30th March 2015 TURBINE AUX1

PART 4 THERMAL CYCLE AND TURBINE AUX.

CONTENTS
CHAPTER DESCRIPTION
1 Main Body of Steam Turbine and Line Drainage System
2 Gland Sealing Steam Of Steam Turbine System And
Vacuum System
3 Extraction Check System
4 Hp & Lp Bypass System
5 Condensate Water System
6 Deaerator
7 Boiler Feed Water System
8 Lubrication Oil of Steam Turbine System
9 Turning Gear Device and Shaft-Jacking Device Of
Steam Turbine
10 Circulation Water System
11 Closed Circulation Cooling Water System
12 Generator Seal Oil System
13 Stator Winding Cooling Water System
 CHAPTER 1
Main Body of Steam Turbine and Line Drainage System

CONTENTS:
1 Main Body of Steam Turbine and Line Drainage System
2 System for Drain Flash Box
3 Condenser
4 Single-Chamber Balance Vessels
1 Main Body of Steam Turbine and Line Drainage System
1.1 System Function
The main function of drainage system is to discharge the condensed water in the main body of steam turbine
and its line when the assembling unit starts, stops or operates under low load or under abnormal conditions so as to
prevent the excess of water from vending the rotor of steam turbine or damaging the internal parts and other serious
accidents.

1.2 Brief Introduction about System

1.2.1 The drainage system is designed by following the relevant regulations in the “Guidelines for Preventing Excess
of Water for Steam Turbines in Power Plants” and absorbing the successful experiences of relevant drainage system
improvements in China.
1.2.2 According to the responsibility of steam turbine works and the common practice of power stations in China,
the responsible range of drainage system includes the drainage of main body of steam turbine and main body line,
i.e. the drainage of main steam valve and line between it and the steam turbine, the drainage of each steam extraction
check valve and line between it and the cylinder, the drainage of exhaust check valve for HP cylinder and line
between it and the HP steam drain, the drainage of HP steam source control station, auxiliary steam source control
station, the overflow control station with self-sealing steam seal system, valves and line as well as the mother pipe
and branch pieces of steam supply. The details can be found in the drainage diagram of main body of steam turbine
and its line. Other drainages to be connected with the drainage flash vessel besides the main body drainages are
illustrated by the dotted lines. The drainage line specifications are only for reference.
1.2.3 The system adopts two side-basket type drainage flash vessels that are placed at the two sides of condenser
shell. Nine drainage manifolds are connected to the flash vessel at the steam turbine side for receiving the
drainage of main body of steam turbine and its line, the drainage of HP mean steam conduit, re-heat steam
conduit and the continuous drainage of LP heater, etc. Six drainage manifolds are connected to the flash vessel at
the motor side for receiving the drainage of HP and LP heaters during accidents as well as the drainage of
deaerator overflow.
1.2.4 Electric control drainage valves, manual cut-off valves and throttle sets are installed on the drainage branch
pieces of main body of steam turbine and its line. The manual cut-off valve shall normally be locked or be fully
opened by other means.
1.2.5 The drainage lines in the system diagram adopt different materials depending on different temperatures.
When the steam temperature at the drainage point is more than 400℃, alloy-steel pipe is used.
1.2.6 The supply range of system includes the main body of steam turbine, drainage throttle set from the main
body lines and electric control drainage valves. Other universal valves, pipes and accessories are supplied by the
project.

1.3 Control Requirement

1.3.1 Start-up and Shutdown of Assembling Unit
Before the start-up of assembling unit, confirm the condenser working properly and make sure certain
vacuum formed. The control system of DEH automatically starts the electric control drainage valve on each
drainage branch piece. When the load is increased to 10%, the electric control drainage valve in the HP section is
closed; when the load is increased to 20%, the electric control drainage valve in the MP section is closed; when
the load is increased to 30%, the electric control drainage valve in the LP is closed. The DEH provides signals
for all the above movements to automatically realize the close of electric control drainage valves through the
interlocking device of auxiliary equipment. The movements can also be displayed with the lights in the
centralized-control compartment. During the shutdown or the reduction of load, when the load is reduced to
 30%, 20% and 10%, the DEH provides signals through the interlocking device of auxiliary equipment to
automatically open the electric control drainage valves in the LP, MP and HP sections. The movements can also
be displayed with the lights in the centralized-control compartment. Refer to the drainage system part in the
diagram of electric monitoring protection system of steam turbine for details.
1.3.2 When the steam turbine trips to stop due to accidents, each electric control drainage valve will automatically
open.
1.3.3 When the HP and LP heaters stop working, the relevant electric control drainage valves will automatically
open.
1.3.4 When the auto opening fails, the operator can manually and remotely open the electric drainage valves in the
control compartment.

1.4 Operation
1.4.1 The operator much master the handling measures for excess of water in the steam turbine under various
working states as well as take quick and specific actions on the preliminary forecast of steam turbine flooding.
1.4.2 The load point for auto drainage mentioned in 4.1, the power plant can adjust it according to actual operational
experience. In particular, when the steam turbine restarts a while after tripping and rejecting the load, the operator
must decide according to the actual situation whether the Electric control drainage valves of main steam conduit and
HIP cylinder shall be opened and the operation procedures shall be fixed to prevent the boiler heater and main steam
line from cooling down dramatically or cause excessive temperature difference between the upper and lower
cylinders due to the pressure reduction of main steam system, etc.
1.4.3 Use thermometers, thermocouples or other methods regularly to check whether each drainage conduit is
obstructed.
1.4.4 During operation, if the steam turbine is flooded, the cause shall be identified immediately. At the same time,
the water source shall be isolated and the accumulated water shall be drained. If the speed is at the rated one and the
load is carried, the problem shall be handled according to the actual situation.
1.4.5 During the shut-down for repairing period, the inside of throttle set shall be cleaned to avoid orifice from being
blocked.

1.5 Test, Inspection and Maintenance

1.5.1 All the electric control drainage valves shall be operated for testing purpose
each month. Visually inspect the monitor of steam turbine to ensure that the meters for the differential expansion,
cylinder expansion, shaft bend, vibration, rotor axial displacement, metal temperature and other are normal with
correct readings.
1.5.2 Use contact thermometers or thermocouples every three months to inspect all the drainage lines to see whether
they are blocked. In the meanwhile, check whether the drainage valves are flexible and the throttle sets are
unobstructed.
1.5.3 During the shutdown for repairing period, inspect all the electric control drainage valves, interlocked devices
and controllers. All the drainage valves controlled by water-level signal shall go through the water-level movement
mechanism test. All the throttle sets shall be cleaned. The inside of obstructed lines shall be inspected to ensure
smooth drainage.
1.5.4 Cleaning the throttle set: disassemble the nuts and bolts from the sealing flange, remove the sealing flange and
washer, remove the throttling cock with a hexagonal head wrench, flush out the defilement in the orifice (Refer to fig
0-1-2 for the structure of throttle set).

2 System for Drain Flash Box

2.1 Application
Some expansion cooling device shall be equipped with certain volume in the steam turbine and the pipeline
drainage system, to eliminate the pressure energy at drainage points and to cool the temperature of drainage water
after expansion down to the extent acceptable by the collection device of condensate water. Under the different
operating conditions such as startup in different modes, normal running and shutdown with sliding parameter, the
drainage water from the steam turbine and the drainage points is discharged into the main drain pipe and the drain
flash box, and then lowers down its pressure rapidly after full expansion. The volume of the Drain Flash Box can
ensure that the pressure inside the flash box will not affect the smooth drainage at the lowest energy-level drainage
points of unit when all the drainage valves are open. After cooling down with spray water, the medium temperature
and pressure into the condenser can satisfy the demand for normal operation of the unit. The steam and condensate
after expansion cooling down is discharged into the steam and water space of the condenser, respectively, which
both ensures smooth water drainage of the unit and the pipeline, and recycles the working medium.
2.2 Structure
The fully welded Drain Flash Box consists of shell, drain spray pipe, spray water pipe, crossover pipe, buffer
plate, waveform expansion joint and other parts. To facilitate installation and arrangement of the power station, the
exterior of the Drain Flash Box is designed in a rectangular structure and it is suggested to place the drain flash
boxes between the main frames of steam turbine on both sides of the condenser. Due to the limits with layout
position and drainage amount of the drainpipe, and arrangement of other auxiliary devices for the power station, as
well as the drainage requirements, the two drain flash boxes are different in external interface.
The drain water from the unit is converged into the main pipeline and enters the Drain Flash Box through drain
crossover pipe and drain spray pipe on the drain flash box. The baffle plates of spray nozzle on the crossover pipe
and drain spray pipe can further reduce the pressure for drain water into the steam flash box and can ensure smooth
drainage for all the drainage points. The cooling water (condensate water) sprays into the Drain Flash Box through
the nozzles on the spray water pipe, and the flashing steam in the drain flash box quickly lowers down its
temperature and condenses, thus to increases the expansion capacity of the drain flash box. Supporting rod and cross
brace are also equipped inside to enhance the rigidity of steam flash box. Buffer plates are fitted at the steam and
water outlets of the drain steam flash box, to avoid the steam and condensed water inside the flash box from
affecting the normal operation of the condenser due to direct impact on the parts inside. The drain flash box has
manhole for maintenance and cleaning.

