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STEAM TURBINE
0PERATION & MAINTENANCE
INSTRUCTIONS

NO.STE-TF-296-MS

DERANG ANGUL-TPS 2X600 MW

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BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR – 249403 (INDIA)
 Steam Turbine Preface
General

This manual contains information on the operation and
maintenance of steam turbine.
The information has been prepared with the assumption
that the O&M personnel have basic knowledge of power
plant engineering and operation.
It is an essential prerequisite for satisfactory operation
and maintenance of the steam turbine that the operating
and maintenance personnel are fully familiar with the
design of the steam turbine plant and receive thorough
training in operating and maintaining the unit.
Extensive operation beyond rated design values will
eventually result in increased maintenance expenses or a
corresponding reduction in the useful life of the steam
turbine. Bharat Heavy Electricals Limited cannot be
responsible for any malfunction occurring as a result of
operation beyond rated limits and such operation, if
undertaken by utilities, must be at their own risk.
The part numbers of components, indicated in the
Description section of the manual should not be used for
ordering spare parts.
Please refer the chapter on Ordering of spares for that
purpose.
Effort has been made to include adequate information in
this manual.
For any further information or clarification please contact:
Field Engineering Services, Steam Turbine Engineering,
BHEL, Hardwar–249403, (Uttarakhand) India.

DERANG ANGUL-TPS, 2X600 MW: Document No.STE-TF-296-MS

KJ RRS SM VS SRP
Prepared Approved
Checked
by by
by

Issued by STE (FES), BHEL, Hardwar Issue

Date

BHEL, Hardwar 6.0-0001-96

 Steam Turbine Contents
Description

Subject Document No Subject Document No

GENERAL ■ Journal bearing IP rear 6.1-0345-01/2
■ Preface 6.0-0001-96/1 ■ Casing supports and guides 6.1-0350-01/2
■ Contents 6.0-0002-96/3 LP Turbine
DESCRIPTION ■ Casing 6.1-1310-01/4
Brief Description ■ Atmospheric relief 6.1-1320-00/1
■ Sectional arrangement 6.1-0001-04/1 diaphragm
■ General description 6.1-0002-04/2 ■ Blading, drum stages 6.1-1330-02/1
■ Fixed points 6.1-0003-02/2 ■ Blading, LP stages 6.1-1340-01/1
Technical Data ■ Shaft seals 6.1-1350-00/1
■ Construction, speed & 6.1-0100-96/3 ■ Rear bearing pedestal 6.1-1360-01/1
Steam pressure ■ Journal bearing 6.1-1370-04/2
■ Steam and casing 6.1-0101-96/2 Turning Gear
temperatures ■ Hydraulic turning gear 6.1-0510-01/1
■ Bearing metal temperatures, 6.1-0102-96/1 ■ Manual turning gear 6.1-0520-01/1
vibration, weights ■ Hydraulic lifting device 6.1-0530-96/2
■
Control System
Oil supply, oil pumps 6.1-0103-96/2
■ Control fluid system and 6.1-0104-96/2 ■ General description 6.1-0600-01/1
control fluid pumps ■ Start-up procedure 6.1-0610-01/2
■ Limit curves: HP stop & 6.1-0110-01/1 ■ Speed control 6.1-0620-01/2
control valve casing ■ Electrical speed measuring 6.1-0621-02/1
■ Limit curves: HP casing 6.1-0111-01/2 ■ Protective devices 6.1-0630-01/2
■ Limit curves: HP shaft 6.1-0112-01/2 ■ Over speed trip test 6.1-0631-01/1
■ Limit curves: IP shaft 6.1-0113-01/1 ■ Testing of stop valves 6.1-0632-01/1
■ Steam purity values 6.1-0120-01/1 ■ LP bypass System (General) 6.1-0640-01/1
■ Oil specification standard 6.1-0130-04/2 ■ Extraction check valve 6.1-0650-01/1
■ Fire resistant fluid (FRF) for 6.1-0140-04/2 ■ Swing check valve (CRH) 6.1-0651-01/1
turbine control system ■ Testing of check valves in 6.1-0652-01/1
HP Turbine cold reheat line
■ Valve arrangement 6.1-0205-00/1 ■ Automatic turbine tester 6.1-0660-00/1
■ Casing 6.1-0210-01/3 general
■ Blading 6.1-0220-02/1 ■ Automatic turbine tester 6.1-0661-00/7
■ Shaft seals and balance 6.1-0230-01/2 for protective devices
piston ■ Automatic turbine tester 6.1-0662-01/3
■ Front bearing pedestal 6.1-0240-01/2 stop and control valves
■ Rear bearing pedestal 6.1-0250-02/2 ■ HP actuator 6.1-0665-00/1
■ Combined journal and thrust 6.1-0260-01/2 ■ Electro hydraulic seal steam 6.1-0670-01/4
bearing pressure control
■ Journal bearing, HP front 6.1-0270-01/2 ■ Governing scheme 6.1-0680-02/1
■ Casing supports and guides 6.1-0280-01/2 ■ Control system diagram 6.1-0681-02/5
IP Turbine legend
■ Lubrication chart 6.1-0690-02/3
■ Casing 6.1-0310-01/3
Control System Parts
■ Blading 6.1-0320-02/1
■ Shaft seals 6.1-0330-01/2 ■ Hydraulic speed governor with 6.1-0710-00/2
■ Rear bearing pedestal 6.1-0340-02/1 starting and load limiting device

BHEL, Hardwar 6.0-0002-96/1

 Subject Document No Subject Document No
■ Adjusting gear 6.1-0720-00/1 ■ Vacuum breaker 6.1-0960-00/2
■ Electro hydraulic converter 6.1-0730-03/3 ■ Changeover valve for 6.1-0980-00/1
for turbine control system testing device
■ Hydraulic amplifier for 6.1-0740-02/3 Oil Supply
turbine control system ■ Oil supply system 6.1-1000-96/4
■ Damping Device 6.1-0750-00/1 ■ Oil vapor extraction system 6.1-1001-96/2
■ Electrical speed pick-up 6.1-0760-01/1 ■ Oil discharge & vent system 6.1-1002-96/2
■ Pressure converter 6.1-0761-00/1 ■ Oil purification system 6.1-1003-96/1
Steam valves and ■ Main oil tank 6.1-1010-01/2
accessories ■ Main oil pump with hydraulic 6.1-1020-01/2
■ Combined main stop and 6.1-0810-01/2 speed transmitter
control valve ■ Auxiliary oil pump 6.1-1030-01/1
■ Servomotor for main & 6.1-0811-00/1 ■ DC emergency oil pump 6.1-1040-01/1
reheat stop valves ■ Jacking oil pump 6.1-1050-00/1
■ Hydraulic servomotor for 6.1-0812-00/2 ■ Oil throttle 6.1-1080-00/1
main & reheat control valves ■ Oil throttle 6.1-1081-00/1
■ Test valve for emergency 6.1-0813-00/1 ■ Three way control valve for 6.1-1090-01/1
stop valve Lubricating oil temp. control
■ Combined reheat stop & 6.1-0814-00/2 Control Fluid Supply
control valves ■ HP control fluid pump with 6.1-1110-00/1
■ Hangers for reheat stop & 6.1-0815-01/1 LP extraction
control valves ■ Plate-type filter 6.1-1120-00/1
■ Steam strainer 6.1-0816-00/1 ■ Duplex filter for pilot control 6.1-1130-00/3
■ Changeover valve for 6.1-0840-00/1 of control valves
bleeder check valve ■ Regenerating plant 6.1-1140-00/3
■ Auxiliary valve of extraction 6.1-0841-00/2 Other Systems
check valve ■ Drain system (MAL) 6.1-1210-96/2
■ Rotary vane actuator for 6.1-0853-01/1 ■ System diagram index 6.1-1220-96/3
reheat swing check valve ■ Component diagram index 6.1-1230-96/10
■ Pilot valve for rotary vane 6.1-0854-00/1 ■ Shaft seal system 6.1-1240-96/5
actuator of swing check valve Operation
■ Auxiliary pilot valve for 6.1-0855-00/1 ■ Introduction 6.2-0001-01/1
rotary vane actuator of ■ Specification of steam, oil & 6.2-0002-00/1
reheat swing check valve control fluid
■ Gland steam control valve 6.1-0860-02/1 ■ Testing of turbine 6.2-0020-00/1
■ Leakage steam control valve 6.1-0870-02/1 Components - General
Protective Devices ■ Turbine systems testing
■ Main trip valve 6.1-0910-00/1 testing intervals
■ Emergency trip valve for 6.1-0911-00/1 □ Controllers 6.2-0021-01/1
manual trip out □ Automatic turbine tester 6.2-0022-01/1
■ Solenoid valve for remote 6.1-0912-00/1 □ Automatic turbine tester 6.2-0023-01/1
trip out □ Protective devices 6.2-0024-01/1
■ Over speed trip 6.1-0920-00/1 □ Safety devices 6.2-0025-01/1
■ Over speed trip releasing 6.1-0921-00/1 □ Valves 6.2-0026-01/1
device □ Monitoring devices 6.2-0027-01/1
■ Over speed trip test device 6.1-0922-00/2 □ Operating parameters 6.2-0028-01/1

