文件号 Doc.No.

0-2520-5371-00

使 用 说 明 书 部
版
门 Dept.
本 Version
工业透平研究院
0
Operating Manual 语 种 Lang. CHN VS ENG

机 组 代 号：
WT5371
Product Code:
机 组 型 号:
ENK 40/45/100
Product Type:

编 制：
祝 伟 荣 2015-05-29
Edited by：
校 对：
潘 志 贤 2015-05-29
Checked by：
审 核：
Approved by： ________
 Operating Instructions
Preface 0-0100-01-01

Preface
Proper installation, operation according to the procedure and well maintenance are the
preconditions for turbine’s long-term, reliable, stable operation with high efficiency.
Therefore, the present Operating Instructions gives the description functions and
structures of turbine main components and the operating procedures that should be
followed during installation, commissioning, operation and maintenance of the
turbine. The user should read and study this Operating Instructions and the related
documents attached to the turbine-set, as well as consult our service engineer to know
the characteristics of the turbine-set before installing and operating. This is important
for the satisfactory operation of the turbine.

The Operating Instructions is subdivided into six sections, including General,

Description, Installation, Operation, Maintenance and Main bought-in component. For
convenient use, the individual item in the each section is identified with a 4-field
number except the section of Main bought-in component. The number meanings of
each field are:
X－XXXX－XX－XX
Version number, language code
Serial number for different structure. In some items,
a 4-digit code xxxx is used, xxxx-- turbine code
Component code (Position number)
Example: -0410- casing
-2300- emergency stop valve
Section number：
0 － General, e.g. table of contents, general
regulation, technical data and etc.
1－ Description
2－ Installation
3－ Operation。
4－ Maintenance

Turbine is a serial product, considering the versatility we do not use continuous page
number in this Operating Instructions. For a special turbine, you can find out the
desired content and number from the table of contents of the Operating Instructions.

The information on spare parts of the turbine is not included in this Operating
Instructions and it is provided as the attached document to the turbine separately.

The Operating Instructions is a part of technical documents attached to the turbine and
should be used together with other related documents attached to the turbine. The
detailed explanation will be given in the corresponding items.

Hangzhou Steam Turbine Company Limited Page 1 of 2

 Operating Instructions
Preface 0-0100-01-01

HTC doesn’t accept any responsibility for the consequences that the user adopts the
parts (including spare parts) manufactured not by HTC in the turbine without our
permission.

In case of any problem occurred during turbine operation, please contact us with
following addresses and inform us the type and the code number of your turbine.

Addresses:
Service department of HTC
Add: No.357 Shiqiao Road, Hangzhou, China
Tel: 0086-571-85780420
Fax: 0086-571-85780264
Email: [email protected]
P.C: 310022

Hangzhou Turbine machine & equipment Co. LTD.

Add: No.357 Shiqiao Road, Hangzhou, China
Tel: 0086-571-85780176
Fax: 0086-571-85780005
Email: [email protected]
P.C: 310022

Hangzhou Steam Turbine Company Limited Page 2 of 2

使用说明书 目录
Operating manual Content 0-0200-5371-00
名 称 资 料 号 页数
Name Document No. Page
前言 Preface 0-0100-01-00 1
0-0100-01-01 2
目录 Content 0-0200-5371-00 6
汽轮机型号和编号 0-0210-01-00 4
Type & Code of Steam Turbine 0-0210-01-01 5
随机资料的使用 0-0220-01-00 2
Usage of document with units 0-0220-01-01 3
图形符号 0-0230-01-00 3
Drawing Sign 0-0230-01-01 4
货物的发运、接收和存放 0-0240-01-00 1
Sending, receiving and 0-0240-01-01 2
storage of steam turbine
技术数据 0-0300-5371-00 6
Technical Data
抽汽温度变化曲线 0-0313-5371-00 2
Extraction temperature
change Curve
汽耗修正曲线 0-0319-5371-00 6
Steam Consumption
Modification Curve
汽轮机启动曲线 0-0320-5371-00 2
Startup Curve of steam
turbine
热平衡图 0-0326-5371-00 6
Heat balance diagram
汽轮机概述 0-0400-5371-00 4
General introduction of 0-0400-5371-01 6
steam turbine
辅机使用说明书 0-2521-5371-00
Operation Manual of 0-2521-5371-01
auxiliary equipment
仪控与监测使用说明书 0-2522-5371-00
Operation Manual of 0-2522-5371-01
instrument and supervisory

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使用说明书 目录
Operating manual Content 0-0200-5371-00
名 称 资 料 号 页数
Name Document No. Page
结构介绍前言 1-0100-01-00 2
Structure introduction 1-0100-01-01 3
preface
汽轮机纵剖面图 1-0204-01-00 1
Vertical section drawing 1-0204-01-01 1
汽轮机横剖面图 1-0304-03-00 1
Horizontal section drawing 1-0304-03-01 1
汽缸 1-0410-02-00 2
Steam Casing 1-0410-02-01 3
角形密封环 1-0411-01-00 2
Angular seal ring 1-0411-01-01 2
偏心导柱 1-0412-01-00 1
Eccentricity guide column 1-0412-01-01 2
蒸汽室 1-0440-01-00 2
Steam chamber 1-0440-01-01 2
导叶持环 1-0450-01-00 3
Blade carrier 1-0450-01-01 4
导叶持环 1-0450-02-00 1
Blade carrier 1-0450-02-01 1
外汽封 1-0460-03-00 2
Outer steam seal 1-0460-03-01 2
平衡活塞汽封 1-0470-01-00 2
Balance piston steam seal 1-0470-01-01 2
转子 1-0510-04-00 3
Rotor 1-0510-04-01 5
前支座 1-0710-03-00 5
Front bearing housing 1-0710-03-01 8
推力轴承 1-0720-02-00 2
Thrust bearing 1-0720-02-01 3
径向轴承 1-0730-03-00 2
Journal bearing 1-0730-03-01 3
后支座 1-0750-04-00 3
Rear bearing housing 1-0750-04-01 5

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使用说明书 目录
Operating manual Content 0-0200-5371-00
名 称 资 料 号 页数
油封环 1-0760-01-00 1
Oil seal ring 1-0760-01-01 1
调节汽阀 EBI 1-0800-01-00 3
Governing Steam Valve EBI 1-0800-01-01 5
调节汽阀 EBII 1-0801-01-00 2
Governing Steam Valve EBII 1-0801-01-01 3
油动机 1-1910-01-00 3
Oil servomotor 1-1910-01-01 5
危急保安器 1-2110-01-00 1
Emergency Safety Device 1-2110-01-01 2
危急遮断油门 1-2200-02-00 2
Emergency Pilot Valve 1-2200-02-01 4
电磁阀 1-2222-01-00 1
Solenoid Valve 1-2222-01-01 1
速关阀 1-2300-02-00 3
Trip Valve 1-2300-02-01 4
汽缸膨胀测量 1-2771-01-00 1
Steam casing expansion 1-2771-01-01 2
measurement
齿轮箱 1-3410-06-00 2
Gearbox 1-3410-06-01 3
主油泵 1-4200-02-00 1
Main Oil Pump 1-4200-02-01 2
润滑油节流阀 1-5501-01-00 1
One-way throttle valve of 1-5501-01-01 1
lube oil
单向节流阀 1-5600-03-00 1
One-way throttle valve 1-5600-03-01 2
盘车机构(手动盘车) 1-7130-03-00 2
Manual barring gear 1-7130-03-01 2

安装部分前言 2-0100-01-00 2
Mount preface 2-0100-01-01 2
基础准备工作 2-0300-01-00 3
Foundation preparative work 2-0300-01-01 3

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使用说明书 目录
Operating manual Content 0-0200-5371-00

名 称 资 料 号 页数
基础二次灌浆 2-0310-01-00 1
Second grouting for 2-0310-01-01 2
foundation
凝汽式汽轮机的安装 2-0400-16-00 11
Mount of condensing turbine 2-0400-16-01 14
汽缸中分面螺栓的拧紧 2-0410-02-00 2
Joint bolts screw of steam 2-0410-02-01 2
casing
轴承装配检测 2-0700-01-00 2
Bearing mount check 2-0700-01-01 2
汽缸保温 2-7600-01-00 1
Temperature holding of steam 2-7600-01-01 1
casing

运行部分前言 3-0100-01-00 2
Running Preface 3-0100-01-01 2
蒸汽品质 3-0310-01-00 2
Steam Quality 3-0310-01-01 3
汽轮机油 3-0320-01-00 2
Turbine Oil 3-0320-01-01 2
油系统冲洗 3-0340-01-00 4
Oil System Flush 3-0340-01-01 6
蒸汽管路的吹扫 3-0350-01-00 2
Swept of steam pipeline 3-0350-01-01 2
汽轮机起动 3-1100-01-00 3
Startup of steam turbine 3-1100-01-01 4
汽轮机起动前的准备工作 3-1220-01-00 3
Preparative work before 3-1220-01-01 4
turbine startup
汽轮发电机组的起动 3-1320-01-00
4
Startup of turbine 3-1320-01-01
5
-generator unit

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使用说明书 目录
Operating manual Content 0-0200-5371-00

名 称 资 料 号 页数
汽轮机试运行 3-1400-01-00
7
Commissioning of steam 3-1400-01-01
9
turbine
汽轮发电机组的停机 3-1720-01-00 3
Shutdown of turbine 3-1720-01-01 3
- generator unit
运行监视 3-2010-01-00 12
Running Monitor 3-2010-01-01 8
不正常振动 3-3010-01-00 4
Abnormal Vibration 3-3010-01-01 5
转子轴位移过大及水冲击 3-3010-02-00
2
More shaft displacement of 3-3010-02-01
3
rotor and water flash
叶片损伤及断落 3-3010-03-00 2
Blade damage and break 3-3010-03-01 2
油系统故障及排除 3-3010-04-00
2
Malfunction and elimination 3-3010-04-01
3
of oil system
调节保安系统故障及排除 3-3010-05-00
2
Malfunction and elimination 3-3010-05-01
3
of control system
凝汽系统故障及排除 3-3010-06-00 2
Condensing system fault and 3-3010-06-01 3
elimination
甩负荷 Load rejection 3-3010-07-00 2
3-3010-07-01 2

维修部分前言 4-0100-01-00 1
Preface to section 4-0100-01-01 2
“maintenance”
检查和试验 4-0200-01-00 5
Check & Test 4-0200-01-01 7

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使用说明书 目录
Operating manual Content 0-0200-5371-00

名 称 资 料 号 页数
汽轮机停机期间的防护 4-0300-01-00 3
Protection of steam turbine 4-0300-01-01 4
during its stop
油系统维护 4-0400-01-00 3
Oil system maintenance 4-0400-01-01 4
通流部积垢及清洗 4-0600-01-00 2
Begriming and Cleaning of 4-0600-01-01 3
through-flow for steam
turbine
检修种类 4-1000-01-00 2
Maintenance Class 4-1000-01-01 2
检修过程中的检验 4-1100-01-00 5
Check during maintenance 4-1100-01-01 7
检修时的检验范围和注意事项 4-1200-01-00 4
Check Range and Notice Item 4-1200-01-01 5
as maintenance
检修示例 4-1300-01-00 6
Maintenance Sample 4-1300-01-01 6
检修成效和结论 4-1400-01-00 2
Maintenance Effect and 4-1400-01-01 3
Conclusion

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 Operating Instructions
Type and Code Number of Turbine 0-0210-01-01

Type and code number of turbine

1. Type of turbine
Reaction multistage industrial steam turbine, called as building-block steam turbine,
is designed and manufactured with the imported technic from Siemens Company of
German. With the principle of the building-block, the main components of the turbine,
such as casing, rotor and etc, are divided into several sectors. Designer will combine
these desired sectors together through thermal and strength calculation based on the
user’s requirements, plus some standard components, to form the turbines with
different types and sizes which meet the user requirements.

HTC mainly supplies the reaction turbine with following 10 basic models: NK, NG,
HG, ENK, ENG, HNK, HNG, EHNK, EHNG and WK. The meanings of each letter
are defined as follow:
N: Usual inlet steam parameters 10.0Mpa(a),510℃, max.
H: High inlet steam parameters 14.0Mpa(a),510℃, max.
K: Condensing steam turbine
G: Back-pressure steam turbine
E: Extraction steam turbine
WK: Condensing steam turbine with double split flow,
Max. inlet steam parameters: 1.6Mpa(a),420℃

The basic model is represented by the letter combination mentioned above. These
letters have other special content in some combinations. The further explanation will
be given below.

The type of each turbine is consisted of the basic model and size, e.g. NK25/28/12.5,
NG32/25/0.

The size is expressed with different digits in certain rule. It shows the turbine physical
dimensions representing the casing and rotor of the turbine.

Based on the principle of the building-block, the turbine casing is divided into front
sector (fresh steam inlet section), middle sector (blading section) and rear sector
(exhaust section). According to the inlet steam parameters (N or H) there are two
structures for the front sector, VN and VH. The dimension series of VN and VH is
divided pro priority number R10-series (common ratio 1.25). For VN there are five
dimensions, 25,32,40,50 and 63. For VH there are four dimensions, 25,32,40 and 50.
These numbers represent the inner radius of the steam inlet section of outer casing, in
cm. The rear sector is divided into K and G pro the thermal characteristic. Based on
the exhaust pressure, the back-pressure steam turbine is classified as GN (Max exhaust
pressure: 2.0Mpa(a)) and GH((Max exhaust pressure: 4.5Mpa(a)). The rear sector of
the model K uses mixing series of R20 (common ratio 1.125) and R10, there are

Hangzhou Steam Turbine Company Limited Page 1 of 5

 Operating Instructions
Type and Code Number of Turbine 0-0210-01-01
28,36,45,56,63,71,80,90. For model G, the rear sector is divided pro R10 series, there
are 20,25,32,40,50,63,80 for GN and 16,20,25,32 for GH. The number of the exhaust
section indicates the nominal diameter of the last stage of the rotor, in cm. meanwhile,
it is also the size number of the exhaust casing. Any front sector may be combined
with one of the rear sector in three different size, except for the model HG, to meet the
requirement of various inlet and exhaust steam volume flow. Of cause, a transition
sector (Ü) is required when connecting the front and rear sectors with different size.
Generally, some extension sectors (LH or／and LN ) will be inserted between the front
sector and rear sector according the desired stages of the through-flow section. For a
condensing turbine, the casing must be accompanied with a flange sector (F) used for
connecting with the model K of exhaust casing. Furthermore, the front sector of the
turbine with the high inlet steam parameters is accompanied with a pressure-reduced
sector (R) except for model HG. It is called as “HN”. The “HN” dose not form a basic
model by itself.

The sector only embodies the building-block principle. In fact, the sectors of the
casing for the turbine with model G is cast integrally during manufacturing. The front
casing (including the sector V、Ü、L、F ) of the turbine with model K is integral cast,
while the rear casing is iron casting or welds. The front and rear casings are connected
at their vertical split flanges with bolts.

For the front casing (outer casing) of model HNK or EHNK (HNG or EHNG), the
inner pressure and the casing material decide whether integral cast or welding with
two castings is used.

In order for uses to understand the type of a turbine fully and clearly, take NG32/25/0,
NG32/25/0, ENG32/32/16/20, NK25/28/12.5, EHNK40/56/20, HG32/20/10,
WK32/36/0 as samples and show the explanation as follows:

NG32/25/0 Fig.1 shows the combination of sectors

NG: Backpressure steam turbine with usual inlet steam
parameters
32: The front sector of the outer casing is VN32, the
inner diameter of steam inlet section is 320 mm
/25: The rear sector of the outer casing is VN32/25,
the diameter of the last stage of the rotor is about
φ250mm Fig. 1
/0: Outer casing without extension sector
The double dot dash line in the figure is the dividing line of wood model
of the blank for outer casing. (It is the same in following figures)

ENG32/32/16/20 Fig.2 shows the combination of sectors

ENG: Extraction back-pressure steam turbine with usual
inlet steam parameters

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 Operating Instructions
Type and Code Number of Turbine 0-0210-01-01
32: The front sector of the outer casing is VN32, the
inner diameter of steam inlet section is 320 mm
/32: The rear sector of the outer casing is VN40/32, the
diameter of the last stage of the rotor is about
φ320mm
/16: There is an extension sector LN32 with a length of
160mm after the outer casing VN32 (the axial
length of a extension sector is half of its nominal
value, the followings are the same)
/20: Because the inner radius of the LN32 is 320mm, while the LN40 is 400mm, a
transition sector Ü32-40 is required between LN32 and LN40. So there is an
extension sector LN40 with the length of 200mm

NK25/28/12.5 Fig.3 shows the combination of sectors

NK: Condensing steam turbine with usual inlet steam
Parameter
25: The front sector of the outer casing is VN25, the
inner diameter of steam inlet section is 250mm
/28: The exhaust casing is K28, the diameter of the
last stage of the rotor is aboutφ280mm
/12.5: The extension sector LN25 with a length of
125mm between the front casing VN25 and
Fig. 3
flange sector F25 (a flange sector F is used for
connecting the front and the rear casings of the condensing steam turbine)

EHNK40/56/20 Fig.4 shows the combination

of sectors
40: The front casing is VH40, the inner
diameter of steam inlet section is 400mm.
A pressure-reduced sector R40 is
immediately connected after the VH40
(after the HN_ of the VH a
pressure-reduced sector R is needed)
/56: The exhaust casing is K56, the diameter
of the last stage of the rotor is aboutφ
560mm Fig. 4
/20: There is extension sector LN40 with an
axial length of 200mm after the extension sector R40. The inner radius of the
LN40 is 400mm, while the one of the K56 matched with the flange sector F50
is 500mm, so the transition sector Ü40-50 is required between LN40 and F50

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 Operating Instructions
Type and Code Number of Turbine 0-0210-01-01
HG32/20/10 Fig.5 shows the combination of
sectors
HG: Back-pressure turbine with high inlet steam
Parameters and high back pressure
32: The front section of the outer casing is VH32,
the inner diameter of steam inlet section is
320mm (no pressure-reduced sector is required
after the VH section of the model HG)
/20: The rear section of the outer casing is GH20,
the diameter of the last stage of the rotor is
about φ200mm Fig. 5
/10: There is an extension sector LN32 with an
axial length of 100mm between the VH32 and the GH20 (the regularity of
the length change of the LH section in the HG type of turbine is different
with other basic model

WK32/36/0 Fig.6 shows the combination of

sectors
WK: Condensing turbine with double-flow
32: The size number of the inner casing
/36: The size number of the outer casing (the
same number for the exhaust casing)
/0: Casings (inner and outer casings without
the extension sector)

Furthmore, the size numbers of the pedestal and

bearing pedestal for a turbine is related with the Fig. 6
type and size of the turbine in a certain rule.

The size numbers of the front pedestal and the front bearing pedestal are the same as
the front section number of the turbine outer casing, except for the model WK.

The size numbers of the rear pedestal and the rear-bearing pedestal are related to the
type and size of the turbine:

For the turbines of the model NG, ENG and EHNG, the number of the second field
will be increased by one step from the size number of the turbine.

For the turbines of the model NK, HMK, EHNK, the number of the second field will
be increased by half a step from the size number of the turbine.

For the turbine of the model HG, the number of the second field will be increase by
two steps from the size number of the turbine.

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 Operating Instructions
Type and Code Number of Turbine 0-0210-01-01
For the turbine of the model WK, the size numbers of the front bearing pedestal and
the rear-bearing pedestal (the front pedestal and the rear pedestal) are the same, they
will be increased by half a step from the size number of the turbine.

According to these rules the bearing pedestals (the pedestals) of the turbine mentioned
above are:
NG32/25/0 front bearing pedestal 32, rear bearing 32
ENG32/32/16/20 front bearing pedestal 32, rear bearing 40
NK25/28/12.5 front bearing pedestal 25, rear bearing 32
EHNK40/56/20 front bearing pedestal 40, rear bearing 63
HG32/20/10 front bearing pedestal 32, rear bearing 32
WK32/36/0 front bearing pedestal 40, rear bearing 40

From the given examples we can see that the number in each field of the size number
for a turbine indicates a certain definite characteristic dimension of the structure. But
there are some exceptions for the condensing turbine, for example, NK25/29/12.5, it
has a different meaning with NK25/28/12.5, where /29 indicates that the standard
low-pressure stage is adopted in such a type of turbine (/28 corresponds to
low-pressure stage HK28 or SK28). The number 29 is related with the diameter of the
last stage of the rotor in another defined relationship. The diameter of the last stage of
the rotor for /29 is not φ290mm, but ～φ360mm. When the numbers /37, /46, /57
or etc appears in the position of /29, indicate that the standard low-pressure stage
LK36, LK45, LK56, or etc is used in the turbine separately. The other characteristics
are not discussed here.

There is another exception for the series-3 steam turbine manufactured by our
company, for example, HGS50/32/32, where the S does not represent the basic model,
but indicates the turbine HG50/32/32 adopts a specific non-standard design.

2.Code number of turbine

The code number of a turbine manufactured by our company is Txxxx, here xxxx is a
sequence number according to the delivery contract. Each turbine has an unique and
definite code number.

From the description above, we find that many turbines, with different performances
and applications (e.g. different inlet and exhaust steam parameter, different power and
speed, driving compressor or generator), have the same type, although the type of a
turbine indicates the kind of a turbine and some structure characteristics. This means
the type is not an unique mark of a turbine, so the user should take the attention when
you contact to us concerning with the issues about the steam turbine, must inform us
the code number and the type of the turbine.

Hangzhou Steam Turbine Company Limited Page 5 of 5

 Operating Instructions
Usage of documents 0-0220-01-01

Usage of documents

1. Operating Instructions and other documents

The Operating Instructions is a part of turbine documents and is related with other
documents supplied with the turbine. A hint will be given in the Operating
Instructions where the relevant document is involved. The user must read the
Operating Instructions and the relevant documents to understand the contents and
requirements given before installing and operating the turbine.

2. Subject number and drawing number

The part number and the drawing number will often be found in the documents
supplied by our company. Generally, the part number indicates the code of a
component or a part, it has a close relationship with computer management and group
machining. The drawing number indicates the number of a drawing or document.
Both the part number and the drawing number are formed with 11-digit in 4 fields,
X-XXXX-XXXX-XX. Where, the number in the first field shows the general
classification:
0— Non-classification document
1— Turbine set
2— Component
3— Part
4— Blade
5— Blank, bought-in part or standard element
Additionally, each field has own regulation and special meaning.

The part number with 2- in the first field indicates a given component (consisted of
two parts at least) and shows the number of the “Parts List” of a component in the
documents attached to the turbine. You may see the columns “part number”,
“drawing number” and “Name” in the technical document (0-0101-T.NR-00). Here,
the part number is the code of the Parts List, while the drawing number indicates the
number of a relevant drawing or document. The drawing number corresponding to a
component can be found in the column of Drawing number at the top right corner. For
a component, its part number and the documents number may be same or different. In
order for user to lookup the required information quickly and easy, the relationship
between Part number and Drawing number as well as the usage of the relevant
documents will be explained below through some examples.

Now, take a turbine body as the example. For the turbine NG32/25/0, the part number
and the drawing number of the turbine body are same, both are 2-8240-3100-30.
While for the turbine EHNG40/32/40, the part number of the turbine body is
2-824704121-01, but the drawing number is 2-8240-0006-00. For all types of turbines,
no matter the part number and the drawing number are same or not, the position
number that is indicated in the drawing of the turbine body is in concordance with the

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 Operating Instructions
Usage of documents 0-0220-01-01
“number” in the Part List. The relations of components of the turbine and the
assembling requirement of the casing, rotor, pedestal and etc are showed in the
drawing of the turbine body and attached document, which is given as “attached
document” at the end of the Part List. For example, 901…909, where, 901 is the
details of the front section structure of the turbine with single-flow, the section details
A1－Z1 902 is the details of the front section structure of the turbine with double-flow,
the section details A2…Z2 903 is the details of the rear section structure of the
back-pressure turbine, the section details A3…Z3 904 is the details of the rear section
structure of the condensing turbine. 909 is the drawing of steam-path section.

The part number 0-xxxx-xxxx-xx will be found in the part number column of
“attached technical Document”. Now take the turbine NK32/36/16 as an example, the
part number and the drawing number of its detail drawing A1－Z1 is 0-2011-1360-08
and 0-2011-1360-00 separately. There are two points should be explained here. First,
the part number 0-xxxx-xxxx-xx has no Part List, secondly, the concept of “variant”.
When the numbers in the first three fields of part numbers are the same but with
different numbers in the fourth field, we call it as variant. The items and contents
involved in the variant are defined in the drawing with a drawing number
x-xxxx-xxxx-00. From the drawing 0-2011-1360-00, we can see that the variant are
corresponding to the different elements such as the position of thermal expansion
indicator, the style of the bearing and the diameter of the journal, etc.

You will find that the word “no drawing” is marked in the drawing number column
in the Part List when consulting the attached documents. Now, we take the
component “plant supervision” as an example, all of the monitoring instruments and
equipments as well as connectors, which the turbine T6xxx is equipped with, is listed
in the Part List 2-8320-6XXX-00. In this Part List some items have the document
number, but some “no drawing”. For the item that has a drawing number in the
Parts List, its code in the Parts List is corresponding to the Part Number in the
drawing, For the item with “no drawing”, the code is corresponding to the Position
number (Pos.) (also see the explanation in the next section). You can look-up the name,
type/size, quantity and setting requirement of instruments that the turbine is equipped
with.

When looking-up the Part List, you will find that numbers of the Part List are not
consecutive, for example, the component “piping of control oil”. Because it has a
large number of components and parts, it is divided into following sorts in precedence
for the standardization: the components mounted on piping, inlet oil piping,
returning oil piping, bolts, gasket and seals as well as piping accessory for site
installation. The number fields are defined for each sort of the piping components and
each field includes various configuration requirements for different types of turbines.
Because it is impossible for using all of the piping components in a turbine, the
non-sequence numbers will appear in the Parts List. Please understand the case when
looking-up the Part List.

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 Operating Instructions
Usage of documents 0-0220-01-01

3. Position number (Pos.)

There is a column “Pos.” in the attached technical document “Bill of Material”. The
“Pos.” is the code of the equipment, component and instrument in the system drawing
(lubricating oil system, control system and steam & drainage system). There are two
kinds of “Pos.”, 4-digit and 3-digit (it also marked according to user’s definition when
the user has special requirement). The 4-digit stands for the equipment or component,
while the 3-digit indicates the instrument and connector. The “Pos.” in the Bill of
Material is conforming with the mark in the related system, corresponding to the
number in the Part List 2-8320-xxxx-xx. (Also see the description above)

4. Table of termination connection

“Table of termination connection” 0-0620-T.Nr-00 is included in the attached
technical documents. It shows the parameters of the size and class for the connection
flanges connecting the pipe of turbine body and the outside piping. The connection
flange is indicated with different letters according to its function and the media that it
carries. These letters are corresponding with the marks in the system drawing.

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 Operating Instructions
Graphic symbols 0-0230-01-01

Graphic symbols
Some simple graphics, markers and symbols are used in the Operating Instructions
and system drawings to indicate the function, work principle and connection of the
piping, component or element. The graphic symbols of the typical piping, signal wire
and special component are listed in the Table 1.

Table 1
Graphic symbol Description Graphic symbol Description

Inlet oil for oil pump

Pressure source

Steam
Gas *

Condensate
Air with oil

Drainage
Electric signal

Cooling Water
Air pressure signal

Pressure oil Cross joint of piping

Return oil Branch joint of piping

Testing oil
Cross piping

Switching oil
Drain into funnel

Primary oil
Drain into pit

Secondary oil
Vent

Trip oil Return above oil level

Starting oil Mechanical

emergency governor

Lubricating oil Mechanic axial

displacement
protector

* the gas name is marked above the symbol except for the air.

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 Operating Instructions
Graphic symbols 0-0230-01-01
The measuring and monitoring instrument of the turbine is indicated with instruments
symbol, letter code and Position Number (Pos.). Table 2 and Table 3 shows the
universal symbol of instrument and the letter code. The examples are showed in
Table 4.

Table 2
Local mount Control room Local panel

Decentralized

instrument

Sharing

display, control

Computer control

Programmable logic

control

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 Operating Instructions
Graphic symbols 0-0230-01-01

Table 3:letter code for typical instrument

The letter code of an instrument is consisted of a first letter that indicates the
measured variable or primary variable and a following letter indicating its function.
First letter Following letter
Measured or primary variable Qualifier Function
A Alarm
C Control
D Difference
E Voltage Sensor (primary element)
F Flow Ratio(Function)
G View window, glass
H Manual High
I Current Indicating
L Level Low Lamp
P Pressure or vacuum Measuring point
R Recordor print
S Speed or frequency Safety switch or interlock
T Temperature Transmitting
V Vibration
Y Key Phase
Z Position or displacement

Table 4: Code example for typical instrument

Measured variable code T P PD S L V Z Y
Measured variable
Shaft vibration

displacement
Temperature

Pressure or

or position
Key phase
difference
Pressure
vacuum

Speed

Level

Axial

Function Function
code
T Transmitting TT PT ST LT VT ZT YT
I Indication TI PI PDI SI LI VI ZI
A Alarm TA PA SA LA VA ZA
S Switch TS PS PDS SS LS ZS
C Control PC SC LC
E Sensor TE SE VE ZE YE

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 Operating Instructions
Graphic symbols 0-0230-01-01

Graph
For example, in the system drawing the position switch locally mounted on the
emergency stop valve is indicated as below.

The labels in the circle ○ are code and Pos. specified by user.

Based on the Pos. you can find the description, type, measuring value and measuring
point of a relevant instrument in the attached document “Bill of Material”.

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 Operating Instructions
Transport, Receipt and Storage of Goods 0-0240-01-01

Transport, Receipt and Storage of Goods

1. Packing and transport
The turbine is delivered in the package after mechanical running test and treatment of
corrosion prevention in manufacturer’s works. In general, the turbine body, base plate,
accessories, pipes, instruments and spare parts are transported in the special cases,
except for the condenser. The turbine body can be packed in a case or several cases
according to the user’s requirement and the transport condition (by railway, road or
ship). The following symbols should be marked on the packing cases (or the goods)
for correct handling and storage of the goods.

Fragile contents Use no hooks Side up Keep dry

Center of gravity No turning No piling Slings here

2. Receipt
Immediately after receipt of the goods, check the external state of the packing. If a
packing and goods in it are found to be damaged, immediately inform the carrier. And
evaluate the extent of the damage together with HTC personnel, if necessary.

Affirmed the case is not damaged, make unpacking inspection. Whether HTC
personnel should be present or not during unpacking inspection is determined
according with the agreement signed by both parties. After unpacking, check the
goods in the packing against the part number, mane and quantity in the packing list. If
any doubt, please contact with Service Department of HTC.

3. Storage
The goods (equipments, tools, instruments and spare parts), no matter whether receipt
or not, should avoid to store in the open as possible. If this cannot be avoided, place
the cases under protective roof or take the appropriate protection. A distance of 30mm
should be kept between case top and the cover.

For indoor storage or outdoor storage, the case should be placed on a firm bearer or
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 Operating Instructions
Transport, Receipt and Storage of Goods 0-0240-01-01
plank for good ventilation and damp-proof. The cases cannot be stored in pile.
The protection treatment has made before turbine delivery. The Guarantee period of
rust protection for the turbine components is 12 months started from the delivery date.
So the turbine should be installed within 12 months after delivery.

For long-term storage, the user should examine the cases or components periodically.
In order to prolong the storage period, using sealed packing or making grease packing
regularly is recommended. The storage period is decided by the performance of the
rust-preventative oil used and the storage environment.

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使用说明书 技术数据 0-0300-5371-00
Operating manual Technical data

技术数据
Technical Data
汽轮机编号 WT5371

Code of steam turbine

汽轮机型号 ENK 40/45/100

Type of steam turbine

被驱动机械 发电机

Driven machine Generator

汽轮机用户 巴基斯坦 ICI Soda Ash 自备电站

User of steam turbine 18MW Power Plant for ICI Soda Ash, Pakistan

蒸汽参数和性能 Parameter and property of steam

表1

Table 1

参 进 汽 抽 汽 抽 汽 排 汽

条 数 Steam Extract Extract Exhaust

件 Parameter 压力 温度 压力 温度 压力 温度 压力

Condition Pres. Temp. Pres. Temp. Pres. Temp. Pres.

MPa(a) ℃ MPa(a) ℃ MPa(a) ℃ MPa(a)

正常
6.60 485 3.4 410.6 0.4 187.7 0.008
Normal

最高允许
6.90 490 3.6 404.7 0.5 192.0 0.008
Max.

最低允许
6.30 475 3.2 0.3 0.008
Min.

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使用说明书 技术数据 0-0300-5371-00
Operating manual Technical data

表2

Table 2

参数 进 汽 抽 汽1

Parameter功率 转速 Steam Extract

工况 Power Speed 压力 温度 流量 压力 温度

kW r/min Pres. Temp. Flow Pres. Temp.

Condition
MPa(a) ℃ t/h MPa(a) ℃

额 定

Rated

正 常
15900 7216 6.60 485 136.1 3.4 410.6
Normal

最 小

Min.

表2续

Table 2 (continue)

抽 汽1 抽 汽2 排 汽 汽耗率

Extract Extract Exhaust Steam

流量 压力 温度 流量 压力 温度 流量 consumpti

Flow Pres. Temp. Flow Pres. Temp. Flow on

t/h MPa(a) ℃ t/h MPa(a) ℃ t/h kg/kW·h

57.2 0.40 187.7 54.8 0.008 41.5

汽轮机转速 r/min

Speed of steam turbine

最大连续：7216

Maximum continuing speed:

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Operating manual Technical data

调速范围：

Speed range:

危急保安器动作：7938

Trip speed:
2
电超速脱扣：7793 转动惯量：46.1 kg×m

Electronic trip speed: Moment of Inertia:

被驱动机最大连续转速 r/min

Maximum continuing speed of driven machine

转向

Rotation direction

汽轮机（顺汽流方向看） 逆 时针方向旋转

Steam turbine(seen along with steam direction) counterclockwise rotation

被驱动机（从汽轮机端看） 顺 时针方向旋转

Driven machine(seen from steam turbine end) clockwise rotation

转子

Rotor

型式：整锻

Type: Found integrally

轴承跨距 2765 mm

Span of bearing

轴承

bearing

前轴承 后轴承 推力轴承

Front bearing Rear bearing Thrust bearing

型式 可倾瓦 可倾瓦
米切尔
type Tilting pad Tilting pad
Michell
（D=160） （D=200）

轴径（面积／瓦块数） 100/214A

Shaft diameter Φ160 Φ200

(aera/pad number)

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使用说明书 技术数据 0-0300-5371-00
Operating manual Technical data

联轴器

Coupling

汽轮机－被驱动机 汽轮机－齿轮箱 齿轮箱－被驱动机

Steam turbine Steam turbine Gearbox-driven

-driven machine -gearbox machine

型式 Type 膜片式 刚性

/Diaphragm Rigidity type

型号 Code

制造厂 Flender Flender

Manufacturer

与轴的配合形式

Assembly type

with shaft

配合直径

Assembly

diameter

装入方式

Assembly type

主调节器

Main governor

受控参量：转速 √ 新汽压力 抽汽压力 补汽压力

Controlled parameter: Speed √ Steam pressure Extraction Pressure

Admission Pressure:

调节器型号： 制造厂家：

Type of governor: Manufacturer:

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使用说明书 技术数据 0-0300-5371-00
Operating manual Technical data

安装位置：机上 就地盘 控制室 √

Mount location: local local panel control room √

调节器性能（NEMA SM23） D 级

Character of governor: D level

盘车机构 Turning gear

型式：手动 √ 液压 电动 √ 油涡轮

Type: Manual √ Hydraulic Motor √ Oil turbo

盘车转速 r/min， °/次 time

Turning speed

汽轮机油牌号 ISO VG46

Turbine oil code

3
用油量 m /h

Oil volume
3
润滑油：62.58 m /h 其中：

Lube oil: herein

3 3 3
汽轮机 27.18m /h (其中：推力轴承：8.88m /h；前轴承：6.2 m /h；后轴承：12.1
3
m /h)

Steam turbine （herein，thrust bearing front bearing rear bearing）

3
齿轮箱 25.8 m /h
3
被驱动机 9.6 m /h

Driven Machine
3 3
调节油：正常：17.05 m /h 瞬时最大用油量：134.61 m /h

Control Oil normal instantaneous maximum oil volume

油涡轮盘车 Oil turbo turning gear

液压蓄能器 Hydraulic accumulator

位号 No.

公称容积 63L

Normal volume

充氮气压力 0.55 MPa(G)

Nitrogen pressure 0.55 MPa(G)

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使用说明书 技术数据 0-0300-5371-00
Operating manual Technical data

主要件材料

Material of main parts

见合格证明书

Refer to quality certification

主要件重量

Weight of main parts

汽轮机本体

Body of steam turbine

汽轮机本体（无底盘整体起吊） 29.5 t

Body of steam turbine(without baseplate)

汽轮机外缸上半（包括组装件）8.0 t

Top casing of steam turbine(including assembly)

汽轮机转子 2.5 t

Rotor

辅机系统技术数据，见 0-2521-5371-00 和 0-2521-5371-01

Technical data of auxiliary system refer to 0-2521-5371-00 and 0-2521-5371-01

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Operating manual General Instruction of Steam Turbine 0-0400-5371-01

General Instruction of Steam Turbine

The code of steam turbine WT5371, which type is ENK40/45/100, single casing double
extraction condensing type, is applied to 18MW power plant for ICI Soda Ash self-owned plant,
Pakistan ,and to drive generator.
Layout drawing of steam turbine refer to 0-2015-5371-00 and 0-2015-5371-01
Steam & drain system drawing of steam turbine refer to 0-0642-5371-00
Lube oil system drawing of steam turbine refer to 0-0640-5371-00
Control system drawing of steam turbine refer to 0-0641-5371-00
According to the layout drawing of steam turbine, this steam turbine is mounted on the
foundation platform which height is 7.00m from the zero plane in the plant. The mark height of
turbine operating level is 7.9m
The rated speed of steam turbine is 7216 r/min. It reduce speed to 3000 r/min by the gearbox
manufactured by the Flender Co.Ltd., to drive generator.
The rotor of steam turbine is connected with the gearbox by the diaphragm coupling
provided by the Flender Co. Ltd,.
The generator is connected with the gearbox by the rigidity type.
The surface type condenser, which cooling area is 800m2, is laid near the steam turbine. It is
laid on the foundation that its height is 2.27m. The exhaust joint pipe connect the condenser
with the exhaust of steam turbine. The exhaust joint pipe is jointed between exhaust outlet and
exhaust pipe. Considering the requirement of steam turbine assembly at site, the height of
exhaust joint pipe is more than its real size. After the steam turbine and the condenser are
mounted on their respective location, the height of exhaust joint pipe is modified to real need
size on site. After doing it, the exhaust joint pipe is welded with the inlet of condenser according
to requirement (refer to the document with unit, Drawing No.:2-6056-5371-00).
The dynamic, static load due to the steam turbine to the foundation, the hot displacement of
flange joint and permitted force and moment refer to 0-2015-5371-01。
The original steam pipe is connected to the trip valve(connection Ta1 and Ta2)from the right
side of steam turbine (seen from the steam flow direction). The original steam flow into the
through-flow section of steam turbine via the trip valve（2301,2302）and high pressure governor
steam valve（0801）in turn. After the steam produce power in the first expanding section（0000）,
one is introduced from the extraction （Te1） of the nether half steam casing via steam governor
(0802) as controllable extraction steam. The other steam continues to produce power via
expansion section (0001), and some steam is extracted after steam governor (0802). The remain
steam continues to produce power via expansion section (0002), and flow into the
condenser(6000)after the steam pressure reduce to the exhaust pressure. The extraction & trip stop
valve(2351 and 2352) supplied by the Hangzhou Steam Turbine Co. Ltd,.(for short,HTC) are
equipped in the extraction piping, while the extraction relief valve (2452 and 2453) must be
equipped in the piping between the steam turbine and the return extraction & trip stop valveso as

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Operating manual General Instruction of Steam Turbine 0-0400-5371-01

to prevent overpressure in piping to assure the safety of the piping and steam turbine. The relief
valve is supplied by HTC.
To prevent the high temperature steam of the front steam seal of steam casing leak into the
bearing house resulting into the temperature of the bearing rising and the lube oil with water and
prevent the air of rear steam seal leak into the exhaust casing resulting into destroy the vacuum,
the steam turbine adopt the close steam gland system , compose mainly of the pneumatic steam
gland pressure controller（7200）,steam gland cooler（7210），piping and valve etc,. The gland
steam pressure is 0.108 MPa(a) when normal running. The steam side of steam gland cooler must
maintain about 0.098MPa(a) negative pressure.
The drain of steam turbine adopts three different type:
valve steam leak E22 of trip valve connect to the gland system；
Kinds of drain mentioned as follow connect to the flash tank（7211）
：
Wheel chamber drain E4
Steam casing drain E7
Balance piping drain E10
Gland, leak piping drain E13 and E15
Controllable steam piping drain E30 and E31
Non-controllable steam piping drain E32
Other drains drain into the ditch by valves.
Before the steam turbine start on the cold condition, the personnel should carefully check
whether every drain valve is open or not. The high temperature steam is condensed into water on
the cold casing wall and blade during the steam turbine is warming up. If the water is amassed in
the steam casing, the steam turbine can’t be heated evenly, and the upper and lower half steam
casing will cause temperature difference, which result in the thermal stress. That a lot of
condensing water flowing into the flow path will cause water hammer phenomenon, will cause
great damage to the blades and result in damaging the turbine or the personnel. When turbine load
rises to about 10%~20% PN, the drainage valves of turbine can be closed. For the condensing type
steam turbine that the steam is discharged upwards, the drainage of exhaust casing must be always
open and keep unimpeded
When the steam turbine is just shut down, the steam casing is still very hot,the intermediate
drain should not be permitted. Open all drain valves after the steam turbine is shut down one hour
so as to drain fully.

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Operating manual General Instruction of Steam Turbine 0-0400-5371-01

Warning
 That the incorrect drain switch mode may cause damage to the
equipment or personal accident.
 If the seal steam temperature is below 200℃ or near saturated
steam, the drain valve of steam seal pipe must be always open to
prevent the steam seal water led the rotor of steam turbine to bend
caused by the uneven heating.
 For the condensing type steam turbine that the steam is discharged
upwards, the drainage of exhaust casing must be always open and
keep unimpeded during running to avoid the water amassing in the
steam casing.

The control and lube oil of steam turbine is supplied by the oil supply device. This oil adopt
the steam turbine oil given by the ISO, which brand is ISO VG46.Supply oil divide into two
paths and connect with the lube oil and control oil piping respectively. 0.25MPa(g) lube oil
supply to the front, rear journal bearing, thrust bearing of steam turbine and other gearbox and
generator etc,. The oil inlet pipe of bearing is equipped with the controllable valve and pressure
gauge so as to satisfy the different oil volume need of per pipe。The purity precision of lube
3
oil≤25μm, normal inlet oil temperature 45  2 ℃.The aggregate oil volume including steam
turbine, gearbox and generator is 62.58m3/h.
Oil pressure of control oil pipe is about 0.80 MPa(g)，purity precision≤10μm ，normal oil
volume 17.05 m3/h，instantaneous maximum oil volume 134.61 m3/h. To reduce the oil pressure
fluctuation result from the change of oil volume, a 63L hydraulic pressure accumulator (4600) is
mounted in the control oil piping.
Instruction of governing and control
The governing and control system of steam turbine’s equipment can refer to the followed
system diagram and instruction:
Governing system diagram: 0-0641-5371-00
Drawing sign for governor system can refer to 0-0230-01-00/-01
The governing system diagram is used to steam turbine to drive generator.
The governing system is consisted mainly of rotate speed sensor(715),extract pressure signal
(161,163),speed control system,electric-liquid converter (1742,1743,1744),oil relay
(1910,1911,1912) and governing steam valve (0801,0802,0803).
Speed control system can receive rotation speed signals of steam turbine monitored by two
rotation speed sensors and extract pressure signal in the same time, compare them with fixed
rotation speed value ,decouple and output governing signal 4～20mA electric current. The

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Operating manual General Instruction of Steam Turbine 0-0400-5371-01

electric current can be converted into secondary oil pressure (1.5bar～4.5bar) by electric-liquid
converter, which can operate governing steam valve via oil relay and adjust steam inflow to
maintain rotation speed stably.
The starting of steam turbine is switching on trip valve, which is consisted of manual switch
valves （1830、1839）in the trip combination （1350）and trip valve (2301,2302).The manual
switch valves （1830、1839）are used to switch on the trip valve. The trip combination has remote
automatic or manual stop and the test of trip valve function. The stroke switches （ZS587、ZS589）
of trip valve interlock speed control system. Only when the trip valve is switched on fully, the
speed control system is permitted to start the steam turbine to make it rotate.
The earth dial and central room of steam turbine are provided with rotation speed indicator
(SI727) to monitor the running of it.
Those guided solenoid valves, which are provided in solenoid valves (2225、2226), are
important parts of trip combination. Solenoid valves are capable of cutting short trip oil path and
make trip valve shut down in no time after they receive kinds of outer synthetic stop signals.
Manual stop valve (2274) is also component of trip combination, which is used to shut steam
turbine down manually under the emergency.
Solenoid valves can cut short oil path in no time and make extract trip valves shut down after
they receive kinds of outer synthetic signals.
The test device (1845) is equipped in the trip combination to check the flexibility of the run
of trip valve when the steam turbine run normally. The calculating formula of admitted calculated
value of test oil pressure are as follow: P1≤A+B（P2-0.1）,herein P2 is the real oil pressure of steam
stop valve. If the real test valve is more than the admitted test value P1, the damping phenomenon
exists in the steam stop valve. Herein, the values of A and B are as follows:
A=0.1867Mpa
B=0.680

The body of steam turbine is composed mainly of rotary and stationary section. The body
structure of steam turbine and the assembly relativity of rotary and stationary section refer to:
Body drawing of steam turbine 2-8250-0033-00
Throughflow drawing 0-2100-5371-11
A1…Z1 detailed drawing 0-2011-1418-00
A4…Z4 detailed drawing 0-2011-4530-00
The stationary section of steam turbine include mainly front, rear support house, outer steam
casing, steam chamber, blade carrier, front, rear bearing house and seal ring etc,.
The horizontal and vertical joint of outer steam casing, upper and nether half casing and front
and exhaust casing are connected by bolts. The outer casing is supported on the support house by
lags. The trip valve is lay in the left and right side of the upper half steam inlet chamber of outer
casing.. The high pressure governor steam valve is mounted in the front end of outer casing. The

Page 4 of 6
Operating manual General Instruction of Steam Turbine 0-0400-5371-01

balance pipe, seal & leak piping connect with the nether casing, while the overflow pipe is
mounted on the upper steam casing. The rotor is consisted of integral shaft, moving blade wheel,
turning gear and steam seal. The moving blade wheel include one stage controllable stage,
eighteen pressure stages and two twist stages moving blades. The signal sending disc, which is
used to measure speed and shaft displacement, is located at the front of shaft section. The rotor has
three balance planes, one is located in the steam casing while other two auxiliary are located out of
the casing, which are used to correct the unbalance of rotor on the no open casing condition. The
steam turbine is equipped with the manual and motor turning gear. The manual turning gear is
mounted on the rear bearing housing, while the motor is mounted on the gearbox. The rotor of
steam turbine can rotate as low speed by turning gear when the steam turbine start up or stop so as
to prevent the bend of rotor of steam turbine.
The technical data of steam turbine refer to 0-0300-5371-00.

Page 5 of 6
Operating manual General Instruction of Steam Turbine 0-0400-5371-01

The structure introduction and mount, run and maintenance specification of steam turbine

refer to the corresponding content in this manual in detail, therein no specified repeatedly.

Page 6 of 6
 编号：0-2522-5371-00

自控与监测使用说明书
MANUAL OF CONTROLS AND INSTRUMENTS CONTROL

用户/CLIENT: 巴基斯坦 ICI Soda Ash 自备电站

机组号/WORK NO：WT5371
汽轮机型号/TYPE：ENK40/45/100

编制 /PREPARED 韦炜
校对 /CHECKED 沈方华
审核 /APPROVED 曹李农
版本 /REVISION 00
日期 /DATED 2015.9.10

浙江汽轮成套技术开发有限公司
Zhejiang Qilun Complete Technology Development Co.,Ltd
前言/Preamble
汽轮机控制系统主要包括调节系统、辅助系统、监测系统（TSI）、保护系统（ETS）等。控制系统

是汽轮机的有机组成部分，为使用户进行正确地操作、维护，掌握相关的内容，将本公司（浙江汽轮成

套技术开发有限公司是杭州汽轮机股份有限公司的控股子公司）所设计和提供的设备编写此说明书。

说明书主要包括就地仪表柜、中控柜、汽封调节装置、液位调节装置、操作柱等部分的图纸以及重

要外购件的资料。

调节系统图：（参见图 0-0641-5371-00）

转速调节：调速控制器接受二个转速探头(SE)监测的汽轮机转速信号(频率信号),二高选一后与内部

转速设定值比较，经转速 PID 放大器作用后, 输出 4-20mA 操纵信号。该信号送经电液转换器 I/H (1742)

转换成二次油压信号,二次油通过油动机(1910)控制调阀开度，调节进汽量。实现转速调节。

辅助系统：主要包括汽封调节装置、液位调节装置，辅助油泵、事故油泵联锁控制，排烟机、加

热器、风机、凝泵等控制。

监测系统（TSI）：由探头、前置器、监测模块组成汽轮机振动、位移、胀差等的连续、在线监测

功能。

保护系统：接受所有停机信号，当停机条件满足时，控制停机电磁阀动作，速关油卸荷，速关阀

在弹簧的作用下关闭，切断蒸汽通道，汽轮机停机。

详细资料请见光盘。

Control system contains the governing system、auxiliary system、monitoring system、protective system

etc.Control system is a organic part of the steam turbine, this operatin manual contains information required by

the customer for satisfactory operation and maintenance, contains information of drawings and equipment

supply by Zhejiang Qilun Complete Technology Development Co.,Ltd (Zhejiang Qilun Complete Technology

Development Co.,Ltd is a subsidiary company of Hangzhou Steam Turbine Co.,Ltd)

This manual contains drawings of Local Control Panel、Center Control Panel、Gland Steam Control

System、Level Control System、Operation and Project Information, contains information of important purchased

parts.
 Principle of the governing system：(reference drawing 0-0641-5371-00)

Speed control：The speed control receives a turbine speed signal from two magnetic pickups. The speed

PID (proportional, integral, derivative) control amplifier then compares the highest signal of two magnetic

pickups to the speed setpoint to generate an output signal (4~20mA),The output signal is changed in the I/H

converter(1742) into a proportional oil pressure(secondary oil pressure),The actuator transmits the secondary

oil position pulse for the control valves to the valve-operating levers,so that the steam flow always corresponds

to the preset.

Auxiliary system：contain Gland Steam Control System、Level Control System，auxiliary oil pump、

emergency oil pump control,mist fan、Ele. Heater、fan、condensate pump control etc.

Monitoring system(TSI)：The TSI system provides continuous, online Vibration 、Position 、Differential

Expansion monitoring. The TSI monitoring system consists of transducer、module.

Protective system(ETS)：The Protective system receives all shut down signal,if the shut down condition

occurred, solenoid valve changes over to trip position,the trip oil flows into the drain line and the emergency

stop valve is immediately closed by the compression sping,cut off the steam supply to the turbine in a minimum

of time ,turbine trip.

All details are included in the CD.