2.3 Precautions for Installation and Operation

2.3.1 Rectangular Drain Flash Box, also called the tabbing-type Drain Flash Box, is installed on both sides of the
condenser. Refer to drawing of cut hole and accessory for condenser in different projects for actual elevation and
location of installation.
2.3.2 The Drain Flash Box Ⅰ, located beside the steam turbine, has totally 9 drainage pipes to accommodate the
drainage from the steam turbine proper and the pipeline, low-heating drainage, and the startup of IP cylinder
drainage, etc. Refer to the Drain Flash BoxⅠand the drainage system drawing of the project for detailed locations of
connecting interfaces between different drainage points and the drain connecting pipes.
2.3.3 The Drain Flash Box Ⅱ, located beside the generator, has totally 6 drain spray pipes to accommodate the high
pressure heater accidental drainage and low pressure heater accidental drainage as well as overflow drainage from
deaerator, etc. The interfaces of different drain connecting pipes are not interchangeable. Refer to the Drain Flash
Box Ⅱand the drainage system drawing of the project for detailed locations of connecting interfaces.
2.3.4 The branch drain pipes, when converging with the main drain pipe, shall be arranged and classified as per
drainage pressures of all drainage points. Branch pipes with relatively higher pressure and connected with the same
main drain pipe shall be switched in at a relatively farther distance from the flash box and those with lower pressures
shall be connected with the flash box at a nearer distance. All the branch pipes shall be connected with the main
drain pipe in a 45℃ angle with the direction towards the flash box, to ensure a smooth drainage at different points.
2.3.5 Airtight test shall be performed together with the condenser after proper installation of the Drain Flash Box
and proper connection of the pipeline along with the condenser. In test, the Drain Flash Box shall be temporarily
braced.
2.3.6 The Drain Flash Box Ⅰmust be sprayed when the unit load is below 30%. The Drain Flash Box Ⅱmust be
sprayed when the accidental drainage valve of heater is actuated. The spray water and spraying volume can be
regulated through the valve set on the spraying pipe, to ensure that the temperature within the drain flash box is less
than 80℃ and the pressure is lower than 0.6kgf/cm2 (absolute). The design water-spraying pressure for each steam
flash box and set the pressure behind valve is 1.0MPa (a).
2.3.7 The spraying pipeline shall be set with filter screen not less than 30 meshes per inch to avoid blockage of the
spray nozzle.
2.3.8 The maximum operating load of the Drain Flash Box generally appears in the process of starting the generating
system. Therefore, attention should be paid to monitoring the running status of drain flash box when a new set of
generating system is put into operation, and when the unit startup, shutdown or the heater accidental discharge
valves are all open. When its temperature and pressure are too high or become abnormal, it is necessary to check all
the drainage points for improvement. The operating laws of the drain flash box should be well known and the
opening degree of the water injection valve should be set well, so that the generating system can operate normally.

3 Condenser
3.1 Applications
As one of the major auxiliary equipment in the steam turbine, the condenser is primarily used to condense the steam
discharged from the steam turbine through recirculated cooling water, establish and maintain the required vacuum
state in the turbine discharge space, and recover the clear condensate to feed the boiler.

3.2 Main characteristic parameters

Condenser type: N-19000
Cooling area 19000m2
Cooling water temperature 33℃
Cooling water pressure 0.4MPa (g)
Cooling water quantity 34500t/h
Steam pressure 10.13kPa (absolute pressure)
Steam flow 656t/h
Furthermore, a well installed condenser without water is about 380t weight (except LP heaters, a temperature-
decreased pressure reducer, and a drain flash tank). During normal running, the water in a condenser is about 310t
weight; when the steam chamber is full of water, the water is about 820t weight.
3.3 Working process
Under normal operations, cooling water is pumped by a water circulating pump to the two front water chambers
in the middle, and then, by way of the two groups of pipe bundles in the middle, flows into the back water chambers,
then turns around and goes through the two groups of pipe bundles in both sides and flows back to the front water
chambers in both sides, and finally flows out of the condenser. Steam enters into the condenser from the turbine
exhaust outlet, then is scattered into the full length of the pipe uniformly, and then enters into the main pipe bundle
zone through the pipe bundles in the middle and in both sides, and finally is condensed through the heat exchange
with cooling water pipe wall; part of the steam, by way of the channels in the middle and in both sides, enters into
the hot well to reheat the condensate to reduce condenser depression. The rest steam-gaseous mixture suffers heat
exchange in the air cooling zone once again, and a little steam and gaseous mixture is drawn out by vacuum
pumping equipment finally. The condensate is collected in the hot well and pumped out by condensate pump, and
input into the full-flow condensate system after boosting pressure.

3.4 Condenser testing

 In order to ensure the unit’s running performance, before a condenser is formally put into service, a hydraulic
pressure test must be conducted for the water side, a water filling test must be conducted for the steam side, and a
gas tight test must be conducted for the vacuum system.
3.4.1 Hydraulic pressure test for the water side
The hydraulic test pressure for condenser is 0.525MPa, and the water temperature shall be lower than 5. The
test procedure is as follows:
3.4.1.1 Close all the valves connected with water chambers.
3.4.1.2 Fill clean water and load a pressure to 0.525MPa (gauge pressure at the water chamber bottom).
3.4.1.3 Keep the pressure for 30 minutes.
During testing, it has to be noted that there shall be no leakage and seepage in the chamber flanges, manholes,
and all attachment welds and the whole water chamber cannot deformation. If any problem is found, testing shall be
stopped immediately and remedial actions shall be taken. If within the time specified the check work cannot be
finished completely, then the pressure hold time shall be prolonged.
3.4.2 Water filling test for the steam side
For the purpose of checking the installation of shell and cooling pipe, a water filling test is necessary prior to
the operation of a condenser; however, it cannot be conducted with the hydraulic pressure test in the water side
simultaneously. The water temperature for a water filling test shall not be lower than 15. When a water filling test
is conducted, temporary supports shall be available for the condenser. Prior to the restart of a steam turbine just after
an overhaul, a water filling test is also required.
The test procedure is as follows:
3.4.2.1 Close all the valves connected with the shell.
3.4.2.2 Fill clean water (the filling height shall be 300mm higher than the joint between condenser and LP cylinder).
3.4.2.3 Maintain such a height for 24 hours.
During testing, if any leakage or seepage in the joints between cooling pipe and end pipe sheet and in the
various attachment welds of the shell or the whole external wall of the shell is deformed, the test shall be halted
immediately. The clean water shall be discharged completely. The causes shall be found and some measures shall be
taken.
3.4.3 Gas tight test for the vacuum system
In order to test the unit’s installation level and learn about the tightness of the whole vacuum system, the gas
tight test shall be conducted. The testing method is to close the electric control valve in the entry of the air extractor
to measure the falling down of vacuum degree’s speed. During testing, the stipulations or requirements related to gas
tight test stipulated by Steam Turbine Start and Operation Illustration shall be followed.
3.4.3.1 Close the electric control valve in the air extractor entry. Note the condenser vacuum shall drop slowly
(during testing, the load shall be 80%~100% of the rated load).
3.4.3.2 Record the vacuum reading per minute a time.
3.4.3.3 Open the electric control valve in the air extractor entry 5 minutes later.
3.4.3.4 Take the average from the third minute to the fifth minute as the speed of vacuum falling.
3.4.3.5 Record the load in the current time and the average of vacuum falling.
According to the testing results, the installation level of the whole vacuum system of the unit can be
determined. If the vacuum falling rate is less than 0.13kPa/min (1mmHg/min), then the installation is excellent; if
less than 0.27kPa/min (2mmHg/min), it is good; if less than 0.4kPa/min (3mmHg/min), it is acceptable. If the
vacuum falling rate is greater than 0.67kPa/min (5mmHg/min), the unit shall be halted to find out causes and cannot
be restarted before the trouble is removed.

