to allow accurate comparison of operating

data from different recorders, these must be
It is in the interest of both the plant operator and synchronised.
the supplier that the causes of faults, severe damage
and unfavourable inspection finding$ be determineQ, Printouts from continoue-line recorders or dotted-
and actions taken to prevent a recurrence of such line recorders should be archiv~d in such a manner
incidents. that they can be retrieved quickly tor subsequent
evaluation.
In order to determine the cause of such faults, it is
essential that information be available, in the form of Before being filled, the individual documents
operating documentation, on the operating history of should be marked with the identification data of the
the turbine generator unit both in the past and turbine generator unit and the measuring points. The
immediately before and during the fault or damage. scales with the associated divisions should be
available for evaluation.
This instruction contains recommendations on the
acquisition and archiving of operating data. Documents from the electronic data acquisition system
Scope of measurements and Instrumentation Processing of analog measured values

If an electronic data acquisition system is available,
The scope of measurements and also, therefore, it should be used to archive all the data specified
the instrumentation of the turbine generator unit are in Table 1 .It should be possible to retrieve data in
dictated by the agreements between plant operators the form of logs or time curves at any time over
and suppliers. the course of the intended archiving period. The
memory should be sized to allow long-term data
The data are of importance for operations archiving.
management. The scope of data recommended in Only those values for an operating parameter
Table 1 should therefore be available to permit post- should be electronically archived which, after the
event analysis. scanning interval has elapsed, lie outside the
scatter band given in Table 1 when compared to
Scope of operating documentation the last recorded value.
Operating documentation comprises the following Argnlvlng of excessive quantities of data can thus
documents: be avoiided,
It is also possible in principle for long-term
Prlntouts from continuous-line recorders or dotted- monitoring of the turbine generator unit to be
lina recorders performed using the electronic data acquisition
Operating data logs or curves ba$ed on the data system. In this case, hand-written logs of operating
archived in the electronic data acquisition system parameters measured at long Intervals are no
Alarm and switching logs printed by the electronic longer required.
data acquisition system; such logs doc\Jment the
histories of faults or damage and should be Processing of binary signals
archived Normally, binary signals resulting from
Logs with handwritten entries are required in cases annunciations and switching operations are
in which certain data are not recorded or archived continuously printed out with high time resolution
Logs used to document the long-term behaviour by the electronic data acquisition system, AIarm
of the turbine generator unit and switching logs are thus generated which form
Documents showing the availability statistics an important source of information for operations
rnanagement.
Printouts from continuous-lino recorders or For troubleshqoting purposes, the alarm and
dotted-line recorder. switching logs printed immedlotely before, during
and after the fault should be retained and archived.
Continuous-line recorders or dotted-line recorder$
can be used for continuous logging of operating data Handwritten documents
on continuous forms.
Logs containing handwritten data, which are
The trend in the measured operating data can be entered at least once during each shift, are required
traced during both operation and svbsequent in cases in which data are neither logged by dotted-
evaluation. line recorders or continuous-line recorders nor
archived in an electronic data acquisition system.

It is recommended that log showing the requiste Evaluation of the fault report and the operating
measuring points be provided for recordirlg operating documentation
data. he complete logs should be archived.
Faults and damage usually occur when several
Documents for long-term monitoring of the adverse influences are present simultaneously.
turbine-ganerator unit Because of the multiplicity of conceivable faults
and their possible influencing factors, it is not
Certain pperating data should be recorded at long possible ill this procedural instruction to present a
Itervals in order to document the long-term behaviour reliable and complete picture of all the correlations
of 1e turbine generator unit. as well as any data involved.
relevant in terms of life expectancy consid~rations.
It is the duty of the operator’s or supplier’s own
The associated logs may be of use in clarifying experts to define the correlation between the event
faults or damage if the cause can be traced back to and the adverse influencing factors and to
or is indicative of a gradually developing adverse evaluate them and decide on countermeasures
charge. to be implemented.
Documents on availability statistics Retention period for documentation
For the purpose of providing information on the The documents described above must be archived
operating behaviour and the status of the plant. it is for consultation for a IQng time after the operating
recommended that availability statistics be compiled data have been logged in order, among other things,
which how, among other things, the causes and to clarify any correlations between component status
duration of eriods of non-availability. and operating conditions.
If the statistics show a frequent recurrence of an Documents containing operating data which are
event vhich leads to plant non-availability. in-depth relevant in terms of life expectancy considerations
investigaions should pe performed. must be archived until the turbine generator unit
is taken out of service.
Processlng of operating documents It is recommended that all other documents be
archived until the next inspection and overhaul has
Fault report been completed.
The control room personnel should prepare Importance of documents for the clarification of
reports on fault or damage, showing all relevant guarantee claims
data on the evolution of the event leading to the
fault or damage. as well as the countermeasures Without the data contained in the documents
implemented. Copies of the printouts from the described above, the supplier of the turbine generator
continuous-line recorder or dotted-line recorder. urlit is not always able to check the legal validity of
operating data tables and curves generated by guarantee claims in the event of damage or a
the electronic data acquisition system, and the complaint regarding component defects and may
fault and damage logs should be appended to the therefore reserve -the right to reject any claims for
fault or damage reports, which the requisite documents are not available.
5.3-0037/2
Table 1
The following table lists the required operating data for acquisition and archiving in accordance with the operating
instruction, in order to permit evaluation of turbine performance. The requirements will have to e adapted on the
basis of the actual measuring point list.
ID Code Measuring point Measuring Scatter band Retention Period

cycie
Power/Speed
MKA CE Active Power 30 s 0.002 Pnom service life
MKA CE Reactive Power 30 s 0.002 Pnom service life
MYA FS Turbine generator speed 5s 0.05 to 0.1 s-1 inspection C’y’cll’:
Steam pressure
LBA CP Upstream MS stop valves 30 s 0.01 Pnom service life
MAA CP Upstream HP blading 30 s 0.01 Pnom service life
LBC/MAA CP Downstream HP blading 30 s 1 bar inspection cycle
LBB CP Upstream reheat stop valves 30 s 0.01 Pnom service life
MAB CP Upstream IP blading 30 s 0.01 Pnom service life
LBQ CP HP extractions 30 s 0.005 to 0.01 Pnom inspection cyc.ie
LBS CP LP extractions 30 s 0.02 Pnom inspection cycle
MAG CP Condenser 30 s 0.01 bar inspection cycle
Steam temperatures
LBA CT Upstream MS-stop valves 30 s 2K service life
LBC/MAA CT Downstream HP turbine 30 s 2K inspection cycle
LBB CT Upstream reheat stop valves 30 s 2K service life
MAB CT Downstream IP turbine 30 s 2K inspection cycle
LBO CT HP extractions 30 s 2K inspection cycle
LBS CT LP extractions 30 s 1K inspection cycle
MAW CT Seal steam header 30 s 1K inspection cycle
Casing temperatures
MAA CT MS-SV/CV 100/50% 30 s 2K service life
MAA/MAB CT Turbine casing 100/90/50% 30 s 2K service life
MAA/MAB CT Turbine casing top/bonom 30 s 2K inspection cycle
MAC CT Turbine casing front/rear 30 s 1K inspection cycle
Bearing temperatures
MAD CT Turbine radiaUaxial bearings 5s 1K inspection cycle’
MKD CT Generator/exciter radial bearings 5s 1K inspection cycle
Vibrations
MAD/MKD CY Turbine/generator bearing casing 5s 1 µm inspection cycle
MAD CY Turbine shaft abs. or rei. 5s 5 µm inspection cycle
MKD CY Generator/exciter shaft rei. 5s 5 µm inspection cycle
Expansion/Shaft position
MAD CY Absolute expansion bearing pedestal 30 s 1 % measuring range inspection cycle
MAD CY Shaft expansion 30 s 1 % measuring range inspection cycle
MAD CY Shaft position axial bearing 30 s 1 % measuring range inspection cycle
Circulating wate/condensate temperatures

PGB CT C. W.Upstream/Downstream condense 30 s 1K inspection cycle
LCB CT Condensate Downstream condenser 30 s 1K inspection cycle

Steam Turbine Remedial Actions for
Maintenance Off-Normal Operating Conditions
Turbine
Off-Normal Condition Action Classification of action
Main steam pressure> Pmax Increase turbine load or reduce In-service correction
(long-term) steam generator output
Main/reheat steam temperature > 9max Reduce main/reheat steam temperature In-service correction
(long-term)
Main/reheat steam temperature < 9design Raise main/reheat steam temperature In-service correction
Steam pressure ahead of turbine Reduce turbine load until pressure In-service correction
blading> Pmax ahead of turbine blading < Pmax
(long-term) (long-term)
HP turbine exhaust steam temperature Take η measurements In-service check

or extraction temperatures> normal
under otherwise comparable operating If internal efficiency η degraded, Maintenance (saturated steam
conditions flush through with saturated steam washing) during short shut-down
Clean blading Maintenance (cleaning) during
overhaul;
Seal steam pressure deviates from Check control system; if necessary In-service check and correction
setpoint or fluctuates correct setpoint adjuster
If necessary repair control system Repair during service or overhaul
Replace filters at seal steam control Maintenance during short shut-down
valves
Seal steam pressure> Pnormal Measure temperature in leak-off In-service check

seal steam leak-off valve 100% steam lines of casings, valves etc.
Check functioning of Gland Steam In-service check .
condenser
Check shaft seal and repair Inspection and repair during
if necessary overhaul
Temperature differential, top and Check temperature instrumentation In-service check

bottom casing> normal
Establish cause of temperature Actions during service or overhaul
differential as per 5.2-0423 depending on findings
Discrepancies at TSE/TSC
- TSE test function not correct Check TSE and/or temperature In-service check and repair
- High wall temperature differen- instrumentation; check and repair
tials during steady-state TSE or temperature instrumentation
operation
Spacer plates at casing supports Check for casing lift In-service check
lot free to move
Clean spacer plates and other fixture In-service check and maintenance
elements; establish freedom of move- (cleaning) only if casing does
ment not lift when fixture elements are
removed; inspection and maintenan
(cleaning) or repair during overhaul
Check forces exerted by piping, check In-service check; correction during,
adjustment of piping hangers shut-down.

Bearing or shaft vibration Perform checks as prescribed in In-service check.

> normal under otherwise 5.2-0420 provided vibrations
comparable operating conditions < trip limits
Actions as appropriate to
findings e.g. ,
- Rebalance rOtor system In-service correction.
- Check alignment, Check during overhaul
bearings. shaft seals or after turbine shut-down
Bearing metal temperatures Perform examinations and checks as In-service check

> normal under otherwise prescribed in 5.2-0421
comparable operating conditions
If temperature changes wide with Immediate. inspection and repair
rapid rates of change, shutdown during forced shut-down
turbine and ins pact bearing
If temperature changes small and Inspection and repair during

slow, inspect and repair at earliest overhaul
opportunit
Drain valves leaking Open drains. blow through and reclose In-service correction
Loss of integrity of stem packing Tighten stem seals In service maintenance

of drain valves
LP turbine outlet temperature leak in interna1 expansion joint In-service check

> normal under otherwise suspected if high temperature .
comparabl~ operating conditions localised
(especially condenser vacuum)
Perform inspection and if necessary Visual inspection and repairs

repair during overhaul or after shut-down
5.3-0040-01/2
Oil system pressures < pnormal Perform examinations and checks as Checks and remedial actiollS may
Prescribed in 5.2-0460 and take in many cases be performed
appropriate action during operation; otherwise
shut down plant and perform
repairs
Lubricating oil pressure downstream Chang over filter and clean In-service maintenance
of filter < pnormal
Control fluid pressure < pnormal Change over filter and clean or In-service maintenance
replace, or clean filter by rotating
filter plates;
011 temperature downstream of oil Perform examinations and checks as In-service checks and
cooler hnormal prescribed in 5.2-0460 check control maintenance
system, if necessary correct setpoint
or repair
Check oil cooler vents;

check that no water is
being admitted to standby oil cooler;
check oil cooler for chocking, where
necessary change over and clean
Oil level in oil tank < normal

- Slow change Top up with oil of same make and type In-service check and maintenance
- Rapid change Locate leak and take appropriate actions In-service check and remedial. “I
e.g. initiate fire protection measures action
Oil level in tank strainer high Change and clean strainer Maintenance during service or
shut-down
Water collecting on oil tank bottom Drain off water In-service maintenance
separate water from oil
Establish cause Gnu eliminate Check and repair during overhaul
Oil escaping at oil guard rings Check if oil vapour exhauster In-service check and correction
of bearing pedestals fan is in operation
Adjust throttle valves on bearing

pedestals
Check leak-tightness of oil tank covers

and if necessary reseal
Oil properties, e.g. air separation Perform additional oil examinations; In-service maintenance
capability and antifoaming, changed consult on appropriate actions with
oil supplier and turbine manufacturer

Control Fluid System
Control fluid level in control

fluid tank < normal
- Slow change Top up with control fluid of same In-service check and maintenance
make and type
- Rapid change Locate leak and take appropriate In-service check and remedial
actions; e.g. initiate fire protec- actions
tion measures
Control fluid level in tank Change ar1d clean strainer Maintenance during service or
strainer high shut-down
Control fluid properties, e.g. Operate regeneration plant In-service maintenance
air separation capability or continuously; shorten sampling
neutralisation value, changed intervals; replace Fuller’s,
earth in filter.
Control fluid temperature Check control system, where In-service checks and
downstream of control fluid necessary adjust setpoint or maintenance
cooler> normal repair; .
check control fluid vents;
check that no water i$ being
admitted to the standby cooler;
check control fluid coolers fo,
fouling, if necessary change over
and clean
Charge pressures of accumulators Recharge accumulators In-service maintenance