序号 资料 日期 图号 版本号 备注
NO. DOCUMENT DATE DRAWING NO. REV. NOTE

仪表盘布置图
1 2015.4.29 0-2017-5371-03 R0 R1 R2
Control Panel Arrange Drawing
仪表接线端子图
2 0-0803-5371-00
Junction Box Drawing
接线盒端子接线图
(1) 2015.4.29 0-0803-5371-00 R0 R1 R2
Junction Box Terminal Drawing
汽封压力变送器安装支架
(2) 2015.2.2 0-0803-5371-00 R0 R1
Gland Steam Pressure Transmitter Drawing
热井液位变送器外形图
(3) 2015.4.29 0-0803-5371-00 R0 R1
Hotwell Level Transmitter Figure Shape
就地操作柱外形接线图
(4) 2015.4.29 0-0803-5371-00 R0 R1
Local Control Station Layout and Wiring Diagram
仪表系统概况
3 2015.5.8 0-0800-5371-00 R0 R1 R2
Instrument System Overview
控制说明
4 0-0801-5371-00
Control Description
联锁、报警、停机
(1) 2015.5.8 0-0801-5371-00 R0 R1 R2
Interlock、Alarm、Trip
启动、辅助控制
(2) 2015.2.2 0-0801-5371-00 R0 R1
Start and Auxiliary Control
汽封调节说明
(3) 2015.2.2 0-0801-5371-00 R0 R1
Description for gland steam Control
热井液位及凝泵控制说明
(4) 2015.2.2 0-0801-5371-00 R0 R1
Description for Hot Well Level and Condensing Pump
盘车说明
(5) 2015.2.2 0-0801-5371-00 R0 R1
Barring Gear Description
I/O 清单
5 2015.5.8 0-0621-5371-01 R0 R1 R2
I/O List
调节阀规格
6 2015.2.2 0-0372-5371-01 R1
Control Valve Specification
TSI柜外形及接线图
7 2015.5.8 0-0804-5371-00 R1
TSI Cabinet Outline and Wiring Diagram
 NOTE
ETS :Emergency trip system RTD :Resistance Temperature Detector

TSI :Turbine Supervisory Instrumentation V :Vibration Signal

DCS :Distributed Control System Z :Displacement Signal

LC :Local K :Key Phase Signal

LCP :Local Control Panel P :Speed Signal

DEH :Digital Electric Hydraulic Control System PT :Pressure Transmitter

OPT :Over Speed Trip C :Dry Contact Signal

A :Standard Analog Signal (4~20mADC) PS :Pressure Switch

NOTE 第 1 页
 DEH_DI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
速关油压力 ???Mpa(g) L 停调速器
1 PS009 1 C LCP→DEH
Trip Oil Pressure Trip Govenor
启动 BUTTON
2 PB1 1 C
Start button LCP→DEH
复位 BUTTON
3 PB2 1 C
Reset button LCP→DEH
升速 BUTTON
4 PB3 1 C
Raise LCP→DEH
降速 BUTTON
5 PB4 1 C
Lower LCP→DEH
暖机/目标 SWITCH
6 PB5 1 C
Idle/Rated LCP→DEH
超速试验 SWITCH
7 PB6 1 C
Overspeed Test LCP→DEH
电网断路器 0→Not Enabled
8 1 C ELE→DEH
Utility Tie(GRID) BKR. 1→Enabled
发电机断路器 0→Not Enabled
9 1 C ELE→DEH
Generator BKR. 1→Enabled
远程转速给定投入 0→Not Enabled
10 1 C DCS→DEH
Remote Speed Setpt Enable 1→Enabled
同期增
11 1 C ELE→DEH
SYN Raise
同期减
12 1 C ELE→DEH
SYN Lower
0→
允许启动
13 1 C Dispermission DCS→DEH
Start Permissive
1→Permissive

DEH_DI 第 2 页
 DEH_DI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
抽汽压力1设定值投入
0→Disalbe
14 Extraction Pressure 1 Setpt 1 C DCS→DEH
1→Enalbe
Enable
抽汽压力2设定值投入
0→Disalbe
15 Extraction Pressure 2 Setpt 1 C DCS→DEH
1→Enalbe
Enable
ETS打闸输入 0→Disalbe
16 1 C ETS→DEH
ETS Trip 1→Enalbe

DEH_DI 第 3 页
 DEH_DO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
DEH报警 1→Alarm
1 1 C DEH→DCS ×
DEH alarm 0→Normal
超速试验已投指示 1→Enabled
2 1 C DEH→DCS
Overspeed Test Enabled 0→Disalbed
远程转速给定已投 1→Enabled
3 1 C DEH→DCS
Remote Speed Setpt Enabled 0→Disalbed
抽汽压力1给定已投
1→Enabled
4 Extraction Pressure 1 Setpt 1 C DEH→DCS
0→Disalbed
Enabled
抽汽压力2给定已投
1→Enabled
5 Extraction Pressure 2 Setpt 1 C DEH→DCS
0→Disalbed
Enabled
DEH跳闸 1→Trip
6 1 C DEH→ETS ×
DEH trip 0→Normal
DEH OK 1→OK
7 1 C DEH→DCS ×
DEH OK 0→Normal
阀位1≥30% 1→≥
8 1 C DEH→DCS ×
Valve Demand 1≥30% 0→Normal
AND
转速＜500rpm 1→＜
9 1 C DEH→DCS ×
Speed＜500rpm 0→Normal

DEH_DO 第 4 页
 DEH_AI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
远程转速给定值
1 1 A 4～20mA DCS→DEH
Remote Speed Setpt
抽汽压力1给定值
2 1 A 4～20mA DCS→DEH
Extraction Pressure 1 Setpt
抽汽压力2给定值
3 1 A 4～20mA DCS→DEH
Extraction Pressure 2 Setpt
抽汽压力1实际值
4 PT161 1 A 4～20mA LCP→DEH
Extraction Pressure 1
抽汽压力2实际值
5 PT163 1 A 4～20mA LCP→DEH
Extraction Pressure 2

DEH_AI 第 5 页
 DEH_AO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
调节信号(去电液转换器)
1 1742 1 A 4～20mA DEH→LC 供电电源24V DC
Regulatory signal(To I/H)
调节信号(去电液转换器)
2 1743 1 A 4～20mA DEH→LC 供电电源24V DC
Regulatory signal(To I/H)
调节信号(去电液转换器)
3 1744 1 A 4～20mA DEH→LC 供电电源24V DC
Regulatory signal(To I/H)
转速实际值
4 1 A 4～20mA DEH→DCS ×
Actual Speed
转速给定值
5 1 A 4～20mA DEH→DCS ×
Speed Setpoint
阀位1
6 1 A 4～20mA DEH→DCS ×
Valve Demand 1
阀位2
7 1 A 4～20mA DEH→DCS ×
Valve Demand 2
阀位3
8 1 A 4～20mA DEH→DCS ×
Valve Demand 3

抽汽压力1实际值
9 DEH-PT161 1 A 4～20mA DEH→DCS ×
Extraction Pressure 1

抽汽压力2实际值
10 DEH-PT163 1 A 4～20mA DEH→DCS ×
Extraction Pressure 2

DEH_AO 第 6 页
 DEH_PI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
转速
1 SE715A 1 P LC→DEH
Speed
转速
2 SE715B 1 P LC→DEH
Speed

DEH_PI 第 7 页
 TSI_DI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip Remark
远程复位 TSI
1 1 C
Remote Rest TSI DCS→TSI

TSI_DI 第 8 页
 TSI_AI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
汽轮机前径向轴承振动
1 VE733 Turbine Front Bearing 1 V LC→TSI
Vibration
汽轮机前径向轴承振动
2 VE735 Turbine Front Bearing 1 V LC→TSI
Vibration
汽轮机后径向轴承振动
3 VE737 Turbine Rear Bearing 1 V LC→TSI
Vibration
汽轮机后径向轴承振动
4 VE739 Turbine Rear Bearing 1 V LC→TSI
Vibration
齿轮箱前轴承振动
5 VE741 Gearbox Front Bearing 1 V LC→TSI
Vibration
齿轮箱前轴承振动
6 VE743 Gearbox Front Bearing 1 V LC→TSI
Vibration
齿轮箱后轴承振动
7 VE745 Gearbox Rear Bearing 1 V LC→TSI
Vibration
齿轮箱后轴承振动
8 VE747 Gearbox Rear Bearing 1 V LC→TSI
Vibration
发电机前径向轴承振动
9 VE749 Generator Front Bearing 1 V LC→TSI
Vibration

TSI_AI 第 9 页
 TSI_AI
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
发电机前径向轴承振动
10 VE751 Generator Front Bearing 1 V LC→TSI
Vibration
发电机后径向轴承振动
11 VE753 Generator Rear Bearing 1 V LC→TSI
Vibration
发电机后径向轴承振动
12 VE755 Generator Rear Bearing 1 V LC→TSI
Vibration

汽轮机位移
13 ZE769A 1 Z LC→TSI
Turbine Position

汽轮机位移
14 ZE769B 1 Z LC→TSI
Turbine Position

键相
15 KE783 1 K LC→TSI
Key Phase

转速
16 SE717A 1 P LC→TSI
Speed

转速
17 SE717B 1 P LC→TSI
Speed

转速
18 SE717C 1 P LC→TSI
Speed

TSI_AI 第 10 页
 TSI_DO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
汽轮机前径向轴承振动
1 VS733/5HH Turbine Front Bearing 1 C × 77.7µm HH SS
TSI→ETS
Vibration
汽轮机后径向轴承振动
2 VS737/9HH Turbine Rear Bearing 1 C × 77.7µm HH SS
TSI→ETS
Vibration
齿轮箱前轴承振动
3 VS741/3HH Gearbox Front Bearing 1 C × ???µm HH SS
TSI→ETS
Vibration
齿轮箱后轴承振动
4 VS745/7HH Gearbox Rear Bearing 1 C × ???µm HH SS
TSI→ETS
Vibration
发电机前径向轴承振动
5 VS749/51HH Generator Front Bearing 1 C × ???µm HH SS
TSI→ETS
Vibration
发电机后径向轴承振动
6 VS753/5HH Generator Rear Bearing 1 C × ???µm HH SS
TSI→ETS
Vibration

汽轮机位移
7 ZS769HH 1 C ×
Turbine Position TSI→ETS +/-0.80mm HH SS

汽轮机前径向轴承振动
8 VA733/5H Turbine Front Bearing 1 C × 53.0µm H A
TSI→DCS
Vibration

TSI_DO 第 11 页
 TSI_DO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
汽轮机后径向轴承振动
9 VA737/9H Turbine Rear Bearing 1 C × 53.0µm H A
TSI→DCS
Vibration
齿轮箱前轴承振动
10 VA741/3H Gearbox Front Bearing 1 C × ???µm H A
TSI→DCS
Vibration
齿轮箱后轴承振动
11 VA745/7H Gearbox Rear Bearing 1 C × ???µm H A
TSI→DCS
Vibration
发电机前径向轴承振动
12 VA749/51H Generator Front Bearing 1 C × ???µm H A
TSI→DCS
Vibration
发电机后径向轴承振动
13 VA753/5H Generator Rear Bearing 1 C × ???µm H A
TSI→DCS
Vibration

汽轮机位移
14 ZA769H 1 C ×
Turbine Position TSI→DCS +/-0.56mm H A

TSI OK继电器输出
15 1 C ×
TSI OK Relay Output TSI→DCS

汽轮机转速高高
16 2 C × 7793r/min HH SS
Turbine Speed High High TSI→ETS

TSI_DO 第 12 页
 TSI_AO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
汽轮机前径向轴承振动
1 VI733 Turbine Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration
汽轮机前径向轴承振动
2 VI735 Turbine Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration
汽轮机后径向轴承振动
3 VI737 Turbine Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration
汽轮机后径向轴承振动
4 VI739 Turbine Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration
齿轮箱前轴承振动
5 VI741 Gearbox Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration
齿轮箱前轴承振动
6 VI743 Gearbox Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration
齿轮箱后轴承振动
7 VI745 Gearbox Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration
齿轮箱后轴承振动
8 VI747 Gearbox Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration
发电机前径向轴承振动
9 VI749 Generator Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration

TSI_AO 第 13 页
 TSI_AO
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
发电机前径向轴承振动
10 VI751 Generator Front Bearing 1 A ×
4～20mA TSI→DCS
Vibration
发电机后径向轴承振动
11 VI753 Generator Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration
发电机后径向轴承振动
12 VI755 Generator Rear Bearing 1 A ×
4～20mA TSI→DCS
Vibration

汽轮机位移
13 ZI769A 1 A ×
Turbine Position 4～20mA TSI→DCS

汽轮机位移
14 ZI769B 1 A ×
Turbine Position 4～20mA TSI→DCS

键相
15 KI787 1 ×
Key Phase TSI→DCS

TSI_AO 第 14 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
0.6Mpa(g) L A
调节油总管压力
1 PS005 1 C LCP→DCS × 联锁辅助油泵
Control Oil Pressure
Interlock Auxiliary Oil Pump
速关油压力 0.15Mpa(g) L 停调速器
2 PS009 1 C LCP→DEH
Trip Oil Pressure Trip Governor
排汽压力
3 PS013 1 C LCP→ETS × 0.07Mpa(a) HH SS
Exhaust Steam Pressure
排汽压力
4 PS015 1 C LCP→ETS × 0.07Mpa(a) HH SS
Exhaust Steam Pressure
排汽压力
5 PS017 1 C LCP→ETS × 0.07Mpa(a) HH SS
Exhaust Steam Pressure
润滑油总管压力
6 PS021 1 C LCP→DCS × 0.15Mpa(g) L A
Lube Oil Pressure
润滑油总管压力
7 PS023 1 C LCP→DCS × 0.15Mpa(g) L A
Lube Oil Pressure

润滑油总管压力
8 PS025 1 C LCP→DCS ×
Lube Oil Pressure
0.10Mpa(g) L A
润滑油总管压力
9 PS027 1 C LCP→ETS × 启动交流盘车油泵/Start AC
Lube Oil Pressure
Turning Gear Oil Pump

润滑油总管压力
10 PS029 1 C LCP→ETS ×
Lube Oil Pressure

润滑油总管压力
11 PS031 1 C LCP→ETS ×
Lube Oil Pressure

LOCAL 第 15 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
0.08Mpa(g) LL SS
润滑油总管压力
12 PS033 1 C LCP→DCS × 联锁事故油泵
Lube Oil Pressure
Interlock Emergency Oil Pump

润滑油总管压力
13 PS035 1 C LCP→DCS ×
Lube Oil Pressure

润滑油滤油器差压 0.08Mpa H A
14 PDS081 Lube Oil Filter Diff. 1 C LC→DCS × 切换滤油器
Pressure Switchover Filter
调节油滤油器差压 0.08Mpa H A
15 PDS365 Control Oil Filter Diff. 1 C LC→DCS × 切换滤油器
Pressure Switchover Filter
排汽压力
16 PT113 1 A 4～20mA LCP→DCS × × 0.04Mpa(a) H A
Exhaust Steam Pressure
0.04Mpa(g) LLL A
润滑油总管压力
17 PT125 1 A 4～20mA LCP→DCS × × 禁止盘车/Turning Gear
Lube Oil Pressure
Forbidden
3.65Mpa(a) H A
可调抽汽压力1
18 PT161 1 A 4～20mA LCP→DEH→DCS × × × 3.15Mpa(a) L A
Extraction Steam Pressure 1
3.10Mpa(a) LL SS
0.55Mpa(a) H A
可调抽汽压力2
19 PT163 1 A 4～20mA LCP→DEH→DCS × × × 0.25Mpa(a) L A
Extraction Steam Pressure 2
0.20Mpa(a) LL SS
汽封压力
20 PT191 1 A 4～20mA LC→DCS ×
Gland Steam Pressure
汽轮机前径向轴承温度
105℃ H A
21 TE383A Turbine Journal Front Bearing 1 RTD PT100 LC→DCS × × ×
115℃ HH SS
Temperature

LOCAL 第 16 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
汽轮机前径向轴承温度
105℃ H A
22 TE383B Turbine Journal Front Bearing 1 RTD PT100 LC→DCS × × ×
115℃ HH SS
Temperature
汽轮机后径向轴承温度
105℃ H A
23 TE385A Turbine Journal Rear Bearing 1 RTD PT100 LC→DCS × × ×
115℃ HH SS
Temperature
汽轮机后径向轴承温度
105℃ H A
24 TE385B Turbine Journal Rear Bearing 1 RTD PT100 LC→DCS × × ×
115℃ HH SS
Temperature
汽轮机推力轴承正瓦温度
105℃ H A
25 TE387A Turbine Thrust Bearing 1 RTD PT100 LC→DCS × × ×
115℃ HH SS
(Positive) Temperature
汽轮机推力轴承正瓦温度
105℃ H A
26 TE387B Turbine Thrust Bearing 1 RTD PT100 × × ×
LC→DCS 115℃ HH SS
(Positive) Temperature
汽轮机推力轴承副瓦温度
105℃ H A
27 TE389A Turbine Thrust Bearing 1 RTD PT100 × × ×
LC→DCS 115℃ HH SS
(Negative) Temperature
汽轮机推力轴承副瓦温度
105℃ H A
28 TE389B Turbine Thrust Bearing 1 RTD PT100 × × ×
LC→DCS 115℃ HH SS
(Negative) Temperature
排汽温度
29 TE391 1 RTD PT100 × × 80℃ H A
Steam Exhaust Temperature LC→DCS
齿轮箱高速轴轴承温度
？？？℃ H A
30 TE401A Gearbox High Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱高速轴轴承温度
？？？℃ H A
31 TE401B Gearbox High Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature

LOCAL 第 17 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
齿轮箱高速轴轴承温度
？？？℃ H A
32 TE403A Gearbox High Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱高速轴轴承温度
？？？℃ H A
33 TE403B Gearbox High Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱低速轴轴承温度
？？？℃ H A
34 TE405A Gearbox Low Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱低速轴轴承温度
？？？℃ H A
35 TE405B Gearbox Low Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱低速轴轴承温度
？？？℃ H A
36 TE407A Gearbox Low Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱低速轴轴承温度
？？？℃ H A
37 TE407B Gearbox Low Speed bearing 1 RTD PT100 × × ×
LC→DCS ？？？℃ HH SS
Temperature
齿轮箱推力轴承温度
TE409A/B/C/ ？？？℃ H A
38 Gearbox Trust bearing 4 RTD PT100 × × ×
D LC→DCS ？？？℃ HH SS
Temperature

发电机前轴承温度/Generator 80℃ H A
39 TE415A 1 RTD PT100 × × ×
Front Bearing Temperature LC→DCS 90℃ HH SS

发电机前轴承温度/Generator 80℃ H A
40 TE415B 1 RTD PT100 × × ×
Front Bearing Temperature LC→DCS 90℃ HH SS

LOCAL 第 18 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)

发电机后轴承温度/Generator 80℃ H A
41 TE417A 1 RTD PT100 × × ×
Rear Bearing Temperature LC→DCS 90℃ HH SS

发电机后轴承温度/Generator 80℃ H A
42 TE417B 1 RTD PT100 × × ×
Rear Bearing Temperature LC→DCS 90℃ HH SS

TE419A/B/C/ 发电机绕组温度/Generator 125℃ H A

43 6 RTD PT100 × × ×
D/E/F Winding Temperature LC→DCS 135℃ HH SS

TE421A/B/C/ 发电机绕组温度/Generator 125℃ H A

44 6 RTD PT100 × × ×
D/E/F Winding Temperature LC→DCS 135℃ HH SS

发电机热风温度/Generator Hot 70℃ H A

45 TE423 1 RTD PT100 × × ×
Wind Temperature LC→DCS 80℃ HH SS

发电机热风温度/Generator Hot 70℃ H A

46 TE425 1 RTD PT100 × × ×
Wind Temperature LC→DCS 80℃ HH SS

发电机冷风温度/Generator Cold
47 TE427A 1 RTD PT100 × × 40℃ H A
Wind Temperature LC→DCS

发电机冷风温度/Generator Cold
48 TE427B 1 RTD PT100 × × 40℃ H A
Wind Temperature LC→DCS

LOCAL 第 19 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
??℃ H A
联锁关电加热器/Interlock
油箱温度 Electric Heater Close
49 TE431 1 RTD PT100 × ×
Oil Tank Temperature LC→DCS ??℃ L A
联锁开电加热器/Interlock
Electric Heater Open

冷油器后温度
50 TIE435 1 RTD PT100 × × 60℃ H A
After Oil Cooler Temperature LC→DCS

前轴承回油温度
51 TIE441 Front bearing Oil Outlet 1 RTD PT100 × × 60℃ H A
LC→DCS
Temperature
后轴承回油温度
52 TIE443 Rear bearing Oil Outlet 1 RTD PT100 × × 60℃ H A
LC→DCS
Temperature
齿轮箱回油温度
53 TIE445 Gear Box Oil Return 1 RTD PT100 × × 60℃ H A
LC→DCS
Temperature
发电机回油温度
54 TIE447 Generator Oil Return 1 RTD PT100 × × 65℃ H A
LC→DCS
Temperature
发电机回油温度
55 TIE449 Generator Oil Return 1 RTD PT100 × × 65℃ H A
LC→DCS
Temperature
热井液位 150mm H A
56 LS523 1 C LC→DCS ×
Conden.hotwell Level
热井液位 -150mm L A
57 LS525 1 C LC→DCS ×
Conden.hotwell Level

LOCAL 第 20 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
油箱液位 ???mm L A
58 LIT535 1 A 4～20mA LC→DCS × ×
OiL Tank Level ???mm H A
热井液位 150mm L A
59 LT537 1 A 4～20mA LC→DCS × ×
Conden.hotwell Level -150mm H A
低加液位 80mm L A
60 LT541 1 A 4～20mA LC→DCS × ×
LP Level -80mm H A
速关阀行程开关
全开
61 ZS587A Main Stop Valve Position 1 C LC→DCS
Full Open
Switch
速关阀行程开关
全开
62 ZS587B Main Stop Valve Position 1 C LC→DCS
Full Open
Switch
速关阀行程开关
全关
63 ZS589A Main Stop Valve Position 1 C LC→DCS
Full Closed
Switch
速关阀行程开关
全关
64 ZS589B Main Stop Valve Position 1 C LC→DCS
Full Closed
Switch
抽汽快速止回阀行程开关
全开
65 ZS591 Non-return Valve Position 1 C LC→DCS
Full Open
Switch
抽汽快速止回阀行程开关
全关
66 ZS593 Non-return Valve Position 1 C LC→DCS
Full Closed
Switch
抽汽快速止回阀行程开关
全开
67 ZS595 Non-return Valve Position 1 C LC→DCS
Full Open
Switch

LOCAL 第 21 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
抽汽快速止回阀行程开关
全关
68 ZS597 Non-return Valve Position 1 C LC→DCS
Full Closed
Switch

喷淋气动阀
69 ZS601 1 C LC→DCS
Spray Air Operated Valve

喷淋气动阀
70 ZS603 1 C LC→DCS
Spray Air Operated Valve

汽轮机前径向轴承振动
71 VE733 Turbine Front Bearing 1 V LC→TSI
Vibration
汽轮机前径向轴承振动
72 VE735 Turbine Front Bearing 1 V LC→TSI
Vibration
汽轮机后径向轴承振动
73 VE737 Turbine Rear Bearing 1 V LC→TSI
Vibration
汽轮机后径向轴承振动
74 VE739 Turbine Rear Bearing 1 V LC→TSI
Vibration
齿轮箱前轴承振动
75 VE741 Gearbox Front Bearing 1 V LC→TSI
Vibration
齿轮箱前轴承振动
76 VE743 Gearbox Front Bearing 1 V LC→TSI
Vibration

LOCAL 第 22 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
齿轮箱后轴承振动
77 VE745 Gearbox Rear Bearing 1 V LC→TSI
Vibration
齿轮箱后轴承振动
78 VE747 Gearbox Rear Bearing 1 V LC→TSI
Vibration
发电机前径向轴承振动
79 VE749 Generator Front Bearing 1 V LC→TSI
Vibration
发电机前径向轴承振动
80 VE751 Generator Front Bearing 1 V LC→TSI
Vibration
发电机后径向轴承振动
81 VE753 Generator Rear Bearing 1 V LC→TSI
Vibration
发电机后径向轴承振动
82 VE755 Generator Rear Bearing 1 V LC→TSI
Vibration

汽轮机位移
83 ZE769A 1 Z LC→TSI
Turbine Position

汽轮机位移
84 ZE769B 1 Z LC→TSI
Turbine Position

键相
85 KE783 1 K LC→TSI
Key Phase

LOCAL 第 23 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
启动 BUTTON
86 PB1 1 C
Start button LCP→DEH
复位 BUTTON
87 PB2 1 C
Reset button LCP→DEH
升速 BUTTON
88 PB3 1 C
Raising button LCP→DEH
降速 BUTTON
89 PB4 1 C
Reducing button LCP→DEH
暖机/目标 SWITCH
90 PB5 1 C
Idle/Rated LCP→DEH
超速试验 SWITCH
91 PB6 1 C
Overspeed Test LCP→DEH
BUTTON（Take
紧急停机
92 PB7 1 C cover）
Emergency Trip
LCP→ETS
准备启动 Lamp
93 LA1 1 C × Power 24V DC
Ready To Start DCS→LCP
就地控制 Lamp
94 LA2 1 C × Power 24V DC
Local Control DCS→LCP
转速 就地转速指示
95 SE713 1 P LC→LCP ×
Speed Local Speed Indicator
转速
96 SE715A 1 P LC→DEH
Speed
转速
97 SE715B 1 P LC→DEH
Speed
转速
98 SE717A 1 P LC→TSI × 7793r/min HH SS
Speed

LOCAL 第 24 页
 LOCAL
杭州汽轮机股份有限公司 I/O清单 资料号：0-0621-5371-01
出图 项目号：18MW双抽冷凝式汽轮发电机组
部门 浙江汽轮成套公司 I/O LIST 机组号：WT5371
序号 位号 名 称 数量 类型 信 号 来自 →去向 指示 报警 跳闸 备 注
No. Tag name Description QT Type Singal From→To Disply Alarm Trip (Remark)
转速
99 SE717B 1 P LC→TSI × 7793r/min HH SS
Speed
转速
100 SE717C 1 P LC→TSI × 7793r/min HH SS
Speed
停机电磁阀
101 SV2225 1 C ETS→LC Power 24V DC
Fast Shutdown Solenoid Valve
停机电磁阀
102 SV2226 1 C ETS→LC Power 24V DC
Fast Shutdown Solenoid Valve
抽汽逆止阀电磁阀
103 SV2351 Check Vavle for Extraction 1 C ETS→LC Power 24V DC
Steam Solenoid Valve
抽汽逆止阀电磁阀
104 SV2352 Check Vavle for Extraction 1 C ETS→LC Power 24V DC
Steam Solenoid Valve

排缸喷淋电磁阀
105 SV6810 1 C DCS→LC Power 24V DC
Spray Solenoid Valve

电液转换器
106 1742 1 A 4～20mA DEH→LC Power 24V DC
Electro-Hydraulic Converter
电液转换器
107 1743 1 A 4～20mA DEH→LC Power 24V DC
Electro-Hydraulic Converter
电液转换器
108 1744 1 A 4～20mA DEH→LC Power 24V DC
Electro-Hydraulic Converter

LOCAL 第 25 页
 Operation Instructions
Preface to Structure Description 1-0100-01-01

Preface to structure description

The structure description section identified by a number 1-xxxx-xx-xx in this Operating
Instructions contains the instructions of function, structure, assembling and adjusting
requirements.

For the configuration and structure of the turbine body, refer to the turbine longitudinal
drawing and cross section drawing.

The detail structure and dimension of the turbine through-flow section, see the attached
document ‘the drawing of the through-flow section” (0-2100-T.Nr-11). The data of the
nozzle, moving and guide blade profile are indicated in the through-flow section
drawing. Now take the blade T3-16-55.1 (13.10) as an example to illustrate the features
of the blade profile.

The data of the straight blade profile is composed of 4 elements in 3 fields(syllable).

The first field indicates the code of the blade type: T1 – nozzle, A1 – moving blade for
the control stage, T2, T4, T6 and T7 – moving blade and guide blade for the pressure
stages. The second field indicates the blade chord in mm. The third one is the blade
mounting angle β. The last number in the parenthesis stands for the axial width b of
the blade in mm.

The terms front, rear, right and left used the Operating Instructions are defined as
following, except for the WK turbine:
Front – the inlet steam end
Rear – the exhaust end
Right, left – the right side or left side of the turbine (look along the steam flow)

For WK turbine, the end with the thrust bearing is taken as the front end, while the end

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 Operation Instructions
Preface to Structure Description 1-0100-01-01
with the turning gear as the rear end.

For structures of the outer gland and outer components of the casing for the turbine,
such as pedestal, bearing pedestal, bearing and etc. please refer to the attached
documents “Body of steam turbine” (2-82xx-xxxx-xx) and its underline documents:
A1…Z1（0－2011－1XXX－00，Body of steam turbine A1…Z1,details of the front
section for the single-flow turbine）
A2…Z2（0－2011－2XXX－00，Body of steam turbine A2…Z2,details of the front
section for the double-flow turbine (WK)）
A3…Z3（0－2011－3XXX－00，Body of steam turbine A3…Z3,details of the rear
section for the back-pressure turbine）
A4…Z4（0－2011－4XXX－00，Body of steam turbine A4…Z4,details of the rear
section for the condensing turbine）

The support mode of static section for the turbine, the thermal expansion of the casing
and rotor, as well as the slide-key system will be introduced in the descriptions of the
relevant components.

For the material of main turbine components, see the product certificate.

Because the structure description in the Operating Instructions only introduces the
function and structure form for the component and is not used as the document for
manufacturing, the illustration in the Operating Instructions may not be conform to the
actual component completely for some components. For example, the number of the
blade rows of a rotor (1-0510-xx-xx) may not be the same as that of the actual rotor and
indicated in the through-flow section drawing. So the difference of the illustration will
not influence the use of the Operating Instructions.

Note: Some threaded taper pins in the horizontal split of the inner casing in half,
steam chamber, guide blade carrier and middle gland, which are mounted
in the casing, are only used for positioning the upper and lower halves
during machining. They are removed when assembling and have no use for
turbine disintegration and re-assembling or overhaul.

Note: After the upper and lower casings assembled, must remove the locating pins
in the casing split and keep them properly for later maintenance.

For monitoring instruments of the turbine, please refer to the following attached
documents:
0-2020-T.Nr-00 Bill of material
0-0101-T.Nr-01 Technical document for device monitor
2-8320-T.Nr-00 Device monitor
0-0640-T.Nr-00 Diagram of lube oil system
0-0641-T.Nr-00 Diagram of control system

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 Operation Instructions
Preface to Structure Description 1-0100-01-01
0-0642-T.Nr-00 Diagram of steam drain system

The above documents show the name, function, quantity, type, measuring range,
installing location of the instruments, which the turbine is equipped with, as well as the
connection and installing requirements for some special instruments.

Hangzhou Steam Turbine Company Limited Page 3 of 3

 Operating Instructions
Turbine longitudinal profile ENK exhaust steam underside 1-0204-01-01

Fig 1

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 Operating Instructions
Turbine horizontal profile ENK with double trip valve 1-0304-03-01

Fig 1

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 Operating Instructions
Turbine casing 1-0410-02-01

Turbine casing
The casing is a container for the through-flow section of the turbine.

The casing consists of the front casing and rear casing (exhaust casing) which have
vertical joint surface. They are also divided along the horizontal plane into top and
bottom halves. The vertical and horizontal split flanges are connected with bolts. The
casing structure is showed in the figure below.

The front casing is a steel casting, while the exhaust casing is iron casting or welds. For
the detailed material and performance, see Product Certificate.

1. Bores for governing

valve stems
2. Lug for guide
blade carrier
3. Exhaust casing
4. Mounting collar
for rear gland bush
5. Mounting surface for rear
bearing pedestal
6. Lug for adjuster of lateral
center
7. Rear paw
8. Bolt hole
9. Mounting collar for guide
blade carrier
10. Front paw
11. Mounting collar for front
gland bush
12. Admission chest
13. Bores for governing valve seats
14. Shell of emergency stop valve
15. Guide key of rear bearing pedestal

The admission chest (12) located on the upper part of the casing front end is a lateral
cylinder. It accommodates the beam and discs of the governing valve. There are guide
and seal components fixed at the location (1) where the valve stem threads through the
admission chest. The seats of the governing valve are mounted in the bores (13) at the
bottom. Usually, the admission chest is welded with the shell of the emergency stop
valve (14). The shell is an individual casting with the same material as the front casing.
It is welded to the admission chest after rough finish, the welding seam is inspected
with the x-ray. This will make the casing suitable for the layout with different steam
inlet directions (up or down) and positions (right or left). But, for some turbines the

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 Operating Instructions
Turbine casing 1-0410-02-01
shell is connected with the admission chest by the flanges. A casing can match with the
emergency stop valve(s) (one or two) with different diameter according to the volume
flow of the live steam. When using one emergency stop valve, the other end of the
admission chest is blocked with a blind flange.

The front casing accommodates the inner casing or steam chamber or nozzle box based
on different turbine characteristic. The outer casing and inner casing (or steam chamber
or nozzle box) are connected with an angle seal ring (see 1-0411 for the details). The
steam from the governing valve enters into the through-flow section via this angle ring.
This make the outer casing simple in shape and a less thermal stress.

The collars (9) for mounting the guide blade carrier on the inner wall of the casing
separate the casing into several departments with different pressure. These departments
should be inspected through the hydrostatic test during machining and the inspecting
result should be recorded in “Hydrostatic Test Report”, which is a part of Product
Certificate.

For the extraction turbine, there is an extraction port opened in the middle section of the
casing. A labyrinth seal, which separates the through-flow section into different
expansion sectors, is fixed behind the extraction port of the regulating extraction. Based
on the practice and the layout requirement, one of the following structures could be
adopted for the governing valve on the second or the second and the third expansion
sector: the shell of the governing valve is cast with the front casing, the other is that a
separated valve shell is connected to the casing via an outer piping.

The collars (11,4) at the front and rear ends of the casing are used for mounting the
outer gland bush bodies.

The connections of the balancing, gland steam and leaking steam piping are located on
the casing bottom half for the exhaust-down turbine, while for the exhaust-up turbine,
the connections on the front casing are located on the bottom half and those on the rear
casing may be located on the top half according to the piping layout.

The casing drains are lead out from the bottom at the casing bottom half.

For some condensing turbines, in order to prevent the exhaust temperature from
excessive high under special operating condition a water injection device is used in the
exhaust casing.

The casing is seated on the front and rear pedestals in aid of the front and rear paws
(10,7). The front paws are integrated with the top half of the front casing, the rear paws
are located at both sides of the rear casing bottom half. The lateral center adjusters,
which are located at the front and rear ends of the casing and symmetrical about axis,
are used for aligning the casing with the pedestal. The mounting surface of the rear

Hangzhou Steam Turbine Company Limited Page 2 of 3

 Operating Instructions
Turbine casing 1-0410-02-01
bearing pedestal (5) is located on the rear end of the bottom half of the exhaust casing.
The guide key (15) is used as a guide for positioning the rear-bearing pedestal. For the
relevant part of the exhaust casing and rear-bearing pedestal of the condensing turbine,
there is another structure that is different from the one showed in the figure above. The
bottom half of the rear bearing pedestal is cast with the bottom half of the exhaust
casing integrally and there are no items (5) and (15) in this structure. For the structures
of the casing positioning and guide, please refer to the descriptions of the front pedestal
(1-0710) and the rear pedestal (1-0750).

The pressure and temperature measuring points of the turbine inlet steam are located in
the shell of the emergency stop valve. The measuring points of the exhaust pressure and
temperature is placed on rear end face of the bottom half of the exhaust casing.
Generally, the pressure measuring point of the chamber (after control stage) is located
on the front end face of the top half of the front casing, but when the inner casing is
used, it is located at the bottom of the outer casing bottom half (there is a pressure
measuring connection tube between inner and outer casings). The extraction pressure
measuring point is usually located on the extraction piping.

The tightened status of the casing split bolt when turbine delivery is related with the
requirements of the packing and transport. The bolt tighten during installation and
service, please refer to the introducing in the installation section 2-0410- .

Hangzhou Steam Turbine Company Limited Page 3 of 3

 Operating Instructions
Seal Ring of L-shaped Cross Section 0-0411-01-01

Seal ring of L-shaped cross section

In the reaction turbine (except for the model WK), an seal ring of L-shaped cross
section is used as the connection between the outer casing and inner casing, nozzle box
or steam chamber. The steam from the governing valve enters into the corresponding
steam dome of the nozzle box via the angle ring. There are two structures of angle ring,
they are showed in figure 1 and figure 2 separately.

1. Outer casing
2. Pin
3. Seat of governing valve
4. Nut
5. Angle ring
6. Threaded bush
7. Inner casing (steam chamber, nozzle
box)
8. Pin

Fig. 1 Structure I

When using the structure I, the seat is loosely fitted in the seat bore in the outer casing
and tightened by the nut (4) and positioned by the pin (2) which is welded at the end
with spot welding.

The angle ring (5) and threaded bush (6) are mounted on the inner casing (steam
chamber, nozzle box). The threaded bush (6) is locked with the pin (8) which is welded
at the end with spot welding.

When using the structure II, the fitting of the valve seat and the seat bore in the outer
casing is shrink fit (the valve seat is frozen before mounting).

The angle ring (3) and threaded bush (5) are mounted in the inner casing (steam
chamber, nozzle box). The threaded bush (5) is locked with the pin (6) which is welded
at the end with spot welding.

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 Operating Instructions
Seal Ring of L-shaped Cross Section 0-0411-01-01

1. Governing valve seat

2. Outer casing
3. Angle ring
4. Inner casing (steam chamber, nozzle
box)
5. Threaded bush
6. Pin

Fig. 2 Structure II

Only one structure of the angle ring is used in a turbine, for the selected seal ring of
L-shaped cross section for a special turbine, please refer to the through-flow section
drawing of the turbine.

There are 4 or 5 governing valves mounted in the first expansion sector of the turbine.
When the fifth valve (in the order of the valve opening and in the middle) is used for
nozzle governing, the angle ring is fixed between the outlet of the valve seat and the
inner casing, while the angle ring behind the valve is not required when the fifth valve is
used for by-pass throttle governing.

A certain gap is exited between the angle ring and the threaded bush in height, so that
the angle ring can move in plane direction. This makes the angle ring to align
automatically when putting on the top half the casing. During turbine operation, the
angle ring not only seals the steam between the departments with different pressure, but
also permits the connected parts expand freely.

The nominal dimension of S in the figure is given in the through-flow section drawing
N5－N5, while the actual measurement is recoded in Product Certificate.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Eccentric guide stem 1-0412-01-01

Eccentric guide stem

The lateral or axial centers of the inner casing, the steam chamber, the guide blade
carrier and the labyrinth seal is adjusted with the eccentric guide stem when mounting
them into the outer casing. In the backpressure turbine, the alignment between the
casing and the rear pedestal is adjusted with the eccentric guide stem.

Structure of eccentric stem

One end of the eccentric pin (1) is a cone, which is matched with the taper hole in the
eccentric bush (2). The other end is a tenon, which is inserted in a groove in the
corresponding component. When the eccentric guide stem is used for adjusting the
center of the inner casing and steam chamber, the part 2 is assembled in the mounting
hole at the bottom of the outer casing bottom half. A elliptical groove is machined
correspondingly at the bottom of the inner casing and steam chamber. For the guide
blade carrier, the part 2 is assembled in a special machined hole at the bottom half of the
guide blade carrier. A groove is machined correspondingly at the bottom surface of the
outer casing. When aligning the casing and the rear pedestal for a backpressure turbine,
the part 2 is assembled in the mounting hole in the lug at the end of the bottom half of
the exhaust casing. In this case the end of the part 1 is not a tenon, but a cylinder, which
is inserted in the positioning hole of the rear pedestal. There is an offcenter of 1.5 mm in
the X direction between the excircle of the eccentric bush and the taper hole, turn the
bush will produce a relative displacement in the Y direction between the fixed part and

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 Operating Instructions
Eccentric guide stem 1-0412-01-01
the adjusted part, so that the lateral alignment or the adjusting of the axial position is
satisfactory. Owing to the groove on the bush, tightening the bolt (3) will lock the bush
with the pin. The threaded hole at the end of the bush is used as a technological hole for
disassembling

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Steam Chamber 1-0440-01-01

Steam chamber
The steam chamber, as showed in Fig.1, is used the turbine of model (E)N_.

1. Steam flow
2. Steam chamber top
half
3. Mounting hole for
ring of L-shaped
cross section
4. Nozzle group
5. Positioning groove
6. Bolt hole
7. Steam chamber
bottom half
8. Gland bush of
balancing piston
9. Positioning pin

Fig.1 Steam chamber

The steam chamber is horizontally split into top and bottom halves, which are
connected with bolts and positioned with positioning pin (9). The seal ring of
L-shaped cross section (see the section “Seal ring of L-shaped cross section” for
details) is fitted in hole (3) on the top of the steam chamber. There are 4 compartments
cast in the steam chamber top half. They are separated each other and the nozzle
groups (4) are installed at the their outlets. The governing valve has 4 or 5 valve cones
based on the operation requirement and characteristic of the turbine. Fig.1 shows the
steam chamber matched to the governing valve with 4 valve cones. When the
governing valve has 5 valve cones, there is a concave-down steam channel cast on the
steam chamber top half at the place corresponded to the fifth valve cone (the fifth
valve cone is placed in the middle and opens in the order of fifth). The steam through
the fifth valve is led behind the control stage via this steam channel, so this valve is
specially used in by-pass control.

The positioning groove (5) on the front-end excircle of the steam chamber is matched
with the collar of the casing. It is used not only for the axial positioning but also as the
dead point of the axial thermal expansion of the steam chamber.

Hangzhou Steam Turbine Company Limited Page 1 of 2

 Operating Instructions
Steam Chamber 1-0440-01-01
The steam chamber is seated on the casing bottom half with the flanges at both sides,
as showed in Fig.2 (the view name and the item No. in Fig.2 are corresponding to that
indicated in Through-flow Drawing). The press plate (320) is fixed on the flange
supporting face of the steam chamber bottom half with the screw (321). The vertical
center of the steam chamber is adjustable with the thickness of the press to meet the
assembling requirement. The steam chamber, together with the press, can slide in the
plane direction. There is axial groove at the bottom face of the steam chamber bottom
half, it is used, with the eccentric guide stem (also see the section “Eccentric guide
stem for details), for adjusting the transverse center of the steam chamber.

320 Press plate 321 screw

Fig.2 L5－L5

A control stage guide ring is machined on the steam chamber bottom half for
reducing windage loss.

The gland bush of the steam chamber consists of two sections: one is the sealing
strips, which are caulked in the rear end inner circle of the steam chamber, for
decreasing the loss of steam leakage for the control stage, the other is the gland
bush of the balancing piston which is formed by the sealing strips on the front end
inner circle and the balancing piston on the rotor.

In some turbine sets, a part of the steam leakage is led out from the middle position
(along the axial direction) of the gland bush of the balancing piston for balancing
the axial thrust. In such a case, the structure of the steam chamber is little different
with that showed in fig.1, please refer to Through-flow Drawing.

The assembling requirement of the steam chamber is given in Through-flow

Drawing. The actual measurements during assembling are recorded in Product
Certification.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Guide Blade Carrier 1-0450-01-01

Guide blade carrier

The guide bland carrier is one of the essential component in turbine through-flow
section and accommodates several stages of fixed blades. There is one or several guide
blade carriers of pressure stages with different size in a turbine according to the
different parameters and characteristics. The structure of the guide blade carrier is
showed in Fig.1.

1. Top half of guide blade

carrier
2. Guide blades
3. Bottom half of guide blade
carrier
4. Holes for joint bolts
5. Pads for adjusting elements
6. Positioning groove
7. Eccentric guide stem
8. Groove at bottom of casing
bottom half

Fig.1 Guide blade carrier

The guide blade carrier is horizontally split into top and bottom halves jointed with
bolts and positioned with the pins.

Fig.2 Adjusting element

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 Operating Instructions
Guide Blade Carrier 1-0450-01-01
There are 2 or 4 pads (5) at the split of the bottom half of the guide blade carrier. The
adjusting element, as showed in Fig.2, is mounted in the thread hole of the pad. The
guide blade carrier is supported on the casing bottom half with the pads and the
adjusting elements, its vertical center is adjustable with the thread seat (13). A requested
clearance between the spherical washer (9) and the top casing is kept through adjusting
the thread seat (10).

The positioning groove (6) on the exterior margin of the guide blade carrier is matched
with the collar of the casing. The axial position is determined by 2 or 4 adjusting
elements for axial position showed in Fig.3, which are mounted in the bottom half of the
guide blade carrier. The value S is indicated in Through-flow Drawing and Product
Certificate.

15 Holding screw 16 Nut

Fig.3 Adjusting element for axial position

The eccentric guide stem (7) that are mounted at the front end on the bottom face of the
guide blade carrier, together with the axial groove in the casing, is used for adjusting the
transverse center of the guide blade carrier (also see the section “Eccentric guide stem”
for details).

As showed in Fig.4, the guide blade carrier is a hollow steel cast with a shape of
truncated cone. The guide blades and the sealing strips are mounted in the grooves that
are machined in the inner wall of the guide blade carrier.

The guide blade is straight blade by drawing or milling and has a shroud band riveted at
its tip in group. The spacer between the roots of adjacent guide blade ensures correct
interval. The first and last spacers of each stage are brazed with the root of the adjacent
guide blade and secured with pin or screw. The structure and dimensions are indicated
in Through-flow Drawing. The shoulder machined on the shroud band of the guide and
moving blades and the sealing strips caulked on the guide blade ring and rotor form
labyrinth gland for reducing the loss of the steam leakage in moving and fixed
clearances caused by the differential pressure before and after the guide and moving

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 Operating Instructions
Guide Blade Carrier 1-0450-01-01
blading. The sealing strip and the square caulking bar are rolled with the material of
1Cr18Ni9Ti. The thickness of the sealing strip is only 0.25 mm, so even when the
moving and fixed parts friction each other the generated heat will not cause the guide
blade carrier and the rotor to be distorted.

Fig.4 Scheme of structure for guide blade

In some of the turbines, the positioning of the guide blade carrier relative to the casing
adopts the structure showed in Fig.5. The cylindrical part of the positioning pin is
matched with the hole machined at the bottom of the bottom half of the guide blade
carrier, while the key-shaped part milled at the middle of the pin is matched with the
axial groove at the bottom face of the casing. In such a case, the adjustment of the
transverse center for the guide blade carrier is not required. It is fully ensured by the
machining. The other part of the guide blade carrier is the same as mentioned above.

Hangzhou Steam Turbine Company Limited Page 3 of 4

 Operating Instructions
Guide Blade Carrier 1-0450-01-01

Fig. 5

At the present time, both of the structures are adopted in reaction turbines, but in a
turbine only one of them is used.

The guide blade profile of each stage, the clearances taking account of relative
expansion and machining tolerance and gland bush structure and dimension are all
indicated in Steam Path drawing. The actual measurements during assembling are
recorded in Product Certificate.

When turbine overhaul, both the guide blade and the sealing strips can be replaced, if
necessary. The guide blade is not a standard component for universal use, it is machined
according to the specific dimension for the specified turbine. If user intends to replace
the guide blade, please contact with us in advance.

Hangzhou Steam Turbine Company Limited Page 4 of 4

 Operating Instructions
Guide Blade Carrier for Low-pressure Stage 1-0450-02-01

Guide blade carrier for low-pressure stage

The guide blade carrier for low-pressure stage is used in the low-pressure section of the
condensing turbine for model K or WK. For its structure, please refer to Through-flow
Drawing, 500 in Turbine Body Drawing and the views T4－T4, U4－U4 and the details
R4 in drawing A4…Z4.

The configuration of the guide blade in the carrier for the low-pressure stage is different
with the turbine characteristics. In most cases, there are 2 stages (matched with moving
blade HK, LK) or 3 stages (matched with moving blade SK) of standard low-pressure
guide blade. But in some of the turbines, in addition to the standard low-pressure guide
blades, several stages of guide blades for pressure stage are also mounted in this carrier.
There is no sealing strip between the moving blade and guide blade carrier in section of
the standard low-pressure stage. The steam passage at the trailing side of the guide
blade ring is machined as a diffuser without blade for reducing the exhaust loss. In order
to fit the assembling request, a part of the guide blade carrier top half for the
low-pressure stage is partitioned and mounted on the top half of the exhaust casing (also
see Turbine Body Drawing for details). Note: the length of item 518 in Turbine
Body Drawing A4…Z4 can not be changed at will, otherwise the partitioned part
will be dislocated with the carrier top half, resulting in turbine vibration and steam
flow noise to be increased.

In addition to all of the above, the structure of the guide blade carrier for the
low-pressure stage is the same as that of the guide blade carrier for the pressure stage.
Please refer to the section “Guide Blade Carrier for details.

Its assembling requirement is given in Through-flow Drawing and Turbine Body

Drawing, while the actual measurements of the controlled parameters during assembling
is recorded in Product Certificate.

Hangzhou Steam Turbine Company Limited Page 1 of 1

Outer Gland Bush 1-0460-03-01

Outer Gland Bush

The outer gland bush is allocated at the place where the turbine rotor penetrates out of
the casing for minimizing the steam inside the casing to leak out and preventing the
high temperature steam from leaking into the bearing pedestal resulting in bearing
temperature rose and lubricating oil contained water. The rear gland bush is used for
preventing the air from entering the casing resulting in the vacuum deteriorated.

The sealing strips which are caulked in the inner circle of the gland housing and the
sealing strips on the rotor or the tooth which are turned on the rotor form the gland bush.
The gland bush of the reaction turbine is a non-contact labyrinth seal. In the gland bush
which is formed by several annular gaps and cavities arranged in sequence, the steam,
through the gap, flows into the cavity with a larger volume at high speed under
differential pressure. Owing to the violent eddy resulting in the sudden expansion of the
steam flow, the most of the kinetic energy is changed into heat energy and only small
amount of the kinetic energy can passes the next gap at leaving velocity. This process is
repeated stage by stage. The sealing function is achieved by the throttle effect of the
steam flow.

The outer gland bush of the turbine consists of the front and rear gland bushes, their
sealing action is showed in the figure above and also see P & I Steam and Drainage
System (0-0642-TNr-00). A part of the steam inside the casing leaks to the cavity II
through the inner section of the gland bush 250 and then led to the gland steam
exhaust piping via the leakage steam pipe which locates outside the casing. The rest of
the leakage steam in the cavity II continues to leak to the cavity I through the outer
section of the gland bush and is then led to the atmosphere through a vapor pipe at the
top part or the gap at the tip of sealing strips. When the turbine start-up and operation,
the inner side of the rear gland bush 275 is under negative pressure. The steam at the

Hangzhou Steam Turbine Company Limited Page 1 of 2

Outer Gland Bush 1-0460-03-01

pressure about 0.103MPaA is supplied to the cavity II of the rear gland bush through the
gland steam piping so as to prevent the air from entering the exhaust casing along the
gland bush resulting in the vacuum deteriorated. A part of the supplied steam enters into
the exhaust casing by the inner side of the gland bush. The other part leaks into the
cavity I by the outer side of the glade bush and then exhausts into the atmosphere
through a vapor pipe and the gap at the tip of sealing strip.

Two discs are machined on the rotor at the places corresponded to the cavities I of the
front and rear gland bushes for drawing the leakage steam to the vapor pipes

The structure of the gland bush and the form and dimension of the sealing strip are
determined by the turbine parameters. For the front gland bush, refer to drawing A1…Z1,
and the rear gland bush is showed in drawing A3-Z4.

A gap of about 0.5mm is kept at the joint of each loop of sealing trip when caulking the
strip on the rotor, furthermore, the joints of adjacent loops are staggered each other.

The sealing strip and the square caulking bar are made of 1Cr18Ni9Ti with a special
rolling machine. The sealing strips and the square caulking bars are turned integrally to
the require dimension after they are inserted in the grooves on the gland housing and the
rotor.

The spare parts of the sealing strip and the square caulking bar are supplied with the
turbine. If the sealing strip damaged, the user can either replace them by himself or ask
HTC to repair.

Hangzhou Steam Turbine Company Limited Page 2 of 2

Gland Bush of Dummy Piston 1-0470-01-01

Gland Bush of Dummy Piston

The reaction turbine is the reaction turbine, the axial thrust acted on its rotor is much
larger than that on the rotor of the impulse turbine and is beyond the capacity of the
thrust bearing. Therefore, all of the reaction turbines are equipped with the dummy
piston with the gland bush, except for the turbine of type WK, to reduce the axial thrust
within the capacity of the thrust bearing.

The gland bush of the dummy piston is a kind of inner gland bush, as showed in figure
above.

During turbine operation, the steam will produce a thrust F1 which is in the same
direction as the steam flow on the rotor due to the different pressure on the moving
bladings and increasing root diameter of the drums along the steam flow direction. At
the same time, a part of the steam in the compartment P1 leaks into the “balancing
compartment” P2. The pressure in P2 is lower than that in P1 and the drum diameter of
the dummy piston is larger than that of the first row of the moving blading, so that the
thrust F2 opposed to F1 is produced on the rotor. The resulted axial force on the rotor is
F=F1-F2+F3, where, F3 is a additional axial thrust of the coupling. The load on the thrust
bearing is checked according with F.

Generally, the axial thrust is in the same direction as the steam flow within the normal
operating range, but for some of the turbines a negative thrust will appear during
start-up, stop or under special working condition.

The most of the steam in the balancing compartment is led to the low-pressure section
in the steam path through an exterior balancing piping for continuing to do work or to
the exhaust section of the turbine, only a small amount of the steam leaks along the
outer gland bush.

Hangzhou Steam Turbine Company Limited Page 1 of 2

Gland Bush of Dummy Piston 1-0470-01-01

The structure of the gland bush of the dummy piston is determined by the arrangement
of the turbine admission section. When using the inner casing in two-half and steam
chamber the gland housing of the dummy piston is integrated with the inner casing and
the steam chamber, while using the nozzle box, it is an independent component.

For the gland housing as an independent component, it is horizontally split into the top
and bottom halves which is jointed with bolts and positioned with the aligning pin for
preventing misalignment each other. The groove on the excircle of the gland housing is
matched with the collar in the casing (the inner casing or the outer casing), ensuring the
correct position of the gland housing in radial and axial directions. Insert the parallel pin
located on the top of the gland housing top half into the counterbore in the casing top
half for preventing rotation. The gland housing adopts an special elastic structure so that
the correct position is guaranteed and the change of the clearance between the moving
and stationary parts, caused by rapidly changed temperature, dose not interrupt the
turbine normal operation.

The structure, form and dimension of the dummy piston gland bush are indicated in
Through-flow drawing.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Turbine Rotor 1-0510-04-01

Turbine Rotor
The moving blades on the rotor and the stationary nozzles and guide blades are the core
of the turbine steam path, in which the thermal energy of the steam is converted into the
mechanical energy for rotating the turbine rotor and driving the machine to which
the turbine is coupled. The Fig.1 shows the structure of the rotor.

1. Emergency governor 10. Low-pressure stage

2. Primary thrust bearing collar 11. Rear gland bush
3. Secondary thrust bearing collar 12. Rear bearing journal
4. Front bearing journal 13. Ratchet wheel for manual turning gear
5. Front gland bush 14. Impeller for oil turbine barring gear
6. Gland bush of dummy piston 15. Coupling hub
7. Control stage 16. Primary balancing plane
8. Pressure stage 17. Secondary balancing plane
9. Middle gland bush
Fig.1 Turbine rotor

The rotor is a single forging together with the control stage disc and thrust collars, on
which the emergency governor, moving blades, sealing strips (of the outer gland bush,
gland bush for dummy piston and the gland bush between stages), ratchet wheel for
turning gear and coupling are mounted. For the extraction turbine, the middle gland
bush (located at item 9 in Fig.1 or between item 7 and 8, or in the middle of item 8) is
equipped.

For the steam path and the dummy piston section of the rotor, refer to Steam Path
Drawing (0-2100-T.Nr-11), for the front and rear bearing journals, see the details A1…
Z1，A4…Z4.