BHEL, Hardwar 6.0-0002-96/2

 Subject Document No Subject Document No
Start-up ■ Oil system 6.2-0460-00/6
■ Starting the turbine 6.2-0110-01/1 ■ Control fluid system 6.2-0470-00/3
■ Startup & shutdown 6.2-0111-00/1 ■ Gland steam system 6.2-0480-01/1
diagrams, symbols ■ Bypass System 6.2-0490-00/3
■ Startup diagram MAINTENANCE
□ General 6.2-0112-00/2 ■ Introduction 6.3-0001-01/1
□ Preparation for startup 6.2-0113-00/1 ■ Inspection schedule 6.3-0010-04/3
□ Operating position of 6.2-0120-00/1 ■ Maintenance schedule
manually operated valves □ Turbine 6.3-0021-02/1
□ Oil System & Turning Gear 6.2-0130-02/5 □ Oil system, seal steam 6.3-0022-01/3
□ Control fluid system 6.2-0135-02/4 system, drains
start-up diagram □ FRF system 6.3-0023-01/2
□ Condensing Plant 6.2-0140-02/4 ■ Testing during start-up 6.3-0030-02/7
□ Bypass System 6.2-0150-00/3 ■ Testing during power 6.3-0035-02/5
□ Warm-up & startup of turbine 6.2-0160-02/6 operation
□ Temperature criteria 6.2-0170-01/4 ■ Acquisition & archiving of 6.3-0037-03/3
□ Controllers 6.2-0180-00/4 operating data
On-load Running ■ Remedial actions for off- 6.3-0040-01/6
■ Load operation, Introduction 6.2-0200-00/1 normal operating conditions
■ Synchronization and loading 6.2-0210-00/5 ■ Measurement of internal 6.3-0050-02/3
■ Power operation, controllers 6.2-0220-00/9 efficiency
■ Actions to prevent 6.2-0230-00/3 ■ Testing during shut down 6.3-0060-01/5
unallowable heat-up ■ Testing during standstill 6.3-0061-02/6
through blade wind age ■ Testing of safety valves 6.3-0062-01/1
Shut-down ■ Testing of signaling devices 6.3-0063-00/2
■ Introduction 6.2-0300-00/1 ■ Testing of TSC 6.3-0064-01/4
■ Shutdown diagram ■ Steam washing of turbine 6.3-0070-02/3
□ General 6.2-0310-01/1 ■ Turbine Oil care 6.3-0080-03/10
□ Turbine-generator 6.2-0320-02/5 ■ Grease and Oil lubrication 6.3-0081-00/1
□ Condensing plant 6.2-0330-01/2 ■ Care of control fluid 6.3-0082-02/9
□ Oil system 6.2-0340-01/2
■ Determination of FRF purity 6.3-0083-01/1
■ Fast cooling down of turbine 6.2-0350-01/1
■ Vibration dampers 6.3-0100-00/2
■ Preventing corrosion in 6.2-0360-00/2
■ Instructions for overhaul 6.3-0200-05/8
idle turbine
■ Turbine restart after boiler 6.3-0210-00/1
Fault Tracing
repairs
■ Introduction 6.2-0400-00/1
■ Turbine restart after major 6.3-0220-00/3
■ Serious faults 6.2-0410-00/8
inspections or repairs
■ Vibration 6.2-0420-00/5
■ Environmental protection 6.3-0250-00/1
■ Bearing temperature 6.2-0421-01/1
□ Fluorelastomer products 5.3-251-00/1
■ Casing temperatures 6.2-0423-02/2
safety notice
■ Turbine stress controller: 6.2-0430-01/5
□ Safe disposal of turbine oil 6.3-0252-00/1
measures to avoid
■ Ordering of spares 6.3-0300-00/1
impermissible operation
■ Stop & control valves 6.2-0440-01/2
■ Protective devices 6.2-0450-01/7
■ Automatic turbine tester 6.2-0455-00/9

