TURBINE ROLLING

OBJECTIVE
THE OBJECTIVE OF STARTING UP OF
THE TURBOGENERATOR IS TO BRING A
UNIT ON LOAD AND RAISE IT TO THE
RATED OUTPUT WITHIN THE OPTIMUM
TIME BUT WITHOUT UNDUE STRESSES
ON THE TURBINE COMPONENTS.

Why Rolling is required..

The starting operations may have an important
influence on the possible curtailment of turbine
life because major thermal and mechanical
stresses will be experienced in the course of
starting.
This hazard will be particularly enhanced when
turbine is started from cold.
Least amount of stresses are observed when the
temperature of live steam during the starting
period can be matched as closely as possible to
the actual temperature of turbine casing.

General Start up Considerations

During the startup the Turbine is subjected
to Non-Steady state operation.
This covers the operating condition where Speed,
steam Pressure and temperature change with
time.
Under these condition turbine components which
are exposed to temperature changes subjected to
thermal stress and expansion.

For turbine life point of view, it is very much

necessary to limit the extent of these
temperature changes.

TURBINE SPECIFICATIONS
Type
Mitsubishi reheat & condensing 3 casing 4 exhaust flow type
Capability
Net power output-700 MW
Speed
3000 rpm Direction of rotation-clockwise (view from Gov. End)
Design Steam Condition
I.
II.
III.
IV.

Steam press at main stop valve inlet

Steam temp at main stop valve inlet
Steam temp at reheat stop valve inlet
Exhaust pressure LP-1:
LP-2:

No. of extractions for feed water heating

Blading
HP Turbine Impulse
Reaction
IP Turbine Reaction
LP Turbine Reaction

247 ata
565 C
593 C
0.0771 ata
0.0976 ata

8 stages

1 stage
9 pairs of rows
8 pairs of rows
8 pairs of rows

TURBINE SPECIFICATIONS

General Preparation of Start up

All the repair works on the turbine are
completed and all PTWs are cancelled.
All the Turbo-supervisory instruments are
available.
Generator excitation system,GT & UAT
cooling system,seal oil system etc.are OK
All the interlocks and protections of Turbine
& Generator are already checked up and
kept I/s.

Start-up type selection

Turbine start up ( Control stage
outlet metal temperature)

Boiler start up (Water separator

inlet metal temperature)

Cold

<150C

<120C

Warm

150<T<375 C

120<T<260 C

Hot

>375 C

> 260 C

Pre Rolling Requirments

circulating water start-up completed
Initial Fill (Circulating water pump discharge pipe
will be filled by cooling tower make up pump)
Pump will be started with discharge valve(HOV)
closed and condenser inlet and outlet valves of at
least one pass open
Ensure following parameters
Design discharge flow for one pump - 43400 cum/hr
Total developed head for CW pump - 28 mWC(2.79)
Rated current / Rated Power
- 294 A/4.3 MW

Pre Rolling Requirments

ACW and CCW system start up completed
ACW pump to be started after ensuring availability of
water in suction(More than 1.2ksc for start
permissive).
Ensure for ACW pump
Rated flow
- 2600 cum/hr
Rated Discharge - 10 ksc

CCW pump can be started after ensuring DM water

filled in expansion cum make up tank.
Ensure for CCW pump
Rated Flow
- 1650 cum/hr
Design pressure - 11 ksc

Pre Rolling Requirments

Service water system ready
Ensure that clarified water level in suction
compartment is not low.
Adjust discharge valve flow to ensure min. flow
through pump
Start the pump.
Ensure following parameters
Capacity
Motor rating
Discharge head

230 cum/hr
75 Kw
60m(6 ksc)

Pre Rolling Requirments

Air Compressors Started
Ensure before starting that cooling water temp.
and press. are normal.
Start the compressor with inlet valve open.

