Standard Operating Procedure for Steam Turbine

Steam turbine is a machine, which converts the heat energy available from Boiler  main steam
into mechanical energy in an economical way. Turbine is associated with Generator, to convert
this mechanical energy into electrical energy. One number 0f 30 MW, single cylinder, horizontal,
impulse, multistage, multi valve, axial flow, condensing, one controlled and one uncontrolled
extractions and down exhaust type turbo generator supplied by “HANGZHOU STEAM TURBINE
CO., LTD “CHINA Turbine is installed in our plant.

The following are the salient features of Turbine:

Machine is having Electro hydraulic governing system assisted with WOOD WARD 505
governor control system, one Emergency stop valve and 2 nos of inbuilt control valves with one
mechanical over speed tripping mechanism. Turbine is having two numbers of steam
extractions,
1st steam uncontrolled extraction for HP heater for feed water heating,
2nd steam controlled extraction for Deaerator, for deareation.

Principle of Operation:
The steam with 62 Kg/Cm2pressure and 470 0C temperatures will enter into turbine through Two
ESV and 4 numbers Governing control valves. The steam entered into the turbine expands over
the moving and fixed blades of turbine releasing the mechanical energy and rotates the turbine
rotor at 3000 rpm. The turbine is coupled with the generator rotor directly and rotates the
generator rotor to convert mechanical energy into Electrical energy. Steam after doing it’s work
in turbine, gets collected into Condenser and forms as condensate by giving it’s latent heat to
atmospheric air flowing over the tubes of air cooled condenser by means of fans.

 
From condenser the condensate is pumped with Condensate Extraction Pumps (CEP) through
ejectors and gland steam cooler up to Deaerator. From Deaerator, feed water is pumped to
boiler Economizer using BFPs through HP heater. Deaerator & HP heaters draw the steam from
the turbine to heat the condensate flowing through them. This is known as “Regenerative feed
heating system.”

The TG set is provided with the following systems:

1. Turbine assembly
2. Turbine lube oil and Governing system
3. Condenser and Air Evacuation system
4. Feed water heating system
5. Turbine gland steam system

OPERATION - PROCEDURES
 Cold, warm and hot start up of TG
 Loading of Turbine
 Planned and Emergency shutdown.
 Emergency conditions during Turbine Operation.
Turbine assembly:

The 30 MW steam turbine, type: NK63/81/40 supplied by “HANGZHOU STEAM TURBINE CO.,

LTD “CHINA is installed in our plant. Steam turbine is horizontal, impulse, multistage, multi
valve, axial flow, condensing, nozzle governing, and extraction. The turbine is provided with 41
Stages of blades. Steam flow to the HP part is regulated by 4nos steam control valves
constituted as a single assembly as HP governor valve. Steam Turbine consists of Casing,
fixed blades, moving blades, rotor (on which moving blades are fixed) bearings (journal and
thrust), steam flow control valves. The casing or cylinder of turbine is a pressure vessel, which is
capable of with-standing the working pressure and temperature. It provides support to the
fixed blades and rotor bearings. The turbine HP part is made up of Cast alloy and LP part is
made up of carbon steel and rotor is made up of Chromium, molybdenum, and vanadium steels.
The moving blades are fixed on rotor and rotate between the stationary (fixed) blades. The rotor
is mounted on two journal bearings. The front side of the rotor is mounted with thrust bearing to
take the axial thrust coming on rotor. Lube oil to the bearings is provided from lubrication
system. The turbine shaft is coupled with generator shaft. Turbine Generator assembly also
consists of Turning gear motor arrangement and “Main oil Pump” in it. The full load parameters
of turbine are “62 kg/Cm2(g)” main steam pressure, 472 0C MS temperature, 3000 rpm,0.1
Kg/Cm2(abs) exhaust steam pressure and131.5 TPH steam flow through it. The two extraction
steam quantities 15.15 TPH for HP heater, 3.88 TPH for Deaerator, And remaining 112.47 TPH
gets collected in condenser where it is condensed by using atmospheric air (ACC). To supply
the atmospheric air for the above condensation process, EIGHT numbers of axial flow fans out
of this six fan of 678.74 m3/hr & two fans of 621.71 m3/hr air flow capacities are installed here.
The blowing atmospheric air gets heated by approx 12 0C in the condenser during condensation
process.

Protections (Trip values) of the Turbine:

The following are the Protections (Trip values) of the Turbine:
1. Steam temperature at turbine inlet high high >487 0C
2. Steam temp. At turbine inlet low low <380 0C,
3. Steam pressure at turbine inlet low low <52kg/Cm2
4. Steam pressure at turbine inlet high high >75kg/Cm2
5. Trip Control oil pressure low low 7.0+/-0.5Kg/sq.cm
6. Lube oil pressure low low< 0.8Kg/Sq.cm
7. Generator heavy fault (Generator trip).
8. Turbine mechanical over speed trip >/=3300rpm
9. Turbine electrical over speed trip >/=3150rpm
10. Governor heavy fault.
11. Remote trip from turbine governor panel.
12. Turbine trip from desk push button.
13. Exhaust steam pressure high high >-0.3Kg/Cm2(g)
14. Exhaust steam Temperature high high >150 0C
17. Hot well high high1400mm
18. Turbine Rotor axial shift high high+0.5, -0.5mm.
19. Turbine front shaft vibration high high150microns
20. Turbine rear shaft vibration high high150microns
21. Generator front shaft vibration high high250microns
22. Generator rear shaft vibration high high250microns
23. Turbine thrust bearing temperature high high (inactive)110Deg.C
24. Turbine thrust bearing temperature high high (active)110Deg.C
25. Turbine front shaft bearing temperature high high120degC
26. Turbine rear shaft bearing temperature high high120degC
27. Generator front bearing temperature high high120degC
28. Generator rear bearing temperature high high120degC
Turbine lubes oil system:
Turbine lube oil system consists of Main oil tank (MOT), Over head emergency oil tank (OHT),
lube oil coolers (2), Main oil pump (MOP), AC driven Auxiliary oil pump (AOP), DC driven
Emergency oil pump (EOP), and oil vapor extraction fans (1, OMF) to supply the lube oil to the
turbine and generator bearings during run up, coasting down and for subsequent turning gear
operations. The MOP is mounted turbine shaft and rotated by turbine rotor and supplies oil to
the lubricating system and as well as trip oil to the governing system. It takes over its duty from
the AOP when turbine speed is of 3000rpm.To maintain lube oil temp at45degC, Lube oil
coolers (2 nos) are provided in the system. One number of vapor fans is provided to extract oil
vapors from MOT and vent them out to atmosphere.

AUXILARY OIL PUMP:

AOP is an AC driven pump which supplies lube oil at 2.5kg/Cm2to Turbine, Turbine and
generator bearings and trip oil at 4.3Kg/Cm2to the governing system during turbine speed run
up and turning gear operations. It has rated capacity of 120 m3/hr at 10 Kg/Cm2and driven
by415V, 55KW and1500- rpm motor. At 3000rpm, MOP takes over the duty of AOP; AOP will be
switched off in auto. This pump comes into service in AUTO if lube oil header pressure is less
than0.87+/-0.2Kg/Cm2and pump is selected in AUTO. In the event of turbine trip due to any
reason, AOP comes into service into operation by interlock when oil header pressure drops
to0.87+/-0.2Kg/Cm2to supply lube oil to all bearings for it’s safe coasting down and subsequent
Turning gear operation. This pump also supplies suction to the Jacking oil pumps. The
discharge of AOP passes through the Lube Oil Coolers.

Start up Procedure for Auxiliary Oil Pump (AOP):

Ensure the following
 AOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on AOP, governing and oil systems.
 Power supply and control supply are available.
 Pressure switches and interlocks are properly checked and incorporated.
 Discharge valve is opened.
 Level of oil in MOT is normal.
 Valves in oil system supply mains are properly lined up.
 Ensure oil vapor fan is in service (at least one).
 Start the pump by pressing the start button on DCS.
 Check the discharge pressure of pump and motor current.
 Keep the pump in auto, in order to come in to service in auto as per the interlock.
 Observe the lube oil filter DP (< than0.8) from local gauge.
 If necessary change the filter.

NOTE:
Before changing the filter, open air vent & Equalizing valve and ensure that both the filters are
equalized with oil. After change over, close the air vent.

Interlocks on AOP:
Auto Start:
Lube oil header pressure low alarm and pump is selected in AUTO, AOP comes in to service in
AUTO.
Auto Stop:
When Turbine speed is greater than 95% of rated speed, AOP will be switched off in AUTO.
EMERGENCY OIL PUMP
The EOP comes into service in the event of an Emergency. A DC motor drives this. It has rated
capacity of 30m3/hr against a1.5Kg/Cm2head and is driven by 5.5 KW, 2950-rpm110V DC
motor. In the event of total power  failure or if AOP fails to start on it’s interlock due to any
reason, EOP comes into operation when lube oil header pressure drops to0.62Kg/Cm2to supply
the lube oil to the TG bearings for its safe coasting down. EOP supplies oil only to the bearings.
The discharge of this pump will not go through oil coolers.

Startup sequence:
Ensure the following.
 EOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on EOP, governing and oil systems.
 DC Power supply and control supply are available.
 Pressure switches and interlocks are properly checked and incorporated.
 Discharge valve is opened.
 Level of oil in MOT is normal
 Valves in oil system supply mains are properly lined up.
 When the above are satisfied, the DC EOP will start by inter lock, if lube oil header
pressure drops to0.62Kg/Cm2. If the interlock does not work, the pump can be started
by pressing the start push button on Turbine governor panel (TGP)
 After starting the pump check the discharge pressure, motor current.

Shutdown sequence:
 The DC EOP can be stopped from TGP when it is no longer required to run, say, when
AC power is restored and AOP has taken into service.
 To stop the pump, press stop button on TGP.
 The pump can only be stopped whenever lube oil header pressure is >0.62Kg/Cm2,
otherwise EOP will come into service in auto.

