NAVA BHARAT FERRO ALLOYS LTD

POWER DIVISION
DHARMAVARAM

STANDARD OPERATING PROCEDURES

FOR 20 MW STEAM TURBINE
MODEL: C9-R16-ER

PREPARED BY
.

Standard Operating Procedure

Steam turbine is a machine, which converts the heat energy available from Boiler
main steam into mechanical energy in an economical way. Turbine is associated with
Reduction gearbox and Generator, to convert this mechanical energy into electrical
energy.
One number 0f 32 MW, single cylinder, horizontal, impulse, multistage, multtivalve,
axial flow, condensing, one controlled and one uncontrolled extractions with
reduction gear and down exhaust type turbo generator supplied by SNM Co Ltd.,
Japan is installed in our plant.
The following are the salient features of Turbine:
Machine is having Electro hydraulic governing system assisted with WOOD WARD
505 governor control system, one Emergency stop valve and 4 nos of inbuilt control
valves with one mechanical over speed tripping mechanism. Turbine is having two
numbers of steam extractions, 1st steam uncontrolled extraction for HP heater for
feed water heating, 2nd steam controlled extraction for Deareator, for deareation and
heating purpose and for the sugar plant purpose.
Principle of Operation:
The steam with 86 Kg/Sq.cm pressure and 515 Deg.C temperatures will enter into
turbine through one ESV and 4 numbers Governing control valves. The steam entered
into the turbine expands over the moving and fixed blades of turbine releasing the
mechanical energy and rotates the turbine rotor at 6194 rpm. The turbine is coupled
with the generator rotor through reduction gearbox (6194/1500 rpm) and rotates the
generator rotor to convert mechanical energy into Electrical energy.
Steam after doing its work in turbine, gets collected into Condenser and forms as
condensate by giving its latent heat to CW water flowing in the tubes of condenser.
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From condenser the condensate is pumped with Condensate Extraction Pumps (CEP)
through ejectors and gland steam cooler upto Deareator. From Deareator, feed water
is pumped to boiler Economizer using BFPs through HP heater. Deaerator & HP
heaters draw the steam from the turbine to heat the condensate flowing through them.
This is known as Regenerative feed heating system.

The TG set is provided with the following systems:

1. Turbine and reduction gear box assembly
2. Turbine lube oil and Governing system
3. Condenser and Air Evacuation system
4. Feed water heating system
5. Turbine gland steam system
OPERATION - PROCEDURES
1. Cold, warm and hot start up of TG
2.

Loading of Turbine

3.

Planned and Emergency shutdown.

4.

Emergency conditions during Turbine Operation.

5.

Important DOs and DONTs

6.

Operating parameters and alarm trip values as Annexure I.

7.

Possible troubles, causes and remedies

I. Turbine and reduction Gearbox assembly:

The 20 MW steam turbine, type: C9-R16-ER supplied by Shin Nippon Machinery
Co. Ltd., Japan is installed in our plant. Steam turbine is horizontal, impulse,
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multistage, multi valve, axial flow, condensing, nozzle governing, extraction and
geared type. The turbine is provided with 16 stages of blades.
Steam flow to the HP part is regulated by 4nos steam control valves constituted as a
single assembly as HP governor valve. Steam Turbine consists of Casing, fixed
blades, moving blades, rotor (on which moving blades are fixed) bearings (journal
and thrust), steam flow control valves.
The casing or cylinder of turbine is a pressure vessel, which is capable of with
-standing the working pressure and temperature. It provides support to the fixed
blades and rotor bearings. The turbine HP part is made up of Cast alloy and LP part is
made up of carbon steel and rotor is made up of Chromium, molybdenum, and
vanadium steels. The moving blades are fixed on rotor and rotate between the
stationary (fixed) blades. The rotor is mounted on two journal bearings. The front side
of the rotor is mounted with thrust bearing to take the axial thrust coming on rotor.
Lube oil to the bearings is provided from lubrication system.
To reduce the speed of the turbine rotor from 6194 to 1500 rpm, which is required for
generator, reduction gearbox was incorporated between turbine and generator rotors.
The turbine shaft is coupled with pinion shaft of gearbox and where as generator shaft
is coupled with wheel shaft of gearbox. Reduction gearbox assembly also consists of
Turning gear motor arrangement and Main oil Pump in it.
The full load parameters of turbine are 86 kg/Sq.cm g main steam pressure, 515
Deg.C MS temperature, 6194 rpm, 0.1 Kg/Sq.cm (abs) exhaust steam pressure and
127.61 TPH steam flow through it. The two extraction steam quantities are 14.114
TPH for HP heater, 7.68 TPH for Deareator, and 12.05 TPH for LP heater. And
remaining 93.37 TPH gets collected in condenser where it is condensed by using
Circulating water. To supply the cooling water for the above condensation process,
TWO numbers of CW pumps each of 6900 Cu.M/Hr capacities are installed here.
The circulating water gets heated by approx 9 Deg.C in the condenser during

condensation process. In order to cool this water by 10 Deg.C, two nos of cooling
towers with induced draught fans are installed.
The following are the Protections (Trip values) of the Turbine:
1. Steam temperature at turbine inlet high high > 543 Deg.C
2. Steam temp. at turbine inlet low low < 460degC, this protection comes in to
service only when MS temperature reaches to 495 deg C and then falls to 460.
3. Steam pressure at turbine inlet low low < 60 kg/sq.cm (may be bypassed initially
for Cold and Warm start ups if required.)
4.Steam pressure at turbine inlet high high >103kg/sq.cm (not incorporated).
5. Control oil pressure low low 8.0+/-0.5 Kg/sq.cm
6. Lube oil pressure low low < 0.62 Kg/Sq.cm
7. Generator heavy fault (Generator trip).
8. Turbine mechanical over speed trip >/= 5632 rpm
9. Turbine electrical over speed trip >/= 5583 rpm
10. Governor heavy fault.
11. Remote trip from turbine governor panel.
12. Turbine trip from desk push button.
13. Exhaust steam pressure high high > 1.3 Kg/Sq.cm (abs)
14. Exhaust steam Temperature high high > 150 degC
15. Lube oil reservoir level (MOT) low low < 350 mm.
16. Hot well level low low < 300mm
17. Hot well high high 1400 mm
18. Turbine Rotor axial shift high high +0.65, -0.65 mm.
19. Turbine front shaft vibration high high 90 microns
20. Turbine rear shaft vibration high high 90 microns
21. Reduction gear pinion front shaft vibration high high 140 microns
22. Reduction gear pinion rear shaft vibration high high 140 microns
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23. Reduction gear wheel front shaft vibration high high 180 microns
24. Reduction gear wheel rear shaft vibration high high 180 microns
25. Generator front shaft vibration high high 160 microns
26. Generator rear shaft vibration high high 160 microns
27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C
28. Turbine thrust bearing temperature high high (active) 120 Deg.C
29. Turbine front shaft bearing temperature high high 120 degC
30. Turbine rear shaft bearing temperature high high 120 degC
31. Reduction Gear pinion front bearing temperature high high 120 degC
32. Reduction Gear pinion rear bearing temperature high high 120 degC
33. Reduction Gear wheel front bearing temperature high high 120 degC
34. Reduction Gear wheel rear bearing temperature high high 120 degC
35. Generator front bearing temperature high high 85 degC
36. Generator rear bearing temperature high high 85 degC
37. HP heater level high high 290mm. (Protection should be bypassed during
charging of HP heater.) not incorporated.
II. Turbine lube oil system:
Turbine lube oil system consists of Main oil tank (MOT), Over head emergency oil
tank (OHT), lube oil coolers (2), Main oil pump (MOP), Control oil pumps (2,COP),
AC driven Auxiliary oil pump (AOP), DCdriven Emergency oil pump (EOP), and oil
vapor extraction fans (2, OVEF) to supply the lube oil to the turbine, reduction gear
box and generator bearings during run up, coasting down and for subsequent turning
gear operations.
The MOP is mounted on reduction gearbox wheel assembly and rotated by turbine
rotor and supplies oil to the lubricating system and as well as trip oil to the governing
system. It takes over its duty from the AOP when turbine speed is above 4650 rpm.
To maintain lube oil temp at 45 degC, Lube oil coolers (2 nos) are provided in the
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system. Two numbers of vapor fans (one working and one standby) are provided to
extract oil vapors from MOT and vent them out to atmosphere.
CONTROL OIL PUMP:
Control oil pump (COP) supplies oil to the governing system during initial start and
continuous operation of turbine. COP is rated to deliver 60 LPM at a head of 16.0
Kg/Sq.Cm (g) and is driven by 415V, 5.5KW, and 2880-rpm motor. Two numbers of
COPs are installed, out of two, one is working and another is standby. The autochange over is incorporated between COP-1 and COP-2.
Startup Sequence:
01. Ensure the following
COP1&2 are ready from Mechanical, Electrical and Instrumentation sides and NO
Line Clearance is pending on COP- 1&2, governing and lube oil systems.
Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valves are opened.
Level of oil in MOT is normal (550mm).
Valves in oil system supply mains are properly lined up.
Ensure oil vapor fan is ready to start (at least one).
02. Start the pump by pressing the start button on DCS.
03. Check the discharge pressure of pump and motor current.
04. Keep the stand by pump in auto, in order to come in to service in auto as per
interlock.
05. Observe the control oil filter differential pressure (DP) (not more than 0.8) from
local gauge. If necessary, change the filter.
NOTE:
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Before changing the filter, open air vent & Equalizing valve and ensure that both the
filters are equalized with oil. After change over, close the air vent.

