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Evonik Energy

Services (I) Private Ltd


Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

GAS TURBINE STARTUP & SHUTDOWN


PROCEDURES
PRE START CHECKUP:
All MCC modules are switched ON and are kept on
AUTO
Lube Oil Level is OK and Oil Temp. is Normal.
Select Cool down ON and ensure that the AC Lube
Oil Pumps Start and Slow roll is OK.
Start EOP and ensure that the Pressure developed is
OK.
Cooling water level is OK.
Visual Inspection of Machine is OK.
NORMAL START:
Select UNIT CONTROL DISPLAY / START UP in
MARK-V or MARK-VI
Operator Selects CRANK/FIRE/AUTO Then
Execute.
Protection System checks Ready to Start Permissive.
1. Generator Lockout Relay is reset.
2. Turbine at zero speed / on slow roll.
3. Flame is not detected in all Scanners.
4. Compressor Bleed valve is open.
5. OFF is not selected.
6. IGV is closed.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

7. Master Protective L4 logic is reset.


8. <R>, <S>, & <T> Master Protective agree.
9. Emergency Lube Oil Pump Voltage is Normal.
10. <R>, <S>, & <T> Communication links are healthy.
11. Generator Breaker is open.
12. Auxiliaries are healthy and Duel System faults reset.
13. Ignition transformers/exciters supply normal.
14. Lube Oil Temp. Normal.
15. Bleed Heat System Fault / TRIP are reset.
16. Primary Purge valves are close.
Then READY TO START DISPLAYED.
Operator Presses START then Execute.
9 Start counter is Incremented.
9 DC Oil Pump is started for EOP TEST.
9 Unit Start continues if pressure switch 63QE-1 senses
EOP discharge pressure within 8 sec. if not, START is
aborted.
9 AC Lube oil pump started, if not already started.
9 Lube oil mist eliminator started along with Lube oil
Pump.
9 Barring Gear is Started ( if OFF COOL DOWN)
9 Master Protective system energizes ( L4 )
Then STARTING displayed,
9 Auxiliary Hydraulic Pump started.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

9 SFC Speed reference is set to PURGE


Value= LK14CX1 for Cold start (30%)
= LK14CXH1 for Hot start (16%)
9 LCI is started.
9 SFC accelerates.
9 Turbine Breaks Away.
9 Exhaust Compartment (88BX) starts.
Then CRANKING Displayed,
9 After reaching beyond 8.4% speed load compartment
vent fan (88VG) started.
9 20TV IGV Solenoid is energized(if NO IGV Trip)
9 Turbine reaches cranking Speed ( about 30% speed
during Cold start and about 16% speed during Hot
Start)
9 ** In CCPP-II, Cranking Speed reaches is only 30%,
there is no provision of Hot/ Cold Start.
9 After reaching cranking speed, turbine is purged for 7
min.
9 Speed reference to SFC is withdrawn after completion
of purge. With this Unit undergoes freefalls.
9 After L14HM Dropout (below 13.5% speed), SFC
reference set to firing value LK14TMF1 (14%). When
L14HM pick up (above 14% speed) firing permissive is
enabled.
Then FIRING Displayed

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

Energies Gas Fuel Trip Solenoid (20 FG ) permissible for


SRV & GCV Enabled

1. Fuel Stroke reference (FSR) is set to firing value.


Opening of GCV is Based on this
2. Ignition Transformers/Exciters is energized and
sparking of spark plug take place for the 30 sec.

No

Failure to Ignite
Alarms appears
Turbine

Flame is detected in
2 out 4 Scanner and
steady for 30 sec

Yes

FSR cuts back to


WARM-UP Value

Then WARM-UP Displayed,


9 WARM-UP Timers starts ( 60 Seconds)
9 Turbine compartment Vent fan (88 BT) Started
9 Fired starts counter incremented. Fired hours timer
energized.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

9 After WARM-UP completion, SFC Speed Reference


set to full Speed Value (100 %).FSR is increased at
predetermined rate to accelerate the turbine.
Then ACCLERATING displayed,
9 After approx. 85% speed, IGV starts opening with
increase @ 5.27DGA/% increase in Speed to the
FSNL, IGV Angle=CSKGVMN1= 54 DGA.
9 After L14HP pick up (approx. 87% speed), SFC
Signal is self Cut Off and the unit become self
sustaining.
9 Compressor bleed valve gets close.
9 Compressor Discharge Pressure reaches from 1 bar to
7 bars.
Unit reaches 100% Speed,
Then Full Speed No Load Displayed,
9 Enables MANUAL RAISE/LOWER of Turbine speed
reference to synchronize the unit.
9 If AUTO SYNCH. Permissive are OK, Generator and
Line are present and above minimums, the control
system will modulate FSR to bring Speed to match the
station line frequency and closes the Generator breaker
when phase angle is OK.
9 Depending upon the load mode selection, turbine is
loaded to the reference and load maintained.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