<pnormal
5.3-0040-01/4
Control System, Protective Devices
Change in control system setting Check control system, if necessary Correction during short shut-
- Control valve lift sequence reset or correct, establish cause downs or overhauls
- Control valve synchronisation of discrepancy and eliminate
- Control valve travel changed
as function of secondary
pressures
Primary oil pressure fluctuates Examine antifoaming performance In-service check

or < pnormal of turbine oil
Check oil supply to hydraulic speed Check during short shut-downs or

transducer overhauls
Open main oil pump and check Check and repair during overhaul
hydraulic speed transducer
Control valve steams not leak-tight
- Control valve opening 100% Replace back seat Repair during overhaul or
short shut-downs
- Control valve opening < 100% Replace stem packing rings
Control valve leaking Replace valve stem; rework seat Repair during overhaul
(internal steam leak)
Load shedding relay defective Repair load shedding relay In-service repair
Faults in valves detected by

automatic turbine tester
- Running time exceeded during Adjust limit switch In-service repair
testing of stop and control valves
Extraction swing valve position Repair position indicators In-service repair

indicators defective

Pumps and Piping

Pump arId motor bearing temperatures Inspect bearing, renew or In-service maintenance
> normal replenish grease or oil charge
Pump shaft seals not leak-tight Tighten and if necessary In-service maintenance
repack shaft seals
Performance degraded Switch in standby unit In-service correction
If necessary perform overhaul Repair during overhaul
Discharge head < normal Switch in standby unit In-service~orrection
under otherwise comparable
operating condltions Perform.system check, if In-service correction
necessary correct system operation
Pipes vibrating Inspect dampers In-service mijintenance
Check and repair piping hangers In-service repair
and supports
Piping and/or pipirlg connections

leaky
- Large-scale escape of flammable Immediately shut down turbine Repair during stoppage
media (initiate fire protection
measures); eliminate leak
- Small-scale escape of flammable Establish cause of leak and Repair during stoppages or
media eliminate overhauls
Valve stem seals not leak-tight Tighten or replace stem seals In-service maintenance, repair
during stoppages and overhauls
-
5.3-0040-01/4
Steam Turbine Measurement of Internal Efficiency
Maintenance
The internal efficiency is an important indicator of

the internal condition of a steam turbine. Changes in
the internal condition are easily recognisable from
variation in the internal efficiency.
Such changes may be caused, for example, by

salt deposition on the turbine bladeS, damage to
blades or seals, aging effect etc.
Steam turbine cylinder internal efficiencies can be

calculated for HP turbine. IP turbine group stages and
sdrne group stages of LP turbine where steam
conditiorls at the inlet and outlet of a turbine section
iie in the superheated region. Steam Er,thalpy and
Entropy can be calculated from measured pressure
and temperature parameters with the help of Steam
Table.
It is recommended that a periodic record may be

maintained for the internal efficiency.
∆h
Internal Efficiency = ____________
∆ had
= h1 – h2
‘
_____________
h1 – h2 ad
Notations:
P1 : Pressure of inlet steam before group stage section

T1 : Temperature of inlet steam before group stage
section
P 2 : Pressure of Exit steam after group stage section
T2 : Temperature of Exit .~team after group stage
section
h1 : Enthalpy of inlet steam corresponding to P1 & T1
(Calculated from steam table)
S1 : Steam Entropy of inlet steam corresponding to PI
&T1
h2 : Enthaply of exist steam corresponding to P1 & T2
: Adiabatic steam Enthalpy corresponding to P2 & S1

Steam Turbine Testing During Start-down
Maintenance
Introduction Test Performance

Test.s that demonstrate the proper functioning of Take care to avoid any risks to people or machines
important components must be performed during while performing tests.
shut.dovin of the turbine generator unit. Any simulated condition necessary for the tests
The scope of the tests performed are listed in Test must be cancelled after completion of tests.
Intervals instruction [1). Steam inlet valves may only be opened for test
purposes if the piping systems upstream of those
Test Procedures valves are not under pressure and the system
Test prerequisites, test activities and criteria in concerned have been cleared for testing.
tabular form is intended to simplify testing. Test performance must be recorded.
The tables can also be used as checklists. When If incorrect operation of the equipment being tested
no specific instructions are given for any test, the test occurs, take action establishing full operational
sequences shown in the table must be followed. reliability of the turbine generator unit immediately.
A number of tests require certain components be Pay attention to fault tracing instructions.
in a definite position (e.g. main trip valves in operating
position, stop valves closed, etc.)
The operating sequence establishing certain
operating conditions is given in the form of general Also refer to the following sections
instructions to avoid constant repetition in the tables [1] 5.2-002.. Testing of turbine components
of test sequences. [2] 5.3-0061 Testing during standstill

Main trip valves in operating position

Stop valves closed Starting and load limit device
not in 0% position
end position (= stop valves open!
(1) Move test valve pilot into right-hand end

position (= stop valves closed)
using handwheel
(2) Bring starting and load limit device into 1

0% position ;
• Main trip valves in operating position

40% position
and ready to trip
Stop valves open Starting and load limit device not

in 0% position
end position

0% position ;


40% position
• Main trip valves In operating position
and ready to trip
Overspeed trip
Overspeed test after test interval Generator not synchronised

or after inspections and repairs, Turbine generator unit at rated spead
see also Instruction 5.3-0030 Turbine at operating temperature
(1) Raise speed reference to maximum
• Speed approx. 107%
(2) Switch off electrohydraulic controller
(3) Run up to trip speed by pressing mechanical
push.button on nydraulic speed governor
(4) Verify operation of overspeed trip
• Trip speed
• Stop and control valves closed
Control valves and reverse power protection relay

Leak test (valves) Generator sYllcnronised”
and Load> 0%
Functional test (reverse power relay) Speed governor effective
(1) Lower speed setpoint
• Secondary pressures < opening pressure
for control valves
• Control valves 0%
(2) Verify operation of reverse power
protection relay
• Reverse power protection relay operated
• Generator breaker tripped
or
• Reverse power protection rel~v not operating
see serious faults 5.2-0410
Auxiliary oil pump

Pressure-dependent on command Stop and Ci)ntrol valves closed
Turbine speed dropping
(1) Verify startup of au)(iliary oil pump 011
pressure-dependent command
• Auxiliary Oil pump on
5.3-0060-01/2
Jacking oil pump

Speed-dependent on command Stop and control valves closed
(1) Verify startup of jack!ng oil pump
on speed-dependent command
• Jacking oil pump on
Turning gear oil valve

Speed dependent open command Stop and control valves closed
(1) Verify opening of turning gear oil valve on
speed-dependent command
• Turning gear oil valve open
Condenser safety devices

Response of electrical condenser Turbine generator unit not operating
safety device Condenser plant operating
Criteria for shut-down of condenser plant
fulfilled
Stop valves closed
(1) Reduce condenser vacuum
(2) Verify operation of electrical condenser
safety device
• Trip initiated
(3) Restore main trip valves to normal
operating position
0 Response of hydraulic jow-vacuum trip Condenser safety device test

(electrical) performed
Condenser vacuum> trip vacuum (hydraulic)
Stop valves closed
(1) Simulate turbine speed by screwing in locking
bolt on low-vacuum trip
(3) Verify operation of low-vacuum trip
• Trip initiated
(4) Restore main trip valves to normal
operating position

(5) Cancel hydraulic speed simulation

(Unscrew locking bolt on low-vacuum trip)
(6) Move test valve into operating position
Condenser safety devices for bypass operation

Response of hydraulic low-vacuum trip Condensate extraction pumps operating
Condenser pressure p.b8 < 0.5 bar
Criteria for shut-down of condenser plant.
fulfilled
Bypass operation ended
(1) Press push-button of LPbypass governor

• Signal pressure for bypass control valves
> 1.7 bar < 2.06 bar
• Bypass stop valves open
(2) Operate push-button of LP Bypass

limit controller to inhibit response
due to reduction of condenser vacuum
(4) Verify operation of low-vacuum trip
• Signal, pressure upstream of bypass colltrol

valves reduced
5.3-0060-01/4
Steam Turbine Testing During Standstill
Maintenance
Introduction operating conditions is given in the form of general

Tests that demonstrate the proper functioning of instructions to avoid constant repetition in the tables
important components must be performed during of test sequences.
standstill of the turbine generator unit.
The time intervals between tests are given in a Test Performance
separate instruction [1). Take care to avoid any risks to people or machines
while performing tests.
Test Procedures
Any simulated conditions necessary for the tests
Test prerequisites, test activities and criteria in must be cancelled after completion of tests.
tabular form is intended to simplify testing. Steam inlet valves may only be opened for test
The tables are also suited to use as checklists. purposes if the piping systems upstream of those
Wherever no specific instructions are prescribed for valves are not under pressure and the system
a test, the test sequences shown in the table are to concerned have been cleared for testing.
be followed. Test performance must be recorded.
A number of tests require certain components be If incorrect operation of the equipment being tested
in a definite position le.g. main trip valves in operating occurs, take action establishing full operational
position, stop valves closed, etc.) reliability of the turbine generator unit immediately.
The operating sequence establishing certain Pay attention to fault tracing instructions.
[1] 5.2-002.. Testing of turbine components


Stop valves closed Starting and load limit device
not in 0% position
end position (= stop valves open)
(1) Place test valve pilot into right-hand end
position (= stop valves closed)
using handwheel
0% position
• Main trip valves in operating position ‘
(3) Bring starting and load limit g~viqe into
40% position
• Main trip valves in oper&ting positipn
and ready to trip
• Stop valves closed’
Stop valves open Starting and lo&d limit device not

in 0% position
end position
(1) Bring starting &nd load limit device into
0% position
• Main trip valves in ()perating position


40% position
and ready to trip
Turbine control
Testing of setting Main trip valves in operating position
hydraulic amplifier Control medium temperature approx. 50llC
(1) Read and record setting date of control

system as a function of travel of
starting and load limit device:
(Use starting arId load limit device to
change auxiliary secondary oil pressure
by 0,1+ 0.2 bar per reading
• Travel of starting and IQad limit device
• Travel of governor bellows
• Auxiliary secondary pres~ure
• Travel of converter (mm or %.1
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by manufac-
turer
(3) If comparison reveals major changes, have
them inspected and corrected by manufac-
turer
Testing of setting Main trip valves in operating position
electrohydraulic Converter Control medium temperature approx. 50°C
(1) Read and record setting data of control

system as a function of input voltage of
turbine valve controller
• Input voltage of turbine valve controller

• Travel of converter
• Secondary pressures
• Travel of control valves
turer
them inspected and corrected by manufacturer
Load rejection relay
Functional test
Control valves open
5.3-0061-01/2
(1) Use contactor to energile solenoid valves

operated by load rejection relay
• Control valves close for as long as
solenoid valve is energized
Bypess control
Testing of setting Control medium system operating
Condenser system operating
Restore simulated conditions.
Control medium temperqture approx. 50o,C
(1) Read and record setting data of control
system as a function of converter travel
• Travel of converter
• Injection water signal pressure
• Signal pressure for stop and control valves
• Opening of injection water valves
• Opening of bypass control valves
• Start of opening of bypass control valves
• Bypass control valves open
turer
them inspected and corrected by manufacturer
Main trip valves

Ease of movement and trip, pressure Main trip valves in operating position
Stop valves closed
(1) Reduce control medium pressure of
governor linkaQe by closing cutoff valve
• Main trip valves close
(2) Measure pressure where main trip valves
close
Remote trip solenoids

Functional test Main trip valves in operating position
Test valves of stop valves in closed position
(1) Press pushbutton to start remote turbine
trip
• Trip initiated
Low vacuum trip

Functional test and testing of setting Condenser vacuum> response level
or
Test pump operating and simulated condenser
vacuum> response level

(1) Reduce condenser vacuum or increase

pump pressure
• Low-vacuum trip responds.
(2) Determine vacuurn where trip started
Fire protection system

Functional test shaft at standstill
Normal operating conditions of oil system
established (exception: jacking oil pump
subloop control off)
(1) Operate fire protection switches 1 and 2
in succession in the control room and at “
the local control stations in the power plant
• Start of all fire protection measures in
accordance with functional diagram
• No annunciation: Fire protection measures
not performed
(2) Acknowledge fire protection measures and
reestablish normal operating conditions
for further testing
Low lub oilpressure trip

Functional test Oil system operating
Control fluid system operating
Stop valve closed
(1) Actuate pressure switches (2 out of 3)
for lubricating oil trip
• Trip started
Stop valves
Exercising Oil system operating
Stop valves open
(1) Actuate main trip valves (Manual trip-out
from control system rack or remote trip)
Cut-off pressure Oil system operating

Stop valve to be tested open
(1) Reduce trip oil pre~sure by means of cut-off’
valve upstream of control system cabinet
• Stop valve closes
(2) Measure and record trip oil pressure
where valve starts to close
5.3-0061-01/4
Turbine control valves

Exercising Main trip valves in operating position
Stop valves closed
No limitation by parallel acting controllers
(1) Open and close control valves by starting

and load limit device
By pass stop and control valves

Exercising By pass interlock criteria not present. .
or
release criteria simulated
(1) Open and close bypass stop and control

valves
Vacuum breakers
Functional test (1) Operate vacuum breakers
Alarms
Functional test 5.3-0063
Binary signal transmitters

Functional testing of pressure switches Remove pressure switches
(1) Test pressure switches with test pump
General measuring instrumentation