Shutdown Sequence:
As these pumps are intended for continuous supply of governing oil to the turbine,
they are to be switched off only when the turbine is not in service. Before switching
off these pumps, ensure that the standby pump is in MAN mode (if pump is in
AUTO mode, it will come in to service on interlock).
Important Note:
When one COP is in service with the turbine running, the standby COP should be in
AUTO selection. Otherwise, auto-change over will not take place when running COP
trips and this results n trip of Turbine.
Interlocks on COPs:
Auto Start: COP discharge pressure low (PSL 510) or running COP off, and pump is
selected in auto, the AUTO selected pump will come into service in AUTO.
Auto Stop: No Auto Stop incorporated.
Pump can be switched ON and OFF at any time if it is selected in MAN in DCS.
AUXILARY OIL PUMP:
AOP is an AC driven pump which supplies lube oil at 1.5 kg/Sq.cm to Turbine,
Reduction gear box and generator bearings and trip oil at 4.3 Kg/Sq.cm to the
governing system during turbine speed run up and turning gear operations. It has
rated capacity of 1019 LPM at 6.5 Kg/Sq.Cm and driven by 415V, 22 KW and 1475rpm motor. At 4650 rpm, MOP takes over the duty of AOP; AOP will be switched off
8

in auto. This pump comes into service in AUTO if lube oil header pressure is less
than 0.87+/-0.2 Kg/Sq.Cm and pump is selected in AUTO.
In the event of turbine trip due to any reason, AOP comes into service into operation
by interlock when oil header pressure drops to 0.87+/-0.2 Kg/Sq.Cm to supply lube
oil to all bearings for its safe coasting down and subsequent Turning gear operation.
This pump also supplies suction to the Jacking oil pumps. The discharge of AOP
passes through the Lube Oil Coolers.

Start up Sequence:
01.Ensure the following
AOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on AOP, governing and oil systems.
Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valve is opened.
Level of oil in MOT is normal.
Valves in oil system supply mains are properly lined up.
Ensure oil vapor fan is in service (at least one).
02. Start the pump by pressing the start button on DCS.
03. Check the discharge pressure of pump and motor current.
04. Keep the pump in auto, in order to come in to service in auto as per the interlock.
05. Observe the lube oil filter DP (< than 0.8) from local gauge. If necessary change
the filter.
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NOTE:
Before changing the filter, open air vent & Equalizing valve and ensure that both the
filters are equalized with oil. After change over, close the air vent.
Shutdown Sequence:
As this pump is intended for initial run up of Turbine, this will be switched off in auto
when turbine speed is above 4650 rpm (>95% of rated speed). Before switching off
AOP manually, keep the pump in MAN selection and ensure that Turbine speed is
>95%( MOP has taken over the job of AOP) and Turning gear motor is not in service.
Interlocks on AOP:
Auto Start: Lube oil header pressure low (PSL504 ) alarm and pump is selected in
AUTO, AOP comes in to service in AUTO.
Auto Stop: When Turbine speed is greater than 95% of rated speed, AOP will be
switched off in AUTO.
Pump can always be switched on and off manually at any time.

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EMERGENCY OIL PUMP

The EOP comes into service in the event of an Emergency. A DC motor drives this. It
has rated capacity of 260LPM against a 1.5 Kg/Sq.cm head and is driven
by 2.2 KW, 1500-rpm 110V DC motor. In the event of total power
failure or if AOP fails to start on its interlock due to any reason, EOP
comes into operation when lube oil header pressure drops to
0.62Kg/Sq.cm to supply the lube oil to the TG bearings for its safe
coasting down. EOP supplies oil only to the bearings. The discharge of
this pump will not go through oil coolers.
Startup sequence:
01.Ensure the following.
EOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line
Clearance is pending on EOP, governing and oil systems.
DC Power supply and control supply are available.
Pressure switches and interlocks are properly checked and incorporated.
Discharge valve is opened.
Level of oil in MOT is normal
Valves in oil system supply mains are properly lined up.
2. When the above are satisfied, the DC EOP will start by inter lock, if lube oil
header pressure drops to 0.62 Kg/Sq.Cm
3. If the interlock does not work, the pump can be started by pressing the start push
button on Turbine governor panel (TGP).
04. After starting the pump check the discharge pressure, motor current.
Shutdown sequence:

11

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

Important Note:
During normal running of turbine, EOP should be ready in all respects to come into
service with out fail. Trail run may be taken in every shift to check the availability
of EOP. While TG is in service or in TGM operation, EOP should be in Auto
Standby mode on TGP.
Procedure to take trail run on EOP
Check the Healthiness of DC supply.
Change the selector switch from USUAL to TEST mode in Governor Control Panel.
EOP will start automatically.
Observe the lube oil pressure.
Check the current.
Ensure AOP is in auto.
Change the Selector switch from TEST to USUAL mode.
Stop the EOP. If lube oil pressure drops to 0.87+/-0.2 kg/sq.cm, AOP will start in
auto.
EOP should be kept in Standby mode.
Observe the lube oil pressure to bearing.
After ensuring the lube oil pressure to bearings, Stop AOP.
Observe the lube oil pressure.

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Inter locks on EOP:

Auto Start: Lube oil header pressure low low (PSLL 504-1) and EOP auto selected
on TGP then EOP come into service in AUTO.
Auto Stop: Auto stop isnt incorporated.
Manual start and manual stop can be done at any time from TGP.

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TURNING GEAR
Before starting of the turbine and as well as after trip, turbine and generator shafts
are to be rotated at certain speed to avoid deflection of rotor due to self
weight in high temperature atmosphere. Turning Gear is incorporated in
the system to facilitate this operation. In our case, turbine rotates at 40
rpm in turning gear operation. 11 kW, 415V, 1450-rpm motor, drives the
turning Gear.
Interlocks on TGM:
Auto Start: TGM comes in to service in AUTO 200 seconds, after the start
permissives were satisfied and if it is selected in AUTO. The start
permissives for TGM are
Turbine speed <10%(490 rpm)
Lube oil header pressure is not low (PSL 504).
Auto Stop: If any one of the above conditions is not present the TGM will trip and
turns to MAN selection. Manual start can be possible if all the start
permissives are satisfied. Manual stop can be done at any time.
During turbine rolling, TGM automatically disengages at 100 rpm (approx) of turbine
rotor, and TGM trip at 490rpm of Turbine.
Whenever the unit trips barring gear will engage automatically, during the barring
gear

operation if power fails after restoration power barring gear

should be manually engaged before starting. If it is not so which will

lead ton damage the gears of barring gear.
Putting Turbine on Turning gear Operation:
Ensure the following:
MOT oil level is normal.
NO line clearance is pending on Turbo Generator, Lube oil and Jacking oil systems
and Turning gear motor.
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Proper functioning of instruments indicating:

Axial displacement
All turbine, reduction gear box, generator bearing vibrations
All bearing metal temperatures
Lube oil temperature and pressure
Jacking oil pressure
Turbine speed
Ensure DC EOP is healthy and in standby mode on the Governor panel.
Start AOP as per the procedure and check the Lube oil pressure and parameters
mentioned in point 1.c.
Throttle the cooling water outlet from oil coolers and maintain oil temperature around
45 Deg.C +/- 5 Deg.C
Engage turning gear pinion by rotating the motor shaft with the lever from local.
Start the turning gear motor (TPBSSBGMT) and check the following:
TGM current
Axial displacement
All bearing vibrations
Turbine speed
Lube oil pressure
It needs approx. 10 hours to cool down the turbine casing and bearings. After turbine
cooling period, the TGM may be stopped. AOP & JOP should be continued in service
for another 2 hours.

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III.CONDENSER and AIR EVACUATION SYSTEM:

CONDENSER:
Condenser is a tubular, non-contact type heat exchanger, which receives the steam
from turbine after doing work, and condenses it to form condensate
using CW system. Condensate Extraction pumps are connected to
condenser, and they will pump the main condensate to Deareator through
Ejector and Gland Steam Cooler. To increase the work done by the
turbine and to avoid backpressure on Turbine rotor, pressure inside the
condenser is maintained below atmosphere pressure (vacuum). To obtain
vacuum in condenser, air and non-condensable gases are to be removed.
For this purpose, air evacuation system with Main ejector has been
provided. The makeup DM water needed for the system is added in the
condenser from UCFT through Normal and Emergency makeup control
valve lines.
Heat transfer area in condenser : 2435 Sq.M
Number of Tubes

: 5016

Dia/Thickness of tubes

: 22.225/0.71mm

Rated CW flow

: 5800 Cu.m/hr

DP across condenser at rated flow: <5300 mmwc

AIR EVACUATION SYSTEM (Ejector system):
One starting Ejector (Hogging ejector), two numbers of two stage steam jet air
ejectors (as a single unit) are installed to create and maintain vacuum in the
condenser.
1. Ensure the following:
TG set is on turning gear operation as per the procedure.
At least one CW pump is in service and two CT fans are ready to start.
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Condenser is charged from CW side.

