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Important Note!
Slide 2 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Plant Overview
Area
Work Area
Button Area
Slide 3 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
HP Control Oil
(example for training purposes only!)
Slide 4 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
(example for training purposes only!)
Steam
Slide 5 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Control
(example for training purposes only!)
Slide 6 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Drain System
(example for training purposes only!)
Slide 7 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Condensate System
(example for training purposes only!)
Slide 8 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Control
(example for training purposes only!)
Slide 9 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 10 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Function Diagram Turbine Controller
Legend and Explanations
Slide 11 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Generator
(example for training purposes only!)
Slide 12 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Bearing Temperature
(example for training purposes only!)
Slide 13 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 14 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Curves
(example for training purposes only!)
Slide 15 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Messages
(example for training purposes only!)
Slide 16 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Introduction
Slide 17 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
1. Live steam
temperature TE001
2. 50 and 100 %
measuring at HP steam
main stop valve (TE
038)
3. Flange temperature
(TE176)
Slide 18 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Explanation of 50% and 100%
Temperature Measurement
S – wall thickness
Thermowell Thermocouple
Slide 19 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Note!
Beginning of operational readiness
Operational readiness of the plant should be established two
hours prior to the planned startup time of the turbomachinery.
Measures
In the PCS7 operator control and monitoring system select the process
display Oil system
The oil pump 4221 and emergency oil pump 4241 are shut down and
their autocontrols are switched off.
The duplex lube oil coolers 4400/4420 are switched such that only one
cooler is in operation.
Cooling water is being supplied to the oil coolers and the water chambers
are vented.
Slide 21 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 22 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up and Shutdown Operation 4
Checks prior to start up
In the PCS7 operator control and monitoring system select the process
display HP Control Oil
The oil pumps 4279, 4280, and cooling oil pumps 4284, 4285 are shut
down and their autocontrols are switched off.
Cooling water is being supplied to the oil coolers 4410, 4412 and the
water chambers are vented.
The duplex control oil filters 4530 are switched such that only one filter is
in its operation position.
Isolating valves to the differential pressure switch PDIS 367 are open.
Isolating valve to the oil accumulator 4605 and 4606 are open
the drain valve of the oil accumulato 4605 and 4606 are closed
Slide 23 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 24 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up and Shutdown Operation 6
Local drain valve check
Condensate Injection
Isolating valves up- and downstream of solenoid valve 6020 are open
Drain Check
The following drain valves are opened manually at the location of the
valves:
Drains of main steam line
Warm-up line near the ESV's partly
Drains on extraction non return valves 2350, 2351
Bypasses with steam traps:
E036, E038, E008, E1, E009, E2, E015, A1, E050 at the drain collector
E198 and E199
Slide 25 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 7
Evacuation and condensing system
Slide 26 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 8
Evacuation and condensing system
¾ Check both isolating valves in the air suction lines at the condenser
are open
¾ Check hand wheels of the pressure relief valve are in the closed
position
¾ Check that all steam and air gate valves at the steam ejectors are
closed
¾ Check drains of inter/after coolers: valves up- and downstream of
the condensate traps must be open, the bypass valves must be
closed
¾ Check that the condensate valves up- and downstream of inter/after
coolers are open
Slide 27 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Startup Automatic
(example for training purposes only!)
Slide 28 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 9
Lube oil system
Slide 29 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 10
Seal steam supply
¾ Set seal steam controller to AUTO and adjust the set point to
10 mbar
Slide 30 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 11
Condensing system
Slide 31 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 12
Seal steam supply
Note!
The maximum permissible period for operation of the turbine with the
sealsteam supply system activated and without operating steam is four (4)
hours. During this period, the turbine must be in turning gear operation
however. At the end of this period, operation with seal steam must be ceased
at least until the rotor and gland casing system has cooled adequately.
The turbine manufacturer will not be liable for any damages resulting when
these guidelines are not observed.
Slide 32 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 13
Warming-up main steam line
¾ Open the main steam header valve and warming up the main steam
line 30 to 50 °C higher than saturated steam temperature
Slide 33 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 34 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 15
Start-up curve
Slide 35 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 36 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up 17
Rotor Sticking Protection and Critical speed band
Slide 37 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Loading
1. starts the excitation system of the generator and raising the voltage.
