Sop of TG & Auxilliaries

ESSAR POWER (ORISSA) LTD
4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Doc No: EPOrL / COMMISSIONING
ESSAR POWER (ORISSA) LIMITED

2X30 MW CPP, PARADEEP
Standard operating procedure

Steam Turbine
INDEX
SR NO.
1
2
3
4
5
6.
7
8
9
10
11
12
CONTENTS
INTRODUCTION
TECHNICAL SPECIFICATION
SAFETY CHECKLIST
COOLING WATER AND AUX COOLING WATER
CHARGING
OIL SYSTEM START UP
BARRING GEAR START UP
TURBINE AUXILLIARY EQUIPMENT START UP
STEAM LINE CHARGING AND VACCUM BUILD UP
DEFINITION OF HOT, COLD STARTUP
TURBINE COLD STARTUP AND SYNCHRONIZATION
TURBINE RE START FROM WORK CONDITION
TURBINE PROTECTION AND INTERLOCKS
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2
3-9
10
11-12
12-14
14-15
15-16
16-18
18-20
21-25
26
27-28
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1

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
1. INTRODUCTION
The purpose of the Turbine system is to convert the heat energy in the steam
from generator into kinetic energy & to drive the TG train.
The SST300 C160 Turbine is a single flow turbine with 15 stage & downward
exhaust. When admission steam reaches the turbine, it first passes through an
emergency shut off valve (ESV) with steam strainer & then continues to a
control valve. A hydraulic servomotor controls the steam valve.
G.A. DAIGRAM
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2

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
2 TECHNICAL SPECIFICATION
Design Data
Make
Type of Turbine
Model
:
No. of stage
:
Rotor blade type
Rotor weight
:
Distance between brg centers
Journal dia. (NDE bearing) :
Journal dia. (DE bearing) :
Turbine Output
Rated
Speed
Rated (Turbine)
Rated (Generator)
Emergency Trip (Turbine)
First Critical Speed
Siemens Limited
:
Single cylinder, single flow exhaust,
Non-reheat, condensing
SST300 C-160
15
:
Impulse/reaction
4750 Kg
:
2798 mm
179.63 mm
199.67 mm
32.450 MW
:
:
:
:
1500
7765
3460
7059 RPM (100%)

RPM (100%)
RPM (110%)
RPM
Direction of Rotation
Seen Turbine Generator :
CCW (Counter clock wise)
Live Steam
Pressure Rated
Temperature Rated
Flow
:
:
:
63 Ata
460C
124.49 TPH
:
:
:
0.100Ata
45.5C
112.46 TPH
Exhaust To Condenser
Pressure
Temperature
Flow
Bleed 1
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3

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Pressure
Temperature
Flow
:
:
CONDENSER: (Thermal Design)

Design data
Make
:
Type
:
Circular surface condenser

Condensing Surface Area :
Cleanliness Factor
:
No. of Passes
:
Plugging Margin
Cooling Water Velocity
Pressure Drop
:
:
3.71 Ata
140.5C
12.03 TPH
Siemens Limited
Single Pressure, Two Pass, Under Slung,
3290 m2
85%
2
:
5%
:
2.07 m/s
<6 mmWC
Main Steam Parameters

Flow
Pressure
Temperature
Enthalpy
:
:
:
:
112.53 TPH
0.100 Ata
45.50C
546.98 Kcal/kg
Condensate Drain from Ejector

Flow
0.299 TPH
Condensate Outlet from Hot well

Flow
:
Temperature
:
Max. Sub Cooling
:
113.04 TPH
45.50C
3C
Steam Dumping Parameters (60% Dumping)

Flow
:
95.14 TPH
Pressure
:
2.5 Ata
Temperature
:
127.5C
Enthalpy
:
648.95 Kcal/kg
Cooling Water
Inlet Temperature
:
33C
Outlet Temperature
:
42C
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4

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Flow Maximum
Flow Rapture Disc

Flow
Set Pressure
Temperature
:
:
:
6400 m3/h
33.76 TPH
1.8 Ata
150C
CONDENSER: (Mechanical Design)

Shell Side
Design Pressure
Test Pressure
Design Temperature
Shell & Hotwell Material
Tube Side
Design Pressure
Test Pressure
Design Temperature
Tube Material
:
:
:
:
:
1.0 Bar(g) & Full Vacuum

Water Fill Test
:
120C
IS 2062 Gr.B
5 Bar(g)
6 Bar(g)
:
60C
:
SA 249 Tp304
Design Temperature for Movement of Condenser Nozzles

Exhaust Duct
:
140C
Shell Side
:
120C
Tube Side
:
55C
Ambient Temp. Max/min :
50 / 10C
Corrosion Allowance
Shell Side
Tube Side
:
:
0.8 mm for CS Parts

1.6 mm for CS Parts
CONDENSER: (Layout & type of Construction)

Tubes
Numbers
Tube Outside Diameter
Tube thickness
Tube to tube sheet joint
Prepared By
:
:
:
:
Checked By
4860
23 mm
0.7 mm
Roller Expanded
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5