Functional and annunciation test (1) Test and calibrate in accordance with
manufacturer’s instructions

Steam Turbine Testing of Safety Valves
Maintenance
Introduction The set values must be entered in the

The set pressure of the safety valves of turbine commissioning protocol.
integral system (e.g. oil or other control media) are Bypass which open in the event of excessive
checked during commissioning. pressure upstream of turbine components may form
The scope of instruction in the turbine manual is, part of the over pressure steam removal system and
apart from certain exceptioos. strictly li~ed to the must be likewise set and tested.
scope of supply of the turbine factory. Safety valves
of the steam and water systems are not normally a Testing of Safety Valves
part of the turbine factory’s scope of supply. Thus Regular testing of the safety valves is the
the following instructions may only be regarded as responsibility of the turbine generator unit operator.
recommendations. The testing intervals must comply with the technical
If the pressure in a system increases requirements and the recommendations of the valve
impermissibly from the operat.ing-pressure, it is the and turbine generator unit manufacturer (2] and must
function of the safety valve to reduce this pressure to be observed.
the normal value thus protecting the system Performance of Testing
concerned from damage. Therefore, the turbine Shut-down call be avoided if the testing is carried
manufacturer must approve the valve settings to be out during operation of the turbine. From the point of
used [1]. view of the turbine manufacturer, however, they can
Setting of the Safety Valves only be performed if the turbine generator unit is not
The set values recommended by the turbine endangered.
manufacturer are contained in the Technical Data [1] Operation of the turbine with elevated reheater
of the turbine manual and must be observed. pressure may lead to impermissible temperatures or
Setting and testing must be carried out in the control and thrust characteristics of the turbine
accordance with ttle technical requirements and the being disturbed.
instructions of the valve manufacturer. Further more, faults in the safety valves may cause
When the initial setting is performed during impermissible load changes or instability of the steam
commissioning of the turbine generator unit, a generator. In this case it is best to carry out testing
representative of the turbine manufacturer is to when the turbine is not operating.
witness the test or be informed of the set values.
[1] 5.1-0100 Tachnical Data

[2] 5.2-002.. Testing of Turbine Components

Steam Turbine Testing of Signalling Devices
Maintenance
Introduction check that the signalling actually reflects the

Signalling devices in their various forms are operating condition accurately. Examples: When
important aids to operational supervision. However, shutting down the turbine the “low oil pressure
they are of value only if they are completely reliable alarm must come on before the auxiliary oil pymp
in operation. starts automatically.
Therefore. the signalling devices must be tested When testing the overspeed trips, the wOverspeed
at regular intervals. trip operated alarm must come.
These instructions deal with the fundamentals of Triggering of the sensor. In this method the sensor
testing and maintenance of signalling devices. is operated without there being any change in
operating value or condition. Examples: The
Types of signalling devices travel-controlle’d limit swit ch which signals
Alarm signalling devices give a visual and audible response of the thrust bearing trip is operated by
indication of operating values reaching predetermined hand.
limits. If this results in automatic intervention in the The pressure switch for the “condenser vacuum
plant process. e.g. triggering of the turbine trip, then low” alarm is isolated and then vented to
this is also signaNed. atmosphere.
Condition signalling indicates the state of control The response limit value is adjusted so that
devices, e.g. whether a stop valve is open or closed. signalling response occurs. (With this method it is
Finally, signalling can provide a reminder that possible for mistakes to be made when returning
certain action needs to be take. the settings to their original values. Therefore the
method should only be used in exceptional cases.)
Basis of signalling device testing Signalling response is produced by an electrical
Whenever r’ossible, testing of the signalling pulse. If, for some reason, none of the previous
devices should be carried out under a close methods can be used, a partial test Qf the
approximation to operating conditions. The test should signalling device must be perfQrmed by mean§
also incl ve all components of the device. of an electrical pulse.
In addition to functional testing, the device settings Examples: If the level in the oil tank does not
should also be checked at longer intervals, especially normally fall to its minimum valu~ during operation,
after inspections. the level monitor is disQQnnected and the alarm
initiated by the application Of an electrical pulse.
Test procedures This method of testing presupposes that the level
sensor itself is not suffering any malfunGtiQn.
There are various ways to test the functioning of
signalling devices. Other tests
Testing during operation by varying the operating The lamp of, visual signalling devices have only a
values.This type of testing is most appropriate limited life. The fefore, they must be tested regularly
whefloperati’ng values can be varied by by means of the Iamp test facility to ensure that they
intervention in the plant process. Example: A water are operative and be replaced if they are.blown. When
level can be.raised to its signalling limit by closing replacing coloul’ed lamps in operating condition
the appropriate ‘drain valve. displays, ensure that the COl’l’ICt colour lamp is used.
Care must be exercised with this method to ensure
that the maximum point reached is not sufficient Malfunctions
to cause an unintentional shut-down. Any malfunctioning of signalling devices must be
Testing during operation by varying the operating rectified Immediately upon discovery.
condition. If necessary. the monitored operating values or
When shutting down and starting up the turbine sensor settings must be subjected to critical
and its auxiliaries. and when testing control and examination. This is particularly true when there is a
protection equipment, all alarms and condition continuous alarm although there is no dangerous
signals must be carefully observed and a record operating condition in the plant.
made of their response. It is also important to

Steam Turbine Test of
Maintenance Turbine Stress Evaluator (TSE)
Turbine Stress Controiler (TSC)
Introduction free operation of the measured value acquisition and

This test instruction describes the plausibility checks evaluation functions.
to be carried out on the measured values acquired by the All steam and component temperatures as well as the
temperature sensors for turbine stress monitoring, as well calculated margins are either recorded on dotted-line
as the recording of measured and calculated values for printers or stored by the computer.
long-term evaluation of temperature acquisition and of The plausibility of the measured data can be checked
calculation circuitry. at a later date using the printed or stored measured and
Using either the turbine stress evaluator (TSE) or the calculated values. It is however possible that, by that time,
stress monitoring function of the turbine stress controller faulty turbine stress monitoring will result in selection of
(TSC). the non-steady-state thermal stresses to which the either too fast an operating mode, which will have an
stearpturbine is exposed during startup and shut-down and adverse effect in terms of the degree of component fatigue,
as a result of changes in heat input to co~ponents during or of too slow an operating mode, which will have an
power opera.tion are acqlJired and compared with the adverse effect in terms of economical operation.
permitted limits. For this reason, plausibility checks should be carried
The margins obtained from this comparison define the stress out on the measured values at the internals specified in
and set the limits for permitted temperature load. Table 1 , in order to detect and correct any functional
Evaluation of measured temperatures recording and defects or faulty circuits within the temperature acquisition
action of the calculated margins on the setpoint control for equipment.
the turbine controller allow an optimum operating mode As part of the long-term monitoring of operating
as regards both degree of component fatigue and parameters, all measured and calculated TS values should
economical operation. be regIstered during steady-state operation under the
same boundary conditions. These values should then be
Test recommendations recorded and archived to allow comparison at a later date.
A prerequisite for the proper functioning of turbine
stress monitoring as described in the introduction is fault- Measurement should be performed at the intervals
specified in Table 1.
Table 1 Test Intervals
Type of check or measurement Boundary conditions Test interval
Plausibility checks on measured Non-steady-state and steady-state After inspections and overhauls or after
values operation work on the TS sensor
Recording of measured and calcu- Steady-state operation 3 months or after work 011 the TS sensor
lated values for long-term monitoring or TS monitoring equipment
purposes
Plausibility checks on measured values - The temperatures at the heated component

When performing plausibility checks on the measured, surfaces are higher during warm-up and lower
TS values, the steam and component temperatures must during cooldown than the temperatures at the
be compared with each other I taking certain criteria into component wall centers.
consideration. During non-steady-state operation, it is also - During line?r changes. the temperature difference
important to evaluate the trend of the measured values L\~ (in KI arising in the component are directly
over time. proportional to the transient. of change d9/dt (in K/
If the actual values do not conform to expected values, minI)
this may be due to incorrect assignment of measuring - During acold start or startup after an extended shut-
points or to a polarity fault, e.g. at the transducers. down, the HP turbine warms up rapidly, even while
As regards the criteria to be considered, a distinction still-operating below rated speed. In the case of
must be made between plausibility checks performed the IP turbine however, warm-up of the shaft takes
during non-steady-state and steady-state steam turbine place to a certain extent as a sudden step change
operation. and occurs only just before rated speed is reached,
and then to a greater extent during subsequent
Criteria for plausibility checks during non-steady-state loading.
operation Criteria for plausibility checks during steady-state
The temperatures at the heated component operation
surfaces must respond faster than those at the - The same absolute temperatures and temperature
component wall centres margins must exist for the same steady-state
operating conditions.

- The steam temperatures upstre~m of the: turbine Long-term monitoring through recording
must be higher than the component temperatures. off all measured and calculated values
- The differences that are in force between the main By registering and recor9ing all measured and
steam temperature and the temperature at the calculated values at the intervals specified in rable 1
heated surfac~ inthe main steam valve bodies or during steady- state turbir’6 operation, the thermal
the steam admission ar~a are only very slight behavior of the turbine and the function of the turbine
(< 5 K), stress monitoring equipment can be monitored on a
- During st,eady-state operation, t~mperature long-tE’rm basis.
differences of approximiltely 1 5 K maximum Long-term monitoring can be used to detect and
develop between the measuring points on the rectify any gradually developing changes.
heated surf aces and at the wall centers Qf valve If the check on the measured values reveals that
bodies or the steam admission area. the margins have changed due to th~ m~asured
- The cioser the turbine operating mode comes to absolute temperatures and the c;Jifferences arising
the conditions for purely constant-pressure between them, this can probabiy be traced to a fault
operation, the stronger will be the Influence of in the cqlculation circuitry. The Cquse of the fault must
turbine output onthe differences between main be determined, e.g. by checking the specified iimit
steam temperatures and the temperatures at the curves in accordance with the procedure described
heated surfaces of the turbine casing and the In the manual for the TS monitoring equipment.
shaft. Table 2 contains a!1 measured and calculated
- The temperatures at the heated surfaces of the values which may be required for the turbine stress
casing and the shaft cannot be higher th~n those monitoring equipment. These myst be adapted to
at the heated surface of the valve body or the plant-specific requirements.
steam admission area.
- For the shafts, the differences between the Actions to be taken when actu~1 conditions
temperatures at the heated surfaces and the mean devillta from reference conditions
integral shaft temperatures are alw1lY~ If actual conditions deviate from reference
approximately O. conditions, the measured value acquisition function
- For the barrel-type casing of the HP turbine, must be carefully checked and any faults corrected.
differences of upto approximately 10K between If the deviations in measured and calculated
temperatures at the heated surfaces and those 9t values are particulqrly large, it must be assumed that
the wall center are normal during steady state the behaviour of the turbine plant will be advcrsely
operation. affected. In this case, action of the TS monitoring
- For the IP turbine, the surface temperature of the equipment on the setpoint control for the turbine
IP turbine shaft is not measured directly but only controller must be temporarily deactivated.
at the heated surface of the inner casing. As long as action of the TS monitoring equipment
Dep~nding on the design-related location of the on the set point control for the turbine ~ontroller is
measuring point, differences of 10 to 40 K between deactivated, the TS limit curves must be used for
the reheat steam temperature and the surface evaluqtiori of the thermal stresses imposed on the
temperatures of the shaft can occur during steady- tutbine components.
state operation.
5.3-0064/2
Table 2 Measured and calcularnd values for long-t-erm monitoring
Measured and calculated values Terms Unit
Effective power and reactive power

effective power P P eff MW
reactive pow-er P react MVA
Main steam upstream of HP turbine

mass flow mMS kg/s
pressure ‘PMS bar
temperature 9MS °C
Exhaust steam downstream of HP turbine

pressure PHPexh bar
temperature 9HPexh °C
HP expansion section
differential temperature gMS -g8xh ∆9 K
Reheat steam upstream of IP turbine

pressure PRS bar
temperature 9AS °C
Exhaust steam downstream of IP turbine

pressure PIPIXh bar
temperature 9IP8xn °C
Wall temperatures, MS admission area

surface 9 i adm °C
mid metal 9 m adm °C
Wall temperatures, HP casi,ng

surface gj HPC °C
mid metal 9m HPC °C
Temperatures. HP shaft
surface 9 i HPS °C
simulated at shaft center-line 9 m HPS °C
Temperatures. IP shaft !
surface 9 j IPS °C
simulated at shaft center-line 9m IPS °C
Upper TS margins
steam admission area ∆ ∆ 9 adm u K
HP casing ∆ ∆ 9HPC u K
HP shaft ∆ ∆ 9HPS u K
IP shaft ∆ ∆ 9IPSu K
Lower TS margins
steam admission area ∆ ∆ 9adm I K
HP casing ∆ ∆ 9HPCI K
HP shaft ∆ ∆ 9HPSI K
IP shaft ∆ ∆ 9IPSI K
5.3-0064/3
Steam Turbine Steam Washing of Turbine
Maintenance
Introduction Steam Washing with saturated steam will only have