BHEL, Hardwar 6.0-0002-96/3

 Steam Turbine Description Cross Sectional Arrangement

BHEL, Hardwar 6.1-0001-04

 Steam Turbine
Description
Construction, Steam Flow
The turbine is a tandem compound machine with separate
HP, IP and LP sections. The HP section being a single-flow
cylinder and the IP and LP sections double-flow cylinders.
The turbine rotors and the generator rotor are connected by
rigid couplings.
The HP turbine is throttle controlled. The initial steam is
admitted ahead of the blading via two main stop and control
valve combinations. A swing check valve is installed in the
line leading from HP turbine exhaust to the Reheater to
prevent hot steam from the reheater flowing back into the HP
turbine.
The steam coming from the Reheater is passed to the IP
turbine via two reheat stop and control valve combinations.
Cross around pipes connects the IP and LP cylinders.
Connections are provided at several points of the turbine for
feed water extraction purpose.
HP Turbine, Barrel Type Casing
The outer casing of the HP turbine is of the barrel type and
has neither an axial nor a radial flange. His prevents mass
concentration which would have caused high thermal
stresses. The almost perfect asymmetric design of the casing
permits moderate and nearly uniform wall thickness at all
sections. The inner casing is axially split and supported so as
to be free to move in response to thermal expansion. As only
slight pressure differences are effective, the horizontal flange
and joint bolts of the inner casing can be kept small. The
barrel type casing permits flexibility of operation in the form of
short start-up times and a high rate of change of load even at
high initial steam conditions.
IP Turbine
The IP turbine section is of double flow construction with
horizontally split casings. Allowance is made for thermal
movement of the inner casing within the outer casing. The
inner casing carries the stationary blading. The reheated
steam enters the inner casing from top and bottom. The
provision of an inner casing confines high steam inlet
conditions to the admission section of this casing, while the
joint flange of the outer casing is subjected only to the lower
pressure and temperature effective at the exhaust from the
inner casing.
BHEL Hardwar
General Description
LP Turbine
The casing of the double-flow LP cylinder is of three-
shell design. The shells are horizontally split and are of
rigid welded construction. The innermost shell, which
carries the first rows of stationary blades, is supported
so as to allow thermal expansion within the
intermediate shell. The intermediate shell rests at four
points on longitudinal girders, independent of the outer
shell. Guide blade carriers, carrying the last
Stationary blade rows are also attached to the
intermediate shell.
Blading
The entire turbine is provided with reaction blading.
The stationary and moving blades of the HP and IP
sections and the front rows of the LP turbine are
designed with integrally milled inverted T -roots and
shrouds. The last stages of the LP turbine are fitted
with twisted drop -forged moving blades with fir-tree
roots engaging in grooves in the shaft with last stage
stationary blades made from sheet steel.
Bearings
The HP rotor is supported on two bearings, a journal
bearing at its front end, and a combined journal and
thrust bearing immediately next to the coupling to the
IP rotor. The IP and LP rotors have a journal bearing
each at rear end. The combined journal and thrust
bearing incorporates a journal bearing and a thrust
bearing which takes up residual thrust from both
directions. The bearing metal temperatures are
measured by thermocouples directly under the babbit
lining. The temperature of the thrust bearing is
measured in two opposite thrust pads.
The bearing pedestals are anchored to the
foundation by means of anchor bolts and are
fixed in position.
The HP and IP turbines rest with their lateral
support horns on the bearing pedestals at the
turbine centerline level. The HP and IP casings
are connected with the bearing pedestals by
casing guides, which
Establish the centerline alignment of the turbine
casing.
The axial position of the HP and IP casings is
fixed at the support brackets on HP-IP bearing
pedestal.
6.1-0002-04/1
The fixed point for the LP casing is at the front point of
support on the longitudinal girder. Thermal expansion of the
casings originates from the fixed points.
Shaft Seal and Blade Tip Sealing
All shaft seals, which seal the steam in the casings against
atmosphere, are axial-flow type. They consist of a large
number of thin seal strips which, in the HP and IP turbines
are caulked alternately into grooves in the shafts and the
surrounding seal rings. In the LP turbine, the seal strips are
caulked only into the seal rings. Seal strips of similar design
are also used to seal the radial blade tip clearances.
Valves
The HP turbine is fitted with two main stop and control valves.
One main stop valve and one control valve with stems
arranged at right angles to each other are combined in a
common body. The main stop valves are spring-action single-
seat valves; the control valves, also of single-seat design,
have diffusers to reduce pressure losses.
These valve combinations are located at both sides of the
turbine with their stems horizontal. The HP valves are
connected to the turbine by easily separable collar couplings,
which contain self-sealing U-rings as sealing elements.
The IP turbine has two reheat stop and control valves. The
reheat stop valves are spring-action single-seat valves. The
control valves, also spring-loaded, have diffusers. The control
valves operate in parallel and are fully open in the upper load
range. In the lower load range, they control the steam flow to
the IP turbine and ensure stable operation even when the
turbine- generator unit is supplying only the station load.
The reheat stop and control valves are supported free to
move in response to thermal expansion on the foundation
cover plate below the operating floor and in front of the
turbine-generator unit. All valves are actuated by individual
hydraulic servomotors.
BHEL, Hardwar
Turbine Control System
The turbine has an electro hydraulic control system. An
electric system measures speed and output and
controls them by operating the control valves
hydraulically via an electro hydraulic converter. The
electro hydraulic controller ensures controlled
acceleration of the turbine-generator up to rated speed
and limits speed overshoot in the event of sudden load
rejection. The linear power frequency droop
characteristic can be adjusted in fine steps even
When the turbine is running.
Turbine Monitoring System
In addition to measuring and display instruments for
pressure, temperatures, valve lifts and speed, the
monitoring system also includes instruments for
measuring and indicating the following parameters:
Rotor expansion measured at the rear-bearing
pedestal of the LP turbine
Axial shift measured at the HP-IP pedestal
Bearing pedestal vibration, measured at all turbine
bearings
Shaft vibration measured at all turbine bearings
Oil Supply System
A common oil supply system lubricates and cools the
bearings. The main oil pump is driven by the turbine
shaft and draws oil from the main oil tank. Auxiliary oil
pumps maintain the oil supply on start-up and
shutdown, during turning gear operation and when the
main oil pump is faulted. DC Emergency oil pump
supplies oil to the bearings during AC power failures.
A Jacking oil pump forces high-pressure oil under the
shaft journals to prevent boundary lubrication during
turning gear operation. The Jacking oil pump also
supplies the high pressure oil to the Hydraulic Turning
gear motor. The lubricating and cooling oil is passed
through oil coolers before entering the bearings.
The control fluid pumps situated on a control fluid tank
supply the hydraulic turbine and bypass control system
and the protective devices and valve actuators with HP
and LP control fluid.
6.1-0002-04/2
 Steam Turbine
Description
Design of the supports for the turbine has to allow for the
expansion of the turbine during thermal cycling. Constrained
thermal expansion would cause overstressing of the
components. The method of attachment of the turbine
components is also critical to the magnitude of the differential
expansion between the rotor and turbine casings which is
given careful attention in the determination of internal
clearances.
The following components form the fixed points for the
turbine:
 The HP, IP and LP turbine bearing pedestals
 The horn supports of the HP and IP Turbine at HP-IP
Pedestal
 At turbine end of longitudinal girder of the LP Turbine
 The thrust bearing in the HP turbine rear bearing pedestal
Casing Expansion
The bearing pedestals are anchored to the foundation by
means of anchor bolts and are fixed in position. The HP and
IP turbines rest with their lateral support horns on the bearing
pedestals at the turbine centerline level. The HP and IP
casings are connected with the bearing pedestals by casing
guides which establish the centerline alignment of the turbine
casings. The axial position of HP and IP casings is fixed at
the HP-IP pedestal. Thermal expansion of the casings
originates from the fixed points. The LP Turbine outer casing
is held in place axially, at turbine end of longitudinal girder by
means of fitted keys. Free lateral expansion is allowed.
BHEL, Hardwar
Fixed Points
Centering of LP outer casing is provided by guides who
run in recesses in the foundation
Cross beam. Axial movement of the casings is
unrestrained.
Hence, when there is a temperature rise, the outer
casings of the HP turbine expand from their fixed
points towards Front pedestal. Casing of IP Turbine
expand from its fixed point towards the generator.
LP Casing expands from its fixed point at front end,
towards the generator.
12
Rotor Expansion
The thrust bearing is housed in the rear bearing
pedestal of the HP turbine. The HP turbine rotor
expands from the thrust bearing
Towards the front bearing pedestal of the HP turbine
and the IP turbine rotor from the thrust bearing towards
the generator.
The LP turbine rotor is displaced towards the generator
by the expansion of the shaft assembly, originating
from the thrust bearing.
Differential Expansion
Differential expansion between the rotors and casings
results from the difference between the expansion of
rotor and casing originating from the HP-IP pedestal.
The largest differential expansions of the HP and IP
turbines thus occur at the ends farthest from the thrust
bearing.
Differential expansion between the rotor and casing of
the LP turbine results from the difference between the
expansion of the shaft assembly, originating from the
thrust bearing and the casing expansion, which
originates from the fixed points on the LP turbine
longitudinal beams.
6.1-0003-02/1
 12

Casing Expansion
Rotor Expansion

BHEL, Hardwar 6.1-0003-02/2

 Steam Turbine Technical Data
Description Construction, Speed
& Steam Pressure

Load
Rated Load 600 MW

Maximum Load under valve wide open (VWO) condition 629.2 MW

Construction
Three cylinder reheat condensing turbine

Single flow HP Turbine with 14 reaction stages Type : H30-100-2

Double flow IP Turbine with 10 reaction stages per flow Type : M30-63

Double flow LP Turbine (2 no.s) with (5 drum + 3 module) stages per Type : N30-4x6.3
flow