3.5 Condenser running

3.5.1 Definition of working pressure
 The manufacturer defines the condenser pressure as the absolute pressure. Due to the difference between the
local atmospheric pressure in the plant installation site and the standard atmosphere pressure, the condenser pressure
measured on site shall be converted into the absolute pressure for pressure assessment:
P k = Po – P p
Where: Po ---- local atmospheric pressure, kPa;
Pp ---- measured condenser vacuum degree, kPa;
Pk ---- condenser absolute pressure, kPa.
Or Pk = 0.13332 (ho-hp)
ho ---- local atmospheric pressure, mmHg;
hp ---- measured condenser vacuum degree, mmHg;
Pk ---- condenser absolute pressure, kPa.
3.5.2 Condenser Startup
Be sure to put the condenser into service prior to the start of steam turbine. First put the air extractor into service
to form a vacuum to some extent within the condenser. Prior to condenser start, check all valves associated with the
condenser to make them in a correct state. Meanwhile, open the air release valves on the tops of both front and back
water chambers. In order to start the condensate pump, fill the condensate from the water tank to the hot well in
advance (the filling level is determined according to the suction head of the condensate pump). Then recycle the
condensate.
When the following cases occur, stop the start:
3.5.2.1 Major meters such as temperature meter, vacuum gauge, and condenser water gauge fail to function.
3.5.2.2 The automatic low vacuum safety device fails to function.
3.5.2.3 Condensate adjusting valves and circulating water valves fail to function.
3.5.3 Half side operation of condenser.
When cooling pipes become dirty and need half-side cleaning, or cooling pipes are damaged and need
plugging operation, the condenser allows half-side operation. During half-side operation, the unit reduces its load to
60% T-MCR.
3.5.4 Maintenance of Condenser Operation
Just like steam turbine, the on-load maintenance of condenser resides in the working conditions of the
supervising device as well as the safety and operating condition parameters of the condenser.
The measurement items for operation monitoring are tabled as below:
No Measurement items Unit Instrument installation Instrument name
site
1 Atmospheric pressure MPa(mmHg) Panel Atmospheric
pressure meter
2 Condenser pressure MPa(mmHg) Condenser throat Differential
manometer
3 Cooling water inlet ℃ Against the cooling Thermometer
temperature water inlet
4 Cooling water inlet MPa Against the cooling Pressure gauge
pressure water inlet
5 Cooling water outlet ℃ Against the cooling Thermometer
temperature water outlet
6 Cooling water outlet MPa Against the cooling Pressure gauge
pressure water outlet
Condensate ℃ In front or back of Thermometer
7
temperature condensate pump
Condensate flow t/h In condensate pipe Flow meter
8
quantity
 Temperature of ℃ At air extraction Thermometer
9 extracted steam-air pipes
mixture
Besides, the water level of hot well and the quality of condensate shall also be monitored. The water level
of hot well is displayed by a water level indicator. During normal operation, the normal water level in the hot
well shall be 0.775m higher or so than the inner side of the bottom plate. For the purpose of safe operation, too
high water level or too low water level is not allowable. To check the condensate quality, the oxygen content, salt
content, hardness, and alkalinity shall be monitored. Under normal operations, the oxygen content shall be no
greater than 30μg/L.
3.5.4.1 In order to ensure the cleanliness of condenser titanium pipes, such cleaning measures as rubber ball
rinsing, half-side rinsing, circulating water dosing, or the combinations of them shall be taken. A power plant can
determine to adopt which cleaning combination based on the quality of circulating water and the operating
experience.
3.5.5 Load-dropping operation and condenser out-of-commission
Prior to the step-out of steam turbine, the load steps down, so does the steam discharged by steam turbine.
During a load-dropping operation, it has to be noted that whether the condensing water level and vacuum are
normal. If not normal, some measures must be taken to bring it back to the normal water level; meanwhile,
attention shall be given to whether the exhaust temperature is normal.
If the idling time exceeds one week, the water in the condenser must be fully discharged and dried against
corrosion.
3.5.6 Operation troubles and treatment
Condenser running failures primarily result from the raising of condenser pressure (falling of vacuum). The
raising of condenser pressure affects not only the economical efficiency of the whole unit but also the life and
reliability of the unit. If condenser pressure rising is found, the causes shall be identified and then removed.
3.5.6.1 Check up the exhaust temperature and condensate temperature, and check whether the load varies.
3.5.6.2 If there are operations at that time, they must be suspended. Restore it to the original state immediately.
3.5.6.3 Check whether the circulating water inlet and outlet pressures and temperature vary.
3.5.6.4 Check whether the air extractor works normally.
3.5.6.5 Check the water level of hot well and whether the condenser booster pump works normally.
3.5.6.6 Check other factors that have an influence on vacuum.
During checking, if the condenser pressure ascends to the unit’s alarm limit or halt limit specified by Steam
Turbine Starting and Running Specifications, corresponding alarming and halting shall be conducted.
For an emergency shutdown, the vacuum breaking valve shall be opened. For a normal shutdown, it is not
allowed to open the vacuum valve.

4 Single-Chamber Balance Vessels

As a single-chamber balance vessel, this device is installed on the side plate of the condenser hot well. The
vessel has two interfaces, used to connect with the water level transmitter, for remote transmission monitoring and
warning of water level signal.
The balance vessel is installed on site. The elevation of installation indicated in the graphic should be ensured and
the exact installation location shall be determined with specific project.
CHAPTER 2
Gland Sealing Steam of Steam Turbine System
And Vacuum System
CONTENTS
1 The turbine steam seal system
 2 Water Filter of the turbine steam seal system
3 steam filter of the turbine steam seal system
4 Vacuum pump
1 The turbine steam seal system
1.1 Overview
The turbine steam seal system is primarily used to prevent steam from leaking outwards along the shaft ends of
HP and IP cylinders and even flowing into the bearing box and resulting in water polluting lubricating oil; it is also
used to prevent air from seeping into the steam cylinder and as a result destroying the vacuum of the unit.
The self sealing turbine steam seal system refers to the system in which the steam escaped from the shaft end
steam seals of HP and IP cylinders is, after spray desuperheating, used for the gland sealing steam supply for LP
shaft ends during the normal operation of a unit. The surplus leaked steam flows to the LP heater or condenser
through an overflow station. During the unit’s start or low load phase, the gland sealing steam supply comes from
the outside. From the start to the operation at full load, the turbine steam seal system can conduct automatic
switching in accordance with the unit’s gland sealing steam supply requirements.
The system has the features of simplicity, safety, reliability, and good applicability.

1.2 System composition and major equipment

The system consists of the steam supply and leakage pipes of gland seal, the valve-stem steam leakage pipes of
main steam valve and main steam control valve, the valve-stem steam leakage pipes of IP combined steam valve,
and other related devices.
A three-valve system is adopted for gland steam supply, that is, under all operation conditions, the steam supply
pressure for a steam turbine is controlled via three control valves, namely, HP steam supply control valve, auxiliary
source supply control valve, and overflow control valve, all of which ensure that the set steam pressure in the steam
supply main pipe can be maintained automatically under any operation condition. The auxiliary source steam supply
station has two steam supply sources. Except the reheating section of the unit itself, auxiliary steam supply from
other than the unit is also available. During start or operation at low load, the auxiliary steam enters into the self-
sealing system through the control valve of the auxiliary source station. The above three control valves, their fore-
and-aft valves, and the necessary by-pass valves make up three pressure control stations. Furthermore, in order to
meet the LP cylinder gland steam supply’s temperature requirement, a spray type desuperheater is set up in the main
pipe of low-pressure shaft gland steam supply. The temperature control station is used to control the working water
jet capacity, which as a result realizes that the desuperheating steam meets the low-pressure shaft gland’s steam
supply requirement.
The actuators for all control valves in the system runs in a [https://www.blogger.com/null] [j1] [file:///C:
/dell/O&M%20manual10-06-08/T-
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DCS. Import components are adopted for all the control valves and actuators, which can perform stably and reliably.
In order to ensure that the main steam supply station is at a hot bank status all along the normal operation, the
bypass with throttling orifice plates is set up in front of the control valve. During the normal operation, the steam
from the gland sealing steam supply main pipe goes to the pressure control station through the bypass with throttling
orifice plates [https://www.blogger.com/null] [j2] [file:///C:/dell/O&M%20manual10-06-08/T-
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state.
In the system there are also set up a steam seal heater and two shaft seal fan (one of them as a standby), which
are used to extract the leaked steam (or air) in the final section of shaft gland chamber and to keep the chamber run
at a minor negative pressure.
In order to prevent foreign substances from entering into the shaft gland, the Y-type steam filter is set up at
each branch pipe of steam supply. In the steam supply main pipe there is set up a safety valve with the set-pressure
of 0.3 MPa(a), which can prevent the occurrence on the over high steam supply pressure.