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 Operating Instructions
Turbine Rotor 1-0510-04-01
There are three kinds of moving blades, the moving blades of the control stage, the
pressure stage (or called as drum stage) and the low-pressure stage. The front two are
the milled straight blades with integral shroud, while the moving blade of the
low-pressure stage is twisted blade made with finish forging or machined
electrochemically. The twisted blade has no shroud since the smaller cross section of
and the large pitch at the blade top, but with the damping wire tied in group for
buffering vibration. Fig.1 shows the twisted blade of type SK. There are only two rows
of twisted blade if type HK or LK is used.

The moving blades are the untuned blades so as to be suitable for the turbine operating
under large speed range.

The profile of the moving blade for the control stage is indicated in Steam Path Drawing.
As showed in Fig.2, 2- or 3- leg straddle root is used depending on the strength
condition. The straddle root is inserted into the groove in the blade wheel and secured
with two axial taper pins. During assembling the taper pin holes in the wheel and
the root are drilled and reamered together. The taper pin with a taper of 1:50 is used for
the 2-leg straddle root, while the pin with a taper of 1:100 for the 3-leg straddle root.
After the pin registered, turn the overmeasure off and tighten at the larger end by
rolling.

The main parameters, structure and dimensions of the moving blade for the pressure
stage are listed in Steam Path Drawing, it has an inverted-T root. The blades are inserted
into the groove in the rotor from the dap of last blade. They are contacted each other and
secured with caulking pieces. The last blade is secured to the rotor with two screw.

Fig.2 Moving blade of control stage

The profile and the number of the rows for the low-pressure twisted blade can be found
in Through-flow Drawing. The root of the low-pressure twisted blade for last stage is
the same as that of the blade of the control stage, with straddle root. For the twisted

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 Operating Instructions
Turbine Rotor 1-0510-04-01
blade of type SK, it is 4-leg, for the type HK or LK, it is 3-leg. The root of the first one
or two rows is the same as the pressure stage, with the inverted-T root.

The low-pressure stages of the condensing turbine work in the wet-steam region, so
the steam flowing out of the guide blade contains the water droplets. The axial distance
between the guide and moving blades in the low-pressure stage is kept large to facilitate
the acceleration, separation and atomization of any water droplets. This will reduce the
impact and corrosion of the droplets on the leading edges of the blades. Taken
the effects of the speed, humidity and condenser pressure into account, the leading
edges of the last moving blades are hardened if necessary.

The required clearances between the moving and stationary blades, in consideration of
the relative thermal expansion and machining tolerance, are given in Through-flow
Drawing. The actual measurements during assembling are recorded in Product
Certificate.

The correct matching between the journals, thrust-bearing collar of the rotor and the
stationary radial bearings, the thrust bearing determine the mechanical and geometric
matching relationships between the rotor rotating at high speed and the stationary
components during turbine operation. The thrust-bearing collar is located on the front
section of the turbine rotor and used, together with the thrust bearing, for maintaining
the rotor in correct axial position and as the relative dead point of the thermal expansion
for the rotor. The size of the collar is based on the thrust bearing style and the thrust that
acts on the rotor. The diameters of the front and rear journals, which is related with the
turbine type, power and speed, are listed in the section “technical data” (0-0300-T.Nr-00)
in the Operating Instructions. They can also be found on drawings A1…Z1 , A4…Z4 in the
attached documents. he journal surface of the rotor is rolled (including the
corresponding zone where the vibration probe is located) so as to increase the surface
strength and measurement accuracy for shaft vibration.

The emergency governor (also see 1-2110- for details) fitted in the front section of the
rotor, together with the emergency trip gear (also see 1-2210- for details), serves for
turbine trip when the turbine speed exceeded the defined value. There is no cam track
on the rotor. The primary thrust collar (item 2 in Fig. 1) is used as signal disk for the
axial-displacement and the key-phase measurement, while the secondary thrust collar
(item 3 in Fig.1) as the toothed disk for speed measurement. When the turbine adopts
the electron overspeed protective system as required by the user, there is no emergency
governor on the rotor.

Based on different requirement, the front end of the rotor is connected with a drive shaft
for driving the mechanical hydraulic governor and main oil pump.

The ratchet, impeller or gear used for the manual, hydraulic, oil turbine or electric
barring gear is mounted on the rotor after the rear bearing journal as required.

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 Operating Instructions
Turbine Rotor 1-0510-04-01

In general, the rear end of the rotor is the driving end and is fitted with the coupling
selected by user (see “Technical Data” for details). For the turbine with both-end power
take-off, both the front and rear ends of the rotor are the driving ends. In this case, the
front section of the rotor should be specially designed.

There are at lest three balancing planes on the shaft section of the rotor within the
casing for correcting of the rotor dynamic balance. The two primary balancing planes
(item 16 in Fig.1) are located on the end face of the dummy piston and the rear end face
of the drum, respectively. There are also one or more balancing planes on the middle
section of the drum, as required. In addition, there is a secondary balancing plane(17)
at each outer side of the front and rear gland bushes. The secondary balancing planes are
used not only for the factory dynamic balancing but also for field balancing without
opening casing. The location of the balancing plane is related to the rotor strength.

⎠ Caution: User should not add the balancing plane on the rotor at will.
Before the turbine test running in factory the dynamic balancing and overspeed testing
of the rotor should be finished.

The rotor dynamic balancing is done on the high speed dynamic balancing machine at
the turbine operating speed to correct the dynamic unbalance quantity within the limit
defined in the relative standard through changing the mass distribution of the balancing
weights or screws on the balancing planes. The dynamic unbalance quantity on the rotor
is caused by non-uniform mass distribution of the rotor material, machining error and
assembling deviation.

The rotor overspeed test is one of the factory inspection items, it should be done on
special device under defined operating condition and environment, at 121% of the rated
speed for the turbine driving the generator and 121 %of the maximum continuous speed
for the industrial turbine, for 2 min.

⎠Attention: The overspeed test mentioned above must not be done at site,
otherwise personal injuring and equipment damage will occur.

The results of the inspection during assembling, dynamic balancing and overspeed
testing for the rotor are recorded in Product Certificate.

⎠Attention: The lifting tool (2-8540- ) supplied with the turbine should be used
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 Operating Instructions
Turbine Rotor 1-0510-04-01
and the rigging must not contact with the blades when lifting the
rotor.

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 Operating Instructions
Front supporting pedestal 1-0710-03-01

Front supporting pedestal

The supporting pedestal fixed on the foundation (concrete foundation or steel base plate)
serves for sustaining the turbine casing and rotor. The correct position of them is
ensured by the sliding-key system.

Fig.1 shows the front supporting pedestal. It mainly consists of the base plate(12), front
bearing housing(8), driving element (1) (to be conditional on the turbine structure),
thermal expansion indicator for the casing as well as the relevant connectors. The brush
also can be fitted on it when required. As showed in fig.1, the gear unit is driven by the
turbine rotor through a flexible shaft. The main oil pump and the transmitter for the
hydraulic speed governor or the speed governor are fixed at the end face of the gear box.
When the main oil pump is driven directly by the turbine rotor, it is fixed on the front
end face of the bearing housing through an adapter (or middle plate). For the turbine
without the driving element and using the outer oil pump to supply oil, a cover plate is
fixed on the end face of the front bearing housing.

The base plate (12) rested on foundation packing plates is used as the connector
between the bearing housing (8) and the foundation (also see the description in the
section “Installation” for details). With 4 adjusting screws (13) that are distributed
symmetrically on the base plate, the level and height of the base plate can be adjusted.
The base plate, which is a casting of QT400-15, is firmly anchored on the foundation.
with the anchor bolts (10).

When you read the below description about the structure and the assembling
requirement for the front supporting pedestal, please also refer to the turbine body
drawing (2-82xx-00xx-00) and the drawing A1-Z1 (0-2011-1xxx-00) in the attached
documents.

For the connection of the front bearing housing and the base plate, please refer to
the views F1-F1 and N1-N1 in the drawing A1-Z1. The front bearing housing is seated on
the adjusting plates (76) (for the item number beyond 16 is indicated in the drawing
A1-Z1, the same below). There are 5 groups of adjusting plates located symmetrically on
each side of the right and left between the bottom face of the front bearing housing and
the mounting face of the base plate. Align the bearing housing with the casing center (in
vertical direction) with the adjusting screws, then correct the thickness of the
adjusting plate. There are 6 projections (11) cast on the edged of the base plate. The
axial position and the lateral center of the bearing housing are adjusted with the
adjusting screws (72) on the projections. After the front bearing housing positioned,
loose the adjusting screw (79), tighten the adjusting screw (72) to retain the bearing
housing and lock it. Then tighten the anchor bolts and joint bolts (80) connecting the
base plate and the bearing housing and lock them. Thus, the front bearing is connected
to the base plate firmly.

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 Operating Instructions
Front supporting pedestal 1-0710-03-01

1. Driving element
2. Emergency trip gear
3. Thrust bearing
4. Speed sensor
5. Radial bearing
6. Oil seal ring
7. Rotor
8. Front bearing housing
9. Joint bolt
10. Anchor bolt
11. Projection
12. Base plate
13. Adjusting screw
14. Guide rod
15. Thrust collar
16. Thrust bearing bracket

Fig.1

The connection of the casing with the front supporting pedestal includes two parts, the
connection between the casing and the base plate and the connection between the casing
and front bearing housing.

For the positioning of the casing with regard to the base plate, please refer to the view
K1-K1 in drawing A1-Z1. The adjusting keys (50) made up in size are fixed at both sides
of the vertical-key located at the center (in axial direction) of the base plate. The key is
matched with the keyway in the guide lug at the front end of the bottom casing. The
sliding surface of the key is painted with the special lubricating film for reducing the
sliding resistance of the casing. This design not only maintains the alignment of the
lateral center between the casing and the pedestal under cold state, but also allows the
casing to expand freely in both axial and vertical directions without changing the center

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 Operating Instructions
Front supporting pedestal 1-0710-03-01
under hot state. The actual measurements of the fitting clearance indicated in the
drawing could be found in Product Certificate.

The casing of the 3-series turbine is supported with the aid of the upper supporting
brackets. Owing to the fact that the casing split and the supporting face is the same
plane, the thermal expansion of the supporting brackets has no influence on the centers
of the casing and the rotor under hot condition. This will be of benefit to the turbines
with high parameters especially.

For the assembling relationship between the casing and the front bearing housing,
please refer to the view M1-M1 in drawing A1-Z1.

During mounting, rest the casing bottom half on the jacking screw (30) and adjust
the position of the casing split (in the vertical direction) with (30). The positioning
dimension of the casing is recorded in Product Certificate. After the joint of the casing
top and bottom halves, correct the thickness of the supporting plate (38) to make the top
casing rest on it. Loose (30) by 3 to 5 mm and lock it with the nut after the casing joint
bolts tightened. The attention should be taken to keep the casing center unchanged
during transferring the casing supporting from the bottom half to the top.

The distant screw (43) that is fixed on the front bearing housing is used to prevent
the casing against tilting. A given clearance is kept between it and the top casing
supporting bracket in the axial and vertical directions so that the casing can expand
freely under hot state. The surfaces of (38) and (39) are painted with the special
lubricating film for reducing the sliding resistance of the casing. During assembling,
mount two disk springs (41) in opposite first, as showed in the details at the left. Then
make the clearance between (40) and (42) be S1 through making up the thickness of
the adjusting gasket (42) under the disk springs unloaded. After that, mount the disk
springs in the same direction, make the clearance between (42) and (43) be S through
correcting the distant screw (43) or the thickness of the washer (42) under the condition
that the top casing supporting bracket contacts with the supporting plate (38) after
the distant screw tightened. The values of S and S1 are given in the details M1-M1 in
drawing A1-Z1. They also can be found in Product Certificate.

During turbine normal operation, the disk springs are unloaded, the clearance between
(42) and (43) is less than or equal to the value of S. If S =0 during operation, it indicates
that the casing has tilted because of the incorrect mounting of the turbine body or piping.
If the turbine vibration increased at this time, the following measurement can be taken
by way of trial for maintaining the turbine operation. Remove the distant screw, take out
two disk springs that are mounted in same direction, mount them again in opposite, then
press them by screwing in the distant screw. The casing supporting brackets are loaded
by the disk springs against the casing tilting. View the turbine operation condition when
tightening the distant screw to press the disk spring. Tighten it until the washer (42)
contacted with the adjusting gasket (40) if necessary. The allowed amount of the

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 Operating Instructions
Front supporting pedestal 1-0710-03-01
compression for the disk spring is S1. It should be pointed out that this measurement is
only the expedience, return the disk springs to the normal state after the reason that
causes the casing tilting found and removed.

The front bearing housing consists of the top and bottom halves, which are jointed with
the bolts. It includes the thrust bearing bracket, thrust bearing, radial bearing, oil seal
ring and the relevant connectors. The arrangement of the front end face for the front
bearing housing is changed with the general requirement of the turbine. Fig.1 shows
the front supporting pedestal with the diving element, the turbine rotor is connected with
the gear unit of the driving element with a coupling for driving the oil pump,
he transmitter for hydraulic governor or the governor. If the turbine with both ends
power taking-off, the coupling shield is mounted on the end face. If no special
requirement, the end face is fitted with the cover plate.

The top half of the bearing housing, on which the emergency trip gear, the sensors for
measuring speed and shaft vibration, has no oil compartment and is used as a cover.
the interfaces for mounting the ventilator and connecting the return oil pipe of
the oil-relay are drilled on it.

Both of the top and bottom halves of the bearing housing are castings, the materials of
HT200 and QT400-15 are used for the top half and the bottom half respectively.

The thrust bearing is fixed in the thrust bearing bracket (see the description in 1-0720-
for details).

The dead point of the turbine is at the exhaust end based on the design of the thermal
expansion and sliding-key system of the turbine, while the relative dead point of the
rotor is at the thrust collar and the thrust bearing. The front bearing housing is fixed
with the base plate and the foundation, so the structure which can move relatively is
used in connection between the thrust bearing bracket and the front bearing housing .
Fig.2 shows the thrust-bearing bracket.

The thrust bearing bracket, which is a steel casing of 2G25, is split horizontally into
the top and bottom halves jointed with the bolts and positioned with the taper pins.
The bracket is seated on the bottom half of the front bearing housing with the aid of
the adjusting plate (item 2, in bilateral symmetry). The vertical center of the bracket is
ensured through making up the thickness B1 of the item 2, while the lateral center is
ensured through making up the guide plate (1), which is fixed on the bracket bottom
half at both right and left sides (on the item 1 at the left side the oil inlet for the thrust
bearing is opened). S that indicated in the figure is the total clearance at both sides.
Make the clearance S2 between the item 4 and item 5 within the required range through
making up the distant dimension of the distant screw (4). The bracket is also connected
to the casing with two guide rods. Owing to the structure mentioned above, the thrust
bearing bracket (including the thrust bearing) will move with the casing axial expansion

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 Operating Instructions
Front supporting pedestal 1-0710-03-01
in the same direction without changing its center during turbine operation. The guide
rod consists of screw stem, bellow element, sealing gasket, locking gasket and nut, also
see the details H1 in drawing A1-Z1. The screw stems are fixed on the casing bottom half
and parallel to the axial line of the turbine. The bellow element and the sealing gasket
are used at the place where the screw stem extends out of the bearing housing for
preventing the oil from leaking. The axial position of the bracket under cold state is
adjusted with the nut, which is locked with the locking gasket. In order to guarantee
the thrust bearing in good working condition, the nut at the casing side must contacts
firmly to the plane of the bracket lug, while at the other side a specified clearance must
be kept between the nut and the plane of the lug.

1. Guide plate 3. Guide rod 5. Press plate

2. Adjusting plate 4. Distant screw
Fig. 2

For the adjusting requirement for the values of S that are indicated in the figure, please
refer to the views G1－G1 and J1－J1 in drawing A1-Z1. The actual measurements of S
and B are recorded in Product Certificate.

For the radial bearing, the two-wedge bearing, four-wedge bearing or tilting-pad bearing
can be selected as required (also see 1-0730- for details). There are two kinds of
the structures for the assembling of the radial bearing and bearing housing. Fig. 3 shows
the radial bearing with the adjusting ring and the radial bearing without the adjusting
ring is showed in Fig.4.

The adjusting ring comprised of the bow-shaped ring (1), half circle ring (5), aligning
block (4) and middle block (6) is severed for adjustment and as the connector between
the bearing and the bearing housing. The item 1 is jointed with the item 5 with the bolt
and positioned with the taper pin. The items 4 and 6 are fixed on the item 5 with screws.
There is a group of adjusting gaskets used for adjusting the bearing center between

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 Operating Instructions
Front supporting pedestal 1-0710-03-01
the item 4 (item 6) and item 5. The adjusting ring is fixed in the bearing housing with
the bolts. The adjusting plate (3) that its thickness is made up according with the
requirement is located between the item 1 and bearing housing. Fig. 3 shows the
two-wedge or four-wedge bearing. When the tilting-pad bearing is used, the top half of
the bearing is fixed in the bow-shaped ring with the screws. In this case the top
clearance S3= 0 between the bearing body and the bow-shaped ring. The top clearance
between the rotor journal and the bearing bushing is indicated with S2 rather than S1. S4
is the total clearance at both sides. The nominal values of S1 to S4 are given in details A1
in drawing A1-Z1. For the actual measurements during assembling, see Product
Certificate. The inner diameter R and L of the adjusting ring, measured at
the orientation of 45°are marked on the bow-shaped ring as showed in figure.

1. Bow-shaped ring 4. Aligning block

2. Radial bearing (two- or four- wedge 5. Half circle ring
bearing 6. Middle bloc
3. Adjusting plate
Fig. 3

For the radial bearing without the adjusting ring, the bearing is directly mounted in
the bearing housing. The bearing cover is jointed to the bearing housing with the bolts
and positioned with the taper pins. The mounting bore for the bearing is machined
integrally. The diameter R and L measured at the orientation of 45°are marked on the
bearing cover as showed in figure.
S3
Fig.4 shows the two- or four-wedge radial bearing. When the tilting-pad bearing is used,
the top clearance between the rotor journal and the bearing bushing is indicated with S2
and the S3 = 0. The values of S are given in the details A1 in drawing A1-Z1 and Product
Certificate.

It must be noted that there is no tightening force between the bearing body and the

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Front supporting pedestal 1-0710-03-00

bearing cover (or the bow-shaped ring) in 3-series turbine, no matter which fitting type
the radial bearing adopts. The bearing housings with and without the adjusting ring are
different not only in structure but also in machining and assembling. When the adjusting
ring is used, the alignment of the bearing housing can be finished in one step, or
pre-align the bearing housing then correct the gasket thickness of the adjusting ring to
meet the alignment requirement when aligning the rotor and the casing. In the case of
no adjusting ring the appropriate fitting between the bearing and the bearing housing is
ensured by machining. The correct alignment between the rotor and the casing can only
be achieved through the adjusting the bearing housing.

1. Bearing cover 2. Radial bearing

Fig. 4

Both of the oil inlet and return oil connections for the bearing housing are located on
the front end face of the bottom half of the bearing housing. The lubricating oil entered
into the front bearing housing is supplied to the thrust bearing and the radial bearing via
the inner channels. The pressure of the lubricating oil is adjustable with the throttle
valve (at left is for the thrust bearing, that at right is for the radial bearing) at the side of
the bottom half. The return oil of the bearing and oil-relay is returned into the oil tank
through the return oil port on the bearing housing and the piping. Owing to the bearing
housing is fixed in regard to the foundation, it is unnecessary to fit an expansion joint on
the lubricating oil inlet and return piping connected to the bearing housing.

For the sealing ring, refer to 1-0760- for details.

A thermal expansion indicator which functions for monitoring the casing thermal
expansion and indicating the absolute expansion amount of the casing. As showed in
Fig.5, a pointer is mounted on the side of the casing upper supporting bracket, the scale
is fixed on the front pedestal at the same side. The pointer will point to the position “0”
on the scale under cold state. When heated, the pointer moves axially with regard to the
scale and indicates the axial expansion amount of the casing.

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Front supporting pedestal 1-0710-03-00

1. Casing upper supporting bracket

2. Pointer
3. Scale
4. Front bearing housing

Fig. 5

When a grounding bush is installed on the bearing housing, please refer to 1-7650- for
details.

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 Operating Instructions
Thrust Bearing 1-0720-02-01

Thrust Bearing
The thrust bearing is accommodated in the front bearing housing. It functions for taking
up the axial thrust of the rotor and fixing the rotor in its correct axial position.

1. Thrust bearing bracket 6. Oil inlet

2. Bearing shell 7. Primary thrust pad
3. Sealing strips 8. Cylindrical pin
4. Secondary thrust pad 9. Oil channel
5. Collar on rotor
Fig. 1

As showed in Fig.1, the thrust bearing consists of the bearing shell (2), thrust pad (4 and
7) and cylindrical pin (8). The bearing shell is horizontally split into the upper and lower
halves, which are jointed with the bolts and positioned with the taper pins. The
bearing shell is accommodated in the thrust-bearing bracket of the front bearing housing
(also see 1-0710-03-xx for details) and is locked to the bracket with the positioning pin
against rotation. Each thrust bearing has two groups of thrust pad ring and each ring consists of 8
sector thrust pads.

The axial position of the bearing shell in the bearing housing is adjusted and positioned
with the gasket (2). There is a dowel pin at the split between the shell and the bearing
housing for preventing the shell against rotation. The outer and inner arcs of the pad is
matched with the groove in the shell to position it radially. The position of the pad in
rotation direction is positioned with the cylindrical pin.

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 Operating Instructions
Thrust Bearing 1-0720-02-01
Because the thrust bearing is a hydrodynamic bearing, it can only work normally under
the following condition.
1. The lubricating oil possesses a certain viscosity.
2. A relative velocity between the moving and stationary parts.
3. Two relatively moving surfaces are tilting so that the oil-wedge is formed.
4. The load is within the specified range.
5. Sufficient oil flow

The conditions mentioned above should be noticed during installation and operation.

The thrust bearing is a kind of Michell bearing. The working face of each pad is lined
with the tin-base babbit (ZChSnSb11-6, or called babbit) with a thickness of 2.0 mm.
On its rear face, each pad carries a pivoting edge around which it is able to tilt under the
oil pressure, so that the wedged gap is formed between the collar and the thrust pad.
When the rotor rotating, the oil is entered into the wedged gap and the hydrodynamic oil
film is formed between the collar and the thrust pads for taking up the axial thrust of the
turbine and transmitting the thrust to the bearing housing. Owing to the formation of the
oil film lubrication, there is no metal friction occurred between the collar and the
pad during turbine normal operation.

The thickness difference among 8 thrust pads of each group is ≤ 0.004mm.

The rotating direction for the each pad is marked on it as showed in Fig. 2.

Fig.2 Mark of rotating direction on pad

⎠ Caution: During turbine first installation or repair, must not mis-mount the
primary thrust pad with the secondary one, otherwise the bearing
loading capacity will be less than 1/3 of the normal allowed thrust
resulting in damage of the thrust bearing during turbine operation,
since the efficient hydraulic oil wedge can not be formed between
the pad working face and the collar.

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 Operating Instructions
Thrust Bearing 1-0720-02-01

The lubricating oil entering at the lower half of the bearing housing flows into the outer
oil channel (9). From there it enters into the pad working area through the oil inlet holes
(6) and the annular groove between the rotor and the shell. The oil flowed out of
the pad working area is drained through the clearance between the sealing strips and the
rotor.

The sealing strips are caulked in the thrust-bearing bracket.

The temperature of the bearing is monitored through measuring the thrust pad
temperature for ensuring the turbine normal operating. The platinum resistance
temperature sensor, as showed in Fig.3, is mounted into the temperature measuring hole
that is drilled on the pad. In this case the mounting and pulling eye is machined on
the bearing shell and the cable fixer is equipped.

Fig.3 Hole for measuring pad temperature

Generally, the direction of the axial thrust is in the same direction as the steam flow
(positive thrust) during turbine normal operation. But it will be opposed to the steam
flow direction (negative thrust) during start-up, stop and under some special conditions
for some turbine set.

The axial clearance S between the thrust pad and the collar as well as the radial
clearance SR1 between the sealing strip and the rotor are given in the details B1 in
attached document A1-Z1. The actual measurements of the clearance are recorded in
Product Certificate.

The spare thrust pads are supplied with an allowance in thickness in consideration that
the user may mill the thrust collar on the rotor in repair after the turbine operating for a
time. It must be noticed that 8 pads in the same group should be the same in thickness
when changing.

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 Operating Instructions
Radial Bearing 1-7-0730-03-01

Radial Bearing
The four-wedge bearings as showed in Fig.1, which are accommodated in the front and
rear bearing housings, are hydrodynamic bearings. They serve to take on the static and
dynamic load of the turbine rotor, keep the rotating center of the rotor in the correct
position with regard to the casing center and make the radial clearances between the
rotor and the static components, such as guide blade carriers and gland bushes in the
casing, within the defined range. At the same time, the bearing characteristics of oil film
rigidity and damp coefficient within the turbine operation condition range (speed and
load) ensure the rotor-bearing system operate stably and safely in long term.

3-series turbine adopts the tilting-pad bearing of 5×50°as its radial bearing, as
showed in Fig.1. It mainly consists of the bearing ring and sector pads.

Fig.1 Radial bearing, tilting-pad

The bearing ring is matched with the bearing housing or bearing adjusting ring. The
lower bearing ring is fitted with a positioning pin against its rotation in circumferential
direction and the upper bearing ring is fixed in the bearing press ring with bolts as

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 Operating Instructions
Radial Bearing 1-7-0730-03-01
showed in section view A-A.

5 sector pads are equispaced along circumferential direction. Two of them, which are
located in the lower bearing ring, are symmetrical to the vertical center. There are two
kinds of pad, with or without hole for pad temperature measurement (11). The hole is
machined in the pads that are located in the lower bearing ring.

The pad inner surface is lined with babbit (ZChSnSb11-6).

Each pad is positioned with the screw (4) that is mounted on the bearing ring and is
matched with the pad. The external diameter of the pad is less than the inner diameter if
the bearing ring so that the arc on the pad back is contacted with the bore of the bearing
ring in a line. The contact place is also the pivoting point for pad swing. Furthermore,
the diameter of the pad inner surface is lager than that of the rotor journal so that when
the turbine speed or load changed the pad can adjust its position around the pivoting
point, resulting in formation of the optimal oil wedge.

The lubricating oil is supplied via the nozzles (5), which are mounted in the annular
groove of the bearing ring. The jet of each nozzle is staggered with the axial direction
by 10°as showed in Fig.1 to eliminate mutual interference of the oil flow jetted from
the nozzles. The number of the nozzles and the size of the nozzle orifice are determined
by the bearing size.

The lubricating oil inside the bearing drains to return oil department of the bearing
housing though the radial gap between the side ring (8) and rotor. The side ring consists
of the upper and lower halves and is secured to the bearing ring in radial and axial
directions. The bolt (9) mounted on the bearing ring also serves as the keeper for the
side ring. The side ring, in addition to against the lubricating oil splashing, hangs
the pad by the aid of the cylindrical pin (6) on both sides of the pad. In this way, the pad
will not fall down during transportation and assemble.

Fig. 2

Two positioning pins fixed on the split of the bearing ring lower half is only used for

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 Operating Instructions
Radial Bearing 1-7-0730-03-01
transportation and should be removed in assembling.

In the turbine with jacking oil system, a jacking oil pocket is machined in two pad that
are located in the lower half, as showed in Fig.2. The jacking oil under high pressure
from the outer piping is admitted into the pocket through an orifice, forming a static
pressure bearing. When the jacking oil pressure reaches the required value, the oil
cushion will lift the rotor and avoid metal-to-metal contact between the rotor journal
and the pad during turbine start-up and shutdown.

The bearing width-diameter ratio B/DN ≈ 0.47, where, B is the width of the pad, DN is
the nominal diameter of the bearing.

The actual measurements of the external diameter and thickness W1 of the bearing ring
as well as the pad thickness WZ are marked at the place “K” showed in figure. The
bearing pad clearance can be calculated with following formula:

S2＝DA-2（W1＋W2）-d where, DA—bore diameter of bearing housing;

d – diameter of rotor journal

The value S2 for the front and rear bearing housings is indicated in details A1…Z1 and
A3…Z3 or A4…Z4, respectively.

The minimum clearance ratio of the bearing pad clearance is S2min/ DN, for the bearing
DN100, 125 and 160, it is 1.5‰, for DN200 and 250, it is 1.2‰.

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 Operating Instructions
Rear Support 1-0750-04-01

Rear Support
The support, which is rigidly bolted to the turbine foundation, serves for sustaining the
turbine casing and rotor and for their alignment relative to each other, as the reference
point of the turbine thermal expansion as well.

The rear support consists of the sole plate, rear bearing housing and relevant connectors.
The Fig.1 shows the rear support for condensing turbine.

1. Exhaust casing
2. Rear bearing housing
3. Guide lug of Exhaust
casing
4. Adjusting element
5. Vertical key of casing
6. Positioning pin (block)
7. Sole Plate
8. Supporting bracket of
exhaust casing

Fig. 1 Rear support for condensing turbine

For the structure, the mounting and adjusting requirements of the rear support, please
refer to the turbine body drawing (2-8250-00xx-00) and the details A4-Z4
(0-2011-4xxx-xx) in attached document.

Two sole plates symmetrical axially are rigidly bolted to the turbine foundation.
the casing is supported on the sole plates with the aid of the supporting brackets and
jointed to the plates with the distant screw (9), as showed in Fig.2. There are 8 groups of
adjusting plates (11) made up in thickness fitted between them. A sufficient clearance is
kept between the screw and the hole of the supporting bracket. At the meantime, a
defined clearance S is also kept between the screw and the washer (10) in vertical
direction. During turbine normal operation, the value S should be always larger than 0,
in other words the washer should be under a loose state so that the casing expands
freely.

The positioning block (6), used for positioning the exhaust casing axially, is located on
the axial centerline of the supporting bracket as showed in Fig.1. The crossing point of t
this center line and the turbine axial line form the reference point of the turbine thermal
expansion, or dead point. Fig2. shows the actual structure of the item (6). The

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 Operating Instructions
Rear Support 1-0750-04-01
positioning block (6-4), on which the making up guide key (6-3) is fixed, is bolted on
the sole plate. One end of the Z-shaped safeguard (6-1) is fixed on the supporting
bracket with the screw, the other end is connected to the bolt (6-2) with point-welding
for preventing the bolt (6-2) loose. The working surfaces (contacted with the supporting
bracket) of the guide key and the adjusting plate are painted with the special lubricating
film to reduce the sliding resistance of the casing when expanding.

6-1 Safeguard, screw, gasket 6-2 Bolt

6-3 Guide Key 6-4 Positioning block
9. Distant screw 10. Washer
11. Adjusting plate
Fig.2

The positioning of the lateral center for the exhaust casing is related to the arrangement
of the vertical key. When the turbine is mounted on the concrete foundation, the vertical
key is embedded in the foundation or fixed on the vertical key bottom plate embedded
in the foundation. In order to facilitate the field installation and adjustment, the
adjusting element showed in Fig.1 is generally used for positioning the casing (also
refer to Fig.5 and Fig.6). It is similar to the front support, please refer to the description
in “Front Support”.

12. Screw, gasket 13. Press plate 14. Guide key

Fig.3

When turbine is delivered integrally with the steel base plate, the vertical key is fixed on
the base plate. In this case, the structure showed in Fig.3 is often used. A longitudinal
keyway is machined on the guide lug of the exhaust casing. In assembling the lateral

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 Operating Instructions
Rear Support 1-0750-04-01
alignment of the casing is ensured through making up the thickness of the guide key
(14). During turbine operation the casing can expands in axial and longitudinal
directions without changing its center. The working surfaces of the guide key are
painted with the special lubricating film to reduce the sliding resistance when the casing
expands.

15. Locking Washer 18. Bolt

16. Nut 19. Eccentric guide stem
17. Safeguard 20. Adjusting element
Fig.4

21. Spherical washer 24. Press cover

22. Thread seat 25. Locking piece
23. Bolt 26. Steel wire
Fig.5

There are two forms of rear bearing housing. One is showed in Fig.1, the lower half of
the bearing housing is a separated component. The other is showed in Fig.7, the lower
half of the bearing housing is cast integrally with the exhaust casing bottom half. When
the former form is used, the assembling relationship between the bearing housing and
the exhaust casing is showed in Fig.4 and Fig.5. The adjusting element (20) fitted on the
mounting face of the exhaust casing bottom half is serves not only for supporting the

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 Operating Instructions
Rear Support 1-0750-04-01
bearing housing but also for adjusting the its height. The axial position of the bearing
housing is adjusted with the eccentric guide stem (19), whose rabbet is inserted in the
lateral groove on the mounting face of the exhaust casing. The bearing housing is fixed
to the exhaust casing with items (15 to 18).

The adjustment and position of the lateral center for the rear bearing housing are similar
to that of the front bearing housing. The structure showed in Fig. 5 or Fig.6 can be used.
No matter which structure is used, the value S indicated in details A4-Z4 is the total
clearance for both sides.

27. Spherical washer 28. Retainer

Fig.6

The bearing housing consists of the upper and lower halves, which are jointed with
the bolts and positioned with the taper pin, including the radial bearing, bearing seal
ring and relevant connectors. The upper half of the bearing housing is also used as
the bearing press cover.

As required, the turbine may equipped with various forms of barring gear, which is
accommodated in the rear bearing housing no matter which form is adopted.

The sensors for monitoring shaft vibration, bearing pad temperature, turbine speed and
key-phase or temperature gauge for measuring the oil temperature are also fitted in
the rear bearing housing based on the user’s requirement.

The lubricating oil enters into the bearing housing from its left side, from there it is
supplied to the bearing through an inner pipe. When the jacking system is used, the
jacking oil enters into the bearing housing from its end face. For the turbine with he oil
turbine barring gear, the working oil of the oil turbine is supplied from the right side of
the bearing housing . The return oil outlet of the bearing housing is located at the
bottom of its lower half.

The bearing housing is made from QT400-15.

The lower half of the bearing housing is cast integrally with the exhaust casing bottom

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 Operating Instructions
Rear Support 1-0750-04-01
half, as showed in Fig.7.

1. Exhaust casing, top

2. Bearing seal ring
3. Bearing housing, upper
4. Rear radial bearing
5. Turbine rotor
6. Return oil pipe
7. Exhaust casing, bottom
8. Lubricating oil inlet
9. Guide lug of exhaust casing

Fig.7

The jointing and positioning between the exhaust casing and the pedestal is the same as
mentioned above. Owing to that the exhaust casing bottom half and the bearing housing
is an integral component, there is neither connector nor adjusting element between them.
Concentricity of the bearing housing with the casing is ensured through machining.
With this structure the bearing housing can accommodate various barring gears except
for the oil turbine barring gear. The lubricating oil entered from the rear end face of the
bearing housing is supplied to the bearing through the oil inlet pipe (8). The throttle
valve for the lubricating oil is fitted in the bearing housing too. The return oil outlet is
located on either right or left side according to the oil piping layout.

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 Operating Instructions
Bearing Seal Ring 1-0760-01-01

Bearing Seal Ring

The bearing seal ring, which is fitted at the front and rear bearing housing end near to
the casing, is functioned for preventing the splashing oil inside the bearing housing
from flowing out along the shaft and the leakage steam from the gland bush against
entering the bearing housing.

1. Bearing housing
2. Grub screw
3. Heat protection shield
4. Bearing seal ring, upper half
5. Seal strips
6. Bearing seal ring, lower half
7. Oil-train hole
8. Radial bearing
9. Sealing edge

The bearing seal ring is split into two halves (4 and 6), which are mounted in the upper
and lower halves of the bearing housing respectively. As showed in the figure below, the
upper half of the bearing seal ring is suspended in the bearing housing upper half with
the grub screw (2). The sealing strips (5) caulked in the inner circle of the bearing seal
ring, together with the sealing edge (9) on rotor shaft, prevent leakage of the lubricating
oil to the outside. The oil trapped by the sealing strips flows back into the bearing
housing through the drain hole (7) drilled in the lower half of the bearing seal ring. In
order to achieve the good sealing, the radial clearance between the sealing strips and the
rotor should be smaller than the bearing clearance. But it must be ensured that the rotor
is supported by the radial bearing other than seated on the sealing strips. Therefore, the
seal strips at the lower half may be trimmed if necessary, making the radial clearance
between the seal strips and the rotor at the lowest point ≥0. Owing to seal strips made
of commercially pure aluminium, the rotor will not be damaged even the strips contact
the rotor shaft. A shield (2) is mounted on the bearing seal ring at the side adjacent to
the casing so as to protect the bearing housing against excessive heat transfer.

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 Operating Instructions
Control Valve 1-0800-01-01

Control Valve
The control valve functions for regulating the steam flow based on the command from
the control unit to make the controlled parameters (output or speed , inlet steam pressure,
back pressure and etc.) of the turbine meet the operation requirement. Fig.1 shows the
structure of the control valve.

1. Lever 6. Valve cone 11. Bracket

2. Link 7. Bush 12. Upper guide bush
3. Cover 8. Valve seat 13. Support
4. Admission chest of casing 9. Valve spindle 14. Spring element
5. Valve beam 10. Lower guide bush 15. Oil relay
Fig. 1

The control valve consists of three main sections, the governing valve-- valve spindle,
valve beam, valve cone and valve seat, the operating mechanism-- support and lever, the
oil relay (refer to 1-1900-01-xx).

Based on the structure of the turbine casing and the requirement of the running
condition, one turbine may be equipped with 5 or 4 governing valves showed in Fig.2.

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 Operating Instructions
Control Valve 1-0800-01-01
In general, the fifth valve (it is fifth in the opening order and located in the middle) is an
inner by-pass governing valve. But in the turbine with the integral inner casing or 360°
nozzle chamber, the fifth valve is nozzle governing valve. The other 4 valves are nozzle
governing valves.

Fig.2 shows assembling of the governing valve schematically. The valve cone bolt (16)
is screwed in the valve cone (6) to the desired tightening moment and locked with taper
pin (17) (for the tightening moment, see the enclosed table below). The end of the pin
hole is flanged and riveted. The opening order and travel of each valve are determined
by the length S of the bush (7). h in the fig.2 means the valve idle travel. For the first
valve, h=2. The valve seat (8) is mounted in the bottom of the admission chest.

16. Valve cone bolt 17. Taper pin

Fig. 2

The admission chest showed in Fig.1 is adopted in most of the turbines. In this case, the
valve cones and the valve beam are mounted into the admission chest from its side after
they are assembled together. The valve beam is suspended in the seam chamber via two
valve spindles (9). The lower end of the valve spindle is shaped into the rabbet of
inverted-T. The rabbet is penetrated the hole in the valve beam and turned by 90 degrees,
so that the valve beam is seized. The valve cone is freely suspended in the valve beam
with the aid of the valve cone bolt. As long as the turbine remains at standstill, the valve
cone is seated upon its valve seat. When opening the valve, the valve beam is lifted by
the valve spindles and after the bush contacted to the valve cone bolt the valve cone will
thus be opened. The cover (3) is mounted at the place where the spindle penetrates
the admission chest. The guide bushes (10 and 12) are fitted at the upper and lower ends
of the cover, between them the seal ring made of flexible graphite is filled. In order to
eliminate the steam leaking around the valve spindle, tighten the press nut on the cover
to increase the tightening force on the seal ring, if necessary.

In some of the turbines the valve spindle packing showed in Fig.3 is used. The leakage

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 Operating Instructions
Control Valve 1-0800-01-01
steam is led to the leakage steam piping through port K (refer to the drawing “P & I
steam and drainage” 0-0642-T.Nr-00 for details). The upper part of the cover with the
seal ring made of flexible graphite and the press nut element is same as that showed in
Fig.1. The nut thread should be protruded from the cover by about 5mm after the seal
ring assembled.

1. Sleeve
2. Bush
3. Bush
4. Seal ring made of flexible
graphite
5. Press nut element

Fig. 3

In the turbines with lower inlet steam parameter, the admission chest is slightly different
to that showed in Fig.1. In this case, the top of the admission chest is opened so as to
facilitate the mounting of the valve beam. The elliptical-shaped opening is covered with
the flat cover of the steam chamber. The valve spindle guide and sealing element are
mounted in the cover.

The support (13) is mounted on the casing top and positioned with the cylindrical pin.
The revolution axis of the support is severed as a pivot point for the lever (1). The one
end of the lever is connected with the valve spindle via the link (2), the other end is
hinged with the joint bearing at the top end of the oil relay connecting rod. When the oil
relay travels the valve beam will be lifted or lowered with the synchronization action of
two valve spindles.

The spring (14) is used against the steam force on the valve spindle and for supplying
sufficient closing force for the valve at the same time.

The bracket (11) used for supporting the oil relay (15) is mounted on the front end face
of the top casing. The oil relay is jointed to the bracket with the joint bearing and pin.
Therefore, the oil relay will swing in a narrow range around the pin during operation.

In order to eliminate the external force and moment that act on the oil relay and disturb
its normal operation, 2 or 3 groups of disk springs are fitted between the oil relay and
the bracket as required. Two groups of disk springs are adjusted according with the

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 Operating Instructions
Control Valve 1-0800-01-01
following method and requirement. Loose the closing spring ( for the control valve
1-0801-, it is unnecessary), disconnect the lever and the oil relay. As the travel of the oil
relay connected with the oil piping is at 0 (upper dead point, secondary pressure P2＝
0.15Mpa), adjust the pre-tightening for the springs to make the oil cylinder vertical in X
direction. This will reduce the wear of the piston rod and prolong their service life.
The disk spring element on the side of the oil cylinder functions to buffer the swing of
the oil cylinder, making the cylinder swing smoothly. When adjusting, make
the cylinder vertical in Y direction and the pre-tightening lengths of the disk springs on
both sides of the bracket equal ( the mounting method and the number of the spring on
both sides are the same, the pre-pressed length should be maintained at factory-adjusted
valve). After the disk spring adjusted, connected the lever to the oil relay and return
the closing spring to original state.

The scale plate mounted on the side of the oil cylinder indicates the travel of the control
valve.

⎠ Caution: The piston rod of the oil relay can only be connected to the lever

when the following requirements are met for avoiding the valve
spindle pressed and bended. The piston of the oil relay should be
at position 0 (upper dead point) and the valve beam does not
contact to the valve cone with a minimum distance of 2 mm (see
Fig.2). The 0 position is indicated on the scale plate.

The first valve adopts the tapered valve cone for increasing the stability the turbine test
running and non-loaded operation of the turbo-generator (for individual turbine,
the second valve adopts the tapered cone too). The others are ball valve. In order to
improve the stress of the casing and the blades of the control stage, the second valve is
pre-opened and has a larger overlap with the first valve.

For the valve opening order , valve travel and flow of the control valve, refer to the
attached document “Characteristic line of control valve” 0-2505-T.Nr-00.

The spare part of the seal element for the valve spindle is supplied with the turbine set
(see “Spare parts list” for details). It can be changed if required.

“Mounting tool for valve beam” 2-8821-9005-xx supplied with the turbine set (only
supplied for the control valve larger than N40 or H32) is used to mount the valve beam
assembly into or dismount it from the admission chest from the casing side opening. For
the turbine with one emergency stop valve, the valve beam is mounted into or
dismounted from the opening located one side of the flange cover. For the turbine with
two emergency stop valves, when dismount the valve beam dismount one emergency
stop valve and valve seat, then take the valve beam assembly out with the mount

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 Operating Instructions
Control Valve 1-0800-01-01
tool. “Guide bush” 3-2182-3190-xx and “Tamping hammer” 2-8820-9001-xx are special
tool for filling the seal element for valve spindle.

Table: Tightening moment for valve cone bolt

Valve size N25 N32 N40 N50 N63
M M20 M24 M27 M33 M39
Minimum tightening
85 140 200 350 550
moment Nm

Valve size H25 H32 H40 H50

M M20 M24 M24 M27 M27 M33 M33 M39
Minimum tightening
85 140 140 200 200 350 250 550
moment Nm
Note: the valve size is correspondence with the front sector size of the outer casing (see
0-0200-02-00 for details).

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 Operating Instructions
Control Valve 1-0801-01-01

Control Valve
The control valve functions for changing the steam flow entering the turbine second or
third expansion zone based on the command from the control unit to make the turbine
output and extraction steam flow meet the operation requirement. Fig.1 shows the
structure of the control valve.

1. Lever 9. Valve spindle 18. Spring cap

2. Oil relay 10. Guide bush 19. Spring
3. Bracket 11. Sleeve 20. Turnbuckle
4. Bush 12. Seal ring 21. Rod
5. Valve cone 13. Valve cover 22. Bridge
6. Valve housing 14. Guide bush 23. Knuckle bearing
7. Valve seat 15. Stuffing nut
8. Drilled hole for cooling 16. Threaded spindle
steam 17. Washer
Fig. 1

The control valve is a pressure relief single-seated valve. The valve housing (6) is
closed at its top end with the valve cover (13) which serves by the inserted bushes (10
and 12) and a group of seal ring made of flexible graphite as guide and seal for the
valve spindle (9). The stuffing nut (15) can be adjusted to eliminate the steam leakage
around the spindle, when necessary. The valve cone (5) connected to the lower end of
the valve spindle will slide in the bush (4) fitted in the valve cover with the valve
spindle travels. The valve cone is drilled with a number of holes (8) for cooling steam,
through which a certain amount of steam will be admitted to the succeeding expansion

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 Operating Instructions
Control Valve 1-0801-01-01
zone even under the valve closed, thus safeguarding that zone against excessive heating.
For the turbine that the leakage steam flow at the middle gland bush is larger than
the required cooling steam flow, there is no cooling hole on the valve cone.

The valve seat (7) is installed in the lower part of the valve housing. The valve cone is
pressed upon its valve seat by the force of the spring (19) via the spring cap (18),
Washer (17) and valve spindle. The one end of the lever (1) is connected with the piston
rod of the oil relay, while the other end is connected with the valve spindle via
the knuckle bearing (23), rod (21) and turnbuckle (20), so that when the oil relay moves
upon an appropriate control signal given by the control unit the valve cone will move
correspondingly.

For the oil relay (2), refer to description in 1-1910-01-.

There are two groups of disk spring fitted between the oil relay and the bracket. For the
function and adjustment of the disk spring, refer to relevant description in “Control
Valve” 1-0800-xx-xx.

⎠ Caution: After turbine installed or overhauled, the connected dimension

between the valve and the oil relay should be checked whether
the idle travel of the valve meets the requirement before
operating the turbine. When the secondary oil pressure
P2ND=0.15MPa and the piston of the oil relay is at its upper limit
under valve close state, the gap S between the rod (21) and
the nut at the top end of the turnbuckle means the required
value of the idle travel (see 0-2505-T.Nr-01). For this purpose the
knuckle bearing at the rod end can be adjusted, when necessary.

There are three different valve housing according with the casing structure and
the turbine layout. One is that the valve housing is cast with the casing integrally,
the other is that the control valve has separated valve housing and the outlet flange of
the valve housing is connected to the casing., the third one is that the control valve is
separately arranged with the turbine and the inlet and outlet of the valve housing are
connected to the casing via piping by flanged or welding. No matter which valve
housing is used, the valve structure is similar to that showed in Fig.1.

Fig.2 and Fig.3 also show the typical structure used in some turbines.

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 Operating Instructions
Control Valve 1-0801-01-01

24. Bush 27. Adjusting gasket 30. Drilled hole for pressure
25. Disk spring 28. Nut relief
26. Spring cap 29. Nut
Fig. 2

Fig. 3

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 Operating Instructions
Oil Relay 1-1910-01-01

Oil Relay
The oil relay serves as an actuator for the control valve. It coverts the secondary oil
signal from the amplifier or electro-hydraulic converter into stroke output with enough
working capacity for operating the control valve and controlling the steam admitted into
the turbine.

The oil relay is a cut-off, double-action reciprocating oil relay, as showed in Fig.1.It
uses the turbine oil at a pressure about 0.8 Mpa as its working medium.

1. Pull-rod
2. Adjusting screw
3. Reset bar
4. Piston rod
5. Oil cylinder
(Cover)
6. Piston
7. Connection piece
8. Pilot valve
9. Feed-back lever
10. Adjusting screw
11. Adjusting nut
12. Bell-crank lever
13. Eyebolt joint head

Fig.1 Oil Relay

The oil relay mainly consists of the oil cylinder, the pilot valve, the connection piece
and the feed-back mechanism.

The pilot valve (8) is connected to the oil cylinder (5) via the connection piece (7)
which connects the oil passages between them. At the oil connections the O-rings are

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 Operating Instructions
Oil Relay 1-1910-01-01
fitted. The cast or forged connection piece are available and the cast one is showed in
Fig.1.

The oil cylinder consists of the base, the cylinder body, the cover, the piston and the
piston rod, which are assembled together with four long bolts. The O-rings are fitted
between the cylinder body and the base and between the cylinder body and the cover.
The special piston ring made of Teflon .is fitted on the piston There is a damping zone
about 10 mm near the top stop for reducing the inertia and the load forces and the
velocity of the piston when it moving. The sealing element is fitted in the cover. On the
topping of the cover the guide rail for the piston rod and the support for the bell-crank
lever are mounted.

The oil cylinder is supported on the bracket via two eyes on the bottom of the base by
connecting to the joint bearing and axle. The pull-rod (4) and the eyebolt joint head (13)
are connected to the top end of the piston rod (4). The piston rod is linked with the
control valve lever through the eyebolt joint head (13).

The pilot valve is showed in Fig.2

The sleeves (25, 26 and 27) are contained in the housing of the pilot valve (8). The up
and the low sleeves (25 and 27) are secured in the housing with the screws at the
juncture, while the middle sleeve (26) is secured with the taper pin made-up during
assembling.

The compartments in the sleeve and the housing forms five oil passages with different
functions, as illustrated in the Fig.1. The oil passage at the middle is for connecting to
the working oil, the two adjacent to it are connected up to the top and bottom of the
piston of the oil relay. The two at the most outside are for oil relay draining. During
working, the oil flow is controlled by the slide piston, which is a assembly of slide-piton
body (17) and the wheel disc (16). Under the steady condition, the force acting on the
slide-piston bottom face by the secondary oil is balanced with the force acting on its top
by the spring (14), bring the slide piston to be at the middle and the collar on the slide
piston just close the oil passages in the middle sleeve. Both of the in- and out-oil
passages of the oil-relay cylinder are blocked, so that the oil-relay piston has no motion
and the opening of the control valve remains unchanged. If the working condition
changes, for example, the instant speed decrease of the turbine brings about an increase
of the secondary oil pressure. The force change on the slide piston makes it move
downwards. Thus, the oil passage to the space above the oil-relay piston is opened and
the working oil is enabled to flow into it. At the same time, the below space of the
oil-relay piston is connected to the oil drain, the oil in the space below the piston is
drained. The down movement of the piston makes the opening of the control valve
increased, resulting in the increase of the steam entering the turbine and the raise of the
turbine speed at last. In the meantime, by means of the reset bar (3), the bell-crank
lever(12) and the feed back lever (9), the spring force of the slide piston is increased

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 Operating Instructions
Oil Relay 1-1910-01-01
with down movement of the oil-relay piston. Once the secondary oil pressure acting on
the slide piston has been balanced with the spring force again, the slide piston returns to
its neutral position and consequently the opening of the control valve reaches to a new
position. Thus the turbine operates stably under a new working condition. When
the secondary oil pressure decreased, the actions take place in an opposite steps as
mentioned above.

14. Spring
15. Axial thrust bearing
16. Wheel disc
17. Slide-piston body
18. Drain hole
19. Throttle valve for vibration
20. Small drilled hole
21. Throttle valve for rotation
22. Inlet of jetting oil
23. Aluminum insert
24. Jetting-oil hole
25. Up sleeve
26. Middle sleeve
27. Low sleeve

C Secondary oil
P Working oil
T Oil drain

Fig. 2 Pilot valve

In order to increase the reacting sensitivity of the oil relay, the special pilot valve which
makes the slide piston rotate and vibrate is adopted in the oil relay. Therefore, the oil
pocket and passages are machined in the slide piston, which is formed with slide-piston
body and the wheel disc. At the up end of the wheel disc a thrust bearing is fitted tightly.

The wheel disc is illustrated in Fig.3. The pressure oil enters into the cavity of the
hollow slide piston through jetting oil inlet (22). From where it passes to three drilled
radial and tangential jetting-oil holes from which it escapes. The permanent flow of the
oil leaving the wheel disc tangentially imparts a continuous rotational motion to the
slide piston. The throttle valve (21) allows adjustment of the speed for the slide piston
by adjusting the oil flow. The recommend speed is 300-800 r/min (using higher speed

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 Operating Instructions
Oil Relay 1-1910-01-01
for smaller piston). The speed can measured in the aluminum insert (23). Generally, it
can be estimated by experience or viewed from the vent port on the cover.

The secondary oil pressure acting on its underside

imparts a constant axial motion to the slide piston. This
is achieved by a small hole drilled into the lower part of
the slide piston. During every complete revolution of the
slide piston, this hole momentarily overlaps the drain
hole (18) in the housing. The quantity of secondary oil is
thus allowed to escape causes a small pressure drop in
the secondary oil circuit making the slide piston to move
downwards by a small amount. When the hole is
covered again the piston is lifted until the next overlap.
During each of the movements by the slide piston,
Fig. 3
minute volume of the working oil flows to the oil-relay
piston. This results in slight vibration of the spindle of the control valve, thereby
ensuring immediate response to the control signal from the governing system. The
vibration stroke of the slide piston can be adjusted by means of the throttle valve (19)
and measured indirectly through the vibration stroke of the piston rod of the oil relay.
Usually, the vibration stroke of the piston rod is controlled within 0.2-0.3 mm.

The housing of the pilot valve is connected to the up and low covers with bolts at two
ends. At the joint face between them the O-ring is fitted (or coated with sealant) against
oil leakage.

The working oil and the secondary oil enter into the pilot valve through the connections
P and C at the side of the housing. the drain oil of the oil relay drains to the oil drain
piping through the connection T at the low cover ( at the bottom or side) of the pilot
valve. A metallic hose is fitted in the drain oil piping because of the flexible connection
between the oil relay and the bracket.