During operation, deposits occur on the turbine blading the desired success if the steam has an adequate moisture
to a greater or lesser degree depending on the steam purity content upstream of the blading.
[1) and the pressures and temperatures of the operating The saturated steam is Introduced into the HP turbine
steam. These deposits cause a reduction of the turbine via the connection flanges provided between the stop and
generator.unit’s efficiency due to . control valves. .
The steam is introduced into the IP turbine between
Changes in the flow profiles, the control valves and the turbine. Appropriate blind flanges
thicker boundary layers in the steam flow as a result of are provided by BHEL.
rough surf aces. The steam line must be blown-out before saturated
steam washing cpmmences.
In extreme cases the flow area of turbine may get It may be ensured that no external condensate can
reduced with consequent reduction in the maximum enter the condenser during steam washirlg.
possible steam flow through the turbine, and corresponding
output. Steam Washing of IP Turbine
Deposits on blades can be detected on the QI$iS of All stop and control valves and all valves in the ex-
internal efficiency (‘1) measurements [2,). traction lines remain closed during steam washing of the
If deposit leads to an increase in stage pressures, the IP turbine. Any isolating valves present upstream of the
maximum stage pressures shown in the Technical Data feedwater heaters must also be closed.
should not be exceeded. If necessary the output must be The drains from the IP turbine between the reheat
reduced. control valves and the IP outlet, the extraction valves or
Complex, i.e. water-insoluble, silicate deposit$ occur the swing check valves in the extraction lines must be
in a temperature range between 500°C and 350°C. Alkali vented during steam washing only to the extent required
silicates and silicic acid are deposited between 350°C and to allow the condensate arising to drain off whilst preventing
60°C. Salt deposits occur at temperatures ranging from excessive loss of steam. All other drains from the turbine
480°C to the blading stages where con. densation begins. generator must be full opened.
Salt deposits are water-soluble and can be removed by After the saturqted steam line (Fig.1, item 2) has been
steam washing with saturated steam. Depending on their joined up at tne QQnn~Gtion points (3), the washing steam
composition, silicate deposits are either water-soluble (e.g. can be routed into the IP turbine, from there via the
alkali silicates) or occur as a hard Water-insoluble coating. cro$s,arpund line$ to the I..P turbine and then to the
In latter case the deposits can only be removed condenser.
mechanically during overhauls. There are twe possible ways of discharging the
condensate condeniing in the concjenser to the
General Instructions atmosphere. These are :
The effort required for saturated steam washing is by opening the blind flange (4) on the condenser. The
considerably lesser than that required Jor opening the cond~nSQr must be under atmospheric pressure. With
turbine. If efficiency reduction occurs, saturated steam ‘hi$ m@thgd of steam washing samples for finding out
washing should be performed first. In that cnse, the major the: sa I’ content may also be taken at this point.
part of the turbine generator unit downtime is accounted with the vacuum Dump \ ejector swit ched on and the
for by the cooling down time of the turbine. Special blind flange (4) closed, i.e. with the condenser at
measures should be taken to accelerate cooling [3]. subatmospheric pressure, via the condensate
For maximum success, Steam Washing should not be discharge line of an operation condensate pump. In
started until the casing temperatures have dropped to< this case, make sure that the condensate is discharged
100°C. to the admosphere downstream of the pump. Samples
When Steam Washing the turbine stages, the initial for finding out the salt contant are also taken at this
saturated steam temperatvres must be as low as possible. point.
Steam Washing with a constant steam condition is not The first method of steam washing with the cordenser
very effective. After a certain time the turbine blading under atrTIQ$pheric preS$ur~ guarantees a slight
reaches the temperature of the washing steam and the overpressure at the drains SQ that it is possible to perform
condensation that brings abbutthe effect is lost. To get additi,onal sampling &, these points. For this purpose, the
maximum success in the shortest possible time, it is approrriate; dra.ins may be cut off at the sludge traps; or
necessary to increase the steam temperature in stages the seem inserts of the drain valves may be removed.
by increasing the pressure. As the temperature is raised It issugges’ed torecord the salt content at the sam!,
the turbine speed will generally increase (take care to avoid piing point continuQusly ‘hroughout the washing P.roc’:
critical speed ranges). Increased speed will also promote ess. Also, water sample~ should be taken every naif hour
cleaning. The steam entering the condenser must be for deposit analysis.
condensed during the entire process i.e. one circulating Steam washing may be stopped when the purity ‘of
water pump must be in operation. steam entering the turbine (as determined by samplingl is
If possible, the turbine generator unit should be started approximately the same a$ that of the condensate or steam
up and loaded after Steam Washing. Any dissolved salt extracted at the di8t;M,’g~ sampling point.
residue remaining on the blading will be blown out due to The steam washing may be stopped when the salt
the high velocity of the steam under load conditions. content in condensate remain constan-~ at a very low level.

Steam Washing of HP Turbine taken to determine the salt content as described in
steam washing of IP turbine, the completion criteria
The main control valves must be open during remaining same.
steam washing of the HP turbine. Restoring the Turbine to Operating Condition
All drains {7 and 8) from the HP turbine situated On completion of steam washing, ali temporary
between the main stop valves and the HP outlet may fittings must be dismantle,d and the flanges closed
be vented during steam washing only to the extent off. Any drain lines cut off must be rewelded.
required to allow the condensate arising to drain off Controllers and control valves must be returned to
while preventing excessive loss of steam. normal position. The temporary. lines are tp be
All other drains particularly those in the cold preserved for future use.
reheat.” line, must be fully open. Local drainage may
also be” provided so that no steam can enter the
reheater if at all possible.
After the steam line (6) has been joined up at
theconnection points (3:), the stream can be routed AIso refer to the following sections
into the HP turbine. The steam leaving the HP turbine
is [1] 5.1-0120 SteamPurity
exhausted to the condenser via the drains (9): [2] 5.3-0050 Measurement of Internal Efficiencv
The condensate is discharged and samples are [3] 5.2-0350 Fast Coplin,Q Down of the Turbine
5.3-0070-01/2
Steam Turbine Oil Care
Maintenance
Introduction can then be drained off. The presence of water in the oil is
The Oil contained in the tank is used for lubricating revealed by a cloudy (emulsified) appearance of the oil or
and cooling the bearings of the turbine and generator. an increase, or constant value for a long period, of the oil
level in the tank.
Quantity of Oil Oil sample should also be taken when the turbine is
The figure of the oil quantity recorded in the data sheet shut down and all oil pumps have been stopped to find out
does not correspond exactly to the net capacity of the oil the water content. If water is found, verify if it is raw water
tank because an extra quantity must be allowed to fill the or condensate..
system, It is also essential to briefly open the drain valve on
It is important to knov.’ how much oil the whole system the oil tank at intervals of two months during normal
contains in order to have sufficient tank capacity available operation in order to check whether any water has se~tled
when draining the oil to clean out the system and so that at the bottorl1 of the tank. Any water which has formed an
the correct quantity can be ordered when the oil in the emulsion with the oil can be removed by centrifuging while
system is being renewed. the plant is running. When the water has been removed
The section on Technical Data [1] gives details of the check the oil to find out if its properties have been affected.
oil requirements during operation and for oil flushing.
Treatment of Leakage Oil
Monitoring the Oil Level and Alarms Any oil collected from leaks must not be returned to
The level of oil in the tank is monitored by means of the system until it has been cleaned and examined. The
the oil level indicator. reprocessing of the oil should be carried out by the supplier
Also the oil level swit ch initiates a visual and audilJle who must also confirm that it is still useable.
alarm should the oil level fall to the minimum permissible
value. Cleaning Out the Oil System During Overhauls
The oil tank must be topped up immediately if the oil During major overhauls the oil system, and particularly
level reaches the minimum oil level. the oil tank, must be thoroughly cleaned. However,
If constant observations show that the level of oil in greacare must be taken to ensure that the cleansers used
the tank has suddenly fallen by a considerable amount. do not leave behind substances which could have an
the cause must be found immediately. adverse effect on the properties of the oil. This rcfers
Any external leaks discovered must be corrected particularly to any substances containing chlorine or
quickly because of the danger of tire. sulphur. Cotton waste or other fluffy materials must not be
The presence of oil leaks can also be seen by an in- used fPT cleaning the system.
crease in the quantity of topping-up 011 used, For this
reason the quantity of topping-up oil lJsed must be carefully Oil Properties
recorded and the specific pil consllmption (quantity/time) The oil must possess the properties specified in the
emered on a graph, section Turbine Oil Speciflcation [2]. The oil Supplier
An increase in the oil level in the tank or a reduction of must confirm that his product meets these requirements,.
the specific consumption, can also be an indication of a
disturbance such as the entry of water into the oil system. Oil Testing
Checking the Oil Level The properties of the oil should be tested at regular
Daily checking of the level in the oil tank and lecording intervals according t{) the supplier’s recommendations. The
the amount make it easier to find Irregvlarities which could turbine manufacturer recommends that the air separation
lead to an operational dl~tvrbance. qualities and foaming characteristics of the oil are also
tested.
Topping-up Oil Semple
The oil used for topping up should be of the same br~nd Oil samples must be taken and analysed
and quality is that already in the systern, Topping-up must
be cerried out in such a fashion that there is no danger of when the system is first filled with oil.
an Oil fire or of the enmery of foreign objects or substances when commissioning is complete.
into the oil tank. at the intervals prescribed by the oii supplier.
Draining Water from the Oil Tank when disturbances occur which bear some relation to
It is possible for vapour and water from the shaft $eals the properties of the oil
to bypass the sealing ring$ In the bearing p~destals and
so entor the oil systern. It Is likely to occur If there is This ensures that the properties of the oil after a 10
excessive vacuum in the bearing pedestals; Water may period in service can be compared reliably with the
also enter the oil system through leaks in the oil coolers. properties of the oil when new.
Since the specific gravity of water is greater than that
of oil, the water settles at the bottom of the oil tank and Also refer to the following section
[1] 5.1- 0103 TlchNcaiData-OilSupply
[2] 5.1- 0130 Turbine Oil Specification

Steam Turbine Oil Care
Maintenance
Introduction type of lubricant deviating from the manufacturer’s

To ensure satisfactory functioning and to limit specification in the maintenance instructions, it must
wear, a small number of components on the turbine be clarified beforehand whether this will be universally
must be lubricated at regular lntervals. suitable.
Scope Application of Lubricants

The following are the individual components which Before reJubricating components which are
require regular lubrication. exposed to the collection of dirt {e.g. shut-off valve
Control device in accordance with the lubrication stems) they must first be carefully cleaned.
Chart [1J. Over-greasing or overfilling must be avoided.
Actuators for remote-controlled governing, control Grease guns, which cause no damage to greasing
and similar devices. nipples, etc. should only be used.
Spindles of hand-operated shut-off devices.
Pumps and similar machines Lubrication Intervals
Drive motors. The lubrication intervals are stated by the
manufacturers in the maintenance instructions. It is
Lubricants essential for them to be maintained, especially in the
Only the lubricants stated by the respective case of motors, pumps and similar equipment.
manufacturers in the maintenance instructions may It is advisable to prepare lists of items requiring
be used. lubrication, noting when the various items are to be
If, for reasons of stocking or for simplifying regular relubricated. This will ensure that lubrication is carried
maintenance, it is desired to use only one particular out at the regular, prescribed intervals.
Also refer to the following section

[1] 5.1- 0690 Lubrication Chart

Steam Turbine Care of Control Fuild
Maintenance
Introduction Refilling with Control Fluid

The use oft..fire resistant control fluid for turbine control
and protection systems reduces the risk of fire. This is The system must be refilled from lead-sealed casks;
due to the higher ignition temperature (compared to mineral precautions must be taken to prevent filling with a
oil) in case of leaks. control fluid that is not identical to the one specified for
use or with mineral oil from similar casks.
Phosphoric esters with a low water and chlorine content Changirlg Control Fluid
(HS-D series) are used and must be carefully maintained
to preserve their properties. The entire system must be drained when changing the
fluid. New filter elements must be installed or those
This instruction contains the following: present thoroughly cleaned.
guidelines for handling control fluid and for treatment If unavoidable, old control fluid residue (up to 3%) may
of control fluid systems. be tolerated.
data on the compatibility of the control fluid with other
materials. The system must be refilled and samples taken for
procedures to preserve the control fluid properties. comparison with the initial filling. The amount of residue
data on sampling points in the cycle. of control fluid within the system and the neutralisation
sampling and analysis programs. number must be checked by analysing and comparing
maintenance procedures to be followed if the property the samples taken before filling and after the system
characteristics of the fluid reach the permissible limits. has been put into operation. If this shows an increase
in thJ neutralisation r)umber, it must be reduced by
Guidelines for Handling Control fluid and for the passing the control fluid through the bypass
Treatment of Control Fluid System regenerating system.
Initial filling of system Treatment of waste control fluid .