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Hotwell
Hotwell retention Time
Hotwell Volume
Weight
Empty
Operating
Flooded
:
:
:
180 sec.
~5.71 m3
69580 kg (Apr.)
:
99000 kg (Apr.)
129000 kg (Apr.)
Make
Flender Graffenstaden
Type
TX90 / 4C
:
:
:
:
:
33651 KW
AGMA 6011-103
7046 RPM
1500 RPM
4.7
GEAR BOX:
Gear data
Gear rated
Service Factor
Rated Input speed
Rated Output Speed
Speed Ratio
Lubrication
Lube Oil Designation
Filtering
Inlet Pressure
:
Normal Oil Inlet Temp.
:
Maximum Oil Inlet Temp. :
Oil Flow
:
Calories to evacuation
Construction Features
Centerlines Distance
Total Weight
:
Upper Casing Weight
Lower Casing empty Weight
High Speed Shaft Weight :
Low Speed Shaft Weight :
Prepared By
:
ISO VG46
:
25 Micron
15 Bar(g)
50C
60C
579 l/mn
:
406677 kcal/h
:
890 mm
14800 kg
:
1900 kg
:
6002 kg
569.2 kg
6642.2 kg
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6

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
LUBE OIL SYSTEM:

Overhead Oil Tank
Oil Type
Empty Weight
:
Working Weight
Working Volume
Working Temperature
Design Temperature
:
Working
:
Design
:
Tank Dia./ height / thickness
:
ISO VG46
900 Kg
:
8550 Kg
:
6000 Liters
:
45C
80C
Atmospheric
Full of water
:
2250 / 1800 / 3 (mm)
Cooler & Filter Skid

Hydro Test Pressure
Lube Oil piping
Control Oil Piping
Cooling Water Piping
:
17.25 Bar(g)
15 Bar(g)
:
7.5 Bar(g)
Oil Data
Oil Type
:
Lube Oil outlet flow
:
Lube Oil outlet pressure
Control Oil outlet flow
Control oil outlet pressure :
ISO VG46
974 LPM
:
3.5 Bar (g)
:
30 LPM
9.5 Bar (g)
Lube
:
:
:
1200 LPM
25 Microns
SS 304
60 LPM
:
10 Microns
Paper
Oil Filter Data

Oil Flow
Mesh Size
Cartridge Material
Control Oil Filter Data

Oil Flow
Mesh Size
Cartridge Material
Cooler Data Lube Oil Side

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7

4 X 30 MW CPP
TURBINE SOP
Revision No : 00
:
:
1200 LPM
6080502 kcal/Hr
67.4C
:
48C
2500 LPM
:
33C
42C
AD Brass
Pump Data
Quantity
Type
Flow
Speed
Pressure
:
:
:
:
:
OIL Pump 1 & 2

Gear with External PRV
6 LPM
1450 RPM
180 Bar(g)
Motor Data
Supply System
Make
KW
Speed
Supply
Supply
:
:
:
:
:
:
AC & DC
Siemens Ltd.
3.7
1450 RPM
415V , 50Hz (AC Motor)
110V (DC Motor)
Oil Flow
Head Load
Oil Temp. Inlet
Oil Temp. Outlet
Cooling Water Flow
C.W. Temp. Inlet
C.W. Temp. Outlet
Tube Material
:
:
:
:
JACKING OIL SYSTEM
Hydro test Pressure

Suction side piping
Discharge side piping
5 Bar(g)
:
300 Bar(g)
MAIN OIL TANK

Pump Data
Item
Make
Type
Flow
Pressure
AOP
Tuschaco
Screw
1200 LPM
12 Bar(g)
EOP
Rotodel
Gear
400 LPM
1.5 Bar(g)
Motor Data
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8

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Item
Make
KW
Supply
AOP
EOP
Siemens
CGL
45
5.5
415V/AC
220V/DC
Vent Fan
Siemens
1.5
415V/AC
Empty Weight
Working Weight
12000kg
:
27000kg
CONDENSATE EXTRACTION PUMP (CEP):

Make
Type
:
:
Pump Operating Data

Capacity
Head
Operating Temperature
NPSHR
Efficiency
Shut off Head
Min. Stable Flow
Barrel capacity
Mechanical Seal Data
Seal Make
API Seal Code
:
:
:
:
:
KSB
Vertical pump
:
120 m3/hr
65 m
:
46C
1.85 m
:
72.6 %
86 m (5%)
:
36 m3/Hr
:
170 liters
EBIPL
BSTFN
3 SAFETY CHECK LIST

Sr
1
Observation
(Yes / No)
DESCRIPTION
Valid work permit is available at site and followed.
Area is barricaded before starting cleaning of

2
equipment.
6
Pipelines/ equipments are Turbine fully insulated.
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9
Remarks

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
PPE's like Hand gloves, apron, face shield, goggles,

helmetand safety shoe are used.
"Work In Progress", DANGER" boards are displayed at
12
work area.
Employees are informed about activity through
13
Training and Tool Box Talks.
10
14
No leakage in the steam pipe line.
16
Fire Extinguisher is kept near the job location.
17
Proper access/ Platform provided for work at height.
18
Communication system like Walkie-Talkie is available.
19
First aid Box is available at the site.
20
Ensure adequate illumination is there.
4 Turbine start up consists of following cycle.