2 Main Stop and Control valves (HP casing mounted) Type : EV 320-1

2 Reheat Stop and Control Valves (Floating) Type : IV 560

1 Swing Check Valve in cold reheat line DN-800

Make : BHEL, Trichy

2 LP Bypass Stop and Control Valves with actuators & HPSU (High Make: CCI
pressure EHA based) Switzerland

Extraction Swing Check Valves

Extraction 1 : No valve

Extraction 2 : 2 Swing Check Valve with actuator and DN 600

2 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 3 : 2 Swing Check Valve with actuator and DN 500

2 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 4.1 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 4.2 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 5 : 1 Swing Check Valve with actuator and 1 Swing DN 400

Check Valve without actuator Make : BHEL, Trichy

Extraction 6 : No valve
DN 250
Extraction 7 : 1 swing check valve with actuator and 1 swing check
Make : BHEL, Trichy
valve without actuator

BHEL, Hardwar 6.1-0100-96/1

 Speed
Rated speed 50.0 c/s

Speed limitation in load and station operation

Max. Speed, no time limitation 51.5 c/s
Min. Speed, no time limitation 47.5 c/s
Permissible for maximum 2 hours during the life of LP blading
Speed below 47.5 c/s
Speed above 51.5 to 60 c/s

Speed exclusion range at operation without load * 7 to 47.5 c/s

Standard over speed trip setting Max. 55.5 c/s

* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance

Steam Pressures
♦ ♣ ♥ Unit
Rated Long time operation Short time operation

Initial Steam 170.0 174.0 203.9 ata

st
Before 1 HP drum stage 159.6 172.9 172.9 ata

HP cylinder exhaust 44.9 51.6 ♠ ata

53.8
IP cylinder stop valve inlet 40.4 40.8 ♠ ata
48.5
Extraction 6 44.9 51.6 53.8 ata

Extraction 5 18.3 21.5 21.5 ata

Extraction 4 7.1 8.48 8.48 ata

Extraction 3 2.8 3.42 3.42 ata

Extraction 2 1.465 1.81 1.81 ata

Extraction 1 0.346 0.43 0.43 ata

LP cylinder exhaust 0.1033 0.31 0.31 ata

♦ These values correspond to 600 MW load with 3 % make-up and 0.1033 ata back pressure
with all heaters in service and rated steam conditions.
♠ The safety valves must be set so that short time values are not exceeded.
♣ Long time operation: Upper limit value, permissible without time limit.
♥ Short time operation: Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in any one year
All pressures are absolute pressures

BHEL, Hardwar 6.1-0100-96/2

 Low vacuum trip, standard setting
Electrical low vacuum trip 0.3 bar

Electrical low vacuum trip bypass operation 0.6 bar

Seal steam supply system

Pressure in seal steam header (above atmospheric) 35 mbar

Axial shift
Alarm ± 0.5 mm

Trip ± 1.0 mm

Direction of rotation
Anti clock wise when viewed from Front Pedestal towards the Generator

BHEL, Hardwar 6.1-0100-96/3

 Steam Turbine Technical Data
Description Steam & Casing Temperatures

Steam Temperatures

Rated value, Long-term 400 hrs. 80 hrs. Per year

Annual value, subject to per year Max. 15 min in
average annual average individual case Unit

Main steam at HP 537.0 545.3 551.0 565.0 °C

stop valve inlet

HRH steam at IP 565.0 573.3 579.0 593.0 °C

Stop valve inlet

Steam Temperatures
Rated value Long term 80 hrs. per year, In special
♦ operation Max. 15 min. in cases at no
Unit
individual case load

HP turbine exhaust 331.6 333.6 423.6 ♥ °C

500.0
Extraction 7 390.9 390.9 453.9 °C
Extraction 6 331.6 333.6 423.6 ♥ °C
500.0
Extraction 5 463.1 468.1 503.1 °C
Extraction 4 327.3 337.3 377.3 °C
Extraction 3 208.2 221.2 268.2 °C
Extraction 2 117.6 137.6 182.6 °C
Extraction 1 74.9 94.9 144.9 °C
LP turbine exhaust 46.0 70.0 70.0 °C
Long-term operation: upper limit value permissible without time limit.
♦ These values correspond to 600 MW Load with 3% makeup and 33 deg. Design CW inlet
with all heaters in service and rated steam conditions.
♥ Only valid for the no load period with high reheat pressure after trip-out from full load
operation. For individual case approx. 15 minutes.
The turbine is immediately re-loaded or the boiler immediately reduced to minimum load if no
load operation is maintained.

Casing Metal Temperatures

Wall Temperatures Alarm at Machine must be shut down at Unit

HP turbine casing exhaust 485 500 °C
Outer casing of LP cylinder 90 110 °C
Spray water to LP turbine must be switched on at 900C

BHEL, Hardwar 6.1-0101-96/1

 Casing Metal Temperature Differences

Temperature Difference Alarm at Machine must be tripped at Unit

Between upper & lower casing ± 90 ± 100 °C

halves of HP turbine, middle

Between upper & lower casing ± 30 ± 45 °C

halves of IP turbine, front & rear

Permissible differential temperature between parallel steam supply lines

No time limitation 17 °C
Short time period (15 min) 28 °C
In the hottest line the limitations indicated for main and reheat steam temperature must not be exceeded

Feed water Heater out of service

Operation with feed water heaters out of service Main steam flow, Kg/s Load,
(indicative) MW
Extraction A6, A5 (Both strings out) 445 600

Output Limit during Testing with Automatic Turbine Tester

Testing of main steam stop and control valves < 300 MW

Testing of HRH steam stop and control valves 300 MW

Motoring
Motoring is the condition in which the turbine is driven by the generator at rated speed with the
stop and control valves closed. In this operating mode, certain turbine components are heated up
by wind age power of the blading.
To prevent heat-up beyond permissible temperatures, motoring must not be allowed to continue
for longer than one minute. If the condenser low vacuum limit of 0.3 bars is exceeded, motoring
must not be allowed to continue for more than 4 seconds.

BHEL, Hardwar 6.1-0101-96/2

 Steam Turbine Technical Data
Description Bearing Metal Temperatures
Vibration, Weights

Bearing babbit metal temperatures

Alarm at Machine must be shut down at

Operation temperature below 75 °C 90 °C 130 °C

Operation temperature 75 to 85 °C 100 °C 130 °C

Operation temperature 85 to 90 °C 110 °C 130 °C

Operation temperature above 90 °C 115 °C 130 °C

Vibration
Absolute bearing housing vibration Absolute shaft vibration
Standard alarm setting 50 μm above normal level
Maximum alarm setting 84 μm 200 μm
Limit value for tripping 106 μm 320 μm

ƒ The normal level is the reproducible vibrational behaviour typical for the machine &
dependent on the operating conditions.

ƒ Vibration readings indicated in control room are peak to peak. The above values are also
given in peak to peak.

Weights
HP turbine, completely assembled 95 T
IP turbine, top half outer casing 26 T
IP turbine, top half inner casing, complete with blading 16 T
LP turbine, top half outer casing complete  T

LP turbine, top half inner outer casing, complete with blading, guide blade carriers &  T
diffusers
HP turbine rotor, complete with blading 16 T
IP turbine rotor, complete with blading 23 T
LP turbine rotor, complete with blading 59 T
Main stop and control valve, complete with servo motors, without bend & pipe section 22 T

Reheat stop and control valve, complete with servo motors, without bend & pipe 32 T
section

All weights have been calculated with safety allowances. Slings chosen must provide sufficient security.

BHEL, Hardwar 6.1-0102-96

 Steam Turbine Technical Data
Description Oil Supply, Oil Pumps

OIL supply
Main oil tank, rated capacity 25/40 M3

First oil filling (estimated) 53 M3

Flushing oil quantity (estimated) 32 M3

Oil cooler for operation, number 1 No.

Oil cooler for reserve, number 1 No.