1.3 System operation

1.31 Preparation for start
1.3.1.1 Shut down all pressure regulating stations, put through the steam supply source, and adjust the temperature
of the steam supply line to a superheating temperature.
1.3.1.2 Confirm that the instruments and meters of the system are normal.
1.3.1.3 Confirm that the barring of steam turbine has been put into service.
1.3.1.4 Confirm that the recirculation of condensate has been established.
1.3.1.5 Open the manual and electric check valves of all the pressure control valves and temperature control valves.
1.3.1.6 Put through the gas source of regulating valves and the EPSs’s of transducer. The gas source is compressed
air which the pressure is 0.6MPa (absolute).
1.3.1.7 Open the manual gate valve in the cooling water (condensate) line of the steam seal heater, which puts the
steam seal heater into service.
1.3.1.8 Open the shaft seal fan, and open the electric butterfly valve in the fan’s admission line. The fan is put into
service normally (one for service, the other for standby). The gland seal’s steam return line maintains a negative
pressure, and the pressure is adjusted to about 95KPa (absolute).
1.3.2 Start
1.3.2.1 Cold start
a. In the cold start, the steam is supplied by the auxiliary source station.
Before the regulating valves of the auxiliary source station, the steam’s parameter is:
a). The temperature of steam supply: 210~260℃,
b). The pressure of steam supply: 0.6~0.8MPa.
b. After closing the control valves in both HP source station and overflow station, open the electric check valves in
the control valve line of the auxiliary steam supply source station; confirm that the system is normal input and runs
automatically in accordance with the following steps:
a). Barring, rolling, and low load phase
The gland sealing steam supply comes from the auxiliary source, and the pressure of the steam supply main pipe
is maintained at 0.124MPa (absolute).
b). 25%-load to 60%-load phase
When the unit load ascends to 25% of the rated load, the cool head of reheat pipe can fulfill all the requirements
of gland sealing steam supply, the steam is supplied by the cool head of reheat pipe, and the main pipe pressure
is automatically maintained at 0.127MPa (absolute).
c). More than 60% load phase
When the load is increased to more than 60%, the quantity of steam leaked from HIP cylinder shaft ends into the
supply main pipe exceeds that required by the LP cylinder gland seal. When the main pipe pressure ascends to
0.129MPa (absolute), the control valves of all steam supply stations are closed automatically; the control valves
in the overflow station are opened automatically and discharge the redundant steam to the condenser through the
overflow control station. Up to this point, the turbine steam seal system enters into the self-sealing state and the
pressure of main pipe maintains at 0.129MPa (a). during a normal operation, the electric check valve in the cool
head of reheat pipe shall be shut down.
1.3.2.2 Hot start
a. If there is the qualified auxiliary steam supply source, the gland sealing steam is supplied by the auxiliary source
station. If the parameters of the auxiliary source fail to meet the requirements, the gland sealing steam is supplied by
the HP source station.
b. If adopting the HP steam source, confirm that after the control valves of the auxiliary source station and the
overflow station are closed and the electric check valve in the control valve line of the main steam supply station is
opened, the steam supply system shall be put into service normally and run automatically in accordance with the
following steps:
a). Turning, rolling, and low load phase
The gland sealing steam supply comes from the main steam supply station, and the pressure of the steam
supply main pipe is maintained at 0.118MPa (absolute).
b). 25%-load to 60%-load phase
When the unit load ascends to 25% of the rated load, the cool head of reheat pipe can fulfill all the
requirements of gland sealing steam supply, the steam is supplied by the cool head of reheat pipe, and the main
pipe pressure is automatically maintained at 0.127MPa (absolute).
c). More than 60% load phase
When the load is increased to more than 60%, the quantity of steam leaked from HIP cylinder shaft ends
into the supply main pipe exceeds that required by the LP cylinder gland seal. By this time the main pipe
pressure ascends to 0.129MPa (absolute), the control valves of all steam supply stations are closed automatically,
and the control valves in the overflow station are opened automatically and discharge the redundant steam to the
condenser through the overflow control station.
Up to this point, the turbine steam seal system enters into the self-sealing state and the pressure of main
pipe maintains at 0.129MPa (a). During the normal operation, the electric check valve in the cool head of reheat
pipe shall be shut down.
c. Unit load rejection phase
When load rejection occurs, it shall be treated by the following two means:
a). If there is the standby auxiliary steam supply source conforming to the temperature requirement, the pressure
of the main pipe for gland sealing steam supply can be down to 0.124MPa(a). Close the overflow control valve
and the gland sealing steam is supplied by the auxiliary source station.
b). If the unit has no standby auxiliary steam sources or the parameters of the auxiliary sources fail to meet the
requirements, the auxiliary sources and cool head of reheat pipe cannot be used. The electric check valve in front
of the control valve of the auxiliary source station must be closed. The pressure of the main pipe for gland
sealing steam supply is down to 0.118 MPa(a). The overflow control valve has already been closed
automatically, and the HP steam supply control valve is opened automatically. The steam is supplied by the main
steam supply station, namely, the HP steam source adjustment station.
1.3.2.3 Putting into service of temperature adjustment station
Under all operation conditions, the temperature adjustment station can maintain the temperature of the LP gland
seal chamber at 160~200℃.
1.3.2.4 Putting into service of by-pass valve
When the throttle pressure of the auxiliary steam supply control valve is 25% lower than the rating, or when the
steam turbine starts with a wearing gland seal, in order to get adequate steam flow to seal the steam turbine, the by-
pass valve of the auxiliary steam station will be open for steam supplement. When the throttle pressure is high
enough to maintain the steam for gland seal, the by-pass valve will be closed. If the by-pass valve is still open, the
surplus steam will be automatically discharged into LP heater or condenser by way of the overflow valve.
1.3.2.5 Steam temperature requirements
a. Auxiliary steam parameters’ requirements
Steam pressure Steam
No. Application Temperature (℃) Used for
(Mpa) source
 1 Warming About 150~260 Cold start Auxiliary
2 Steam turbine 0.588~0.784 About 208~375 Hot start steam
gland sealing About 150~260 Cold start header
b. Steam turbine gland sealing’s temperature requirements
In order to avoid the inconsistency between the temperature of seal steam and that of turbine rotor, the
steam supply temperature must meet the required needs.
Generally, in the main pipe of gland seal with the absolute pressure of 0.127Mpa, it is allowed that the
temperature of seal steam is 167℃ higher or 167℃ lower than that of the metal. Excessive temperature
differences between seal steam and rotor will result in the high heat stress on the rotor surface in the gland seal
zone. Each heat stress cycle well result in the alternate life loss of part of the metal, while the recurrence of
excessive temperature difference of rotor will give rise to heat fatigue cracking on rotor surface; meanwhile, the
excessive temperature difference will also bring about excessive expansion difference between the rotor and the
stator.
c. Specific steam temperature requirements
In a cold state (when the first shell temperature of steam turbine is lower than 150℃);
When the maximum steam temperature under the main pipe pressure is 260℃ and when the minimum steam
temperature under the main pipe pressure is 150℃.
In a hot state (when the first shell temperature of steam turbine is higher than 150℃);
When the maximum steam temperature under the pressure in the main pipe for gland sealing is 375℃ and
when the minimum steam temperature under the pressure in the main pipe for gland sealing is 208℃ (the
maximum temperature of gland-packing leakage minus 167℃).
1.3.3 Emergency adjustment
1.3.3.1 In order to prevent the occurrence of steam supply overpressure accident, there are set up the full-open-type
safety valve with radiator spring with the set pressure of 0.3Mpa in the main pipe for steam supply. In order to
guarantee the safe operation, there shall be set up sound and light alarm devices for overpressure alarming with the
alarm pressure of 0.25MPa(a) in the main pipe for gland sealing steam supply, so that the system operation can be
monitored at any time.
1.3.3.2 Gland sealing back-steam pressure adjustment
If end steam leakage is found during operation, the throttle of shaft sealing fan can be adjusted to guarantee the
certain negative pressure is maintained in the gland sealing back-steam chamber, about 95 KPa(absolute).
1.3.3.3 When there are failures in the steam supply stations and overflow stations, control valve hand wheels and by-
pass valves can be used to adjust the system.
1.3.3.4 Under the abnormal working condition, if the bypass channel of the steam supply control valve is opened or
the control valve of the steam supply station is open, excessive steam will enter into the main pipe for steam supply
by way of the steam supply station. No matter which case occurs, the overflow control valve will be automatically
opened. If the overflow control valve also goes wrong, the electric gate valve in the bypass of overflow station can
also be opened.
1.3.4 System shutdown
1.3.4.1 Confirm that the steam turbine is in the shutdown and barring phase. Cut off the electric check valves of all
steam supply pipes.
1.3.4.2 Cut off the electric valve in the water inlet of the desuperheating station.
1.3.4.3 Cut off the gas source of the gland sealing control valve and the power supply the transducer.
1.3.4.4 Confirm that all the drainage points are free from obstruction.