1-Cooling water and Aux.cooling water charging
2-Lube oil system start up

3-Turbine Aux. starts up.
4-Steam line charging and vacuum bildup
5-Turbine rolling and synchronization
1- Cooling water and Aux.cooling water charging
SOP for cooling water system
1-Check cooling water basin level 80-90 %.
2-Select the Pump.
3-Ensure the pump lubrication.
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10

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
4-Cooling water pump suction valve is in open condition and discharge is in

closed condition.
5-Rotare the pump by hand. Ensure that pumps rotate freely.
6-Ensure that the Motor is in Healthy condition.
7-Condenser cooling water side I/L, O/L valve, Riser valve and condenser vent is
in open condition.
8-Ensure that mechanical seal water valve is in open condition.
9-Open pump priming valve.
10-Start the pump.
11-Close the priming the valve after priming.
12-Open the discharge valve.Ckeck vibration, Temperature of Bearing and
Current.
13-Ensure that cooling water passing through condenser and cooling tower.
Close condenser vent after venting.
14-Ensure that cooling water cycle is ok.
SOP for ACW pump
1-Ensure Cooling tower Basin level is in normal condtion.
2-Select the Pump.

4- Aux. Cooling water suction valve is in open condition and discharge is in
closed condition.
6-Ensure that the Motor is in Healthy condition
7-Ensure that mechanical seal water valve is in open condition.
8-Open pump priming valve.
9-Start the pump.
10-Close the priming the valve after priming.
11-Open the discharge valve. Check vibration, Temperature of Bearing and
Current.
12-Charge Lube oil Coolers, Compressor cooler and Alternator cooler.
5 TURBINE LUBE OIL SYSTEM START UP

Lube oil philosophy
1. Oil system consists of AOP-1, AOP-2, and DC EOP.

2. AOP-1 / AOP-2 supplies oil to the governing system and lubrication system
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11

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
while startup and shutdown.

3. Oil flow from AOP-1 /AOP-2 is 1200 LPM.( Lube oil system oil flow is 974 LPM,
for Controlling system oil flow is 30 LPM).
4. AOP-1 /AOP-2 discharge pressure is between 11-12 kg/cm2
5. Lube oil header pressure is 3.0 kg/cm2
6. Lube oil pressure at inlet of bearings to be between 1.0 1.2 kg/cm2
7. Control oil pressure is 9.5 kg/cm2.
8. Oil temperature at inlet to bearings is maintained between 45-48C while
turning gear is in operation.
9. A.O.P and Turning gear should be kept running 24 hrs. before to turbine start
up.
SOP FOR LUBE OIL SYSTEM START UP
1.
2.
3.
4.
Ensure that lube oil tank tank level 60%

Ensure that OHT tank level normal.
Line up One stream of Lube oil complete lube oil system.
Ensure that Lube oil cooler-1,Lube oil filter-1 and Control oil filter -1 valve
are in open condition
5. Ensure that All iso. Valves of PG,Temp,level gauge,DP gauge are in open
condition
6. Ensure that all instrument are health as well as site and DCS
7. Check vaccum in MOT.
8. Check VEF fan feeder is in Healthy condition.
9. Ensure VEF I/L and O/L damper is in close condition.
10.
Start VEF fan. Check vibration and noise.
11.
Open VEF O/L damper and Maintain vacuum by controlling the I/L
damper.
12.
Ensure AOP-1 rotate freely By hand.
13.
Ensure AOP-1 discharge valve is in open condition.
14.
Ensure AOP-1 & 2, EOP, JOP Feeder is Healthy condition.
15.
Ensure all heater and Instrument are healthy condition
16.
Switch on the AOP-1 motor, and check the direction of rotation of pump
with the arrow mark provided on pump/motor casing.
17.
Need to heat up the oil to 30-45 deg C by using heater in MOT.
18.
Ensure cooling water availability to Oil cooler.
19.
Cut in all electrical alarm and signal devices.
20.
Check all valves of pressure gauges, pressure switches, level
switches if they are open.
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4 X 30 MW CPP
Revision No : 00
TURBINE SOP
21.
Start auxiliary oil pump and switch over the emergency oil pump to
AUTO.
22.
Start the oil pump well in advance of turbine start because for
starting up the turbine
TGSET should be on barring gear for above
mentioned hours and also inlet oil temperature should be at least 40C. To
increase the oil temperature use the oil heaters in oil tank (simultaneously
with the auxiliary oil pump operation).
23.
Oil pumps are not allowed to be started with the oil temperatures
under20C
After start AOP, go through the following checks:

1.
2.
3.
4.
5.
6.
7.
8.
Control and lube oil pressures and oil temperature after cooler.
Control and lube oil filter-fouling degree on p indicator.
Oil level in the main oil tank.
Any leakages in joints/flanges, coolers, filters etc.
Check whether all instruments are working.
Check for operation of all valves.
Check AOP discharge Pressure -12 kg/cm.sq
Ensure discharge Header pressure 3 kg/cm.sq
Sop for jacking oil system:

1- Ensure lube oil header pressure 3 kg/cm.sq
2- Check pump suction and discharge valve is in open condition.
3- Check All pressure gauge, diff.pressure gauge iso. Valve is in open
condition.
4- Ensure JOP feeder Healthy condition.
5- Start JOP check discharge pressure.
Cut in oil mist extraction unit. Put the switch over device of the main oil cooler and
filters at its mid position both chamber in use and open the air vents of both
chambers. Let the air out and close the vents again. Operate the switch over
device to isolate one chamber.
6 BARRING (TURNING) GEAR

Operation Philosophy
1- Contentious rotation of the shaft with the barring gear prevent the
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13

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
development of temperature gradient and thus deformation of rotor and

the turbine casing and also prevent over heating of white metal bearing
2-
By turning the shaft you can avoid the shaft deformation (deflection)
caused by accidental
steam leakage into the casing at turbine
standstill.
Before startup the turbine must be on turning gear for the following
minimum periods of time.
Shaft stand Still
Minimum Turning Time
Less than 1 day
2 Hours
Upto7 days
6 Hours
7to 30 days
12 Hours
More than 30 days
24 Hours
If the above time requirements cant meet, the vibration level must be
observed thoroughly.
Startup permissive for Barring Gear

1- Ensure lube oil system normal running condition
2- Jacking oil pressure =>p*0.5 kg/cm.sq
3- Lube oil pressure => 1.95 kg/cm.sq
4- Check lube oil Temp.
5- Check Turbine and Alternator Front bearing, rear bearing pressure 1.2 to 1.4.
6- Check Gear box front and rear bearing pressure 1.2 t0 1.4 kg/cm.sq
7- EOP ready for operation.
SOP for barring gear

1- Ensure all permissive are found ok.
2- Check Barring Motor is in healthy condition.
3- Start barring gear motor.
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4 X 30 MW CPP
Revision No : 00
TURBINE SOP
4- Check the orientation of shaft.

5- Check current of barring gear motor.
6- Check Barring gear Speed.
Preparing of Controls
1. Check that all valves of pressure and temp gauges are open.
2. Check control oil filter fouling on delta p indicator. If required, change to
prepared clean section.
3. Check wiring and cable connections at first commissioning or after longer
stand still periods.
4. Cut in voltage supply.
7 Turbine Aux. Start up.
Condensate extraction pump
Condenser Extraction pump is provided to pump the condenser hot well to the
Deaerator or condensate storage tank through ejector. The pump is operated by
varying the discharge flow so as to maintain the hot well level constant in normal
operation. There are 2 nos C.E.P provided where one is running condition and
another is stand by.
SOP for C.E.P
1-Ensure Hot well level is in normal condition 40 %.

2-Select the Pump.
4-Ensure that C.E.P 1 & 2 suction valve is in open condition .
6-Ensure that the Motor is in Healthy condition
7-Ensure that mechanical seal water valve and Jacket cooling water is in open
condition.
8-Ensure Strainer DP is OK.Ensure all pressure gauge ISO. Valve is in open
condition.
9-Ensure equalizing line is in open condition.
10-Ensure C.E.P recirculation line is open condition.
11-Ensure Ejector I/L and O/L of water side valve is open condition.
12-Start the pump.
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4 X 30 MW CPP
Revision No : 00
TURBINE SOP
11- Check vibration, Temperature of Bearing and Current and Discharge

pressure.
8 Steam line charging and Vacuum Build up

PRDS charging
1 Open the MSSV one pulse upto 100% so as to bring the temperature of
turbine inlet header upto 430 Deg. C and pressure 40-45 Kg/cm2.
2 Along with Main steam line also charge the ejector steam line, PRDS line
by slowly opening the respective isolation valves from De- aerator floor,
check that air side isolation valves which are connected to condenser are
open, PRDS drain and ejector drains should be open.
3 PRDS inlet isolation valve to be opened slowly by observing condensate
draining of PRDS line.
Gland Steam line up
2 Ensure GS header outlet valve at 4.5 m floor is closed. Header drain should
be open.
3 Now by opening the PCV of PRDS increase the pressure and temperature of
PRDS and Gland steam supply line. Temperature rate of increase should not
be more than 5 Deg/min. Since the vent valve of Gland Steam supply line is
open the Gland steam header pressure will come around 0.06 kg/cm2.
EJECTOR LINEUP PROCESS
REQUIRED PARAMETERS:
a) Main steam temperature > 350 C
b) Main steam pressure 10 bar
EJECTOR PREMISSIVES: 1) TO TAKE HOGGER EJECTOR IN SERVICE

Ejector steam isolation valve should be in closed condition.
Ejector steam line drain valve should be opened.
Hogger Ejector, Y- Ejector and Z- Ejector steam inlet isolation valve and air
inlet isolation v/v should be closed.
Ejector condenser, condesate inlet and outlet valves should be opened.
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4 X 30 MW CPP
Revision No : 00
TURBINE SOP
Ejector steam isolation valve at Deaerator floor should be opened slowly for
line charging.
Water must be observed at ejector drain and must be waited still steam
appears.
Hogger Ejector steam inlet isolation valve should be opened slowly for line
charging.
After observing steam in silencer drain, Hogger Ejector air isolation valve
must be opened.
Thus startup of Hogger Ejector is done.
Vaccum is created in Condenser by Hogger Ejector. After synchronization, Main
Ejector is taken into line and Hogger Ejector is closed for preventing the waste
of steam.
2) TO TAKE MAIN EJECTOR IN SERVICE
The steam outlet valve of Y- Ejector is opened.