Min. 38 °C
Oil temperature at cooler outlet, unit in operation Normal 45
Max. 47

Oil temperature at cooler outlet, unit shut down Max. 75 °C

Temperature rise of oil in bearings Normal 20 °C

Max. 25

Estimated oil requirement for Bearing 1 0.8 dm3/s

Estimated oil requirement for Bearing 2 15.4 dm3/s

Estimated oil requirement for Bearing 3 4.55 dm3/s

Estimated oil requirement for Bearing 4 9.29 dm3/s

Estimated oil requirement for Generator front bearing 7.92 dm3/s

Estimated oil requirement for Generator rear bearing 7.92 dm3/s

Estimated oil requirement for Exciter bearing 0.70 dm3/s

Estimated oil requirement for Hydraulic Barring at 4.5 – 5.0 bar 57.4 dm3/s

Duplex oil filter- full flow, Type: 2.68.2, size 355/750, Nb 150 1 No.
Make: MS HYDAC FILTER TECHNIK GMBH.

Filtration particle size of duplex filter element 25 μm

Filtration particle size of main oil tank filter element 250 μm

Safety valve in jacking oil system, setting 200 bar

Pressure limiting valve in jacking oil system, setting 178 bar

BHEL, Hardwar 6.1-0103-96/1

 Duplex oil filter for jacking oil, Type: DFDK 330 D40 W/Hc/-V-So212 1 No

Make: M/s: HYDAC FILTER TECHNIK GMBH.

Filtration particle size of jacking oil filter 37 μm

Jacking oil pump, cut-in and cut-out speeds

ƒ Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid
damage to bearings.
ƒ Jacking oil pump should be cut-out at speeds above approx. 540 rpm.
Oil pumps
Auxiliary oil DC emergency Jacking oil pump
pump oil pump

Quantity 2 1 AC: 1 DC: 1

Quality Make Rated Discharge Speed

Capacity
Main oil pump 1 BHEL 350 9.1 3000

BHEL, Hardwar 6.1-0103-96/2

 Steam Turbine Technical Data
Description Control Fluid System &
Control Fluid Pumps

CONTROL FLUID SYSTEM

A Fire Resistant Fluid (FRF) is used for the control system

Control fluid tank, rated capacity 10/16 M3

First fill quantity (estimated) 15 M3

Flushing fluid quantity (estimated) 12 M3

Control fluid cooler for operation 1 No.

Control fluid cooler for reserve 1 No.

Control fluid regeneration system

Gear pump Make: Tushaco

Fluid flow 0.25 dm3/s

Gauge pressure 3 bar

speed 1410 rpm

Motor power 0.55 KW

1 No. Drying filter

1 Nos. Fuller’s earth filter
1 No. Fine filter

BHEL, Hardwar 6.1-0104-96-1

 Control Fluid Pumps

Control fluid pumps 2 Nos.

Manufacturer KSB, Type: WKVM80/1+3

Speed 2982 rpm

Drive A.C. motor, Manufacturer – Siemens AG Type: ILG4313-2AB94-Z

Enclosure IP 55

Voltage 400V V

Frequency 50 Hz

Motor rating (at 50ºC) 121 KW

Motor rating (at 40ºC) 132 KW

Rated current 196 A

Starting current 1614 A

Control fluid pumps operating characteristics Fluid flow Discharge

(dm3/s) Pressure (bar)

Operating point I (normal operation)

Low pressure leakage fluid 7.60 11.5

High pressure leakage fluid 6.16 38.5

Operating point II (during start & opening of stop valve servomotors)

Low pressure leakage fluid & low pressure control fluid 20.60 10.8

High pressure leakage fluid 6.16 37.8

Operating point III (during opening of CV servomotors)

Low pressure leakage fluid 7.60 10.0

High pressure leakage fluid & high pressure control fluid 16.16 31.0

All pressures are gauge pressures.

BHEL, Hardwar 6.1-0104-96-2

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference Δθ in the wall of HP stop and control valve casing during Sliding
Pressure Operation Mode

140

120 Δθ = f(θm )
Heating up
100
F
80

N
60

40 S
Δθ[K] OPERATION MODE
F=Fast
20 N=Normal
S=Slow

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600

θm [°C]

Δθ = (θi - θm) on the wall temperature sensor

θI = temperature of inner layer
θm = temperature of middle layer

BHEL, Hardwar 6.1-0110-01

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference Δθ in the wall of HP casing during

Sliding Pressure Operation Mode

140

120 Δθ = f(θm)

100 Heating up

80 F

60

N
40
Δθ[K] OPERATION MODE
F=Fast S
N=Normal
20 S=Slow

-20

-40
Cooling down

-60

-80
0 100 200 300 400 500 600

θm [°C]
Δθ = (θi - θm) on the wall temperature sensor
θi = temperature of inner layer
θm = temperature of middle layer

BHEL, Hardwar 6.1-0111-01/1

 Permissible temperature difference Δθ in the wall of the HP casing during
Constant Pressure Operation Mode

140

120 Δθ = f(θm )

100
Heating up

80 F

60
N

40
OPERATION MODE
S
F=Fast
N=Normal
20 S=Slow
Δθ[K]
0

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600

θm [°C]
Δθ = (θi - θm) on the wall temperature sensor
θi = temperature of inner layer
θm = temperature of middle layer

BHEL, Hardwar 6.1-0111-01/2

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference Δθ in the HP turbine shaft during

Sliding Pressure Operation Mode
200
180
Δθ = f (θ m )
160
Heating up
140
120 F
100
80 N
Δθ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

220

200

180

160

Δθ[K] 140

120

100

80

60
θax [° C]
0 20 40 60 80 100 120

Δθ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL, Hardwar 6.1-0112-01/1

 Permissible temperature difference Δθ in the HP turbine shaft during
Constant Pressure Operation Mode

180
160
Δθ = f (θm)
140
Heating up
120
100 F
80
60 N
Δθ[K]
40
S
20 OPERATION MODE
0 F = Fast
N = Normal
-20 S = Slow
-40
-60
Cooling down
-80
-100
θm [°C]
0 100 200 300 400 500 600

200

180

160

140

120
Δθ[K]

100

80

60

40
θax [° C]
0 20 40 60 80 100 120

Δθ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL, Hardwar 6.1-0112-01/2

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference Δθ in the IP turbine shaft during

Sliding Pressure Operation Mode
200
180
Δθ = f (θm)
160
Heating up
140
120 F
100
80 N
Δθ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

20

00

80

60

40

Δθ[K] 20

00

80

60
θax [°C]
0 20 40 60 80 100 120

Δθ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL, Hardwar 6.1-0113-01

 Steam Turbine Steam Purity values
Description for main steam condensate

The deposits which occur in turbines due to impurities in the
steam can lead to thermodynamic and mechanical
inefficiencies and, with the presence of salts, especially
chlorides, and sodium hydroxide also causes damage to
turbine parts. The corrosion stressing caused by active
deposits, for example, has an adverse effect on the fatigue
strength of the blade material when the steam is in the
transition zone between the superheated and the saturated
state.
Compliance with the target values is mandatory in
continuous operation, with the values in the normal
operation column preferable. With the commissioning of a
new plant and starting-up operation, however, these values
cannot be attained with an economical outlay. The values
listed in the column “starting-up operation “are then valid.
It should be pointed out that adherence to the target values
does not rule out deposition in the turbine with absolute
certainty. Wherever possible every effort should be made to
achieve the values in the normal operation column.
A recording instrument may be used to continuously
monitor the electrical conductivity of the main steam and
turbine condensate following a strongly acid cation
exchange unit. In order to determine slight impurities, the
sodium concentration should be measured in addition to
this. Should saline contamination occur, the turbine is to
be immediately washed with saturated steam to remove
salt deposits?
Whether an alkaline, neutral or combined method is used
for conditioning, the water steam circulation is for the
customer to decide. If an alkaline method is used, the
oxygen content in the main steam condensate can be
max. 0.02 mg/kg and the pH value in the turbine
condensate max.9.3 with brass condenser piping. When
the condenser piping is of copper-nickel alloys, the pH
value must not exceed 9.5. There is no limitation for the
pH value with non- corroding steel or titanium.