Hot well level is normal.
CEP is running on re-circulation through Main Ejector, Gland steam cooler.
PRDS steam is available at rated pressure and temperature.
Ensure water sealing is provided for all valves connected to condenser and vacuum
break valve.
2. Close the following valves:
Hand operated valve in airline connected to hogging ejector and

main ejectors.

All drain valves and control valves connected to condenser.

Close the vacuum break valve.
3. Warm up the PRDS header by opening the drain valves.
4. By operating the PRDS pressure control valve and Temperature control Valves
attain the required 5. PRDS pressure and Temperatures.
6. Ensure PRDS steam is available with 8Kg/Sq.cm and 210 Deg.C
7. Start the GSC exhaust fan.
8. Charge the Gland steam cooler.
9. Open the steam valve to the starting ejector gradually.
10. Slowly open the air valve and watch for vacuum. After attaining required Value,
-0.6 Kg/Sq.Cm make ready the main ejector for Keeping in service.
11. Open the steam valves of main ejector slowly and then open-air valve and
discharge valve.
Charge the glands by opening the HOV in gland sealing line. Ensure Turbine gland
sealing steam pneumatic control valve is operating and Gland steam pressure is
normal (0.1 to 0.2Kg/Sq.Cm (g)).

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After attaining 0.70Kg/Sq.Cm (g) of vacuum, isolate the startup ejector by Closing
air valve first and steam valve next. With the main ejector in service we can attain
0.9 to 0.95 Kg/ Sq.Cm (g).
Important Note:
a. Before charging the main ejector, ensure flow of main condensate (CEP
discharge) through ejector.
b. While charging the ejector, open steam valve and air valve next gradually.
c. During cut off of the ejector, close air valve first and steam valve next and
discharge valve next.
d. Ensure tightness of vacuum break valve manually. Provide water sealing.
e. Do not open any drain valve connected to condenser when there is no
sufficient vacuum (>0.5Kg/Sq.Cm (abs)).
f. Ensure that the drain line isolation valves of condensate trap & casing drain of
the running exhaust fan are in open position.
g. While charging the main ejectors, ensure that Rotameter isolation valves drain
line isolation valves of Condensate Trap are in open position.
h. Ensure that the suction valve& casing drain valves of the standby exhaust fan
on Gland steam condenser are in closed position.

IV. Main condensate and Feed water system:

Main condensate system:

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After condensing of Exhaust steam in condenser, condensate forms. This condensate

is pumped to Deareator using Condensate Extraction pumps through Main ejectors,
GSC. The discharge of CEP is also used for 1. Flash box attemperation,2. Valve
sealing. From CEP discharge header one line is connected to UCFT with Motor
Operated Valve, to drain the excess condensate from the hot well.
CONSENSATE EXTRACTION PUMPS:
Two numbers of CEPs (one working and one standby) are installed to pump the main
condensate from condenser to Deareator through main Ejectors and gland steam
cooler. It has rated capacity to deliver 125 METER CUBE/HOUR at 111.6 Kg/Sq.cm
and is driven by 415V, 1475 rpm, 75 KW motor. As this pump supplies cooling
medium to Main Ejector and GSC, 100% availability of this pump is essential to run
the plant.
STARTING OF CEP:
1. Check no line clearance is pending on CEP and Condensate system
2. Ensure that hot well level is normal >700mm & UCFT level is > 1500mm.
3. Ensure that suction valve is opened and DP across suction strainer is <0.3
Kg/Sq.cm
4. Ensure that the Pump is primed with condensate by opening air vent. (When there
is no vacuum.)
5. Open HOV in line from CEP discharge to mechanical seal.
6. Ensure that MC PCV TLIC430AM in MC line to Deaerator is closed and PCV
in re-circulation line is full opened.
7. Ensure that the discharge valve (HOV) is closed.
8. Ensure MOV TPBOCMV350 in CEP shell UCFT line is in closed condition.
9. Ensure that Electrical supply is available.
10.Ensure that valve sealing line is through to suction valves.
11.Open CEP air removal line valve to condenser.
12.Check the lube oil level in the bearing oil cup.
13.Start the Pump from DCS.
14.Check disch. Pressure, Motor current, Brg. temp and hot well level.
15.Open MC PCV gradually and maintain the discharge pressure above 8.0
Kg/Sq.cm.

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SHUT DOWN SEQUENCE:

When there is no vacuum in Condenser, the pump can be stopped by keeping the
Pump in re-circulation.
WHAT NOT TO DO:
1. Dont allow any leakage in suction side.
2. Dont open any valve, fitting, flange in the suction side.
In normal working condition (Condenser is in vacuum), this will cause vacuum
to drop the Pump to loose its suction.
3. Dont allow the Pump to start or run with the protection/interlock by pass.
4. While cleaning suction strainer of stand by CEP, ensure the closed position of
the respective suction, discharge valves, air removal valve to condenser, all drain
valves between pump suction, discharge valves and open position of suction
valve sealing line valve.
AUTO CHANGE OVER OF CEP:
1. Check no line clearance is pending on standby CEP.
1.
Standby pump should be selected in AUTO mode in DCS.
2.
Suction and discharge valves should be in open position.
3.
HOV in line from CEP discharge to mechanical seal is in open
position.
Interlocks on CEP:
1. When hot well level Hi switch (TLT300A1) is acted (cond. Level >1000 mm)
auto stand by pump comes into service in Auto.
2. When hot well level Low switch (TLT302A) is acted (cond. Level < 550 mm)
auto stand by pump trips in Auto.
3. When hot well level Low Low switch (TLT303A) is acted (cond. Level < 300
mm) both pumps will trip. (Turbine trip)

Feed water Heating System (Regenerative system):

The thermal gain and economics of feed water heating given rise to regenerative feed
heating system. It consists of HP heater and Deareator. Feed water heater is a simple
heat exchanger, which is arranged so that water leaving the condenser is preheated
before it is fed to the Boiler. HP heater is of surface type heat exchangers, where as
deareator is direct type heat exchanger. These feed water heaters extracts the steam
20

from the turbine at high pressure and temperature and heats the feed water flows
through them. The condensed steam from HP heater are connected to condenser and
deareator respectively.
The presence of certain gases like oxygen, carbon monoxide and ammonia, dissolved
in water is harmful because of their corrosive attack on metals. Hence these gases are
removed in deareator unit. Spraying the water and heating the same by steam achieve
the same. The Deaerator consists of two chambers, the deareating column and feed
storage tank.

HP heater charging procedure:

1. Ensure open position of air removal line to condenser
2. Ensure Feed water is charged through HP heater
3. Ensure extraction line drain valves before and after Check valve are in open
position.
4. Open the extraction check valve of HP Heater
5. Open the HPH extraction motor operated valve
6. Maintain the heater level by operating HPH level control valve to Condenser up
to 5Kg/sq.cm extraction steam pressure, and at above 5 Kg/sq.cm pressure
maintain the HPH level by operating the level control valve to Deareator..
7. After charging of heater close the drains before and after check valve.
Note: 1. Do not charge the heater with out water flowing through them
1. During cut out of heater, close steam valve first.
Charging procedure for Deaerator:
Charge the De aerator. after 10 MW load it can be charged from its extraction line.
Open drains before and after HPH extraction check valve
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Open HPH extraction check valve