1.4 The calibration and operating conditions of the control valves in all control stations are as follows (see
table 0-1-1).
Table 0-1-1
 Pressure of HP steam Auxiliary steam Overflow control Running status
gland sealing source control source control station
main pipe station station
(MPa)
0.124 Close Open and adjust Close Vacuum phase
(cold start)
0.127 Close Open and adjust Close ~ 25% load
0.129 Close Close Open and adjust Self sealing
0.118 Open and adjust Close Close Load rejection
0.118 Open and adjust Close Close Vacuum phase (hot
start)
Note: The valve set pressures in Table 0-1-1 are only for onsite adjustment reference. Power plants can adjust the
pressure setting value based on actual operating conditions. If no smoking occurs in all HP, IP and LP gland seals
and the vacuum is not unaffected by the adjustment, it is appropriate.

1.5 Simple manipulation measures for common troubles (see table 0-1-2)
Table 0-1-2
Failure Failure source Simple manipulation measures
Too high 1 The steam supply control 1 Check the control signals of the control
pressure in valve is not tightly closed. valve and its tightness. If having confirmed
main pipes for 2 External steam goes into that it is not tight, inform the manufacturer or
gland steam the system. the support plants.
supply 3 There are unclear leakage 2 Identify the external source and cut off it.
points near the gland seal. 3 Find out the leakage points near the gland
seal.
Smoking in the 1 The outlet valve of the 1 Open the outlet valve of the shaft seal
gland seal shaft seal blower fan is blower fan.
closed. 2 Adjust the cooling water quantity in the
2 The quantity of cooling steam seal heater to make the pressure in the
water in the steam seal heater heater no greater than 95kPa (a).
is too small. 3 Let the steam-air mixture return line be
3 The steam-air mixture inclined continuously towards the shaft seal
return line is not rationally heater direction with a slope of 1/50, and do
arranged. not let the mixture enter into the inlet pipe
4 The drainage for the low section of gland sealing heater from lower
level point of steam-air part.
mixture is not clear. 4 Keep clear the passage for drainage in low
level point.
High 1 Desuperheater nozzle 1 Clean the nozzle.
temperature for fouling. 2 Clean the water filter.
low pressure 2 Water filter fouling 3 Check the power source and control signals
steam supply 3 The spraying control valve of the control valve.
fails.
Low 1 The spraying control valve 1.1 Check the power source and control
temperature for is not tightly closed. signals of the control valve.
LP steam 1.2 Check whether the control valve has
supply internal leakage. If it has, please contact the
manufacturer or support plants for treatment
measures.

2 Water Filter of the turbine steam seal system

Specification for Water Filter
2.1 Application
In the low-pressure shaft seal steam supply and desuperheating system of steam turbine, Water Filter is applied
for filtering condensate used by spray desuperheater, to prevent the contaminants in the condensate from blocking
the spray nozzle of the spray desuperheater or entering the steam seal, so as to ensure the normal work of the spray
desuperheater and the safety operation of the unit.
2.2 Performance Data
Working Pressure: 3.92MPa
2.3 Structure and Working Process
2.3.1 The filter is mainly composed of cylinder, end plate, flange, filter screen, and screw plug, etc. (see figure
0-1-1), of which the filter screen is a stainless steel tube opened with a number of Φ1 small pores.
2.3.2 During normal operation, the condensate from the condensate water system enters the filter screen, is filtered
through the small pores on the filter screen, and flows out of the filter after the contaminants in the water have been
removed, to be used by the spray desuperheater.

3 Steam filter of the turbine steam seal system

3.1 Application:
In the steam seal steam supply pipeline, the main function of steam filter is to prevent the contaminants in the
steam supply pipeline from entering shaft-end steam seal of the steam turbine, to ensure a safety operation of the
unit.
3.2 Performance Data:
Model:
Max. Working Pressure: 1.6MPa
Max. Working Temperature: 400℃
3.3 Structure
This steam filter is mainly composed of shell, filter screen, and cover plate, etc. (see figure 0-1-1). The shell is
in Y shape. The filter screen is the stainless steel wire mesh made of Ocr18Ni9. The cover plate is actually a
plain flange. The under part is set with water drain screw plug for drainage when the unit starts heating coil. If
the filter screen needs cleaning, it is very easy to withdraw it by removing the cover plate.

3.4 Installation and Operation Requirements

The steam filter shall be installed horizontally, and it is to be ensured that the water drain plug is located in the
lowest position and connected with the blow-down drainpipe. It is to be guaranteed that the minimum extraction
distance of filter screen is L3. The direction of steam supply flow should be the same as that as indicated in the
chart.
In the stage when the unit starts the heating coil, the drain plug should be opened and a smooth drainage is
ensured, to avoid steam with water from entering the shaft-end steam seal.
At the initial stage of unit trial run, when it is shut down for fault elimination, the steam filter must be cleaned.

4 Vacuum pump
4.1 Overall Unit Operations
Liquid compressed (seal water) in the Condenser Exhaust Unit is circulated through a closed loop that consists
of a two-stage vacuum pump, a separator, a centrifugal pump and a heat exchanger. Seal water is pumped by the
centrifugal pump from the separator through the heat exchanger to the vacuum pump. As the seal water flows
through the heat exchanger, it is cooled to a temperature approximately 2℉ to 4℉ (1℃ to 2℃) above the inlet
temperature of the cooling water that flows through the heat exchanger. Seal water from the heat exchanger
outlet flows to the vacuum pump where it is fed to the head of the vacuum pump.
Seal water entering the head is applied through open spray nozzle that is threaded into the head. The spray
nozzle form the seal water into a spray pattern through which the system air-water vapor mixture entering the
vacuum pump must pass. As the system air-water vapor mixture contacts the seal water spray, most of the water
vapor in the mixture is condensed. The condensed water vapor, the balance of the air-water vapor mixture and seal
water spray flow through inlet passages in the first stage head into the vacuum pump.
At the same time, the seal water fed directly to the vacuum pump from the heat exchanger flows through the
passages in the first stage head into the pump to seal clearances in the vacuum pump.
Within the pump, the seal water contacts the mixture flowing from the head. Water vapor in this mixture is
thereby condensed, reducing the volume of air that has to be removed by the two-stage vacuum pump.
The inlet air is partially compressed in the first stage of the vacuum pump and is discharged with the seal water
to the inlet of the second stage of the vacuum pump. The second stage compresses the air to atmospheric pressure
and discharges all of the seal water and compressed air into the separator. Within the separator, the seal water drops
from the air stream to the bottom of the separator. An automatic float switch and make-up solenoid valve, and an
over-flow loop maintain the proper level of seal water. The discharge air, from which the seal water has been
separated, passes through the separator outlet and through the air leakage test valve to the atmosphere.
An automatic float switch senses the level of water in the separator. If the level is too low, the float switch
opens the make-up solenoid valve, permitting make-up water to flow into the vacuum pump. When the water level
in the separator is high enough to provide the proper reservoir of seal water, for the vacuum pump, the float switch
closes the make-up solenoid valve. An overflow loop automatically controls the maximum water level in the
separator.
4.2 Control Operation
When the Condenser Exhaust Unit is shut down, the solenoid valve in the control panel is deenergized. With
the solenoid valve deenergized by the force of air supplying through actuator port of solenoid valve, the air pressure
in the actuator of the system inlet valve is vented through the solenoid valve to atmosphere, allowing the system
inlet valve to remain closed.
A float switch senses the level of water in the separator. If this level is too low, the float switch opens the make-
up solenoid valve, permitting seal water to flow from the water supply into the separator, when the water level is
high enough to provide the proper reservoir of sealant for the pump, the float switch closes the makeup solenoid
valve. An overflow loop, with a check valve to prevent flow back into the separator, automatically controls the
maximum water level in the separator.
A differential vacuum switch in the control panel is connected to the system piping upstream from the system
inlet valve, and to the vacuum pump head. The differential vacuum switch is closed when the vacuum pump inlet
pressure is within 1 inch of mercury of the system pressure. With the differential vacuum switch in the closed
position, solenoid valve in the control panel can be energized to direct control air to the system inlet valve actuator.
At initial start-up with the system at atmospheric pressure, the differential vacuum switch is in a closed position
(the system and vacuum pump head are at atmospheric pressure). When the vacuum pump motor is energized, the
solenoid valve is energized, and control air flows to the system inlet valve actuator, opening the inlet valve.
If the system is at a pressure less than atmospheric and the vacuum pump is shut down, the differential vacuum
switch is in an open position (the pressure in the pump head is greater than the system pressure). When the vacuum
pump motor is energized the system inlet valve remains closed while the vacuum pump is running until the pressure
in the head is within 1 inch of mercury of the system pressure. At this vacuum pump inlet pressure, the differential
vacuum switch closes, energizing the solenoid valve. Control air then flows to the system inlet valve actuator,
opening the valve.
With the system valve open, air from the condenser system can flow through the head of the vacuum pump.
During hogging, the discharge from the first stage pump flows through the head to the second stage discharge.
The system leakage discharged from the vacuum pump is measured on a rotameter mounted on the separator.
The rotameter ball valve is opened and the air leakage test valve is held closed with the handle mounted on the test
valve shaft. The air now discharges through the rotameter, and the leakage rate in SCFM of air can be read directly
from the rotameter scale.
 Deenergizing the vacuum pump starter is the only step required to shut down the unit and place it in the standby
state. Deenergizing the starter deenergizes the solenoid valve and the control air pressure on the system inlet valve
actuator exhausts through the solenoid valve to atmosphere, allowing the system inlet valve to close. The air
pressure in the actuator of the system inlet valve is vented through the solenoid valve to atmosphere, allowing the
system inlet valve to remain closed.
4.3 Safety Features
Safety provisions of a dual nature have been incorporated in the Condenser Exhaust Unit: the system inlet valve
and check valves in all lines to atmosphere.
The system inlet valve has a bonded soft seat liner in the valve body in order to prevent leakage when the Condenser
Exhaust System is shutdown. If the electric controls should fail, the system inlet valve closes automatically.
The proper level of seal water is automatically maintained in the separator. This prevents the loss of vacuum
pump capacity due to insufficient seal water reservoir, and prevents condensed vapor from accumulating in the
separator and entering the discharge vent piping.
The seal water circulating (centrifugal) pump is used to ensure sufficient flow of seal water to the vacuum
pump to maintain full pump capacity during hogging operation. During high-vacuum operation, the vacuum pump
inlet vacuum is sufficient to maintain proper flow of seal water to the pump. Therefore, should the centrifugal pump
fail when the vacuum pump unit is holding condenser back pressure, the vacuum pump automatically maintains
proper flow of seal water and full holding capacity.
The centrifugal pump also provides a nominal pressure in the seal piping and heat exchanger. Should a failure
in the exchanger occur, the seal pressure prevents the entry of relatively impure cooling water into the sealing water
system.