Recommended values for main steam condensate

Quantity Target Value Normal Start Up
* Operation **
Conductivity at 25°C, down stream of highly μS/cm < 0.2 0.1 < 0.50
acidic sampling cation exchanger,
continuous measurement at sampling point
Silica (SiO2) mg/kg < 0.020 0.005 < 0.050

Total iron (Fe) mg/kg < 0.020 0.005 < 0.050

Total copper (Cu) mg/kg < 0.003 0.001 < 0.010
Sodium (Na) mg/kg < 0.010 0.002 < 0.020
* To avoid any drop in efficiency, it is recommended that values be kept below the target values
and into the range of the values for normal operation.
** The target values must show a noticeable downward trend. On initial start-up of new plants the
values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours
for other start-ups.

BHEL, Hardwar 6.1-0120-01

 Steam Turbine Oil Specification
Description Standard

Introduction
This standard specifies the turbine oil recommended for
use in governing and lubrication systems of BHEL make
steam turbo set.
Description
Oil of viscosity class ISO VG 46 shall be used. The oil
shall be a petroleum product with or without additives to
meet the requirement of this standard. The finished oil
shall be clear and free from water, suspended matter,
dust, sediment and other impurities.
Compatibility
For topping up of the oil system, it is preferable if the oil
used is of the same brand and quality as that already in
the system. However, if the same brand of oil is not
available and where it is intended to mix in different
products that individually conform to this standard, a
compatibility test should be conducted before actually
mixing the oils. Samples of both the oils in equal volume
should be mixed and centrifuged for about 40 hrs. And
then mixture must comply fully with the requirements of
this standard.

The turbine oil shall not contain additives having any
negative effect on the materials of the oil system. The
turbine oil must be capable of withstanding bearing
temperature of max. 130°C and oil tank temperature of
max. 80°C without physical and chemical degradation.
The properties of the oil shall not be affected by
centrifuging, water washing or filtering.
Properties
The oil should comply with the requirements given in
table below when tested according to the test methods
given in the respective standards mentioned against each
property. For obvious reasons, we do not give any special
recommendation to a particular brand of oil to be used in
the oil system of our turbo sets. Any brand of the oil
complying with the above standards may be used.

Properties of turbine oil ISO VG 46 shall be as follows:

Sl. No. Properties Value Unit Test Method
1. Kinematic Viscosity at 40ºC 41.4 – 50.6 cst IS: 1448, P-25 ASTM D445
Kinematic Viscosity at 50ºC 28 cst
2. Viscosity Index 98 Min. IS: 1448, P-56 -----

3. Neutralization No. (Total ≤ 0.20 mg IS: 1448, P-1 ASTM D974

acidity) KOH/g
4. Colour ≤2 Max. IS: 1448, P-12 ASTM D1500

5. Specific gravity at 50 ºC 0.85 --- IS: 1448, P-32 ASTM D1298

Specific gravity at 15 ºC 0.90 ---
6. Flash point (Cleveland > 200 °C IS: 1448, P-69 ASTM D92
open cup)
7. Copper strip corrosion test at Not worse --- IS: 1448, P-15 -----
100 ºC for 3 hrs. than No.1

8. Pour point ≤-6 °C IS: 1448, P-10 ASTM D97

9. Rust preventing ≤ 0-B --- DIN: 51585 ASTM D665

characteristics

BHEL, Hardwar 6.1-0130-04/1

 Properties contd.
Sl. No. Properties Value Unit Test Method
10. Emulsion characteristics ≤ 20 minute DIN: 51599 ASTM D1401

11. Total acidity after 2500 ≤ 0.2 mg DIN: 51587 ASTM D943
hrs oxidation KOH/g
12. Foaming characteristics at ----- ASTM: D892
25°C
- Foaming tendency ≤ 400 cm3
- Foaming stability ≤ 450 s s
13. Deaeration capacity at 50°C ≤ 4 minutes DIN: 51381 ASTM: D3427

14. Ash (by weight) ≤ 0.01 % IS:1448, P-4 -----

15. Water content by weight ≤ 0.01 % DIN: 51777-1 ASTM: D1744

16. Solid particles by weight ≤ 0.05 % DIN: 51592 -----

17. Particle distribution -/17/14 Minimum ISO: 4406

(Class-8) (NAS: 1638)
18. Water release ≤ 300 s DIN: 51589-1

Following brands of oil are acceptable

Supplier Brand Supplier Brand

lOC Servo Prime 46 Castrol lndia Ltd. Castrol Perfecto T-46-Superclean

Gulf Oil India Ltd Gulf Crest 46 Bharat Petroleum Turbol 46
Apar Ltd. Power Turbo-46 Indo Mobil Ltd. Mobil DTE Medium / DTE798
Caltex Regal R&O 46 Savita Chemicals Daphne Super Turbine oil 46
HPCL Turbinol 46 Bharat Shell Ltd. Shell Turbo oil T46
TOTALFINAELF Total Preslia 46

Also refer to the following sections:

[1] 6.3-0080: Turbine oil Care

BHEL, Hardwar 6.1-0130-04/2

 Steam Turbine
Description
This specification is valid for Fire Resistant Fluids (FRF)
recommended for BHEL make steam turbine control
system. According to ISO 6743/4, FRF is a fluid based on
triarylphosphate ester marked ISO-L-HFDR.
General Requirements
The FRF shall not cause corrosion to Steel, Copper and
its alloys, Zinc, Tin or Aluminum.
The FRF must provide sufficient corrosion protection to
the materials used in the FRF system.
The FRF shall be continuously regenerated with Fuller’s
earth or an equivalent regeneration agent.
Note: Before using regeneration agents other than
Fuller’s earth (e.g. ion exchangers) BHEL and FRF
manufacturer or supplier shall be contacted.
The FRF must not cause any erosion or corrosion on the
edges of the control elements.
The FRF must be shear-stable. It should not contain any
viscosity index improver.
FRF leaking from the system, if any, must not ignite or
burn in contact with hot surfaces (up to 550 ºC).
The FRF must be capable of withstanding continuous
operating temperatures of 75 °C without physical or
chemical degradation.
The FRF must be miscible with traces (max. 3 % by vol.)
of TXP of another brand. There should be no
deterioration of the FRF in presence of such trace
quantities.
BHEL, Hardwar
Fire Resistant Fluid (FRF)
for Turbine Control System
The air release of the FRF should not deteriorate in
presence of Fluorelastomer seals and packing used in
the FRF system.
The FRF must be free of ortho-cresol compounds.
The FRF must not pose a safety or health hazard to the
persons working with it, provided that the requisite
hygiene regulations are observed.
Limit values
The following limit values are not to be exceeded during
the life time:
Kinematic viscosity - maximum variation ± 5% with
reference to delivery condition.
Neutralizations number - maximum increase 0.20 mg
KOH/g with reference to delivery condition.
Air release -maximum 12 minutes.
Foaming at 25 °C -Tendency maximum 200 ml, Stability
maximum 450 sec.
Disposal
Supplier to be contacted for ‘Buy Back’ of used fire
resistant fluid.
In consultation with supplier, liquid material should be
incinerated and material absorbed on sand should be
disposed off as hazardous solid waste.
6.1-0140-04/1
 Recommended Properties of new batches of FRF
Property Numerical Unit Test method
Value
DIN / ISO ASTM
Kinematic Viscosity at 40 °C 41.4 - 50.6 mm2/s DIN 51 562-1 D 445
(ISO VG 46)
Air release at 50 °C ≤3 minutes DIN 51 381 D 3427
Neutralisation number ≤ 0.1 mg KOH/g DIN 51 558-1 D 974
Water content ≤ 1000 mg/kg DIN 51 777-3
Foaming at 25 °C Tendency ≤ 100 ml D 892
(Seq. 1)
Stability ≤ 450 sec
Water separability ≤ 300 sec DIN 51 589-1
Demulsification ≤ 20 minutes DIN 51 599 D 1401
Density at 15 °C ≤ 1250 kg/m3 DIN 51 757 D 1298
Flash point (Cleveland open cup) > 235 °C DIN/ISO 2592 D 92
Ignition temperature > 550 °C DIN 51 794
Wick flame persistance time ≤5 sec DIN/ISO 14935
Pour point ≤ −18 °C DIN/ISO 3016 D 97
Particle distribution * ≤ 15/12 Code ISO 4406
Chlorine content ≤ 50 mg/kg DIN 51 577-3
Oxidation stability ≤ 2.0 mg KOH/g DIN 51 373
Hydrolytic stability ≤ 2.0 mg KOH/g DIN 51 348
Change of neutralisation number
Electrical resistivity > 50 MΩm IEC 247
* The required system cleanliness is dependent upon the system design. Suitable measures (e.g.
filtration, separation) have to be taken to achieve this cleanliness level.