Open HPH extraction bypass to Deareator MOV
Maintain the Deaerator pressure at 4.9 to 5.0 kg/sq.cm by operating the Deareator
pressure control valve.
After charging of Deaerator close the drains before and after check valve.
Charging of Deaerator from its extraction line
Open drains before and after Deareator extraction check valve
Open Deaerator extraction check valve
Open Deaerator extraction MOV and close the HPH extraction bypass to Deaerator
MOV
Maintain the Deaerator pressure by operating the Deareator pressure control valve.
After charging of Deaerator close the drains before and after check valve.
Check the following during increase of pressure in Deareator:
1. Deareator expands freely.
2. No abnormal hammering is there in the pipe line.
3. Steam and air mixture is being vented through the vent line.
4. No major steam/water leakages are there.
Note: Do Not Delay In Charging Deaerator After Charging Of LP Heater.
V. Turbine Gland Sealing System:
If the pressure at the turbine cylinder (Casing) is higher than the atmosphere
pressure, there will be a leakage of steam (from clearance between rotor and stator of
turbine) into atmosphere causes wastage of steam. The pressure is less than the
atmospheric pressure there will be ingression of air into condenser causing falling of
vacuum. To avoid this problem gland sealing is provided with 200 0C temperature and
0.1-to 0.2-kg/sq.cm steam. One 3-way pneumatic control valve is provided for this
purpose.
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During turbine rolling and up to 10MW load the aux. Steam with 8Kg/sq.cm; 180 0C
is being used for sealing. After 10MW load, the turbine HP gland leak off steam is
being used for turbine LP gland sealing. To collect and condense the gland leak off
steam from turbine front and rear glands, gland steam piping and gland steam cooler
are provided. Turbine glands are to be sealed with gland steam during vacuum pulling
after attaining () 0.70Kg/sq.cm (g) vacuum in condenser.
After trip of turbine, to kill the vacuum stop the glands sealing by closing the hand
operated valve before 3 way pneumatic control valve.
VI. Cold, Warm and Hot start of Turbine:
Cold Start Of Turbine
Turbine start up is termed as cold start up, if it is being started 10 to 12 hours after
shutdown or the metal temperature is < 1700C. The main steam parameters should be
maintained 30 kg/sq.cm and 350 deg C. However, according to the site conditions, we
are able to achieve 40 Kg & 400 deg C.
An average increase rate of metal temperature of MS line, ESV, Turbine chest and
Turbine casing, should not to exceed given values as below.
Metal temperature

increase rate of metal temp. Deg.c/min.

100 deg C to 200 deg C

4.0

200 deg C to 300 deg C

3.0

300 deg C to 400 deg C

2.0

400 deg C to 500 deg C

1.0

500 deg C to 515 deg C

0.6

The maximum increase rate of metal temperature of the ms connecting pipe should
not exceed 15deg.c/min.
I. Ensure the following:
No line clearance is pending on TG set.
23

Boiler is steaming and steam is available.

All TG interlocks and protections are checked and checking of all motor operated
valves, Pneumatic
Operated control valves closing and opening is completed.
TG instrumentation / annunciation system is OK. Root valves to transmitter lines are
in open
Position.
DC supply is healthy for EOP and trail run was taken.
MOT level is normal.
Overhead tank level is normal.
Auto start of EOP, COP - 1&2, AOP, are checked.
II. Carry out related operations and ensure the following
AOP&JOP are running as per the procedure.
COP is running as per the procedure.
EOP is selected in standby mode on the Governor panel.
Oil flow is normal through the bearings (observe from sight glass).
Circulating water is charged in condenser and ACW pump and CW pumps are in
service.
TG is on Turning Gear Operation as per the procedure. During cold start up, Turbine
should be kept
in TGM operation 2 hours prior to turbine rolling.
Oil cooler is charged from cooling waterside to maintain oil temperature 45 +/- 5 deg
C.
Ensure ACW to Generator air coolers line valves are in open position.
Condenser hot well level is normal and CEP is running through Main Ejector and
GSC.
Main steam line is charged up to MSV (T).
Start vacuum pulling as per the procedure.
24

Check the set pressure of sealing steam (PIC 107) is 0.1 to 0.2Kg/Sq.Cm (g) then
open the sealing
Steam HOV.
After attaining 0.5 Kg/Sq.Cm (a) pressure in condenser, open the drains in extraction
lines to
remove the Condensate in the pipelines.
Ensure the following drains are open
Drain before MSV (T).
Drain valves in extraction before check valves lines.
Isolate the Steam traps of ESV, Turbine Casing and Turbine Chest.
Turbine casing drain (Wheel chamber) through Steam trap bypass.
ESV drain through Steam trap bypass.
HP governor chest drain through Steam trap bypass.
Ensure all extraction check valves and MOVs are in closed position.
Meanwhile, attain condenser vacuum to -0.9 Kg/Sq.cm (g).
Check and record the following Turbovisory readings:
Rotor axial displacement
Thermal expansion (Local measurement)
Turbine, Reduction Gear and Generator rotor vibrations
Turbine speed
MOT level
Lube oil pressure and temperature
All bearing temperatures
Casing metal temperature
MS pressure and temperature
Gland steam pressure and temperature
Condenser vacuum
PRDS pressure and temperature
25

Ensure main steam line is warmed upto MSV (T), then open MSV (T) bypass valve
(H.O.V) and open the drains in MS line and ESV body slowly. (Ensure ESV is in
closed condition before doing the above).
After warming up ESV body, ensure that no Turbine protection is active (from
Turbine Protection graphic) and then give RESET ON command from DCS. This
will reset all the protections.
Reset fault signals by pressing Governor Clear button on TGP.
Check lube oil pressure, trip oil pressure, control oil pressure and lube oil
temperatures.
Check the auto-standby position of COP, & EOP.
Open the ESV by pressing the Turbine Reset button on TGP. Check the open feed
back on TGP and warm up the chest at least 20 min. This is tentative, ensure the chest
drain temp. is equal to the MS metal temp.
Ensure the Hotness of ESV and Turbine Chest drains.
Check AOP & Turning Gear are in service and selected in auto.
Open the MSV (T) before going to roll the turbine.
Start the Turbine rolling by pressing the START button on TGP. The governor will
accelerate the speed of the turbo generator and hold it at idle speed 750 rpm. During
the speed rise, check for Turning gear motor stop at the set rpm (> 10% of rated rpm).
Ensure the Hotness of Turbine Casing drain.
Observe the exhaust hood temperature .
Observe all the Turbovisory readings. (Mentioned earlier).
Feel and listen for any rubbing and abnormal noises during warm up.
Check and record the shaft vibrations and axial displacement monitor on TGP.
Check whether the turbine casing expansion has started and its pointer is moving on
local scale, near turbine front bearing.
After ensuring expansion by 1.0 to 1.5mm, Press the RATED SPEED button on
TGP. The governor will accelerate the speed of the turbine generator automatically to
26

4897 rpm. Observe for the bearing vibrations in the Critical speed range from 1650
2050 rpm.
Check AOP are stopped at > 95%(4650 rpm) respectively.
Start the CT fans before synchronizing the generator as for the procedure.
Synchronize the generator with the GRID as per the procedure.
Increase the load on generator to 3 MW.
Close all the MS drains.
Gradually increase the load (not more than 1.0mw/min) by means of SPEED/LOAD
SETTING lever on TGP or Generator control panel.
At 6.0 MW load, operator can select for load control when connected with grid.
Steam traps of ESV, Turbine Casing, Turbine Chest drains should be kept in service
and close the bypass valves.
Ensure the Steam traps are working or not. If they are not working open the bypass
valve slightly.
Gradually increase the load as per the loading procedure.
After paralleling with both the boilers gradually increase the load to 30MW as per the
procedure.

27

Warm start up and Hot start up

Turbine start up is termed as Warm startup if it is being started 3 to 4 hours after
trip of turbine. Turbine start up is termed as Hot Startup if it is being started with
in 2 hours after trip of the turbine. Follow the procedure for the cold startup upto
speed up to idle speed (i.e 750 rpm). After reaching 750 rpm, allow the machine for
soaking at the idle speed. Ensure that casing expansion has started from local scale
during soaking than previous condition. After ensuring that casing expansion has
started, then give command for Rated Speed. MS temperature should be maintained
50 0C more than MS skin / MS temp.at Turbine inlet. (Subjected to operating
temperature 530 0C at Turbine inlet.)

For warm and hot startup following parameters can be maintained.

If the metal temperatures are

inlet steam parameters must be

300deg.c (warm)

40kg/sq cm and 400 deg.c

350deg.c

50kg/sq cm and 450 deg.c

400deg.c

65kg/sq cm and 480 deg.c

450deg.c

75kg/sq cm and 500 deg.c

During any start of turbine, do not forget to open all the Turbine drains.
VII. Loading of Turbine:
After synchronizing the turbo generator with grid the minimum load to be maintained
is 4MW.
Check all Turbovisory instrument readings are normal.
Check rise of turbine casing metal temperature and its casing expansion.
Ensure smooth running of Turbine.

28

Raise the load at 0.5MW increment (1.0mw/min) by observing MS pressure and

temperature at turbine inlet.
At above 6 MW load take Generator Automatic Power control in to service.
At 8MW stable load charge the Deareator as per the procedure.
At 12 MW stable load charge the HP heater as per the procedure.

IX. Planned and Emergency Shutdown of Turbine:

Planned shut down:
Reduce the load on TG gradually to 3 MW, by operating the load/ speed switch on
GCP.
When load is at 12 MW cut off HP Heater.
When load is at 8 MW cut off Deaerator.
Open generator breaker as per the procedure.
Manually shut down the turbine (decelerate the turbine speed by pressing the
Remote Trip button on TGP). Ensure the actuator, ESVand MSSV closes
automatically.
Ensure all extraction check valves and extraction motor operated valves (MOVs) got
closed on interlock.
Open all the Before QCVs drains.
Close HP heater drip to deaerator & condenser control valves and LP heater drip to
condenser.
Open MS drains to atmosphere.
Ensure COPs, AOP, JOPs, TGM turns to AUTO selection on interlock at 95% speed.