 Important Note:
During normal running of turbine, EOP should be ready in all respects to come into service
without fail. Trail run may be taken in every shift to check the availability of EOP. While TG is in
service or in TGM operation, EOP should be in ‘Auto Standby’ mode on TGP
TURNING GEAR 
Before starting of the turbine and as well as after trip, turbine and generator shafts are to be
rotated at certain speed to avoid deflection of rotor due to self weight in high temperature
atmosphere. Turning Gear is incorporated in the system to facilitate this operation. In our case,
turbine rotates at 6.2 rpm in turning gear operation. 7.5 kW, 415V, 1454-rpm motor, drives the
turning Gear.

Interlocks on TGM:

Start: TGM comes in to service in after the starts permissive were satisfied. The
start permissive for TGM is Turbine speed (0 rpm) Lube oil header pressure is not low.

Auto Stop: If any one of the above conditions is not present the TGM will trip. Manual start can
be possible if all the start permissive is satisfied. Manual stop can be done at any time. During
turbine rolling, TGM automatically disengages at 150 rpm (approx) of turbine rotor.

Whenever the unit trips barring gear will engage manually, during the barring gear
operation if power fails after restoration power barring gear should be manually engaged
before starting. If it is not so this will lead ton damage the gears of barring gear.

Putting Turbine on Turning gear Operation:

Ensure the following:
 MOT oil level is normal. 
 NO line clearance is pending on Turbo Generator, Lube oil and Jacking oil systems and
Turning gear motor.
Proper functioning of instruments indicating:
 Axial displacement
 All turbine, generator bearing vibrations
 All bearing metal temperatures
 Lube oil temperature and pressure
 Jacking oil pressure
 Turbine speed
 Ensure DC EOP is healthy and in standby mode on the Governor panel.
 Start AOP as per the procedure and check the Lube oil pressure
 Throttle the cooling water outlet from oil coolers and maintain oil temperature around
450C +/- 5 o C
 Engage turning gear pinion by rotating the motor shaft with the lever from local.
Start the turning gear motor check the following:
 TGM current
 Axial displacement
 All bearing vibrations
 Turbine speed
 Lube oil pressure
 It needs approx. 10 hours to cool down the turbine casing and bearings.
 After turbine cooling period, the TGM may be stopped. AOP & JOP should be continued
in service for another 2 hours.
Air Cooled Condenser (ACC) and AIR EVACUATION SYSTEM:

Air Cooled Condenser (ACC):

Low pressure steam from the turbine exhaust is conveyed through main steam exhaust duct to
air cooled condenser fin tube bundle through distribution duct. The steam is condensed in the fin
tube bundles. The required air is blown by axial flow fans which are located under the bundles.
The bundles are arranged in the form of “A”. For effective removal of non condensable gases
(where in steam & condensate flow from top to bottom) called the “Condenser Bundles” (56
Nos) & balance steam is condensate in counter flow bundles (wherein steam flows from bottom
to top in upward direction & condensate flows in down ward direction called “Dephlegmator
Bundles” (8 Nos). The accumulated non condensable gases at the top of dephlegmator are
evacuated through a steam jet ejector system. The steam jet ejector system also maintains the
vacuum in the system.

The condensate is collected in the condensate receiver tank (CRT) through condensate
collection headers. Condensate extraction pumps located under condensate receiver tank will
pump the condensate to Deaerator & other downstream equipment.

A Hot well is provided in the turbine exhaust duct to collect any associated water with the
exhaust steam. The collected condensate in the hot well is pumped by means of hot well drain
pumps to the condensate receiver tank.

Technical Data of ACC:

Heat transfer area (Finned) : 213,353Sq.M 
Heat transfer area (Tube) :2654.92 Sq.M
Number of Tube Bundle (K-Type) : 56 Nos
Number of Tube Bundle (D-Type) : 8 Nos
Number of Tubes (K-Type) : 7560 Nos
Number of Tubes (D-Type) : 512 Nos
Dia/Thickness of tubes (K-Type) :31.8/1.65mm
Dia/Thickness of tubes (D-Type) :38.1/1.65mm
Rated Air flow : 678.74(K)/621.71(D) m3/sec

AIR EVACUATION SYSTEM (Ejector system):

To increase the work done by the turbine and to avoid backpressure on Turbine rotor,  pressure
inside the condenser is maintained below atmosphere pressure (vacuum). To obtain vacuum in
condenser, air and non-condensable gases are to be removed. For this purpose, air evacuation
system with Main ejector has been provided.

One starting Ejector (Hogging ejector), two numbers of “two stage steam jet air ejectors (as a
single unit)” are installed to create and maintain vacuum in the condenser.

Ensure the following:

 TG set is on turning gear operation as per the procedure.
 At least two ACC fans are running.
 Hot well level is normal.
 CEP is running on re-circulation through Main Ejector, Gland steam cooler.
 PRDS steam is available at rated pressure and temperature.
Close the following valves:
 Hand operated valve in airline connected to hogging ejector and main ejectors.
 All drain valves and control valves connected to condenser.
 Close the vacuum break valve.
 Warm up the PRDS header by opening the drain valves.
 By operating the PRDS pressure control valve and Temperature control Valves attain the
required PRDS pressure and Temperatures.
 Ensure PRDS steam is available with 10Kg/Cm2and 300 0CStart the GSVC exhaust fan.
 Charge the Gland steam cooler.
 Open the steam valve to the starting ejector gradually.
 Slowly open the air valve and watch for vacuum.
 After attaining required Value,-0.6 Kg/Cm2make ready the main ejector for Keeping in
service.
 Open the steam valves of main ejector slowly and then open-air valve and discharge
valve.
 Charge the glands by opening the valve in gland sealing line.
 Ensure Turbine gland sealing steam pneumatic control valve is operating and Gland
steam pressure is normal (0.1 to 0.2 Kg/Cm2(g)).
 After attaining –0.70Kg/Cm2 (g) of vacuum, isolate the startup ejector by closing air valve
first and steam valve next. With the main ejector in service we can attain –  0.8 to –0.95
Kg/ Cm2 (g).