The control fluid system must be cleaned after
assembly. The same control fluid as is to be used as Biological decomposition of control fluid is difficult;
the service filling rrlay be used for flushing the system. control fluid is heavier than water and affects it
However. when the control fluid has been regenerated adversely and therefore must not be passed into the
by the manufacturer. especially after filtering through sewage system.
5 µm fine mesh filters, the property characteristics of
the control fluid must comply with the requirements of The competent Regional Water Authority is responsible
ttle specification [1]. for determining the maximum concentration limit in ppm
for sewage water.
All moisture must be carefully eliminated from the
system (e.g. by drying and/or evacuation) otherwise All containers for storing new or used control fluid must
the control fluid forms acid componente when in contact be clearly and permanently marked. A record of the
with water. The control fluid tank must be thoroughly quantity of used control fluid and of fluid lost due to
cleaned before it is filled with control fluid for flushing maintenance, leakage and damage must be kept.
or service. Check for dust and dirt by first wiping with
white filter paper. All traces of detergent must be For disposal, control fluid may be mixed with sawdust
removed. and burned in. incinerating plants or mixed in small
quantities of used oil for burning.
Although the control fluid manufacturer must ensure
that there are no solid or liquid impurities in the control When control fluid is burned, carbon dioxide (C01) and
fluid supplied for the initial filling, the tank must be filled phosphorus pentaoxide (P 4°,0) are: produced: the
through the Fuller’s earth and fine-mesh filter latter in such small quantities, making it harmless.
equipment.
Disposal mus’t be done by comp~nies authorized and
Baseline reference samples for later comparison must licensed by legislation for the collection, storage and
be taken before filling With control fluid for flushing the dispos~1 of waste materials.
system and after regeneration of the fluid used for
flushing. Control fluid leaks must be absorbed by using sawdust
or oil binding granules and removed immediately.

toxic properties of the control fluid. Follow
Control fluid has the same effect on concrete as minerai
manufacturers instructions and/or other legal
oil. Floors or foundations made of asphalt are not
provisions. Here are some recommendations:
compatible with control fluid.
- All containers for control fluid must be kept tightly
Preservative Agents in Control Fluid System
sealed and permanently marked with the Health
Hazard danger sign.
Spare parts are maintained in serviceable condition
- Do not eat, smoke or drink when working with
by using anti-corrosion agents andlor suitable packing
control fluid or parts in contact with control fluid.
(enclosing in plastic foil and use of desiccants); storage
- Keep control fluid away from foodstuffs.
in dry area is recommended.
- Keep control fluid away from skin, eyes and clothes.
- If control fluid gets into eyes, sponge carefully and
When removing anti-corrosion agents,or cleaning
rinse with water. Obtain medical attention if irritation
spare parts, take care to ensure the parts are dry and,
persists.
above all, that all traces of solvents containing chlorine
- After handing control fluid, wash hands
have been removed. Then apply an intermediate
immediately.
protective coating immediately to .protect the fre$hly
- Wear protective clothes, gloves and goggles.
cleaned surface against corrosive- attacks by the:
- Change any article of clothing that comes into
control fluid used.
contact with control fluid: If skin contact occurs, flush
areas with water. Obtain medical attention if
Note: Chlorine presence in the control fluid causes
irritation persists.
erosion-corrosion at the control edges of the control
- If control fluid is swallowed, give large amounts of
components.
warm salty water to cause vomiting; if unsucc?ssful
tickle back of patients throat with a finger. Obtain
Only the following may be used for cleaning: Nonfelting
medical attention if stomach discomfort persists.
textile and paper clothes, benzene, white spirit and hy.
- Avoid inhaling spray clouds (aerosols) or
drochloric aciq based cleaning agents approved for
decomposition products (e.g. use clothes to protect
general use.
respiratory tract).
- Wear gas mask if thick clouds of control fluid are
Caution: Observe all safety regulations when using
present.
cleaning agents to clean the tanks interIor.
Compatibility with other matElrials c,
Precautions to Ensure Compatibility of the Control Fluid
with other Materials.
Control fluid’s foaming, air release capability and its
resistance to aging are impaired by contact with materials
All components of the control fluid system are selected
incompatible with control fluid;
by the turbine manufacturer in regards to their material
to ensure they are compatible with control fluid and
Furthermore materials which are incompatible with
that no interactions are to be anticipated between the
control fluid can be attacked.
control fluid and materials used.
Metallic materials
To avoid confusion, all spare parts and materials used
Phosphoric esters have a negligible effect on steel,
in the control fluid system must be stored separate from
copper alloys, zinc, tin and aluminium alloys provided
other materials and clearly marked.
the neutralisation numbeJ1swithin the admssible limits.
The solid outer oxide loycer o.f aIuminium alIoys must
Caution: Not aIl components withe compatIble with
not be destroye,didue to frirtion.
control fluld8r. 81so compatibls’.witholl.
Pure copper cannot be used due to its catalytic effect
Where possible, components and materials for use in
on the decomposition of the phosphoric ester. Sealing
, the contf~ fluid system should be obtained from the
material made of copper does not apply since the
turbine manufacturer. This will make sure compatibility
surface area exposed to control fluid is small.
with control fluid by prescribing spec;ifications to be
used by subcontractors and by using suitable materials.
Only austenitic steel may be used for filter meshes;
If parts must be obtained from other sources, the
brass is unsuitable.
chapter referring to the compatibility of the control fluid
must be observed.
Materials for pumps and electric motors Bearing and
shaft seals and the nonmetallic parts of couplings on
Whenever an order is placed with the-turbine
pumps and their drive motors most be compatible with
manufacturer or with third parties for parts or materlals,
control fluid.
it must be expressly stated that these will be used for
the control fluid system.
Since aerosols of the fluid may reach the motors
wingndings through the motor ventilation system, the
Health care measures
windings must be designed to be compatible with
No special safeguards are required to protect against
control fluid.
5.3-0082/2
Materials for tools toxic vapour When exposed to heat. (e.g. during
welding or grinding). Repair procedures must
Nonmetallic parts of tools (handles) must be made of specify the presence of such paints. figns on parts,’
material compatible with control fluid or covered with containers with these paints must not be removed.
suitable surface protection. (See plastics). Remember
this when ordering new tools. Control Fluid properties
Plastics Requirements
Requirements for control fluid are listed in the specifi-
Plastic materials are susceptible to swelling, shrinking cations for contrpl fluid (1).
and surface deterioration. Special care must be taken during commissioning and
Plastic incompatible with control fluid may impair the operation to preserve control fluid properties.
contro1’fluid properties. Following plastics are Keeping a daily service log is recommended; all values
from analysis and details of important events (filter
compatible with control fluid:
changes and exchange of filter mass, refilling) must
be entered. All changes and their cause should be
Fluorcarbon elastomers FKM Viton
readily detectable on the basis of these records.
Butyl rubber IIR Butyl IIR-40
Polytetrafluorethylene PTFE Teflon
Preservation of Properties
Polyethylene PE Hostalene
- Stability
Polyamide PA Nylon Acid and aging products may cause a loss of
stability; the speed of aging increase in the manner
Following Plastics are incompatible with control fluid: of a chain reaction, drastically reducing the service
PVC plastic, Polycarbonate-Makrolon, normal life of the control fluid (res’Jlting from chemical
plexiglass. reactions of the control fluid with water, air and other
impurities).
Only glass or Plexi<Jur T may be used for sight glasses.
Protective caps on switches, plurlgers and valves must + Removal of acids and aging products
be of metal or plastic material compatible with control The presence of acids and aging products
fluid. raises there,eutralisation number; the
permissible limit is O:Smg KOH/g.
Sealing material, hose, cable insulation and Acid and aging product must be eliminated from
accumulator bladders the con~rol fluid by continuous bypass filtration
Following sealing materials are compatible with through a Fuller’s earth filter.
phosphoric esters: Regeneration through a Fuller’se~rt,h filter is
based on an ion exchange reaction.
- For o-rings, packing rings, collars and diaphragms: The Fuller’s earth used must be dry (1 % by
viton, teflon, butyl rubber and composite material weight ,expellable water at:105 0 C). We
such as cotton-viton, teflon-white asbestos, viton recommened drying the Fuller’s ,earth! before
asbestos. filling. The design of the Fuller’s,earth and filter
- For flat gaskets: regenerating equipment conforms; to the control
viton, teflon, butyl rubber and compressed asbestos fluid manufacturer’s requirments,
- For hoses and cable insulation: Design,and functioning of the filters are plained
- viton, teflon and nylon coatings. in the Description Section. The flow diagram of
- For accumulator bladders: butylllR-40 (up to SooCI, the regenerating plant is alsQ givel:) in the
viton relevant,chapter.
- Liquid sealing materials: The grain size of the fuller’s earth should be
Hylomar SQ32L, Loctite 270, ciba-geigy CY246. US screen number 16/30 to 30/60 mesh. The
Caution: Butyl rubber I/R is not compatible with dust portion must not be used.
When filling the filter, ram down and/or shake
oil Silicon rubber must not be used since it
the earth into the filter elements to prevent
Severly impairs the propertios of the control
formation of gaps or channels that wou)dJeduce
fluid (reduces its air release capability).
the efficiency of the Fuller’s earth.
Unnoticed exhaustion of the Fuller’s earth is
Paints
prevented by changing the earth filling at six-
month periods, unless this interval does not
Only two-component, desmodur/desmophene (DD) have to be reduced for qther reasons.
base and epoxy resin base lacquers may be used. Since the control edges of electrohydrauJic
When painting the inner surface of containers, make servo valves are subjected to eros!on-corrosion
sure the coating is applied properly. If the paint flakes if the control fluid is not suitably treated, regular
off, it ~ay cause considerable damage. regeneration of the Fuller’s earth is always
necessary, even if there is no increase in
Caution: Paints compatible with control fluid (epoxy neutralisation number.
resin and desmodur/desmophene base) givp off Regeneration should be started about 48 hours
5.3-0082/3
before commissioning of the servo valves. colour. Evaporating moistl)re is necessary in the
The control element of control circuits actuated absorbers during deaeration. Refill Silica gel if
by servo valves must be.filled with new contra! a permanent change in colour is noticed.
fluid through the r~generation equipment even A large absorber or filter is used when the
when the fluid supplied by the manufacturer has system is vented or deaerated via exhaust fans
the specified neutralisation number. This to ensure that the control fluid is separated from
applied both for initial and refills. the air downstream of the fan.
A fine-mesh mechanical filter (polishing filter) When deaerating using fans, the system must
downstream of the Fuller’s earth filter traps Full- not be under a substantial vacuum.
er’s earth particles and other foreign matter that If deaerating valves are used that open when a
would act as a catalyst in the control fluid. The slight internal over pressure has built up, make
fine-mesh filter has the added function of
sure the m.oist air is unable to enter into the
establishing the required purity of the contrdl
fluid in the overall system. system.
The fine-mesh filter must be cleaned in the Accumulated water is annunciated by using
same way as other fitters in the system. When electrodes. The cause of water accumulation
changing the filter elements, do not remove the must be located immediately and corrected.
protective covers from the new elements until Water accumulating on the surface of the
just before they are installed. control fluid tank due to its low density, must be
Strainers must be cleaned using the cleaning. removed by siphoning or pumped off.
agents recommended by the filter and control Condensate occurring in small amounts
fluid manufacturer; make sure that dirt does not evaporates at service temperature. Increase
get onto the clean side.. monitoring the neutralization number if and after
Immerse filters in the cleansing fluid only up to the accumulation of the water is detected.
their upper edge. Filters must always be blown-
out from the clean side towards the di/1y side.
Use only dry air for blowing-out (relative Fire resistance
humidity 60% at 20OC). Followi[1g are the causes of impairing the fire-resistant
Confirm absence of oil and dust by using filter properties of the control fluid:
paper test. + Mixing of mineral oil by mistake; this can be
Use a magnifying glass to check the per-vented if filling guidelines are followed.
completeness of the cleansing process. + Penetr~tion of mineral oil from the lubricating
oil circuit.
+ Prevention of thermal influences The control Design measures have been taken to prevent
system requires a service medium viscosity that oil and control fluid from intermixing.
complies with the specification at a control fluid Contact points between the lubrication oil
service temperature of 55:t5 0C. control system are separated by interface made
No adverse effects on the stability of thecontrpl of metal bellows be~ween which there is a drain
fluid due to thermal influences are to be
line to the leakage tanks; the tank has a device
expected at this service temperature.
A maximum temperature of 90°C is admissible to annunciate the accumulation of control fluid
locally, for example, at heating element/ due to leaks.
protective pipes with he~t conducting oil fillings. The bellows are arranged if ene ruptures, the
Compliance withe this limit temperature is second takes over its shielding function.
monitered the heating elemant be.ing cut out Penetration of one medIa into the other is only
as soon as the limit is reached. possible if both ‘(jividing elements have leak.
Temperature a,bove 75°C are admissible for a About 3-4 % mineral oil will dissolve in, control
short period oiIly during flushing procedures. fluid between room temperature and 50°C. If
oil enters the control fluid circuit, the conttol fluid
Note: If the temperature rises from 60°C to manufacturer must examine the effect this has
70°C, the speed of oxidation doubles. on the fluid’s fire resistance properties. It is
impossible to separate oil from the control fluid
+ Prevention of influence due to foreign matter
Measures must be taken to stop the entry of since the mixture is a genuine solution. Only
solid or liquid foreign matter or other impurities when the oil content exceeds 3-4% does a two-
with a view to maintaining the stability of the phase liquid result.
system. All possible measures must be taken
to protect the system from rust. - Air release capability
The system is vented and deaerated via a The air release capability of the fluid depends on
defined opening to stop degeneration of the the presence of foreign matter. The chapters on the
control fluid due to moisture and contamination. subject of stability and prevention of the influences of
The opening is sealed by absorbers or filters to foreign matter must be observed to ensure the air
prevent the entry of moisture and contamination release capability complies with the requirements.
when venting and to ensure adequate
deaeration. - Purity
Silica gel absorbers are used to indicate the
SAE guidelines (Fig.1) govern the purity
buildup of absorbed mQ!$ture by changing
requirements for media used in hydraulic systems.
5.3-0082/4
Magnitude Particles /1 OOmI
0 1 2 3 4 5 6
5 - 10 µm 2700 4600 9700 24000 32000 87000 128000
10 - 25 µm 670 1340 2680 5360 10700 21400 42000
25 - 50 µm 93 210 380 780 1510 3130 6500
50 - 100 µm 16 28 56 110 225 430 1000
> 100 µm 1 3 5 11 21 41 92
Fig.1 SAE permissible degrees of contamination for hydraulic systems
Class classification applicable for maintaicicg the where a certain amount of control fluid mixture from each
service reliability for protection a;)d control systems individual container has been retained. The ftrst control
(according to the latest state of the art) are as follows: fluid container opened is to be useE! as the collecting
container to prevent C{)ntamination due to use of a vessel
Class 6 Protection and Control systems without that was not a part of the control fluid consignment.
servo valves In Fig.2 the number given in the columns apply to the
Class 3 Protection and Control systems with purity categories in accordance with the SAE classification
servo valves system.
Sampling and analysis 6 Control fluid systems without servo valves for control
Samples must be taken and examined to be able to equipment
ensure the control fluid meets the purity requirements. 3 Control fluid systems with servo valves for control
Samples must be taken at sampling points from the equipment
flowing liquid into clean laboratory bottles. Take care to
avoid any secondary contamination. The sampling bottles Sampling points are marked:
must be permanently marked with this data: facility,
sampling point, fluid manufacturer and type, date, sampler. Sampling point -Supply (PNV)
They must then be sent to’ a laboratory (turbine manu.
facturer, control fluid supplier or operator) for examina- The PNV is provided within the supply unit. Analysis
tion. of the samples from this point makes it possible to
It is possible to filter the samples at the site by using ensure the degree of purity of the fluid downstream of
the field monitoring method so only the diaphragm filter the fine-mesh filter, before it enters control system
has to be sent for analysis to a laboratory outside the power sections susceptible to contamination, and at the same
plant. time to check the function of the fine-mesh filters.
Performing routine analysis of the same fluid filling in.
volves relating the degree of colour change of the test Sampling point -Return (PNR)
filter (relative measuring method) to the quantitative degree The PNR is provided in the return line. Analysis of the
of contamination as determined by counting the samples from this point makes it possible to determine
contamination particles. the degree of purity of the fluid in the overall system
The precondition for application of the field monitoring without the direct influence of the serYice filters.
method using diaphragm filters or of the relative measuring
method is the availability of reliable sajr,pling and analysis Sampling point. Fluid Tank (PNB)
equipment at the plant site. The PNB is provided at the tank.
Sampling points downstream of the circulation pump
Sampling and analysis program (PNU), downstream of Fuller’s earth filter (PNFB) and
The sampling and analysis program according to Fig.2 downstream of the fine-mesh mechanical filter (PNMF)
makes it possible to perform the essential assessment of are provided.
the control fluid properties and purity at all stages of Samples from the sampling points (PNU, PNBF and
commissioning and during continuous service. PNMF are used to determine the efficiency of the
Besides, it allows assessing the flushing procedures regeneration and filtration processes.
and the condition, efficiency and regeneration of the filter The sampling program appfies both to the initial filling
equipment. and to all fillings thereafter.
When required, it is possible to compare the results of
the routine analysis with the analysIs of thebase/ine Maintenance measures to be carried out to ensure
reference samples taken before filling and completion of Fluid property characteristics
commissioning. The table in Fig.3 contains maintenance
The samples taken before filling the control fluid system measures to be taken if analysis values obtained for the
must be representative of each consignment delivered; samples approach the limits prescribed in the specification
the samples must be taken from a collecting container [1].
5.3-0082/5
Examination of system components If any deposits are found, they must be analysed in
During inspections and major overhauls, carefully consultation with the control fluid manufacturer.
examine the system components for formation of deposits Then checks must be carried out to find aut if rust or
or scale and for erosion-corrosion at the control edges of other forms of corrosion h~vedeveloped within the system.
sensitivity control equipment.
Time of Sampling Degree of purity NZ ASC H2O Density Kinem. Anti.
Discolora- Particle KOH min content gfcm 3
Visco Corr.
tion test count mg/fg % by vol V mm2/s props.(2)
Before filling FRF