4.4 Operation
4.4.1 Preparation for Initial Start-Up
4.4.2 Draining and Flushing
WARNING: Isolate power source to drive motor to ensure that accidental starting cannot occur.
Before starting the Condenser Exhaust Unit after coupling alignment, remove; the drain plugs from the heads
of the vacuum pump; the drain plug from the seal water line strainer; the separator drain plug; and the drain plug
from the heat exchanger shell side drain . Remove the coupling guard.
Open the initial fill and manual bypass ball valve and the seal water make-up ball valve . The vacuum pump is
flushed with a water-soluble preservative oil prior to shipment which will be visible as a cream colored liquid.
Manually rotate the vacuum pump in the direction of rotation indicated by the arrows on the head and body while
allowing the seal water to flow until there is a clear flow from each drain, Replace the drain plug or plugs using a
pipe thread compound.
Allow the seal water to flow until all the drain plugs have been replaced.
4.4.3 Preliminary Inspection
Perform the following preliminary inspections before starting the Condenser Exhaust Unit
WARNING: Perform all of the following steps in order to ensure personnel safety and equipment protection.
a. Isolate all power sources to the drive motor to make certain no accidental starting occurs.
b. Inspect the unit to make certain that all drain plugs have been installed. Inspect all piping to make certain that
proper connections have been made to the unit and its basic system in accordance with the Nash installation
drawing(s) supplied with your unit. Vent the heat exchanger; open the initial fill and manual bypass ball valve and
the seal water make-up ball valve. Allow the separator to fill until water is seen flowing out of the overflow drain.
Close the initial fill and make-up bypass ball valve. Allow any excess water to drain from the separator overflow
drain.
CAUTION: Never operate the unit without adequate prime and seal water and cooling water flow, even if the
unit is only being operated to check direction of rotation.
Note:
Priming the separator and the pump's first and second stages is required to perform an initial start-up only.
During shut-down, water remains in the separator and pump casing up to the overflow loop level.
4.4.4 Start-Up and Operating Checks
WARNING: Notify the appropriate plant personnel before starting the condenser exhaust unit, particularly when
placing the unit on-line for the first time. Starting up a system unexpectedly may cause personnel injury.
Note: Refer to Troubleshooting, Section 4 if any operating difficulties arise when performing the following
steps.
a. Make certain that the vacuum pump first and second stages and the separator are primed and that the seal water
make-up ball valve for the make-up water supply to the separator is open. Open the shut-off valve for the cooling
water supply to the heat exchanger.
WARNING: Make sure that the coupling guard is installed before performing the following step.
b. Refer to the Bash wiring diagram for the sequence of operations. Energize the Condenser Exhaust Unit smarter to
start the unit. Check that the vacuum pump turns freely and in the direction cast on the head and body of the pump.
Note: If vacuum pump operation becomes unstable, vacuum pump vibration levels will increase and the
pumping volume will decrease. IF THE VACUUM Pump DOES NOT STABILIZE, SHUT DOWN THE UNIT
IMMEDIATELY AND DETERMINE THE CAUSE.
c. Check the speed of the vacuum pump shaft rotation with a tachometer and compare the measured speed with the
rated rpm for the unit. The rated rpm can be determined from the Engineering Data Sheet or by consulting your Nash
representative. (A test rpm is shown in the nameplate fastened to the vacuum pump body; however, this nameplate
data may not show the exact operating speed for your application.)
d. Maintain a constant check on the temperature of the vacuum pump casing. If the temperature rises rapidly or is
25℉ (14℃) or more above the temperature of the inlet gas or seal liquid, SHUT DOWN THE UNIT
IMMEDIATELY AND DETERMINE THE CAUSE.
e. Monitor the temperature of the bearing housings of the vacuum pump heads until the bearing housing
temperatures stabilize for a minimum of 30 minutes.
CAUTION: If a bearing housing temperature is more than 30℉(17) above the pump casing temperature and
above 140(60), shut down the unit immediately and determine the cause.
CAUTION: If abnormal bearing noise, vibration, odor or smoking occur, shut down the unit immediately and
determine the cause.
f. Check the unit for vibration and noise. If there is excessive vibration and/or noise (an abnormal condition), shut
down the unit immediately and determine the cause.
g. After the unit has been running for 10 minutes with steady leakage from the vacuum pump stuffing boxes, tighten
the gland nuts evenly one-quarter turn. Repeat at 10 minute intervals until there is a leakage of approximately 45 to
60 drops per minutes from the gland with no overheating. Subsequent tightening of the gland nut one-quarter turn
should be done with the unit operating at normal working temperature and vacuum.

4.4.5 TROUBLESHOOTING
Locating Troubles
Mechanically the vacuum pump is so simple that there is seldom any reason for inspecting the interior. The
only moving part is a one-piece cast rotor which is rigidly mounted on a shaft. If condenser back pressure is high or
increasing, the following items should be checked:
a. High condenser back pressure is a function of cooling water temperature, its flow rate, and load, more than the
evacuation equipment Review these operating conditions carefully.
b. Air Leakage - Measure air leakage as indicated below. If leakage is greater than 8 SCFM (3.78 L/s) at 1 inch
(25.4mm) of mercury absolute, check system for leaks.
a). Open the rotameter ball valve.
b). Manually hold the handle of the air leakage test valve in the closed position.
c). Read the leakage rate directly from the rotameter. If the rotameter float does not move. Clean the rotameter
(Paragraph 1-6-18) and then repeat the air leakage check.
c. Two Stage Vacuum Pump Free Discharge - Back pressure in excess of 5 inches (127.0mm) of water in the
discharge separator will reduce the vacuum pump capacity and increase the vacuum pump inlet pressure and
horsepower required
d. Restriction In Suction Line - Check the inlet vacuum gauge installed in the inlet horn of the vacuum pimp,
floating bearing end head. A substantially higher vacuum at this point than at the condenser will indicate an
obstruction in the suction line.
e. Correct Speed - Speed is stamped on the vacuum pump nameplate and is a function of the drive motor. Refer to
Paragraph 1-3-4, step c.
f. Seal Water Flow - Check temperature difference of seal water into and out of the heat exchanger. This temperature
drop should be about 15 (8). If excessive, inspect strainer, orifice unions, and inlet spray nozzle for blockage.
Refer to Paragraph 1-6-19.
g. Heat Exchanger - Check temperature difference between the cooling water into the heat exchanger and the seal
water into the two-stage vacuum pump. Normal temperature difference is 2˚to 40 (1˚to 2). If the temperature
difference is excessive, the heat exchanger tubes should be checked for blockage. The heat exchanger heads can be
removed for inspection and cleaning.
h. Separator Seal Water Level - Check that level in gage glass is within limits. If level is below minimum, check
operation of low level make-up solenoid valve and level float switch. Inspect the check valve for proper operation,
and strainer and orifice union for blockage.
If the two-stage vacuum pump shows no capacity either as indicated by checking leakage with the rotameter or
by observing that turning the unit on has no effect on the system, the following items should be investigated :
a. Instrument control air pressure should be 80 to 120 psig (653 to 929 kPa A) at the pressure gauge on the control
panel. If there is no pressure, check all valves between the pressure gauge at the control panel and the instrument air
source to be sure they are open.
b. Check the solenoid valve located inside the control panel. Check the coil to see if it is energized. Check the
exhaust port for leakage of instrument air inside the solenoid valve from the supply connection to the exhaust
opening.
c. Check the differential vacuum switch located inside the control panel to see if it is closed.
Chapter 3
Extraction check valve