Steam inlet valve of Y- Ejector is opened
Air inlet valve of Y- Ejector from Inter condenser is opened
The steam outlet valve of Z- Ejector is opened
The steam inlet valve of Z- Ejector is opened
Air Inlet valve of Z- Ejector from condenser is opened.
After taking main ejector in line, Hogger ejector should be stopped for
maximum utilization of steam
To isolate the Hogger Ejector
The air isolation valve of Hogger Ejector is closed first.
Then the steam isolation valve is closed and thus hogger ejector is isolated
During taking in line of Main ejector, the Drip line of inter condenser and
after condenser bypass valve must be in open condition.
Deaerator Charging
Pre Checks
1. Ensure all permits are cleared.
2. Ensure that the de aeration tank manual vents are in full open condition.
3. Ensure that the de aerator overflow v/v is in closed condition.
4. Ensure that the drain v/v is in closed condition.
5. De aerator floor should be cleared from foreign materials.
Operation
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17

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
1. Wear PPE. Hand gloves, ear plugs, helmet, safety shoes for de aerator
charging.
2. Start D.M transfer pump and fill de aerator up to 80%.
3. Ensure that PRDS outlet temperature below 250C and pressure is below 5
kg/cm2.
4. Ensure drain valve after initial heating valve is in open condition.
5. Slowly open (crack) the initial heating line valve and observe the de aerator
pressure.
6. Stop the opening of initial heating valve, if de aerator pressure reaches to
0.1kg/cm2.
7. The water temperature in the de aerator storage tank starts increasing.
8. Observe the any abnormalities and leakages during Deaerator charging.
9. Continuously monitor the Deaerator temperature and pressure.
10.
Keep the initial heating valve in open condition until unless water
temperature reaches 100C and there is a no continuous water flow to the
Deaerator.
11.
If water temperature rises to 100C. and there is a continuous water
flow to the
Deaerator, and then charge the pegging line.
12.
Keep the Deaerator PCV outlet isolation valve full open and open the
inlet isolation is 5%, and then controls the Deaerator pressure with PCV.
13.
Maintain the de aerator pressure at around 0.3-0.4 kgcm2
14.
Then slowly close the initial heating valve.
15.
Chemical preparation in L.P dosing tank (Maintain 50% tank level, add
4 liters of hydrazine or 10 liters of hydrazine. Run both dosing pumps @80 %
stroke until turbine rolling. After rolling monitor the feed water DO and adjust
the dosing.)
16.
Measure for DO in continuous running.
De aerator charging from turbine extraction:
1. Ensure that steam flow through extraction line.
2. Ensure that Deaerator pressure and extraction pressure is same.
3. Open the turbine Extraction drain.
4. Then open the QC NRV.
5. Then slowly open the Extraction isolation valve. If the condensate is
completely removed from drain, open the isolation valve fully.
6. Then slowly open the Extraction isolation valve.
7. Once Deaerator pressure stabilizes, then slowly isolate the pegging line.
Isolation of Deaerator:
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18

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
1.
2.
3.
4.
Cut off the steam supply to the Deaerator from turbine extraction/ PRDS.
Cut off the water supply to Deaerator.
Ensure L.P dosing stopped condition.
Observe the de aerator storage tank pressure and temperature.
Dos and Donts:

1. Dont close the steam vent valves during Deaerator in operation. If the vent
valve is closed or throttled too much, air and non-condensable gases will
accumulate in the Deaerator. This condition will result incomplete deaeration
and caused air blanketing.
2. Dont open the overflow line during de aerator in operation.
INTERLOCKS:
1. Boiler feed pump will not start if Deaerator storage tank level is below 20
%.
9 Definition of Steam Turbine Starts

General
The steam turbine must always be started up in accordance with the plantrelated start up diagram. The live steam must be super-heated by at least
20C up stream of the last drain before main stop valve.
Cold Start (shutdown time > 72
Hours)
The turbine is cold, i.e. the determined flange temperature is less than or
equal 40C.
A cold start occurs only after a longer stand still duration, during which
repairs may have been made. In this case it is absolutely necessary to
inspect until through prior to start up ensuring all valves and switches are
returned to the position for normal operation.
Warm
Start
time<12Hours)
(Shutdown
The turbine is warm, i.e. the determined flange temperature is less than or
equal 280C
A warm start occurs for some minor repair
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
19

4 X 30 MW CPP
TURBINE SOP
Revision No : 00
works.
Hot
time<2Hours)
Start
(Shutdown
The turbine is hot, i.e. the determined flange temperature is less than or
equal to 360C
Turbine Rolling Permissive

1. Lube oil pressure healthy, header pressure > 0.9 kg/cm2.
2. Vacuum healthy > 0.65 kg/cm2.
3. Steam temp. > 430 Deg.C
a)
Axial shift ok < + 0.6 to 0.6mm.
b)
Generator healthy no trip commands existing.
4. Hot well level normal, around 40%
c)
Differential Expansion < - 4.5 or + 4.5 mm
d)
Trip command has been reset.
TURBINE STARTS UP.