The change range of the secondary oil entering into the oil relay is 0.15-0.45 Mpa. The
relationship of the secondary oil pressure P2 to the stroke hZ of the piston rod is
determined by the profile of the reset bar (the track of the roller bearing on the
bell-crank lever on the reset bar). Based on the characteristics of the control valve, two
profiles are available, linear or special curve. In a certain profile, the P2－hZ relationship
can be adjusted by changing the mounting angle of the reset bar with the adjusting
screw (2). But it should be noticed that the change of the mounting angle for the reset
bar will change the initial value of the action for the oil-relay piston. It is usually
adjusted with the adjusting screw at the top of the pilot valve and also can be adjusted
by means of the adjusting nut (11) (the adjusting nut has opposite threads at its two
ends).

Six normal diameters of the oil cylinder are available, they are 100, 125, 160, 200, 250

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 Operating Instructions
Oil Relay 1-1910-01-01
and 320. There are six pilot valves with different slide-piston diameters, they are 16, 22,
32, 45, 60 and 90. The different oil cylinder and pilot valve can be used together based
on the turbine characteristics.

For the pilot valve ＜45 the housing and cover is made of a forge piece, while ≥45
the aluminium cast are used. When the pilot valve 90 is used, two follow-up piston
should be used in the amplifier to match with it.

Please refer to the attached document 0-2505-T.Nr-xx for the relationship of

the secondary oil pressure to the stroke of the piston rod of the oil relay. The test data
measured in the workshop is recorded in the Product Certificate.

Hangzhou Steam Turbine Company Limited Page 5 of 5

 Operating Instructions
Emergency Governor 1-2110-01-01

Emergency Governor
The emergency governor is a mechanical protection equipment of the turbine. It will
close the emergency stop valve and control valve via the emergency trip gear when the
turbine speed rose to the set tripping speed.

1. Eccentric bolt 5. Compression spring 9. Screw plug

2. Guide ring 6. Guide ring 10. Headless screw
3. Guide bush 7. Counterweight screw
4. Guide bush 8. Threaded cap

Usually, the emergency governor is fitted in the turbine rotor at the section located in
the front bearing housing, as showed in figure above. The guide ring (2) is fitted in
suitably machined bore in the rotor and pressed by the compression spring (5), which
presses the shoulder of the eccentric bolt (1) with other end. The supporting surface of
the eccentric bolt is against the positioning surface of the guide ring (6) that is pressed
on the positioning surface in the bore by the threaded cap (8) tightly. The threaded cap
and the screw plug (9) are locked with the headless screws (10). The counterweight
screw (7) is screwed in the hole of the eccentric bolt. If reducing the its length (cut it at
the end with groove), the action speed of the emergency governor will be increased. In
the guide rings the guide bushed (3 and 7) made of Teflon is fitted , which are used for
positioning and guiding the eccentric bolt and reducing the friction resistance when it
acts.

An eccentricity exists between the centroid of the eccentric bolt with

the counterweight screw, so when the rotor rotating, the eccentric bolt will produce a
centrifugal force. Since the spring force is always larger than the centrifugal force of

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 Operating Instructions
Emergency Governor 1-2110-01-01
the eccentric bolt within the operating speed range, the eccentric bolt remains at its
mounted position and does not move. Whenever the turbine speed is about to exceed
the set trip speed, the centrifugal force of the eccentric bolt overcomes the spring force,
diving the eccentric bolt in outward direction. The centrifugal force will increase steeply
with the increase of the eccentricity. Thereby the eccentric bolt moves out of the rotor
(stroke H) and strikes the pawl of the emergency trip gear. This triggers the
emergency trip gear to close the emergency stop valve and the control valve.

The reset speed (the speed at which the eccentric bolt return to its mounted position) of
the emergency governor for 3-series turbine is higher than the rated speed, so
the emergency trip gear can be reset when turbine speed dropped to the rated
speed, restarting the turbine.

The setpoint of the trip speed for the emergency governor is given in the technical data
section 0-0300-T.Nr.-xx of the Operating Instructions.

The action speed of the emergency governor when testing in the workshop of
the manufacturer is recorded in the “Report of Dynamic Balance and overspeed test for
Rotor” and the “No-load Test Report” of the Product Certificate.

When examining and repairing the emergency governor, use the attached tool
“Tow-hole Nut Driver” No.2-8811-0002-xx to mount or dismount the threaded cap. To
mount or dismount the counterweight screw, turn out the screw plug, turn in
the attached tool “Adjusting Bolt” No.2-7760-0001-xx to fit its taper end tightly against
the tapered hole in the eccentric bolt. In this way, the rotation of the eccentric bolt can
be prevented when the screw turned.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Emergency Trip Gear 1-2200-02-01

Emergency Trip Gear

The mechanical-hydraulic emergency trip gear is one of the protective devices in
the turbine. If during turbine operation a disturbance happens to occur, it serves for
draining the trip oil to close the emergency stop valve and the control valve, resulting in
the turbine tripped immediately.

1. Hand lever 8. Sleeve 15. Pawl

2. Sleeve 9. Piston 16. Tripping lever
3. Control collar 10. Front bearing housing P Pressure oil
4. Slide valve 11. Bracket E Trip oil
5. Control collar 12. Housing H Test oil or switch oil
6. Control collar 13. Throttle orifice T Oil drain
7. Spring 14. Rotor
Fig. 1
The emergency trip gear showed in the picture above is used in the turbine with
the front bearing housing ≥32#.

The housing (12) of the emergency trip gear is bolted to the bracket (11), which is fixed
on the front bearing housing and positioned with the taper pins. Two sleeves (2 and 8)
are inserted into the housing and serves as the guides for the slide valve (4) that is
movable in the axial direction. The control collars (5 and 6) on the slide valve and
the seating surfaces of the sleeves (2and 8) form the oil-tight seals and limit

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 Operating Instructions
Emergency Trip Gear 1-2200-02-01
the movement of the slide valve. The left end of the slide valve is machined into a tenon,
which is inserted in the groove of the tripping lever (16) and hinged with it using the pin.
The right end of the slide valve is fitted with the piston (9).

During the normal operation of emergency trip gear (as showed in picture above),
the pressure oil serving as the trip oil is admitted to the emergency trip gear through
the connection P and the throttle orifice (13). Since the control collar (3) has a smaller
area than the collar (6), the force of the oil pressure is able to overcome the force of
the spring (7) and will press the collar (6) against the seal face of the sleeve (8).
Therefore, the trip oil under the normal pressure will flow to the trip-oil circuit via
connection E.

When the following conditions occur or operating the emergency trip gear, the slide
valve will move and drain the trip oil:

1. When the turbine speed exceeds the setpoint of the trip speed, the eccentric bolt in
the emergency governor moves out of the rotor and strikes the pawl (15) jointed
with tripping lever (16), pulling the slide valve (4) to the left and separating
the collar (6) from the seal face of the sleeve (8). At the same time, the collar (5) is
pressed onto the sleeve (2) by the spring force, thus the oil passage P-E is blocked
and the oil passage E-T opened, draining the trip oil to the bearing housing.
2. When the axial displacement of the turbine rotor is ≥1mm, the cam on the rotor
strikes the pawl (15). The same action mentioned above occurs.
3. Pushing down the hand lever (1) will swing the tripping lever counterclockwise and
move the slide valve to the left. The oil passages are transferred as the same
mentioned above.
4. When the trip-oil pressure is ≤0.28Mpa, the oil pressure acting on the slide valve
will be inadequate for overcoming the spring force, thus the slide valve is pushed to
the left, draining the trip oil.

After the normal operation of the oil-supply system in turbine start-up reset
the emergency trip gear through pulling up the hand lever by hand, resulting in the slide
valve to move left and oil passage E-T closed. Release it after the trip-oil pressure
established. The emergency trip gear also can be reset automatically and remotely. With
the auto reset, the “reset oil” is led into the emergency trip gear through connection H.
The oil pressure acting on the piston (9) overcomes the spring force, moving the slide
valve to its working position as shown in picture. But it has to be noted that the “reset
oil” must be drained after the trip-oil pressure set-up. Otherwise, it will disturb
the normal function of the emergency trip gear.

Normally, the emergency stop valve will be opened within 1 minute when the oil
pressure is ≥0.7Mpa. The throttle orifice (13) fitted in the trip gear satisfies this
requirement and ensures the trip gear to trip quickly at the same time. Attention:
enlarge the orifice at will makes the quick-trip function of the trip gear lost and

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 Operating Instructions
Emergency Trip Gear 1-2200-02-01
consequently endangers the safety operation of the turbine.

Based on different turbine installations, the corresponding emergency trip gears with
different functions are available.

When a Auxiliary slide valve is used in the governing system (refer to 1-12242-),
the emergency trip valve has no throttle orifice in it.

When a test slide valve is used in the governing system (refer to 1-2810-), “test oil” is
connected to the connection H. If either “test oil” nor “reset oil is used in the turbine,
the connection H is blocked with a screw plug.

If a non-contact position switch is mounted on the cover at the housing right side,
the emergency trip gear is able to send out signal indicating its state.

To monitor the axial displacement of the rotor, a displacement transducer can be fitted
on the ribbed plate of the bracket (11).

In some turbine installations, the emergency trip gear is mounted on the side of
the bearing housing as shown in Fig.2. Its structure and functions are same as
mentioned above, except for the mount position.

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 Operating Instructions
Emergency Trip Gear 1-2200-02-01

1. Hand lever 7. Spring 13. Sleeve

2. Slide valve 8. Piston 14. Tripping lever
3. Throttle orifice 9. Housing 15. Rotor
4. Control collar 10. Bracket 16. bearing housing
5. Control collar 11. Sleeve seal face
6. Sleeve 12. Sleeve seal face
Fig. 2

Hangzhou Steam Turbine Company Limited Page 4 of 4

Operating manual Solenoid Valve 1-2222-01-01

Solenoid Valve

Function

Two position Three way solenoid valve is mounted on the pressure oil pipe,

which is into the emergency system. It is able to cut off the pressure oil that is into

the emergency safety device, also result in the reaction of the emergency safety

device to make the trip oil discharge and make the trip valve shut down rapidly at

last.

The solenoid valve is controlled by the central control room or some protect

device (according to the actual need the solenoid valve is interlocked with the

protective physical value, which is converted into the electrical signal by the real

protect device).

Structure and Function Principle

Because the solenoid valve is the purchasing part, the detailed introduction is

referred to the relative manual provided by the solenoid valve manufacturer.

Hangzhou Steam Turbine Company Limited Page 1 of 1

 Operating Instructions
Emergency Stop Valve 1-2300-02-01

Emergency Stop Valve

The emergency stop valve is the fundamental shut-off organ between the live-steam line
and the turbine. Under an emergency condition, it cuts off the steam supply to the
turbine immediately, resulting in the turbine shutdown quickly. It will be in the closed
position when the turbine is at standstill and in the fully opened position during turbine
start-up and normal operation.

The emergency stop valve is mounted horizontally on the admission chest of the casing.
The housing of the emergency stop valve is integrated with the admission chest of the
turbine casing, so the emergency stop valve has no independent valve housing. One
turbine may be equipped with one or two emergency stop valves based on the volume
flow of the live steam admitted to it.

The emergency stop valve mainly consists of three sections, steam section, hydraulic
section and connection part, as showed in Fig.1.

1. Valve cone 12. Piston rod 22. Seal ring

2. Relief cone 13. Connection part 23. Valve seat
3. Steam strainer 14. Pressure gauge
4. Guide and labyrinth bush connection D Live-steam inlet
5. Valve cover 15. Test piston E Trip oil
6. Bolt 16. Piston F Starting oil
7. Segment ring 17. Spring H Test oil
8. Press ring 18. Spring cap K Leak-steam drain
9. Valve spindle 19. Piston disc T1 Oil drain
10. Heat shield 20. Oil cylinder T2 Leak-oil drain
11. Oil-retaining cone 21. Flexible joint
Fig. 1 Emergency stop valve

The steam section mainly consists of items 1 to 9 and item23.

Hangzhou Steam Turbine Company Limited Page 1 of 4

 Operating Instructions
Emergency Stop Valve 1-2300-02-01
Before the emergency stop valve opens, the live steam, after having passed the steam
strainer (3), arrives to the compartment before the valve cone (1). The valve cone is
pressed on the valve seat (23) under the steam force and the spring force (17), blocking
the live steam to the turbine. The relief cone (2) is provided in the valve cone, which
helps in reducing the actuating forces when the emergency stop valve is being opened,
because it tends to balance the pressure differential existing between the upstream and
downstream sides of the valve cone.

Most of the steam strainers used in the emergency stop valve are made of corrugated
stainless steel band through winding. But the welded steam strainer made of stainless
steel band with holes is also used in some of the turbines.

In order to eliminate the steam leaking out, a corresponding sealing is adopted between
the moving and stationary sections of the valve. The segment ring (7) cut in 4 pieces is
flush-mounted in the admission chest, the seal ring (22) is pressed by the valve cover (5)
and contacted tightly to the inner wall of the admission chest under the action of the bolt
(6) via the press ring (8) and the segment ring. This structure will have self-sealing
function under the steam pressure. In this way, the steam leakage from the stationary
part is eliminated. During the emergency stop valve being closed or opened, a part of
steam leaking out between the valve spindle (9) and the sleeve (4) will be drained off
through connection K. As long as the emergency stop valve is open, the valve cone
contacts to the seal face of the sleeve tightly, blocking the steam leaking along the valve
spindle.

In order to facilitate the assembling or disassembling of the segment ring (7), an access
hole is machined in the housing and blocked with the screw plug. The steam section is
connected to the hydraulic section via the connection part (13). A heat shield (10) is
mounted on the connection part at the side near the steam section to reduce heat
radiation to the oil cylinder. The valve spindle (9) is jointed to the piston rod (12) via a
flexible joint (21), on which the oil-retaining cone is fitted. In the event of the sealing
element of the piston rod damaged, the oil-retaining cone will take up the oil leaked
form the oil cylinder and drain it out through connection T2.

The hydraulic section mainly consists of oil cylinder (20), piston (16), spring (17),
piston disc (19) and sealing element. The oil cylinder is bolted on the connection part
(13). On the end face of the oil cylinder three extension bolts are fitted for safety in
mount and dismount. The bolt holes on the oil cylinder are fitted with thread bushes.
Caution: the extension bolts and the nuts must be used in mounting or
dismounting the oil cylinder; otherwise the human injury can result.

The emergency stop valve is hydraulically actuated by the oil pressure. The valve
opening operation is initiated by the starting control (refer to 1-1840- ). Firstly, the
starting oil F enters into the space at the right of the piston (16). By overcoming the
action of the spring (17), the piston is tightly pressed against the piston disc (19). Then

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 Operating Instructions
Emergency Stop Valve 1-2300-02-01
the trip oil E enters to the left of the piston disc, making the sealing faces of the piston
disc and the piston remain to contact each other. After that, the staring oil begins to
drain under control. Thus the piston disc and the piston, as an integral part, move
rightwards under the pressure difference at both sides until limited by the test piston (15)
so that the emergency stop valve is opened by means of the piston rod, the flexible joint
and the valve spindle with the movement of the piston disc.

Once any of the loops in the protection system acts, the trip-oil pressure will be lost.
The piston will separate from the piston disc under the action of the spring force, the
trip oil at the left of the piston disc drains through connection T1, the piston disc,
together with the piston rod, the valve spindle and the valve cone, are pushed to the
close position, closing the emergency valve.

As showed in Fig.2, a test piston (15) is equipped in the hydraulic section. It, together
with the test valve and the pressure gauge, forms a test device of the emergency stop
valve for checking its proper function during turbine operation.

Fig.2 Test device of emergency stop valve

The test valve is a manual reversal valve (or electric reversal valve) mounted in the
piping or integrated in the trip block (refer to 1-2001- ). Through operating the test
valve the pressure oil is admitted via an orifice to the right of the test piston. Since the
area of the test piston is larger than that of the oil-cylinder piston, when oil pressure P2
reached a certain value the test piston pushes, under the action of the oil pressure, the
piston together with the piston disc and valve spindle and cone to move in close
direction by a distance h, which has on effect on the normal turbine operation. So the
check may be carried out during normal turbine operation under an load up to and
including rated load. When the test valve is switched to the position as shown in the
picture, the test is disabled.

If the emergency stop valve functions properly, P2<P1. Here, P1 is the permissible test
pressure; P2 is the actual test pressure at which the test piston begins to move.

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 Operating Instructions
Emergency Stop Valve 1-2300-02-01
The permissible test pressure can be calculated with the following formula:
P1≤A＋B（P4－1）
Where:
A, B The characteristic value related with the size of the emergency stop valve,
see Technical data 0-0300-T.Nr-00
P4 Trip-oil pressure when turbine operation

If the pressure P2 observed on the pressure gauge happens to be in excess of the

permissible pressure P1, this will be indicative for deposits of salt on the valve spindle
or deposits of oil carbon on the piston. In such a case the above testing operation has to
be repeatedly a couple of times in order to recondition the emergency valve to proper
function. If this fails to reduce P2 below P1, the emergency stop valve must be
disassembled and the fault cleared as could as possible.

The emergency stop valve can be equipped with the position switcher, as required, for
sending out a corresponding signal when the valve is at full-opened or full-closed
position.

Based on the diameter of the live-steam inlet, the emergency stop valve is divided into
five sizes with same structure; they are 100, 125, 150, 200 and 250.

Hangzhou Steam Turbine Company Limited Page 4 of 4

 Operating Instructions
Measurement of casing expansion 1-2771-01-01

Measurement of Casing Expansion

Function

The casing expands absolutely in axial direction due to the turbine heated. The
supervision of the expansion process indicates whether the support surface of the
bearing pedestal is glided freely and the tilted displacement exists during casing
expansion. Continuous monitoring is required, especially for the load changing, start
and shutdown processes. In order to measure the casing expansion, a pointer (2) is
fixed on the right or left side of the front bearing pedestal (1). When the casing
expands the pointer moves relative to the scale on the soleplate or baseplate.

Hangzhou Steam Turbine Company Limited Page 1 of 2

 Operating Instructions
Measurement of casing expansion 1-2771-01-01

1. Front bearing pedestal 2.Pointer 3. scale 4. Soleplate or baseplate

Figure 1

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Reduction Gear 1-3410-06-01

Reduction Gear
The reduction gear matches the working speed of the main oil pump to that of the
turbine.

1. Gear casing 5. Flexible shaft 9. Radial bearing

2. Gear wheel 6. Pinion shaft 10. Connection bush
3. Drive shaft for oil pump 7. Radial bearing 11. Radial-thrust bearin
4. Radial bearing 8. Pinion
Fig. 1

The reduction gear consists basically of the gear casing, gears, shafts and bearings.

The casing (1) is horizontally split into two halves as showed in Fig.2. They are bolted
together and their position to each other is secured with the taper pin.

The reduction gear is mounted on the

front end of the front bearing housing
via its vertical flange. The installation
requirement is given in the attached
documentNo.0-2248-0081-00
(connection drawing of transmission
case – bearing housing).

The main oil pump is mounted on the

front end of the gear casing via an
adapter. Fig. 2

The pinion shaft (6, input shaft) and the drive shaft for the oil pump (3, output shaft) are

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 Operating Instructions
Reduction Gear 1-3410-06-01
supporting by the bearings. The input shaft is formed by the flexible shaft (5) and pinion
shaft (6). The flexible shaft is connected to the turbine rotor through a flange at one end
and to the bore of the pinion shaft with interference fit at the other end for transmitting
the torque. The input shaft thus follows all axial movement of the rotor.

The selection of the reduction gea is related to the turbine speed and the size of oil
pump. When the pump with a capacity of 60 m3/h is used, the reduction gear 120#
(center distance: 120mm, modulus: 2, total teeth: 116) is selected. When the pump with
a capacity of 160m3/h is used, the reduction gear 160# (center distance: 160mm,
modulus: 2.5, total teeth: 124) is selected. For the oil pump with a capacity of 1003/h,
when the turbine rated speed ≥7888r/min, the reduction gear 120# is used, when the
turbine rated speed ≤7563r/min, the reduction gear 160# is used.

The gear wheel (2) is bolted on the drive shaft (3) of the oil pump. The pinion (8) has
two structures according to the number of teeth. The integral one is showed in Fig.1.
The other is that the pinion (8) is fixed on the shaft (6) with bolts.

The threads of the joint bolts for

connecting the gear and shaft as well as
the flexible shaft and the rotor are
coated with the binding agent during
assembling. If the bolts are required to
remove in repair, heat the bolts to a
temperature of 150～180℃.

There are four pairs of bearings. The

bearings (7) and (11) are horizontally
split, while (4) and (9) are unsplit. The
bearing (11) is a radial-thrust bearing
for positioning the drive shaft for the
oil pump and taking on the thrust from
it. All of the radial bearings are
four-wedge bearings and secured in the
gear casing by positioning pins.
Fig. 3

The lubricating oil enters into the gear casing from the connection Z and lubricates the
bearings and jets to the gears through oil passages drilled in the gear casing, as showed
in Fig.3. The return oil drains to the front bearing housing.

The connection bush (10) serves as a connector for leading in the test oil for the
emergency governor. The test oil connection is located on the adapter. If the
emergency-governor testing device is not used, the connection bush (10) will not be
used.

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 Operating Instructions
Reduction Gear 1-3410-06-01
During assembling the reduction gear in the workshop of the manufacturer, the
positioning pins have been fitted between the lower half of the gear casing and the
bearing housing after the pinion shaft with the turbine rotor aligned. When installation
on user’s site, if the center of the turbine rotor is changed in aligning it with the
driven-machine rotor, the attention must be paid that the center of the reduction gear
must be rechecked. Fit the positioning pin again after the center is adjusted to the
requirement. Otherwise the flexible shaft and the gear can be damaged.

Hangzhou Steam Turbine Company Limited Page 3 of 3

 Operating Instructions
Main Oil Pump 1-4200-02-01

Main Oil Pump

The main oil pump provides the turbine-set with governing oil and lubricating oil. It is a
single-stage, horizontal centrifugal pump and is directly driven by the turbine rotor.

1. Gear casing
2. Adapter
3. Seal ring
4. Impeller
5. Feather key
6. Sleeve
7. Shaft
8. Nut cap
9. Pump housing
10. Balance hole

P Outlet
S Inlet

The main oil pump consists basically of the pump housing, shaft, impeller, , sea rings
and etc.

It is mounted at the end face of the gearbox via the adapter (2) and seal ring (3).
Positioning pins are fitted between the adapter and the pump housing (9) as well as the
adapter and the gear casing (1) for securing their positions with respect to each other.
The adapter not only facilities the mount/dismount and alignment of the pump with the
gearbox, but also serves as the pump cover.

The pump housing (9) is of single-cast design with an axial suction compartment and a
circumferential ring-shaped discharge compartment. The suction and discharge
compartments are sealed off from one another by the seal ring (3) fixed on the adapter
and the sleeve (6) fitted in the pump housing. The sleeve, at the same time, functions as
a baffler to ensure the inflow swirl-free.

The impeller (4) is a cast of aluminum alloy. It is mounted, after machined and

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 Operating Instructions
Main Oil Pump 1-4200-02-01
dynamically balance, on the shaft (7) and fixed by the nut cap (8) and the feather key
(5). Balance holes (10) are drilled on the impeller for balancing the axial force acted on
the impeller by the oil pressure. The residual thrust is taken on by the radial-thrust
bearing in the gearbox.

In order to enhance the suction performance of the pump and ensure its reliable
operation, the main oil pump is always equipped with a suction injector (see 1-4205- ).

According to the rated flow, three sizes of pumps are available (60 m3/h, 100 m3/h and
160 m3/h). They all have a similar structure with a rated speed of 5000 r/min and a
discharge pressure of approximately 0.75 MPa.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Lube-oil Throttle 1-5501-01-01

Lube-oil Throttle
The throttle is used in lube-oil line for control the oil flow. Its structure is shown in the
picture.

There are two forms of casing (4) available; one for connecting to the piping with the
welding connection (5) as showed in the picture, the other is connected to the piping
with flanges. The casing is made of carbon steel or stainless steel as required.

The oil flow to the bearing is adjusted through varying the stroke of the throttle screw
(6), keeping the temperature rise of the bearing within the permitted range during
turbine operation. To adjust, remove the cover screw (1), after loosing the cap nut (2),
turn the throttle screw counterclockwise with a screwdriver or inner-hexagon spanner to
make it move upwards. This will increase the opening of the throttle and decrease the
differential pressure before and after the throttle, resulting in oil flow increased. The
opening of the throttle is restricted by its structure. It cannot be opened fully even if the
throttle screw is at its maximum stroke, because the excessive oil will fill up the bearing
housing. Turning the throttle screw clockwise will reduce the oil flow. In order to avoid
blocking the oil due to misoperation, the minimum flow about 0.5m3/h is permitted in
its lowest position.

1. Cover screw
2. Cap nut
3. Seal ring
4. Casing
5. Welding connection
6. Throttle screw
7. Seal ring

After adjusted, the cap nut must again be firmly tightened and the cover screw must be
screwed in again.

Hangzhou Steam Turbine Company Limited Page 1 of 1

 Operating Instructions
One-way Throttle Valve 1-5600-03-01

One-way Throttle Valve

The one-way throttle valve is mounted in the secondary-oil line in proximity of the oil
relay. Its purpose is to prevent the transmission of possible pressure fluctuations arising
in the secondary-oil circuit, bringing about the stable operation of the pilot valve
without disturbance.

1. Adjustable sleeve
2. Spring seat
3. One-way valve
5. Retaining ring
6. Retaining ring
7. Spring
8. Valve casing
9. O-ring

The secondary oil enters into the valve casing (8) from the end B. The one-way valve (3)
is pressed against the valve seat under the action of the spring force (7) and oil pressure,
the secondary oil flows to the end A through bypass holes on the one-way valve and the
throttling passage between the valve casing and the adjustable sleeve (1). If the pressure
at end A is higher than that at the end B by 0.05 MPa, the one-way valve is opened. The
oil flows in the opposite direction without throttling, so as to unload the turbine quickly.

Turn the adjustable sleeve to change the area of the throttling passage infinitely. Turning
the sleeve clockwise (looking from B to A) will decrease the area of the passage, while
turning it in the opposite direction will increase the area. There are a scale ring on the
conical surface of the sleeve (1) in proximity of the end A and reference scale and
indicating ring on the end A of the valve casing, which indicate the working position of
the one-way throttling valve.

When adjusting, if pressure gauges are fitted at both ends of the valve, turn the sleeve
and observe the readings on the gauges. When the pressure after the valve decreases
modestly and the differential pressure between two ends reached 0 <△P<0.01MPa, turn
bake the sleeve by 1 to 2 scales. If there is no pressure gauge after the valve, it is
recommended to set the one-way throttling valve during static adjusting of the control
system before turbine start-up. In this case, turn the sleeve counterclockwise to fully
open the valve, and then change the secondary-oil pressure from the amplifier (or
electro-hydraulic converter) to bring the oil-relay stroke corresponding to the
secondary-oil pressure 0.15 to 0.45MPa in correspondence with the requirement defined
on the Characteristics Line (No.0-2500-T.Nr-00). After that, set the secondary-oil
pressure at 0.15MPa and the oil-relay stroke at 0, turn the sleeve clockwise until the
reset bar of the oil relay separates from the rolling bearing. Turn back the sleeve by 1 to

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 Operating Instructions
One-way Throttle Valve 1-5600-03-01
2 scales. Then recheck the oil-relay stroke corresponding to secondary oil pressure 0.45
MPa.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Manual Barring Gear 1-7130-03-01

Manual Barring Gear

After the turbine has been shutdown, the rotor is not being rotated any more. It very
likely will suffer from heat warping during cooling-down period due to uneven cooling
of the upper and lower halves of the casing and the rotor. Any attempt to re-start the
turbine in this condition would therefore produce rubbing contact between the moving
and stationary parts with resulting vibration exceeded the permitted range. In order to
avoid this accident occurring, a barring gear is provided.

After the turbine has been shutdown, turn the rotor by 180°in regular interval with the
manual barring gear to reduce and correct the heat warping of the rotor.

For the condensing turbine, before the rotor is rotated during start-up the rotor should be
rotated with the manual barring gear to prevent distortion of the rotor caused by the
gland steam.

The manual barring gear is a useful auxiliary tool in turbine assemble and installation. It
also can be used to supplement hydraulic barring gear (1-7140- ) for reducing the
breakaway torque of the latter.

The manual barring gear is incorporated in the rear bearing housing at the left side for
the turbine rotating in clockwise and at the right side for turbine in counterclockwise.

The picture below shows the structure and working principle of the manual barring gear
(view the rotating direction of the turbine along the steam flow).

1. Cover
2. Lever
3. Nut
4. Bracket
5. Rear bearing
housing
6. Turbine rotor
7. Ratchet wheel
8. Detent
9. Axle
10. Extension tube
11. Hinge bolt
12. Safety latch

The manual barring gear consists of cover, bracket, lever, ratchet wheel, detent and etc.

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 Operating Instructions
Manual Barring Gear 1-7130-03-01
Two positions A and B of the detent (8) corresponding to two specific states of the
barring gear. Position A is the disabled position, or starting position for each barring
operation. At this position, the detent is restricted by the mounting-hole wall in the
bearing housing and locked; it is separated from the ratchet wheel. The position B is the
ultimate contacting position of the detent to the ratchet wheel.

To turning rotor, screw out the nut (3), remove the cover (1), churn up the safety latch,
mount the extension tube on (10) on the lever (2) and turn the rotor with the tube in the
turbine rotary direction. Since the bracket (4) is mounted in the bearing housing and the
lever is jointed with it by means of the axle (9), the lever will swing around the axle.
The detent is engaged in the slot on the lever via the hinge bolt (11), thus when the lever
moving the detent will come away the locked position and swing around the axle, and
thus the tip of the detent will fall in the tooth space on the ratchet wheel (7). When the
lever turned by approximately 45°(shown by the dash line in the picture) the detent
will be at the position B. The ratchet wheel with 24 teeth is shrunk-mounted on the
turbine rotor (6), therefore, pulling the tube once a time the ratchet wheel together with
the rotor will rotate by 15°. The rotor can be turned continuously by pulling the tube
back and froth.

To disable the barring gear, place the lever to the vertical position as showed in the
picture, lock it with the safety latch and then mount on the cover. The cover of the
manual barring gear should not be removed during turbine operation. Risk of accidents!

The manual barring gear only can be put in operation when the turbine is at standstill
and the lubricating oil is supplied normally.

If the turbine is equipped with a shaft jacking system, the jacking system must be put in
operation before operating the barring gear.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Foreword to Installation Section 2-0100-01-01

Foreword to Installation Section

The Installation Section in the Operating Instructions mainly describes the gist,
recommended procedures and binding requirements necessary for proper installation of
the turbine.

The turbine installation means to fix the turbine on a given location and the assembling
between components should be satisfied the requirements specified by the turbine
manufacturer.

For the turbine that is delivered completion and has no need be open the casing on site,
the procedures and requirements on installation for the complete machine are introduced
in this Installation Section. The assembly and adjustment of the attached components
are described in the Structure Section.

For the turbine that are delivered in several packages, the mount procedures and
requirements for the pedestal, casing, rotor are introduced here. The assembly and
adjustment of the attached components are described in the Structure Section.

For the turbine mounted on a common baseplate, the description for the junction of the
baseplate with the foundation can be found in the relevant document supplied by the
baseplate manufacturer.

Before turbine delivery the surfaces of the inside components should be painted with 2#
rust proof oil to prevent corrosion during transportation and storage. For the turbine
delivered in packages. the rust proof oil painted on the surfaces of the parts and
components should be cleaned be mounted. For the turbine delivered in completion, the
rust proof oil on the parts and components in the steam path will be flushed out by the
steam during commissioning. It is unnecessary to open the casing for cleaning.

When turbine positioning, the positioning dimension of axial coupling for the driven
machine should be met to the requirement of the thermal expansion for the turbine rotor
(see the attached document 0-0341-T.Nr-00 Axial expansion amount for turbine rotor).It
is specially important for the turbine connected to the driven machine with a rigid
coupling. The mounting dimension must be carefully measured and checked, so as to
prevent collision between the static and rotating components during turbine operation.

The different industries will adopt different standards in construction, additionally the
different site layout, construction organization and equipments, and working custom, so
it is impossible for the turbine manufacturer to make out an all-purpose and standard
installation procedure. The user should do preparation and make out the procedure for
the installation before installing the turbine, based on these instructions.

When installing the turbine, the following conditions should be provided:

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 Operating Instructions
Foreword to Installation Section 2-0100-01-01
1. Building projects
1.1 The foundation pouring has been finished. The concrete has reached above 70% of
the designed strength and has been checked out.
1.2 The traveling crane rail has been laid. the back grouting of the concrete has reached
the designed strength and has been checked out.
1.3 The turbine building has been roofed and walled. The locations at where the
installed equipments may be damaged during building fitment should be fitted
before the equipments installation.
1.4 The shuttering, scaffold, remaining material used for the civil work and the raffles
and garbage left behind have been cleaned off.
1.5 Each foundation has the clean and correct center line. The elevation lines are
available for the ground and working floors. The longitudinal and transverse center
lines, elevation and positions of the embedded parts for the foundation should be all
in accordance with the design.

2. Installation site
2.1 The turbine being installed should be in completion, with all of the tools supplied
with the turbine.
2.2 The installation site should have enough space for storing and handling the
equipment.
2.3 The enough light, water, electric power and compressed air are available on the site.
the necessary devices such as welding machine and etc. should be in ready.
2.4 A proper isolation should be set up between the installation site and the production
run site, if there is any.
2.5 Before turbine installation, the traveling crane should be checked out. The lift
capacity and height, the traveling speed and limit range of the traveling crane should
be met the requirement on installation.
2.6 The installation should be done at an ambient temperature of above 5℃. If the
temperature drops to below 0℃,the necessary anti freezing measurements should be
taken, as required.

3. Technological preparation
3.1 The attached document should be in completion.
3.2 The technicians in charge of the installation must be familiar with the technical
document in job range and know the principle and structure of the installed devices.
The installation works should be familiar with the construction regulations,
installation procedures and methods and required to master the relevant
measurement technics.

In addition to the mentioned above, the local regulations, such as the safety,
environment, labor protection and anti-explosion and fire rules should be observed
during installtion.

Hangzhiu Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Preparation for Foundation 2-0300-01-01

Preparation for Foundation

1. Embedding packing plate
Mark the seating areas for the packing plates on the foundation according to the Layout
Drawing 0-2015-TN.r-00 ( or the attached information 0-2015-T.Nr-01 to the Layout
Drawing). An uneven foundation surface does not ensure a horizontal position of the
packing plates. Therefore, an approx. 20 mm thick layer of mortar is to be applied to the
foundation surface (the oil stain and loose layer of the tabby should be cleaned off in
advance. The packing plates are embedded into this layer (see Fig.1). The excess mortar
squeezed out at the edges is to be smoothed into a slope towards the top. The mortar
surface around the packing plate should be a little lower than the top of the packing
plate. Check the level of the top surface for the packing plate by means of a spirit level
in two axes perpendicular to each other before the mortar solidified. Beat the packing
plate slightly to make the air bubble in the level be at the middle.

1. Level
2. Packing plate
3. Layer of mortar
4. Foundation

Fig. 1 Before Turbine Installation

1. Pedestal (support plate)

2. Sizing Block
3. Packing plate
4. Layer of mortar
5. Foundation

Fig.2 After Turbine installation

The packing plates are supplied by user, for the dimension of the cross section, see
Layout Drawing. The surface roughness of the packing plate topping should be .
The deviation of the flatness should be less than 0.1.

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 Operating Instructions
Preparation for Foundation 2-0300-01-01
The cement mortar( cement, sand and water) or epoxy mortar ( epoxy, curing agent and
quartz sand) can be used. When the cement mortar is used, the packing plate can be
loaded after the mortar solidified for at lest 24 hours. The strength of the mortar after 72
hours should be ＞ 60N/mm2. If the epoxy mortar is used, the relevant safety
measurement should be taken for the toxicity of epoxy during working. And at the same
time, the foundation and the packing plate surfaces that contacted with the mortar
should be treated according to the relevant specification. In order to prevent the epoxy
mortar aging and strength decreasing in the air, after grouting the mortar surface should
be protected with a layer of cement mortar.

2. Embedding bearing plate for trimming screw

The mounting position of the bearing plate should be corresponded with the position of
the trimming screw on the pedestal (or soleplate). The seating area on the foundation for
the bearing plate should be flattened by chiseling or scraping so that the whole bearing
plate is contacted with the seating face evenly. The bearing plate is treated by user. Its
surface should be flat and without burrs. The thickness of the bearing plate is about 30
mm (see Fig.3). The dimension of the cross section can be calculated based on the load
indicated in the Layout Drawing. The pressure intensity on the bearing face should be
≤24.5N/mm2.

1. Pedestal (soleplate)
2. Trimming screw
3. Bearing plate for trimming screw
4. Foundation

Fig.3

3. Anchor-bolt holes
The anchor-bole holes should be cleaned of sundries.

Check the contact condition between the bottom plate of the anchor bolt and the
foundation surface around the hole. Under normal condition, the pre-tightened force of
the anchor bole acts on the concrete foundation via whole bearing face of the bottom
plate. If the protruding edge-angles and stones are existed around the anchor-bolt hole,
the load on the foundation becomes unevenly distributed. This will cause part of the
foundation cracked and damaged in a short time, resulting in the tightened force of the
anchor bole lost and then endangering the normal operation of the turbine. Therefore, an
approx. 5mm thick layer of high viscosity and stagnation cement mortar is to be applied

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 Operating Instructions
Preparation for Foundation 2-0300-01-01
on the bottom plate or the corresponding surface on the foundation, if necessary (see
Fig.4). Tighten the nut to press the bottom plate and it will do just for the mortar
beginning to be pressed out. This will not only benefit the turbine in long period
operation but also prevent the mortar leakage during filling the hole with the mortar.
The anchor-blot hole only can be filled after 12 hours. The strength of the filled mortar
after 72 hours should be ＞60N/mm2.

1. Asphalt tape
2. Anchor bolt
3. Anchor-bolt hole
4. Foundation
5. Filled cement
6. Bottom plate of anchor bolt
7. Nut

Fig. 4

4. Pre-treatment of anchor bolt

In order to allow the anchor bole to be in elastic strain when tightened after back
grouting, the mortar is not allowed to attach on the bolt or enter into the nut during
grouting. So the bolt should be wrapped upwards from the nut to the thread end with the
asphalt tape (see Fig.4) in the direction as the nut turning direction. When screwing in
the nut the tape will be pushed upwards and form a ball-like ferrule.

After the turbine installed, the anchor bolt should be secured by spot welding and the
exposed thread should be coated with thick grease for corrosion prevention.

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 Operating Instructions
Back Grouting for Foundation 2-0310-01-01

Back Grouting for Foundation

After the turbine ( including the gear box) has been installed and it is sure that the
position of the turbine set will not be moved, grout the bottom part of the pedestal
(support plate or baseplate) with specified mortar to connected it to the foundation
firmly.

The material and formulation of the mortar is independent of turbine type and size, it is
selected by user and construction company. But we recommend:

When the thickness of the grouting layer ≤60mm, either the cement mortar mixed with
cement, sand and water in a given proportion or the epoxy mortar prepared with epoxy,
curing agent and quartz sand can be used.

When the thickness of the grouting layer is 60 to 100 mm, either the concrete with
pebble in the specified granularity or the cement mortar can be used.

No matter which grouting material is used, the following requirements should be

satisfied:

1. Compression strength
≥40N/mm2, after 24 hours
≥60N/mm2, after 72 hours
≥70N/mm2, final strength

2. Volumetric change
The contraction is not allowed. The grouting material should expands slightly within 24
hours after grouting so as to ensure that there is enough cohesion between the
foundation and pedestal, but the further expansion is not allowed after 24 hours.

3. Expansion coefficient
The coefficient of the linear expansion for the mortar after solidified should be in
conform with that of the foundation.

4. No cracking on impact and vibration

Before back grouting fill the anchor-bolt holes with the cement mortar, first. The back
grouting only can be done at least after 24 hours.

Mounting or dismounting heavy component on the pedestal only can be done after back
grouting finished at least for 24 hours.

The anchor bolt only can be retightened after back grouting finished at least for 72
hours.

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 Operating Instructions
Back Grouting for Foundation 2-0310-01-01
when the epoxy mortar is used for back grouting, the relevant safety measurement
should be taken for the toxicity of epoxy during working.

The preparation for the foundation before grouting and the maintenance should be done
according with the construction procedure.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01

Installation of condensing Turbine

The turbine has been assembled and has passed the test running under no-load in
the workshop of the manufacturer. It is demounted and packed in several boxes when
delivering to the user. The installation procedure described below is to begin from
the positioning of the pedestal in the installation of the turbine body. But for the turbine
that the pedestal is assembled and fixed together with the casing in delivery, it is
recommended that when installing the turbine on site, do not demount the component
that has been assembled as could as possible. You have only to check the related
assembling dimensions against the actually measuring records in the Product Certificate
and make proper adjustments, if necessary. The check results during installation should
be recorded.

The installation for the turbine of model ENK may be carried out following
the guideline below.

The fixers for shipping (see the Shipping Drawing No.2-8470-xxxx-xx) should be
removed timely during turbine installation.

The installation steps:

1. Preparation for foundation
According to the description in 2-0300-01-xx.

2.Positioning condenser
Install the condenser according to the Layout Drawing No.0-2015-T.Nr-00, the
Assembly Drawing of Condenser No.2-3580-xxxx-xx and the Exhaust nozzle Drawing
No.2-6056-T.Nr-00.

Lift the condenser and place it on the foundation pier. The bearing plate (slide plate)
should be fitted between the pedestal of the condenser and the foundation pier. Adjust
the condenser to the proper position based on the longitudinal and lateral centerlines of
the foundation pier. The condenser pedestal near the water inlet and outlet piping is the
fixed end; the other pedestal with the oval anchor-bolt hole is a movable end. During
operation the condenser can be slide on the bearing plate towards the movable end.

The exhaust nozzle is delivered with an allowance about 50mm in length. After
the turbine positioned in field installation, make up the length of the exhaust nozzle
according with the actual distance between the exhaust port on the casing and the steam
inlet of the condenser. Weld the exhaust nozzle to the steam inlet on the condenser
following the requirement after the turbine body installed and adjusted. The given
cold-draw clearance (see The Layout Drawing) must be pre-kept between the exhaust
nozzle and the flange of the exhaust port on the casing. The clearance should be even
around the flange surface. On the flange seal surface and the gasket the sealing coating
must be mopped. When connecting the flanges, tighten the bolts evenly and

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
symmetrically so as to ensure the tightness of the connection.

The foreign materials must not fall into the condenser during installation.

3. Positioning front pedestal

The structure and adjustment of the front pedestal are described in 1-0710-01-xx.

Suspend the pedestal horizontally and clean its bottom face. Coat the threads of the
trimming screws at the bottom of the pedestal with the lubricating agent and then screw
down them until they protrude from the bottom surface about 20mm. Lower the
pedestal, making all of the trimming screws contact to the packing plates on the
foundation.

When positioning it, the position of the pedestal should be in consistent with the
centerline of the foundation. Penetrate in the anchor bolts and tighten the nuts with
hand.

Remove the upper half of the front bearing housing, the radial bearing and the thrust
bearing. Clean the bearing housing.

Adjust the center height and the level of the pedestal with the trimming screws on it.
Check the axial and lateral levels of the front pedestal on the split of the front bearing
housing with flat ruler and level gauge. The deviation should be ＜0.06mm/m.

4. Positioning casing
For the turbine that the inner casing (inner casing in halves, steam chamber or nozzle
chest, the same below), the guide-blade carrier, the middle gland bush, the front and rear
gland bushes are mounted with the bottom casing in delivery, the components
mentioned above should be removed first when installation.

The rear pedestal (see 1-0750-xx-xx) of the condensing turbine is usually integrated
with the lower supporting bracket of the exhaust casing. Lift the bottom casing
horizontally, coat the threads of the trimming screws on the rear pedestal with
lubricating agent and screw down them until they protrude from the bottom face about
20mm. Then lower the casing; now the front end of the casing is supported on the
jacking screws by means of the bottom-casing supporting bracket, the rear end is
supported on the packing plate via the trimming screws. Screw down the trimming
screws, making all of them contact to the packing plate, and then penetrate the anchor
bolts into the pedestal and tighten the nuts with hand.

Before positioning the bottom casing, remove the pull rods at the front end of the casing
and penetrate them into the eye-ring on the front bearing housing. Screw the pull rods
into the lugs on the bottom casing and lock them with nuts after the bottom casing
positioned.

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01

Figure
Usually, the adjustment of the relative position between the bottom casing and the
pedestal is carried out alternately with the adjustment of the casing center height and
level. The dimension L, which is given in the Product Certificate, is taken as the
reference of the axial position when positioning the bottom casing.

Adjusting height of casing center:

Adjust the jacking screw of the lower supporting bracket of the front casing to make
the central height of the casing split in conformity with that of the bearing-housing split.
During adjusting, the dimension B (see the picture), which is the distance from the
casing split to the topping of the pedestal, must be compromised. After adjusted B to the
value given in the Product Certificate, lift and mount the top casing, bringing the
supporting bracket of the top casing to support on the spherical washer. Adjust the
thread seat under the spherical washer, making B unchanged when the thread seat is
loaded and locked by the locking screw. Then, adjust the jacking screw of the lower
supporting bracket to bring the splits of the top and bottom casings to contact each other.
The contact condition of the splits can be checked only in a part extent around them for
the split bolts are not tightened (the positioning pin should be fitted). The adjusted
amount of the jacking screw for the lower supporting bracket may be monitored with
the dial gauge fitted on the upper supporting bracket. After the position of the bottom
casing adjusted, the jacking screw should be locked (when locking it the position of the
bottom casing should not be changed). After that, lift and remove the top casing. This
not only can re-check the position of the casing with respect to the pedestal from the
clearance (usually the adjustment for the axial position of the casing is based on this
clearance, L is only taken as a reference) between the screw hole in the upper
supporting bracket and the distant screw (see the Product Certificate) but also reduces
the adjustment work on aligning the rotor with the casing.

Leveling-up casing:
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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
The axial level of the casing is adjusted based on requirement for the rotor elevation..
Bridge a level gauge on the splits of the bearing housing and the casing. Adjust
the thread seat of the spherical washer under the split flange of the bearing housing or
the jacking screw of the lower supporting bracket to make the axial levels of the casing
and the bearing housing in conformity with each other. Check the lateral level with a
flat ruler and a level gauge. The deviation should be ＜0.06mm/m.

After the casing positioned, check the relative position of the casing to the front and rear
bearing housings (see the Turbine-Body Drawing No.2-825x-xxxx-xx), by way of
parenthesis, to make sure that the center distance of the bearings is in accordance with
the requirement. When necessary, adjust the position of the bearing housing. The axial
position of the front bearing housing is adjusted with the nut on the pull rod. While the
rear bearing housing is adjusted with two eccentric guide stems. The position
adjustment of the bearing housing is mainly for satisfying the requirement on the
alignment of the rotor with the casing and the axial position of the rotor.

The positioning of the casing is also related with the vertical key of the exhaust casing.
The relative adjusting element for positioning the casing should be assembled into the
positioning guide-lug of the exhaust casing. For the turbine that the vertical key of the
exhaust casing is embedded in the foundation, when positioning the bottom casing, the
lateral center of the casing is adjusted with the adjusting element. For the turbine that
the bottom plate of the vertical key is embedded in the foundation, after the lateral
center is adjusted secure the vertical key to the bottom plate and make-up the
positioning pin.

Tighten the anchor bolts to the initial tightening torque listed in the attached table (Note
1) after the center height and level of the casing adjusted

5. Initial alignment of bearing housing with casing

Usually, the “draw-wire ” method (thin nylon wire) or a laser collimator is used in
alignment.

When the “draw-wire” method is adopted, measure the recesses of the front and rear
bearings and the gland bushes with a steel ruler. Adjust the central lines of the front and
rear bearing housings and the recesses of the front and rear gland bushes to be on
the same vertical plane basically and the center deviation to be ＜ 0.5mm.
The parallelism between the central lines of the front bearing housing and the casing is
adjusted with the nuts on two pull rods. With the eccentric guide stem the position of
the rear bearing can be adjusted. The lateral centers of the front and rear bearing housings
can be adjusted with the adjusting element of the spherical washer between the bearing
housing and the guide-key of the pedestal (exhaust casing).

6. Alignment of rotor-casing
Clean the front and rear bearings and the thrust bearing and mount the lower half of the

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
radial bearing into the bearing housing.

Lift and put the rotor into the casing with the Lifting Tool (2-8540-xxxx-00). The
journal must be cleaned first.

The lift of the rotor should be in command of the person specially assigned. When
lifting it, the rotor should be remained level axially. The ends of the rotor should be
buttressed by the skilled installation personnel when positioning the rotor. It must be
noticed that do not collide the moving components with the stationary ones. Lower
the rotor until the journal is away from the bearing pad about 150 mm, pour the pad
with clear turbine oil and seat the rotor on the axial bearings. Then, mount the thrust
bearing and turn the rotor to check whether it is seized by or collided with the stationary
parts.

The alignment of “rotor – casing” is done through aligning the rotor with the recess of
the gland bush. Make the axial line of the rotor be in consistent with the central line of
the casing as could as possible.

On the recess end face of the front and rear gland bushes of the casing there is an
annular groove called as “measuring ring for casing”, as showed in details C2 and C3 on
the Shipping Drawing. During assembling the turbine in the workshop of
the manufacturer, the measurement is made at the measuring ring and recorded after the
alignment of the rotor with the gland-bush recess. R4 and r4 in the Product Certificate
are the alignment values of the front and rear gland-bush recesses, while R3 and r3 are
the measurements at the front and rear measuring rings. During installation or after
turbine has been operated for a period, to check whether the casing center changes or
not, it is only needed to make a measurement at the measuring ring and compare the
measured results with the original records, opening the casing is not necessary (Note2.1
and 2.2).

The alignment tool supplied with the turbine includes a thread steel tape (100), a fixed
connection (101) and an angle plate for direction change (102). It is contained in
the instrument box for delivery. To check the alignment, attach the alignment tool to
the rotor and the dial gauge and its seat to the fixed connection, as showed on
the Shipping Drawing. There are six measuring spots for each checkpoint. The number
and position of the measuring spot are indicated on the Shipping Drawing. The values
R 3 , r 3 , and R 4 , r 4 in the Product Certificate are the measured values after
the casing jointed. During aligning the rotor with the casing in field installation, the top
half of the casing has been removed, so there are only 3 measuring spots at each
checkpoint. Make the measurements at the measuring spots 3, 4 and 5 in the recesses of
the front and rear gland bushes of the casing. If the deviation of the rotor center with
respect to the casing is ＜0.05mm and the rotor center is lower than the casing one,
the installation can be carried on. If not, the adjustment is required. To adjust the casing
or the bearing housing is determined by the field condition. After the center adjusted to

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
the requirement, put on the top half of the casing. Now, the casing is still supported by
the jacking screws of the lower supporting brackets. Fit the positioning pins and tighten
the split bolts of the casing at intervals of one bolt. After that, carry out
the supporting transfer for the casing. If the upper supporting bracket is padded with the
spherical washer, loose the jacking screw of the lower supporting bracket, transferring
the support of the casing from the jacking screw to the thread seat of the spherical
washer. The monitor should be made at the recess of the gland bush with a dial gauge
when transferring the casing support. If the casing center moves down after the transfer,
bring the reading on the dial gauge to the original value through adjusting the thread
seat and then lock the thread seat. Subsequently, make the measurements at the recesses
of the front and rear gland bushes of the casing. When the center of the rotor with
respect to the casing is in accordance to the requirement, measure the measuring ring of
the casing and record the results as the reference for latter center checking (see 10.4).
Then lift and remove the top half of the casing. It is required to jack the lower
supporting bracket with the jacking screw before loosing the split bolt. Turn it until the
reading on the dial gauge begins to change.

7. Check bearing housings and bearings

This is usually done during aligning the rotor with the casing.

The values R1, R2, r1 and r2 in the Product Certificate are the actual measurements
during centering the front and rear bearings and bearing housings. When positioning the
bearing housing in assembling the turbine, various adjustment requirements should be
compromised, and additionally the various deflections exist in the fabrication of the
bearing housing. Thereby, the values R1, R2, r1 and r2 are just taken as the reference for
judging whether the center line of the bearing housing is parallel to that of the rotor
when aligning the bearing housing with the casing. If R1, R2, r1 and r2 are not in
coordination with the requirements for leveling the turbine and centering the rotor
during assembling, the alignment of the rotor with the casing and the bearing good
contact should be ensured first.

When the front bearing housing contains a thrust-bearing carrier the value R5 and R6,
which are the measurements for centering the inner circle of the thrust-bearing carrier
and the runout on the carrier end face, will be found in the Product Certificate.

For the check of the bearing, refer to 2-0700-01-xx.

8. Checking other assembling dimensions

8.1 Steam-path section
Lift and remove the rotor, mount the lower half of the inner casing, the guide-blade
carrier and the middle gland bush.

Lift in the rotor again, mount the lower halves of the front and rear gland-bush
housings.

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 Operating Instructions
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Check the assembling dimensions of the steam-path section taking the actual
measurements in the Product Certificate as the reference, according to the Steam Path
Drawing No.0-2100-T.Nr-11.