 Important Note:
 Before charging the main ejector, ensure flow of main condensate (CEP discharge)
through ejector.
 While charging the ejector, open steam valve and air valve next gradually.
 During cut off of the ejector, close air valve first and steam valve next and discharge
valve next.
 Ensure tightness of vacuum break valve manually. Provide water sealing.
 Do not open any drain valve connected to condenser when there is no sufficient vacuum
(>-0.5Kg/Cm2 (g)). 
 Ensure that the drain line isolation valves of condensate trap & casing drain of  the
running exhaust fan are in open position. 
 While charging the main ejectors, ensure that after condenser vent isolation valves drain
line isolation valves of Condensate Trap are in open position.
 Ensure that the suction valve& casing drain valves of the standby exhaust fan on Gland
steam condenser are in closed position.

Start Up of Air Cooled Condenser:

 Ensure that condensate receiver tank is filled with makeup DM water up to normal level.
 Select the operating Condensate extraction pump, drain pump & holding ejector.
 The selected condensate pump is started & condensate is circulated via minimum
recirculation line.
 The regulation to start up the steam turbine are to be strictly followed i.e. gland steam to
turbine is in “ON “position.
 Switch on hogging ejector and start hogging.
 Pre evacuation of the vacuum system is finished after when the exhaust pressure has
reached 0.1 Kg/cm2 (a). At this stage open one of the holding ejector & close the hogging
ejector & now ACC is ready to receive steam.
 Switch on the fans as per turbine load.
 Now all the controls are put in AUTO MODE after the system stabilizes.
 Shutdown of Air Cooled Condenser:

Following are the sequence of operation to be followed for shutdown of ACC

 Reduce the steam flow to the ACC gradually.
 As the steam flow is reduced stop condenser fans first & after about five minutes stop the
dephlegmator fans.
 Cut off motive steam to operating holding ejector & isolate ejector.
 Switch off hot well drain pump.
 Switch off condensate extraction (CEP) pump.

Note:

If steam admission to condenser is to be disconnected for a shorter period of time & vacuum is
to be maintained then the evacuation system as well as the condensate pumps & drain pumps
must continue to run. Also the turbine glands are to be steam loaded.

CONSENSATE EXTRACTION PUMPS:

Two numbers of CEPs (one working and one standby) are installed to pump the main
condensate from condenser to Deaerator through main Ejectors and gland steam cooler. It has
rated capacity to deliver 150 m3/hr at 10.0 Kg/cm2 and is driven by 415V, 2965 rpm, 90 KW
motor. As this pump supplies cooling medium to Main Ejector and GSVC, 100% availability of
this pump is essential to run the plant.

STARTING OF CEP (Condensate Extraction Pump):

 Check no line clearance is pending on CEP and Condensate system
 Ensure that hot well level is normal >700mm
 Ensure that suction valve is opened and DP across suction strainer is<0.3 Kg/Sq.cm
 Ensure that the Pump is primed with condensate by opening air vent. (When there is no
vacuum.)
 Ensure that control valve in line to Deaerator is closed and control valve in re-circulation line
is full opened.
 Ensure that the discharge valve is closed.
 Ensure that Electrical supply is available.
 Open CEP air removal line valve to condenser.
 Check the lube oil level in the bearing oil cup.
 Start the Pump from DCS.
 Check discharge. Pressure, Motor current, bearing temp and hot well level.
 Open motorized discharge valve gradually and maintain the discharge pressure above10.0
Kg/Sq.cm.

WHAT NOT TO DO:

 Don’t allow any leakage in suction side.
 Don’t open any valve, fitting, flange in the suction side. In normal working condition
(Condenser is in vacuum), this will cause vacuum to drop the Pump to loose it’s suction.
 Don’t allow the Pump to start or run with the protection/interlock by pass.
 While cleaning suction strainer of stand by CEP, ensure the closed position of the respective
suction, discharge valves, air removal valve to condenser, all drain valves between pump
suction, discharge valves and open position of suction valve sealing line valve.
 
AUTO CHANGE OVER OF CEP:
  Check no line clearance is pending on standby CEP.
 Standby pump should be selected in “AUTO” mode in DCS.
 Suction and discharge valves should be in open position.

Interlocks on CEP:
 When CRT level Low switch is acted auto stand by pump trips in Auto.
 When CRT level Low Low switch is acted (CRT level < 300mm) both pumps will trip.
 When CEP discharge pressure cames < 8 Kg/cm2 stand by CEP will start.