Ensure Instrument air pressure more than 4.5

Ensure Service air pressure more than 4.5

Pre Rolling Requirments

DM water system ready
Ensure DM tank and CST level adequate for makeup water supply during start up.
Ensure availability of Hotwell makeup and DM
transfer pump so that they could be started as and
when required.

Pre Rolling Requirments

LDO system started
Ensure LDO tank level should be adequate.
Ensure suction and discharge valves fully open.
Ensure following parameters
Capacity
Discharge pressure Motor rating
-

9500 Kg/hr
15 ksc
9.3 Kw

Pre Rolling Requirments

Aux. Steam available
Aux. steam could be made available via 2nd unit(if
running) or Auxiliary boiler.
Ensure steam of following parameters are
available at HT and LT header Temp. (HT)
Temp. (LT)
Operating Press.

305 deg
215 deg
15-16 Ksc

Pre Rolling Requirments

HFO system started
HFO tank level should be adequate and mat coil
heaters should be operational ( maintaining temp. 50
deg).
HFO pump should be started with suction and
discharge valves fully open.
Ensure heaters in HFO discharge are operational.
Ensure following parameters of pump

Flow
Discharge pressure
Motor power
Current

65 cum/hr
27 ksc
75 Kw
130 Amp

Pre Rolling Requirments

Turbine Oil supply started
After starting TOP, AOP, JOP and EH oil pump
confirm that following parameters are achieved-:
TOP discharge pressure: 3.5 KSC
AOP discharge pressure: 10.8 KSC
JOP discharge pressure: 160 KSC

Pre Rolling Requirments

Seal oil system started
Ensure that seal oil system taken in service before
turbine is put on barring.
Ensure that Air side seal oil pressure is 0.85 ksc
above hydrogen pressure at generator seals; and
hydrogen side seal oil pressure is same as that of
air side seal oil.

Pre Rolling Requirments

Turbine Barring gear in operation
Ensure turning gear ac motor power supply is
available.
Ensure lube oil supply is available to the gear
assembly.
Turning gear speed is 3 RPM

Pre Rolling Requirments

Hydrogen filling done:
Make sure ccw water system is available (required for
H2 driers)
Aux. steam is available and heaters in filling are
available (required for CO2 filling)
Ensure H2/CO2 purity measuring device condition is
healthy and it is well calibrated.
Check that the hydrogen pressure is 3.8KSC after
filling.
To maintain H2 purity and its dew point temp. Ensure
H2 driers are in service. Fill H2 and purge air to
maintain purity.

Pre Pre Rolling Requirments

Turbine drains in open condition

Main steam inlet lead pipe drain valve open.

HP turbine inner casing drain motor valve open.
HP turbine outer casing motor drain valve open.
Reheat steam inlet pipe drain motor valve open.
CRH (L&R) drain valve open.

Pre Rolling Requirements

Vacuum pulling done:
Ensure turbine is on barring gear and generator
seal oil system is in service.
Ensure aux steam is available to unit aux PRDS
header
Ensure gland steam temp. between 120-180 deg
Condenser vacuum should be:
0.0976 ksc for HP shell.
0.0771 ksc for LP shell.

Ensure Following During Rolling

(Turbine constructional limits)

Steam purity
Presence of unwanted corrosive impurities can
cause damage to turbine components by
corrosion, stress corrosion and corrosion fatigue
Hence continuous monitoring of following must
be made-:

Ensure Following During Rolling

(Turbine constructional limits)

Casing expansion
Monitors axial expansion of total HP-IP & LP
casing by measuring relative motion between no.
1 bearing pedestal and seating plate .

Rotor eccentricity
Rotor eccentricity to be noted till 600 rpm and
after this, eccentricity recorder is cut off. Rotor
eccentricity limit is 75 microns. In normal
operating conditions it has to be kept under 25
microns.