There is no adjusting element so that the axial position of the moving blade for each
stage on the rotor is guaranteed by machining. Also, the positions of the inner casing,
the guide-blade carrier and the gland-bush housing in the casing are fixed. This can be
seen from the real rotor and the Steam Path Drawing. Therefore, the requirement of
each section should be compromised and the clearance of each section should be
re-allotted reasonably when positioning the rotor. On the whole, the minimum axial
clearance between the rotor and the stationary section is at the front gland bush (or at
the dummy piston gland). The axial positioning of the rotor should ensure the required
clearance of the gland bush as well as that clearances at the leading and trailing edges of
the moving blades of each stage are larger than the specified minimum value (Firstly,
the clearance at the trailing edge of the moving blade must be larger than the specified
minimum value). When assembling in the workshop of the manufacturer the axial
positioning dimension E1 (E1 is the distance from the reference face at the front end of
the casing to the end face of the dummy-piston drum and is listed in the column
“Positioning of main shaft” of the Product Certificate) is determined after synthesized
the measured data of the axial clearance between the moving and the stationary parts for
each section. The axial position of the thrust bearing is decided based on the E1. To
make the position of the thrust bearing be fitted with E1, adjust the position of the front
bearing housing or the thrust-bearing carrier with the pull rod when necessary. The axial
position of the rotor is ensured by the thrust bearing.

The X+ and X- in column “Positioning of main shaft” of the Product Certificate denote
the backward (primary thrust direction) and forward (secondary thrust direction) plays
of the turbine rotor with respect to its positioning reference E1, with the thrust bearing
removed.

After the thrust bearing mounted the axial clearance between the rotor and
the stationary parts must be checked under the condition that the collar on the rotor
contacts to the primary thrust pad. Usually, the clearances between the moving blade
and the nozzle and guide blade and between the moving and stationary seal strips are
measured with the feeler gauge or vernier calipers.

Usually, the axial clearance of the twisted blade is not measured. But the clearance
between the tip of the blade and the conical surface in the guide-blade ring should be
checked with feeler gauge.

The radial clearances between the guide-blade carrier and the rotor gland at right and
left sides are measured with the feeler gauge. Adjust the lateral center of the guide-blade
carrier with the eccentric guide stem at the bottom of the guide-blade carrier to make

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
the clearances at the right and left sides equal. Then lock the eccentric guide stem (for
the turbine using the guide-blade carrier without the eccentric guide stem, the
adjustment is not required). The clearances in the vertical direction are measured in the
following method. Mount the upper half of the guide-blade carrier, fit the positioning
pins and tighten the split bolts. Put a dial gauge with the seat on the casing split at the
right and left sides of the guide-blade carrier and the gauge outfit on the proper position
of the carrier flange. Set these two dial gauges to the same readings (0). Then, at the
time when turning the rotor move the carrier down parallelly with the lower thread seat
of the adjusting element until it contacts to the rotor and the rotor can not be turned
(only two on the cross are required to be adjusted for the carrier with four adjusting
elements). The reading indicated on the dial gauge is just the minimum upper clearance
between the carrier and the rotor gland. In the same way, the minimum lower clearance
can be measured through moving the carrier up. Two data listed in the column “Vertical
Clearance” of the steam path in the Product Certificate denote the actual measurements
of the upper and lower clearances, respectively.

The clearance between the adjusting element of the guide-blade carrier and the casing
split can be measured with the large leveling rule and feeler gauge or the depth calipers.

The upper and lower clearances between the carrier and the rotor gland can be adjusted
with the lower thread seat in the adjusting element of the carrier, while with the upper
thread seat the clearance between the spherical washer in the adjusting element and
casing split can be adjusted. After adjustments, the thread seats must be locked under
the precondition that the adjustment is not changed.

The top clearance between the moving-blade shroud of the control stage and the gland
bush in the inner casing (inner casing in halves, steam chamber and nozzle chest, the
same below) is measured with the feeler gauge and can be adjusted with the adjusting
gasket (plate) of the inner casing.

The axial positioning clearance between the carrier and the casing is measured with the
feller gauge.

When installing the turbine of model N, it is not required to measure the seal ring of
L-shaped cross section in the inner casing, except for replacing the seal ring and
the thread bush. But it is needed to check the seal ring whether it can move freely in
circumferential direction and the positioning pin of the thread bush is welded firmly.

8.2 Assembling dimension beyond steam-path section

Check the radial and axial clearances of the front and rear gland bushes, the positioning
dimension of the emergency trip gear, the adjusted data of the front and rear pedestals
(supporting brackets, bearing housings, guide of the casing and bearing-housing
connectors) and the clearance of the oil-seal ring in the bearing housing taking the
actual measurements recorded in the Product Certificate as the reference, according to

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
the Turbine-body Drawing No.2-825x-xxxx-xx, the view A1-Z1 on the drawing
No.0-2011-1xxx-00 and the view A3-Z3 on the drawing No.0-2011-4xxx-00.

Check the stroke of the control valve according to the Characteristic Line of Control
Valve No.0-2505-T.Nr-00 and the Product Certificate.

The checks mentioned above can be done in the intervals of the installation steps before
the back grouting of the foundation depended on the site condition.

9. Initial alignment with driven machine

For turbine directly coupled with the driven machine, the turbine rotor is usually taken
as the reference. The adjusting value for the rotor center of the driven machine is
determined by the alignment value (0-0340-T.Nr-00) of the turbine rotor under cold
state and the alignment data of the driven machine.
For the turbine that is connected with the driven machine via the gear box or that drives
a multi-cylinder compressor, the common central line of the rotors is usually fixed on in
such a way that make the driving shaft of the gear box remain level or the position for
one of the compressor rotor fixed, move the other machines’ rotors through adjusting
the position of the bearing housing, so as to achieve the couplings to be concentric and
the end faces parallel during turbine-set operation.

For the turbine with the drive element for driving the speed governor and main oil pump,
the alignment of the coupling between the driving shaft of the drive element and
the turbine rotor should be checked.

10. Joining top and bottom casings

The join of the turbine casings will spend a lot of time and need a lager amount of
human labor. The casing jointed in good or not will have a direct effect on the project
quality and the turbine safety operation. So the casing-joined work must be scheduled
deliberately and done carefully.

10.1 Preparation before joining casings

10.1.1 Preparation for appliances and tools
The required parts in joining the casings must be counted, checked and placed in order,
in advance.

The required tools must be counted and registered. After the casing joined the tools
must be counted again, ensuring no tool lost.

Clean the split of the casing and prepare coating for the split.

10.1.2 Preparation for assembling

Remove the alignment tool, mount the upper half of the bearing and bearing housing as
well as the oil-seal ring.

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 Operating Instructions
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Fit the specified pins between the inner casing (inner casing in halves, steam chamber
and nozzle chest) and the upper/lower halves of the guide-blade carrier, tighten the split
bolts and spot-weld them against loose. Mount the gland bushes.

Connect the nozzle for pressure measuring inside the casing, if there is any.

Inspect carefully and make sure that there is no sundry in the casing.

10.2 Joining casings

10.2.1 Lifting and mounting top casing
After the guide stem mounted, mop a layer of seal coating (approx. 0.3-0.5mm in
thickness) on the casing split.

Lift the top casing horizontally at the specified lifting position. When lowering it, the
check should be made at any time. Uniform lowering and jamming are not allowed.
When the casings are about to joint, fit in the positioning pins of the casing.

Loose the lift rigging. Turn the rotor, listen carefully and make sure that there is no
sound caused by friction in the casing.

10.2.2 Tightening split bolts of casing

For tightening the split bolts, refer to 2-0410-02-xx.

10.3 Support transfer for casing

The gross structure of the turbine determines that the casing is supported with the upper
supporting bracket. Before and during joining the casing in turbine installation, the
casing is temporarily supported with the lower supporting bracket. It should be
transferred to the upper supporting bracket after the split bolts tightened as required.
Before transferring, the spherical washer should contact to the upper supporting bracket
tightly. After the thread seat locked with the locking screw according to the specified
torque (see views A1-Z1 and A3-Z3), Check the contacting face between the spherical
washer and the upper supporting bracket, the feeler gauge of 0.03 mm should not be
inserted. After that, loose the jacking screw of the lower supporting bracket by 3-5 mm,
and then lock it.

10.4 Re-check alignment of rotor-casing

The alignment of the rotor with the casing may be varied in support transfer of the
casing. This is mainly caused by:

The saddles of the front and rear pedestals are thread-connected to the thread seats.
When the thread seat is loaded, the clearance of the thread causes the casing to move
down.

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 Operating Instructions
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Before and after the support transfer of the casing, the force acted by the casing on
the pedestal and the distance from the force acting point to the center of the pedestal are
different. Therefore, after the support transferred, the axial level of the front bearing
housing will be changed to be lower at front and higher at rear, while the rear bearing
housing becomes higher at front and lower at rear.

The tightness of the casing-split bolt and the coating on the split have an effect on
the deformation of the casing recess and measuring ring

Therefore, the values R3 and r3 should be rechecked after support transferred. If

the center deviation compared with the original record is ＞ ± 0.03mm,
the readjustment must be done.

11. Connecting exhaust nozzle

Connect the exhaust nozzle according with the instructions in item 2.

12. Aligning coupling

After the exhaust nozzle connected, recheck the alignment of the coupling that connects
the turbine with the driven machine. Readjust the pedestal, if necessary, bringing the
alignment of the coupling to the state before the nozzle connected.

13. Making-up raising blocks

The raising blocks are supplied with the turbine. Each group includes seven flat raising-
blocks with different thickness. During installation, select the combination of
the raising-blocks according to the actually measured distance between the packing
plate and the bottom face of the pedestal and mark them. The number of the piled
raising-blocks in a group should not excess 3 pieces. Usually, mill the thickest one to
meet the requirement. After made-up, insert them into the space between the packing
plate and the pedestal firmly according to the marks made on them. Then loose the
trimming screws by 1/2-1 turns.

After the turbine support transferred from the trimming screws to the flat raising blocks,
tighten the anchor bolts to the initial tightening torque. Then recheck the alignment of
the turbine with the coupling of the driven machine. Re-adjust it through changing
the thickness of the raising block, if necessary. Or based on the field condition, adjust
the bearing housing to meet the alignment requirement of the coupling, but the
alignment of the rotor with the casing must be satisfied first.

14. Ending turbine assemble

Dismount the alignment tool, clean the color left on the rotor and the bearing pad during
penetrant inspection. Mount the upper half of the bearing and the bearing housing as
well as the oil-seal ring.

Mount the barring gear. For the manual barring gear, check its function through

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
operating it repeatedly during assembling. If the hydraulic barring gear is used, check
the axial clearance between the frame and the ratchet wheel. The clearance at the
backside should be larger than or equal to that of the rear gland bush. If the oil-turbine
barring gear is used, check the axial and radial clearances between the impeller and the
rear bearing housing (see view A4-Z4). If the electrical barring gear is used, check the
engagement and drive of the gears through manual operating and the engagement and
disengagement functions during turbine test running.

Remove the positioning pin of the casing split. Spot-weld the nut on the pull rod of the
front bearing housing as required (see view A1-Z1).

Mount the connectors between the turbine and driven machine.

15. Back grouting

Make sure that the pedestals of the turbine will not be moved again, carry out the back
grouting for the foundation. The back grouting of the turbine and the driven machine
should be done simultaneously and finished at one time.

For the requirement on the back grouting, see 2-0310-01-00.

Mounting or dismounting heavy component on the turbine only can be done after
the back grouting finished at least for 24 hours.

After back grouting finished for 72 hours, tighten the anchor bolts to the final tightening
torque listed in the attached table so as to make the anchor bolts still has the enough
remaining stress after long period operation, ensuring the pedestals to be connected with
the foundation firmly.

16. Other installation

16.1 Installation for relevant equipments
The installations for the centralized oil-supply unit or the bulk oil tank, oil cooler and
oil filter, the SRIV governor, the trip block, the local instrument cabinet, the ejector, the
expansion tank of drainage, the condensate pump and etc can be carried out
simultaneously with the installation of the turbine.

16.2 Installation for seam, water and oil piping

The piping supplied with the turbine has been pickled in the workshop of
the manufacturer (except for the straight piping that is not concerned with the no-load
test run). The field fabrication piping only can be connected after pressure test and
cleaned. Either chemical cleaning or water flushing can be adopted. The piping should
be purged with compressed air or steam according with the field construction procedure.

The steam piping connected with the turbine body, such as the balance pipe, the gland
and steam pipes and the vent pipe may be connected before back grouting.

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 Operating Instructions
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The installation of the oil piping, the drainage piping, the steam, air and water piping for
the ejector may be carried out before and after the back grouting based on the piping
location and construction progress. The drainage piping should be so installed that the
drainage must not flow back to the turbine and the drainage valve must be located at the
place convenient for operating. The drainage from the negative-pressure zone during
turbine start-up should be led to the expansion tank of the drainage. The connections on
the tank for drainage must be arranged in the specified order, i.e. the drainage piping at
the high pressure should be connected to the tank at the end far from the condenser,
while the one at the lowest pressure to the end near the condenser. In this way the
high-pressure drainage will not interfere with the flow of the low-pressure drainage.

The inlet and outlet piping of the condensate pump can be connected after the pump and
the ejector positioned.
The distance between the steam piping and the oil piping should be as large as possible.
In the event that the steam piping is crossed to and under the oil piping, it should be
shielded to avoid the oil drop being on fire under the high temperature.

The steam inlet and exhaust piping should be connected after the back grouting and the
anchor bolts tightened to the required tightening torque. When connecting, the monitor
in three directions (X, Y and Z) at the supporting bracket of the casing should be carried
out, ensuring the casing not to be moved.

Before turbine start-up, the oil piping must be cleaned by means of oil cycling (see
3-0340-) and the steam inlet piping must be blown with steam (see 3-0350-).

17. Instruments
It is batter to mount and verify the primary and secondary instruments supplied with the
turbine according to the Bill of Material 0-2020-T.Nr-00 and the attached document of
the Plant Monitoring 0-0101-T.Nr-01, after back grouting. Verify the instruments that
have been mounted on the turbine before or during turbine installation. After installation,
check whether the instruments is in completion.

18. Heat-insulating lagging

The layout of the heat-insulating lagging should be carried out after the oil cycle (see
3-0340-) and the steam piping blown (see 3-0350-) according to the description in
2-7600-.

19. Encloser
In general, the encloser is installed after turbine test running alone according to the
Layout Drawing No.0-2015-T.Nr-00 and the Encloser Drawing No.0-2018-xxxx-00.

Note:
1. If the trimming screw is required to be adjusted after the anchor bolt have been

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 Operating Instructions
Installation of Condensing Turbine 2-0400-16-01
tightened to the initial tightening torque, the turning angle in one time for each
screw should not be in excess of 30°for preventing thread damage due to overload.
During adjusting, make all trimming screws carry an equal share of load as could as
possible.

2. The description of the alignment data in the Product Certificate.

2.1 When assembling the turbine in the workshop of the manufacturer, the reading at the
measuring spot 5 (the spot at the left bottom near the split) is usually corrected to
“0” and taken as the comparing reference. Therefore, the datum of the measuring
spot 5 in the alignment data of the Product Certificate is always 0.
2.2 From R3 and r3 we may see that the measuring ring may not be a perfect circle. This
is caused by the error in selecting the split during machining the casing, the coating
on the split of the casing or the deformation of the casing recess. Despite all this, R3
and r3 as the relative comparing reference will not influence the accuracy
in alignment.

Table: Tightened torque for anchor bolt

Size of anchor bolt M30 M36 M42 M45 M48 M52 M56 M64

Initial tightened torque Nm 1) 20 30 40 50 50 60 70 80

Final tightened torque Nm 2) 510 890 1420 1770 2150 2750 3430 5110
1) The allowed deviation is ±10％
2) When the turbine is mounted on the concrete foundation that has been used for about 3 years,
the 70% of the value listed in the table is taken.

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 Operating Instructions
Tightening Casing-Split Bolts 2-0410-02-01

Tightening Casing-Split Bolts

The state of the turbine casing-split bolt in delivery is determined by the conditions of
the turbine delivery and shipping. For the turbine delivered in completion, the
casing-split bolts have been tightened in the factory according to the requirement. For
the turbine that is delivered in several packages or is disassemble and reassemble on site
as required by user, the casing-split bolts are only tightened approximately when the
turbine being delivered and retightened during installing on site.

Fig.1 Tightening order of bolts for horizontal casing split

The tightening method varies with the material and size of the bolt. For the bolt made of
NiCr20TiAl, 21Cr1Mo1VtiB (thread diameter ≥M52), 21CrMoV (thread diameter ≥
M64) or 35CrMo, heat-tightening or hydraulic-tensioning method must be adopted in
tightening the casing-split bolts. The other bolts can be tightened with special extension
wrench. The special tool for tightening the bolt in heat-tightening or
hydraulic-tensioning method is provided with the turbine. The tightness of the bolt
should be in accordance with the value given in the attached document
No.0-3400-T.Nr-00 (Data sheet of bolt tightness). When tightening the bolt with wrench
it is not allowed to beat the wrench using a hammer because the tightening torque
cannot be controlled and the thread of the bolt will be damaged in hammer beating.

During turbine installation or overhaul, tighten the casing-split bolts in a reasonable

order to avoid the split flange being deformed and resulting in split leakage. Fig.1
shows the tightening order of the bolts for the turbine of model NK. For the turbine of
model ENK or EHNK with extension sector and transition sector, the locations and
number of the casing-split bolts will be different to that showed in the picture, but the

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 Operating Instructions
Tightening Casing-Split Bolts 2-0410-02-01
tightening order is the same, i.e. tighten the bolts, from the one before the flange of the
first guide-blade carrier, forwards in turn, and then, from the middle, backwards in turn.
The blot numbers in the picture indicate the tightening order.

The bolts of the vertical split between the front and rear casings have been tightened in
the workshop of the manufacturer. If it is necessary to tighten them on site, one of the
tightening orders shown in Fig.2 can be selected.

Fig. 2 Tightening order of bolts for vertical casing split

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 Operating Instructions
Checking Bearings 2-0700-01-01

Check Bearings
This section mainly describes the key points that should be noticed in checking the
bearing during turbine installation. For the structure, assembling and adjusting of the
bearing, bearing carrier and bearing adjusting ring, please refer to 1-0710-, 1-0720 and
1-0730-.

Check the bearing taking the actual measurements recorded in the Product Certificate as
the reference. It may be carried out alternatively with the alignment of the rotor.

1. Radial bearing
1.1 Crest clearance
For two- and four-wedge radial bearings, measure the inner diameter of the bearing and
the outer diameter of the shaft journal. The difference between them represents the crest
clearance of the bearing.

For the tilting-pad bearing (see 1-0730- ), measure the aperture DA of the bearing
housing, the thickness W1 of the bearing ring, the thickness W2 of the pad and the
diameter d of the shaft journal. Calculate the bearing clearance S2 from the formula
below:
S2 = DA - 2 (W1+W2) - d

1.2 Side clearance of bearing pad

Usually, the side clearance of the two- and four-wedge bearing is measured with feeler
gauges with different thickness, in succession from the thicker to the thinner. If the
feeler gauge can be inserted into about 20 mm, and the measurements at four measuring
points (front and rear, right and left) are the same, the coincidence of the bearing
centerline with the axial line of the rotor is indicated. When checking the four-wedge
bearing, the bearing split is at a horizontal position, which differs with the operation
position by 45°.

1.3 Contact between bearing pad and shaft journal

In general, the staining method with red oil or blue oil (0.003~0.006mm in thickness) is
used for checking the contact mark between the bearing pad and shaft journal. After
cleaned the pad and journal (see the note), coat the journal uniformly with red oil (or
blue oil) in a length longer than the pad width. Turn the rotor slowly and uniformly, then
take out the pad and check the contact mark.

For the two-wedge bearing, the contact mark at the middle of lower pad bottom should
be continuous and even in a width about 10mm within the whole pad width. The
narrower is the contact mark, the smaller is the temperature rise of the bearing during
operation.

For the four-wedge bearing, it is at the position as mentioned in 1.2 when checking. On

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 Operating Instructions
Checking Bearings 2-0700-01-01
its lower pad there are two contact marks distributed continuously and evenly along the
axial line, with a width of 3~5mm for each. For the width of the mark, the narrower the
better, because with the narrower mark the bearing temperature will be lower during
operation.

For the tilting-pad bearing, the contact marks on two pads in the lower half of the
bearing should be distributed continuously and evenly along the axial line, with a length
longer than 90％ of the pad width.

For the turbine using titling-pad bearing, the values R1 and R2 (r1 and r2) of the bearing
housing at the same side should be equal so as to ensure that the centerline of the
bearing housing parallels to the axial line of the rotor.

2. Thrust bearing
2.1 Axial clearance
Two dial gauges are used in measurement, one for monitoring the bearing body, and
other for measuring the axial play of the rotor. After the thrust bearing (including the
adjusting gasket) mounted, turn the rotor in the sense of operation, while push the rotor
forwards and backwards. Keep the reading on the first gauge unchanged, thus the
difference of two readings on the second gauge represents the axial clearance of the
thrust bearing.

2.2 Checking the contact of the thrust pad

Coat two faces of the rotor collar with red oil (or blue oil). Turn the rotor when the
collar contacts to the primary and secondary thrust pads respectively. Then check the
contact marks on the pads. The mark area on each pad should be larger than 80 % of the
pad area.

The checks mentioned above can be carried simultaneously.

Note:
To remove the radial bearing in the turbine delivered in completion, grasp the sling with
hand making the shaft journal separate from the pad; turn out the lower half of the
bearing. Attention: When the front and rear bearing removed, the rotor is
supported on the gland bush, it is not allowed to turn the rotor at this time. For the
turbine that is delivered in several packages, the bearing is checked before the casing
jointed with the same method as that used in the turbine delivered in completion, or lift
the rotor directly and remove the lower half of the bearing. For the heavy rotor, the tool
(2-8540-00xx-xx) for raising rotor, which is provided with the turbine, can be used in
raising the rotor during removing the lower half of the bearing.

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 Operating Instructions
Heat Insulation of Turbine Casing 2-7600-01-01

Heat Insulation of Turbine Casing (Aluminum Silicate)

The heat-insulating lagging supplied with the turbine is used for heat insulation of the
turbine casing, emergency stop valve, control valve and extraction stop valve.

Preserving the turbine casing with heat-insulating lagging reduces not only the turbine
thermal lose and but also the temperature difference at the same cross-section of the
casing and consequently the heat deformation caused by the temperature difference. At
the meantime, it lowers the ambient temperature around the turbine, enhancing the
working condition for operator.

After the piping that are connected to the casing and the instruments installed, the oil
system and steam piping scavenged, the installation of the heat-insulating lagging can
be carried out.

The heat-insulting lagging is formed by irregular-shaped blanket tailored by fibergalss

cloth with aluminum-silicate filled. The shape and the thickness of the blanket are
determined by the turbine type and steam temperature. The heat-insulating lagging is
divided into inner and external layers. Each blanket has its own identification number.
The number of the first layer (inner layer) is I-xx, the second layer (outer layer) is II-xx.

The instructions, developed diagram and diagrammatic map of identification numbering

for the heat-insulating lagging can be found in the document container delivered with
the turbine. For the newly installed turbine the mounting of the lagging must be made
with great care. The blankets should adhere to the casing over their entire surface so that
no air cushions will be formed. In addition, adjacent blanket should abut tightly at the
joints without leaving any gaps. If the gaps appear due to mounting deviation, the spare
blankets can be used to fill them. For opening the turbine casing during turbine overhaul,
only the blankets at the casing-split bolts are required to be removed. After overhaul,
mount the blankets removed to the original positions. Replace old ones with spare
blankets, when necessary.

Attention: The unused blankets should be stored properly. Dragging the blanket
on the ground, standing or placing the heavy subjects on the blanket are not
allowed.

Flammable substance must not be infiltrated into the blanket. The blankets
infiltrated with turbine oil or adhered with grease must not be used.

The installation personnel should dress the tight work-clothes and rubber glove
when mounting the heat-insulating lagging.

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 Operating Instructions
Preface of Operation Section 3-0100-01-01

Preface of Operation Section

The Operation section (document No. 3-xxxx-xx-xx) in this Operating Instructions
deals with turbine operation (No. 3-1xxx-xx-xx) and common malfunctions and remedy
(No. 3-2xxx-xx-xx).

This section describes the operating requirements and key points that are to be strictly
observed during turbine start-up, operation and shutdown. Furthermore, the operating
procedure should be worked out based on these essential requirements. The user must
write up a special operating procedure that applies to individual turbine according to the
turbine application and performance, the attached documents and the laws and
regulations issued by local authority. Usually, the operating procedure includes the
responsibility of operating personnel, the specification of the turbine, the operating
program and adjustment, test and maintenance prescripts for main and auxiliary
equipments, the treatment of accident, the system diagram for equipment running and
etc.

To facilities the description, some of the operation and check items are numbered. But
these numbers do not present the order of operating steps.

In order to ensure the turbine safety run in long term the operating personnel, in
addition to understanding and observing strictly the operating procedure, should
acquaint the working principle, structure and performance of the turbine, should be
familiar with the demands of turbine operation requested by the plant process, the
changing regularity of turbine operation and characteristic under various conditions, the
functions and usage of the adjusting and operating elements and the instruments, should
remember the critical operating data and monitoring limits in heart, should summarized
the operating experience continuously and treat the various abnormal conditions timely
and correctly, and eliminate the hidden troubles and prevent the accident occurring

The Operation section in this Instructions also describes the turbine monitoring which
aim to ensure safe and efficient operation. The operation safety of the turbine, or the
reliability has a direct effect on the economical running of the turbine and plant.
Generally, the reliability means that the turbine can normally operate under a specified
output and the operating parameters are within the given range in the due operation
period, the parts and components will not damage in their normal service life. In order
to prevent the equipments from damage caused by improper operating or accident, the
turbine is equipped with the monitoring, safety and protective devices as well as the
displaying, recording instruments, audible and visible alarm and interlocking trip
system which are cooperated with the formers for realizing their functions. The
monitoring devices are used for indicating the operation parameters, such as pressure,
temperature, speed, vibration, displacement and etc, from which the operating personnel
can know the characters of the operation parameters and discover the deviation with
respect to the setpoint. The safety devices serves to emit the unfavorable conditions in

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 Operating Instructions
Preface of Operation Section 3-0100-01-01
operation by acting before the operation parameter reaches to the acting value of the
protective device, avoiding turbine trip, e.g. the safety valve for exhaust. The protective
devices function for manual or auto emergency trip once the operation parameter
reached the given limit. During turbine operation, the operating personnel should
observe the operation parameters regularly; judge the operating condition through
analyzing the displayed and recorded data. The operating personnel should immediately
report abnormal condition, if there is any detected, to the chief on duty and take the
corresponding measure to correct them. If one or several parameters alarmed and the
condition will deteriorate judged from the changing tendency and rate of the alarmed
parameter, trip the turbine decidedly to prevent person injury and equipment damage.

The safety operation of the turbine cannot rely on the monitoring devices completely,
the operating personnel should make the perambulation for the operating equipments
regularly, checking the leakage of steam, water and oil, as well as the operation state of
the auxiliary devices carefully. In the event that the abnormal conditions or faults are
detected, find out the reasons and correct them immediately, eliminating the accident in
the nascence as could as possible.

The turbine is a machine formed by thousands of parts with various functions, structures
and materials. The defects in manufacturing, improper installation and service, incorrect
operating or accidental reasons will disturb the turbine normal operation. So, in the
section numbered with 3-3xxx-xx-xx, we gave out some common faults and treatments,
which are collected by our service engineers from the field service for many years. But
they are applicable in a general way because of the different turbine types, operation
conditions and operating customs. Therefore, we are grateful to our users for giving us
their experience in turbine operation and service.

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 Operating Instructions
Steam Quality 3-0310-01-01

Steam Quality
The turbine is a rotary thermal power machine with steam as its working medium, the
quality of the steam entering into the turbine will not only has an effect on economical
operation but also be related with safety operation and service lift of the turbine. The
deposits that occur in the steam path of a turbine due to impure steam can lead to a
reduced section area of the steam path, decreased turbine output and an inefficiency,
also to increased axial thrust. The deposits that occur on the blades will increase the
stress of the blade, resulting in blade breakages. Furthermore, the deposits can lead to
seizure of the spindles of the emergency stop valve and /or control valve. Therefore, in
order to operate the turbine safely and economically in a long term, the qualities of the
steam and boiler feed water should be in line with the standard listed in the tables below.
The standard value is the limit value, while the expected value is much favorable for the
safe operation of the turbine.

1. Steam quality standard

The quality of the saturated and overheated steam from the drum boiler with natural
circulation and forced circulation and concurrent boiler should be in accordance with
the valves specified in the table 1.

Table 1: Steam quality standard

Boiler Drum boiler One-through boiler
Pressure MPa 3.5～5.8 ≥5.9 ≥5.9
项目
Standard Standard Expected Standard Expected

Parkering ≤10 -
Sodium，μg/kg ≤15 ≤10 ≤5
Volatilizing ≤10 ≤5
Parkering - -
- ≤0.30
Conductivity（after Volatilizing ≤0.30
hydrion exchanged, Neutral-water
at 25℃） treatment and
- - ≤0.20 ≤0.15
μs/cm combined-water
treatment
Silicon dioxide μg/kg ≤20 ≤20 ≤20

In order to prevent the metal oxide deposited inside the turbine, the content of the
iron and copper in the steam should be in accordance with the valve given in the table 2.

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 Operating Instructions
Steam Quality 3-0310-01-01
Table 2: Steam quality standard
Boiler type Drum bolier
Pressure MPa ≥3.8
Item Standard Expected
Iron，μg/kg ≤20 -
Copper，μg/kg ≤5 -

2. Boiler feed-water quality standard

Table 3: Boiler feed-water quality
Overheat Conductivity （after Dissolved
hydrion exchanged, Hardness Iron Copper Sodium
steam oxygen
Boiler at 25℃）
pressure μS/cm
type
of boiler μmol/L
Standard Expected Standard Standard Standard Expected Standard Expected
MPa

Drum 3.8～5.8 - - ≤2.0 ≤15 ≤50 ≤10 - - -

boiler 5.9～12.6 - - ≤2.0 ≤7 ≤30 ≤5 - - -

One-

through ≥5.9 ≤0.30 ≤0.20 ≌0 ≤7 ≤10 ≤5 ≤3 ≤10 ≤5

boiler

Overheat Silicon dioxide

steam Mg/kg
Boiler PH Hydrazine Oil
pressure
type （25℃） mg/L mg/L
of boiler Standard Expected

MPa

3.8～5.8 The content of 8.8～9.2 - ＜1.0

Drum Silicon dioxide in

boiler 5.9～12.6 the steam should 8.8～9.3（system with ≤0.3

meet the standard copper）or 10～50 or

One- 8.8～9.5（system without 10～30（volatilzing）

through ≥5.9 ≤20 - copper） ≤0.3

boiler

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 Operating Instructions
Steam Quality 3-0310-01-01
3. Water quality in the boiler
Table 4: Water quality in the drum boiler
Overheat Phosphate，mg/L
Total Silicon
steam Chloridion Evaporated in PH Conductivity
Treatment salt dioxide
pressure One-step steps （25 （at 25℃）
method
of boiler evaporated Clean Salt ℃） μs/cm
mg/L
MPa step step

3.8～5.8 - - - 5～15 5～12 ≤75 9.0～11.0 -

Parkering
5.9～12.6 ≤100 ≤2.0 - 2～10 2～10 ≤50 9.0～10.5 ＜150

The quality of the make-up water and the turbine condensate should also be
controlled according to the standard “The water and steam quality for thermal generator
set and steam power equipment” GB/T12145-1999.

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 Operating Instructions
Turbine Oil 3-0320-01-01

Turbine Oil
Usually, turbine oil of the type L-TSA46 or L-TSA32 is selected for lubricating and
control system of the turbine, except for the electric-hydraulic control system with
fire-resistant oil.

The type of the turbine oil that is used for your turbine is specified in the Technical Data
(0-0300-T.Nr.-00).

The fresh oil quality should be in compliance with the specification given in the
standard GB11120.

The inspection items and period, the quality standard that should be reached for the oil
during turbine operation are listed in the table 2.

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 Operating Instructions
Turbine Oil 3-0320-01-01
Table 1: Specification of turbine oil L-TSA
Quality index Test
Item
Prime class First class Qualifier method
46 46 46
Viscosity class（according to GB3141） -
32 32 32
Kinematic viscosity（at 40℃），mm2/s 28.8～35.2 41.6～50.6 GB265
Viscosity index not less than 90 GB1995
Pour point ℃ not higher than -7 GB3535
Flash point（open cup）℃
180 GB3536
not lower than
GB1884
Density ( at 20℃) kg/m3 See report
GB1885
Acid number mg koH/g
- - 0.3 GB264
not larger than
Neutralization number mg koH/g
See report See report - GB4945
not larger than
Mechanical impurities Nonexistence 1） GB511
Water content Nonexistence 2） GB260
Emulsification number（40-37-3）ml
15 GB7305
at 54℃，min not larger than
Foambility test ml/ml
450/0 450/0 600/0
at 24℃
100/0 100/0 100/0 SY2669
at 93℃
450/0 450/0 60/0
after 24℃
Oxidation stability
a. Total oxidate See report See report
Deposite See report See report GB8119
When the Acid number reached at SY2680
2.0mg koH/g after oxidized h 3000 2000 1500
not less than
Liquid-phase rust teat
Without rust GB11143
（syntheticseawater）
Copper-strip test （100℃，3h），class
1 GB5096
not larger than
Air separation（at 50℃），min 6 6
- SY2693
not larger than 5 5
1) With the method given in GB511, if the content of mechanical impurities is less than
0.005%, that is deemed to be non-existed.
2) With the method given in GB260, if the water content in the sample is less than
0.03%, that is deemed to be vestige. If there is no water existed in the receiver after
the instrument removed, the sample is deemed without water.

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 Operating Instructions
Turbine Oil 3-0320-01-01
Table 2: Turbine-oil quality standard during operation (GB/T7596-2000)
Inspection
No. Item Quality index
method

Visual
1 Appearance Transparence
inspection

Kinematic viscosity（at 40℃），

2 Deviation from≤20％ GB/T265
mm2/s

Not less than 15 , comparing to

3 Flash point（open cup）℃ GB/T267
original value of fresh oil

Visual
4 Mechanical impurities Nonexistence
inspection

Acid number Without antirust ≤0.2 GB/T264 or

5
mg koH/g With antirust ≤0.3 GB/T7599

6 Liquid-phase rust Without rust GB/T11143

7 Emulsifiability min ≤60 GB/T7605

GB/T7600 or
8 Water content mg/L ≤200
GB/T7601

The inspection items listed in the table 2 are the routine inspection items, all of them are
required to be carried out before the newly mounted turbine put into operation or after
the turbine overhaul. After the turbine has been operated, the inspections should be
carried out at least once a time for every year. The item 1 and 4 should be made at least
once a time for every week. The period of the inspection may be prolonged properly if
the turbine runs normally. However, if the oil is found with water, the inspections
should be increased and the proper treatment should be made in time.

The item 4 “Mechanical impurities” in the table 2 is checked with eyes. If the solid
pollutant is not visible in the oil sample, it is assumed that there is no impurity
(Nonexistence) in the oil. Since the human eyes can not see the particle smaller than
40μm. The “nonexistence” only indicates that there is no solid pollutant larger than
40μm in the oil. The visual inspection is a quick and ease method but with a rough
result. The user is recommended to inspect the mechanical impurities contained in the
oil quantitatively with proper instrument.

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 Operation Instructions
Scavenging with Oil 3-0340-01-01

Scavenging with Oil

Following completion of the installation and before the commissioning, the entire oil
system should be thoroughly scavenged with the oil (oil circulation) to eliminate all
solid pollutant which possibly had been introduced into the oil system during
installation.

For the inspection items and range for flush of the oil system after the turbine overhaul,
please refer to this instruction.

For the turbine using the electric-hydraulic control system with fire-resistant oil, the
flush for the fire-resistant oil system should be carried out according with the relative
procedure.

It is recommended that the oil system is flushed with the same type and performance of
oil that is employed for normal turbine operation.

1. Preparations
1.1 Oil tank
Before filling up with the scavenging oil, the strainer must be cleaned first. Clean the
inside of the oil tank with the new cloth and then clean out the residues with paste.

1.2 Oil filter: according to the arrangement.

1.2.1 For the system with a common filter for lubricating oil and control oil, dismount
the filer element. After one cycle period of flushing (see 2.4), mount in the
element again.
1.2.2 If the lubricating oil and control oil use their filters separately, dismount the
element of the lubricating-oil filter. After one cycle period of flushing, mount in
the element again.

1.3 Oil cooler

Connect a temporary pipe from the drain port of the cooler to the oil tank for avoiding
deposit of dirt in the oil cooler.

1.4 Bearings
For the turbine below size 40 (including size 40), remove the radial and thrust bearings.
the turbine rotor is supported on the gland bush temporary during oil flushing.

1.5 Emergency stop valve

Dismount the piston, spring and spring seat.
Close the cylinder end with blank flange.

1.6 Oil relay

Take out the plunger, spring and spring seat of the pilot valve.

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 Operation Instructions
Scavenging with Oil 3-0340-01-01
Fit an orifice at the pressure oil inlet connection on he pilot valve temporary. The
diameter of the orifice is selected within a range of 2 to 4 mm based on the size of the
pilot valve.
Block the secondary-oil inlet connection on the pilot valve.

1.7 Speed governor

For the turbine with SRIV hydraulic governor or PG-PL mechanical-hydraulic governor,
lead the input pressure-oil of the amplifier to the return oil with a temporary pipe.

1.8 Electric-hydraulic converter

The electric-hydraulic converter does not participate in the flush with oil.
For the converter that is mounted in the piping or the on a separated support, lead its
input pressure oil to return oil with a temporary pipe.
If the converter is mounted on trip block, mount the blank plate reversedly (the face
with groove is towards the trip block)

1.9 Trip Block

Lead the input pressure oil of the trip block to return oil with a temporary pipe.
Return it to the original connection since the second cycle period of flushing.

1.10 Emergency trip gear

Remove the throttle orifice at the pressure-oil inlet.

1.11 Extraction stop valve

Lead the input pressure oil of 操纵座 or oil cylinder for the extraction stop valve to the
return oil with a temporary pipe.

1.12 Jacking-oil piping

The jacking-oil pump does not participate in the flushing.
Short-connect the inlet and outlet piping of the pump so as to flush the jacking oil
piping.

1.13 Barring-oil piping

For the turbine with a hydraulic barring gear (linear stroke), lead the input oil of the
barring-oil pump to the return oil by connecting a temporary pipe.

1.14 For the turbine with its own main oil pump, block the inlets and outlets of the main
oil pump and injector. Remove the regulating valve of the injector. connect the inlet and
outlet piping of the main oil pump to the cycle piping for flushing with oil.

1.15 Instruments
The instruments in the oil system should be blocked off, except for the instruments at
the necessary monitoring points of pressure and temperature.

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 Operation Instructions
Scavenging with Oil 3-0340-01-01
1.16 Locality
Clean the surfaces of the oil piping and the equipments and surroundings.
There is no flammable substance on site and no works carried out with open fire in
surroundings.
Prepare the fire extinguisher for using at any time.

1.17 Filling oil tank

Fill the oil tank with 50 to 60% of the volume normally used for turbine operation. The
oil can not be directly filled into the tank, it should be filtered by a oil filter or strainer.

The containers for storing the oil should be clear and not confused with the containers
for other oil during transportation and storage.

2. Flushing steps and operating points

2.1 It is suggested that the flush of the oil system be carried out step by step. Flush the
lubricating-oil system first. After one cycle period, but the control-oil system in the
flushing.
2.2 During flushing, open the throttle valves at each bearing oil inlets further based on
the return oil from the bearing housing.
2.3 During flushing, run the main and auxiliary oil pumps alternatively. The Emergency
oil pump may be put in operation at the same time, making the scavenging-oil
pressure to be approximate to operating pressure of the oil system as could as
possible.

2.4 In order to increase the flushing efficiency and shorten the flushing time, besides
increasing the scavenging oil flow, alternate the oil temperature between 25 ℃ and
75℃ as showed in picture. One cycle period will last 8 hours. It should be noticed
when heating oil the temperature must not exceed 80℃ so as to avoid the oil
deteriorated. During heating
the oil, all of the piping, in temperature ℃
which the oil flows, should be
warmed up. If some of them
are still cold, find out the
reason and eliminate it. In the
course of flushing, beat the
piping, with wood or copper
hammer, especially for the
welded junctions, making the time
impurities fall off and be flushed out.

2.5 The strainer in the oil tank should be washed at least once a time for every cycle
period. After the element has been mounted in the filter, it should be cleaned
regularly. Once the differential pressure between inlet and outlet approached to the
permitted up limit, switch over and wash the filter immediately, regardless of the

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 Operation Instructions
Scavenging with Oil 3-0340-01-01
specified washing time.

2.6 Flushing the control and protection system as following procedures respectively
according with the different arrangements:
2.6.1 For the turbine with hydraulic or mechanic-hydraulic governor, at the beginning
of the second cycle period, put the trip solenoid valve into the normal operation
position, place and lock the handle of the emergency trip gear at the engaged
position. After the second cycle period, return the oil inlet piping of the governor
to normal connection. From the third cycle period, operate the starting control to
switch it between two positions, the starting position and the operating position
to flush the trip-oil piping and starting-oil piping to the emergency stop valve.
Operate the test valve of the emergency stop valve regularly so that the test-oil
piping can be washed.
2.6.2 For the turbine with trip block, place and lock the emergency trip gear at the
engaged position (it is not required for the turbine without trip block) at the
beginning of the second cycle period. From the third cycle period, return the
inlet piping of pressure oil for the trip block to normal connection and place the
manual and remote controlled trip valve in the block to the normal operation
position. Regularly operate the control valves (manual and electric) for the
starting oil and trip oil, so that the starting- and trip-oil piping to the emergency
stop valve can be flushed. Place the test valve of the emergency stop valve to
test position timely for flushing the test-oil piping.

3. Evaluation of cleanliness for oil system after flushing

When cleaning the filter element after the third cycle period, check the element through
visual inspection or touching with fingers. If no evident hard granular impurities found
on the element, it is possible to begin with the cleanliness inspection for the oil system.

There are several evaluation methods due to the different implement standards and
inspection methods. Some typical methods are given below. It is suggested to use one of
them in evaluating the cleanliness for the oil system.

3.1 Weight method I:

Fit a strainer with 120-mesh at the oil inlet of each bearing. After flushed under normal
flushing oil flow for 2 hours, take out the element and wash it with gasoline in a clear
circumstance, and then filter the gasoline with a strainer of 150-mesh. The total mass of
the filtered impurities after dried should be less than 0.2 g/t, without hard granules. This
will indicate the cleanliness of the inspected oil system qualified.

3.2 Weight method II

Sampling from the oil-line downstream the filter, filter the sample oil that has been
diluted by solvent with filter or filter paper. If the mass of the filtered impurities after
dried is less than 0.05% of sample-oil mass, the cleanliness is considered to be
qualified.

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 Operation Instructions
Scavenging with Oil 3-0340-01-01
3.3 Granule counting method I
Fit a cone strainer of 150-mesh at oil inlet of any bearing. After flushed under normal
flushing oil flow for 30 minutes, taken out the strainer and wash it with gasoline in a
clear circumstance, and then filter the gasoline with a strainer of 200-mesh. Collect all
of the impurities that are filtered out. Classify and count the impurities under a
magnifier with a magnifying ratio of 10 times at least and a scale. If the granule of the
impurity is conformed to the requirement given in table 1, the cleanliness of the
inspected oil system is considered to be qualified.

3.4 Granule counting method II

Fit a strainer of 100-mesh at the typical part in the oil system. Flush the oil system with
the normal flushing-oil flow at the temperature of 66 to 77℃ (or lower) for one hour
and hammer the piping, oil cooler and valves from time to time during flushing. After
that, take out the strainer for inspecting. If the maximum granule of the filtered
impurities does not exceed 0.25mm, the number of the granules that are distributed
randomly on the strainer is conformed to the limit listed in table 2 and there is no visible
impurities (oxide skin, scraps and sand) and touchable ash in the sample oils sampled
from at least two different parts of the oil system (downstream the oil filter), the oil
system is considered to be clean.

Table 1: Cleanliness requirement for oil system

Granule size of impurity（mm） Quantity （piece）

＞0.25 Without

0.13～0.25 ≤5

Table 2: Limit of granule quantity

Quantity
Pipe DN（inch） Wall of pipe（mm）
（piece）

2 ≤3.91 20

3 ≤5.49 45

4 ≤6.02 80

6 ≤7.11 180

4. Work after oil flushing

4.1 Restoring oil system
Remove the temporary piping, orifices and blank plugs for flushing, restore the piping
to normal connection.

Clean the insides of the oil cylinder of the emergency stop valve and pilot-valve housing,
wash the removed parts and components, including the bearings, restore the bearings,
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 Operation Instructions
Scavenging with Oil 3-0340-01-01
turbine rotor, emergency stop valve, oil cylinder and emergency trip gear to the original
states.

For the turbine bringing its own main oil pump, connect the inlet and outlet piping of
the oil pump and mount the regulating valve of the oil injector.

For the turbine with the electric-hydraulic converter mounted on the trip block, the
attention should be taken that the blank plate between the converter and the trip block is
just used in oil flushing, is must be removed after flushing.

4.2 Replacement of oil

The flushing oil has to be thoroughly drained at the end of the flushing operation so that
absolutely no residues will be left. Clean the insides of the oil tank, bearing housing,
gearbox and oil filter, wash the filter element, and then fill up the oil tank with qualified
turbine oil to the quantity required for the turbine normal operation. The measures
should be taken during filling operation for preventing the oil from contaminating.

4.3 Checking oil quality

The quality of the oil that is going to be filling or replacing should be checked first. Two
sample oils are required, one for test and other for keeping in sealed and against light as
the control sample in oil quality checking later on. The quality requirement for new
turbine oil is given in 3-0320-xx-xx (GB11120) and only the qualified oil can be filled
into the tank.

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 Operating Instructions
Purging Steam Piping 3-0350-01-01

Purging Steam Piping

The purge of the steam piping is an important measure for ensuring the turbine safety, it
should be carried out after the tightness test has been passed.

During manufacturing, welding and installing the steam piping, not only the dirt will
enter into the piping but also the oxide and welding spatter will be attached on the inner
wall of the piping. Therefore, the solid impurities with the size less than the hole of the
strainer will enter into the steam path at high speed through the strainer, colliding with
and damaging the blade and gland bush. In order to eliminate this hidden risk, the steam
inlet piping should be purged with steam prior to first commissioning after turbine
installed.

To purge the steam inlet piping with steam, the emergency stop valve must be removed
in advance, mount the “Purging tool”(2-8535-xxxx-xx) supplied with the turbine for
blocking the passage through which the steam enters into the steam path.

A temporary exhaust pipe is required for purging, the inner diameter of the exhaust pipe
should be equal to or larger than that of the purged piping with a length as short as
possible for reducing the exhaust resistance. The outlet of the exhaust pipe should be
tilted up (by approx. 30°) to the air. The exhaust pipe should be fixed by the firm
support to bearing the reaction force of the exhaust. In order to reduce the noise level
produced by exhaust, a muffler may be mounted in the temporary exhaust pipe. But the
muffler mounted will increase the exhaust resistance.

To get the efficient purging, the scouring force against the piping wall during purging
should be larger than that during normal operation. Therefore, the purging-steam
parameters is determined and controlled by a momentum coefficient K, which is the
ratio of the steam momentum m1c1 under purging condition to the steam momentum
m0v0 under rated condition, i.e.:
m ⋅v
2
mc
K = 1 1 = 12 1 K should be ≥1.2～1.5
mo c o m o ⋅ v o
Where:
m1—Purging-seam flow
m0—Steam flow under rated condition
v1—Special volume of purging-steam
v0—Special volume of steam under rated condition

Before purging, the piping should be warmed up and all of the joint bolts for flanges
should be tightened under hot state. The purging is carried out in several times, which is
based on the clean condition of the piping. Each time of purging will last for 10 minutes.
The interval time between two purges is determined by the time required for the piping
temperature to drop below 100℃. When the temperature of the piping wall dropped

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 Operating Instructions
Purging Steam Piping 3-0350-01-01
below 100℃, the impurities deposited on the wall will fall down and be blown off in the
next purging.

In order to examine and evaluate the purging result, a checkerboard may be fitted in the
exhaust pipe (Fig.1) or at the outlet of the exhaust pipe (Fig.2). It consists of a support
and target plate made of new aluminum plate with thickness of 1mm and width of
30mm, the length of the checkerboard is decided by the diameter of the exhaust pipe.
the target plate should be replaced and examined after each purging. On the premise that
the scouring force of the steam does not decrease, when the impacting blemishes on the
target plate in two adjacent purges has been ≤ 0.8mm and number of the blemishes is
less than 8, the purging is considered to be qualified.

Following the purging, remove the temporary exhaust pipe when the piping temperature
dropped to room temperature. Carefully clean the emergency stop valve housing and
remove the purging tool. Make sure that there is no impurity in the steam inlet
compartment and mount the emergency stop valve.

Hangzhou Steam Turbine Company Limited Page 2 of 2

 Operating Instructions
Turbine Start-up 3-1100-01-01

Turbine Start-up
Turbine start-up is a process in which the turbine is brought to a certain load from
standstill. This section simply describes the change rules of the factors that are related to
turbine safety and life during start-up. The proper operation is based on mastering and
observing the objective laws of the start-up. Please see the instructions in 3-13xx- for
the detailed starting procedure.

The working condition and stress of the main components in the turbine (casing, rotor
and etc) are going to be changed severely and complexly in the course of starting, due to
heated. When starting, the steam, under high temperature, entering into the turbine will
pass the heat to the components that are exposed to it through condensation heat transfer
and thermal convection. Thus, the heated components will be bound to expand. Once
the expansion is restricted, the thermal deformation and stress will appear. Although the
thermal expansion, deformation and stress as well as the differential expansion between
the casing and the rotor are inevitable during turbine starting, they can be controlled
within the permissible range through proper operating, ensuring the turbine for
successful start-up and safety operation.

The steam enters into the turbine through the emergence stop valve. The uneven
temperature distribution in the valve housing after it heated by steam will produce a
tremendous thermal stress in it. In order to improve the stress of the valve housing, it
required to be preheated for a certain time during turbine start-up. Usually, the preheat
of the valve housing is carried out during turbine warming-up at low speed.

After the steam entered into the turbine casing, it will heat the inner wall of the casing,
then transfer the heat to the outer wall and the split flange. Due to the thermal resistance
in the course of heat transfer, a large differential temperature will appear between the
inner and outer walls of the casing as well as the inner and outer sides of the flange. The
expansion of the inner wall is larger than that of the outré wall, thus the casing and the
flange will be deformed horizontally and vertically during heating. This may cause the
moving and stationary parts to collide each other. If the stress exceeds the permitted
valve due to the excessive temperature difference, the plastic deformation of the casing
and the flange will occur and so far to cause the casing cracked in the control stage zone.
Once the casing is deformed plastically, it is evitable that the sealing function of the
casing split becomes inefficient, resulting in leakage.

During starting, the heat is transferred from the casing wall to the flange and then to the
split bolts. Since the temperature of the flange is higher than that of the bolt, the
expansion amount of the flange in thickness is larger than the elongation amount of the
bolt. The bolt will be deformed plastically if the its stress exceeds the permitted value
due to the excessive temperature difference between the flange and the bolt, resulting in
split leakage.

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 Operating Instructions
Turbine Start-up 3-1100-01-01
Except for the full-admission turbine with high parameters and the turbine of WK
model, most of the turbines adopt the top-half-admission, and additionally the heat
radiation of the bottom casing is faster than that of the top casing. Therefore, the
temperature of the top casing will be evidently higher than that of the bottom casing.
The excessive temperature difference between the top and bottom casings will hog the
casing. This may cause the moving and stationary parts to collide each other. In addition,
if the rotor is heated at standstill, the uneven temperature distribution between the upper
and lower parts of the rotor will cause the thermal flexure of the rotor. Usually, the
thermal flexure of the rotor is a kind of elastic deformation, but it will become plastic
permanent deformation under improper treatment. To rotate the rotor when it has a
larger flexivity is not allowed, because this will cause not only the vibration aggravated
but also the moving and stationary parts to collide each other, resulting in the flexivity
increased and plastic permanent deformation. Therefore, the rotor can not be heated at
standstill.

During turbine start-up or stop, the expansion amounts of the casing and the rotor are
not same because of the different heated conditions, materials and masses. The
difference between them is called as differential expansion. In the course of starting, the
casing heated by the high temperature steam will expand along the axial line taking the
dead-point (Exhaust end) as the reference. And at the same time, the front bearing
housing or thrust bearing carrier that is used as the axial positioning for the rotor moves
forwards too. Since the rotor is surrounded by the steam and additionally the rotor mass
is much less than the casing one, the temperature of the rotor rises faster than the casing.
The elongation amount of the rotor along axial line is larger than the expansion amount
of the casing and they expand in opposite directions. At this moment, the differential
expansion is called as a positive differential expansion. In the course of turbine stop, the
differential expansion between the casing and the rotor is negative differential
expansion. When the differential expansion reaches to the specified limits, it indicates
that the clearance between the moving and stationary parts is less than the required
minimum valve. For the turbine connected to the driven machine with a rigid coupling,
the excessive differential expansion may cause the axial clearance between the moving
and stationary parts in the driven machine to be changed beyond the limits. The
collision of the moving part with the stationary one is bound to damage the equipment.

The description above shows, during the turbine starting the temperatures of the casing
inner wall and the outer part of the rotor is rising continuously with the rise of the steam
parameter and the increase of the flow. Since the temperature rise in the outer wall of
the casing and the centric part of the rotor lags behind that in the outer wall of the
casing and the outer part of the rotor, the compressive stress will be produced in the
inner wall of the casing and the outer part of the rotor. The process of the turbine stop is
a cooling down process of the casing and rotor. With the decrease of the steam
parameter and flow, the temperature at the rotor surface and casing outer wall will be
lower than that at the centric part of the rotor and casing inner wall. Thus, a tensile
stress is produced in the casing inner wall and outer part of the rotor. This will

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 Operating Instructions
Turbine Start-up 3-1100-01-01
completes an alternating thermal stress cycle, which is also called as low-cycle fatigue,
from the turbine starting to stopping. The low-cycle fatigue will shorten the turbine lift
and make the turbine aged, risking the accident. Therefore, the starting and stopping
times should be reduced as could as possible and the frequent load change should be
avoided during turbine operation.