29

Observe AOP to start in auto when lube oil header pressure drops to 0.87+/-0.2
Kg/Sq.Cm.

If it is not started, start the pump manually and observe discharge

pressure.
Ensure TGM starts in auto at <10% speed with time delay of 150 seconds. If it is not
started, engage the turning gear manually at 0 rpm of the turbine and start TGM
from DCS.
When the shut down period is less than 1.0 hour, maintain the vacuum in condenser.
During this period, ensure that gland seal exhaust fans are in continuous service and
the PRDS parameters should be reduced to 7.0kg/sq.cm & 150deg.c gradually i.e
5deg.c/min.
When the shut down period is more than 1.0 hour, kill the vacuum in condenser by
opening the vacuum break valve. Before opening the vacuum break valve, make sure
that hand operated valve in gland sealing steam supply line is closed and isolate the
Main ejector as per procedure.
Before killing the vacuum close all the Before QCVs drains.
1. Stop COP as per the procedure.
2. Run the CW pump 2 hours.
3. Run the CEP in recirculation around 4 hours.
4. Run the GSC Exhaust fan around 4 hours.
5. The coasting down period of the turbine will be approximately 20 minutes.
6. Normal TGM operation period is 10 hours after trip of turbine as per SNM
manual, as per SNM Engineer Instructions it is also a measurement of Casing
Expansion should be <2 mm on local indicator but practically it is taking 14 to
20 hours to cool down the turbine casing, rotor and the bearings.
7. After cooling down period, stop TGM and run the AOP, OVE fans further 2
hours.

30

8. After ensuring the bearing Babbitt, oil inlet and drain oil temperature becomes
near equal. Stop AOP, When AOP is stopped EOP will start in auto. Stop EOP
from TGP.
9. Stop (OVEF) oil vapour fan.

Emergency Shut Down

1. In case of emergency, the turbine can be stopped by either of the following
methods.
Remote trip button on TGP and GCP.
Manual trip cock lever from front bearing (i.e Hand Trip)
Turbine trip from Desk push button.
02. For the Emergency shutdown due to abnormality of M/C or tripping of the TG on
protection following steps are to be taken:
Ensure ESV, MSV (T) are closed, all extraction MOVs, extraction check valves
Ensure COPs, AOP, JOPs, TGM turns to AUTO selection on interlock.
Ensure AOP has started on Lube oil pressure low interlock.
Ensure TGM started in AUTO as per the interlock
If required kill the vacuum as per the procedure.
Continue AOP, TGM, GSC exhaust fan, OVE fan, CEP, CW pumps in service as per
the procedure.
03. Follow the activities mentioned in the above Planned Shutdown.

WORK INSTRUCTIONS

31

X. Emergency conditions during Turbine Operation:

The following emergency conditions may occur during Turbine operation. The
turbine operator should always be ready to take correct decision and act as per the
operating procedures. It is also necessary that he should know about the boilers
loading status, Tie- feeders positions, import and export power details in his shift.
a.
b.
c.
d.

Total power failure

Island mode operation
Any one boiler trip
DCS failure

a. Total power failure:

During total power failure, there will be no power supply to the AC drives (BFP, CW
& ACW pumps, CEPs, COPs, AOP, Turning Gear, Oil Vapor Exhaust Fans & GSC
Exhaust Fans). BFP, CW & ACW pumps, CEP, COP, Oil Vapor Exhaust Fan & GSC
Exhaust Fan will be tripped. Turbine will trip on heavy fault protection.
In this case, the following operations are to be carried out by the Turbine desk
operator:
Inform to Turbine field operator about total power failure and subsequent operations
to be carried out.
Ensure ESV is closed and Extraction check valves are closed on interlock. If not,
close them from DCS.
Check EOP starts on interlock at < 0.62 Kg/Sq.Cm. If not, start EOP from TGP.
Close the following control valves:
Normal & Emer. Make up valves by observing the condenser level
PRDS pressure control valve to isolate the ejectors and glands.
PRDS temperature control valve
LPH drip CV to Condenser.
HPH drip CV to Condenser
HPH drip CV to Deaerator
Deaerator pressure control valve to depressurize the Deaerator.

32

Close the Isolation valves in PRDS Pressure CV and Temperature CV. Close HOVs in
air and steam lines of Ejector from local.
Close HO isolation valve in Gland sealing line.
Close all drain valves connected to condenser. And open Vacuum break valve.
After restoring the Emergency DG set power, close the following valves:
All three extraction MOVs
Main steam stop valve (Turbine)
Discharge valve of BFP
Start AOP after informing to Switchgear operator.
Start JOP as per the procedure.
After turbine reaches to <10% of rated RPM start TGM as per the procedure.
Field Operators duty during total power failure:
Close isolation valves of PRDS Pressure CV and Temperature CV.
Close Main ejector air valves and steam valves.
Ensure EOP is started and Lube oil pressure is normal.
Close HOV in gland sealing line.
Close discharge valves of CW pumps.
Close all drains connected to condenser. Ensure turbine gland sealing steam
pneumatic control valve is operating and gland steam pressure is normal (0.1 to
0.2Kg/Sq.Cm (g)).
b. Island Mode Operation
Unit turns to Island mode in the following cases:
1. Sudden rise / drop in frequency
2. Sudden drop in load
3. Internal disturbance in LT / HT systems
4. Mal operation / mal function.
33

The following procedure is to be followed:

Load drops / rises as per the FAP demand. The turbine rotor speed and MS pressure at
turbine inlet will change.
Maintain the Generator Frequency at 50HZ by changing the turbine speed from
load/speed change lever from TGP.
Ensure the steam being supplied from the Boiler is sufficient to generate the load on
the turbine. If steam flow is less, MS pressure will drop. Ask shift engineer to
decrease the load on FAP to the suitable limits.
Observe the turbovisory readings like axial shift, all bearing vibrations, all bearing
temperature and casing expansion for any change. Do not allow MS temp to fall
sharply.
LP heater levels, HP heater levels and Deareator pressure may disturb due to load
fluctuations. Control the above parameters in manual mode.
. DCS failure condition:
Course of action for turbine desk operator and field operator, when total DCS CRTs
are not available. Obtain the instructions to run or to trip the unit from GM (PP)/
DGM (O&M)/ Manager (O)
Procedure to be followed to run the unit
All control loops work in auto. We do not have monitoring from CRT. All protections
and interlocks may work.
Ensure turbine load / MS pressure control remains in Auto mode.
MS pressure, Turbine RPM, Governor valve actuator position can be monitored from
WOOD WARD system.
Monitor and Control PRDS pressure and temperature from local.
Condenser level should be monitored from local gauge glass.
Deaerator level has to be monitored from local gauge glass.
CEP discharge pressure should be observed form local pressure transmeter and gauge.
34

Observe HP, LP, Deareator extraction pressures from local pressure transmitters.
LP, HP heater levels to be monitored from local gauge glass and level transmeter
analog indication.
Observe lube oil pressure, governing oil pressure, trip oil pressure, MOT level,
vacuum and Gland steam pressure local gauges/transmitters.
Maintain the same load.
Observe BFP parameters from local. Inform to Boiler operator to maintain constant
feed water flow
Procedure to be followed to trip the turbine:
If any abnormality is found during this period trip the turbine as per the procedure
given:
Inform the Boiler operator about tripping.
Trip the turbine from local hand trip lever or remote trip from TGP.
Ensure ESV, all extraction check valves and extraction MOVs closed from TGP and
local.
Ensure AOP / JOP / TGM has started in sequence as per the interlock. If not start
them as per procedure from MCC. If AOP has not started in AUTO, Start EOP from
start push button on TGP.
Isolate the PRDS station by closing the PRDS pressure CV and Temperature CV
isolation hand operated valves.
Isolate the Gland sealing line by closing the hand-operated valve in GS supply line.
Close LP heater and HP heater drains to condenser CVs isolation valves.
Continue AOP, COP, , TGM, OVEF, GSCEF, CEP, CW Pumps, ACW Pump to run.
Stop the BFP after taking clearance from Boiler operator from local. (After box up of
boiler)
Run the CEP in complete Re-circulation.
Cut off the lube oil coolers if necessary.
35