Main Steam Line Charging & Turbine Cold Start up Parameters.
1. MSSV bypass opening should be started by the following parameters of Boiler.
a) Pressure
:
25 30 kg/cm2
b) Temperature :
350 -360 Deg. C.
2. MSSV Bypass valve should open fully before opening of MSSV.
3. MSSV opening should start by the following parameters of Boiler.
a) Pressure
:
40 - 45kg/cm2
b) Temperature :
400 460 Deg.C.
4. PRDS Charging should start by the following parameters of Boiler.
a) Pressure
:
40 - 45kg/cm2
b) Temperature :
400 460 Deg.C.
5. Ejector and Gland steam Charging should start by the following parameters of
Boiler.
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
20

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
a) Pressure
:
40 - 50kg/cm2
b) Temperature :
400 420 Deg.C.
6. Vacuum pulling and Gland steam Charging should start by the following
parameters of Boiler.
a) Pressure
:
40 - 45kg/cm2
b) Temperature :
420 430 Deg.C.
7. TG Rolling should start by the following parameters of steam.
a) Pressure
:
40 - 45kg/cm2
b) Temperature :
430 450 Deg.Cent.
10
TURBINE COLD START UP PROCEDURE
4 Ensure all Governing Valves, MSSV, Bypass of MSSV, all QCNRVs and manual
isolation valves of Extraction lines are closed.
5 All Main Steam Line drains, ESV and Casing drains, extraction line drain,
ejector drain, Gland steam header drain, PRDS I/L & O/L drain, De-aerator
initial heating line drain, De-aerator PCV bypass line drain and air evacuation
lines from heaters to condenser are in open condition.
6 Start the cooling water pump and deaerate the condenser water box and
cooling water O/L lines and make the system through.
7 Start ACWP, de-aerate oil cooler water side (TUBE) and make the system
through.
8 Maintain hot well level around 40% through hotwell make up line. Start CEP
and de-aerate water side of ejector (both inter and after condenser water
side), and Gland Steam Condenser waterside.
9 MOT level should be normal i.e. before starting AOP/AOP-2.
10 Start the AOP/AOP-2 and de-aerate both the oil coolers (shell side oil), lube oil
filters and control oil filters.
11 Oil temperature at outlet of cooler to be maintained between 32 to 35 Deg. C.
12 Observe oil flow through the bearing drain sight glasses of lube oil system.
13 Observe lube oil header pressure and control oil pressure, oil pressure at inlet
of individual bearings.
14 Start the turning gear motor from control room and keep its control in manual
mode. Turning gear should be started before 4 hours of turbine rolling.
15 Check for any kind of abnormality during turning gear operation. If anything
found abnormal check and inform to the concerned.
16 Start heating of Main Steam Line by opening one pulse of the bypass of MSSV
.While heating the steam lines; observe the rise of steam temperature. It
should not exceed more than 5 Deg/Min, observe drains of MSL. Open the
valve fully. Keep open the ACW valve to flash tank, which is at TG Building
G.floor.
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
21

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
17 Observe condensate coming from drains, in any case the increase rate of
steam temperature must not be more than 5 Deg./minute.
18 Open the MSSV one pulse upto 100% so as to bring the temperature of
turbine inlet header upto 430 Deg. C and pressure 40-45 Kg/cm2.
19 Along with Main steam line also charge the ejector steam line, PRDS line by
slowly opening the respective isolation valves from De- aerator floor, check
that air side isolation valves to LP Heaters which are connected to condenser
are open, PRDS drain and ejector drains should be open.
21 Ensure GS header outlet valve at 4.5 m floor is closed. Header drain should
be open.
22 When superheated steam starts coming from the PRDS line drain, slowly open
the Gland Steam supply isolation valve from De-aerator floor.
23 Heat the ejector line fully observing the drains; open the ejector isolation
valve from De-aerator.
24 Open the Hogger ejector steam side isolation valve when line pressure gauge
shows 17 kg/cm2 slowly @ 6m, also the drain valve of the silencer should be
kept open.
25 Slowly slowly open the hogger ejector steam valve fully @ 4.5 m, and also
valve from De-aerator floor. Now open airside valve of ejector side. While
starting, always open the steam side valve first and then open the airside
valve and while closing vice-versa.
26 Before opening the G S Supply isolation Valve ensure that the vent valve of
gland steam supply which is at turbine floor is kept in open condition so that
condensate forming during heating comes out.
27 Now by opening the PCV of PRDS increase the pressure and temperature of
PRDS and Gland steam supply line. Temperature rate of increase should not
be more than 5 Deg/min. Since the vent valve of Gland Steam supply line is
open the Gland steam header pressure will come around 0.06 kg/cm2.
28 After 15 minutes of taking hogger ejector in line vacuum will come around
0.60 kg/cm2
29 Close the Gland Steam supply line vent valve, which is at Turbine floor. The
Gland steam header pressure increase upto 0.155 kg/cm2 and vacuum
improves to 0.85 kg/
Turbine is ready for rolling; reset the trip command from control room,
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
22