The starting characteristic of the turbine is varied with the turbine size, steam parameter
and application. The starting curve 0-0320-T.Nr-00 in the attached document is
applicable to your turbine. The starting time given in the curve is calculated through
controlling the temperature change rate in consideration of the thermal stresses in the
emergency stop valve housing, casing and rotor as well as the expansion difference
between the casing and the rotor. It is the shortest time required to bring the turbine to
the rated operating condition from standstill under rated steam parameter. The actual
lasted time during turbine starting must not be less than the given starting time.

The turbine can be started with the constant-parameter or variable-parameter. In the

former, the fresh steam pressure and temperature are constant and at rated value in
whole starting process, while in the latter the steam parameters are changing gradually.
With the variable-parameter starting, the turbine is rotated with the lower pressure steam
with a superheat degree above 50℃. After that, rise the pressure and temperature of the
fresh steam gradually until to rated values. For the cold starting of the turbine of model
H (the temperature of the casing and rotor is less than 150 ℃ ) , use the
variable-parameter starting as could as possible if the operating conditions of the boiler
and plant are permitted. This is because during cold starting the high temperature steam
will be cooled and condensed when it contacts with the components at lower
temperature, the steam passes the heat to the turbine through condensation heat transfer
and the surface temperature of the component rise quickly, once the steam temperature
reached to the saturation temperature corresponding to the throttled steam pressure the
heat transfer becomes thermal convection. The coefficient of the condensation heat
transfer of the steam is much larger than that of the thermal convection and increases
with the pressure rising, therefore to start the turbine with lower pressure steam with a
certain superheat degree will slowdown the temperature change rate of the component
when in is heated, eliminating excessive temperature difference and thermal stress.
Another advantage of the variable-parameter starting is shortening the starting time.
When starting the turbine under hot state, the temperature of the fresh steam must be
higher than that of the casing.

In order to ensure the successful starting (or stopping) and safety of the turbine, it can
be equipped with following monitoring instruments according to the requirement:

Casing thermal expansion indicator: It is mounted on the front pedestal of the turbine.
The operating personnel can locally monitor the absolute expansion of the casing from
the indicator pointer. In the normal condition, the free expansion of the casing under
guiding is guaranteed by the sliding-key system of the turbine, the pointer will move

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 Operating Instructions
Turbine Start-up 3-1100-01-01
continuously. If one of the sliding keys is seized due to improper in installation during
starting, the movement of the pointer will be seized or jumped, the turbine vibration will
be increased at the same time. In this case, decrease the turbine speed to a certain value
and run it for a period of time. If the condition has not been improved yet, the turbine
must be stopped and handled.

Casing absolute dilatometer: It consists of sensor, preamplifier and indicator and may be
used in the control room for monitoring the casing expansion.

Differential expansion detector: It consists of sensor, preamplifier, indicator and relay

module and used for monitoring the differential expansion between the casing and the
rotor. Besides indicating the normal differential expansion, it has two alarm points, the
warning alarm and risk alarm. Once the differential expansion reached to the preset
limits, it will send out alarm or trip signal respectively.

Eccentricity detector: The eccentricity detector of BENTLY company is a

microprocessor-based detector. It serves to indicate the deflection of the rotor for
determining whether the turbine can be started normally or not.

Casing temperature detector: The differential temperature is calculated by a computer

according to the temperatures of the top and bottom casings measured with
thermocouples. When the differential temperature reached to the permitted limit it will
alarm. The speed (load) change of the turbine will be forbidden by the command from
the controller.

The monitoring instruments mentioned above are optional, except for the casing
expansion indicator.

During turbine start-up, the speed, shaft vibration and displacement, bearing
temperature and etc must be monitored. Please refer to section “Operation monitoring”
3-2010- for details.

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 Operating Instructions
Preparation prior to Turbine Starting 3-1220-01-01

Preparation prior to Turbine starting

Prior to the turbine starting, some necessary operations and checks should be carried out
so as to ensure the turbine successful start-up. This section will describe the
preparations prior to turbine cold starting. The preparation concerning in turbine hot
starting will be decided based on the shutdown duration. The preparations of the
operating circumstance, boiler, driven machine and auxiliary devices should be carried
out in accordance with the related procedures.

1. Steam system
1.1 The isolated valve and bypass valve before the emergency stop valve are closed.
1.2 The emergency stop valve and control valve are closed.
1.3 The drain valves to the air in the main steam and extraction piping are opened. The
drain valves in the piping connecting the casing, balance pipe and extraction pipe to
the drain flash tank are closed.
1.4 The inlet valve and drain valve in the steam supplying piping for the gland bush are
closed.
1.5 The extraction stop valve and isolated valve are closed.
1.6 The Steam inlet valve, the air valve and the drain valve for the air ejector are closed.
1.7 The steam inlet valve and the drain valve for the gland steam cooler are closed.

2. Oil system
2.1 Oil quality is checked off.
2.2 Oil level of the oil tank is at normal position.
2.3 The isolated valves of the inlet and outlet for the oil pump and the inlet and outlet
valves of the oil cooler and filter are opened. The changeover valves of the oil
cooler and filter are placed at the working position. The cooling water inlet valve is
closed and outlet valve is opened.
2.4 If the oil temperature in the tank is lower than 20℃, it is required to be heated by a
heater or through putting the oil pump into operation in advance. The inlet oil
temperature of the bearing during turbine starting must be ≥35℃ .
2.5 Starting oil pump: Where the main oil pump is driven by the turbine, start the
auxiliary oil pump. Where the oil is supplied by an external pump, start the electric
main oil pump. After the oil pump operated, the vibration and noise of the pump
should be within normal range, the output oil pressure stable, the control-oil
pressure ≥0.8Mpa, the oil pressure in the lubricating-oil header approx. 0.25Mpa.
2.6 Observe whether the return oil of each bearing is normal or mot through the viewer.
Check all of the oil piping joints for no leakage.
2.7 Where the hydraulic accumulator is provided, check the nitrogen filling pressure.
The required pressure is given in attached document 0-0300-T.Nr-00.
2.8 Start vapor exhaust fan to form a weakly negative pressure inside the oil tank,
return-oil tank, return-oil piping and bearing housing. Usually, it is within 5 to 10
mm H2O during normal operation. Before turbine starting, the vacuum in the oil
tank may be a little higher than this valve. But the excessive vacuum will cause a

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 Operating Instructions
Preparation prior to Turbine Starting 3-1220-01-01
large amount unclean air and steam to be drawn into the oil system

3. Steam condensing system

3.1 Where the exhaust is led to the common condenser, the vacuum butterfly-gate is
closed tightly.
3.2 Fill up the steam side of the condenser with water, which should be the condensate
in accordance to the requirement or treated chemically, to the level of 3/4 indicated
by the level gauge of hot well.
3.3 Fully open the outlet valve of the cycling water and slightly open the inlet valve.
3.4 Open the water inlet valve of the condensate pump and the cut-off valve in the air
piping from the condensate pump to the steam side of the condenser. Close the water
outlet valve to the boiler feed water system. After the condensate pump operated,
gradually open the outlet valve of the condensate pump. Open the recycle valve, the
water-supplying valve to the water-sealing element of the vacuum system. The level
auto control system of the hot well is disabled temporarily.
3.5 Putting the air ejector into operation
Gradually open the steam inlet valve of the starting air ejector until the pressure after
the valve reached to 0.2 MPa. Warm up the piping for 5 minutes, and then rise the
pressure to the normal working pressure. Slowly open the air valve between the air
ejector and the condenser, building up vacuum in the system. When the vacuum reached
to –0.04 MPa and the condensate pump has worked normally, start the main air ejector.
Warm up the piping of the main air ejector; open the drain valve of the cooler when the
steam admitted. Put the second stage of main air ejector first and then the first stage.
After the main air ejector has operated normally, stop the starting air ejector. During
stopping, close the air valve first and then the steam inlet valve.

When turbine starting, the vacuum should be at –0.06 MPa, the minimum value cannot
be less than –0.053 MPa.

4. Supplying gland steam and barring

In order to build up the vacuum in the condensing system quickly, it is required to
supply the gland steam for the gland bush during barring. The attention must be paid
that supplying the steam for the gland bush under rotor standstill should be avoided.
Adjust the supplying steam flow based on the vacuum change in time. Meanwhile, once
the gland bush has be supplied with the steam, rotated the rotor as soon as possible, so
as to avoid the excessive temperature difference between the upper and lower parts of
the gland bush.

The attention must be paid during turbine hot starting, under barring the gland bush
should be supplied with gland steam first and then start the air ejector to build up the
vacuum. The cold water or cold steam (the temperature lower than casing temperature)
should be avoided entering into the gland bush during supplying the gland steam.

Before turbine staring, the barring gear must be put into operation in advance, it is

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 Operating Instructions
Preparation prior to Turbine Starting 3-1220-01-01
important especially for turbine hot starting. Where the shaft jacking system is provided,
enable the barring gear after the jacking system has worked normally.

For the turbine with manual or hydraulic discontinuous-type barring gear, the barring
gear must be disabled before the rotor rotates. But the interval from stopping barring to
rotating the rotor should not be longer than 5 minutes.

5. Protection system
Before checking and adjusting protection and control system, the steam source to the
turbine must be cut off.

5.1 The emergency trip gear is engaged. The manual trip valve, trip solenoid valve and
extraction solenoid valve are at normal operation states.
5.2 Opening emergency stop valve and trip test:
Where the trip block is provided, refer to the description in 1-2001-xx-xx. For the
turbine without the trip block, see 1-1840-xx-xx. For the extraction turbine, open the
extraction stop valve following the emergency stop valve fully opened, and then
under valve fully opened, carried out trip tests manually and remotely, respectively.
After received the trip command, the emergency stop valve and the extraction stop
valve should close immediately. The closing time of the stop valve should be less
than 1 second.
5.3 Where the test slide valve for the overspeed governor is provided, the slide valve
should be at the normal operation position.
5.4 The pressure protection functions for exhaust and extraction are leased temporarily.

6. Control system
The control system should be adjusted and tested prior to the first starting for the newly
installed turbine or after turbine or control system overhauled. Otherwise it is not
required to readjust before turbine starting, except for the routine inspection. If the
adjustment is necessary, please refer to section 3-1400-01-xx “Turbine commissioning”.

For the turbine with hydraulic or mechanic-hydraulic governor, continue to operate the
starting control after the emergency stop valve opened for building up the secondary-oil
pressure. The secondary-oil pressure 0.15 MPa and 0.45 Mpa correspond to the zero and
full openings of the control valve, respectively. When the emergency stop valve tripped,
the control valve should be closed simultaneously. Before the turbine starting, set the
speed governor at its low limit. Where the extraction is provided, set the extraction
controller at zero extraction position. For the turbine with the controlled backpressure or
fresh-steam pressure, set the backpressure or fresh-steam pressure controller at its low
limit before they take over the control.

For the turbine with digital controller, select the manual control mode in open loop on
the controller. Change the output of the controller after the emergency stop valve
opened. The minimum output of the controlled corresponds to the secondary-oil

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 Operating Instructions
Preparation prior to Turbine Starting 3-1220-01-01
pressure 0.15 MPa from the electric-hydraulic converter and zero opening of the control
valve, while the maximum output of the controller corresponds to the secondary-oil
pressure 4.5MPa and full opening of the control valve. When the emergency stop valve
tripped, the control valve should be closed simultaneously. The controlling functions for
extraction pressure and backpressure or fresh-steam pressure in the controller are all at
the “disabled” states.

7. Instruments
All of the readings on the primary and secondary are in accordance with current states
the measured parameters.

8. Warming up piping
Warm up the main steam piping before the isolated valve.

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Manual Instruction Starting Turbo-generator 3-1320-01-01

Starting Turbo-generator
Make sure that the preparations have been ready, commence to start the turbine.

1. Warm up pipe
Warm up the main steam pipe between the emergency stop valve and the isolated
valve, gradually open the bypass valve of the isolated valve and then open the isolated
valve slowly. The pipe warming operation should be carried out according to the
pressure and temperature rising rate specified in the whole procedure. After the
pressure before the emergency stop valve reached to the rated value, open the isolated
valve.

2. Starting Curve
The attached document 0-0320-T.Nr-00 contains the turbine starting curve as
shown in the picture below. It contains two groups of curves. The longitudinal

coordinate of the upper group curve is power ratio P ( P = P / PN ). In the equation, P

is turbine actual power, PN is turbine rated power. The horizontal coordinate is the
time required for starting, express it using tA. For the lower group of the curves, the

longitudinal coordinate is speed ratio n ( n = n / n N ). In the equation , n is actual

speed , n N is rated speed. The horizontal coordinate is the time required for starting,
express it using tN . It is the shortest time that the turbine speed rises to rated speed
from stillness including the pre-warming time of the emergency stop valve housing. tA
is the shortest time the turbine load rises to rated value from stillness, which includes
tN.
Manual Instruction Starting Turbo-generator 3-1320-01-01

Each group of curves includes several starting curves suitable for different state.
The cold state means that the temperature of the turbine casing is at room temperature
during starting. If the temperature of the casing inner wall in the governing stage is
higher than 150℃, it is called hot state. The starting curves for hot state are usually
given out based on the interval from stopping to restarting. When the stopping time is
between the given time, the starting curve can be deduced with interpolation method.
When the measuring point of the casing temperature is provided, the starting curve for
hot state is given out based on the temperature of the casing inner wall at the
governing stage.
If the forbidding speed to stay area exists in the turbine, its up and low limit will
be indicated in the starting curve. The speed must pass through this speed area quickly
and continuously during speed raising.

3. Open emergency stop valve

Open the emergency stop valve with the starting governor (1-1840-) or the starting
valve mounted in the trip block (1-2001-).

4. Rotate rotor and warm up turbine in low speed

Open the casing and the drain valves of extraction pipe. The manual or hydraulic
discontinuous-type turning gear must stop before rotating the rotor. The interval from
stopping turning gear to rotating the rotor should not exceed 5 minutes.
For the turbine using a hydraulic governor, the governing valve is opened
through continuing to operate the starting governor after the emergency stop valve has
been fully opened. If the electric-hydraulic control system is provided, increase the
Manual Instruction Starting Turbo-generator 3-1320-01-01

governor output in a preset operating mode (speed control or valve-position control).

The governing valve will be opened with the raising of the secondary-oil pressure
from the electric-hydraulic converter.
When rotating the rotor under the same working condition as the test running, if
the secondary-oil pressure P2> P2’+0.015 Mpa, and the rotor is not yet be rotated,
stop turbine immediately and find out the reasons. P2’ is the secondary-oil pressure
when the rotor begins to rotate during test running.
After the rotor has been rotated, run the turbine stably in the warming -low speed
via controlling the opening of governing valve. The warming -low speed is usually 10
to 15% of the rated speed. During the speed time, check the rotating condition of the
turbine carefully.
After the rotor has been rotated, check and make sure that the electric turning
gear has been locked at the quit position, if it is used. For the turbine with the oil
turbine turning, close the oil inlet valve and stop the shaft jacking system.
During the rotor rotating and the turbine warming up at low speed, the attention
should be paid to drain. When the colorless steam is emitted from the drain port, close
the drain valve in time.
When the level of the condenser hot-well has been raised and the water quality
qualified, gradually open the condensate outlet valve of the feed water system. The
automatic control system of the hot-well level may be enabled at this moment.

5. Raise speed
Raise the turbine speed from the low warming-up speed to the rated step by step.
After the speed reached to 80％Nn , the inlet oil temperature of the bearing should
not be lower than 42℃. When it is higher than 42℃, adjust the opening of the water
inlet valve of the oil cooler to keep the inlet oil temperature within the range of 45±3
℃.

When the main oil pump is driven by the turbine shaft, switch the auxiliary oil
pump to the main if the turbine speed reached to 80～85％Nn . For the turbine speed
and outlet pressure of the oil pump when switching, please refer to the recorded data
Manual Instruction Starting Turbo-generator 3-1320-01-01

during test running.

When the turbine speed reach to the low limit of the governor, increase the speed
given point of the governor for raising the turbine speed to the rated.
Usually, the abnormal condition, such as excessive vibration, occurs during
speed raising, lowers the speed firstly and continues to raise the speed after stabilizing
for a while.
For the turbine with gland steam condenser or gland steam regulator, it is
required to adjust according to the gland steam condition during speed raising and
load exerting in time.
After the turbine speed reached to the rated, the vacuum of the condenser should
reach to the rated value. The vacuum monitoring can be enabled at this moment. At
the same time, carry out an overall inspection for turbine operation and prepare for
paralleling in grid.
When the turbine is running with no-load, the steam flow passed through the
turbine is very small. It is not enough to carry off the heat in the exhaust section,
resulting in the exhaust temperature rising. The excessive high temperature of the
exhaust not only will change the turbine center, resulting in vibration, but also may
cause the expand joint of the cooling pipe in the condenser loose. Therefore, the
turbine can not run under no-load at rated speed for a long time and the exhaust
temperature must not exceed 120℃.

6. Exert loading
Once the turbo-generator has been paralleled in the grid, load up it with
approximate 5% PN to avoid impact of the reversal load immediately.
During load setting, the loading rate should be controlled. This is because the
steam pass through the turbine under no-load operation is smaller, so that the turbine
is not warmed-up completely. With the steam flow increasing during loading, the
pressure and temperature in steam flow is increased, the turbine is heated
continuously. In order to keep the expansion and thermal stress of the heated
components within the permitted range, the loading rate must be controlled.
Manual Instruction Starting Turbo-generator 3-1320-01-01

According to the changing rule of the temperature permitted rising rate, the loading
rate in the low-load zone may be a little fast, but in the high-load zone the loading rate
must be slow down. For a cold-starting turbine, it will take approximate 0.35 tA for
power increasing from 5％ PN to 50％PN. And approximate 0.65tA from 50％PN to
100％PN . For the hot-starting turbine, the ratio of the time in different load zone is
different for the stopping time. In general, with the shortening of the stopping time,
the ratio of the time lasted in low-load zone will decrease, while that lasted in
high-load will increase.
When turbine load rises to 30% PN, the drain valves of front turbine casing
should be closed. For the condensing steam turbine that the steam is discharged
upwards, the drain of exhaust chamber must be always open and keep unimpeded so
as to prevent the water in the steam casing from causing water hammer on the blade
and resulting in damaging to the turbine or the personnel.
For the turbine with controlled extraction, the extraction control can be enabled
after the turbine power reached to the minimum value under extraction operating
condition, which is given in the Power & Flow Curve (0-0306-T.Nr-00). When the
pressure at the extraction port is higher than the pressure in the extraction line, open
the extraction stop valve to supply steam to the extraction line. After that, close the
drain valve in the extraction pipe and enable the extraction pressure monitoring. The
change rate of the extraction flow (increasing or decreasing) should not be too fast. It
is about 5% of the rated extraction flow per minute usually.
For the turbine with non-controlled extraction, when the pressure at the
extraction port is higher than that in the extraction line behind of the check valve in
loading, open the non-extraction stop valve or isolated valve to supply the steam to
the extraction line, and then close the drain valve of the non-extraction line.
The monitoring demanding of the shaft vibration, shaft displacement, bearing
temperature, casing expansion and parameters of the main steam and exhaust during
starting, please refer to the document 3-2010-xx-xx.

When the H and HN type (inlet temperature is greater than 510 ℃ or inlet
Manual Instruction Starting Turbo-generator 3-1320-01-01

pressure is greater than 10MPa ) turbine starts, in order to prevent large temperature
difference of the upper and lower cylinder caused by uneven heating, sliding pressure
start is recommended to use, if the boiler conditions is allowed. For the specific
operation method, you can contact to the field service personnel or the designer of our
company. If starting the turbine in the rated steam condition, the temperature changing
can be measured timely through measuring element installed on the upper and lower
cylinder for the larger size turbine. At the same time, the turbine is operated stably in
more than 20% load condition to make uniform heating. If the unit is equipped with
external cylinder temperature compensation device, it should be opened in time.
 Operating Instructions
Turbine Commissioning 3-1400-01-01

Turbine Commissioning
The commissioning must be carried out first after the turbine-set installed and before
put into production.

The main purposes of the turbine commissioning are:

1. All-round assessment of the quality for whole engineering.
1.1 The quality of the civil-work design and construction and the quality of the
equipment installation.
1.2 The synthesis performance of the boiler, steam turbine, driven machine and
auxiliary devices.
2. All-round assessment of the capacity of the leader, organization, technic and
management, as well as the staff diathesis
3. Understanding and mastering the operation rule and eliminating the defect to lay
good foundation for normal production.
4. Offering the grounds for perfecting and revising the operating procedure and technic
renovation.

In general, the commissioning is carried out in two steps, turbine sole test running and
turbine-set loaded test running. The Commissioning should be also carried out after the
turbine overhaul.

Turbine sole test running

1. Preparation before test running
The preparation related to the turbine before test running should be made according to
the description in the section “Preparation before turbine starting” of the Operating
Instructions”. For the backpressure turbine or the condensing turbine, see 3-1210-01-xx
or 3-1220-01-xx, respectively.

1.1 Flushing oil system, see 3-0340-01-xx.

1.2 The steam piping blowing includes the main steam piping, the steam inlet piping of
the ejector and the gland steam piping (condensing turbine). The blowing of the
main steam piping, see 3-0350-01-xx.

1.3 Inspecting tightness of vacuum system

For a condensing turbine, the vacuum tightness at the steam side of the condenser, in the
exhaust section of the rear casing and of the device and piping that are under vacuum
state during turbine no-load operation should be inspected.

With the water-filling test method, the chemical treated water or industrial water can be
used as the filling water. Usually, the water filling level is 100 mm below the gland-seal
recess. Connect a transparent plastic tube as a water gauge before filling the water for
observing the water level. After inspection, drain out the filled water (the chemical

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
treated water can be delivered to the deaerator).

When inspecting with the pressuring method, fill the compressed air with a pressure
≤0.1Mpa into the casing, the end of the outer gland seal of which is wrapped with
rubber or plastic strap. Check the leakage at the flange joint, welding seam, connection,
choke-plug, cooling piping of the condenser and expanded joint with soap lye.

No matter which method is used, the operating pressure of the exhaust relief valve
should be set higher during inspection and restored to the normal value after inspection.
Where the rupture disc is provided for the condenser, the disk should be removed and
the connection blocked with the blind flange.

1.4 Prepare enough turbine oil with the same type and characteristic as the operating oil
for adding or replacing when the oil quality disqualified in test running.

1.5 Disconnect the coupling between the generator and the turbine (or geabox).

1.6 Steam and water systems

1.6.1 Set the operating pressure of the exhaust relief valve for the backpressure turbine.

1.6.2 Carry out the changeover test of the condensate pumps and adjust the controller of
the hot-well level for the condensing turbine.

1.6.3 Performance test of the air ejector

Before starting a condensing turbine, the air ejector has to be operated normally. Put the
starting ejector into operation first after the condensate pump has supplied the ejector
with cooling water. Open the drain valve of the cooler for main ejector, and then open
the steam inlet valves of the second and first stage ejectors in turn. The reading in the
vacuum gauge of the main ejector should be reached to the theoretical value
(corresponding to the saturation-steam pressure under condensate temperature) when
the air valve of the ejector closed. When the air valve has been opened, the turbine
turned and the gland seal supplied with the gland steam, the vacuum in the condenser
should be reached -0.06Mpa. It cannot be lower than –0.053 Mpa. If this requirement
cannot be met, the relative examination and handling should be carried out according to
the description in “Abnormal operation of the air ejector” 3-0320-02-xx.

1.7 Oil system

1.7.1 Interlocking start and stop test of the emergency oil pump.

1.7.2 For the turbine with external oil pump, carry out the interlocking changeover test
between the main and auxiliary oil pumps.

1.7.3 Verify the oil-level alarm of the oil tank.

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
1.8 Protective system
Before adjusting the emergency stop valve and control system, it must be ensured
that the steam source to the turbine has been blocked.

Measuring the closing oil pressure of the emergency stop valve: After the emergency
stop valve opened, lower the trip-oil pressure and record the oil pressure at which the
valve closed. Where the trip block is provided, lower the trip-oil pressure through
closing the valve in the trip-oil line or the discharge valve of the oil pump. When the oil
pressure drops to approximate 0.45 Mpa, slow down the lowering rate. For the turbine
without the trip block, lower the trip-oil pressure by turning the starting control
clockwise.

1.9 Control system

The adjustment of the control system should be carried out when the system oil
temperature is higher than 35 ℃ under the slide valve of the pilot valve rotated. The
adjusting result should be recorded.

1.9.1. For the turbine using SRIV governor (see 1-1110-01-xx), input a simulated
primary oil temporarily from outside to the governor for measuring the relationship
between the primary oil pressure P1 and the secondary oil pressure P2, the speed control
range as well, against the Governor Characteristic Line (0-2500-T.Nr-00) in the attached
document. The speed droop δ is calculated with the formula
δ = ΔP1 / P10 + 1 − 1 (where, P10 - primary-oil pressure under rated operating condition,

ΔP1 - speed difference between the primary-oil pressure at no-load speed and P10

under the speed setpoint unchanged. Measure the relationship among the secondary-oil
pressure P2 and the oil-relay stroke hZ and the control-valve stroke hV against the

Control Valve Characteristic Line (0-2505-T.Nr-xx) in the attached document. If there is

no stimulated primary-oil source available in site, the secondary-oil pressure can be
changed through operating the comparator lever of the governor with the starting
control (1-1840-01-xx).

Whether the stimulated primary oil is used or not, the “overshoot point” of the governor
and the “cut-off point” (see 1-1830-xx-xx) of the amplifier should be checked during
adjusting. Readjust them when necessary.

If the relationship of P2 with hV and hZ is required to reset during adjusting, the

setting method is given in sections “Control Valve” 1-0800-xx-xx and “Oil relay”
1-1910-xx-xx.

For the turbine with controlled fresh steam pressure or backpressure, check the related

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
functions of the control system through changing the output of the pressure controller.

Where the controlled extraction is provided, set the extraction controller at “zero” or
“max” extractions respectively for checking the relationship between the secondary-oil
pressure and the stroke of the control valve under different extraction conditions. Check
the hydraulic reference value relay (1-1114-01-xx) if it is functioned.

1.9.2 For the turbine using WOODWARD 505, 505E or other digital governor, check
the governor configuration item by item against the Programming Worksheet. If there is
no error in the governor configuration, switch the governor to the run mode, change the
governor output manually for check the relationship between the governor output signal
and the secondary-oil pressure delivered by the electric-hydraulic converter. Measure
the relationship among the secondary-oil pressure P2 and the oil-relay stroke hZ and

the control-valve stroke hV against the Control Valve Characteristic Line

(0-2505-T.Nr-xx)

When the turbine uses 505E governor, check the entered data for operating condition
whether they are met with the requirement in service mode.

1.10 Instruments
Verify the alarm value and trip value of the instruments used for monitoring the speed,
bearing temperature, shaft vibration, axial displacement, lubricating-oil pressure,
extraction and exhaust pressures.

2. Turbine sole test running

Start the turbine following the instruction in 3-13xx-01-xx. The starting time should be
prolonged properly for the first start-up, compared with the starting curve.

During test running, fill in the log and make the operation record as required.

For the high parameter turbine (e.g. H model), the lower pressure steam can be used in
sole test running.

2.1 Rotating rotor for low-speed warming up

Record the inlet steam parameters, the secondary-oil pressure and the stroke of the
control valve during rotating the rotor.

Usually, the speed for low-speed warming is 10 to 15% of the rated speed.

2.2 Raising speed

Raise turbine speed according to the starting curve. After the speed reached to the speed
low limit of the governor, change the speed setpoint until to rated speed.

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
2.3 Adjusting and testing
2.3.1 Verifying function of trip device
During low-speed warming or raising speed, make the emergency trip gear, manual stop
valve and trip solenoid valve act respectively, the emergency stop valve and the control
valve should be closed immediately. The close time of the emergency stop valve must
be less than 1.0 second.

2.3.2 Switching from auxiliary oil pump to main oil pump

Where the main oil pump is driven by the turbine shaft, switch from the auxiliary oil
pump to the main oil pump when the turbine speed reached 80 to 85% n N and measure

the turbine speed and discharge pressure of the oil pump while changeover. Since the oil
system used in workshop test running differs with that in site, the changeover speed and
oil pressure recorded in the Product Certificate is for information only. The data
measured in this test running will be taken as the reference for starting later on.

2.3.3 Setting speed governor

After the turbine speed reached the minimum governor speed, change the speed setpoint
to examine the minimum and maximum governor speeds whether they are in
conformance to the requirement. For the turbine using SRIV governor (see
1-1110-01-xx for details), if the synchronizing range is not in conformity with the
requirement, correct the length of the threaded rod for the manual reference-value setter,
or adjust the position of the limit nut for the electric positioning gear (1-1850-01-xx).
Where the electro-hydraulic control system is used, the actual values of the minimum
and maximum governor speeds are usually in conformity with the data entered in
programming. If the adjustment is required, correct the assignments for the minimum
and maximum governor speeds only under turbine shutdown.

2.3.4 Functional test of emergency stop valve

During normal turbine operation, carry out the functional test for the emergency stop
valve with the test valve (see 1-2300- for details). The oil pressure P2 at which the test
piston begins to move must less than the permitted test pressure P1. Record the valve of
P2 as the comparison reference for this test later on.

2.3.5 Functional test of emergency governor

Where the emergency-governor testing valve is provided, the functional test of the
emergency governor can be carried out under normal speed, taking the test data in the
Product Certificate as the reference value.

2.3.6 Overspeed trip test

When the turbine speed reached the maximum governor speed and under the condition
that all of the monitoring parameters are in normal, commence the overspeed trip test.
The overspeed trip speed is 1.09 to 1.11 n N . Here n N is the turbine rated speed.

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
For the turbine using hydraulic control system, raise the turbine speed continuously with
the conical handle at the front end of the speed governor (see 1-1110- for details).
During operating, observe the speed change and listen the sound inside the turbine
carefully. Especially when the turbine speed has been close to the acting speed of the
emergency governor, press the handle slowly and stably. Once the sound that the
eccentric bolt strikes the trip lever of the emergency trip gear is heard and the
emergency trip gear is tripped, release the handle immediately. The acting speed of the
emergency governor must be witnessed and recorded by assigned person.

The reset speed of the eccentric bolt of the emergency governor is higher than the
turbine rated speed n N . Therefore, when the speed has lowered to n N after the

emergency governor acted, the emergency stop valve and the control valve closed, reset
the emergency trip gear; restart the turbine to carry over the next test.

The times of the test should be in accordance with the operating procedure.

If the emergency governor does not act yet when the turbine speed has been raised to
1.11 n N , stop the turbine immediately for examining and handling. After that, test it

again.

For the turbine using electro-hydraulic control system, carry out the electric and
mechanical overspeed trip tests respectively with the overspeed test function of the
governor. Usually, the electric trip speed is 1.08 n N .

If the turbine adopts the electric overspeed prevention system (two-out-of-three) and has
no emergency governor, it is only required to verify the electric trip speed.

2.4 Operation supervision

During commissioning (including the turbine-set test running described below), monitor
the turbine inlet team and exhaust parameters, shaft vibration and displacement, bearing
temperature, casing expansion according to the requirements given in section
“Operation Supervision” 3-2010-xx-xx.

For the first starting, the special attention should be paid in monitoring the vibration and
inspecting the leakage of the steam and oil.

2.5 Stable operation

After all of the tests finished, run the turbine stably at rated speed, the duration should
be determined based on the test-running outline and the actual operation condition.

2.6 Stopping

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
After the stable operation, stop the turbine.

2.6.1 Measuring race time

Where the main oil pump is driven by the turbine shaft, gradually lower the turbine
speed from rated speed. After the auxiliary oil pump has been put into operation, trip the
turbine and measure the race time and plot the race curve. For the condensing turbine,
the vacuum must be maintained during coasting operation.

2.6.2 Barring
Put the barring gear into operation after the turbine stopped.

Turbine-set commissioning
Start the turbine according to the requirement given in 3-13xx-01-xx. During test
running, fill in the log and make the operation record as required.

The continuous operation duration of the turbine-set under full load is specified by the
test-running outline.

1. Preparation
Make sure that the generator and electric system are ready for operation.

The instruments required for testing the performance of the turbine-set has been
connected and are ready for using.

Connect the coupling between the turbine and generator.

2. Measuring and tesing

2.1 During rotating, record the inlet steam pressure and temperature, the exhaust
pressure (or vacuum), secondary-oil pressure and the control-calve stroke, at which
the rotor begins to rotate or accelerate, as the comparison reference for the starting
later on.

2.2 Whether the overspeed trip test for the turbine-set under no-load should be made is
determined by the operating procedure.

2.3 After the speed reached the rated speed, measure the steam flow of the turbine
under no-load and measure the turbine thermal performance and turbine=set
performance during loading.

2.4 Determine the relationship between the chamber pressure and steam flow for
evaluating the deposit extent of the steam path and load monitoring in operation
later on.

2.5 Determine the relationship between the casing expansion and speed (or load).

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 Operating Instructions
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2.6 Record the relationship between the axial displacement and the thrust bearing
temperature.

2.7 Carry out the tightness test of the vacuum system for the condensing turbine. This
should be made periodically after the turbine-set put into operation. To make the
test, stabilize the load at approximate 80% of the rated load and close the air valve
connected with the air ejector. After 30 minutes, record the vacuum value once a
minute for 5 minutes. The average vacuum drop value per minute in 5 minutes
should not larger than 667 Pa. If not, the leakage of the vacuum system is in
existence. It should be found out and eliminated.

2.8 For the condensing turbine, the condenser thermal performance curves, including
the following items, are required to measure. Usually, These tests can be made
during turbine-set operation.

2.8.1 The relation curve of difference between ends and cooling-water temperature vs.
the condenser load;

2.8.2 The relation curve of the cooling-water flow and steam flow entered into the
condenser vs. the temperature rising of the cooling water;

2.8.3 The relation curve of the absolute pressure in condenser and cooling-water vs.
the steam load of the condenser.

2.9 Load rejection test

The load rejection only can be carried out under the approval by the local electric-power
authority.

After the full-load test running of the turbine-set has been normal, arrange to make the
load rejection test. Before testing, inspect the interlocking protection devices that are
related with the load rejection and release the unnecessary interlocks. At the beginning
of the test, the inlet steam and exhaust parameters should be at the rated values and the
frequency of the network in normal value.

The times and the operating conditions of the load rejection test is decided based on the
actual condition, Usually, reject 1/2 of the rated load first, then the rated load, once for
each test.

When testing, the relative parameters should be plotted, the data before load rejection
and the peak values in load rejection and the table values after load rejection should be
recorded by an assigned person.

For the extraction turbine, the load rejection test under the maximum extraction should

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 Operating Instructions
Turbine Commissioning 3-1400-01-01
be carried out after the load rejection under zero extraction has been passed.

The control system should be able to stabilize the turbine speed rapidly when load
rejection. The highest speed must be lower than the acting speed of the emergency
governor. If the turbine speed rises beyond acting speed of the emergency governor but
the turbine still not be tripped on load rejection, the turbine must be tripped manually.

3. Stopping
Stop the turbine following the instrument in 3-17xx-01-xx.

4. Measuring race time

To stop the turbine set, unload the turbine until to zero load and decouple the generator
from the network, then trip the turbine. The speed change with the time from close of
the emergency stop valve to rotor standstill should be recorded, based which the
race-time curve can be plotted. Where the main oil pump is drive by the turbine shaft,
trip the turbine after the auxiliary oil pump has been put into operation. The vacuum
should be maintained constant when measuring the race time for the condensing turbine.

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 Operating Instructions
Shutdown of Turbo-generator 3-1720-01-01

Shutdown of Turbo-generator
The shutdown is usually divided into two conditions, the normal stopping and the
emergency stopping. The stopping following the schedule arranged in advance or based
on the operation condition is normal stopping, called as scheduled shutdown or routine
shutdown. The force stopping for avoiding the accidence worse due to the equipment
fault or accidence during operation is emergency shutdown. Because of the different
reasons and purposes for these two kinds of shutdowns, the stopping operations differ
accordingly.

Normal stopping
To stop a turbine normally, unload it first. Because the unloading process is also the
temperature deceasing and cooling process for the turbine, it is certain to produce
thermal deformation and stress on the turbine components. The condition occurred is
just opposite to that during turbine starting. In general, the drop rate of the temperature
for the heated components in the turbine is restricted through controlling the unloading
rate, so that the changes of the thermal stress and the negative expansion for the casing
and rotor can be limited within the permissible range. In principle, the operation in the
cause of the stopping is a converse operation of the starting up.

During normal stopping, the inlet steam parameters are usually kept constant. The
turbine is unloaded through reducing the steam flow entering it, operating in contrary
motion according to the starting curve. This method is mostly used for the turbine that
will be shutdown for a long time or overhauled after stopped, which the lower casing
temperature is required. For the turbine that will be restarted after shutdown for a short
time, the faster rate of unloading can be used in stopping, so that the higher temperature
of the casing can be kept when shutdown, benefiting the restart.

For extraction turbine, cut off the extraction duly based on the unloading condition to
prevent the steam in the extraction line from entering back into the turbine.

After disconnected the generator from the network, the turbo-set runs under no-load
controlled by the governor, the no-load running time should be as short as possible.
Then trip the turbine and record the running-out time, which is compared with that
measured during commissioning. Where the main oil pump is driven by the turbine,
lower the speed gradually after the generator disconnected from the network and trip the
turbine after the auxiliary oil pump has been put into operation.

During stopping, the attention should be taken in checking the hot-well level of the
condenser and adjusting the recycling flow of the condensate.

A certain vacuum must be kept during a normal stopping (except the emergency
stopping, which requires the rotor to stop as could as possible through destroying the
vacuum), so that the seeper and moisture in the turbine can be vaporized and drawn out,

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 Operating Instructions
Shutdown of Turbo-generator 3-1720-01-01
keeping dry inside the turbine and avoiding corrosion during shutdown. Therefore, the
harmonizing operation of the air ejector and the gland steam supply should be carried
out during stooping, otherwise a series of problem will occur. Should the gland steam
supply be stopped too early, the cold air will enter into the casing through gland seal,
resulting in a rapid cooling of the casing and the rotor partially and wear of the gland
seal under serious condition. If the gland steam is still supplied after the vacuum has
dropped to zero, a part of steam entered into the casing cannot be exhausted. This may
cause corrosion during shutdown and partial deformation of the casing and the rotor.
Generally, stop the air ejector stage by stage with decrease of the speed to drop the
vacuum. After the speed lowered below 500r/min and the vacuum dropped to -0.03～
-0.02Mpa, stop the air ejector and gland steam supply.

Stop the condensate pump after the steam inlet valve of the ejector closed.

After the emergency stop valve has been closed, close the isolated valve in the
live-steam line. Open the drain valve and close the drain valve of the turbine body.

Where the oil-turbine barring gear is provided, put it into operation when the speed will
have dropped to about 300 r/min for continuous barring. For the electric barring gear,
put it into operation after the rotor came to a full stop for continuous barring (where the
zero-speed detector is provided, it can be put into operation automatically). For the
hydraulic barring gear, commence a durative barring after the rotor has stopped. The
duration of the continuous or durative barring after turbine stopped should not be less
than 3 hours. After that, a periodic barring should be carried out. Turn the rotor by 180º
in every 30 minutes in first 4 hours and then in every 60 minutes. After 24 hours turn
the rotor by 180º in every 2 hours. Before 2 hours the turbine restart, carry out the
continuous or durative barring again. Should the shutdown duration be in a long time,
the barring may be stopped when the casing temperature ≤150℃ (where the casing
temperature measuring point is not divided, the casing temperature can be evaluated
from axial expansion amount of the casing, or measured with the temperature gauge at
the location of the wheel-chamber under the heat-insulating lagging).

After the turbine has been stopped, keep the lubricating oil system in operation for a
period to cool the relative components, such as the rotor journal and etc. Stop the oil
pump and the oil cooler when the outlet oil temperature of the oil cooler ≥35℃, the
return-oil temperature from the front bearing ＜40℃ and the temperature rise of the
bearing ＜15℃ after the oil pump has been stopped.

The bearings must be supplied with lubricating oil during barring. Where the jacking
system is provided, put it into operation before barring.

After the turbine has been stopped, the speed set-point, backpressure controller,
extraction controller and other auxiliaries should be returned to their initial position.

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 Operating Instructions
Shutdown of Turbo-generator 3-1720-01-01
Emergency stopping
Any of the following condition occurs in operation, trip the turbine immediately
1) When the turbine speed has been raised to the overspeed trip speed, but it is not
tripped.
2) The vibration of the turbine-set increased suddenly to or over the specified limit.
3) The metal contact sound can be distinctly heard inside the machine.
4) Water hammering
5) Sparking at the gland seal.
6) The temperature of any bearing rose rapidly to the specified limit.
7) The axial displacement of the rotor increased suddenly over the specified limit.
8) The oil system was on fire and furthermore the fire cannot be extinguished soon.
9) Breakage of the live-steam piping and pressure-oil piping.
10) Vacuum or extraction pressure was suddenly beyond the limit.
11) The generator fault.
12) The auxiliary equipment fault.

For items with the interlocking protection, such as 2), 6), 7), 10) and etc, the emergency
trip is trigged by the trip solenoid valve that received a trip signal from such protection
system. Where the items are not provided with the interlocking protection or the
protection system is failed, the operator should close the emergency stop valve and the
control valve with emergency trip gear, manual trip valve or trip solenoid valve. At the
same time, inform the center control room to disconnect the generator from the network.
For quick stopping the vacuum may be destroyed after the emergency stop valve and the
control valve closed When necessary, the excitation is required for lower the speed
quickly.

The other operation after the emergency stopping is the same as that for the normal
stopping.

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 Operation Instructions
Operating Supervision 3-2010-01-01

Operating Supervision
This section describes the monitoring requirements of the main operation parameters for
the turbine. For the instrument configuration and function (including monitoring limit)
of individual turbine, please refer to “Bill of Material” 0-2020-T.Nr-00.

Pressure and temperature of live steam

To obtain the economic and efficient operation of a turbine, the pressure and the
temperature of the admission for the turbine should be kept with the ranges (Excluding
the boiler feed pump turbine), which are given in the Technical Data 0-0300-T.Nr-00.

When the admission pressure of the turbine has exceeded the normal value and tends
toward the upper limit, the turbine operator should inform the boiler operator to reduce
the pressure at once. When necessary, turn down the isolated valve in the live steam line
for reducing the pressure; decrease the turbine load through reducing the opening of the
control valve.

When the admission pressure of the turbine has exceeded the normal value and tends
toward the lower limit, the turbine operator should reduce the turbine load and inform
the boiler operator to raise the pressure.

When the admission temperature of the turbine has exceeded the normal value and tends
toward the upper limit, the turbine operator should inform the boiler operator to reduce
the temperature. When necessary, decrease the turbine load through reducing the
opening of the control valve.

When the admission temperature of the turbine has exceeded the normal value and tends
toward the lower limit, the turbine operator should inform the boiler operator to raise
the temperature. When necessary, open the drain valve in the live steam line; decrease
the turbine load through reducing the opening of the control valve.

The continuous operation under the upper limits of both pressure and temperature for
the admission cannot exceed 15 to 20 minutes. The cumulated time in a year should not
exceed 20 hours.

The pressure and the temperature are monitored with pressure switch and thermal
coupling. When the admission pressure and/or temperature reached the reset limit, the
alarm and shutdown signal will be sent out.

Under the special conditions, such as start-up and commissioning, the admission
pressure and temperature of the turbine can differ to the normal values mentioned
above.

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 Operation Instructions
Operating Supervision 3-2010-01-01
Wheel chamber pressure
The wheel chamber pressure is the steam pressure in the department behind the control
stage. It is used for monitoring the turbine operating condition and the working
condition of the steam-path section.

The chamber pressure has a coincidence relation with the steam flow. Under normal
condition, the chamber pressure changes with the change of the live-steam flow, please
see the attached documents No. 0-2505-T.Nr-00 “Characteristic Line of Control Valve”.
The maximum steam flow can be restricted through monitoring the chamber pressure,
so as to avoid over loading. Chamber pressure also reflects the deposition of the
steam-path section, which is related with the steam quality. The deposit on the blade
surface not only increases the blade stress, but also decreases the section area of the
steam-path, resulting in turbine output and efficiency reduced and the axial thrust
increased. If the steam-path is deposited, the chamber pressure will rise under the same
steam parameters and flow. With this characteristics, the measured relation of the
chamber pressure to the steam flow during operation can be compared with that
measured (the live-steam pressure and temperature under different operating conditions
should be kept constant) under the clean condition for the steam-path after the turbine
has been put into normal operation against “Characteristic Line of Control Valve”
0-2502-T.Nr-00. The relative increment Δ P is calculated with the formula
PR − PRO
ΔP = × 100% , here PRO is the chamber pressure corresponding to the
PRO

measured flow under clean steam-path, PR is the chamber pressure in current

operation with the same steam parameters and flow. ΔP should not exceed 10%,
otherwise the immediate flushing is required (see 4-0600-).

Exhaust pressure
The exhaust pressure deviation from the normal value for the backpressure turbine will
have effect on the turbine output and the safety as well. The excessive high exhaust
pressure is going not only against the casing strength, nut also to increase the axial
thrust, while the excessive low exhaust pressure will endanger the blade safety.
Therefore, the exhaust pressure during turbine operation is not allowed to exceed the
permitted range.

The exhaust pressure of the turbine is monitored with the pressure switch. When the
exhaust pressure reached the preset limit, the alarm or shutdown signal will be sent.

Vacuum in condenser
During condensing turbine operation, the vacuum in the condenser will drop and the
exhaust pressure rise due to excessively high temperature of the recycling water, lack of
the cooling water flow, deposit of the cooling pipe in the condenser, leakage of the
vacuum system or bad work of the air ejector.

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 Operation Instructions
Operating Supervision 3-2010-01-01
The drop of the vacuum will lower the economical efficiency of the turbine-set
operation and affect the safety operation as well. Besides the increase of the axial thrust,
the exhaust temperature will rise with the increase of the exhaust pressure. The risen
temperature of the exhaust portion of the casing may cause the vibration increasing. For
the turbine that the bearing housing is integrated with the casing, this will also raise the
rear-bearing temperature. The rise of the working temperature of the condenser can
affect the condenser performance and safety. Therefore, when the vacuum dropped
during operation, the turbine load should be reduced. When the vacuum dropped to
–0.06Mpa, the turbine load should be reduced to zero for driving the generator, For the
turbine driving the compressor (including blower, pump and etc.), the speed should be
lower to the low governor speed or further and the output of the compressor should be
disconnected with the system. If the vacuum is kept ≥-0.06Mpa and the vibration and
bearing temperature are at normal values, the turbine can run under no-load or small
load. However, the check should be made in the shortest time to eliminate the defect. If
the vacuum continues to drop, the turbine should be stopped.

During turbine operation, the exhaust temperature under load should not exceed 70℃,
and 120℃ under no-load.

Extraction pressure
For the turbine with controlled extraction, the extraction pressure is either the exhaust
pressure of the first expansion section or the admitting steam pressure for the second
expansion section, so that it should be controlled within a permitted range.

In some of turbines, the extraction temperature is also be monitored besides the

extraction pressure.

Bearing temperature
The journal and thrust bearings used in turbine and gearbox are hydrodynamic bearings,
their normal working is lied on the oil film that can build-up loading capacity. The
viscosity of the lubricating oil, which is related with the bearing temperature, plays an
important role in influencing the loading capacity in the case that other factors have
been decided. Therefore, the bearing temperature must be strictly limited. When the
bearing temperature exceeded the specified stop value, the strength of the bearing babbit
may be reduced obviously. In order to insure the reliable operation of the bearing, the
bearing temperature should be kept within the normal range during turbine operation.

The rise of the bearing temperature during turbine operation is caused by friction power
of the bearing and the heat produced in heat exchange. When the heat the lubricating oil
takes out is equal to the heat the produce, the temperature tends to be stable. The
bearing temperature: t = t o + Δt . Here, t o is the lubricating inlet temperature, which

should be maintained within the range of 45℃（±3℃）, Δt is the permitted

temperature rise of the bearing, which is determined by the measuring method. When

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 Operation Instructions
Operating Supervision 3-2010-01-01
using the thermal resistance or thermocouple thermometers to measure the bearing-pad
temperature, the up limit of the normal range for the bearing temperature should be
t o +45℃, while measuring the return-oil temperature of the bearing, it should be

t o +20℃.

The temperature rise of the journal bearing is related with the speed and load.
Measuring the babbit temperature with the thermal resistance or thermocouple at the
minimum oil film at the lower half of the bearing can make a quick reflection of the
temperature change for the bearing pad. Where two temperature sensors are equipped
for one journal bearing as required by user, the temperature readings on each measuring
point are bound to be different. In this case, the journal-bearing temperature monitored
should subject to the reading on the measuring point at the minimum oil film related
with the rotating direction.

When using the thermal resistance or thermocouple thermometer to measuring the

thrust-bearing temperature, two temperature sensors (up to four) are usually fitted in
each primary and secondary thrust pad. The temperature rise of the thrust bearing is
determined by the speed and axial thrust. In general, the temperature of the primary
thrust pad is higher than that of the secondary one. The load on the individual thrust pad
at the same side may be uneven, so when the bearing temperature rose, make sure
whether the temperature of one measuring-point rose or that of all measuring-points
rose. The former indicates that one of the pads is overloaded, while the later reflects the
thrust increased.

For the monitoring of the temperatures of the journal and thrust bearings, not only the
absolute value ( t o + Δt ) should be observed, but also the change of the bearing

temperature rise should be noticed. Compared with the highest temperature under same
working condition in the operation record before, if the temperature rise of the bearing
increased suddenly, it cannot be treated lightly even the bearing temperature has not
reached the alarm value yet. Should the bearing temperature rose instantaneously and
lasted for a very short period, and then it retune to the temperature in normal operation,
the partial damage of the bearing is often indicated. In this case, the continuous
operation of the turbine may cause the severe damage of the bearing.

For the alarm and stop limits of the bearing temperature, see 0-2020-T.Nr-00.

Oil pressure
For the turbine with the oil system using turbine oil as its working medium and the main
pump driven by the turbine shaft, the pressure of the pressure-oil is between 0.6～
1.3Mpa, which is related with the turbine speed. It will be ～0.8Mpa at rated speed. For
the turbine with an external oil pump, the pressure of the pressure-oil is ＞0.8Mpa. The

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 Operation Instructions
Operating Supervision 3-2010-01-01
pressure in the lubricating header is about 0.25Mpa. For the setpoints of the alarm and
stop values for drop of the trip-oil and the lubricating-oil and excessive differential oil
pressure between the inlet and outlet of the oil filter, see 0-2020-T.Nr-00.

Where the pressure gauge is fitted in the oil inlet piping of the bearing, when adjusting
the oil flow to the bearing with the throttle valve based on the bearing temperature, the
oil pressure is only taken as the reference. The oil pressure behind the throttle valve is
not stipulated.

In general, the throttle valve is not required to readjust after adjusted in turbine
commissioning.

For the supervision of the high-pressure fire-resistant oil system, please refer to the
related instructions.

Shaft vibration
Usually, the shaft vibration of the turbine is continuously monitored with the
two-channel vibroscope.

The turbine has passed the high-speed balance and no-load test run in the workshop
before delivering. The value of the shaft vibration recorded in the Product Certificate is
the p-p value. The non-vibration deviation of the rotor resulted from the electric and
mechanical deviation in the workshop is limited within 6μm.

It is bound to produce slight vibration during turbine operates at the given speed and
within the given load range. The amplitude will increase in the process of the start of
stop, especially when turbine speed passes through the forbidden- to-stay-zone. As long
as it does not exceed the permitted range, such a vibration is still normal.

Under the good installation condition, there are many factors that will aggravate the
vibration during turbine operation, such as the uneven expansion of the turbine due to
the over-fast rate of loading or unloading, the change of the damping characteristic due
to the worsen bearing working status, the change of the original balancing state, water
hammer, compressor surging and etc. The abnormal sound is often companied with the
aggravating vibration. Therefore, listening the operation sound may be taken as the
auxiliary method for monitoring the shaft vibration.

When judging whether the vibration is normal or not, the absolute value of the
amplitude cannot be taken as the only reference. For example, the measured amplitude
is increased from 25μm to 30μm under a certain working condition, while under other
working condition it is increased from 5μm to 25μm. The former condition does not
always indicate the existence of some disturbances, while the latter may foreshow the
appearance of the fault, which must be put on alter. The cause resulting in the abnormal
vibration should be found out even it does not reach the alarm value, the corresponding

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 Operation Instructions
Operating Supervision 3-2010-01-01
measures should be taken for preventing the operation worsen further.

Most of the turbines are equipped with key-phase sensor, as required, to measure the
frequency and phase of the shaft vibration for analyzing the vibration characteristic with
the frequency spectrograph.

At present, the larger one of two P-P values measured in two orthogonal directions is
usually taken as the estimating index for the shaft vibration. The alarm and stop values
given in 0-2020-T.Nr-00 is not unique but for suggestion. User can reset them based on
his experience in operation and the standard adopted.

We recommend assessing the mechanical vibration of a turbine-set according to the

standard ISO 7919-3.

Axial displacement
There are to kinds of axial-displacement protective devices, mechanical and electrical.
In some of turbines both of them are used, for the others, only one of them is used.

The limit value of the axial displacement for the mechanical protective device is about
±1.0mm. When the thrust bearing damaged in operation and the axial displacement of
the rotor exceeded the clearance between the tripping lever and the cam on the rotor,
which has been adjusted in installation, the emergency trip gear acts and trips the
turbine, so as to prevent the rotor from colliding with the stationary parts in axial
direction and accident from going worse.

The electric axial displacement protective device continuously monitor the axial
position of the rotor with respect to the thrust bearing through the approximant sensor
and the position detector. It can send an early warning for the thrust bearing damage to
avoid the severe damage of the turbine. For the alarm and stop limits of the axial
displacement for the rotor, see 0-2020-T.Nr-00. When adjusting the sensor in
installation, The middle value of the total clearance between the thrust collars of the
rotor and the primary, secondary thrust pads is take as the zero position.