1 laboratory sample x x x
1 control sample (3 + 6) (3 + 6) (3 + 6)
2 weeks after filling
FRF. if flushing not x x x
yet started (3+6) (3+6) (3+6)
Before commencing (6) PNB (3) PNR
flushing for docu-
mentation of as- .
delivered condition
Continuous sampling (6) PNR
during flushing (3) PNR
Before end of flushing (3) PNR
Towards end of re- (3) PNB x x x x
filling via superfine (3+6) (3+6) (3+6) (3+6)
filter
Continuous monitor- 3 + 6 PNB(3)
ing during superfine 3 + 6 PNU
filtering 3 + 6 PNBF
3+6 PNMF
Before commencing x x x
hot operation /Iast (3 + 6) (3 + 6) (3 + 6)
sample taken more .
than 2 weeks earlier)
24 h after commencing x x x x x
hot operation (3 + 6) (3 + 6) (3 + 6) (3 + 6) (3 + 6)
1 month after com-
mencmg ot x x x
operation: weekly (3+ 6) (3 + 6) (3 + 6)
1 month after com-
mencing hot (3) PNV x x x x x
operation: monthlycD and PNR (3+ 6) (3+ 6)
Before handing over (6) PNR x x x x x
Wlthfmallog (3)PNV (3+ 6) (3+ 6) (3+ 6) (3+ 6) (3+ 6)
and PNR
Fig.2 Sampling program SAE purity grade classes 3 and 6 ( )
Entire program applies for refills also
(1) Continuous monitoring progralTl aftar handing over

(2) Anti-corrosion propertias to DIN 51585, ASTM D 665-60
(3) Test intervals according to filter capacity
PNB = Tank PNU = downstraam of recirculating pump
PNV = supply line PNBF = downstream of fuller’s earth filter
PNR = return line PNMF = downstreem of mechanical filter
5.3-0082/6
Perameter and Inspection method Permlssible limit Inspection interval Measures to be taken if
dimensions limits exceeded
Water content Not free water weekly Evaporate, suction-extract, ladle-off,

% by vol. visible to naked centrifuge using special device
eye
Neutralisation DIN 51 558 weekly Check regeneration plant

number NZ ASTM D974 0.5 if negative trend, Replace fuller’s earth
(mg KOH/9) monthly Check effects by frequent measure-
ment of NZ
Kinematic DIN 51561 monthly Replace filling

viscosity at 40°C ASTM D445 26-50
(mm2/s)
Solid impurities Particle count and SAE purity grade monthly Check filters for proper functioning
discolouration test class 6 or class 3 If necessary, replace filter elements
Examine deposits on filter elements
Air separation DIN 51381 Proper functioning every 4th month Check fluid for contamination
capability of system must (chemical and mechanical, entrained
(min. at 50°C) be assured oil)
Density at 15°C DIN 51757 every 4th month Check points in system where oil
(g/cm3) ASTM D1298 can enter FRF system
Examine fluid for entrained oil, air
or water
Fire resistance 5 second test see note (1) after determining Replace FRF filling
test oil content
Anti-corrosion DIN 51585 no corrosion every 4th month Have anti-corrosion additive’
properties ASTM D665-60 permissible analysed by fluid manufacturer.
Replace FRF filling if necessary.
Oil content nuclear resonance 3% max. see not (2) Replace FRF filling.
% by vol. test, density perform fire resistance test.
Fig. 3 Maintenance Meaaures.
(1) DIN method in preperation

(2) If examination of the points in the system where the oil and FRF loops are structurally separated reveal that oil has
entered the FRF system es a result of structural failure, the oil content in the FRF must be determined.
[1] 5.1-0140 Fire Resistant Fluid

[21 5.1-1110 ControlFluidPunip
[3] 5.1-1120 Plate Type Filter
[4] 5.1-1130 Duplex Filter
[5] 5.1-1’140 Regenerating Plant
[6] 5.3-0083 Analysis of Fire Resistant Fluid
5.3-0082/7
Steam Turbine Fire-Resistant-Fluid
Maintenance Determination of Fluid Purity
Introduction Sampling
A fire-resistant control fluid (FRF) is used in control Always perform sampling at the same location
and governing systems. The purity of the fire-resistant directly from the system [2).
fluid is of vital importance to the reliable operation of Recirculate the fire-resistant fluid long enough prior
the plant and must be monitored continuously. to sampling to avoid settling and give a
homogeneous sample.
Brief Description of the Procedure Always perform sampling while the FRF system
To determine its purity, a defined quantity of the is in operation.
fire-resistant fluid is dissolved inn-heptane and filtered Flush the sampling point prior to sampling by
through a diaphragm of pore size 0.45 Jim. Size and draining about 10 litres of fire-resistant fluid into a
quantity of the separable foreign matter particles are clean receptacle; return this into the system after
then determined. A comparison shows whether the sampling.
fire-resistant fluid lies within the purity requirements Allow about 10 litres of fire-resistant fluid to pass
established in the specification [1). through the sampling point before performing
sampling by filling the fire-resistant fluid directly
Equipment and Chemicals Required into the cleaned ground-glass flask.
Do not use aids such as syringes or beakers.
membrane filters, 50 mm dia., 0.1J1m and 0.45 Always identification-mark the specimens uniquely
Jim pore size and durably.
filtering device and aspirator Complete the sampling records and send to the
n-heptane, p.a., purified by filtration analysing laboratory together with the FRF
Filter the quantity of n-heptane p.a. that is required sample.
for dissolving and washing of the fire-resistant-
fluid specimen through a membrane filter of pore Determination Procedure
size 0.1 Jim four times to exclude even the most Measure 20 ml (about 23 g) of fire-resistant fluid
minute impurities. into an Erlenmeyer flask previously.cleaned with
100 ml ground glass flasks purified n-heptane, p.a., and dissolve in 80 ml of
100 ml Erlenmeyer flasks with ground glass purified n-heptane, p.a.
stoppers Use a clean hair brush to remove any dust from
vacuum pump, e.g. water jet pump the membrane filter and clamp the filter into the
microscope slides filtering device.
adhesive tape Connect up’the water jet pump to the aspirator
and filter the fire-resistant fluid/n-heptane mixture
Preparation of Sampling Vessels through the membrane filter.
Note.. Flasks cleaned by a normal cleaning procedure Then flush the Erlenmeyer flask five times with
still contain far too many minute impurities which can about 50 ml each purified n-heptane. p.a. and also
give a false impression of purity. pass the n-heptane used for flushing through the
For this reason, the ground glass flasks and filter.
Erlenmeyer flasks must be flusher! three times with After drying the filter, place it between 2 cleaned
extra-purified n-heptane. microscope slides and seal the edges with
adhesive tape.
Determine the sizes and quantities of the
separable foreign matter particles.

Steam Turbine Vibration Dampers
Maintenance
Introduction Another point to watch are the attachments of the

If the piping of the lubricating and control fluid dampers to the piping and to any thermal in$tallation
system is excited to vibration, the deflections involved plates installed between thern, as these connections
could cause inadmissib1e stressing of the piping may work loose. For these reasons, regular
material. inspections are necessary to er1s.ure that the
Dampers are used to attenuate piping vibration. vibration dampers are in good condition and
There consist essentially of a cylindrical CRsing functioning properly.
enclosing a plunger embedded in a viscous bitumen
mass that performs the actual damping function. The Inspection Intervals, Scope of Inspections
upper part of the damper is sealed by a fabric-base The Table Fig. 1 gives all important criteria to be
plastic guard sleeve. reviewed during vibration damper inspections. The
This damper design is not subject to wear, but the intervals between inspections are given in “y” (years).
damping medium properties may be impaired by The inspections may also be performed during
temperature influences or, if the guard sleeve is plant operation.
damaged, by contamination with foreign matter.
Inspection Scopo of Inspection

Intervals - Criteria
1y Damper Attachment
- firm seating of damper components on pipe and support sides (and at thermal insulation plates,
if applicable)
Motion reserve
- cold condition: position of plunger as in support drawing
Guard sleeve
- correct and firm seating
- tension of the clamps
- damage (cracking or perforations)*
External influences
- effects of water, oil or similar *
5y as for 1 y
Condition of the damper medium
- surface appearance
- elasticity
Fig. 1 Inspection Intervals, Scope of inspections and Criteria
Points to Noto If cracking, crumbling or loss of elasticity is

If welding work is to be performed close to the discovered on the surface of the damper medium, or
piping dampers, take care to protect the dampers (and if the plunger has worked itself out of the medium,
particularly the guard sleeves) from weld spatter and thi$ indicates that ambient temperatures in excess of
other potential damage. design have caused deterioration in the damper
To preclude any deterioration due to ingress of medium properties.
foreign matter such &s water, oil, etc., replace guard Consult the damper manufacturer if the damper
sleeves as soon as any dameg5 is discovered. In medium is unserviceable and has to be replaced.
this event, also check the condition of the damper Damper medium can be removed from the casings
medium immediately. without leaving residue if heated to about 80°C.

Steam Turbine Instructions for Overhaul
Maintenance
In this chapter scope and schedule of overhaul Detailed knowledge of the next *major overhaul*
has been described. can be gained from the *medium overhaulw.
The following criteria form the basis for deciding
Types of Overhaul whether or not to open a casing: conclusions
drawn from long-term observation, operating
1.1 Minor Overhaul (inspection, servicing) experience and manufacturer’s
A “minor overhaul” should be carried out as recommendations.
required simultaneously with st)utdowns of other 1.3 Major Overhaul (inspection, servicing, repair)
plant components or durirlg standstill of the A “major overhaul” is a planned shutdown. It
turbine-generator unit due to faults. permits detailed inspection and the determination
The purpose of the minor inspection is to avoid of the condition of all components. All casings
reduction in availability ~ue to forced outages by are opened.
inspection and servicing and, if necessary, by Schedule inspection interval: after 50,000
preventive maintenance, equivalent operating holjrs.
The casings are not opened, The term “equivalent operation hours” is defined by
Detailed knowledge of importance for the follo:wing equation:
“intermediate overhaul” or “major overhaul” is
gained during “minor overhaul”. Te = T0 + ns
Scheduled interval: after about 25.000 eqlJivalent
hours of operation. Where
1.2 Medium Overhaul (Inspection, servicing, repair)

A “Medium Overhaul” is a planned shutdown -if Te = equivalent operating hours
possible simultaneously with other plant
components-during which a casing may be T0 = actual operating hours
opened, if necessary. It covers all work which
has a bearing on the availability of the turbine- ns = the number of starts, without differentiation
generator unit. between cold and hot starts.