XI. Important Dos and DONTs during Turbine Operation:

DOs:
1. The turbine has to be shutdown immediately in the following cases.
When the turbine rotor speed increases higher than 5200 rpm.
Whenever oil pipes, steam pipes, main condensate pipes, feed water pipes are
broken or some cracks / leaks are found in them.
Whenever some hydraulic shocks are occurred in the piping or in the turbine
casings.
Some metallic noise is heard clearly in the turbine
When the mechanical over speed lever is defective
2. The turbine is to be tripped emergently with breaking vacuum manually in the
following cases:
When the lube oil header pressure drops to <0.45Kg/Sq.cm
When the oil catches fire and fire could not be extinguished immediately.
When the turbine tripped on Rotor Axial Displacement protection
3. DO in every shift:
Check Main oil tank level is normal.
Check oil vapour fan and GSC exhaust fan are in service.
Check the availability of DG set.
Check the availability of AOP, Stand by COP and DC EOP.
Check the open position of Discharge valves of AOP, EOP, standby COP.
Ensure the Steam traps of ESV, Turbine Casing and Turbine Chest drains
are working normal.
Ensure condensate system and feed water systems are running normal
Ensure CW system is running normal

36

 Ensure Glands sealing steam control valve is functioning normally

Ensure the parameters of turbine and its auxiliaries are within the limits
Check the sealing water to Condenser connected valves are given
Check starting ejector air valve and vacuum break valve are tightly closed
Ensure that all instruments functioning properly
Ensure that standby ACW and stand by CEP discharge valves are in open
position.
DONTs
1. Do not operate the turbine, any equipment bypassing the interlocks
2. Do not operate the turbine with high vibration values and high bearing
temperatures conditions
3. Do not allow sudden drop or rise in MS temperature and MS pressures.
4. Do not start the vacuum pulling with out turbine on Turning Gear operation
5. Do not start the Glands charging with out turbine on Turning Gear operation
6. Do not continue turbine on TGM operation if unusual sound / vibration comes
from gland seal, bearings etc.
7. Do not operate the turbine with LOW main oil tank levels.
8. Do not start the TGM with out Over head oil tank level normal
9. Do not start the Turbine with out Over head oil tank level normal
10.Do not start the TGM with out running the AOP&JOP.
11.Do not run Lube oil system with out running the oil vapor exhaust fan.
12.Dont run Oil vapor Exhaust Fan when MOT level is high.
13.Do not allow hot rotor to stand with out rolling (with out TGM operation)
14.Do not overlook abnormality in any important reading
15.Do not forget to check stand by position and healthiness of DC EOP
16.Do not allow any leakage in the suction side of the CEPs.
17.Do not start the CEP with out opening of Air removal and Gland sealing.
37

18.Do not open any valve, fitting, flange in the suction side of CEPs in normal
working condition. When condenser is in vacuum this will cause vacuum to
drop and pump (CEP) to loose its suction.
19.While cleaning suction strainer of stand by CEP, ensure closure of suction
valve.
20.Do not keep the steam valve of main ejector open for long time if condensate
flow is not there through main ejector.
21.Do not run the turbine with open or un tightened flanges on oil tank, oil piping,
steam piping. etc.
22.Dont charge the PRDS line without closing the Turbine Glands Isolation
Valve.
23.Do not open the Vacuum break valve with out Isolating the Glands Isolation
valve and Steam lines connected to Condenser.

BOILER FEED PUMP:

In thermal power plant cycle the feed pumps are placed in the feed water system and
are intended to deliver the feed water to the boiler. 100% availability of these pumps
are essential to run the plant.
This pump delivers feed water at higher pressure against boiler resistance, through
feed control station. The feed control station regulates the feed water flow according
to drum level.
Two numbers of diffuser type boiler feed pumps supplied by KSP make, are installed
here. The BFPs are rated to deliver each 150 cu.m/hr. feed water against a head of
1275 Mlc and is driven by 730 KW, 2980-rpm motor.
*/Technical Data/*
Type of pump
: Diffuser
Feed water temperature
: 158 Deg.C
Flow rate
: 166 TPH
Developed head
: 1285 Mlc
Speed
: 2980 rpm
Net positive suction head
: 5.8mlc
Recirculation flow
: 40 TPH
Direction of Rotation
: CCW from Motor DE.
38

STARTING OF BFP:
Ensure no line clearance is pending on BFP, its auxiliaries and its connecting piping
and valves. Ensure supply to the Motor is available.
Ensure Deaerator level is normal and CEP is in service to maintain its level.
Check the lube oil levels of pump DE & NDE bearings.
Ensure ACW pump is in service.
The inlet and outlet valves of ACW water to BFP should be in open position and
check the ACW pressure at BFP is 2.5 Kg/ Sq.cm
The following inlet and outlet valves should be in open position: a. Pump NDE side Thrust bearing housing
Stuffing box
Seal water cooler
b. Pump DE side -

Journal bearing housing

Stuffing box
SSeal water cooler

Ensure the feed water system is through to HP Heater.

Ensure open position of suction valve of BFP.
Ensure discharge valve is in closed position.
Check that hand-operated valves (2 nos) in balancing leak off line (one is at pump
and another at Deareator tank) are in open position.
Check the HOV in recirculation line (at Deareator tank) is in open position.
Ensure all isolation valves in impulse lines are open.
Ensure the local Push Button is released.
Close the warm up valves for starting the pump.
*Ensure that PRDS Attemperation is isolated from BFP discharge.
Close the warm up.
Start the Pump from DCS and keep the pump in recirculation for 2 minutes and
observe the following:
a. Suction & discharge pressures.
b. Suction & discharge temperatures.
c. Bearing temperatures.
d. Seal water temperatures.
e. Differential pressure across the suction strainer.
f. Balancing leak off & re-circulation line pressures.
g. Motor currents.
h. Any abnormal sounds.
39

i. Lube oil levels in bearing cups.

Open the discharge valve from control room DCS.
Ensure balancing leak off pressure is higher than suction pressure.
Observe the parameters in point no 16.

Shut down sequence:

1. Close the discharge valve.
2. Keep the Pump in re-circulation.
3. Stop the Pump from Control room.
NOTE*
1. Observe Motor currents shouldnt exceed >47 amps.
2. When the Motor currents have crossed 47 amps and tending to increase,
inform Shift In charge or Boiler Desk Operator.
3. Dont allow the Pump to start or run with Protection interlock bypass.
WHAT NOT TO DO:
1.
2.
3.
4.

Dont close the valves in re-circulation and balancing leak off lines
Dont allow the BFP to run when the bearing temperatures exceeds>80 deg.
Dont run the Pump without ACW pump is in service.
Dont allow the Pump to run when the seal water temp. Exceeds the limit.
(>80 deg)
5. Dont switch on the pump during discharge valve is in open position.
STARTING PERMISSIVES:
Ensure the following permissive at DCS & Local.
1. Discharge valve is in closed position.
2. Deaerator level is not low >900mm
3. DP across suction strainer is not high.
PROTECTIONS FOR BFP:
a. Deaerator level low
: < 400mm.
b. BFP suction pressure low (trip not incorporated).
c. DP across strainer high
: > 0.5 Kg/Sq.cm.
40

d.
e.
f.
g.
h.
i.

BFP Brg. temps high

DT across pump
Discharge Pressure low
Suction temp. Switch active
Balancing leak Off pressure is high,
ACW pump discharge pressure
with time

J. BFP motor winding temp.high high

K. BFP motor bearing temp. high high

:
:
:
:
:

> 80 Deg C.
20 Deg C.
< 105 kg/sq.cm
160 Deg C.
>12.0 kg/sq.cm
: < 2 .0 Kg/Sq.cm

Delay of 15 sec.
: 140 deg.c.
: 95 deg.c

Note: For Point f, initial bypass of protection for a period of 70 seconds is

incorporated.
CW PUMPS
2 CW pumps (both working) are installed to supply cooling water to condenser. It is
rated to deliver 6900 TPH, at 2.10Kg/Sq.cm and is driven by 415V, 550 KW, 740-rpm
motor. The cooling water pump receives its suction from CT Sump and discharge is
returned to CT sump through Condenser and riser pipes.
STARTING OF CW PUMPS:
1. Check no line clearance is pending on CW system.
2. Ensure LT supply to the Motor is available.
3. Ensure Sump level is normal. If low, make it normal with CT Sump Make up
Pump. (Sump level is > 2800 mm)
4. Ensure CW to Condenser I/L and O/L valves and CT raiser valves are opened. (For
one pump one CT riser valve, and for two pumps in operation two riser valves)
5. Open all the 4 air vents of Condenser Water box during initial starting of pump.
Close them after air vented out
6. Open Air release cocks located above the Pump to ensure that the Pump is full of
water.
7. Ensure Gland cooling water valves are open.
8. Ensure suction valve is opened and discharge valve is in closed position.
9. Release Local Push Button.
10. Start the Pump from DCS.
11. After speed pick up and restoration of normal currents, slowly open the discharge
valve.
12. Observe the discharge pressure should be > 1.5 kg/sq.cm at pump.
13. Check the bearing & Glands temperatures Physically.
14. Observe the gland leakage water from Pump DE and NDE.
41

SHUT DOWN SEQUENCE:

1. Close the discharge valve.
2. Switch off the Motor.
STARTING PERMISSIVES:
1. CW Sump level is > 2800 mm.
PROTECTIONS:
1. Sump level low low. (Value not incorporated.)
IMPORTANT NOTE:
1. Dont start the Pump keeping Discharge valve in open position.
2. Maintain sump level between 2800 and 3000 mm.
3. When both the pumps are in service, ensure that at least two riser valves must be
in open position.
4. Discharge valve of the stand by pump should be in closed position.
5. Dont allow the pump to start or run with protection interlock bypass.