2. starts the synchronsing system to adjust the speed (frequency), voltage and
phas angle to the existing grid parameters
4. applying a small amount of load to avoid the response of the reverse power
protection
Slide 38 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Start-up curves depending on casing temperature
Increase of turbine load
casing wall temperature TE176 before start-up
Slide 39 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Slide 40 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Initation of HP inlet pressure controller
In the operator control window, the setpoint and actual value for the
inlet pressure are displayed for the load that is currently set in the
"Manual limiter mode".
The required setpoint is specified for the boiler by making several small
step changes in the setpoint.
Set the inlet pressure controller to "Automatic" when the required actual
value has been reached.
Slide 42 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Lube oil temperature and filter diff.-press.
The oil temperature to the bearings is regulated automatically by the
oil temperature control valve 5550 to 45 ±6 °C. To accomplish this,
cold oil is mixed with hot oil at port B (bypass) via port C.
Hot oil is routed to the standby filter via the filling valve to heat
the vent line.
Danger!
Risk of escaping oil - potential burn hazard!
The filling valve must be closed and the body drained via the discharge
cock with the vent is open before opening the casing.
Slide 44 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
The body can be filled via the filling valve after the filter elements
have been cleaned. Warming up of the vent line is an indication
that filling has been adequate and successful.
Note!
Leave the filling valve open
It has proven useful in the past to always leave the filling valve open so
that in the event of a fault hot oil can flow to the bearings while switch-over
is made to the standby filter.
Slide 45 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Shutdown
Shutdown concept
The "SHUTDOWN" step program has the task of shutting down the
turbine from power operation to a defined state of turbine standstill.
The SHUTDOWN program can be initiated
- From the unit control level
- By initiation of a turbine trip or
- Manually from the control room
Slide 46 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Controlled via the speed, the jacking oil pump and the hydraulic turning gear
cut in.
The turning gear begins turning operation of the turbomachinery when the
overrunning clutch engages:
The supply of seal steam to the shaft seals is discontinued as soon as there
is no longer a vacuum present in the turbine.
Slide 47 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Emergency shut-down 1
In the case of less severe danger to the turboset, the turbine can be
also be unloaded by reduction of the speed or load setpoint at the
turbine controller
Slide 48 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Emergency shut-down 2
Note!
Measures subsequent to emergency tripping
All the necessary measures described in the
operating instructions for "Shutdown" must also be
carried out or be initiated subsequent to emergency
tripping.
Slide 49 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Synchronization 1
The level of the generator voltage and the voltage downcircuit of the machine
transformer are shown in the process display.
Slide 50 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Synchronization 2
When voltage is nearly the same downcircuit and upcircuit of the generator
circuit-breaker, press the button "Start" in the synchronization window, after
previously pressing the button "Syn".
If no faults or blocking conditions are present, the field "running" will then
show the execution of the automatic synchronization procedure.
This is shown in the process display by the symbol for the generator
circuit-breaker.
Slide 51 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Loading of Turbomachinery 1
The subgroup control (SGC) "Load" for the load controller is set to
"Automatic".
After selecting the faceplate for the load controller the load setpoint can
be set to the required load.
Slide 52 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
The load controller modifies the load applied to the turbine using the
load increase gradient that is calculated and given in the startup
curve; this gradient is a function of the temperature measured at
measuring point TE 176 and is displayed in MW/min under the load
control symbol.
Note!
Limiting of load increase
Limiting of the load increase when applying a load to the turbine prevents
the defined temperature change rates from being exceeded in thick-walled
items, such as turbine rotors, inlet end section, outer casing.
Slide 53 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Allowable Load Changes out of
thermal steady conditions
Slide 54 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Unloading
Attention!
Observe the load change rates
The load change rates specified in 0-2040-6497-51, Load Changes, may
not be exceeded.
Slide 55 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Testing of Reverse Power Protection 1
Removing the Load and Testing of Turbine Reverse Power Protection
Loading of the turbomachinery can be reduced by entering lower
setpoints for load control and higher ones for inlet pressure control.
The long-term reverse power protection, as the most important turbine
protection system, is tested as follows:
Switch from inlet pressure to speed control;
Reduce the load by entering stepwise lower speed setpoint SP values,
e.g. –5 rpm per step down to 1 MW; the speed control still operates as
a P-action controller whose setpoint is considerably higher than the
process speed PV. Note the value of the SP.