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
30 At turbine inlet header pressure 63 kg/cm^2 and temperature 460 Deg.C the
machine is ready for rolling. Slowly open the ESV and observe turning gear
disengages at >240 rpm automatically.
31 Increase turbine speed up to 500 rpm, hold 15 minutes. Observe all bearing
vibrations, drain oil temperatures, any abnormal noise, axial shift, casing
expansion, differential expansion, casing temperatures, exhaust hood
temperature, hotwell level, drain oil coming out thru sight glass, Steam inlet
temperature and Pressure, Condenser Vacuum, Exhaust Hood Temperature,
Lube oil cooler DP, Control oil DP, Seal steam Pressure, Generator Stator
Temperatures, Compare if earlier readings are available at same RPM.
32 Increase the rpm slowly upto 1000 rpm and hold for 20 minutes. Observe all
bearing vibrations, drain oil temperatures, any abnormal noise, axial shift,
casing expansion, differential expansion, casing temperatures, exhaust hood
temperature, hotwell level, drain oil coming out thru sight glass. Compare if
earlier readings are available at same RPM.
33 With the increase in RPM primary oil pressure starts building up. Increase the
RPM upto 3700 beyond the critical speed. Dont hold the turbine rpm near the
critical speed 3460 rpm.
34 Slowly to 7059 RPM. Check the function of governing valves must go down,
Slowly full open the other ESV.
35 Open the manual isolation valve of Exhaust Hood Spray @ 4.5m when
exhaust hood temperature starts increasing i.e. > 45 Deg. C.
36 Observe all bearing vibrations, drain oil temperatures, any abnormal noise,
axial shift, casing expansion, differential expansion, casing temperatures,
exhaust hood temperature, hotwell level, drain oil flow thru sight glass.
Compare if earlier readings are available at same RPM.
SYNCHRONIZING
Synchronizing can be carried out manually or
automatically.
For synchronizing follow special instructions.
a) Before synchronizing: Check the over speed trip test of TG SET. In this
test both electrical and mechanical trips to be carried out at least twice
at the time if initial commissioning. Speed details are given in turbine
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
23

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
technical data.
b) Manual synchronizing: The speed is adjusted by pushing the
corresponding WOODWARD keys until the turbine speed is synchronized
with network frequency. The generator circuit breaker can be then
closed, if the frequency, voltage, relationship and sequence of phases
and rotating field direction of generator and of the mains are equal.
c) Auto synchronizing: The speed of the turbo set is now maintained by
the frequency of the external grid.
For automatic synchronization see special instructions given in Woodward
manual.
LOADING
Aft e r synchronizing increase the load to app.2% of its rated load in
order to avoid the activation of reverse power relay.
C o n t i n u e increasing the load according to the start-up graphs by
pushing the corresponding keys on the WOODWARD GOVERNOR.
D u r i n g loading check all parameters and check also the control
stage pressure.
C l o s e all manually controlled drains and vents.
C h e c k the cooling air temperature of generator and open cooling
water to the air cooler according to special instructions.
C h e c k the seal-steam pressure and temperature.
37 If all the functions are normal, the turbo set is ready for Synchronizing.
38 After Synchronization take load upto 3 MW.
39 Depending upon the generator winding temperatures take Generator air
coolers inline.
40 At this load (3 MW), heat the turbine for 40 minutes. Observe all bearing
vibrations, drain oil temperatures, any abnormal noise, axial shift, casing
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
24

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
expansion, differential expansion, casing temperatures, exhaust hood

temperature, and drain oil flow thru sight glass. Compare if earlier readings
are available at same LOAD.
41 Increase further load with a rate of 1 MW / 3 minute.
42 Now it is possible to close direct drains of main steam line, and open the
steam trap isolation valve.
43 When the generator load increases >10 MW take Extraction 2 in line, i.e.
extraction to de-aerator.
44 Open the QCNRV from control room, take local feedback and confirm open
limit at DCS. Slowly open the manual isolation valve. Observe condensate
coming out from the extraction drain line. After every opening wait for 10
minutes and slowly open the manual isolation valve fully. Open slowly the
manual isolation valve at De-aerator floor with 10 minutes time interval.
45 Now all extractions are in line and the turbine can be loaded up to rated load.
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
25

4 X 30 MW CPP
Revision No : 00
TURBINE SOP
11RE START FROM WARM CONDITION OF TURBINE

Tripping of warmed - up turbine up to a standstill of 5
minutes
If the turbine is tripped during the starting-up process and the trip
reason is clearly detected, the turbine may be restarted up to the
previous speed or output respectively without delay.
Shut down of the warmed-up turbine with standstills longer

Than 5 minutes up to about 8 hours
When after a clearly detected tripping the causes is eliminated or when
the turbine is shutdown intentionally, observe the following for
standstills longer than 5 minutes up to max.
8 hours
Keep the live steam line up to the emergency stop valve pressurized
and gland steam open unless turbine rests far longer than 60
minutes.
Pre warming the control valve block is not required.
Open turbine drain (live steam)
The oil unit remains in full operation, the turbine oil should not be
cooled below 45C.
Keep the turning gear in permanent operation.
Prepared By
Checked By
Approved By
Commissioning Team
GENERAL MANAGER
26