Content:
1 Purpose and Feature
2 Composition of System
3 Working Principle
4 Air Source and Signal Source in the System as well as the Requirements of Installation
and Maintenance
5 System Test and Method
 Specification of Control System of Steam Extraction Check Valve of Steam Turbine
1. Purpose and Feature
The pneumatic control system of steam extraction check valve is the dynamic control center of steam extraction
check valve for each section of steam turbine and exhaust check valve for HP cylinder for each section of steam
turbine. It introduces various set signals into the electromagnetic valve in the system according to the requirements
of assembling unit to control the working states of relevant check valves so as to meet the needs of various working
states of assembling unit. The system adopts the compressed air with 0.6MPa (absolute) pressure as the dynamic
source. It has the merits of simple structure, easy setup of dynamic air source, free of contamination, etc. When the
dynamic source of compressed air acts on the operating devices of valves in the system, it enables the steam
extraction check valve for each section and exhaust check valve for HP cylinder at the free-state. When the medium
flows in the positive direction, the valve opens; when the medium flows in the reverse direction, the valve closes.
When the controlling air source is lost, the steam extraction check valve and exhaust check valve for HP cylinder
rely on the spring operating force and go to the closed state. Therefore, the system has the features of safety and
reliability.

2. Composition of System
The air source part in the system adopts the mother pipe system. It consists of the air cylinder, cut-off valve, air
filter, pressure gauge, etc as well as the air filter, relief valve, two-position three-way electromagnetic valve, manual
test valve, pneumatic control valve, etc. Among them, the air cylinder, cut-off valve, air filter and pressure gauge
shall be prepared by the project. The air filter on the mother pipe of air source is used to filter the sundries in the
compressed air to ensure the cleanness of compressed air. The cut-off valves at the two ends are used to cut-off the
gateway when the air filter on the mother pipe needs to be repaired or replaced. At the same time, a cut-off valve is
installed on the air supply branch piece of each check valve to facilitate the replacement and maintenance when the
electromagnetic valve, pneumatic control valve and manual test valve are damaged. When one group of branch
pieces is under repair, the entire system can still work properly. When one group of branch pieces is under repair, the
entire system can still work properly. This has been taken into the consideration during the system design. It shall be
noted that during the normal operation period of assembling unit, only one group of branch pieces is permitted for
repairing. Repairing more than two groups of branch pieces at the same time will affect the system reliability and the
safe operation of assembling unit.
The control of check valve adopts the mode of one-to-one correspondence of branch pieces. Based on the
structural features of operating device of check valve and the operational requirements of assembling unit for valve
performance, the check valve adopts the two-position three-way single normal power-on type of electromagnetic
valve, manual test valve and pneumatic control valve as the controlling and switching components. When the power
is off, the steam extraction check valve and exhaust check valve for HP cylinder are at the closed state to ensure the
safety and reliability of system.

3. Working Principle
Based on the requirements of various operating states of assembling unit, relevant open and close signals are
introduced into the corresponding electromagnetic valves in the system. The valves are activated so as to enable
each steam extraction check valve and exhaust check valve for HP cylinder at the working states required by the
operating state of assembling unit.
When receiving the open signal, the electromagnetic valve on each air passage is powered on and connected to
the air source. The compressed air enters into the operating device (cylinder chamber) of corresponding check valve
to enable the check valve at the free state. Under the action of steam flow in the positive direction, the check valve
opens.
 If the steam turbine rejects the load or the main steam valve closes, for each steam extraction check valve on
each air passage and exhaust check valve, when receiving the close signal, the electromagnetic valve loses the power
and cuts off the gateway between the air source and the operating device of check valve to enable the connection
between the operating device and the air exhaust orifice of pneumatic control valve. Under the action of spring
force, the operating device closes the check valve. When the internal water level of heater in the corresponding
section rises to the critical water level that needs to cut-off the steam extraction, the electromagnetic valve loses the
power and disconnects the air source, and then the steam extraction check valve closes.
The detailed operating principles of steam extraction check valve and exhaust check valve for HP cylinder can
be found in the manual of valves supplied with the machine.

4. Air Source and Signal Source in the System as well as the Requirements of Installation and
Maintenance.
4.1 Air source: clean compressed air with 0.6MPa (absolute).
4.2 The air source shall dry, clean with adequate air quantity and constant pressure.
4.3 The air filter shall be periodically cleaned.
4.4 Working power for two-position three-way single electronic control electromagnetic valve: AC240V.
4.5 Before installation, all the lines in the system shall go through picking and phosphorizing. The system equipment
shall be cleaned.
4.6 The lowest point of system line shall have a drainage point. Depending on the water accumulation situation in
the system, regular drainage time shall be specified.

5. System Test and Method

5.1 After repairing or before the star-up of assembling unit, the system linkage test and activation test of check valve
shall be performed.
5.2 During the normal operation period of assembling unit, the activation test of steam extraction check valve shall
be performed monthly to check its flexibility.
5.3 Regular activation test shall be performed one by one. Only when one group is finished and reset, the test of next
group can be performed.
5.4 Procedures of Activation Test
5.4.1 Procedures of Activation Test of Check Valve
Press the test button on the manual test valve to connect the compressed air gateway that goes into the part
under the piston of operating device of valve with the atmosphere. Thus, the compressed air in the chamber under
the piston of operating device will leak to outside. Because the chamber above the piston of operating device is
connected with the atmosphere, under the action of spring force, the piston will move downward. When the
movement closes to the half of stroke, release the manual button on the test valve to enable the check valve return to
the free state. The activation test is finished.
5.4.2 It shall be noted that the movement stroke shall not be excessive during the activation test; otherwise the
normal operation of assembling unit will be affected.
5.4.3 The activation test for the exhaust check valve for HP cylinder shall be performed once per 2~3 months.
 Chapter 4
HP & LP Bypass System