Interlocks on Hot Well Drain Pump:

 When hot well level high high (>1500 mm) turbine will trip.
 When hot well level low low (< 300 mm) hot well drain pump will trip.

Feed water heating System (Regenerative system):

The thermal gain and economics of feed water heating given rise to regenerative feed heating
system. It consists of HP heater and Deaerator. Feed water heater is a simple heat exchanger,
which is arranged so that water leaving the condenser is preheated before it is fed to the Boiler.
HP heater is of surface type heat exchangers, where as Deaerator is direct type heat
exchanger. These feed water heaters extracts the steam from the turbine at high pressure and
temperature and heats the feed water flows through them. The condensed steam from HP
heater is connected to condenser and Deaerator respectively. The presence of certain gases
like oxygen, carbon monoxide and ammonia, dissolved in water is harmful because of their
corrosive attack on metals. Hence these gases are removed in Deaerator unit. Spraying the
water and heating the same by steam achieve the same. The Deaerator consists of two
chambers, the deareating column and feed storage tank.

HP heater charging procedure:

 Ensure open position of air removal line
 Ensure Feed water is charged through HP heater 
 Ensure extraction line drain valves are in open position.
 Open the extraction motor operated valve
 Maintain the heater level by operating level control valve to Condenser upto
5Kg/Cm2extraction steam pressure, and at above 5 Kg/Cm2pressure maintain the level
by operating the level control valve to Deaerator.
 After charging of heater close the drains valve. 

Note:
 Do not charge the heater without water flowing through them
 During cut out of heater, close steam valve first.
Charging procedure for Deaerator:

Charge the Deaerator. After 8 MW load it can be charged from its extraction line.
Open drains before and after extraction control valve
Open extraction control valve to maintain the Deaerator pressure at 1.2 to1.4 kg/Cm2by
operating the Deaerator pressure control valve.
After charging of Deaerator close the drains before and after control valve.
Check the following during increase of pressure in Deaerator
 Deaerator expands freely.
 No abnormal hammering is there in the pipe line.
 Steam and air mixture is being vented through the vent line.
 No major steam/water leakages are there. 
Cold, Warm and Hot start of Turbine:

 Cold Start of Turbine

Turbine start up is termed as cold start up, if it is being started 10 to 12 hours after shutdown
or the metal temperature is <1700C.

Ensure the following: 

 No line clearance is pending on TG set.
 Boiler is steaming and steam is available.
 All TG interlocks and protections are checked and checking of all motor operated valves,
Pneumatic Operated control valves closing and opening is completed.
 TG instrumentation / annunciation system is OK.
 Root valves to transmitter lines are in open Position.
 DC supply is healthy for EOP and trail run was taken.
 MOT level is normal.
 Overhead tank level is normal.
 Auto start of EOP, AOP, is checked.
 Carry out related operations and ensure the following AOP & JOP are running as per the
procedure.
 EOP is selected in standby mode on the Governor panel.
 Oil flow is normal through the bearings (observe from sight glass).
 ACC fans in condenser and ACW pump and are in service.
 TG is on Turning Gear Operation as per the procedure.
 During cold start up, Turbine should be kept in TGM operation 2 hours prior to turbine
rolling.
 Oil cooler is charged from cooling waterside to maintain oil temperature 45 +/- 5 degC.
 Ensure ACW to Generator air coolers line valves are in open position.
 Condensate receiver tank (CRT) & hot well level is normal and CEP is running through
Main Ejector and GSVC.
 Main steam line is charged up to MSSV (Header).
 Start vacuum pulling as per the procedure.
 Check the set pressure of sealing steam is 0.08 to 0.090Kg/Cm2(g) then opens the
sealing Steam solenoid valve.
 After attaining -0.5 Kg/Cm2(g) pressure in condenser, open the drains in extraction lines
to remove the Condensate in the pipelines.
 Ensure the following drains are open
 Drain before MSSV (T).
 Drain valves in extraction before check valves lines.
 Isolate the Steam traps of ESV, Turbine Casing and Turbine Chest. Turbine casing drain
(Wheel chamber) through Steam traps bypass.ESV drain through Steam trap bypass .HP
governor chest drain through Steam trap bypass.
 Ensure all extraction check valves and MOVs are in closed position.
 Meanwhile, attain condenser vacuum to -0.8 Kg/Cm2(g).Check and record the following
Turbovisory readings:
 Rotor axial displacement
 Thermal expansion (Local measurement)
 Turbine, Reduction Gear and Generator rotor vibrations
 Turbine speed
 MOT level
 Lube oil pressure and temperature
 All bearing temperatures
 Casing metal temperature
 MS pressure and temperature
  Gland steam pressure and temperature
 Condenser vacuum PRDS pressure and temperature