Following fire Resistant Fluids are approved:

Brand Supplier

1. Reolube Turbofluid 46XC M/s. Chemtura, UK

2. Fyrquel EHC-N M/s. Supresta, USA

Also refer to the following sections:

[1] 6.3-0082: Care of control fluid

BHEL, Hardwar 6.1-0140-04/2

 Steam Turbine
Description HP Turbine
Valve Arrangement

General Arrangement The short length of the admission section between

the control valves and the casing results in a very low
The HP turbine has 2 main stop valves and 2 control steam volume in this section, which has a beneficial
valves located symmetrically to the right and left of the effect on the shutdown characteristics of the turbine-
casing. generator unit.

The valves are arranged in pairs with one main stop valve Valve Actuation
and one control valve in a common body.
Each main stop valve and control valve has a
Steam flow dedicated hydraulic servomotor (3; 5).

The main steam is admitted through the main steam inlet The servomotors are mounted above floor level so
passing first the main stop valves and then the control valves. that they are accessible and can be easily maintained.

From the control valves the steam passes to the turbine

casing (1).

BHEL, Hardwar 6.1-0205-00

 Steam Turbine HP Turbine
Description Casing

Barrel type Casing The inner casing too is almost cylindrical in shape as
the joint flanges are relieved by the high pressure
The HP outer casing is designed as a barrel-type casing
acting from the outside and can thus be kept small.
without axial joint.
For this reason, turbines with barrel type casing are
An axially split inner casing is arranged in the barrel-type
especially suitable for quick start-up and loading.
casing.
Because of its symmetrical construction, the
Seals
barrel - type casing retains its cylindrical shape and remains The pretension U-shaped seal ring that is forced
leak proof during quick changes in temperature (e.g. on start- against the axial sealing surfaces by the steam
up and shut down, on load changes and under high pressure and the I-shaped seal ring that allows axial
pressures). displacement of the inner casing seal the space
between the inner casing and the barrel type outer
casing from the adjacent spaces.

Fig. 1 HP Turbine

BHEL Hardwar 6.1-0210-01/1


3 Outer Casing
4 Inner Casing
6 U Seal Ring
7 Cylindrical Pin
8 Breech Nut
9 Inlet Pipe from Main Stop and Control Valve
Connection to Main Stop and Control Valves
The steam lines from the main stop and control valves are
connected to the inlet connections of the outer casing by
Breech Nuts (8) (Fig.2) through buttress threading.
Fig.2 Inlet Connection
Sealing is achieved by U-seal rings (6) which are
forced against the outer sealing surface by inlet steam
pressure.
The annular space around the sealing ring is
connected to the condenser through a steam leak-off
line.
Cylindrical pins (7) located at the joint flange
prevent rotation of the inlet pipe with respect to the
outer casing.

3 Outer casing
3 Outer casing 4 Inner casing
4 Inner casing 10 Fitted Key
11 Fitted Key

Fig. 3 Centering and support of Fig.

Inner casing (Admission side)
Fig.4 Centering and support
4 Centering of
and support of
inner casing (Exhaust side)
Inner casing (Exhaust side)

BHEL Hardwar 6.1-0210-01/2

Attachment of Inner Casing

The inner casing (4) is attached in the horizontal and

vertical planes in the barrel-type casing(3) so that it can freely
expand radically in all directions and axially from a fixed point
when heating up while maintaining concentricity relative to
the turbine rotor.
On the admission side, four projections of the inner casing
(4) and on the exhaust side three projections fit into
corresponding grooves in the barrel-type casing (3).
In the horizontal plane these projections rest on fitted keys
(10) and in the vertical plane they are guided by the fitted
keys (11) (Fig.3&4).
Radial expansion is therefore not restricted by this
suspension.
As shown in fig.6 the axial fixed point of the inner casing is
provided by a shoulder in the barrel-type casing (3) against
which a collar of the inner casing (4) rests.
The axial thrust to which the inner casing is subjected is
transmitted to and absorbed by the thrust ring (14) via thrust
pads (13).
The thrust ring is held in position by support ring (15).
Outlet Connections
The exhaust end of HPT has single outlet connection from
bottom.
At the flange connection a U-seal ring (19) is provided to
prevent any leakage (Fig.1)

3 Outer casing 13 Thrust pads

4 Inner casing 14 Thrust pads
12 U- seal ring 15 Support ring

Fig. 6 Axial Retention of Inner casing and Centering in vertical plane (Detail E from Fig.1)

BHEL Hardwar 6.1-0210-01/3

 Steam Turbine HP Turbine
Description Blading

Moving and Stationary Blades

The HP turbine with advance blading consists of 17drum
stages. All stages are reaction stages with 50% reaction.
The stationary and moving blades of all stages (Fig.1) are
provided with inverted T-roots which

A 2

B
.
The moving and stationary blades are inserted into
4
corresponding grooves in the Shaft (4) and inner
casing (1) and are caulked at bottom with caulking
piece (5).
5 The insertion slot in the shaft is closed by a locking
blade which is fixed by taper pins or grub screws.
End blades are used at the joint plane in L/H & U/H of
inner casing along with predetermined interference.
Gap sealing
Fig. 1 Drum Stages Sealing strips (6) are caulked into the inner casing (1)
and the shaft (4) to reduce leakage losses at the blade
tips.
1 Inner casing 4 Turbine shaft
2 Guide blade 5 Caulking piece Cylindrically machined surface on the blade shrouds
3 Moving blade are opposite the sealing strips.
Also determine the distance between the blades. The The surfaces have stepped diameters in order to
shrouds are machined integral with the blades and form a increase the turbulence of the steam and thus the
continuous shrouding after insertion. sealing effect.

From 1st. to 8th. Stages are provided with ‘3DS’ blades, 9th. to
13th. Stages with ‘TX’ blades and
14th. to 17 th. Stages with ‘F’ blades.
Should an operational disturbance cause the sealing
strips to come into contact with opposite surfaces, they
are rubbed away without any considerable amount of
heat being generated.
They can easily be renewed at a later date to provide
the specified clearance.