The axial displacement of the rotor is caused by the change of the axial thrust, which is
related with the turbine working condition and statues. The axial thrust in backpressure
or condensing turbine is approximately proportional to the live steam flow. The
maximum axial thrust will appear at maximum power. For the extraction turbine, it does
not appear under the rated working condition but under a certain middle working
condition, such as zero extraction condition. During normal operation, the axial thrust
will be within the permitted range when the load is changed within the given range, so
that the thrust bearing is safety. But under abnormal condition, such as overload, worn
inner gland seal, deposit of steam path, over-low live steam temperature and water
hammer, the axial thrust will be increased additionally.

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 Operation Instructions
Operating Supervision 3-2010-01-01
When the axial displacement is gradually increased during turbine operation, the special
attention should be paid to the monitoring of the thrust-bearing temperature. If the thrust
bearing temperature exceeds the up limit with the increased axial displacement, reduce
turbine load at once. Should the axial displacement continue to increase towards the
stop setpoint after the measures have been taken, trip the turbine immediately.

Speed
Usually, tachometers are mounted on the local instrumentation panel and in the center
control room for monitoring the turbine speed in operation. Where the electric-hydraulic
control system is adopted, the digital governor also has the monitoring function for
speed. Additionally, some of turbines are equipped with the overspeed protective system
using two-out-of –three logic. They will continuously indicate the actual speed of the
turbine in operation. When the speed exceeded the rated speed or the maximum
continuous speed rose to the reset acting value, the alarm or stop signal is sent.

For the turbine with continuous barring gear, the barring speed should not be lower than
the specified minimum barring speed.

If there is any forbidden-to-stay zone (including the forbidden-to-stay zones for turbine
and driven machine) in the process of the turbine starting and stopping, make the
turbine speed pass through this zone quickly and continuously in operating.

With the governing system the turbine runs stably within the specified speed and load.
For the turbo-generator, after load rejection of the generator, the speed will rise
instantaneously and then stabilize at the up governor speed under normal condition.

During turbine operation, If the turbine speed is out of the control and rise to the stop
value reset but the protective device has not acted yet, manually trip the turbine at once
with the manual stop valve, emergency trip gear or the stop solenoid valve that receive
the stop command from the control room.

Thermal expansion of casing

During turbine starting and operating, the sliding-key system can guarantee the casing
to expand freely but maintain the center unchanged. If it is not adjusted properly in
installation or the foreign force and moment that exceed the permissible value are acted
on the casing, the expansion of the casing in radial or axial direction is obstructed,
causing abnormal vibration of the turbine.

The thermal expansion of the casing in the axial direction is usually monitored with the
expansion indicator mounted on the front pedestal. The casing expands forwards when
heated and constricts when stopping, taking the dead point as the reference. The
expansion of the casing when heated should be continuous. The appearance of the step
change in expansion indicates the expansion obstructed. It is required, at any moment,
to check the clearances of the bolt washers on the front and rear supporting brackets of

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 Operation Instructions
Operating Supervision 3-2010-01-01
the casing. The washers should be always in free statues.

Race time
The soundness of the turbine can be judged through measuring the race time during
normal stopping and comparing it with the race time measured in commissioning under
the same operation condition. If the race time measured currently is shorted obviously,
the rotor may be contacted with the stationary parts or bearing defect existed. While the
prolonging race time indicates that the steam leaked into the casing because of the
untight close of the emergency valve and control valve.

As the requirement in the order, the turbine may be equipped with casing-temperature
detector, absolute casing-expansion detector, differential expansion detector, rotor
eccentricity detector and etc. for monitoring the temperature deference between the top
and bottom casings, the thermal expansion of the casing in axial direction, the relative
expansion of the casing and the rotor and the flexural deformation of the rotor.

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 Operating Instructions
Abnormal Vibration 3-3010-01-01

Abnormal Vibration
The turbine is a rotary machine in high speed, so vibration in different amplitude and
direction will occur in its operation. Any of the vibration that is within the limited
range is permitted and has no harmful to the machine. But some times the abnormal
vibration will occur during turbine operation for various reasons, especially during
commissioning. According to the statistics of the vibration troubles, most of the
abnormal vibrations are caused by improper installation or misconduct in operation
and maintenance. Since the turbine rotor has been balanced and passed the no-load
running test before delivery, it usually is not required to rebalance, except for the rotor
that has been repaired, bended permanently or which parts have been replaced. If the
abnormal vibration occurred during turbine-set starting and operating, carry out the
test and analysis by means of the frequency spectrograph or other real-time analyzer
for finding out the reason and resolving it based on the vibration characteristics.

1. Poor quality of installation or overhaul

1.1 Due to the poor quality of the back grouting, the turbine pedestal (baseplate) did
not joint to the foundation tightly, the anchor bolts ware loosen and the foundation
sunk unevenly. If you stand near by the turbine when raising the turbine speed,
you will fell the foundation is vibrating with the turbine. The amplitude change of
the shaft vibration is not evident; the vibration signal contains the low-frequency
component. While the amplitude of the bearing housing increases obviously and is
unstable.
In this case, the best solution is to reinstall the turbine.

1.2 Piping
1.2.1 Steam piping
Due to forced connection of the mis-positioned flanges or unreasonable piping layout,
the force and torque acting on the turbine exceed the permitted values. The abnormal
vibration is marked by: the vibration is related with the turbine hot state, the
amplitude will increase obviously at a certain load (temperature), the vibration
frequency is in step with the turbine speed, the vibration signal contains the
low-frequency component. Measure the vibration of the shaft and the bearing housing
at the front and rear sections of the turbine, if the larger vibration appears at the front
section, the steam inlet piping is likely to be with the problem. If the larger vibration
is at the rear section, it is mostly caused by exhaust piping.
Measure: Reconnect the piping according to the requirement or adjust the piping
supports.

1.2.2 Inlet and outlet piping of the main oil pump

The disturbing force of the piping caused by forced connection of the mis-positioned
flanges make the turbine vibrate abnormally. With the rising speed, the vibration at
the front bearing housing will increase obviously. The vibration signal contains the
low-frequency component.

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 Operating Instructions
Abnormal Vibration 3-3010-01-01
Measure: Reconnect the piping according to the requirement.

1.3 Improper assemble and adjustment of turbine slide-key system

The thermal expansion of the turbine is restricted during start-up and operation, so
that the alignment of the rotor with the casing and bearing housing is destroyed,
resulting in vibration, which is related with the turbine hot-state. The vibration
frequency is in step with the turbine speed. Measure the vibration at the front and rear
bearing housings for judging which guide key to be seized.
Measure: Stop for inspecting and readjust the guide element.

1.4 Poor alignment

1.4.1 Poor alignment of turbine rotor with casing
If the rotor is not aligned with the casing properly during turbine installation, the
abnormal vibration will occur during turbine test running. In the course of the turbine
starting, the moving parts will collide with the stationary parts with the increasing
speed and inside temperature so that the amplitude of the shaft vibration will increase
with a squeal of metal friction. The vibration signal contains high-frequency
component, with disturbing waveform.
Measure: Stop the turbine and recheck the alignment, repair or replace the damaged
sealing strips.

1.4.2 Poor alignment of turbine rotor with driven-machine rotor

The turbine has passed the test running, but the abnormal vibration occurs during
turbine-set test running. If the double frequency harmonics is included in the vibration
waveform, the abnormal vibration is caused by the poor alignment of the rotors.
Measure the vibration of the bearing housing; the increase in the axial amplitude
indicates that the parallelism of the end face is out of condition, while the increase in
the radial amplitude indicates that the deflection of non-axiality is excessive. The both
often exist simultaneously.
Measure: Stop the turbine and realign the rotor. If the realigning is not allowed at the
moment for some external reasons, the imbalance correction can be carried out at the
secondary balance surface of the rotor. But this is only a makeshift, the final solution
is to realign and rebalance the rotor after the turbine stopped.

1.4.3 Alignment under cold state is conformed with the requirement, but the center is
deviated during operation
In addition to the same characteristics mentioned in 1.4.2, the vibration characteristic
is related with hot state of the turbine set. For the backpressure turbine, the vibration
at its driving end will increase obviously when the load or the exhaust temperature
reached to a certain value. For the condensing turbine, the temperature of its exhaust
nozzle during operation is high than the ambient temperature when installation. If the
pre-pulling amount is too small when installing, the expansion of the exhaust nozzle
during operation will raise the center of the turbine rear bearing. Meanwhile, the
inside of the exhaust casing is under vacuum during operation, the exhaust casing

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 Operating Instructions
Abnormal Vibration 3-3010-01-01
under the action of the atmospheric pressure will lower the center of the rear bearing.
Therefore, the vibration resulting from the center change of the bearing is related with
the exhaust temperature and vacuum.
Measure: For the backpressure turbine, re-measure the aligning data immediately after
the turbine stopped and correct the aligning value under cold state based on these
measured data. For the condensing turbine, maintain the vacuum as could as possible
through barring and supplying the gland steam after the turbine stopped, check the
aligning value and correct the aligning value under cold state based on these measured
data.

1.4.4 For the turbine coupled with the driven machine via a gearbox, if the offset of
the gear shaft when aligning the rotor is not conformed with the actual condition, the
vibration and noise of the turbine will increase obviously when the load reached to a
certain value. The vibration waveform contains high frequency harmonics. The high
frequency is synchronous with the working frequency.
Measure: Stop the turbine and check the aligning valve of the turbine rotor with the
gear shaft. Correct the aligning value according to the direction of the gear engaging
force.

1.5 Bearing
The carrying capacity of the multi-wedge bearing is related with the arrangement of
the oil wedge. The split of the four-wedge bearing should be angled of 45 °to the
split of bearing housing, this makes the load just be supported on the center of the
oil-wedge during operation. If the four-wedge bearing does not be turned by 45°
when installing on site, the carrying capacity of the bearing will decrease. Therefore,
during turbine operation the vibration will be increased in a sudden once the load
reached to a certain value. The vibration signal contains eddy signal at a frequency
lower than the working frequency.
Measure: Reassemble the bearing according with the requirement.

1.6 The axial positioning between the turbine and the driven machine is not
conformed to the requirement, especially for turbine that is directly coupled with the
generator. During operation, the expansion of the turbine rotor will push the generator
rotor to move axially. If the axial clearance between the moving and stationary parts
of the generator is less than the axial expansion of the turbine rotor, the moving part
will collided with the stationary one, resulting in turbine to vibrate violently with a
loud noise, finally damaging the equipment.
Measure: The turbine must be positioned correctly when installation. The amount of
the axial expansion for the turbine rotor is given in the attached document
0-0341-T.Nr-00.

2. Operation
2.1 Poor behavior of bearing
Insufficient lubricating oil, disqualified oil quality (emulsification, a lot of bubbles,

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 Operating Instructions
Abnormal Vibration 3-3010-01-01
impurities and water contained in the oil), abnormally low oil temperature, excessive
bearing clearance will cause the oil film of the bearing unstable. The eddy motion of
the oil film results in discontinuous vibration with irregular waveform and abnormal
noise. The vibration frequency is not in step with the speed.
Measure: Take the corresponding measures according to the reason found out.

2.2 The water contained in the steam causes the temperature of the admitted steam to
drop suddenly, forming a water hammer. The turbine set vibrates intensively
companied by toneless roar.
Measure: Stop the turbine immediately, drain the inlet steam and exhaust piping
thoroughly, reinforce the monitoring of the boiler operation.

2.3 The deposit and corrosion of the steam path section due to the poor steam quality
will destroy the rotor dynamic balance, resulting in turbine vibration. In this case, the
vibration is increased gradually with prolong of the operation duration. Usually, it
does not occur suddenly, except for blade breakage. The vibration frequency is in step
with the speed.
Measure: The deposit content on the blade can be evaluated from the temperature of
the thrust bearing and the pressure change after the control stage. Clean the deposit in
time when necessary or during overhaul.

2.4 The drop of the vacuum for the condensing turbine will raise the exhaust
temperature and consequently change the rotor alignment under hot state, resulting in
turbine vibration. In this case, the vibration at the rear end of the turbine often
increases obviously. The vibration frequency is in step with the speed.
Measure: decrease the load and raise vacuum. Return the turbine to original operating
condition after the vibration reached to the normal value.

2.5 For the turbine that has been put into operation, most of the abnormal vibrations
occurring during starting or changing load are caused by improper operating, such as
improper barring after last stopping and insufficient warming-up during staring. If the
abnormal vibration occurs during raising speed and the noise of the metal friction at
the front and rear gland bushes can be heard, it indicates that the rotor has been
warped (where the eccentric monitor is provided, it can be used in measuring the
warping amplitude for the rotor. At this moment, the turbine speed should be lowered
and maintained at a stable value after the vibration returned to normal for warming-up
for about 15 minutes (the speed can not stay in the prohibition range), and then raise
the speed again. If the abnormal vibration still cannot be eliminated after 3 repeats,
the turbine must be stopped, check and repair the rotor.

Fast load changing also causes the vibration due to deformation of the uneven
expanded components. If the vibration occurs in loading, unload or lower the turbine
speed immediately. After stabilized, load the turbine (or raise speed) according to the
change rate given by the staring curve. If the vibration occurs in unloading, operate

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Abnormal Vibration 3-3010-01-01
the turbine in steps opposite to that mentioned above.

2.6 For the turbine driving compressor, if the abnormal vibration only appears under a
certain load, it is mostly caused by the compressor and the characteristics of the pipe
network.
Measure: When changing load to near this load, slow down the changing rate
properly.

2.7 For the turbine diving compressor, the imprudent operation when reducing the
compressor flow or the improper set of the surge-proof system will cause the turbine
set running in the surging zone, resulting in sharp fluctuation of outlet pressure of the
compressor and consequently intensive vibration of the turbine and the compressor
outlet piping companied with a loud noise.
Measure: Trip the turbine set. Operate the turbine set according with the related
operating procedure to prevent the compressor running in the surging zone.

3. Defect of equipment
3.1 Toothed coupling
The eccentric load produced by the floating parts of the coupling under the centrifugal
force due to the existed backlash will cause vibration. Under the normal condition, the
vibration of the turbine will increase with the raising speed after the turbine started,
but the amplitude is within the permitted range. Additionally, under the action of self-
centering the eccentric load will decrease with the increase of the torque the coupling
is transferring, stabilizing the operation. But the excessive backlash resulted from
machining error or wearing may cause the amplitude to exceed the up limit with the
increase of the turbine speed.
Measure: Check the coupling during overhaul, improve the lubrication and replace the
coupling when necessary.

3.2 Generator
The vibration occurs when raising the generator voltage, but it disappears after the
excitation of the generator released. This indicates that the vibration is caused by the
unbalance magnetic field, which is arose from short-circuit of the generator winding
or the uneven air gap between the generator rotor and stator.
Measure: Inquire the electric technician.

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 Operating Instructions
Excessive Axial Displacement of Rotor and Turbine Water Hammer 3-3010-02-01

Excessive Axial Displacement of Rotor and Turbine Water Hammer

Usually, the increase of the axial displacement for the turbine rotor is caused by the
following reasons:
Increase of the load or steam flow;
Damage of the steam path section;
Severe deposit in the steam path section;
Wear of the thrust pad;
Turbine water hammer;
Rise of the turbine exhaust pressure (for the condensing turbine, drop of the condenser
vacuum);
Play of the generator rotor in turbo-generator;
Compressor surge in the turbo-compressor;

The measures that should be taken under some of the common conditions:

Increase of load or steam flow

For the different turbine sets, the axial displacement is increased under different
working condition.

1. When a non-extraction turbine is overloaded, the axial thrust on turbine rotor is

bound to increase with the excess increase of the steam flow. If the thrust exceeds
the permitted value, the thrust bearing may be damaged, resulting in the excessive
displacement of the rotor. In order to avoid this faulty occurring, when continuing to
load the turbine near the rated power, the attention should be paid in monitoring the
temperature of the thrust bearing, axial displacement of the rotor and the pressure of
the wheel chamber. Once any of the former two approached to the alarm value,
unload the turbine immediately.

If the plant requires the turbine to operate under overload, it only can run
occasionally in a short time. When the operating condition of the plant has been
changed and the turbine cannot be suitable for this new requirement, the proper and
reasonable solution is to innovate on the turbine for increasing its output.

2. For the turbo-generator paralleled in the network, the automatic increase of the
opening for the control valve when the frequency of the network lowered may result
in the turbine overloaded. Therefore, the attention must be paid in monitoring the
operation when the frequency of the network lowered. Decrease turbine load when
necessary.

3. When the inlet steam pressure and temperature decreased or the exhaust pressure
rose, the steam flow must be increased to maintain the original power output for the
turbo-generator. The excessive steam flow may increase the axial thrust force on the
turbine rotor even the turbine is not overloaded. For the Compressor driven turbine

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 Operating Instructions
Excessive Axial Displacement of Rotor and Turbine Water Hammer 3-3010-02-01
with the control system using a PI or PID speed governor, in this case, the opening
of the control valve will be increased automatically. The axial thrust is bound to
increase with the increase of the steam flow. Therefore, when the turbine inlet steam
parameter lowered or exhaust parameter rose, the admitted steam flow to the turbine
must be limited when necessary, besides restoring the steam parameter to normal
value immediately.

4. When loading a controlled extraction turbine under “zero” or small extraction flow
condition, the axial thrust may exceed the permitted value, although the admitted
steam flow and the output of the turbine are far from the rated values. Therefore, the
extraction turbine must be strictly operated according to the limited condition given
on the extraction flow vs. power curve (Working condition chart).

Seal strip wear of inner gland seal

The relative position of the turbine rotor with respect to the stationary parts will be
changed for some reasons during turbine starting, operating and stopping, causing the
seal strips collide each other. In especial, the damage of the seal strip for the dummy
piston and middle gland seals may result in the axial thrust increased. Usually, an
abnormal noise is generated inside the turbine and the vibration is increased when the
seal strips collided. In this case, decrease the load first. If decreasing load cannot
improve the condition and the temperature of the thrust bearing has exceeded the up
limit, stop the turbine at once and carry out the check and repair.

Deposit in steam path section

The deposit, caused by the salt and SiO2 contained in steam, reduces the steam passage
area, increasing the axial thrust and consequently the axial displacement of the rotor.
The deposit is gradually increased with the prolongation of the operation duration and
can be judged through analyzing and comparing the steam pressure in the wheel
chamber. Clean the through flushing when necessary (see 4-0600-).

Misplacing thrust pads

Misplacing the first thrust pads with the secondary ones is caused by negligence during
installation or overhaul and will be discovered during commissioning. When loading the
turbine to a certain load the turbine is tripped suddenly due to the excessive axial
displacement. Restart the turbine, the same condition occurs again. Stop the turbine and
check the bearing, the thrust pads are found damaged. The load capacity of a misplaced
pad is only 1/3 of that for a correctly mounted one. The decrease of the load capacity
causes thrust pads damaged. The attention must be paid in replacing the thrust pads; the
spare pads that have an allowance in thickness must be additionally machined to the
size given in the Product Certificate and the rotor-positioning dimension in assembling.
A set of eight pads should be machined together so as to ensure the same thickness.

Water hammer
Water hammer is one of turbine major accident. During turbine operation, if the steam

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 Operating Instructions
Excessive Axial Displacement of Rotor and Turbine Water Hammer 3-3010-02-01
temperature drops sharply, the white steam emits or water drops splash from the gland
seal, the temperature of the thrust bearing rises or the axial displacement increases,
vibration is abnormal, these indicate the water hammer occurred. The turbine must be
tripped immediately.

Most of the water hammer occurred in the turbine are caused by improper operation, but
some of them caused by the water flowing back into the turbine from the piping due to
the check valve in the extraction piping is not tightly closed. If the boiler is overflowed
or the azeotropy of the steam and water occurs, the steam entered into the turbine will
contain water. Since the water drops flow in a low speed, they will produce a braking
action when colliding on the blade convex, making the turbine output decreased
obviously. The steam containing water will significantly increase the blade stress,
resulting in blade broken and abnormal vibration of the turbine set. It also reduces the
steam path area, causing the thrust increased rapidly and endangering the thrust bearing.

In order to avoid the water hammer occurring, the change of the steam temperature must
be noticed when paralleling boilers for preventing it to be too low. For the turbine with
different steam sources, the thorough drain must be carried out when switching steam
source. During boiler operation the attention should be noticed in keeping the steam
pressure and temperature within the specified range.

Should the drain of the steam inlet piping be not complete in turbine starting, the water
hammer will occur due to the water accumulated in the piping. The piping and the
turbine set will vibrate intensively, companied with a loud tedious noise. In this case,
the turbine must be stopped at once.

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 Operating Instructions
Blade Damage or Breakage 3-3010-03-01

Blade Damage or Breakage

During turbine operation the blade will be damaged by various causes, such as the
foreign hard granular impurities entered into the turbine, the bad alignment of the rotor
with the casing or friction of the blade with the seal strips. This section will mainly
demonstrate the damage of the blade caused by the corrosion due to the poor steam
quality. The corrosion damage will occur not only in an operating turbine, but also
during shutdown.

Under the normal circumstances, owing to the layer of compact and stable oxide-proof
film formed on the surface the blade made of heat-resisting stainless steel, the blade has
a good corrosion resistance. The protective film of the blade surface will be erode when
the steam contains the Co2, and So2, especially the chloridion. Furthermore, the
corrosion will develop towards the depth quickly and corrode the blade, resulting in
rapid drop of the blade strength. Take the stainless steel 2Cr13 as the example, its
endurance bending strength in the air at normal temperature is 390 N/mm2 (a
un-notched teat piece under a number of stress cycles n=5×107, the same below), it
will still be 275 to 315 N/mm2 in the clear condensate. But it rapidly reduces to 115 to
135 N/mm2 in the chloride solution containing NaCl under a content ≥1％. The
reduction denotes shorten of the blade life. The corrosion can be found when check the
blade in overhaul. Most of the blade corrosion occurs on the stages in the wet steam
zone. Usually, the corrosion begins on the blade surface under the deposit layer and then
develops to crack. If continuing to operate, the blade will break due to corrosion fatigue.
The examination and analysis of the broken blade show that the deposit on the fracture
contains chlorides.

The corrosion of the turbine blade will occur not only during operation, but also during
shutdown, it is so-called as stand-by corrosion. After the turbine shutdown, the steam
left or leaked in the casing will condensed with cooling down of the turbine to dissolve
the deposited salt on the blade, producing a corrosion action to the blade. In this case,
the corrosion damage will occur on all of the blades other than the blades working in the
wet steam zone.

In order to reduce and avoid the corrosion damage of the blade, the boiler feed water
treatment should be perfected so as to ensure the steam quality. Additionally, much
attention should be paid in shutdown maintenance (see 4-0300-xx-xx for details).

If the crack on the blade is found during overhaul, the cracked blade should be replaced.

Blade breakage seldom occurs during turbine operation, but once occurring, it can cause
the severe accident in damaging the equipment and injuring the person. The blade
breakage during turbine operation will have following phenomena:

An irregular load (speed) impact occurs suddenly;

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 Operating Instructions
Blade Damage or Breakage 3-3010-03-01
A suspicious noise is generated from the steam path section of the turbine (When the
last row of the blade broken for condensing turbine, the metal colliding noise will
generated in the condenser. If the broken blade damaged the cool-water piping in the
condenser, the conductivity of the condensate will be increased);

The turbine vibration increases suddenly, especially for the blade breakage on the
low-pressure stage, companied with an obvious increase in amplitude.

If the phenomena mentioned above occur during turbine operation, stop the turbine
immediately. After shutdown, open the casing for inspecting. Contact us as soon as
possible on affirmed the blade breakage for repairing. Send the rotor and damaged
component to our company for replacing the blade and rebalancing the rotor, when
necessary. The blade breakage of the middle stage will often damage the adjacent
stationary and moving blade. If the barring cannot be carried out caused by the broken
blade, the rotor should be checked whether it is bent.

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 Operating Instructions
Oil-system Fault and Elimination 3-3010-04-01

Oil-system Fault and Elimination

The description in this section is applicable to the normal pressure system with
turbine oil as its working medium and exclusive of high-pressure-fire-proof oil
system.

1. Oil pressure too low

1.1 Accidental leakage of pressure
1.1.1 The check valve of the auxiliary oil pump does not be closed tightly, a part of
oil discharged from the main oil pump drains into the tank through this valve.
If the oil pressure is normal before changeover from the auxiliary oil pump to
the main oil pump, but the pressure dropped after the auxiliary oil pump
stopped, it is mostly caused by the leakage of the check valve.

1.1.2 For the oil system using positive displacement oil pump, the drop of oil
pressure may be caused by excessive bleed-off flow due to improper set of the
releasing valve at the outlet of the pump.

1.1.3 For the turbine equipped with elevated oil tank, the excessive overflow
throughput of the oil tank due to improper governing of the oil inlet valve will
reduce the oil pressure.

1.1.4 For the vertical oil pump mounted in the oil tank, the leakage of the
connecting flange in the discharging piping causes a part of the oil discharged
from the oil pump to inject into the tank.

1.2 Wrong rotary direction of the electric oil pump

1.3 The level in the oil tank is too low. It will cause not only the pressure drop but
also the pressure fluctuation.

1.4 Defect in system arrangement

The oil pressure drops instantaneously when changeover between the main and
auxiliary oil pumps, or oil pressure is in normal during turbine stable operation but it
will drop when the oil-relay acts in large amplitude, even causing the emergency stop
valve closed. In order to avoid these conditions occurring, an accumulator can be
mounted in the pressure-oil or the working oil piping of the oil relay. In this case, the
nitrogen filling pressure must be in conformed to the requirement; otherwise the
accumulator will be in malfunction.

1.5 The normal oil consumption of the turbine set is larger than the rated flow of the
oil pump, causing a drop in oil pressure. The oil pressure is too low after the main
oil pump put into operation in test running. If it has been verified through

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 Operating Instructions
Oil-system Fault and Elimination 3-3010-04-01
examining that the low oil pressure is not caused by the reasons mentioned above,
try to reduce the oil consumption of the system, such as the lubricating oil to the
bearings and gears as could as possible. It is not worked, the oil pump should be
replaced.

1.5.1 Changing the oil pump with a larger one;

1.5.2 Where the main oil pump is driven by the turbine shaft, raise the running
speed of the oil pump through changing the gear ratio of the driving element.

2. Trouble in changeover between main and auxiliary oil pumps

Where the main oil pump is driven by the turbine shaft, after the changeover speed
has been reached in turbine staring, the turbine cannot continue to run when the
auxiliary oil pump stopped. The main reasons are:

2.1 The oil tank position lower than the elevation specified on the layout drawing
increased the suction height of the oil pump or the inlet pressure is reduced due to
the increase in the length of the inlet piping and in the number of the elbows. This
will make the main oil pump suck with difficult and cannot work normally. In the
event that the increase in the oil flow of the oil injector cannot improve the
situation, it is better to modify the suction piping of the main oil pump.

2.2 The bottom valve of the oil injector cannot be opened to the required opening. The
increase in suction loss of the injector causes the main oil pump to suck with
difficulty. Check and repair the bottom valve. Re-filtrate the oil in the tank with a
filter, when necessary.

3. Oil leakage
3.1 Poor sealing caused by the improper assembling of the components or the
improper connection of the oil piping, or sealing surface damage will result in oil
leakage, which will be unveiled in test running. The corresponding treatment
should be carried out according to the examination for the leakage part to
eliminate the oil leakage.

3.2 The oil leakage caused by the worn sealing element during turbine operation can
be handled accordingly based on the component feature. For the devices that can
be repaired in the operation, such as the stop valve and gate valve, if the oil
leakage at the valve spindle occurs, press the seal packing properly. The further
treatment can be carried out when overhaul. When the oil leakage at the shaft seal
of the electric oil pump, which can be switched over in operation, start the spare
oil pump and stop the fault pump for repairing or replacing the damaged shaft seal.
For the component that only can be repaired after the turbine shutdown, such as
the oil relay, should be carefully inspected in regular examination. The oil
penetrating at the piston rod must be taken in account and recorded. If it is

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 Operating Instructions
Oil-system Fault and Elimination 3-3010-04-01
increasing day to day, repair the piston rod or replace the seal element in time,
making the using of the turbine shutdown so as to avoid turbine forced stop due to
the leakage of the oil relay.

4. Oil-piping vibration
The oil-piping vibration that is caused by the improper connection and will result in
turbine vibration is usually eliminated through taking the corresponding measure
when test running. But the other oil-piping vibrations are ignored. For some of the
turbines, the high-frequency vibration of the secondary-oil piping will occur during
operation. For the others, the protective-oil piping vibration will occur when tripping
the turbine. The oil-piping vibration will produce a dynamic load on the piping and at
the connection and welding seam. This will probably cause the restraining force of the
connection reduced and welding seam broken, resulting in oil leakage. Therefore, the
piping vibration must be eliminated in time. The oil-piping vibration is related with
the initial stress of the piping when connected, the velocity and the state of oil flow in
the piping. It can be eliminated through installing proper piping supports in most
cases.

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 Operating Instructions
Control-protection System Fault and Elimination 3-3010-05-01

Control-protection system Fault and Elimination

1. Abnormal in opening emergency stop valve
1.1 For the turbine using the starting control to open the emergency stop valve,
improper operating will cause that the emergency stop valve cannot be opened
normally. In the course of the emergency stop valve opening, the starting oil will be
switched to the trip oil. If operate the handwheel of the starting control
continuously at a fast rate the decreasing rate of the starting-oil pressure will faster
than the increasing rate of the trip-oil pressure, so that the piston disk is separated
from the piston and the emergency valve cannot be opened. The proper operation
should be in such a way, observe the pressure gauge while operating the handwheel,
when the trip-oil pressure is built-up and the starting-oil pressure begins to drop,
slow down the operation of the handwheel as could as possible or stop for a few
seconds, then continue to operate until the valve in full open.

1.2 The inner leakage of the oil cylinder will cause that the emergency stop valve
cannot be opened normally. This is because the excessive radial clearance between
the oil cylinder and the piston causes leakage of the starting oil in a large quantity;
the staring-oil pressure is not able to push the piston to the piston disk. In this case,
the trip-oil pressure cannot be built-up and emergency stop valve cannot be opened.
This fault can be removed through repairing, for example, Fitting sealing element
between the oil cylinder and the piston or using a specially mated piston.

1.3 The deposit and bend of the valve spindle will also cause that the emergency stop
valve cannot be opened normally. Therefore, the functional test of the emergency
stop valve should be carried out regularly (see 1-2300- and 1-1400- for details). If
the test-oil pressure rose, the probability is that the deposit of the valve spindle or
oil cylinder or the bend of the spindle exist. In this case, the repairing should be
arranged in time for finding the reason and eliminating it.

In order to avoid the valve spindle being bended, the spare spindle should be stored in
hanging instead of in lying.

2. Oil leakage of oil cylinder for emergency stop valve (leaking out)
2.1 This is caused by the improper assembling of the seal ring. In this case, the sealing
element should be re-assembled and the seal ring pressed tightly. If the wrong size
of the seal ring is used, it must be replaced with the right size one.

2.2 The disalignment of the valve spindle with the bush of the seal element or the
contact of the valve spindle to the sleeve caused by the bended valve spindle can
rough the spindle and damage the seal ring, resulting in the leakage of the oil
cylinder. In this case, repair and replace the valve spindle or sleeve, replace the seal
ring, and reassemble them carefully.

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 Operating Instructions
Control-protection System Fault and Elimination 3-3010-05-01
3. Fault of slide valve in pilot valve
The slide valve is formed by the rotating disc and the valve body through sticking (see
1-1910- for details). In some of turbines, the rotating disc can be separated from the
valve bode due to the additional resistant moment of the rotating slide valve or the
decreased strength of the adhesive. The delay rate of the control system will be
increased obviously because the valve body is no longer rotated. When changing the
setpoint of the governor, the oil relay will have no reaction or overshoot in large
amplitude. Meanwhile, the oil overflows from the ventilator. If touch the inlet and outlet
oil piping of the pilot valve with hand, there is no vibration can be filled.

Measure: Stop the turbine in time and replace the slide valve. The replaced slide valve
can be stuck again user himself. Before sticking, clean the solidified adhesive on the
jointing surface with knife and sand cloth. The single-component anaerobic adhesive
with shear strength higher than 14.7 Mpa at room temperature can be chosen as the
adhesive. The sticking operation should be carried out according to the requirement for
the adhesive.

4. High-frequency oscillation of secondary-oil pressure

For the turbine using the hydraulic amplifier, in some times the pointer of the gauge for
the secondary-oil pressure swings, the secondary-oil piping vibrates, the turbine load or
speed fluctuates quickly and without attenuating under a certain operating condition
because of the secondary-oil pressure oscillation. In this case, turn down the one-way
throttle valve in the secondary-oil line or adjust the adjusting valve of the pilot valve to
reduce the rotation frequency of the slide valve for decreasing the amplitude of the slide
valve and eliminating the oscillation of the secondary-oil pressure. The pipe clips can be
mounted additionally for the secondary-oil piping when necessary.

4.1 Turbine cannot be started normally

When starting the turbine with hydraulic or mechanical-hydraulic governor, the control
valve closed suddenly during raising speed, causing the turbine cannot be started
normally. This is mostly caused by the improper setting of the “cut-off point” of the
amplifier. See 1-1830- for details.

4.2 Load (speed) fluctuation

For the turbine using hydraulic or mechanical-hydraulic governor, the un-attenuating
load (speed) fluctuation may occur in some of them during operation. There are many
reasons that can cause the control system unstabilized. Here we enumerate two of them”

4.2.1 The play of the fork of the amplifier caused by the excessive axial clearance at
the joint of the fork and comparison lever can disturb the normal work of the
following-up piston, resulting in ripple of the secondary-oil pressure and
consequently the fluctuation of the load or speed.
Measure: Make-up the washer again in overhaul. The axial clearance at the joint
should be within 0.02 to 0.03 mm, making the fork swing flexibly without play

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 Operating Instructions
Control-protection System Fault and Elimination 3-3010-05-01
in axial direction.

4.2.2 For the turbine using PG-PL governor, the unsuitable opening of the
compensating needle valve in the governor to the turbine performance can cause
the control system unstabilized. The needle valve can be adjusted during turbine
operation. The low fluctuating velocity indicates the opening of the needle valve
is too small, turn the needle valve counterclockwise to increase its opening.
While the fluctuating period is very short, the valve should be turn down. The
needle valve should be adjusted slowly and the turbine operation should be
observed when adjusting until the system stabilized. The adjustment of the
needle valve is considered to be in conformed to the requirement, when
changing the setpoint of the governor, the system can react immediately and
after a trifle overshoot it will return to the stable state. Usually, once the needle
valve adjusted, readjusting is not required.

4.3 Electric-hydraulic converter

For the turbine with the electric-hydraulic converter, the output oil pressure of the
converter will drop at the same electric signal comparing to the data measured in
commissioning after turbine has been operated for a period. This is probably that the
inlet oil strainer of the converter is blocked due to the poor cleanness of the oil system.

Measure: After the normal stopping, clean the oil strainer and verify the relationship
between the electric signal and the oil pressure. If the relationship returns normal, it can
be put in operation. And meanwhile, the maintenance of the oil system should be
strengthened for improving the cleanness. If it is still abnormal, try to reset the initial
valve and range of the converter.

When the electric-hydraulic converter fault caused by inner reason occurred during
operation, it is better to stop the turbine and replace the converter with spare one.
Contact to the converter supplier for repairing.

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 Operating Instructions
Condensing System Fault and Elimination 3-3010-06-01

Condensing System Fault and Elimination

During the condensing turbine operating, the vacuum drop of the condensing system
often occurs. There are many causes that have influence on the condensing system
vacuum. When the vacuum drop is discovered, find out the reason based on the features
and take the corresponding measures. Some of the main reasons are list below:

1. Interruption of cooling water

If the vacuum inside the condenser becomes zero, meanwhile the exhaust temperature
rises sharply and inlet pressure of the cycling water for the condenser is lost during
turbine operation, it is sure that the cooling water has been interrupted. At this moment,
trip the turbine immediately and close the inlet valve of the cycling water. The
condenser can be supplied with the cycling water only after the condenser temperature
dropped below 50℃.

2. Shortage of cooling water

Under a certain load, the shortage of cooling water will cause an increase in the
differential temperature between the inlet and outlet of the cycling water and a slow
drop in the vacuum of the condenser. This is especially in summer, the required vacuum
cannot be kept even if the cooling-water flow is increased for some of turbines because
of the increased temperature of the inlet cycling water. In this case, the turbine load
should be limited for reducing the exhaust flow and returning the vacuum to the normal
value.

The shortage of the cooling-water flow is usually resulted from the block of a part of the
cooling pipe in the condenser or abnormal operation of the cycling-water pump. If it is
caused by the former, an increase in differential pressure between the inlet and outlet of
the cycling water must be companied with.

3. Water level in condenser too high

When the condensate level in the condenser is beyond the up limit of hot-well nilometer
and a part of the cooling pipes is flooded by the condensate, the vacuum will drop
slowly because of the decrease of the cooling area at the steam side of the condenser.
Under the worse condition, the condensate will enter into the air-bleeding pipe so that
the vacuum drops quickly and the water is injected from the exhaust piping of the air
ejector. The another endanger caused by overtopping water level is to increase the
condensate depression. The overtopping level is mainly caused by:

3.1 Condensate pump fault: Pump or motor fault causes that the condensate cannot be
drawn out. Whether the pump fault or the motor fault can be judged from the change
of the pump discharge pressure of the motor current.

3.2 The cycling water leaks into the steam side of the condenser, caused by the broken
cooling-water pipe or the loose joint of the pipe to the pipe plate. This can be judged

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 Operating Instructions
Condensing System Fault and Elimination 3-3010-06-01
through chemical analysis of the condensate.

3.3 Excessive opening of the recycling valve in the condensate line.

3.4 The check valve at the output of the spare condensate pump is not closed tightly,
resulting in the condensate flowing back to the condenser.

4. Improper adjustment of gland steam

Since the gland steam pressure is too low, a lot of air is inhaled from the rear gland seal
of the turbine, causing the vacuum to drop rapidly.

5. Leakage of vacuum system

The leakage of the vacuum system will cause an increase in the amount of air leaked
into the air side of the condenser, resulting in the vacuum drop due to the overloading
operation of the air ejector. When the vacuum dropped, close the air valve of the ejector
for a short time (less than 1 minutes), if the vacuum of the ejector rises but that of the
condenser continue to drop, indicating that the drop of the vacuum is caused by the
increase of the air leaked into.

If the vacuum drops when the load decreased, while it returns to normal when the load
increased, the drop of the vacuum is usually caused by the leakage at the joint of the
connecting piping for the low-pressure casing.

The leakage of the vacuum system may occur at the following parts: the flange between
the exhaust casing and the exhaust nozzle, the welded junction, the exhaust relief valve,
the drainer, the valve and the joint. To find the leakage requires not only being familiar
with the vacuum system but also being careful and patient. Once the leakage is detected,
handle it immediately.

6. Abnormal operation of air ejector

The abnormal operation of the air ejector in bound to cause the vacuum drop of the
condensing system. When the vacuum dropped during operation, close the air valve of
the ejector for a short time (less than one minute), if there is no obvious change in the
vacuum of the main ejector, the ejector fault is indicated. The abnormal operation of the
air ejector may be mainly caused by:

6.1 The working steam parameter of the air ejector is deviated from the normal value
significantly, decreasing the ejector efficiency.

6.2 The shortage of the cooling-water flow to the cooler caused that the steam in the
drawn mixture of steam and air cannot be condensed completely and a good deal of
steam emerged from the exhaust pipe of the air ejector.

6.3 The cooler was full with water due to the obstructed draining or broken water pipe.

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 Operating Instructions
Condensing System Fault and Elimination 3-3010-06-01
If the second stage cooler is full with water, the mixture of steam and water drains
from the exhaust pipe.

6.4 The drainer fault or loose close of the drain valve caused the air to leak into the air
ejector.

6.5 The improper distance between the ejector nozzle and the diffuser decreased the
capacity of air bleeding. Usually, this will be found and eliminated in test running.

6.6 The steam strainer or nozzle of the air ejector was blocked. It is because that the
steam inlet piping of the air ejector does not blown thoroughly, the impurities enters
into the ejector with the steam to block or even damage the steam strainer, making
the nozzle blocked. This will occur during test running and normal operation as
well.

When the strainer or nozzle blocked, the vacuum of the air ejector drops and the cooler
temperature decreases obviously and the ejector operates with an abnormal sound (the
steam jetting sound lowers and even disappears. When the second stage air ejector is
blocked, a sniffing sound can be heard in the exhaust pipe).

Should the vacuum drop during operation, start the spare air ejector when necessary. If
it is caused by the abnormal operation of the main ejector and cannot be eliminated
under operation, stop the faulty ejector for repairing.

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 Operating Instructions
Load Rejection 3-3010-07-01

Load Rejection
The electric load may drop to zero suddenly during the turbo-generator operating, this
is called as load rejection. The load rejection of the turbo-generator should be handled
according to the feature and reason.

1. Load rejection caused by electrical accident

When the generator load rejected and decoupled from the network, the reading in the
wattmeter drops to zero. The turbine speed rises instantaneously and tends to stabilize
after fluctuated for a short time. The control valve closes to the opening of no-load
automatically.

In this case, set the speed setpoint of the governor to the rated speed and adjust the
gland steam, immediately. Cut off the extraction for the extraction turbine and adjust
the recycling flow of the condensate for the condensing turbine. Should the
turbo-generator operate normally, it can be incorporated in power network and loaded
again after the electric fault eliminated.

2. Load rejection caused by electrical accident, turbo-generator stopped due to

control system defect of turbine
When the generator load rejected and decoupled from the network, the reading in the
wattmeter drops to zero. Turbine overspeed makes the overspeed protection system
acted, the emergency stop valve and the control valve closed, resulting in shutdown of
the turbo-generator.

In this case, in addition to take the measures mentioned in item 1, check whether the
oil supply system operates normally. If there is no other fault, reset the overspeed
protection system and the emergency trip gear. After the control system adjusted,
restart the turbine, raise turbine speed, synchronize and load on.

3. Load rejection caused by electrical accident, turbo-generator stopped due to

protection system defect of turbine
When the generator load rejected and decoupled from the network, the reading in the
wattmeter drops to zero. After a slight increase the speed dropped with the close of the
emergency stop valve and the control valve, resulting in shutdown of the
turbo-generator.

For the extraction turbine using hydraulic control system, the hydraulic
reference-value relay (see 1-1114-01-xx for details) will act when load rejection. The
improper adjustment of the hydraulic reference-value relay will cause the momentary
oil flow of the working oil to the oil relay too large. Thus the trip-oil pressure is
dropped, making the emergency stop valve and the control valve closed.

In this case, the measure mentioned in item 2 may be taken. At the same time, the

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 Operating Instructions
Load Rejection 3-3010-07-01
acting stoke of the lower piston in the hydraulic reference-value relay should be
reduced properly. Where the accumulator is fitted in the working oil line of the oil
relay, check whether the nitrogen filling pressure of the accumulator is conformance
with the requirement. If the accumulator is not provided, mount an accumulator when
overhaul.

4. Load rejection caused by false action of turbine protection system

The generator load is rejected due to the close of the emergency stop valve and the
control valve. The reading in the wattmeter drops to zero, but the current reading is
not zero. The turbo-generator speed keeps unchanged, this indicates the generator is
not decoupled from the electric network. This accident is often caused by the false
action of the emergency trip gear or trip valve (manual or remote).

In This case, the turbo-generator runs in motor mode must not exceed 3 minutes. The
fault should be eliminated immediately, then reopen the emergency stop valve and the
control valve and load the turbo-generator again. If the fault cannot be eliminated in 3
minutes, inform the control room for decoupling and stop the turbine. After the fault
eliminated, restart the turbine.

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 Operating Instructions
Preface to section “maintenance” 4-0100-01-01

Preface to section “maintenance”

The section “maintenance” in this Operating Instructions deals chiefly with the
demonstrations and suggestions for turbine maintenance, inspection and repair.

The maintenance of the turbine includes the maintenance when operation and the
protection during shutdown.

The operation maintenance is a regular job for the operator. He should strive for the
turbine operating under optimal state through proper operating with the help of the
monitoring instruments during turbine starting, operating and stopping. In case the
abnormal condition occurs, the operator should make a judgment for fault trend calmly
and rapidly. For the defect that does not endanger safety but can not be eliminated
temporarily, adjust or limit the operating condition of the turbine-set in time and make a
record in details and truth at the same time, which will be taken as the basis for
determining the repairing time and program. For the serious fault under which the
turbine must be stopped immediately, stop the turbine decidedly to avoid the fault
expanding further. In general, the reason causing fault can be divided into two kinds.
One is not influenced by the operation duration, such as the construction quality, the
design and manufacture level, the improper assembling and adjusting in installation and
overhaul, the false operation and etc. The other is related with the operation duration,
such as the normal wear, corrosion, deformation, material ageing, the expiring of the
service life, the deposition and consequent damages, the abnormal disturbance in
operation and etc. Most of problems caused by the first kind of reason (except for the
false operation) will come in light in the test running after installation and overhaul.
Typically, this kind of problems can be handled through “defect eliminating”. From the
second kind of reason and practical experience, it is known that the proper operation and
the careful maintenance will not only enhance the turbine usability, but also prolong the
service life within the expected lifetime. To ensure economic and reliable operation of
the turbine, must pay sufficient regards to the canonical operation during starting and
stopping, the avoidance of the intensive change of the steam parameter deviated from
the normal value, the limitation of the load change-rate, the monitor of the steam quality
and maintenance of the oiliness, scheduled overhaul and etc.

The turbine maintenance also includes the test carried out during operation. Before
testing, the operator must know fairly well about which parameters will change in the
process of the test, so as to avoid mishandling.

Protective care is required during turbine shutdown, so the necessity of protection and
the related measures that may be taken during shutdown are explained here.

Overhaul is to examine and repair the turbine (including the auxiliaries) during
shutdown. A reasonable overhaul schedule is based on the operation supervision and the
fault diagnosis. The operation statue of the turbine-set can be improved and the turbine

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 Operating Instructions
Preface to section “maintenance” 4-0100-01-01
efficiency can be enhanced through overhauling purposefully in time and eliminating
the defect founded, replacing the worn parts and leaning the deposit. Also, with such
overhaul, the factors and hidden troubles, which will cause the fault, can be found out
and removed to reduce or avoid stopping. Meanwhile the collected data is useful for
estimating the turbine statue completely. When necessary, amend the operation
procedure accordingly. It has been proved in practice that the careful overhaul is the
absolutely necessarily important measure for insuring the optimum and safety operation
of the turbine.

The necessity and essentiality of the preventative examination in the process of the
overhaul is cognized now days. The examining items and methods during overhaul will
be explained in the following sections to aid to the examinations.

Of cause, to overhaul the turbine-set must be shutdown and the production of the plant
must be stopped. Therefore, the examining items and the schedule should be made out
based on the operation state of the turbine-set and the production schedule in
consideration of the spare-parts reserve, the personnel and the cost, carrying out the
overhaul duly.

After the overhaul, the result should be estimated and the necessary preparation for next
overhaul should be made. When necessary, amend the operation procedure according to
the overhaul result. The overhaul effect must be verified through re-commissioning after
the turbine overhauled.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Checking and Testing Schedule

It is an integral part of the turbine maintenance to check and test the protective, safety
and monitoring equipments of the turbine at regular intervals. The table below shows
designation and the period (interval) of the main checking and testing item and the
turbine state when carrying out the checking and testing. Here, the period and state are
represented with following codes:

h: Hourly
d: Daily
w: Weekly
m: Monthly
y: Yearly

The combination of the digit and letter is used, such as 3m, that means every 3 months.

State codes:
A: On start up
B: On shutdown
R: In normal operation
S: After stopped or overhauled

The items listed in the table are not the unique, user can add or omit some items
according to the requirement on his turbine. The condition and the result of the checking
and the testing should be recorded.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

Leakage of front and d R Under the approximately similar operating condition, the
real gland seals increase of the steam leakage from the gland seal usually
indicates the increase of the radial clearance of the gland
seal. The clearance of the inner gland seal (including the
gland seal of the dummy piston) will change with the
change of the clearance of the outer one. The clearance
increase of the gland seal will increase not only the loss of
the steam leakage but the axial thrust as well. Therefore, the
checking and handling should be made.
Temperature of h R The bearing temperature is continuously recorded or
journal and thrust observed regularly by operator based on the configuration of
bearings the monitoring instrument. If the temperature rises, pay
attention to its change. When the it has approached or
reached to the alarm value, the load must be reduced. When
it reached the stop value, stop the turbine at once and find
out the cause.
Control valve
1.Check freedom of w A/R Change the valve opening through controlling a step change
movement of the actuating command of the oil relay and observe
whether the control valve reacts quickly. For the non-electric
system, briefly operate the accelerator lever on the speed
governor to carry out the test. Any deposit on the valve stem
will be cleaned at the same time.
2.Check tightness B Judge the valve tightness based on the race time.
3.Vlave-stem leakage R If the leakage at the position where the valve stem
penetrates through the valve bonnet, retighten the seal nut of
the valve stem. This should be done under the condition that
the admitted steam pressure has been reduced. The
replacement of the seal ring, if necessary, only can be done
after shutdown and cooled down.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

4.Check setpoint and ≥3m S For the turbine operated above 3 months, check the relation
sluggishness between the actuating command (secondary-oil pressure for
non-high-pressure-fire-resistant-oil system) of and the oil
relay travel, the control valve lift after shutdown. Determine
the sluggishness and readjust when necessary.
d R During operation, Check whether the valve opening, the
power (speed), steam flow and the wheel-chamber pressure
change smoothly with the change of the secondary-oil
pressure.
Hydraulic governor S The following examinations should be made after the
governor repaired or turbine overhauled:
1.Check static Check the static characteristic of the control system against
characteristic 0-2500-T.Nr-00, following the method described in 1-1840-.
2.Check the speed Connect the coupling to the driven machine, check the up
regulating range and and low limits of the speed regulating range, and reset them
droop when necessary. Determine the speed droop when the
condition is permitted.
3.Check stability Produce a step disturbance with the accelerator lever and
observe the transition. Under normal condition, the speed
will swing instantaneously and stabilize at the value before
disturbed.
Mechanical-hydraulic s The following examinations should be made after the
governor governor repaired or turbine overhauled:
1.Check static Check the static characteristic of the control system against
characteristic 0-2500-T.Nr-00, following the method described in 1-1840-.
2.Check the speed Connect the coupling to the driven machine, check the up
regulating range and and low limits of the speed regulating range, and reset them
droop when necessary. Determine the speed droop when the
condition is permitted.
3.Check stability Produce a step disturbance with the accelerator lever and
observe the transition. Under normal condition, the speed
will swing instantaneously and stabilize at the value before
disturbed.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

Speed transmitter Y R/S The filter of the breather should be cleaned at least once
every year.
Digital governor According to the Instructions of the governor.
Electric-hydraulic Y S Clean the filter after shutdown, as required.
converter Determine the characteristic once every year, mainly for the
relation between the electric signal and the secondary-oil
pressure.
Adjust the initial value and the range of the secondary-oil
pressure, when necessary. In case of fault, it is better to
replace it with the spare one, and then contact with the
supplier of the converter for repairing.
Oil relay D R Check for leakage.
Breather of pilot valve 6m R/S Clean the filter of breather.
Test valve of 3m R The test must be done periodically, no matter where the test
emergency stop valve valve is mounted, in the trip block or the piping. Compare
the measured test pressure P2 (see 1-2300-) with that
recorded in commissioning, if P2 increases, the
corresponding handling should be made during overhaul.
Teat valve of 3m A/R During start-up or operation, check for proper functioning
emergency governor of the emergency governor using the test valve (see
1-2810-).
Functional test for trip S/A/B Before turbine start or during starting or stopping, check for
components proper functioning of the trip action through operating the
trip device manually (such as manual stop valve,
remote-controlled stop solenoid valve, emergency trip gear
and etc.).
Extraction stop valve S After shutdown, check whether the open and close of the
controlled and non-controlled extraction stop valves are in
normal when the oil system is still running. Before testing,
it must be ensured that the isolated valve in the live steam
line has been closed.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

Speed measuring 3m R Check the speed measuring instruments for monitoring in

instruments operation, including the speed indicators on the instrument
panel, digital governor and speed monitor, with manual
speed measuring instrument.
Pressure measuring 6 S For the turbine operated above 6 months, verify all of the
instruments pressure gauges and switches after shutdown.
Exhaust safety valve Y B Check whether the action of the safety valve is conform to
the requirement through raising the exhaust pressure in the
process of stopping, at least once every year.
Casing expansion d A/R/B Check the axial expansion of the casing during starting and
stopping and load changing. The casing can move freely
and smoothly with respect to the pedestal. The bolt washer
of the casing-bracket must always be easily movable. There
is a clearance between the washer and the bolt head should
amount to 0.10 mm.
The casing temperature (average temperature) can be
calculated approximately form the axial expansion of the
casing
Vibration monitor The shaft vibration must be monitored when starting or
1. Monitoring shaft D A/R/B stopping the turbine. The change of the vibration should be
vibration recorded with a recorder.
During long-term operation, provided that there is no
change or very small change in vibration under the same
operating condition, the turbine operation can be considered
in a good state.
To judge whether the vibration is in normal or not, pay
attention firstly to the deviation from the normal value, then
the actual amplitude.
2. Calibration 6m S For the turbine operated above 6 months, calibrated the
sensor with portable calibrator.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

Monitor and verify of d A/R/B The continuous monitoring of the rotor axial position may
monitor for rotor axial indicate:
position The thrust direction of the turbine rotor;
The displacement caused by the worn thrust bearing;
The elastic deformation of the thrust bearing and the
pedestal.
Under normal condition, the rotor position should be the
same under same operating condition.
The axial displacement monitor can be calibrated with the
same calibrator at the time when the vibration sensor
calibrated.
Oil system See 4-0400-
Grounding brush d R Check for the wear of the brush through view window,
replace it following the instructions in 1-7650, when
required.