SPINNING RESERVE for CCPP-I/PART


LOAD/PRESELECTED LOAD/BASE LOAD
Displayed.
CHECKS DURING START UP:
Flame is sensed in all Flame Scanners.
Exhaust Temperature are uniform and Spread is
normal.
Acceleration is smooth and time taken is in line with
earlier values.
Rise in Exhaust Temperature is uniform.
Exhaust Temperature profile is OK and Spread
values are within limits.
Rise in Wheel Space Temperature is uniform.
Vibrations are within limits and as per earlier values.
Bearing Oil Drain Temperatures are normal.
GAS TURBINE SHUTDOWN:
SHUTDOWN OPERATIONS:
Gas Turbine Shutdown can be achieved by two means.
NORMAL OR FIRED SHUTDOWN
EMERGENCY SHUTDOWN
MANUAL EMERGENCY SHUTDOWN

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

PROTECTIVE EMERGENCY SHUTDOWN


FIRED SHUTDOWN:
o Normal Shutdown reduces the fuel to the Turbine in a
controlled way ( Up to 20% of Speed and shuts of the
fuel totally) so as to reduce the overall thermal shock to
Turbine Internals
o It is executed by using STOP Push buttons on UNIT
CONTROL DISPLAY in MARK-V/ STARTUP
display in MARK-VI.
o This is the most preferred shutdown mode.
EMERGENCY SHUTDOWN:
o Shuts of the Fuel Immediately by closing the Fuel Stop
Valves.
o Manual Emergency Stop to be used judiciously.
o Emergency Push Buttons are provided on
- MARK-V/ MARK-VI Control Panels.
- The Manual push lever on over speed bolt.
STANDBY OPERATIONS:
When the machine is not run for long time?
Put the machine on Ratcheting/Barring for at least 30
min daily.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

Crank the turbine once in a fortnight to drive away


moisture.
Operate the GT to FSNL once every month to avoid
corrosion of turbine wheel dovetails.
Daily Check Battery System, Oil levels etc.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

Dos and Donts in Shutdown, Startup and Running GT


1. Check the Evaporating cooling system parameters DP after
evaporating system, Relative humidity; ambient temp and also
check Air pulsating system should be in service daily. DM
water to be used in evaporating cooling system.
2. Ensure all the Doors of Turbine compartment, Diffuser
compartment and Load Gear Compartment to be in closed
position otherwise GT will trip. Advantage of closed doors,
bearings have thin casing. If doors opens continuously casing
may be cooled and causes rotor rub.
3. Venting and draining of filters and line of water injection
system and after water injection put in service.
4. IGV, SRV and GCV sluggishness /stroke operation manually
checked in every shutdown as per earlier values.
5. Water injection Purge feed valves sluggishness/stroke
operation manually checked in every shutdown. Operated as
per earlier time
6. Compressor Bleed valves passing of valves /Sluggishness
+/stroke operation manually in every shutdown operated as per
earlier time.
7. Air inlet DP Switches, AFPCS and AFPAP impulse line
flushed in every shutdown.
8. Lube oil filter to be cleaned in every shutdown and also check
its oil pressure and hydraulic oil pressure as per earlier values.
9. All pumps, vent fans and blowers actual current rating to be
measured weekly and change over the entire stand by drives
every 15 days.
10. Turbine and Diffuser compartment DP switches checked in
every shutdown.
11. Mark-V Card Inspection Inspect all PWB in each core. Verify
all plug in relays are firmly connected into their sockets.

Evonik Energy
Services (I) Private Ltd
Prepared by
Arvind Patil, EESI, Hazira

GT-6FA
STARTUP & SHUTDOWN
PROCEDURE

Rev: 00
Date: 09.05.2011

Check to see each card is held firmly. Check to see card


identifier is on left top corner in each core. This is to ensure
card orientation.
12. Mark-V card inspection using appropriate caution while
replacing cards in card carriers. Avoid binding/
pinching/chafting of ribbon cables and wire hardness.
13. Verify polarity and voltage of DC/AC supplies of Mark-V
14. Energies the processors (<R>,<S>, & <T>, <C>) one at a time
while monitoring the supply. The LCC display should indicate
state A4,A5,A6 or A7 and possibly with several messages in
Mark-V
15. Control constants are to be verified or updated as per site
control specification document. Approximation of any number
or constant is strictly not allowed. Qualified Person only
should update the control constants and such up dation or
amendment to be avoided when the Gas Turbine is running.
16. Do not force any logic for Startup.
17. Do not attempt subsequent starts without troubleshooting if
machine trips during startup.
18. Maintain AC temperature between 16 deg C min to 20 deg C
max for Mark-V panel.
19. Record the TREND and ANALYZE present operation.
a. Load Vs Exhaust Temperature
b. Load Vs FSR
c. Load VS CPD
d. Load Vs Vibration.
e. Load Vs Wheel space Temp.
f. Load Vs IGV and load tunnel temp.
g. Load Vs GCV, SRV etc
h. Use all trend from MARK-V/MARK-VI to notice
incipient problem.