42

DESK OPERATORS GUIDE:

The following are the Protections (Trip values) of the Turbine:
1. Steam temperature at turbine inlet high high > 543 Deg.C
2. Steam temp. at turbine inlet low low < 460degC, this protection comes in to
service only when MS temperature reaches to 495 deg C and then falls to 460.
3. Steam pressure at turbine inlet low low < 60 kg/sq.cm (may be bypassed initially
for Cold and Warm start ups if required.)
4.Steam pressure at turbine inlet high high >103kg/sq.cm (not incorporated).
5. Control oil pressure low low 8.0+/-0.5 Kg/sq.cm
6. Lube oil pressure low low < 0.62 Kg/Sq.cm
7. Generator heavy fault (Generator trip).
8. Turbine mechanical over speed trip >/= 5632 rpm
9. Turbine electrical over speed trip >/= 5583 rpm
10. Governor heavy fault.
11. Remote trip from turbine governor panel.
12. Turbine trip from desk push button.
13. Exhaust steam pressure high high > 1.3 Kg/Sq.cm (abs)
14. Exhaust steam Temperature high high > 150 degC
15. Lube oil reservoir level (MOT) low low < 350 mm.
16. Hot well level low low < 300mm
17. Hot well high high 1400 mm
18. Turbine Rotor axial shift high high +0.65, -0.65 mm.
19. Turbine front shaft vibration high high 90 microns
20. Turbine rear shaft vibration high high 90 microns
21. Reduction gear pinion front shaft vibration high high 140 microns
22. Reduction gear pinion rear shaft vibration high high 140 microns
23. Reduction gear wheel front shaft vibration high high 180 microns
43

24. Reduction gear wheel rear shaft vibration high high 180 microns
25. Generator front shaft vibration high high 160 microns
26. Generator rear shaft vibration high high 160 microns
27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C
28. Turbine thrust bearing temperature high high (active) 120 Deg.C
29. Turbine front shaft bearing temperature high high 120 degC
30. Turbine rear shaft bearing temperature high high 120 degC
31. Reduction Gear pinion front bearing temperature high high 120 degC
32. Reduction Gear pinion rear bearing temperature high high 120 degC
33. Reduction Gear wheel front bearing temperature high high 120 degC
34. Reduction Gear wheel rear bearing temperature high high 120 degC
35. Generator front bearing temperature high high 85 degC
36. Generator rear bearing temperature high high 85 degC
37. HP heater level high high 290mm. (Protection should be bypassed during
charging of HP heater.) not incorporated.

ANNEXURE-I, Turbo Generator Set - Alarms and Trip values

S.N Tag No
01
02
03
04
05

Description of Tag
Condensate System
TPT106 Exhaust steam press.
(Vacuum) Kg/Sq.cm (abs)
TTI800 CW Temperature at Cond
I/L-1 Deg.c
TTI801 CW Temperature at Cond
O/L-1 Deg.c
TTI802 CW Temperature at Cond
I/L-2 Deg.c
TTI803 CW Temperature at Cond
O/L-2 Deg.c
44

Nor

Lo

Hi

LL

HH/Trip

0.086 0.05 0.3 0.02

0.5/1.3

30

26

34

25

36

38

34

42

33

44

30

26

34

25

36

38

34

42

33

44

06
07
08
09
10
11
12
13
14
15
16

TTI106

Exhaust steam temperature 44

Deg.c
TLT300A Condenser Level mm
800

120

150/15
0
600 100 300/30 1400/1
0
0
400
16501900
5300 4500 60003500 7000

TLT440 UCFT Level mm

TDPT40 DP across Cond. Left
0A
mmwc
TDPT40 DP across Cond. Right
5300 4500 60003500
0B
mmwc
TCV440 Emergency Makeup CV
AFB
Feed back
TCV440 Normal Makeup CV Feed
BFB
back
TCV300 CEP Recirculation CV Feed
AFB
back
TLCV430 Deareator level CV Feed
FB
back
TPT321 CEP Discharge Pressure
9.0
7.0 11 6.0
Kg/Sq.cm
Hot well Temperature Deg.c 44
40
52 35

7000

14.0
55

19

TDPT43 Main Condensate Flow TPH 106

0A

80

120 50

140

25

CPT480 CW Header pressure

Kg/Sq.cm

1.6

1.4

1.8 1.0

2.0

158

130 165 100

158

130 165 100

158

140 160 120

BFP & Feed water system

01
02
03

TTI470A FW temperature at BFP-1

Suction Deg.c
TTI470B FW temperature at BFP-2
Suction Deg.c
TTI471A FW temperature at BFP-1
45

170/17
0
170/17
0
160

04

TTI471B

05

TPT460

06

TPT470

07

TTI468A

08

TTI468B

09

TTI469A

10

TTI469B

11

TTI466A

12

TTI466B

13

TTI467A

14

TTI467B

15

TPT103

16

TTI103

17

TTI702A

S.N Tag No

Disch Deg.c
FW temperature at BFP-2
Disch Deg.c
BFP-1 Discharge Pressure
Kg/Sq.cm
BFP-2 Discharge Pressure
Kg/Sq.cm
BFP-1 DE Bearing
Temperature Deg.c
BFP-2 DE Bearing
Temperature Deg.c
BFP-1 NDE Bearing
Temperature Deg.c
BFP-2 NDE Bearing
Temperature Deg.c
BFP-1 Motor DE Bearing
Temp Deg.c
BFP-2 Motor DE Bearing
Temp Deg.c
BFP-1 Motor NDE Bearing
Temp Deg.c
BFP-2 Motor NDE Bearing
Temp Deg.c
HPH Ext. Steam pressure
Kg/Sq.cm
HPH Ext. Steam
temperature Deg.c
HPH Drain temperature
Deg.c
Description of Tag

158

140 160 120

120.5 110 135 105/10 140

5
120.5 110 135 105/10 140
5
60
70
80/80
60

70

80/80

60

70

80/80

60

70

80/80

70

90

80/95

70

90

80/95

70

90

80/95

70

90

80/95

20.5 18

22

15

300 350 280

360

154

140 165 120

180

Nor

Lo

Hi

LL

HH/Trip
160
235
240/29
0
240/29
0

TTI704A FW temp at HPH I/L Deg.c 158

TTI703A FW temp at HPH O/L Deg.c 220
TLT420A HPH level 1 mm
180

135 155 120

190 225 180
170 220 160

21

TLT420B HPH level 2 mm

170 220 160

22

TCV420F HPH drain to Deareator CV

B
Feed Back
TCV420 HPH drain to Condenser CV
46

25

337

18
19
20

23

160

180

27

BFB
Feed Back
TPT104 Deareator Extr Steam
5.00
Pressure Kg/Sq.cm
TTI104 Deareator Extraction Steam 219
Temp Deg.c
TPT430 Deareator Pressure
5.0
Kg/Sq.cm
TLT430A Deareator Level 1 mm
1150 650

28

TLT430B Deaerator Level 2 mm

29

TLT430S Deareator Level Selection

EL
mm

24
25
26

5.51

240

300

5.5

6.0

146
5
1150 650 146
5
1350 650 166
5

500/40 1665
0
500/40 1665
0
500/401865
0

90

80

95

60/60 105

90

80

95

80

530

485 538 460/46 543/54

0
3
63
67

Main Steam/Aux./Gland steam

sys
01
02
03
04
05
06
07
08
09
10
11
12

1PT001 M S press at common

header Kg/Sq.cm
TPT101 Steam pressure at turbine
I/L
TTI101 Steam temperature at
turbine I/L Deg.c
TPT102 Steam pres aft turbine 1st
stage Kg/Sq.cm
TTI1021 Steam temp after turbine
1st stage Deg.c
TPT164APRDS Pressure Kg/Sq.cm
TTI152A PRDS steam Temperature
Deg.c
TPT107 Gland steam Pressure
Kg/Sq.cm
TTI108 Gland steam temperature
Deg.c
TTI108 Gland leak steam pressure
TTI1022 Metal temp at turbine 1st
stage Deg.c
TTI1023 Metal temp at turbine 1st
stage Deg.c
47