VARIANT 1 1 VARIAN 2T
MINOR MAJOR OVERHAUL MEDIUM OVERHAUL

OPERATING HOURS
OVERHAUL
OPERATING YEARS
TURBINE BRGS.
TURBINE BRGS.
TURBINE BRGS.
H.P. TURBINE
H.P. TURBINE
L.P. TURBINE
L.P. TURBINE
EQUIVALENT
I.P. TURBINE
I.P. TURBINE
COUPLING
COUPLINE
COUPLINE
TURBINE
TURBINE
TURBINE
VALVES
VALVES
VALVES
CHECK
CHECK
CHECK
8600 01
02 × ×
25800 03
04 × ×
43000 05
06 × × × × × × ×
60200 07
08
77400 09 × ×
10
94600 11
12 × × × × × × ×
111800 13
14
129000 15 × ×
16
1462000 17
18 × × × × × × ×
× MANDATORY
OPTIONAL
TURBINE OVERHAUL
5.3-0200-01/2
Medium Overhaul
Minor Overhaul
Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul
Check guides of inner casing for freedom of movement and wear. Overhaul.
Measure permanent elongation of bolts mhigh temperature zone and check them for embrittlement,
check all bolts for cracks.
Check shaft seals and labyrinth glands for abrasion and scaling. Check springs of spring-mounted
ring segments.
Check shaft for cracks. Perform runout check, eliminate score-marks in shaft journals. Inspect
coupling.
Clean complete blading assembly and examine for damage. Pa’y particular attention to scaling of
seal strips. Check freestanding LP moving blades for cracks,
Visually examine last stage blades of LP turbine (check for cracks if necessary).
Check earthing brush contact surface of shaft.
Open main oil pump, check bearings, seal rings, shaft, impeller etc. Open auxiliary oil pump only
it necessary.
Check control and protective devices. Pay particular attention to parts subject to wear or deposits:
replace these if necessary.
Perform mechanical, electrical and or hydraulic functional tests on monitoring instrumentation; if

necessary, overhaul and re-calibrate.
Disconnect couplings, measure elongation of coupling bolts, check axial and radial alignment,
perform runout check, clearance check.
Disassemble bearings, check babbitt surface, measure clearances, check :;eat of bearing in bearing
pedestal.
Check, overhaul and, if necessary, replace seal rings of bearing pedestals.
Check casing guide for deposits, if guides jammed, removed clean and overhauls keys.
Check stop valves, contro! valves, bypass valves; if necessary, repla.f” lorn parts on the hydraulic’
and steam sides.
Remove and check steam strainers for deposits and damage replay necessary.
Check drains for foreign material, open and clean sludge traps.
Measure casing distortion, check casing joints for erosion, check for cracks.
Drain oil/FRF tank, separate impurities, change if necessary. Inspect oil/FRF tank. Clean strainers.
= if necessary = mandatory
if applicable
5.3-0200-01/3
Medium Overhaul
Minor Overhaul
Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul
Check oil/ FRF filters for leaks, remove and clean the inserts, pay attention to damage.
Examine oil/FRF lines for damage, eliminate leaks
Examine steam turbine integral piping for cracks, deformation and ballooning.
Check pipe supports and hangers and readjust if necessary.
Replace TSE Thermocouples fitted in IP inner casing (whenever IP turnine is overhauled)
= if necessary = mandatory
if applicable
5.3-0200-01/4
1.1 Minor Overhaul SLIDING PECES IN CASING GUIDES AND
Casings are not opened. Bearing check, SUPPORTS
coupling check, if necessary, checks of controls, Inspect keys and sliding pieces tor fouling
safety and protective equipment (on steam and (carbon and crack formation; if there are
oil sides). indications of jamming, dismantle and overhaul.
1.1.1Colnp.olicnts to be inspacted CONTROL VAL VE:S, BYPASS IJ AL VES
Coupling (if necessary)
BearirlQS Activities should generally be concerned with
Oil guard rings of bearing pedestals c:heckirl\l of parts subject to ‘Near. Decisions
Sliding pieces in casing guides and supports on further activities and valves to be covered
Contrul valves, bypass valves are to be taken according to the circumstances
Emergency stop valves and extraction on the basis of performance in the preceding
non return valves period of operation. Spindle seals consisting of
Control and safety equipment paclc.ing materia! are to be replaced in all cases.
Piping supports and hangers Clearances between moving and stationary
Steam strainers parts should be checked and corrected.
Drains
Oil lines EMERGENCY STOP VALVES
Pumps (main oil pump, jacking-oil pump,
auxiliary oil Emergency stop valves should always be
pumps and emergency oil pumps, if necessary) inspected completely (steam and oil side). This
Oil/FRF tanks includes spindle, cone, seat, bush, actuator.
Oil/FRF filters With mechanical drives (lever linkage) in
Last stage of LP Turbine particular, attention is to be givel! to compliance
Monitoring equipment with plays and travel reserves.
1.1.2 Scope of activities PIPING SUPPORTS AND HANGERS
COUPLINGS
If couplings are to be disengaged measure the Check and measure alignment dimensions ill
pretension of the coupling bolts, on loosing and thf~ l-:old conditions and correct, if necessary.
tightening. Check the alignment radially and Check pipes for visible changes. “ .
axially. If deviations exceed the permissible
tolerance, realignment is required. STEAM STRAINERS
If couplings are disengaged it is advisablt: to Dismantle and check for foreign bodies and
perform a roll check, especially if the couplings damage. Replace gasket.
need to be realigned. At the same time measure
the axial dispiacement of the rotors relative to DRAINS
the casing. If disengagement of the couplings is
not performed, coupled runout checks are to be The scope of activities depends on performance
performed in the vicinity of the bearing as a during the preceding period of operatio:1 and
minimum requirement. susceptibility to malfunctions. The sludge legs
should be opened in all cases.
BEARINGS
Dismantle bearings, it is necessary to check the OIL LINES
babbitt metal lining for the damage and
looseness by UT. Check seat of bearing in Remove leaked oil, inspect pipes and molmtillg
bearing pedestal. Measure clearances of for fretting point and strengthen accordingly.
bearings.
PUMPS
OIL GUARD RINGS OF BEARING PEDESTALS
Remove contaminants and abraded particles on The main oil pump is to be opem;d in order to
the seal edges to prevent oil leakage. Replace inspect bearings, sealing rings, shaft, impeller
oil guard ring in case of excessive clearaflce. and coopling. Check other pumps in redundancy
configriltion only as necessary.
5.3-0200-01/5
OIL/FRF TANKS BLADING
Clean strainers Clean entire bladrng with casing open and

inspect for damage and incipient cracks, Check
OIL/FRF FILTERS shrouds for scale accordin@ to temperature.
Check for blade looseness and lock blade lift.
Remove elemerlts and clean. Check for
damage. GLANDS AND LABYRINTHS
LAST STAGES OF LP TURBINE Check for abrasion and ~cale (dependent on

temperatur~), Check condition of springs,
Visual inspection of condition (crack
examinationwnef necessary) ROTOR .I
MONITORING EQUIPMENT Check for cracks in .fillets. Perform runout

Check that mechanical, electrical and hydraulic check,’ Eliminate scoring in the journals. Check
monitoring equipment function properly and coupling.
repair or recalibrate as necessary.
TSE THERMOCOUPLES
1.2 Medium Overhaul
At least one casing is to be opened and the rotor Replace TSE thermocouples fitted in IP inner casi()g,
lifted out. Otherwise as for minor overhaul. whenever IP Turbine in opened for overhaul.
Take advance action for procuremel1t of the
1.2.1 Components to be inspected TSE thermocouples and associated fittings,
As for minor overhaul but augmented by the 1.3 Major Overhaul

following: All casings are tobe opened and the rotors lifted
out. Otherwise as 1or medium overhaul, but
Inlet and outlet connections. instruction .’ -if necessary-.is inapplicable.
Casings
Inner casing guides . 1.3.1 Components to be. inspected
Blading - As for medIum overhaul but instruction ~if
Glands necessary” is inapplicab.le~ ~nd augmented by
Rotors the following:
Oil and FRF tanks
1.2.2 Scope of activities Steam lines
Casingcenter guides
As for minor inspection but augmented by the
following 1.3.2 Scope of Activities
As far medium overhaul of valves, pumps and
INLET AND OUTLET CONNECTIONS drains. but instruction “if necessary” is
i1"applicable. and augmented by tne foTlowing:
Inspect for scale and freedom of movement at
I-and L-seal rings. Inspect U-seal rings and OIL AND FRF TANKS
measur precompression. Drain and clean tank Separate oil/FRF, change
if necessary.
CASING
STEAM LINES.
Measure for deformation, crack examiriatit>n if
required. Rework according to findings. .Inspect- Check Steam lines exposed to rnain or reheat
casing joint plane for erosion steam for expan,sion, deform~tion and cracking,
INNER CASING GUIDES CASING CENTRE GUlpES
Check for freedom of movernent Hnd wear. Disasse’mbJe and overhaul.
5.3-0200-01/6
2. Suggested inspection and testing procedures
2.2.1Dye penetration test (OPT)
During inspection, in particultur major steam turbine
generator unit inspections, certain components are 2.2.2Magnetic particle inspection (cannot be used on
required to be inspected in-depth to achieve more austenitic materials)
accurate evaluation of their condition. The findings
are to be documented (descriptions, check 2.2.3Eddy-current examination
calculations, dra’Nings and photographs).
2.2.4Crack depth determination as far as possible
Depending on the results of the inspection the with capacitance probe or ultrasound
examined components are to be:
2.3 Ultrasonic examintltion
a) left in the as-inspected condition, because no
faults have been found. 2.4 X-Ray examination
b) left in the as-inspected conditions aithouJh
damage (e.g. crack formation) has been four.d, 2.5 Detection of permanent deformations
Continued operation, either in an unaltered or
altered mode, is to be justified. The propagation 2.5.1 Out:of-roundness, “ ovality measurements”.
of the damage is to be kept under observation; angle of bend (in pipe elbows), warp
spare parts, often requiring lengthy delivery
periods, are to be ordered. 2.5.2 Expansion measurements (measurement of
c) replaced with spare parts. (e.g. parts subject to diameter. length, circumference; tools: external/
wear such as spindles; in genera! small parts, internal micrometer, vernier caliper, caliper.
which are customarUy always kept in stock.) measuring tape)
d) repaired by reworking at site or in the works of
the supplier 2.6 Wall thickness m6asurement
It is necessary to increase the scope of the inspection
as soon as the units have achieved about 80,000 to 2.6.1 Callipers
100,000 hours of operation. Inspection planning must
allow for the additional time and costs consumed by 2.6.2 Ultrasound
the inspections. Apart from this, the intervals between
major overhauls necessitate the coverage of 2.7 Surface micro-structure examination
considerably more components by the inspection as
has beeo.cu~tomary hitherto. Experience with turbine 2.7.1 Microscopic examination at site
generator units whictr have achieved., O! already
exceeded, 200,000 hours of operation in the 2.7.2 Contact print procedure after etching material
meantime must also be taken into account. surface.
When stipulating the scope of the inspection the 2.8 Hardness test
experience gained from comparable units should be
taken into account in the plans and/or the 2.9 Materla1 verification test
manufacturer is to state at which highly stressed Manual spectroscope
points the various components are to be inspected.
It is advisable to get thsspecial checks and tests 2.10 Material testing
conducted by the specialists from turbine plant.
Depeflding on the requirement following examination/ 2.10.1 Tensile test to determine yield strength, tensile
inspection/te,sting of steam turbine parts may be strength, elongation after fracture and necking
done. down.
2.1 Visual Inspection 2.10.2 Notched bar impact test
2.1.1 With the naked eye and good illumination e.g. 2.10.3 Chemical composition
500 Watt photographic lamp, mirror.
2.1.2 Magnifying glass 2.10.4 Metallographic microstructu/,e evaluation
2.1.3 Borescopes (rigid and flexible; accessories; TV
camera, monitor. video-recorder) 2.11 Testing of electrical insulation against shaft
2.1.4 Microscope currents
22 Surface crack examination
5.3-0200-01/7
Steam Turbine Turbine Restart after Boiler Repairs
Maintenance
Introduction remaining in the system are blown down into the

Following extensive boiler repairs, measures must condenser, which prevents them from causing particle
be taken to protect the turbine against erosion by solid erosion on the turbine blades Partic;&3 blown down
particles. into the condenser must be removed from into hotwell
before commencement of process operation. The
Bypass Operation bypass steam mass flow rate must comply with the
When extensive repairs have been carried out on limits (mass flow rate and duration of operation)
the boiler, it is not possible to prevent solid particles defined in the specifications.
remaining in the system in spite of chemical cleaning. The bypass stop and control val’/es may suffer
For this reason, provision must be made for a lengthy slight damage to their seats and discs as a result of
period of bypass operation “,lith the highest possible steam dumping and must where necessary be
bypass steam mass flow rate at the time of unit restart. checked by sampling.
During this bypass operation all solid particles

Steam Turbine Turbine Restart after Major
Maintenance Inspections or Repairs
Introduction In-Service Inspections