Content:
1 Function description HP Bypass control
2 Function description LP Bypass control
3 Operation of HP & LP bypass
4 Temperature-decreased Pressure Reducer
1 Function description HP Bypass control
1.1 Overview
The HP-Bypass Controller consists of the following parts:
1) Pressure set point generation
2) Pressure controller
3) Temperature controller
4) Spray water isolation control
1.2 Pressure set point generation
1.2.1 Startup
1.2.1.1 Mode Selection
The “startup mode” is set by the operator or by the signal “Boiler fire on” from the DCS. When the “startup
mode” is selected, the set point generator can be in three different operating conditions:
1) Min pressure
2) Pressure ramp
3) Restart
The “min pressure” is active whenever the main steam pressure is below “Pmin”. The “pressure ramp” is active
when the main steam pressure is above “Pmin” and below “Psync”.
The “restart” is active when the pressure is above “Pmin” and the BP valve is closed. The signal “start
sequence” is generated when the operating “min pressure” or “pressure ramp” is on.
The “startup mode” is deselected as soon as the pressure reaches “Psync” and the BP valve is open. The
“startup mode” is also deselected when the signal “HP Turbine loaded” is active or when the pressure controller is
switched to manual.
The “fixed pressure mode” is active when the “startup mode”, the “follow mode“and the “shut down mode” is
not active.
The “follow mode” is active when the BP valve is closed and the DEH signal “HP Turbine loaded” is on or the
DCS signal “Boiler fire on” is off. Or when the Further the “Follow mode” is on when BP controller is in manual.
1.2.1.2 Set point Generator
At startup, with no pressure in the boiler the set point generator is in the “min pressure” condition. The pressure
set point “Ps actual” is then set at pressure value “Pmin”. And the pressure controller opens the BP valve to a
minimum position value “Ymin”.
As soon as the main steam pressure is above “Pmin” the “pressure ramp” condition is activated. The pressure
set point “Ps demand” is increased, whenever the BP valve position “Yset” exceed the position value “Ym”. The
increase of the pressure set point is limited by the gradient limiter and only positive pressure gradient are allowed
during “pressure ramp” operation, decrease of the pressure set point “Ps actual” is not permitted in this operation
mode.
As soon as the main steam pressure reaches “Psync” the “startup mode” is deselected and the “fixed pressure
 mode” is activated. The pressure set point “Ps demand” is set at the current last pressure set point “Ps actual”. In
“fixed pressure mode” the “Pressure set point” can be adjusted by the operator.
When the “HP turbine loaded” the BP valve will close automatically due to pressure dropped. As soon the BP
valve is closed the set point generator will switch over to “follow mode” (see: 2.2 Load Operation). In this mode
pressure set point “Ps actual” will follow main steam pressure.
In case of pressurized boiler at startup the “restart” condition is selected while the BP valve is closed. In the
“restart” condition the pressure set point “Ps actual” is following the main steam pressure but only negative pressure
gradients are allowed. As soon as the boiler pressure starts to increase the bypass valve will start to open. When the
BP valve open the set point generator will go to “pressure ramp” condition if the pressure is still below “Psync” or to
“fixed pressure mode” if the pressure at startup is already above “Psync”.
1.2.2 Load Operation
During load operation, i.e. when the HP turbine is taking over all the produced steam, the bypass valves are
closed. The “follow mode” is activated.
In the “follow mode” the pressure set point “Ps actual” is following the actual main steam pressure. The
ximum pressure gradient is limited, depending on the actual main steam pressure. A differential pressure “dP” is
ded to the pressure set point “Ps actual” to keep the BP valve closed (see: 3. Pressure Controller).
If the main steam pressure is increasing above the Bypass controller set point “Ps actual + dP” the BP valve starts
open. The set point generator is switched over to “fixed Pressure mode”.
.3 Shut down
.3.1 Mode selection
When a plant shutdown is planned the “Shut down mode” can be selected by the operator. The “Shut down mode”
n only be selected when the DEH signal “HP Turbine loaded” is active and the BP controller is on auto. As soon as
DEH signal “HP Turbine loaded” is deactivated the “Shut down mode” is deselected and the set point generator
ange to “fixed pressure mode”.
When the boiler shuts down, the DCS signal “Boiler fire on” is deactivated, the BP valve will close and the set
nt generator is switched to “follow mode”
.3.2 Set point Generator
At “Shut down mode” the pressure set point “Ps actual” is following the main steam pressure but only negative
dients are allowed. As soon as the boiler pressure starts to increase the BP valve start to open.
After the “Shut down mode” is deselected the set point generator is on “fixed pressure mode”. At “fixed pressure
de” the set point generator controls the actual pressure. As soon the boiler shuts down the BP valve is closing and the
ssure generator is switched to “follow mode”. In “follow mode” the pressure set point will again follow the actual
in steam pressure.
Pressure Controller
The pressure controller is receiving the actual main steam pressure signal and the pressure set point “Ps actual”
m the set point generator. It is generating the BP valve position demand signal.
The pressure controller has one M/A station to control the BP valve.
At signals “BP open “the BP valve will open to 100%. During this signal controller is set manual and follow the
valve position. After the signal the controller set automatic
At signal “BP close trip” the BP valve will be closed by the close command signal to the valve. The controller
is set to manual.
In “follow mode”, when the “dP on” is active by a differential pressure is added to the pressure set point “Ps
actual” to keep BP valve close.
At “startup mode” when the “min pressure” condition is active the BP valve are opened to a minimum position
“Ymin”. The “Ymin on “is deselected when position is above the minimum position “Ymin”.
1.4 Fast open / close logic
 The “BP open” command for the BP valve is generated from DEH signals “Turbine trip” or “Generator switch
trip” or when the main steam pressure has reached the quick opening pressure threshold “dp max” above the
pressure set point “Ps actual”. The “BP open” is blocked when pressure is below the pressure “Pfo” and the “startup
sequence” is active or when the “BP close trip” is active.
The “BP close trip” command is generated when the BP outlet temperature exceed the pressure “Tmax”.
1.5 Temperature control
The temperature controller is receiving the actual signal “HP-BP outlet temperature” from the transmitter and
the “Temp set point “set by the operator. The controller is generating the spray water valve position demand signal.
The feed forward signal is generated from “Main steam pressure” and BP valve position and is added to the
valve position demand signal. With the adjustable value “wpl” the feed forward signal can be adapted.
The temperature controller has one M/A station to control the spray-valve BPE valve. The temperature
controller is set automatic mode as soon the BP valve is open.
When the BP valve closes the spray water valve closes also, and the temperature controller is set to manual.
1.6 Spray water isolation valve control
The spray water isolation valve is open as soon the BP valve is open. When the BP valve is closed the spray
water isolation valve is closed again.
Function description LP Bypass control
.1 Overview
The LP-Bypass Controller consists of the following parts:
1) Pressure set point generation
2) Pressure controller
3) Condenser protection
4) Temperature controller
5) Spray water isolation control
.2 Pressure set point generation
In the “min pressure” operation the turbine is not on load. The pressure set point “Ps RHH actual” is set to the
ressure “Pmin”. The minimum pressure set point can also be increased by the operator if a higher set point is
equired.
At “load pressure” operation the pressure set point “Ps RHH actual” is generated from the transmitter signal
Turbine 1st stage pressure”. The pressure set point “Ps RHH actual” changes in function of the turbine load of the
nit.
.3 Pressure controller
The pressure controller is receiving the actual hot reheat steam pressure signal (1 out of 2 selections of two
ansmitter signals) and the pressure set point “Ps RHH actual” from the set point generator. It is generating the LBP
alves position demand signal.
Each LBP valve has one M/A station. At signal “LBP close trip” from condenser protection the LBP valves will
e closed by the close command to the valves and the controller is set to manual. The PI controller is set to manual
when both LBP valves are set to manual. The controller then is tracking the max valve position. The maximal LBP
alve opening is limited by the steam flow to the condensator. As soon the “LBP steam flow” the LBP valve start to
lose.
.4 Condenser protection
The “LBP close trip” command for the LBP valve is generated from condenser protection switches. Each one of
he following criteria is activating the “LBP close trip” command:
1) Condenser press high (2 out of 3);
2) Condenser temp high;
3) Condenser level high;
 4) LBP spray-water pressure low.
2.5 Temperature controller
The temperature controller is receiving the actual signal Fw “LBP spray water flow” from the transmitter. The
spray water set point Fws is calculated out of the steam pressure, steam temperature and LBP valve position. The
controller is generating the spray water valve position demand signal.
The temperature controller has one M/A station to control the spray-valve LP-BPE valve. The temperature
controller is set to automatic mode as soon the LBP valve is open. When the LBP valve is closed the spray water
valve is also closed, the controller is set to manual.

3 Operation of HP & LP bypass

Refer the instruction of HP& LP bypass which provided by the manufacture.

4 Temperature-decreased Pressure Reducer

4.1 Application
The temperature-decreased Pressure Reducer, when used for startup of and load rejection for steam turbine,
reduces the temperature and pressure of steam from the secondary bypass station of the steam turbine to the
allowable value acceptable to the condenser. This reducer is welded on the end plate of the condenser or exhaust
device throat. Refer to the drawing of condenser or exhaust device opening and fittings for its installation position
and layout of reinforced rib.
4.2 Main Performance Data
Inlet steam pressure 0.86MPa
Inlet steam temperature 175
Inlet steam flow 465t/h
Water-spraying pressure 0.8 MPa (a)
Outlet steam pressure 0.0311 MPa
Outlet steam temperature 70
Structure and Operating Principle
This Temperature-decreased Pressure Reducer adopts the three-stage pressure reducing and one stage
mperature-reducing structure as shown in design diagram. The steam from the secondary bypass station enters the
mperature-decreased Pressure Reducer through the steam pipe, passes through the end pore plate flow direction, and
n sprays towards the shell. The steam flow goes through the eyelets in the end opening area of the steam pipe for the
ial pressure reduction via critical expansion. 4 atomizer are distributed uniformly on the external wall of the cooling
ter from the condensate water system with the steam, thus to lower the temperature. The steam after the first-stage
uction of temperature and pressure experiences the secondary pressure reduction via critical.
Expansion through the eyelets on the conical screen of the shell which diffuses to the after part of the reducer. At
t, the steam will be diffuses to the entire condenser through the eyelets one the reducer shell which implementation
tertiary reduction of temperature and pressure (0.0311MPa/70).
The spraying water passes the water-spraying control valve and connects with the reducer after filter. The specs of
filter should grater than 32-eyes/square inch. Periodically clean the filter in order to prevent blockage.
The pressure of spraying water is 0.8MPa with a total spraying flow of about 10kg/s from outlet of condensate
mp.
Operations and Maintenance
The cooling spraying water must also be engaged during the bypass operation. Otherwise, the steam temperature
o the condenser will exceed the allowable value to cause damage to the Temperature-decreased Pressure Reducer and
condenser or exhaust device. So, the water-spraying control valve in the water spraying system for the cooler and
ucer shall be interlocked with the operating signal of LP bypass valve. When the LP bypass valve takes action, the
ter-spraying control valve shall actuate correspondingly to spray in cooling water.
Manhole cover is installed on the Temperature-decreased Pressure Reducer to facilitate necessary
maintenance and cleaning.
Posted 30th March 2015 by kishorereddy kattukolu

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