Now, enter a speed setpoint that is markedly lower than the rated
speed 3000 rpm, e.g. 2900 rpm, to force the generator to
accommodate reverse power.
The turbine control valves then close completely due to the great
divergence between the setpoint and actual value.
After a trip time of around 20 seconds, the generator circuit
breaker opens and a corresponding message is issued.
Slide 56 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Note!
Generator circuit-breaker fails to open
In the event that the generator circuit-breaker does not open, the
control valves must be re-opened by entering a higher speed
setpoint as displayed and noted at 1 MW
Danger!
Do not initiate turbine trip - risk of windage in the turbine!
In the event that the reverse power protection system fails, do not
initiate turbine trip, as the turbine is held at rated speed by the
generator and, since the control valves are closed, no cooling steam
can flow through the turbine
Slide 57 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Startup and Function Tests
of Lube Oil System (1)
In the PCS7 operator control and monitoring system select the process
display "Oil System".
Switch on the he oil tank heater, set it to "AUTO" and heat the oil in the
tank up to 35°C.
The emergency oil pump must start due to the low lube oil pressure
Preselect oil pump 1 or 2 as main oil pump and set the standby oil pump
to "AUTO".
the standby oil pump must start due the low lube oil pressure
Slide 58 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Set the emergency oil pump to "MANUAL", STOP the pump and set it
back to "AUTO"
Set preselected main oil pump to "AUTO", set the standby oil pump to
"MANUAL" and STOP the standby oil pump
the preselected main oil pump must start due the low lube oil
pressure
Slide 59 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual shutdown of oil system
Do not shut down the lubricating oil system before the hydraulic turning
gear has been switched off and it has been established that the
turbomachinery has come to a complete standstill.
Set the auxiliary oil pump autocontrols to "Manual" and switch it off
Slide 60 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Danger!
Danger - rotating shaft!
All service work in the area of the rotating shaft should be concluded.
Ensure that no persons are standing in the vicinity of the rotating shafts.
Clear the turbine and generator rotor for turning gear operation.
If the jacking oil pressure exceed the 70 bar, the hydraulic turning gear
starts up and accelerates the turbomachinery to the specified speed.
Slide 61 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Manual Shutdown of Turning Gear
Shut down the hydraulic turning gear once the temperature at the HP
outer casing (see measuring point TE 176) has fallen below 150°C:
Slide 62 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Limit Monitoring
• These devices are designed and set such, that they intervene in advance
of the corresponding protective devices and their associated trips in an
attempt, to prevent disruption of operation where at all possible. The
devices are designed and adjusted such that they act before the
corresponding protective devices and, where possible, prevent protective
devices being tripped, thereby causing an outage.
• The task of protective devices is to shut down the turbine itself, or other
sections of the plant, as soon as conditions occur which pose a risk to
the turbine.
Slide 63 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Important criteria for recognizing during normal
operation
¾ the speed.
Slide 64 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
The radial bearings keep the turbine rotor at a central position with respect
to the fixed guide blade carrier and the outer casing. Bearing damage can
trigger substantial consequential damage as a result of bridging of
clearances and thus give rise to repair and outage costs.
The bearing ability of the lubricating oil film is dependent mainly on the
viscosity of the oil employed. This is strongly dependent on the
temperature of the oil film.
Slide 67 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Pressure Distribution in an elliptical bearing
Slide 68 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Types of damage
Apart from damage due to foreign bodies, a distinction can be made between
the following main types of damage:
Slide 69 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Scoring at Tilting Pads
Cracking
Inter-granular craze
cracking on white metal
due to overheating and
partial seizure.
Overload on a small
steam turbo-generator
thrust bearing due to
water passing through the
turbine.
Slide 71 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Pitting
Electrical discharge
erosion on a thrust pad
Pitted zone
Unaffected zone
Slide 72 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Excessive temperature
Slide 73 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Vibration
Vibration measurement provides an insight into
changes in the running condition, caused by:
¾ Blade fracture,
¾ deposits,
¾ erosion,
¾ changes in alignment,
¾ shaft bowing,
¾ temperature-related imbalance;
¾ Dynamic overloading, in particular at the bearings. This leads to
premature decline of the load-bearing capacity.
¾ Reduction of radial clearances that are significant during non-steady-
state operating conditions, especially during startup.
Slide 77 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
The End
Slide 78 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training