65

94/102

475

480

24
370

22
27 20
360 380 340

30
400

0.2

0.08 0.4 0.06

0.45

400

360 410 350

420

465

475

480

465

475

480

Turbovisory
01

TLT500A Lube oil tank level mm

550

02

TPT531ALube oil pressure to

Bearings Kg/Sq.cm
TTI510A Lube oil temp at cooler I/L
Deg.c
TTI511A Lube oil temp at cooler O/L
Deg.c
TPT530 Control oil Pressure
Kg/Sq.cm
TTI804 ACW temp at I/L of oil
cooler Deg.c
TTI805 ACW temp at O/L of oil
cooler-1 Deg.c
TTI806 ACW temp at O/L of oil
cooler-2 Deg.c
TTI807 ACW temp at I/L of Gen
cooler Deg.c
TTI807A ACW temp at O/L of Gen
cooler-1 Deg.c
TTI807B ACW temp at O/L of Gen
cooler-1 Deg.c
TTI807C ACW temp at O/L of Gen
cooler-1 Deg.c
TTI807D ACW temp at O/L of Gen
cooler-1 Deg.c
TSE2011Turbine Seed rated rpm

1.5

03
04
05
06
07
08
09
10
11
12
13
14

Turbine Seed 16% rpm

Turbine Seed 95% rpm
S.N Tag No
Description of Tag
15 TZE2011Axial shift mm
16

TZE2012Axial shift mm

48

65

400 800 350/35 870

0
1.17 1.7 0.62/0. 2.0
62
40
70 30
75

45

40

14

50

12

30

55

10

17

30

25

34

20

36

35

27

39

25

42

35

27

39

25

42

30

25

34

20

36

35

30

39

25

41

35

30

39

25

41

35

30

39

25

41

35

30

39

25

41

4900 4700 533 4652 5632

8
816
4650
Nor Lo Hi LL/Tri HH/Trip
0
-0.45 0.45 -0.65 0.65/0.
65
0
-0.45 0.45 -0.65 0.65/0.
65

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

TTI201

Turbine bearing
temperature 1 Deg.c
TTI202 Turbine bearing
temperature 2 Deg.c
TTI203 Turbine bearing
temperature 3 Deg.c
TTI204 Turbine bearing
temperature 4 Deg.c
TTI205 R/G pinion front bearing
temp-1 Deg.c
TTI206 R/G pinion rear bearing
temp-2 Deg.c
TTI207 R/G wheel front bearing
temp-3 Deg.c
TTI208 R/G wheel rear bearing
temp-4 Deg.c
TTI209 Generator front bearing
temp-1 Deg.c
TTI210 Generator rear bearing
temp-2 Deg.c
TVXT201Turbine front shaft vib,
Horizontal microns
TVYT201Turbine front shaft vibr,
Vertical microns
TVXT202Turbine rear shaft vibr, Hor
microns
TVYT202Turbine rear shaft vibr,
Vertical microns
TVXT203RG pinion front shaft vibr,
Hor microns
TVYT203RG pinion frt shaft vibr,
Vertical microns
TVXT204RG pinion rear shaft vibr,
Hor microns
TVYT204RG pinion rear shaft vibr,
Vert microns
TVXT205RG wheel front shaft vibr,
Hor microns
TVYT205RG wheel front shaft vibr,
Vert microns
49

60

110

75

120/12
0
120/12
0
120/12
0
120/12
0
120/12
0
120/12
0
120/12
0
120/12
0
85/85

60

110

60

110

60

110

75

85/85

45

90/90

45

90/90

45

90/90

45

90/90

96

140/14
0
140/14
0
140/14
0
140/14
0
180/18
0
180/18
0

100
100
100
100

96
96
96
120
120

37
38
39
40
41
42
43
44
45
46
47
48

01
02
03
06
07
08
09
10
11
12
13
14
15

TVXT206RG wheel rear shaft vibr,

Hori microns
TVYT206RG wheel rear shaft vibr,
Vert microns
TVXT207Generator front shaft vibr
hor microns
TVYT207Generator front shaft vibr
Vert microns
TVXT208Generator Rear shaft vibr
hor microns
TVYT208Generator Rear shaft vibr
vert microns
TTI254 Gen cold air temp
TTI255 Gen cold air temp
TTI256 Gen hot air temp
TTI251 Gen Winding temp-1
TTI252 Gen Winding temp-2
TTI253 Gen Winding temp-3
Currents / Winding
Temperatures
CCT626
A
CCT626
B
CCT626
C
CCT625
A
CCT625
B
CCT625
C
CCT670
CCT671

50

CW Pump 1 Motor current,

Amp
CW Pump 2 Motor current
Amp
CW Pump 3 Motor current
Amp
CT Fan-1 Motor current Amp
CT Fan-2 Motor current Amp
CT Fan-3 Motor current Amp
BFP-1 Motor current Amp
BFP-2 Motor current Amp
CEP motor current Amp
AOP motor current Amp
COP motor current Amp
JOP motor current Amp
EOP motor current Amp

120
120
100
100
100
100
50
50
77
100
100
100

80
80
80

110 70
110 70
110 70

180/18
0
180/18
0
160/16
0
160/16
0
160/16
0
160/16
0

120
120
120

S.N Tag No
16
17
18
19 TTI460A
20

TTI460B

21

TTI461A

22

TTI461B

23

TTI462A

24

TTI462B

25

TTI463A

26

TTI463B

27

TTI464A

28

TTI464B

29

TTI465A

30

TTI465B

51

Description of Tag
OVEF motor current, Amp
GSCEF motor current Amp
TGM motor current Amp
BFP-1 Winding
temperature-1 Deg.c
BFP-2 Winding
temperature-1 Deg.c
BFP-1 Winding
temperature-2 Deg.c
BFP-2 Winding
temperature-2 Deg.c
BFP-1 Winding
temperature-3 Deg.c
BFP-2 Winding
temperature-3 Deg.c
BFP-1 Winding
temperature-4 Deg.c
BFP-2 Winding
temperature-4 Deg.c
BFP-1 Winding
temperature-5 Deg.c
BFP-2 Winding
temperature-5 Deg.c
BFP-1 Winding
temperature-6 Deg.c
BFP-2 Winding
temperature-6 Deg.c

Nor

Lo

Hi

LL/Tri HH/Trip

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

95

140

110

COMMUNICATION
To avoid communication gap among all the power plant staff the following
stationary to be maintained in addition to the walke talkies and phanes.
1. Line Clearance form for safety.
2. complaint register to enter abnormalities.
3. Instructions register.
4. Log sheets for each field.
5. Log books for each field.
6. Running hours log book.
7. Coal & bagasse stock log book.
8. Coal & ash analysis log sheets.
9. Daily Generation & consumption log sheets & log books.
10. Water and steam analysis log sheets.
Line Clearance form for safety:
Before doing any work on running or stanby equipments in running or in shut
down the respective maintenance persons should take the Line Clearence from the
shift in charge/engineer.
The shift in charge/engineer should understand the work to be carried out. If he
feels the work can be caried out with out disturbing the running of the plant then he
should in form the line or equipment to be Isolated to the concerned field operator.
After the isolating the equipment/line the field operator will sign on the line clearence

52

form. After ensuring the line /equipment isolated the shift in charge/engineer con give
Line Clearence to carryout the work to concerned maintenance department.
Before starting the work the maintenance person should ensure that the
field operator & shift in charge/ engineer signed on the L.C form and the
equipment is isolated.
After completion of the work the maintenance persons has to return the L.C.
The concerned operator should keep the equipment ready for operation. The
same is to be ensured by shift in charge/engineer.
If needed the trail run of the equipment/line to be carried out in presence of
shift in charge/engineer & maintenance person.
complaint register to enter abnormalities:
If any abnormalities observed in the system/equipment concerned operator should
bring to the notice of shift in charge/ engineer. The shift in charge/engineer should
check the equipment/system parameters and the abnormality to be registered in the
complaint register and inform to the concerned department.
If the abnormality is emergency then the maintenance people should be called
immediately and the same is to be informed to C.M.(O&M).
Instructions register:
If any special instructions in operations of any equipment/system the same is to
be entered in the Instruction register by the maintenance depart and the instruction
to be duly signed by the C.M(O&M). The instruction should contain the reasons
for the specialty and the valid period.
Log sheets for each field:

53

Each field operator and desk operator should enter the parameters
periodically in the log sheet. The log sheet should be duly signed by the shift in
charge in each shift.
Log books for each field:
Each field operator and desk operator should enter all the events in the log
book with time. The log books should be duly signed by the shift inc harge in each
shift.
Running hours log book:
Every day in the C shift the shift in charge should enter the day running hours
of every equipment in the register.
Coal & bagasse stock log book:
All the coal & bagasse receipts and consumptions to be entered in this log book
shift wise by the shift in charge/engineer and available stock to be evaluated daily.
Coal & ash analysis log sheets:
The log sheets to be filled daily wise by quality control department and to be
sent to shift in charge.
Daily Generation & consumption log sheets & log books:
Daily in 1st shift the consumptions of all the equipments to be recorded for the
previous day. The previous day total generation, total auxiliary consumption, PLF,
average frequency and percentage of auxiliary consumption to be recorded. The
reasons for any change in the generation & consumption also to be recorded.
Water and steam analysis log sheets:
54

The DM plant chemist should enter the periodical water and steam analysis in
the log sheets and the duly signed log sheets to be sent to shift in charge for reference
and recording.

55