Ensure Following During Rolling

(Turbine constructional limits)

Ensure Following During Rolling

(Turbine Trip Condition)

BEARING VIBRATION HIGH HIGH(> 250 m)

THRUST BEARING WEAR( 1 mm)
EMERGENCY OIL PRESS LOW (70 BAR)
BEARING OIL PRESSURE LOW LOW(0.5 BAR)
ELECTRICAL OVERSPEED TRIP
MECHANICAL OVERSPEED TRIP
TURBINE TRIP PB
LP-1 TURB EXH STM TEMP HIGH HIGH(T>120C)
LP-2 TURB EXH STM TEMP HIGH HIGH(T>120C)

Ensure Following During Rolling

(Turbine Trip Condition)

TURB INL MAIN STM TEMP (LEFT) LL (<460C)

TURB INL MAIN STM TEMP (RIGHT) LL(<460C)
TURBINE TRIP REQUEST(GPR)
BOILER TRIP (MFT)
ALL CWP STOP-2
CONDENSER VACUUM LOW LOW(<0.680kg/cm)
TCS FAILURE

Steam Admission Condition

Turbine steam admission condition OK(P> 87ksc &
Temp.- 330<T<427 at least 50 deg superheat)
All LDO burner valves closed and either any coal
burner or fuel oil burner in service
Cold start mode not selected or boiler hot cleanup
recirculation completed.

RESETTING THE TURBINE

When the Turbine trips due to Electrical or
Mechanical Protection Trip oil drains quickly.
In the absence of the Trip oil Turbine Stop
and Control vlvs closes quickly.
So the Trip oil is basically required for
keeping the ESVs and IVs in open condn
and getting required Secondary oil pressr
for opening the HPCVs and IPCVs.
The Trip oil again can be generated again
by Resetting the Turbine.

ROLLING PROCEDURE
Give command for 500 rpm for Rub check of turbine, it will
reach 500 rpm and then will try to come at barring speed.
Observe turbine vibrations and noise.
If rub check is Ok, raise turbine speed to 500 rpm and hold
turbine at 500 rpm for 10 minutes for heat soaking.
Raise turbine speed to 1950 rpm and do 3 hours heat
soaking.
Raise turbine speed to 3000 rpm.
Carry out turbine valve transfer from MSV control to GV
control. Now Generator is read for synchronisation.
Observe stator water temperature at winding inlet and
charge stator water cooler.

Valve operation
Pre
warming

Rolling

Put on
line

FWHTR in
service

FWHTR
out of
service

MSV HP stem leak

FC

GV HP stem leak

FO

RSV and ICV stem

leak and trip pilot
valve

RSV drain

FO

Main steam inlet

piping

FO

HP inner casing

FO

HP outer casing

FO

Reheat steam inlet

piping

C(CLOSED AT
10 %)

O (OPENED
AT 7 %)

FO

Gland sealing and

gsc shell drain

Name of drain

20 % load

15 % load

Take
off
line

Failure
position

Start UP Timings
COLD START-UP
Sr No

ACTIVITIES

Duration

WARM START-UP

Cumulative
Duration
time

HOT START-UP

Cumulative
Duration
time

Cumulative
time

HP/LP Bypass charging

110

110

35

35

12

12

Pr raising to 87 ksc

100

210

45

80

18

30

MS flow and Temp raising for Steam Admission

100

310

40

120

30

60

20

330

18

138

0 to 500 rpm for Rub check, again rolling to 500 rpm and hold at
500 rpm

500 rpm to 2000 rpm

10

340

hold at 2000 rpm for warming

180

520

Rolling to 3000 rpm

525

143

10

70

Electrical testing at 3000 rpm

240

765

143

70

10

Synchronisation and block loading

10

775

150

78

11

Hold at 5% Load

40

815

20

170

12

90

12

Load raising to Full Load

120

935

120

290

65

155

Light-up

Boiler Start-up
Curves

Not Required
Not required

Turbine Start-up
curves

THANK

YOU

Valve transfer
The turbine
speed control is
automatically
transferred from
MSV to GV.