 Ensure main steam line is warmed up to MSSV (T), then open MSSV (T) bypass valve
(MOV) and open the drains in MS line and ESV body slowly. (Ensure ESV is in closed
condition before doing the above).
 After warming up ESV body, ensure that no Turbine protection is active (from ‘Turbine
Protection’ graphic) and then give “RESET ON” command from DCS.
 This will reset all the protections.
 Reset fault signals by pressing “Governor Clear” button on TGP.
 Check lube oil pressure, trip oil pressure, control oil pressure and lube oil temperatures.
 Check the auto position EOP.
 Open the ESV by pressing the “Turbine Reset” button on TGP.
 Check the open feedback on TGP and warm up the chest at least 20 min.
 This is tentative, ensure the chest drain temp. is equal to the MS metal temp.
 Ensure the Hotness of ESV and Turbine Chest drains.
 Check AOP & Turning Gear are in service and selected in auto.
 Open the MSV (T) before going to roll the turbine. Start the Turbine rolling by pressing
the “START” button on TGP.
 The governor will accelerate the speed of the turbo generator and hold it at idle speed
500 rpm.
 During the speed rise, check for Turning gear motor stop at the set rpm (> 10% of rated
rpm).
 Ensure the Hotness of Turbine Casing drain.
 Observe the exhaust hood temperature.
 Observe all the Turbovisory readings. (Mentioned earlier).
 Feel and listen for any rubbing and abnormal noises during warm up.
 Check and record the shaft vibrations and axial displacement monitor on TGP.
 Check whether the turbine casing expansion has started and its pointer is moving on
local scale, near turbine front bearing.
 After ensuring expansion by 0.2 to 0.4mm, Press the “RATED SPEED” button onTGP.
 The governor will accelerate the speed of the turbine generator automatically to3000rpm.
 Observe for the bearing vibrations in the Critical speed range from1650
– 2250rpm.Check AOP are stopped at > 95 % (3000 rpm) respectively.
 Start the ACC fans before synchronizing the generator as for the procedure.
 Synchronize the generator with the GRID as per the procedure.
 Increase the load on generator to 6 MW.
 Close all the MS drains.
 Gradually increase the load (not more than 1.0mw/min) by means of
“SPEED/LOADSETTING” lever on TGP or Generator control panel.
 Steam traps of ESV, Turbine Casing, Turbine Chest drains should be kept in service and
close the bypass valves.
 Ensure the Steam traps are working or not. If they are not working open the bypass valve
slightly.
 Gradually increase the load as per the “loading procedure”.
 After paralleling with both the boilers gradually increase the load to 30MW as per
the procedure.
Warm start up and Hot start up
Turbine start up is termed as “Warm startup” if it is being started 3 to 4 hours after  trip of turbine.
Turbine start up is termed as “Hot Startup” if it is being started within 2 hours after trip of the
turbine.
Follow the procedure for the cold startup up to speed up to idle speed (i.e. 500rpm).
 After reaching 500rpm, allow the machine for soaking at the idle speed.
 Ensure that casing expansion has started from local scale during soaking than previous
condition.
 After ensuring that casing expansion has started, then give command for Rated Speed.
 MS temperature should be maintained 450 OC more than MS skin / MS temperature at
Turbine inlet. (Subjected to operating temperature 472 OC at Turbine inlet.)
 For warm and hot startup following parameters can be maintained.
 During any start of turbine, do not forget to open all the Turbine drains.

Loading of Turbine:
 After synchronizing the turbo generator with grid the minimum load to be maintained is 10
MW.
 Check all Turbovisory instrument readings are normal.
 Check rise of turbine casing metal temperature and its casing expansion.
 Ensure smooth running of Turbine.
 Raise the load at 0.5MW increment (1.0mw/min) by observing MS pressure and
temperature at turbine inlet.
 At above6MW load take Generator ‘Automatic Power control’ in to service. At 8MW
stable load charge the Deaerator as per the procedure. At 17 MW stable load charge the
HP heater as per the procedure.

Planned and Emergency Shutdown of Turbine:

Planned shut down:

 Reduce the load on TG gradually to 3 MW, by operating the load/ speed switch on GCP.
 When load is at 12 MW cut off HP Heater.
 When load is at 8 MW cut off Deaerator.
 Open generator breaker as per the procedure.
 Manually shut down the turbine (decelerate the turbine speed by pressing the “Remote
Trip” button on TGP).
 Ensure the actuator, ESV and MSSV closes automatically.
 Ensure all extraction check valves and extraction motor operated valves (MOVs) got
closed on interlock.
 Open all the Before QCVs drains.
 Close HP heater drip to Deaerator & condenser control valves.
 Open MS drains to atmosphere.
 Ensure COPs, AOP, JOPs, TGM turns to AUTO selection on interlock at 95% speed.
 Observe AOP to start in auto when lube oil header pressure drops to 0.87+/-0.2Kg/cm2.
 If it is not started, start the pump manually and observe discharge pressure.
 Ensure TGM starts in auto at <10% speed with time delay of 150 seconds.
 If it is not started, engage the turning gear manually at “0” rpm of the turbine and start
TGM from DCS.
 When the shut down period is less than 1.0 hour, maintain the vacuum in condenser.
 During this period, ensure that gland seal exhaust fans are in continuous service and the
PRDS parameters should be reduced to 7.0kg/Cm2& 150deg.c gradually i.e5deg.c/min.
 When the shut down period is more than 1.0 hour, kill the vacuum in condenser by
opening the vacuum break valve. Before opening the vacuum break valve, make sure
 that hand operated valve in gland sealing steam supply line is closed and isolate the
Main ejector as per procedure.