The operational reliability and availability of a steam The tests. which could not be carried out in the
turbine unit are determined by, among other factors, the preservice phase because the boundary cor,ditions had
care with which the unit was initially star:ed up. The same not been fulfilled, must be performed during the service
rule also applies to restarts after large scale maintenance ~)hase subsequent to the pre-service inspections. The
and repair work, e.g. in the course of major inspections. essential step-by-step test schedules appear in.
maintenance instruction 5.3-0060.
Infurmation Required for Restart
In restarting a turbine it is useful to possess the Protective devices
following data:
Service p’hase testing applies mainly to those device
which protect the turbine against overspeed. The test
the performance of the turbine unit tlnd its components
programs of the automatic turbine tester may also be
p!ior to inspection
executed if required.
The scope of the inspection
findings and checks made during the inspection
repairs carried out on the basis of the findings Controllers
retrofitting and upgrading measures taken The performance of the controllers must be obsefved
checks planned for the restart period throughout the restart phase.
The control range of the hydraulic controller must be
The information required may be found in the following checked and if necessary corrected during no-load
documents: operation.
reports on turbine performance prior to inspection Automatic functional group controls

operating parameters and setting records for the unit The turbine systems and the turbine generator unit
when new or at the last restart should be started up with the aid of the automatic
reports on inspections, findings and repairs functional group controls, and checks carried out to
documents on retrofitting and modifications. establish whe,her all criteria for the execution of the
The following are also required: step programs are fulfilled.
diagrams showing current contro: system setting (in
the case of special settings the most recent records Operating parameters
are binding) The values of all operating parameters must be
documents from the turbine manual, such as controller recorded during steady-state operation when they have
circuit diagrams and descriptions.
remained constant for an adequate length of time, and
then compared either with the set point or with previous
Pre-service Inspections
recorded values.
The functioning and the setting of all of the major
equipment of the turbine must be checked. This applies
both to mechanical/hydraulic components and to - output
instrumentation and control devices. The scope of - control system characteristics
inspection and testing of defined in instruction 5.2-002.. - steam mass flow rates
and covers: - Feedwater/condensate mass flow rates
- steam pressure and temperatures
all ciosed-ioope controls + main steam
all protective devices + extraction steam
all subloop controls and automatic changeover controls + exhaust steam
- casing temperatures
The characteristics of all electrohydraulic controllers - expansions
must be recorded. The test programs appear in - vibrations
maintenance instructions 5.3-0030 and 5.3-0061. - oil pressure and temperatures
- bearing metal temperatures
Alarm system and monitoring equipment must like wise - control fluid pressures and temperatures
be overhauled and tested. - circulating water temperatures
+ condenser.
If the result of operating parameters and setting checks + coolers
reveal changes from earlier results, new records must be - condensate temperatures
prepared.
- conderlser leaktightness (leak test)

During non-steady-state operation, e.g. during a cold Pre-service inspe<:tiol) and testt’1t1 of loci/or C “~ I
start, all operating parameters which .are subjected to hardware
large-scale challges in this phase must bt:: recorded. - controllers and protective devices
The operating parameters of the turbine stress - turbine stress evaluator/controller
evaluator I controller must be subjected to critical analysis. - automatic testers
because the strat-up time, and hence the cost-efficient - automatic functional group controls
operati.on of the turbine unit, is largely determirled by the Pre-service inspection and testing oj controls, interlocks
limits set by the TSEfTSC.
- and alarms by owner/operator’~ personnel:
Evaluation of Tests and Operating Parameter Records
Summary of Results from Major
The test results and the operating parameter records Inspections and Repairs
provide vital information on the compliance of the turbine Full documentation of the” history of a turbine unit
and its components with the performance specifications. includes, among other-elements, reporting on turbine
Malfunctions and other major discrepancies must be reSTilrt following major inspections or repairs,
eliminated as far as possible. especially when they The report on restart should make reference to certain
constitute a hazard to the operational reliabijjty of the preceding reports, namely:
turbine unit.
Where necessary, spare parts must be ordered and/
report on the performance of the turbine unit prior to
or measures to facilitate future elimination of the off-norn1al
conditions detected. must be defined. the major inspection
These measures may include further measurement of report on the scope of the inspection
off.normal conditions. rebalancing and other similar report on the fin,dings and checks mC)de
actions. report on repairS’and other actions
report on the replacement and spare parts used or
Re.Commissionlng of the set required
Most of the activities which have to be performed in
the course of turbine restarts go beyond the scof:e of
If these special reports are not available, brief details
normal maintenance work. They call for special knowledge
must be given on these subjects under the above headings.
which is too detailed to be described in full in the 1urbine
manual. especially where fault elimination is involved. The main section of the reports must cover’:
It is therefore expedient to assign commissioning
personnel to assist in restarting the turbine. the scope and nature of pre-srevice inspections
findings from the pre-service inspections
The following is one conceivable allocation of functions: the scope and nature of in-servige testing
Pre-service inspection and in-service testing of the unit evaluation of turbine performance
by one specialist engineer each for turbine and findings from in-service testing
generator from the supplier company
matters remaining open (actions, replacement parts,
implementation deadline, etc.)
5.3-0220/2
Steam Turbine Envirmental
Maintenance Protection
It is the social and moral obligation of all concerned Oil Leakage does not only pollute the environment
to ensure adequate protection of the environment in but is also a potential fire hazard. Oil leakage from
every wake of operetion. any source is to be quickly attended. In the viscinity
of high temperature equipment & pipes, any oil
During maintenance inspection and capital overhauls, leakage has to be immediately attended, even if it
it is of paramount importance. to ensure safety of work calls for unit shutdown.
force by adhering to the applicable safety codes. In
addition, while handling and disposing hazardous Steam leakage from any source is associated with
materials, necessary precautions, as published from thermal & noise pollution of the environment.
time to time, are to be adhered. Depending on the source & parameters of the leakage
steam, it can be injurious to the associated equipment
Some material, through harmless in normal regime, and also to any individual coming in contact. Any such
may become quite hazardous under different leakage is to be quickly attended.
circumstances. Gaskets made of Fluorelastomers
(viz. Viton), when exRosed to temperatures in the Proper upkeep & periodic lubrication of all rotating
region of 400°C or higher due to fire or any other equipment as per the manufacturer’s instructions
reason, get decomposed. One of the product of such goes a long way in ensuring their smooth and noise-
decomposition is Hydrofluoric acid, which is highly free operation.
corrosive and any skin contact with it must be
prevented. To promote environment friendly aesthetic
appearance, the external surface of all the equipment
To protect the natural environment and to control should be painted once in two years. General upkeep
pollution from disposed hazardous or non-bio- and cleanliness standard should be maintained all
degradable material, a proper system of disposal is around, especially around the turbine floor to promote
to be evolved and compliance ensured. a pleasing look.
Also refer to the following section

[1] 5.3- 0251 Safety notice

Steam Turbine Envirmental Protection
Maintenance Fluorelastomer Products
Safety Notice
Precautions to be taken during handl ing of involved. Meanwhile, access to the equipment
Viton synthetic rubber and other should be denied to unauthorised or unprotected
Fluorelastomer products after they have personnel and warning notices posted.
been exposed to very high temperatures.
The affected areas must be decontaminated
Fluorelastomers are synthetic rubber like before either inspection or maintenance is
materials commonly used for making gaskets resumed. Do not touch anything in the vicinity
and seals of various kinds. of the decomposed material until it has been
‘Viton’ is used extensively in control fluid (FRF) decontaminated.
system due to its compatibility with phosphate
ester fluids. It is also compatible with mineral oil Decontamination procedures for
and can appear in ‘0’ ring decomposed Fluorelastomer products
form in the lubricating oil, jacking oil and power
oil systems. In normal use, fluid temperature Decontamination of equipment exposed
excursions beyond 100 °C are rare and therefore decomposed Fluore/astomer products
the use of ‘Viton’ seals does not constitute a If decomposed fluorelastomer products are
hazard to safety. However, extreme care should suspected, great care must be taken when
be taken when dismantling equipment which removing the residues from equipment.
may have been subject to fire damage. Protective equipment and clothing must be used
and worn, including heavy duty rubber gloves
When exposed to temperatures in the region of and full face protection, to prevent accidental
400 °C or higher, fluorelastomers do not burn skin contact with the Hydrofluoric Acid (H-F).
but decompose into a number of materials, one
of which is hydrofluoric acid. This is corrosive The residues should be disposed of with great
and almost impossible to remove once it care, such as very high temperature incineration.
contaminates the skin. All containers or bags used to transport the
residues must be clearly marked to ensure
Personnel who could come into contact with careful handling to the point of disposal.
degraded ‘Viton’ (or any other fluorelastomer)
should be made aware of its hazardous nature. H-F residues may be washed away using
Equipment which has been exposed to a very sufficient quantities of water to dilute them to
high temperature (e.g. equipment which has harmless concentrations.
been involved in a fire), and which may contain
fluorelastomer components, should not, under Decontamination of personnel exposed to
any circumstances, be touched until it has been decomposed Fluorelastomer products
visually inspected for gaskets or seals which
have suffered decomposition. If decomposition H-F residues should not be handled without
has occurred, the component will appear as a adequate protection. If accidental exposure
charred or black sticky mass. occurs, wash well with water and apply an H-F
Antidote Gel as directed. Medical attention
Supervisory staff should be informed should be obtained immediately. A Calcium
immediately and inquires made to confirm Gluconate injection is the normal treatment for
whether fluorelastomer components are Hydrofluoric Acid Burn.

Steam Turbine Order
Maintenance of Spares
While ordering for spares complete identification details of the required component should be furnished. The
details of components described in various chapters of this manual are given only to understand the functioning.
For ordering spares, only the project specific drawings supplied separately should be referred and following
details may be furnished.
Enquiry for Steam Turbine O&M Spares
Name of the project:
Capacity:
Unit No. :
Previous enquiry / offer / order reference:
A] BHEL Supplied Spares
SI.No. Drg.No. Item No. Qty. Description Part Drg.No. / Application

Code No.
1.
2.
3.
4.
5.
Additional information to be given
KKS Tag No. in case of instruments.

Name plate/Rating plate details in case of purchase resold items.
8] Purchase resold items
1. Name of the supplier:

2. Model:
3. Year of manufacturing / supply:
4. Equipment SI. No. :
5. KKS Tag No. :
6. Other details noted from name plate:
7. Supplier’s catalogue reference No.
8. Supplier’s Sketch / Drg. No.
9. Application / location where installed:
10. Details of spares

SI. No. Description as above Installed Quantit Required Quantit

500 MW Simhadri O&amp;M Manual

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STEAM TURBINE

OPERATION & MAINTENANCE

BHARAT HEAVY ELECTRICALS LTD.

BHEL, Hardwar 5.0-0001-04

GENERAL Rear bearing pedestal 5.1-0340-01

Technical Data Journal bearing 5.1-0470-01/2

HP Turbine Swing check valve 5.1-0651-01

IP Turbine Governing scheme 5.1-0680-01

BHEL, Hardwar 5.0-0002-04/1

Construction, Steam Flow lower pressure and temperature effective at the

BHEL, Hardwar 5.1-0002-04/1

BHEL, Hardwar 5.1-0003-01

BHEL, Hardwar 5.1-0100-04/1

Speed limitation in load and station operation

Speed limitation in load and station operation

BHEL, Hardwar 5.1-0100-04/1

Hydraulic low vacuum trip 0.3 bar

Seal steam Supply system

stop valve inlet

Stop valve inlet

Extraction 5 412.8 417.8 452.8 C

Extraction 4 290.8 300.8 340.8 C

Extraction 3 185.2 196.2 240.2 C

Extraction 2 126.0 146.0 186.0 C

Extraction 1 65.4 85.4 130.4 C

LP turbine 46.4 70.0 70.0 C

Long-term operation: upper limit value permissible without time limit.

Casing Metal Temperatures

BHEL, Hardwar 5.1-0101-04/1

Temperature Difference Alarm at Machine must be tripped at

Between upper & lower casing ± 90 ± 100 C

halves of HP turbine, middle

Between upper & lower casing ± 30 ± 45 C

halves of IP turbine, front

Between upper & lower casing ± 30 ± 45 C

halves of IP turbine, rear

Permissible differential temperature between parallel steam supply lines

Short time period (15 min) 28 C

Feedwater Heater out of service

Output Limit during Testing with Automatic Turbine Tester

Bearing babbit metal temperatures

Alarm at Machine must be shut down at

BHEL, Hardwar 5.1-0102-04

BHEL, Hardwar 5.1-0103-04/1

Filtration particle size of jacking oil filter 37 µm

Jacking. oil pump, cut-in and cut-out speeds

Control fluid system

Control fluid regeneration system

BHEL, Hardwar 5.1-0104-03/1

Control pumps 2 Nos.

Control fluid pumps operating characteristics Fluid flow Discharge

All pressures are gauge pressures.

BHEL, Hardwar 5.1-0110-01

Permissible temperature difference ∆θ in the wall of the HP casing

BHEL, Hardwar 5.1-0111-01/1

Permissible temperature difference ∆θ in the wall of the HP turbine shaft

BHEL, Hardwar 5.1-0112-01/1

Permissible temperature difference ∆θ in the wall of the HP turbine shaft

BHEL, Hardwar 5.1-0112-01/1

QUANTITY TARGET VALUE NORMAL OPERATION START UP

Silica (SiO2) mg/kg < 0.020 0.005 < 0.050

Total iron (Fe) mg/kg < 0.020 0.005 < 0.050

Total copper (Cu) mg/kg < 0.003 0.001 < 0.010

500 MW Simhadri O&M Manual

500 MW Simhadri O&M Manual