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 Operating Instructions
Checking and Test Schedule 4-0200-01-01

Item or Period State Remarks

component name

Overspeed trip test of 3m* B/S The reliability of the overspeed trip for the emergency
emergency governor governor is dependant on the flexibility of the eccentric bolt,
(For turbine without which may be locked by following causes:
test valve) Scraped sliding surface of the eccentric bolt;
The oil contains water or other causticity substance;
The oil contains foreign impurities;
The part is damaged by the shaft current caused by invalid
brush or without mounting the brush;
Improper operation in supplementing oil, the oil mud
separated out the oil is deposited in the emergency governor.
To ensure the reliability of the emergency governor, the trip
test of the emergency governor should be made under
following conditions:
After turbine overhaul;
After the emergency governor dismounted and adjusted;
Restarting after shutdown for a month;
* After the turbine operated for 3 months.
* After the turbo-generator operated for 3 months, the
overspeed trip test should be made when the turbine-set is
connected from the net.
For the turbine driving compressor or pump, when it
operated continuously above 3 months, disconnect the
coupling between the turbine and the driven machine and
carry out the overspeed trip test of the emergency governor
after shutdown.
For the test method and requirement, see 3-1400-.
The turbine-set cannot be put into operation when the
emergency is abnormal.

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 Operating Instructions
Protection during Turbine Shutdown 4-0300-01-01

Protection during Turbine shutdown

The turbines are constantly being taken out of service for shutdown of varying duration
due to various reasons. After shutdown the turbine will suffer the damage caused by the
corrosion under the action of the internal and external factors. Therefore, some
necessary provision must be made for internal corrosion protection during turbine
shutdown.

The corrosion of turbine interior can occur in a few days after the turbine has cooled.
For example, the blade can be corroded because of the presence of salt deposit in
conjunction with moisture. Such shutdown corrosion will not only produce chemical
corrosion on the scatheless blade but also cause secondary corrosive damage of the
corroded parts, resulting in an obvious decrease in the endurance limit of the blade.
Therefore, the protective measure must be taken even for short shutdown.

For the condensing turbine that will not be restart immediately after shutdown, make the
turbine interior as dry as possible through proper operation in stopping. This is one of
the protective measures in common use.

For long-term shutdown (for turbine overhaul or seasonal shutdown), one of the
necessary protective measures, without opening the casing, is to block the steam inlet
and outlet of the turbine for separating the turbine from the steam and condensing
system and avoiding the steam and vapor entering into the turbine. However, This can
not remove the possibility of the corrosion inside the turbine, because the temperature
of the parts inside the turbine will change with the ambient temperature in the workshop
(see Fig 1). The volume of the air contained inside the casing will change with the
change of the temperature. The interchange will occur between the airs inside the casing
and the exterior through shaft gland and other openings. Fig.1shows that the casing
(including the rotor) temperature is always lower than the temperature of the external air
entering into the casing within a larger range. It will transfer the heat to the turbine parts,
so that the air temperature will drop below the dew point forming water drops under
corresponding relative humidity, which supplies a prerequisite for corrosion. The test
also indicates: when the relative humidity is less than 60%, the corrosion rate for steel
decreases rapidly (see Fig.2). When the relative humidity is less than 35%, the corrosion
rate becomes zero soon. The polished surface of steel will not be rusted for a long time
at a relative humidity less than 35%. Therefore, to avoid corrosion of the turbine interior
during shutdown, the air inside the casing must be kept at a relative humidity less than
50%.

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 Operating Instructions
Protection during Turbine Shutdown 4-0300-01-01

Fig. 1 Temperature change inside workshop and turbine in three days

Fig. 2 Corrosion rate for steel versus relative humidity

Hot air method

This is easy and efficient method for reducing the air humidity inside the casing. The
hot air is injected into the turbine to reduce the air humidity and dry the parts inside the

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 Operating Instructions
Protection during Turbine Shutdown 4-0300-01-01
casing. At the time when the hot air absorbs the moisture inside the turbine the inner
parts is heated by it and remain at a temperature higher than the ambient temperature.
The hot air should be injected from the lowest point (e.g. connection of the gland steam)
of the turbine as could as possible and is discharge via the shaft gland and opened drain
ports. To ensure that the air discharged at the remotest point is 8 to 10 ℃ above the
ambient temperature, the flow and temperature of the air injected should be regulated as
required.

Nitrogen method
Fill the casing with inert gas, such as nitrogen, for protecting corrosion..

Before filling nitrogen, dry the turbine interior first and then close the steam and drain
connections tightly and seal off the lead-throughs of the shaft gland and valve stem with
airproof tape carefully. The nitrogen may be injected into the casing from the exhaust
casing or a drain port. The nitrogen pressure inside the casing should be kept at 0.5 to 1
Mbar.

Before restarting the turbine protected with nitrogen, the nitrogen inside the casing must
be vented thoroughly.

The nitrogen content in the air under normal condition is 78%. When it is higher than
84%, it will be harmful to human. So the measure must be taken in using the nitrogen
method for preventing accident

Protective coatings
For the turbine stopped not for overhaul, the application of the protective coatings only
can be used if the casings are opened.

Coat the surfaces of the parts inside the casing with antirust oil according to the
instructions for antirust oil.

Should the rotor coated with antirust oil still rest on the bearings, the oil film at the
journals will break or be squeezed out under the action of the rotor weight and outside
force (e.g. the foundation vibration), resulting in journal rusted. So it is better to lift out
the rotor from the casing and rest it on the special pedestal after coated with antirust oil.

The protection effect can be inspected regularly, because of the opened casings.

Protection of other components

For the turbine that its oil system can still run after shutdown, run the oil system for 1 to
2 hours every two weeks, making the part surface contacted with the oil be covered with
a layer of oil film having the protective function.

For the turbine that its oil system cannot run after shutdown, when the expected

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 Operating Instructions
Protection during Turbine Shutdown 4-0300-01-01
shutdown duration exceeds 1 month, dismount the bearings and clean them with
cleaning liquid, such as gasoline, dry and coat them with antirust oil, then mount them
again. Should the shutdown duration exceed 3 months, the coating protection should be
taken for components of controlling and protective system (governor, oil relay, oil
cylinder of emergency stop valve, emergency trip gear and etc) and the gearbox of
driving element, especially for the turbine located in south and rainy region.

If the shutdown duration is less than 3 days, the cycling water for the cooler, such as
condenser, oil cooler and etc, may not be interrupted, otherwise, it should be cut off.
Drain away the water in the water chamber, make the walls of the water chamber and
piping as dry as possible. The accumulated water inside the equipments and piping must
be drained away to avoid the damage of equipment caused by freezing during shutdown
in winter.

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 Operating Instructions
Maintenance of Oil System 4-0400-01-01

Maintenance of Oil System

During turbine-set operation, the check should be made for operating state of the devices and
the oil quality in oil system following the operation procedure.

1. Oil level in oil tank

The oil level in the oil tank not merely indicates the amount of the filled oil but from which
change the troubles appeared in oil system can be found. A drop of oil level will indicate a
leak-out is existed in the oil system, e.g. opening of the drain valve by mishandling, break of
the cooling piping in the oil cooler and etc (Usually, the pressure at oil side in the oil cooler is
higher than that at the water side, so that the oil will be found in the outlet water of the oil
cooler when the cooling piping broken or the expansion joint loosen). An insufficiently high
oil level is likely to cause irregular operation of the oil pump due to increased bubbles in the
oil with the decreased circulating ratio and consequently disturb the normal operation of the
bearings and control system. Therefore, the reason should be found out when the oil level
dropped and the same brand of turbine oil should be filled up when required. When the water
entered into the oil and the air separation capacity of the oil decreased the oil level will be
rose. With too high an oil level, the return-oil port of the oil tank is flooded partially, the
ventilation spaces of the oil tank and bearing house is reduced, resulting in oil returning
difficult and oil leaking at the seal ring of the bearing housing. At the same time, part of the
turn-oil will flow over the partition wall entering directly into the oil tank without filtered,
increasing the impurities in the oil. When the oil level rose, the cause must be found out and
the corresponding measures must be taken.

2. Oil temperature and oil cooler

The rise in outlet oil temperature of the oil cooler is bound to increase the temperatures of the
inlet oil to each bearing and whole oil system. It is required to increase the opening of the
water inlet valve for increasing the cooling water flow to the cooler water when the outlet oil
temperature of the oil cooler rose, maintaining it within the normal range. If the oil
temperature does not lower obviously after the opening of the inlet valve has been increased,
it is likely caused by insufficient water supply or severe deposit in the oil cooler. Usually, the
drop of inlet water pressure or the increase of the temperature difference between the cooling
water inlet and outlet will indicate the insufficient water. If the deposit appears at the oil or
water side of the piping in the oil cooler, the heat transfer coefficient will be reduced, causing
the effect of the heat transferring worse. This will be bound to increase the temperature
difference between the inlet water temperature and the outlet oil temperature. For the rise of
the oil temperature caused by the former, the reason should be found out to insure the required
water flow. If it cannot be solved in time, the turbine must be operated under reduced load.
Should it be caused by the latter, switch the oil cooler and clean the deposited one.

Where the temperature of the cooling water changes with the change of the ambient
temperature, the cooling water flow to the oil cooler is small, at a slow velocity of flow in the
cooling piping. In order to avoid and reduce the settlement of the feculence in the piping,
further open the inlet valve at least once a time every day for about 10 minutes to flush out the

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 Operating Instructions
Maintenance of Oil System 4-0400-01-01
deposits that may be settled in the piping with the cooling water at high velocity.

3. Check for leakage of the system during regular inspection

4. Check for operation of the oil pump during regular inspection. Start the auxiliary and
emergency oil pumps periodically for functional examination.

5. Check the filling pressure of the nitrogen in the accumulator periodically.

6. For the system with the ventilator, check the vacuum in the oil tank periodically. The
vacuum in the oil tank and the return-oil header should be kept at 5 to 10 mm WS. A too
high vacuum will cause a large amount of dust and water vapor to be imbibed into the oil
system.

7. Oil quality
The reliable operation of the turbine is closely related with the usability of the oil system,
which is mainly affected by the oil quality.

The reasons that will cause the oil quality dropped and deteriorated are: gaseous, solid, and
liquid pollutions.

Gaseous pollution:
The main and frequent gaseous pollution is the oxidizing action. During using, the turbine oil
will contact with the air ceaselessly and make oxidizing reaction continuously. The water or
the metal particulates, if there is any contained in the oil, will has a catalysis on the oxidizing
reaction. The oxidizing action will translate the hydrocarbon molecule into acid, raising the
acid number of the oil, which will increase the corrosion action. The oxide will form jelly or
solid leavings to increase the viscidity, to block the oil passage, baffling the normal operation
of the hydraulic elements. Along with the increase in the oxidizing degree, the oil color will
become dark and turbid, the transparence of the oil drops. In addition, for the turbine driving
the compressor, the leakage of the process gas (such as ammonia, sulfureted hydrogen and
etc.) of the compressor under failure also will pollute the oil and deteriorate the oil quality.

In order to improve the antioxygenic property of the turbine oil, antioxidant, such as butylated
hydroxytoluene (T501) is added in the oil, which will restrain the oxidizing action, reducing
the oxidizing rate of the oil and prolong the oil service life. The T501 content in the new or
regenerated oil should not be lower than 0.3 ~ 0.5% (mass ratio), while the T501 content in
the operating oil should not be lower than 0.15%. When it is lower than 0.15%, the oil with a
PH number above 5.0 should be supplemented.

Solid pollution:
The solid impurities in the oil will speed the ware and make the oil thick, blocking the filter
and oil passage. Furthermore, the solid contaminations will reduce the air separation ability of
the oil, resulting in the oil being oxidized easily.

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 Operating Instructions
Maintenance of Oil System 4-0400-01-01
Flushing of the oil system must be carried out after installation or overhaul (see 3-0340-xx-xx
for details). The solid contaminations, such as scrap, foundry sand, welding spatter, metallic
oxide, paint film, fabric fibre, in the oil can be cleaned off through oil circulation. However,
the flushing of the oil system may be not thorough, resulting in the solid contaminations still
remaining in some components and piping, which will interfuse into the oil under the action
of the vibration, change of the oil temperature and flow rate after the turbine put into the
operation. Additionally, abrasive dust produced by wearing parts of the gear and bearing and
the dust inhaled from the air will also worsen the oil cleanliness and consequently the oil
quality.

During operation, the solid contaminations are mainly cleaned off with the oil filter. Under
normal condition, the filter element must be cleaned in time when the oil pressure difference
between the inlet and outlet of the oil filter approached its up limit. For the newly installed
turbine, it is better to clean the filter once a week at least in the initial stage of operation.

Liquid pollution:
The moisture pollution is a main liquid pollution. The moisture makes the acid out of the oil
and become chemical soap that has strongly corrosive action. In this case, the oil is emulsified
to greasy stain, blocking the oil passage. In addition, the mixture of the other brand of oil in
the turbine oil will also worsen the oil quality.

Usually, the water will enter into the oil mainly under the following condition: the leaking
steam from the turbine shaft gland enters into the oil system through the bearing house; for
the oil system with a higher pressure at the water side than that at the oil side in the oil cooler,
the cooling water will enter into the oil system through the oil cooler when the water piping
broken of the expansion joint loosen; for the turbine using filling air structure at the seal ring
of the bearing house, the water will enter into the oil system when the filling air without
depurating contains water; the water vapor is inhaled into the oil system with the air.

Under normal condition, the water entered into the oil will be separated soon and settled at the
bottom. Find out from whence the water comes through assaying the water drained from the
oil tank and take the measure based the assaying result.

For the turbine with oil containing water, the antirust additive T746 may be added in the
turbine oil with an amount of 0.02 ~0.03% of the oil amount (mass ratio).

The oil quality will be changed during turbine operation, so that examination of the oil must
be made periodically. For standard on turbine oil quality, see 3-0320-xx-xx. When necessary,
purify and regenerate the oil. If it cannot reach the requirement after that, the oil should be
changed.

The main cause to affect the oil service life is oxidizing action. The oil should be changed
every 2 or 3 years at an operation temperature about 50℃. The period of oil change should be
shortened at a higher temperature.

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 Operating Instructions
Maintenance of Oil System 4-0400-01-01
8. Requirement of supplement oil
For the turbine having been put into operation, when the oil level in the oil tank lowered, it is
required to supplement the same supply and brand of oil with the same additive as the
working oil. The property indexes of the supplement oil (new or treated used oil) should not
be lower than that of the working oil. Should the amount of the supplement oil exceed 5% of
the working oil quantity, the mixing test with the sample in pro rate should be made before
supplementing oil to the oil tank. The oil supplement only can be carried out if it is sure that
no deposit produced, so as to avoid the oil sludge being separated out after oil supplemented.

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 Operating Instructions
Deposition of Steam-path Section and Cleaning 4-0600-01-01

Deposition of Steam-path Section and Cleaning

The steam admitted into the turbine always carries, more or less, some impurities,
which will adhere to and settle on the blade surface to form a deposit during flowing
with the steam. The layer of the deposit will greaten surface roughness of the blade,
alter the blade profile, narrow the steam path and consequently decrease the turbine
output due to reduced steam flow and efficiency. Besides an increase in the axial thrust,
the deposit on the blade not only increases the flexure and centrifugal stresses of the
blade but also corrode the blade resulting in blade service life shortened. Meanwhile,
the deposit on the valve stem spindle is likely to cause the emergency stop valve and
control valve stuck. A great deal of turbines operating experience has shown that the
deposition of the steam-path section impairs not only the economical operation but also
the safety and reliability of the turbine. Therefore, it must pay enough attention to the
control of steam quality. The steam quality will be affected by various factors. It is
mainly related with the treatment of the boiler water and feed water and the operation of
the boiler with the given boiler type and inner devices. The steam quality can be
enhanced through perfectly treating the water and properly operating the boiler. Of
course, the perfect treatment of the feed water requires a certain cost, especially for the
turbine that needs a large amount of the supplement water. However, if only the turbine
output is sought for but the control of the steam quality omitted, the result should be not
worth the candle.

The increase of the steam quality may prolong the efficient operation duration of the
turbine. However, the in the turbine is unavoidable. The extent of deposition of the
steam-path section can be judged though monitoring the chamber pressure (see 3-2010-
for details). When the chamber pressure exceeds the permitted value, the cleaning
should be carried out in time.

Based on the deposit components, which are related with the feed water quality and
treatment equipment and technics, various methods may be adopted in leaning the
steam-path section. In the most cases, the deposition includes salt and silicon deposits.
The salt deposit mainly contains NaCl, Na2So4, silicate and etc, which are soluble in
water, while the silicate deposit contains insoluble SiO2，SiO2 with different crystal
structures and very strong depositing potency. Its deposited layer is very hard.

Usually, the method of manual cleaning, flushing with wet steam or chemical flushing is
used in cleaning the deposition.

When the manual cleaning method is used during turbine overhaul, lift out the rotor and
place it on the supports prepared. Firstly, flush the rotor with high-pressure water or
solvent, and then remove the deposit manually with scraper and sand paper. It should be
careful so as not to damage the blade when doing so.

Flushing with wet steam is one of the common cleaning methods. The saturated steam

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 Operating Instructions
Deposition of Steam-path Section and Cleaning 4-0600-01-01
produced by the cleaning device (temperature-decreased pressure reducer) is led in the
turbine under operation state for flushing the deposits. The salt deposit will be removed
by the condensate in the wet steam. For the deposit formed by the compound of salt and
SiO2, after the soluble compound has been flushed off, the layer of insoluble SiO2
deposit will be consequently disintegrated and removed.

In some cases when the flushing with wet steam cannot clean the silicon deposit
efficiently, the chemical flushing should be used. With this method, the chemical, such
as NaOH solution, is added in the flushing steam. Owing to the generation of Na2Si2O5
resulted from the reaction of the NaOH and SiO2, the silicon deposit can be removed.
Since the chemical will corrodes the turbine components, the concentration of the
additive and flushing temperature should be strictly controlled. Furthermore, the turbine
should be flushed with pure wet steam again after chemical flushing to avoid the
residual additive corroding the blade.

In order to prevent the deformation of the casing, the casing temperature should be
reduced to the temperature of the flushing steam before flushing. If the operation
condition permitted, reduced the inlet steam parameters gradually in the process of
unloading and stopping to decrease the casing temperature. This may shorten the
cooling time of the casing before flushing.

In order to reach the good effect n flushing, the saturated steam admitted into the turbine
should not be throttled, namely the nozzle controlling valves should be fully opened
(the valves 1st to 4th are nozzle controlling valves for most of the turbines).

The turbine speed when flushing is decided based on the actual condition. It may be any
speed between the rated and governor lower limit speeds.

During flushing, regularly sample the condensate for chemist analysis, sampling at the
drain port of the exhaust piping for backpressure turbine and the discharge of the
condensate pump for condensing turbine.

In order to keep the validity of the flushing, it is required to adjust the parameter of the
flushing steam continually. This is because when the temperature in the steam-path
section reached the temperature of the saturated steam, the steam cannot be condensed
to generate the condensate on the blade surface so that the flushing action is weakened.
Therefore the temperature and pressure of the flushing steam should be adjusted in time
during flushing based on the analysis result of the condensate.

The draining in the process of flushing must be thorough, closely monitor the turbine
speed, listen in the sound from the turbine, preventing water hammer.

After flushing, the turbine interior should be kept dry and start the turbine as early as
possible to prevent the corrosion during shutdown.

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 Operating Instructions
Deposition of Steam-path Section and Cleaning 4-0600-01-01
After the turbine has been put into operation again, assess the flushing effect based on
the chamber pressure.

The flushing under load for the turbine driving the generator may be carried out
according to the “turbine operation procedure” prepared by ministry of electric power.

For the turbine driving the machine, it is recommended to flush the turbine after the
driven machine is separated from the process.

For the user lacking of the experience in turbine flushing, especially for the chemical
cleaning, it is better to flush the turbine together with the professional cleaning
company.

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 Operation Instructions
Types of Overhaul 4-1000-01-01

Types of Overhaul
Based on the range and work amount of inspection and maintenance involved in the
overhaul, the turbine overhaul can be divided into four types, i.e. minor overhaul,
intermediate overhaul, major overhaul and componenet overhaul. However, the
overhaul mentioned in this Operation Instructions does not including the repair after the
event (the overhaul after the forced outage).

Minor overhaul
The minor overhaul is an overhaul method, which will spend shorter time with smaller
amount of inspection and repair. It is not required to open the turbine case. The minor
overhaul is basically restricted to the inspection and repair of the individual item
external casing and determined in advance, such as the inspection of the bearing and
coupling, measurement of the alignment, the visual r examination of the gear, the reset
of the controlling and protective systems, the checkout of the operating instrument and
etc. It mainly involves the examination and treatment aimed to the defect that is
discovered in operation and does not require forced outage. The forced stop of the
turbine can be avoided through such minor overhaul.

Usually, the minor overhaul is carried out on schedule as necessary. In some cases, it
might be possible to make use of a shutdown caused by other device of the plant..

The inspection and test data and experience got in the minor overhaul can be used as the
reference for the intermediate and major overhauls.

Intermediate overhaul
The intermediate overhaul is carried out during a planned shutdown of the turbine. The
work is approximately the same as for the minor overhaul but the percentage of
involved item is greater, e.g. radial runout checks, axial displacement check with thrust
bearing removed, check and measurement of rotor alignment to casing without opening
the casing.

Usually, the casings are not opened this overhaul. However, should the intermediate
overhaul be combined with a componenet overhaul, opening of the casing may be
required.

The inspection and test data will provide detailed information for the next overhaul.

Major overhaul
The major overhaul requires a planned shutdown of the turbine. The duration of the
shutdown will depend on the size of the turbine, the amount of labor available and the
diathesis of the service personnel, the overhaul schedule, the local conditions and the
availability of spares.

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 Operation Instructions
Types of Overhaul 4-1000-01-01
This overhaul involves the dismount of most components and detailed inspection and
repair of all components and all auxiliaries of the turbine (e.g. casings, rotor, bearings,
piping and etc.). it enables an assessment to be made of the condition of the equipment.
The damaged or worn the parts can be replaced by spares.

Should the turbine be renovated during major overhaul, the overhaul only can be carried
out when the substitutions has been got, so as to carry out the overhaul on schedule.

Modular overhaul
The modular overhaul is mainly to check and repair the turbine components, such as
main oil pump, governor, controlling valve, emergency stop valve, steam chest,
guide-blade carrier, seal gland and etc.

The modular overhaul may be carried out together with the intermediate overhaul.

The modular overhaul may be considered as the staged overhaul. It is very useful for the
turbine that cannot be stopped long time for overhaul due to the production.

During overhaul, the casings may be opened or not as required.

The detailed inspection in the process of overhaul, please refer to 4-1100- and 4-1200-.

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Inspection during Overhaul

During an overhaul the precautionary inspections for the defects should be performed so
as to discover and eliminate the hidden troubles as soon as possible for preventing fault.

The following are the principal methods for the inspection and testing of the turbine
parts (including the auxiliary components). Being convenient for illuminating, they are
identified by the various codes.

A. Function test
This is an inspection and testing method for the components such as governor,
emergency stop valve, pump control system and etc, in order to ascertain what checks
and adjustments are necessary.

B: Visual inspection
-- Appearance inspection by eye or optical device with good illumination.
-- Inspection with a microscope for determining the nature of damage.
-- Inspection with endoscope, together with the camera or vidicon, especially for
inaccessible part surface, such as control valve seat, inner wall of the piping in cooler.
-- Inspection of the surface roughness of the part.

C: Surface crack testing

-- Chalk test
-- Magnaflux test
-- Ultrasonic test
-- Eddy-current test

D: Ultrasonic testing

E: X-ray testing

H: Sounding testing
Excitation by a blow from a tool and judgment of the defect from the sound produced.

I: Measurement of wall thickness

K: Measurement of dimension and shape

-- Measurement of length, for checking relaxation, ovality and etc.
-- Measurement of runout, for checking the distortion of the rotor.
-- Gauging of components for actual shape, for checking bending angle, parallelism of
the flanges and etc.

L: Other nondestructive testing

-- Examination of grain structure of the part surface with “print” method.

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01
-- Hardness testing.
-- Spark test for material identification.

O: Static and dynamic balances

P: Pressure testing
Pressure or leak testing with water or working medium for checking tightness.

R: Testing of insulation and earthing of shafting system by measuring resistance

T: Sampling analyzing test.

The followings are required to consider in determining the method and range of
the testing.
1. Lift time of the equipment
2. Operation mode (stable or frequently changed operating condition)
3. The experience from a comparable machine
4. The data from the fault
5. Structure and type of the turbine
6. Operating parameters (steam, output and etc.)
7. The abnormal conditions occurred in operation by accident (quick drop of
temperature, overspeed and etc.)

The following table lists the item and method of testing for main components of the
turbine. Here, the testing item means the defect to be found out. The overhaul type is
identified with code:
1—Minor overhaul; 2—Intermediate overhaul;
2—Major overhaul; 4—Modular overhaul.

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Component Testing item Testing Overhaul Remarks

method type

Outer casing Intern. And ext. cracks, B,C,E,K 3 Inspection of

(including admission distortion, erosion, corrosion, mating and

chest and emergency leaks sliding surfaces

stop valve shell)

Seal ring of L-shaped Abrasion B,K 3

cross section

Inner casing

Intern. And ext. crack, B,C,K 3

distortion, erosion, corrosion,

Steam chest (Nozzle leaks

box) Distortion, abrasion B,C,K 3

Inner gland bush

Outer gland bush Distortion, abrasion B,K 3

Distortion, abrasion B,K 3

Emergency stop valve

Valve seat Deposits, corrosion, erosion, B 3, 4 Functional

mechanical damage testing before

Valve cone Deposit, corrosion, erosion, B 3, 4 and after

mechanical damage overhaul

Valve stem Mechanical damage, permanent B, C, K 3, 4

distortion, cracks

Valve gland Mechanical damage, corrosion B 3, 4

Steam strainer Mechanical damage, deposit, B, K 3, 4

distortion

Oil cylinder Abrasion, deposit, leak B, K 3, 4

Valve bonnet Damage on sealing faces, crack B, C 3,4

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Component Testing item Testing Overhaul Remarks

method type

Control valve (EB1)

Valve seat Deposit, corrosion, erosion, B 3, 4 Functional

Deposit, corrosion, erosion, testing before

Valve cone mechanical damage, abrasion B 3, 4 and after

Valve stem mechanical damage, deposit, B, C, K 3, 4 overhaul

crack, distortion

Valve beam Abrasion B 3, 4

Valve bonnet and Sealing faces, leak B 3, 4

sealing element

Joint Abrasion, rust B 2, 3, 4

Oil cylinder Abrasion, mechanical damage, B, K 2, 3, 4

leak

Split bolt Distortion, crack, mechanical B,C,D,K 3

damage

Nozzle Deposit, erosion B,T 3, 4

Guide blade Deposit, radial displacement, B, K, T 3, 4

erosion, scrape

Rotor (shaft) Scuffing B 3, 4 Attention to

Crack B, C 3, 4 checks of

Flexural distortion B, K 3, 4 shoulders and

Abrasion and electron erosion B,C,K,R 1,2,3,4 relief grooves on

of journal and thrust collar the shaft

Corrosion B 3, 4

Dynamic balancing D 3, 4

Radial and end-face runouts at K 2, 3, 4

rotor ends

Changes of alignment and axial K 2, 3, 4

displacement

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Component Testing item Testing Overhaul Remarks

method type

Ratchet, gear or Loose B, D, H 3, 4

impeller of barring Mechanical damage B, K 3, 4

gear Crack B, C 3, 4

Moving blade Deposit B, T 3, 4 Including the

Corrosion, crack B, C checks of blade,

Displacement B, K shrouding, tie

Scrape B, C, K wire, taper pin

of root, blocking

screw of last

blade and etc.

Coupling Loose B, D, H 3, 4 Rigid, gear or

Crack B, C 3, 4 flexible coupling

Backlash K 2, 3, 4

Radial and end-face runouts B, K 2, 3, 4

Distortion and damage of bolt B, K 3, 4

and bolt hole

Bearing Mechanical damage, abrasion B,K 1,2,3,4

Electron erosion B.R 1,2,3,4

Cavitation B.D 1,2,3,4
Corrosion
B.C 1,2,3,4
Bond
B 1,2,3,4
Crack
B,C 2,3,4
Babbit separation
B,D,H 1,2,3,4
Deposit
B 1,2,3,4

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Component Testing item Testing Overhaul Remarks

method type

Gearing Tooth flank bedding pattern B, K 1,2,3,4

Change in clearance B, K 2,3,4

Abrasion or bond B 1,2,3,4
Pit corrosion and crack
B, C 2,3,4
Electron corrosion
B, C, R 1,2,3,4
Plastic distortion
B, K 1,2,3,4

Turbine exterior and Surface crack B,C,I,L 3, 4 Including checks

steam piping of turbine Permanent distortion B, K 3, 4 for piping,

body Change in support position B, K 2, 3, 4 connection,

Non-straightway draining drain port,

B 1, 2, 3, 4
Pre-stress, tightness exhaust nozzle,
B, K, P 2, 3, 4
especially for

supporter and

hanger, welding

seam and flange

Oil piping Leak B, P 1,2,3,4 Including checks

Crack B, C 3, 4 for piping,

Corrosion, deposit B 3 valve, fitting and

Tube.

Attention to

fireproofing

requirement

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 Operating Instructions
Inspection during Overhaul 4-1100-01-01

Component Testing item Testing Overhaul Remarks

method type

Heat exchanger Flow A,B 1,2,3,4

Condenser Leak B,P 1,2,3,4

Oil cooler Corrosion B 3,4

Deposit B 3,4

Loose and crack of expansion B,C 3,4

joint

Damage of protection film on B 3,4

piping wall

Pump Functional disturbance A 2,3,4

Mechanical damage B 3,4

Cavitation B, C 3,4

Abrasion B, K 3,4

Corrosion B, C 3,4

Loose impeller B, K 3,4

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 Operating Instructions
Inspection Scope and Cautions during Overhaul 4-1200-01-01

Inspection scope and cautions during overhaul

Final readings of all operating data at various loads should be taken prior to shutting
down the turbine. After the coastdown time and the characteristic of cooling process
have been measured it is essential to measure the alignment between the turbine and
driven machine. Check the following before dismantling the machine:
Coupling assembly and clearances
Deposit in the half-coupling
Axial relative position of the coupling sleeve
Alignment of the rotor to the bearing housings and outer casing
Relative position of the pedestal to the casing
Axial positioning dimension of the rotor in relation to the casing
Axial movement of the rotor with the thrust bearing removed

Generally, the control-oil and lubricating oil piping are not required to dismantle so as
to avoid readjustment of the throttle valve, entering of the dirt into the system and
leakage when restarting up after the overhaul.

When lifting the top half of the casing it is essential to check that all of the split bolts
have been removed and that the guide bolts have been fitted. During dismantling, all
important components should be marked or documented (including sketches or
photographs) so that a subsequent reassembling in every details in always possible.

When opening up the machine take particular notice of any wear and deposit. If there
is any visible sign of leak on sealing surface found, it is necessary to check the
flatness and opening of the mating surfaces by means of blueing, taking leads or using
feeler gauges.

Very accurate records must be taken of any deposit on the blade and its position in the
turbine. Sample should be taken and analyzed to determine under which state
(running or shutdown) and with which method (steam flushing or chemical cleaning)
in cleaning deposit.

For the damage caused by solid foreign matter, it is necessary to specify the
cleanliness of the steam system besides checking of the steam strainer and etc.

Bearings, journals and oil seal rings should be inspected visually for damage.

A close check for the grooves in the gland bush or the shrouding can provide
important clues to the running state of the rotor during startup and operation. It also
indicates the presence of any distortion of the rotor and casing. The required clearance
and alignment can be gained through analyzing.

Worn or corroded sealing strips will indicate the maloperation during stopping and

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 Operating Instructions
Inspection Scope and Cautions during Overhaul 4-1200-01-01
startup, e.g. starting up while the rotor is still distorted after a brief shutdown, the
leakage of wet steam into the turbine when shutdown, the action piping force or
moment, the movement of the pedestals.

The admission section, beginning with the steam strainer, must be inspected very
carefully for damage. The working reliability of the emergency stop valve and the
operating performance of the control valves must also be checked closely.

The moving and fixed blades should be examined thoroughly, cleaning the deposit on
the blade surface if there is any. The cleaning process is also an essential preparation
for crack testing (magnetic or dye-penetration testing).

The adjusting elements of the guide-blade carriers should be inspected closely. From
the measurements of the relative position of the supporting surface and casing split to
the guide-blade carrier the clearance and adjusting value can be obtained. The guide
elements of the bearing housings, casing and carrier should also be checked. An
assessment of their condition can be made through clearance measuring.

The checks described above provide the findings from which the decisions on the
repairs, modifications and spares required can be taken.

After all the checks and necessary corrective work have been carried out, the
reassembly can begin. Special care must be taken with the lifting or the rotor, the
measurement of the clearances and the reassembly of the bearings.

Another important aspect of the work is the measurement of the relative position
between the individual sections of the plant:
Turbine to turbine
or turbine to gearbox
or turbine to driven machine
or gearbox to driven machine

In calculating the alignment valve and correcting, the relative movement between the
sections of the plant during operation must be considered. Checking firstly the radial
and axial runouts is an important method for correct adjustment.

In the process of reassembly, measure the actual values against the reference values,
which are given in the Product Certificate, steam-path drawing and initial installation
record, and log the measured results.

The next work is to mount and connect the supervisory system. Thorough check and
testing of all instruments, protection and safety systems are essential.

The oil supply system should also be checked. The cleaning of the oil system, the

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 Operating Instructions
Inspection Scope and Cautions during Overhaul 4-1200-01-01
check and readjustment of all valves are required if the lubricating oil and control oil
piping have been reconnected after dismounted in overhaul.

Reset the control system and check all of the steam piping.

The code in the table means as following:

1—Minor overhaul
2—Intermediate overhaul
3—Major overhaul
4—Modular overhaul
*-- When needed
**--Recommended
***-- Essential

NO.
Scope of overhaul 1 2 3+4

1 Inspect setting of control system * ** ***

2 Inspect alignment between individual section of turbine ** *** ***

Inspect gearing (We recommend inspecting gearbox within the first

3 *** *** ***
8000 operating hours)

Check earthing insulation shafting system of the bearing at the side of

4 *** *** ***
exciter

Dismantle coupling (gear-type), measure gear backlash and check free

5 * *** ***
axial movement and play of sleeve.

6 Check alignment of casings to bearing housings * ** ***

Dismantle bearings, check bearing pads, journal and thrust collars,

7 measure bearing clearance. Check thrust bearing bracket and adjusting *** *** ***

ring (A type pedestal)

Check adjusting washers (or plate) of casing supporting brackets and

8 * ** ***
bearing housings

Check seal rings of bearing housing, repair or replace them as

9 ** *** ***
necessary

Check casing and bearing-housing guides for dirt and jamming, dismantle,
10 ** *** ***
repair and readjust them when necessary

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 Operating Instructions
Inspection Scope and Cautions during Overhaul 4-1200-01-01
NO.
Scope of overhaul 1 2 3+4

Check emergency stop valve, control valve and etc, replace any worn part at
11 - ** ***
both hydraulic and steam sides

Dismantle steam strainer, check for foreign bodies or damage, replace it

12 * ** ***
when necessary

13 Check shutoff devices in extraction lines ** ** ***

Open up casings, check and measure casing splits, supporting surfaces

14 - * ***
and split bolts. Check casing for deflection, distortion and corrosion

15 Check sliding surfaces of casing and bearing housing - ** ***

16 Check drains for foreign matter and dirt * ** ***

Check connections and joint bolts of initial steam and extraction steam
17 - * ***
lines

18 Examine internal components of casing for rust, deposit and wear - * ***

Check movement and wearing conditions of the supporting surface of

19 inner casing (steam chest) and guide-blade carries, replace when - * ***

necessary

Test bolts in high temperature zone for looseness and crack, check
20 - * ***
thread

Inspect seal ring of L-shaped cross section, measure clearance and

21 - * ***
dimension, replace when necessary

Measure openings between splits of two-half inner casings and

22 guide-blade carries with feeler gauge or taking leads under bolts loosen - * ***

and tighten. Check split bolts for distortion

Check shaft glands and labyrinth seals for wearing, corrosion, warping
23 - * ***
and breakage, replace when necessary

Check radial runout and axial play of rotor, mounting position of

coupling, re-measure dimension of steam path and determine whether

24 - * ***
dimension deflection exist comparing with Product Certificate and

initial installation recoord

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 Operating Instructions
Inspection Scope and Cautions during Overhaul 4-1200-01-01
NO.
Scope of overhaul 1 2 3+4

Check the fixed and moving blades for deposit and corrosion, cleaning

as necessary, examine for crack, sign of rubbing and damage caused by

25 - + ***
foreign impurity, inspect for gaping of shrouding and displacement of

blades

26 Dynamic balancing of rotor - - ***

27 Check the earthing brush and clean up the contact surface ** ** ***

28 Inspect the main and auxiliary oil pumps (including coupling) ** *** ***

Dismantle the oil pump for checking bearings, seal rings, shaft,
29 * ** ***
impeller and etc.

Check the easily worn locations in the control, monitoring and

30 protection devices, replacing as necessary. The disabled parts must be ** ** ***

replaced

Inspect the level gauge and drain the oil tank, examine and purify the
31 - * ***
oil, check the tank and clean the strainer

Check the oil filter, remove the elements, clean and examine, test for
32 * ** ***
leaks

33 Check the oil cooler, withdraw the tubes, clean and examine * ** ***

Examine the pressure oil and return oil piping, eliminate any leak,

34 replace the fittings as necessary. If the oil piping is disconnected in - * ***

subsection, cleaning and examining should be made

Inspect the steam piping of the turbine body for crack, distortion and
35 - - ***
rust

36 Check the pipe supports and hangers, record positioning data *** *** ***

Inspect tubes and waterbox of condenser for deposit, damage and leaks,
37 * *** ***
check the air ejector

Inspect the proper functioning of the monitoring devices and automatic

38 *** *** ***
gear (electric and hydraulic), reset as necessary

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 Operating Instructions
Overhaul Example 4-1300-01-01

Overhaul Example
This section, taking a condensing turbine as the example, introduces the steps of the
check and repair for turbine body in overhaul.

When establishing the overhaul schedule, the user should draw up the complete
overhaul items and timetable based on the turbine structure, operation condition and
local condition (field, staff, equipment and etc.).

1. Preparation
1.1 Preparation and check of the necessary tools and equipments for overhaul.
1.2 Vibration measurements with frequency analysis (shaft vibration, bearing housing,
foundation).
1.3 Final operating data logging, including the records of various operating condition
stopping and coastdown time, the barring gear put into operation until to turbine
cooled.
1.4 Check of spare parts.
1.5 Functional test of oil cylinder.
1.6 Leak check by sight and touch.
1.7 Test of shafting system earthing.

2. Dismantling turbine
2.1 Removal of encloser.
2.2 Removal of lagging.
2.3 Disconnection of initial-steam and extraction-steam piping, blanking off the
openings.
2.4 Removal of control-oil and lubricating-oil piping.
2.5 Disconnect of the couplings between the turbine and driven machine, turbine and
main oil pump.
2.6 Opening of the bearing housings, checking of differential expansion indicator and
lifting of bearing upper halves.
2.7 Measurement positioning dimension of rotor relative to casing and bearing housings,
inspection of alignment value.
2.8 Measurement of radial and axial runout of the rotor at coupling end.
2.9 Removal of casing split bolts and supporting bracket bolts.
2.10 Raising of casing top half with jacking bolts after fitting the guide bars, lift-off of
top half.
2.11 Release of the jointing blots of inner casing (two-half inner casing), guide blade
carriers and shaft glands, lift-off of top halves.
2.12 Radial runout check along full length of rotor, measurements of static and dynamic
clearances of each stage.
2.13 Lift-out of rotor.
2.14 Removal of bottom halves of inner casing, guide blade carriers and shaft glands.
2.15 Dismantling of emergency stop valve, control valves and main oil pump (see, 3.9,

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 Operating Instructions
Overhaul Example 4-1300-01-01
3.10, 3.11 and 3.12)
2.16 Inspection of all parts, deciding on overhaul measures required, use of spares,
cleaning method and further examination needed.
2.17 Writing of dismantling note.

3. Inspection and overhaul

Look round the initial condition and record before inspecting and repairing the
following components (outer casing, rotor and etc.).

3.1 Outer casing

3.1.1 Clean split measuring and mating faces, checking according to the inspection
items decided.
3.1.2 Examine the clearance and gaping between top and bottom casings with blots
loosen and tighten respectively and correct as necessary.
3.1.3 Inspect the bolts and nuts, especially for that located in the high temperature area
(the front section before the first flange for H-type turbine), for loosen, crack.
Check bolt holes in casing split.
3.1.4 Check guide elements interior the casing, repair when necessary.
3.1.5 Check supporting faces of the inner casing, guide blade carriers, correct when
necessary.
3.1.6 Check and correct the supporting faces of the casing.

3.2 Inner casing

3.2.1 Clean split measuring and mating faces, checking according to the inspection
items decided.
3.2.2 Examine the clearance and gaping between top and bottom casings with blots
loosen and tighten respectively and correct as necessary.
3.2.3 Inspect the bolts and nuts, especially for that located in the high temperature area
(≥450℃), for loosen, crack. Check bolt holes in casing split.
3.2.4 Inspect the guide blading, shrouding and gland strips.
3.2.5 Check the nozzles for damage caused by foreign impurities.
3.2.6 check the seal ring of L-shaped cross section, measure the clearance and
dimension, repair or replace conditionally.
3.2.7 Check the supporting and guide faces, repair when necessary to make them flat
and smooth.

3.3 Guide blade carriers

3.3.1 Dismantle the adjusting element for cleaning and checking, replace spherical
washers when necessary.
3.3.2 Smooth guide faces of the guide blade carriers and guide stem (radial and axial).
3.3.3 clean and examine the split and positioning faces, correct when necessary.
3.3.4 Inspect guide blading, shrouding and gland strips.
3.3.5 Check positioning pin and hole, make up again when necessary.
3.3.6 Check bolts and nuts.

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 Operating Instructions
Overhaul Example 4-1300-01-01
3.4 Dummy piston labyrinth ring
3.4.1 Clean, check and correct the split and mating faces.
3.4.2 Check gland strips, repair and replace conditionally.
3.4.3 Measure the roundness of inner and outer circles.

3.5 Outer gland seal

3.5.1 Clean mating and split faces, check connectors.
3.5.2 Replace gland strips.

3.6 Rotor
3.6.1 Remove and inspect emergency governor.
3.6.2 Check journals and thrust faces, smooth when necessary.
3.6.3 Smooth bearing seal ring section.
3.6.4 Smooth earthing brusher section.
3.6.5 Check gland strips, repair or replace conditionally.
3.6.6 Check moving blades (straight blade), shrouding, twist blades and tie wire, inspect
the blades for deposit, corrosion and crack.
3.6.7 Crack-test shaft.
3.6.8 Clean and finish half coupling.
3.6.9 Reassemble emergency governor, overspeed-test before test running again.
3.6.10 Rebalancing of rotor.

3.7 Front pedestal

3.7.1 Clean bearing housing and check seal face, refit when necessary.
3.7.2 Dismantle emergency trip gear, clean, inspect and reassemble.
3.7.3 Clean and inspect bearing seal rings, replace seal strips when necessary, making
up the inner circle according to the shaft dimension.
3.7.4 Clean and refit radial bearing, replace if the damage is severe or the bearing
clearance is excessive.
3.7.5 Clean and refit thrust bearing. Should the pads be replaced, the attention must be
paid that the set of pads should be supplemental-machined together.
3.7.6 Loosen distant screws of bearing housing, check adjusting and guide elements of
the bearing housing, smooth or replace as required.
3.7.7 Readjust bearing housing.
3.7.8 Check pedestal, foundation and anchor bolts.
3.7.9 Check spherical washers (plate) of casing supporting bracket, refit or replace
conditionally.
3.7.10 Check casing guide, refit guide face when necessary.

3.8 Rear pedestal

3.8.1 Clean bearing housing and refit split.
3.8.2 Overhaul barring gear.
3.8.3 Clean and inspect bearing seal rings, replace seal strips when necessary, making
up the inner circle according to the shaft dimension.

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 Operating Instructions
Overhaul Example 4-1300-01-01
3.8.4 Clean and refit radial bearing, replace if the damage is severe or the bearing
clearance is excessive.
3.8.5 Check adjusting, guide and positioning elements of bearing housing, smooth or
replace as required.
3.8.6 Readjust bearing housing.
3.8.7 Check pedestal, foundation and anchor bolts.
3.8.8 Check positioning and guide elements of casing.

3.9 Emergency stop valve

3.9.1 Release bolts connecting valve cover and admission chest, dismantle emergency
valve, steam strainer and valve seat.
3.9.2 Dismantle oil cylinder, when dismantling the attention must be paid that it only
can be done by means of the special bolts at valve cover side (see 2-2300- for
details). Loosen nuts, the nuts at the oil cylinder cover end can be loosened only
after the spring fully released.
3.9.3 Disconnect piston disc from valve stem.
3.9.4 Clean oil cylinder, check oil cylinder, piston, piston disc, test piston, refit as
required.
3.9.5 Check valve stem and sealing elements, replace sealing elements and repair valve
stem when necessary.
3.9.6 Inspect valve cone, valve seat, refit if contacting surfaces are damage.
3.9.7 Check guide bush, sealing sleeve, clean deposit. Repair and replace if mechanical
damage is found.
3.9.8 Inspect sealing face of valve cover.
3.9.9 Reassemble emergency stop valve (after control valve has bee overhauled).
Functional test after turbine overhauled.

3.10 Control valve (first expansion section)

3.10.1 Measure connection dimensions of oil relay, lever, and control valve and
assembly dimension of closing spring and disk spring in damper.
3.10.2 Release the close spring, disconnect the oil relay from the lever and bracket,
remove the oil relay.
3.10.3 Disconnect the lever from valve stem, remove the lever.
3.10.4 Remove the parts on the upper section of the valve stem, disconnect the valve
from valve beam through turning the valve stem by 90°, remove the valve
cover and stem.
3.10.5 Remove the valve beam, together with the valve cones out of the admission chest
with installing tool of valve stem.
3.10.6 Check, clean and refit the valve cone and seat, replace if it is damaged severely.
Inspect the valve-cone stroke. Usually, the sleeve is required to replace if the
stroke is changed.
3.10.7 Check, clean and refit the valve stem, replace when necessary. Check the guide
bush, refit or replace conditionally. Replace the sealing stuff..
3.10.8 Check driving parts, such as pin, bush, knuckle bearing.

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 Operating Instructions
Overhaul Example 4-1300-01-01
3.10.9 Dismantle and clean the oil cylinder, replace piston ring and sealing elements
when necessary.
3.10.10 Dismantle the pilot valve, clean the valve shell. Check the slide valve and
sleeve, replace when necessary.
3.10.11 Assemble the components and control valve, reset before test running.

3.11 Control valve (second expansion section)

3.11.1 Measure connection dimensions of oil relay, lever, and control valve and
assembly dimension of closing spring and disk spring in damper.
3.11.2 Release the close spring, disconnect the oil relay from the lever and bracket,
remove the oil relay.
3.11.3 Disconnect the lever from valve stem, remove the lever.
3.11.4 Remove the parts on the upper section of the valve stem, disconnect the valve
from valve beam through turning the valve stem by 90°, remove the valve
cover and stem.
3.11.5 Check, clean and refit the valve cone and seat, replace if it is damaged severely.
Inspect the valve-cone stroke. Usually, the sleeve is required to replace if the
stroke is changed.
3.11.6 Check, clean and refit the valve stem, replace when necessary. Check the guide
bush, refit or replace conditionally. Replace the sealing stuff..
3.11.7 Check driving parts, such as pin, bush, knuckle bearing.
3.11.8 Dismantle and clean the oil cylinder, replace piston ring and sealing elements
when necessary.
3.11.9 Dismantle the pilot valve, clean the valve shell. Check the slide valve and sleeve,
replace when necessary.
3.11.10 Assemble the components and control valve, reset before test running.

3.12 Main oil pump

3.12.1 Dismantle valve housing (or volute casing, end cover), check impeller and seal
ring, refit or replace conditionally.
3.12.2 Realign and make up positioning pin when necessary.

4. Others
4.1 Check and maintenance of the digital controller and electro hydraulic converter
should be carried out according to the relevant product manuals.
4.2 Check and verify of the operation supervision instruments.
4.3 Check and overhaul of the oil system (e.g. oil tank, auxiliary oil pump, oil cooler, oil
filter, accumulator and etc.), condensing system (e.g. condenser, condensate pump,
level controller, air ejector, gland steam pressure controller, exhaust safety valve and
etc.), steam line (piping, supports and hangers, extraction stop valve and actuator,
safety valve, exhaust nozzle and etc.), oil line (piping, expansion joint, tube, fittings
and etc.) should be carried out according to the overhaul schedule and procedure.

5. Reassembly of turbine

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 Operating Instructions
Overhaul Example 4-1300-01-01
For assembly, adjustment program and requirement of each component after turbine
overhaul, see installation section of Operating Instructions.

6. Functional testing of component

6.1 Clean oil system through oil cycle when necessary.
6.2 Functional testing of jacking system.
6.3 Functional testing of barring system.
6.4 Functional testing of emergency stop valve.
6.5 Setting of control valve.
6.6 Functional inspection of governor.
6.7 Performance inspection of air ejector.

7. Overhaul report
The overhaul items, personnel, schedule, problems discovered and measures taken,
measurement records of reassembly, the results of the functional testing for components
should be reported in written, the chart and photos can attached when necessary (see
4-1400- for details).

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 Operating Instructions
Effect and Conclusion of Overhaul 4-1400-01-01

Effect and conclusion of overhaul

This section deals mainly with the works in the endgame of turbine major overhaul,
which can be taken as a reference for other overhaul.

Recommissioning
Commissioning must be carried out after turbine major overhaul. For the commissiong
steps and requirements, please refer to 3-1400-.

The first startup during recommissioning should be made carefully and must be
monitored closely. All operating data should be recorded, especially for the attention to
the monitoring of the shaft and bearing housing vibration, casing and rotor thermal
expansion, bearing temperature, wheel-chamber pressure and etc. At the initial stage of
commissioning, notice the leakage of oil and steam.

The sealing stuff of the valves should be re-pressed under hot state of the turbine.

The alignment of the machines can be known through the vibration analysis during
stable operation.

The wheel-chamber pressure, exhaust pressure, thrust and radial bearing temperatures
and secondary-oil pressure during recommissioning should be compared with the data
under the corresponding condition during initial commissioning and normal running
before overhaul. The cause of any deviations should be sought and eliminated
immediately, if there is any existed. For the excessive deviation, the readjustment and
re-repair should be made when necessary.

The performance of the turbine can be checked after the operation has been stabilized.

The operating data should be recorded once the recommissioning begins. The recorded
data should have the comparability with that recorded during initial commissioning and
operation before overhaul, and are enough for proper assessment of the overhaul effect
and turbine condition.

After the recommissioning finished, all parts should countersign the commissioning
report.

Necessary documentation
The report for overhaul condition and result should be submitted at the final stage of
overhaul, it should contain the following information:
1. Operating data before turbine shutdown, e.g. inlet and exhaust steam parameters,
valve positions, wheel-chamber pressure, casing and rotor thermal expansion, oil
pressure and temperature, bearing temperature, vibration and etc.
2. Measuring data before and during turbine dismantling, e.g. alignment, position

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 Operating Instructions
Effect and Conclusion of Overhaul 4-1400-01-01
dimension, clearance and etc.
3. Findings of all parts after partial or complete dismantling should be illuminated
with photographs and diagrams as can as possible, state the refitting measures and
consequent result.
4. Component test and special item inspection records should be compiled, including
rotor radial runout record, rotor balancing report, adjusting record of control system,
testing record of monitoring and protective devices and etc.
5. Lists of spares used and spares required for next overhaul should be drawn up,
especially for deciding to replace the blade, the spare blades must be ordered as
early as possible. Any required modification to spares must be specially noted.
6. Reassembling record.
7. The data obtained during recommissioning will be taken as the reference value for
latter operation supervision after assessed. The old reference data should be either
to reconfirmed or altered
8. State the verifying results and requiring altering of drawings, diagrams and
procedures.
9. Record and data analysis of special testing items, e.g. efficiency, thermal loss,
steam flow and etc.
10. Variety and quantity of material used in checking.
11. List of the items that should be include in the next overhaul job.
12. Assessment of overhaul schedule based on actual condition met in overhaul, time
and cost for reference for next overhaul.

Conclusion and notices:

There is normally no restriction on turbine further operation when an overhaul has been
carried out properly, provide:
1. All inspected components permit unrestricted operation.
2. All damaged parts have been replaced with spares or restored to a suitable condition
for unrestricted operation by repair.
3. The age of the turbine allows.
4. The operating condition is unchanged from the original order.

When inspection reveals damage which cannot be repair at once (e.g. the crack in the
casing that will influence the service lift but not the safe operation, material corrosion,
rust and etc.) but the turbine has to operate continuously, the corresponding measures
must be taken. The main reasons that can lead to this situation are as follow:
1. No spares, or spares no longer available.
2. Service life reached.
3. The repair can be carried out when condition permitted.
4. Cost of repairs (time, cost) compared with replacement.
5. Only short-time duty requirement, used as emergency device.

Under above conditions, the following measures should be taken:

1. Change of operating mode, e.g. starting up with variable parameters.

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 Operating Instructions
Effect and Conclusion of Overhaul 4-1400-01-01
2. Strengthen operating supervision in pertinence.
3. Shorten overhaul interval.
4. Contact us for repairs and modifications.

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