 Run the ACW pump 2 hours.

 Run the CEP in recirculation around 4 hours.
 Run the GSVC Exhaust fan around 4 hours.
 The coasting down period of the turbine will be approximately 20 minutes.
 Normal TGM operation period is 10 hours after trip of turbine it is also a measurement of
Casing Expansion should be <2 mm on local indicator but practically it is taking 14 to20
hours to cool down the turbine casing, rotor and the bearings.
 After cooling down period, stop TGM and run the AOP, Oil mist fan further 2hours.
 After ensuring the bearing Babbitt, oil inlet and drain oil temperature becomes near equal.
Stop AOP, When AOP is stopped EOP will start in auto. Stop EOP from TGP.
 Stop (OMF) oil vapour fan.

Emergency Shut Down

In case of emergency, the turbine can be stopped by either of the following methods.

 ‘Remote trip’ button on TGP and GCP.

 ‘Manual trip cock’ lever from front bearing (i.e Hand Trip)

For the Emergency shutdown due to abnormality of M/C or tripping of the TG

on protection following steps are to be taken:

 Ensure ESV, MSV (T) are closed, all extraction MOVs, extraction check valves
 Ensure AOP, JOPs, TGM turns to AUTO selection on interlock.
 Ensure AOP has started on Lube oil pressure low interlock.
 Ensure TGM started in AUTO as per the interlock If required kill the vacuum as per the
procedure. Continue AOP, TGM, GSC exhaust fan, OMF, CEP, ACW pumps in service
as per the procedure.

  Important Dos and DON’Ts during Turbine Operation:

DOs:
The turbine has to be shut down immediately in the following cases.
 When the turbine rotor speed increases higher than 3300rpm.
 Whenever oil pipes, steam pipes, main condensate pipes, feed water pipes are broken or
some cracks / leaks are found in them.
 Whenever some hydraulic shocks are occurred in the piping or in the turbine casings.
 Some metallic noise is heard clearly in the turbine
 When the mechanical over speed lever is defective
The turbine is to be tripped emergently with breaking vacuum manually in the following
cases:
 When the lube oil header pressure drops to <0.45Kg/Sq.cm
 When the oil catches fire and fire could not be extinguished immediately.
 When the turbine tripped on “Rotor Axial Displacement” protection.

DO in every shift:
 Check Main oil tank level is normal.
 Check oil vapour fan and GSC exhaust fan are in service.
 Check the availability of DG set.
 Check the availability of AOP and DC EOP.
 Check the open position of Discharge valves of AOP, EOP.
 Ensure the Steam traps of ESV, Turbine Casing and Turbine Chest drains are working
normal.
 Ensure condensate system and feed water systems are running normal
 Ensure CW system is running normal
 Ensure Glands sealing steam control valve is functioning normally
 Ensure the parameters of turbine and its auxiliaries are within the limits
 Check the sealing water to Condenser connected valves are given
 Check starting ejector air valve and vacuum break valve are tightly closed
 Ensure that all instruments functioning properly
 Ensure that standby ACW and stand by CEP discharge valves are in open position.
DON’Ts
 Do not operate the turbine, any equipment bypassing the interlocks
 Do not operate the turbine with high vibration values and high bearing temperatures
conditions
 Do not allow sudden drop or rise in MS temperature and MS pressures.
 Do not start the vacuum pulling without turbine on Turning Gear operation
 Do not start the Glands charging without turbine on Turning Gear operation
Do not continue turbine on TGM operation if unusual sound / vibration comes from gland
seal, bearings etc.
 Do not operate the turbine with LOW main oil tank levels.
 Do not start the TGM without Over head oil tank level normal
 Do not start the Turbine without Over head oil tank level normal
 Do not start the TGM without running the AOP & JOP.
 Do not run Lube oil system without running the oil vapor exhaust fan.
 Don’t run Oil vapor Exhaust Fan when MOT level is high.
 Do not allow hot rotor to stand without rolling (without TGM operation)
 Do not overlook abnormality in any important reading
 Do not forget to check stand by position and healthiness of DC EOP
 Do not allow any leakage in the suction side of the CEPs.
 Do not start the CEP without opening of Air removal and Gland sealing. 
 Do not open any valve, fitting, flange in the suction side of CEPs in normal working
condition. When condenser is in vacuum this will cause vacuum to drop and pump (CEP)
to loose its suction.
 While cleaning suction strainer of stand by CEP, ensure closure of suction valve.
 Do not keep the steam valve of main ejector open for long time if condensate flow is not
there through main ejector.
 Do not run the turbine with open or un tightened flanges on oil tank, oil piping, steam
piping. etc.
 Don’t charge the PRDS line without closing the Turbine Glands Isolation Valve.
 Do not open the Vacuum break valve without Isolating the Glands Isolation valve and
Steam lines connected to Condenser
Emergency conditions during Turbine Operation:
The following emergency conditions may occur during Turbine operation.
The turbine operator should always be ready to take correct decision and act as per the
operating procedures. It is also necessary that he should know about the boilers loading status,
Tie- feeders’ positions, and import and export power details in his shift.
 Total power failure 
 Island mode operation
 Any one boiler trip
 DCS failure

a. Total power failure:

During total power failure, there will be no power supply to the AC drives (BFP, CW& ACW
pumps, CEPs, AOP, Turning Gear, Oil mist Exhaust Fans & GSVC Exhaust Fans). BFP & ACW
pumps, CEP, Oil mist Exhaust Fan & GSVC Exhaust Fan will be tripped. Turbine will trip on
heavy fault protection. In this case, the following operations are to be carried out by the Turbine
desk operator:
 Inform to Turbine field operator about total power failure and subsequent operations to be
carried out.
 Ensure ESV is closed and Extraction check valves are closed on interlock.
 If not, close them from DCS.
 Check EOP starts on interlock at < 0.62 Kg/Sq.Cm.
 If not, start EOP from TGP. Close the following control valves: Normal & Emer. Make up
valves by observing the condenser level PRDS pressure control valve to isolate the
ejectors and glands.
 Deaerator pressure control valve to depressurize the Deaerator.
 Close the Isolation valves in PRDS Pressure CV and Temperature CV.
 Close HOVs in air and steam lines of Ejector from local.
 Close HO isolation valve in Gland sealing line.
 Close all drain valves connected to condenser. And open Vacuum break valve.
After restoring the Emergency DG set power, close the following valves:
 All three extraction MOVs
 Main steam stop valve (Turbine)
 Discharge valve of BFP
 Start AOP after informing to Switchgear operator.
 Start JOP as per the procedure.
 After turbine reaches to <10% of rated RPM start TGM as per the procedure.

Field Operator’s duty during total power failure:

 Close isolation valves of PRDS Pressure CV and Temperature CV.
 Close Main ejector air valves and steam valves.
 Ensure EOP is started and Lube oil pressure is normal.
 Close HOV in gland sealing line.
 Close discharge valves of CW pumps.
 Close all drains connected to condenser.
 Ensure turbine gland sealing steam pneumatic control valve is operating and gland steam
pressure is normal (0.1 to0.2Kg/Cm2(g)).

b. Island Mode Operation

Unit turns to Island mode in the following cases:
 Sudden rise / drop in frequency
 Sudden drop in load
 Internal disturbance in LT / HT systems
 Mal operation / mal function.
The following procedure is to be followed:
 Load drops / rises as per the FAP demand.
 The turbine rotor speed and MS pressure at turbine inlet will change.
 Maintain the Generator Frequency at 50HZ by changing the turbine speed from
“load/speed change” lever from TGP.
 Ensure the steam being supplied from the Boiler is sufficient to generate the load on the
turbine. If steam flow is less, MS pressure will drop. Ask shift engineer to decrease the
load on FAP to the suitable limits.
 Observe the turbovisory readings like axial shift, all bearing vibrations, all bearing
temperature and casing expansion for any change. Do not allow MS temp to
fallsharply.LP heater levels, HP heater levels and Deaerator pressure may disturb due to
load fluctuations. Control the above parameters in manual mode.

DCS failure condition:

Course of action for turbine desk operator and field operator, when total DCS CRT’s are not
available
 Obtain the instructions to run or to trip the unit from GM (PP)/DGM (O&M)/ Manager (O)
 Procedure to be followed to run the unit
 All control loops work in auto.
 We do not have monitoring from CRT.
 All protections and interlocks may work.
 Ensure turbine load / MS pressure control remains in Auto mode.
 MS pressure, Turbine RPM, Governor valve actuator position can be monitored from
“WOOD WARD” system.
 Monitor and Control PRDS pressure and temperature from local.
 Condenser level should be monitored from local gauge glass.
 Deaerator level has to be monitored from local gauge glass.
 CEP discharge pressure should be observed form local pressure transmitter and gauge.
 Observe HP, Deaerator extraction pressures from local pressure transmitters.
 HP heater levels to be monitored from local gauge glass and level transmitter analog
indication.
 Observe lube oil pressure, governing oil pressure, trip oil pressure, MOT level, vacuum
and Gland steam pressure local gauges/transmitters.
 Maintain the same load.
 Observe BFP parameters from local. Inform to Boiler operator to maintain constant feed
water flow

Procedure to be followed to trip the turbine:

 If any abnormality is found during this period trip the turbine as per the procedure given:
 Inform the Boiler operator about tripping.
 Trip the turbine from local hand trip lever or remote trip from TGP.
 Ensure ESV, all extraction check valves and extraction MOVs closed from TGP and local.
 Ensure AOP / JOP / TGM has started in sequence as per the interlock.
 If not start them as per procedure from MCC.
 If AOP has not started in AUTO, Start EOP from start push button on TGP
 Isolate the PRDS station by closing the PRDS pressure CV and Temperature CV
isolation hand operated valves. Isolate the Gland sealing line by closing the hand-
operated valve in GS supply line.
 Close HP heater drains to condenser CVs isolation valves.
 Continue AOP, TGM, OMF, GSVC, CEP and ACW Pumps to run.
 Stop the BFP after taking clearance from Boiler operator from local. (After box up
of  boiler)
 Run the CEP in complete Re-circulation.
 Cut off the lube oil coolers if necessary.