4 X 30 MW CPP
TURBINE SOP
Revision No : 00
12
Turbine Protection and Interlocks
Turbine Trip
The Turbine will trip due to any of following fault condition as listed below
S.N
o.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Normal
status
Logic out
1
Logic out
1
Description
Set point
Main steam pressure low low
31kg/cm2
Main steam pressure high high
68kg/cm2
Logic out
1
Main steam temperature low

low
350C
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
Main steam temperature high

high
Turbine exhaust temp high
high-1
Turbine exhaust temp high
high-2
Turbine exhaust press high
high
Emergency trip from TSP
474C
Active
out
Generator differential (channel1)

Generator differential (channel2)
Lube oil header pressure low
low
Control oil header pressure low
low
2 o/o 3 Over speed trip
out
Over speed trip_ governor
out
Hot well level high high
=110%20rpm
1234mmW
out
out
out
out
out
out
out
out
out
Prepared By
Checked By
Remarks
MS temp. to
be
implemented
=120C
=105C
For 1 hr
Refer I/O list
Active
Active
<=1.8kg/c
m2
<=7.5kg/c
m2
=110%
Approved By
Commissioning Team
GENERAL MANAGER
27

4 X 30 MW CPP
TURBINE SOP
Revision No : 00
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
out
Emergency trip soft PB
out
Turbine front shaft vibration

high high
Turbine rear shaft vibration
high high
Gearbox HS DE shaft vibration
high high
Gearbox HS NDE shaft
vibration high high
Gearbox LS NDE shaft vibration
high high
Gearbox LS DE shaft vibration
high high
Generator front shaft vibration
high high
Generator rear shaft vibration
high high
Rotor axial displacement high
high
No load trip
out
out
out
out
out
out
out
out
out
out
out
out
out
out
out
out
out
Turbine thrust pad temp non

active top high high
Turbine thrust pad temp active
top high high
Turbine thrust pad temp non
active bottom high high
Turbine front bearing temp high
high
Turbine rear bearing temp high
high
Gearbox HS DE bearing temp
high high
Gearbox HS NDE bearing temp
high high
Gearbox LS NDE bearing temp
Prepared By
Checked By
C
Active
=82 micron
=82 micron
HMI
=107 micron
=107 micron
=232 micron
=232 micron
=232 micron
=232 micron
=0.6mm
=100C
=105C
=105C
=120C
=120C
=110C
=110C
=110C
Approved By
Commissioning Team
GENERAL MANAGER
28

4 X 30 MW CPP
TURBINE SOP
Revision No : 00
1
Logic
1
Logic
1
Logic
1
Logic
1
Logic
1
35
36
37
38
39
out
out
out
out
out
high high
Gearbox LS DE bearing temp
high high
Generator front bearing temp
high high
Generator rear bearing temp
high high
Governor emergency shutdown
Main steam temp gradient high
high
=110C
=90C
=90C
Active
5C/min
Generator trip:The Generator will trip due to any of following fault condition as listed below
S.N
o
Normal
status
Logic out 0
Logic out 0
Logic out 0
Logic out 0
Logic out 0
Logic out 0
7
8
9
Logic out 0
Logic out 0
Logic out 0
10
Logic out 0
Prepared By
Description
Generator
1
Generator
2
Generator
3
Generator
4
Generator
5
Generator
6
Generator
Generator
Generator
Generator
winding temperaturewinding temperaturewinding temperaturewinding temperaturewinding temperaturewinding temperaturecore temperature-1

core temperature-2
core temperature-3
due to turbine trip
Checked By
Set points
130C
130C
130C
130C
130C
130C
130C
130C
130C
Active
Approved By
Commissioning Team
GENERAL MANAGER
29
Remarks
Hardwire
d

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ESSAR POWER (ORISSA) LIMITED

Standard operating procedure

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7059 RPM (100%)

CCW (Counter clock wise)

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CONDENSER: (Thermal Design)

Circular surface condenser

Main Steam Parameters

Condensate Drain from Ejector

Condensate Outlet from Hot well

Steam Dumping Parameters (60% Dumping)

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Flow Rapture Disc

CONDENSER: (Mechanical Design)

1.0 Bar(g) & Full Vacuum

Design Temperature for Movement of Condenser Nozzles

0.8 mm for CS Parts

CONDENSER: (Layout & type of Construction)

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LUBE OIL SYSTEM:

Cooler & Filter Skid

Oil Filter Data

Control Oil Filter Data

Cooler Data Lube Oil Side

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OIL Pump 1 & 2

JACKING OIL SYSTEM

Hydro test Pressure

MAIN OIL TANK

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CONDENSATE EXTRACTION PUMP (CEP):

Pump Operating Data

3 SAFETY CHECK LIST

Valid work permit is available at site and followed.

Area is barricaded before starting cleaning of

Pipelines/ equipments are Turbine fully insulated.

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PPE's like Hand gloves, apron, face shield, goggles,

No leakage in the steam pipe line.

Fire Extinguisher is kept near the job location.

Proper access/ Platform provided for work at height.

Communication system like Walkie-Talkie is available.

First aid Box is available at the site.

Ensure adequate illumination is there.

4 Turbine start up consists of following cycle.

2-Lube oil system start up

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