BHEL, Hardwar 6.1-0220-02

 Steam Turbine HP Turbine
Description Shaft seals and Balance Piston

Function Diameter is suited to the requirements for balancing

The function of shaft seals is to seal the interior of the casing
from the atmosphere at the ends of the shaft on the
admission and exhaust sides. The HP Turbine has shaft
seals in front and rear. The front shaft seal is of labyrinth
type, while the rear shaft seal is of ‘see through’ type. The
difference in pressure before and after the raised part of the
shaft seal on the admission side serves to counteract the
axial thrust caused by steam forces. The raised part is called
Balance piston. The effective seal
the axial thrust.
Gap Seals
Sealing between the rotating and stationary parts of
the turbine is achieved by means of seal strip (6)
caulked into seal rings (2, 7, 9) and into the rotor (3)
(details D and E). The pressure gradient across the
seal is reduced by conversion of pressure energy into
velocity energy which is then dissipated as turbulence
as the steam passes through the numerous
compartments according to the labyrinth principles.

Fig. 1 Shaft Seal Admission side Seal Rings

1 Inner casing 2 Seal ring The seal rings (2), the number of which depends on
3 Turbine rotors the pressure gradient to be sealed are divided into
4 Shaft seal cover several segments as shown in Section A-A, B-B
5 Caulking wire
6 Seal strip
and C-C and mounted in T -shaped annular grooves in
the inner casing (1 ) and shaft seal cover (4) such that
they are free to move radially. Each segment is held in
position against a shoulder by helical springs (11). This
provides the proper clearance for the seal gaps.
Should rubbing occur, the segment concerned can
retreat? The heat developed by light rubbing of the
thin seal strip (6) is so slight that it cannot cause
deformation of the rotor (3).

Fig. 2 Shaft seal Exhaust side

BHEL, Hardwar 6.1-0230-01/1


When the turbine is started from the cold or warm state, the
seal rings naturally heat up faster than the casing. However,
they can expand freely In the radial direction against the
centering force of the helical spring (11).
The shaft seals are axial-steam flow non-contacting seals.
In the region subjected to the low relative expansion in the
vicinity of the combined journal and thrust bearing, the seal
strips are caulked alternately into the shaft and into spring-
supported segmented sealrings in the casing, forming a
labyrinth to impede the outflow of steam (Detail D).
BHEL, Hardwar
In the region subject to greater relative expansion at
the exhaust end, see through seals are used in which
the seal strips are located opposite each other, caulked
into the shaft and into seal rings centered in the outer
casing (Detail E).
The outer seal rings can be removed for inspection and
if necessary, seal strips can be replaced during short
turbine shut down.
Steam Spaces
Steam spaces are provided within the shaft seals.
From spaces ‘Q’ and ‘R’ leakage is drawn off to
another part of the turbine for further use. The steam
seal header is connected to space ’S’. The slight
amounts of leakage steam which are still able to pass
the seal ring are conducted from the space ‘T’ into the
seal steam condenser.
6.1-0230-01/2
 Steam Turbine
Description HP Turbine
Front Bearing Pedestal

Arrangement Connection of Bearing Pedestal and Foundation

The front bearing pedestal is located at the turbine-
Side end of the turbine generator unit. Its function is to
support the turbine casing and bear the turbine rotor. It
houses the following components and instruments.
Journal bearing [1]
Hydraulic turning gear [2]
Main oil pump with hydraulic speed transducer [3]
Electric speed transducer [4]
Over speed trip [5]
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Details of casing supports and casing guides are given in
description 6.1-0280.
The bearing pedestal (1) is aligned to the foundation
By means of hexagon head screws that are screwed
into it at several points. On completion of alignment,
the space beneath the bearing pedestal is filled with
special non-shrinking grout. The bearing pedestal is
anchored to the foundation by means of anchor bolts
(13). The anchor bolt holes are filled with gravel, which
gives a considerable vibration damping effect.
The defined position of the bearing pedestal on the
foundation is established by a projection in the middle
of the bearing pedestal base engaging in a recess in
the Foundation. On completion of alignment, the
remaining space in this recess is likewise filled with
grout.

1 Bearing pedestal 7 Hydraulic turning gear

2 Main oil pump 8 Bearing pedestal vibration pick-up
3 Hydraulic speed transducer 9 Shaft vibration pick-up
4 Electric speed transducer 10 Journal bearing
5 Gear coupling 11 HP turbine rotor
6 Over speed trip
Fig.1 Axial Section through HP Turbine Front Bearing
Pedestal

BHEL, Hardwar 6.1-0240-01/1

 Fig. 2 Cross section of main oil pump

Fig. 3 Cross Section of Journal Bearing

[4] 5.1-0760Information
Also Refer to the Following Electric Speed Transducer
9 Journal bearing also refers to the [1] 6.1-0270 Journal Bearing
following information [2] 6.1-0510 Hydraulic Turning Gear
12 Foundations [3] 6.1-1020 Main Oil Pump with Hydraulic Speed Transducer
13 Anchor bolts [1]Speed
[4] 6.1-0760 Electric 5.1-0270 Journal Bearing
Transducer
14 Hex head screw [2] 5.1-0510
[5] 6.1-0920 Over Speed Trip Hydraulic Turning Gear
[3] 5.1-1020 MainOilPump with Hydraulic Speed Transducer

[5] 5.1-0920 Overspeed trip

BHEL, Hardwar 6.1-0240-01/2

 Steam Turbine HP Turbine
Description Rear bearing Pedestal

Arrangement
The bearing pedestal is located between the HP and IP
turbines. Its function is to support the turbine casing and bear
the HP and IP turbine rotors.
The bearing pedestal houses the following turbine
Components:
Combined journal and thrust bearing
Shaft vibration pick-up
Bearing pedestal vibration pick-up
Thrust bearing trip (electrical)
Details of casing supports and casing guides are given in
descriptions 6.1-0280 and 6.1-0350.
Connection of Bearing Pedestal and Foundation
The bearing pedestal is aligned on the foundation by means
of hexagon head screws that are screwed into it. On
completion of alignment, the space beneath the bearing
pedestal is filled-in with special non-shrinking grout. The
bearing pedestal is anchored to the foundation by means of
anchor bolts. The anchor bolt holes are filled with gravel,
which gives a considerable vibration damping effect. The
defined position of the bearing pedestal on the foundation is
established by a projection in the middle of the bearing
pedestal base engaging a recess in the foundation. On
completion of alignment, the remaining space in the recess is
likewise filled with grout.
8

1 HP turbine rotor
2 Combined journal and thrust bearing
3 Bearing pedestal vibration pick-up
4 Shaft vibration pick-up
5 Thrust bearing trip (electrical)
6 Coupling bolts
7 IP turbine rotor
8 Foundation

Fig. 1 Axial Section through the HP Turbine Rear

bearing pedestal

BHEL, Hardwar 6.1-0250-02/1

 9 8

2 Combined journal and thrust bearing 10 Straight pin

8 Foundations 11 Anchor bolt
9 Hex head screw 12 Plate
13 Round nut
Fig. 2 Cross Section through Combined Journal and 14 Hex nut
Thrust Bearing 15 Guard cap
Fig. 3 Connection between Bearing Pedestal and
foundation

BHEL, Hardwar 6.1-0250-02/2

 Steam Turbine Combined Journal and Thrust Bearing
Description

Function The journal bearing is constructed as elliptical sleeve

The function of the combined journal and thrust bearing is to
support the turbine rotor and to take the residual axial thrust.
The magnitude and direction of axial thrust to be carried by
the bearing depends on the load conditions of the turbine.
This bearing is located in the bearing pedestal between HPT
& IPT. The thrust bearing maintains desired axial clearances
for the combined turbine generator shaft system.
Construction and Mode of Operation
The combined journal and thrust bearing consists of the
upper and lower bearing shells (4, 12), thrust pads (6), cap
(2), spherical blocks (14, 16) and keys (10, 17). The upper
and lower halves (4, 12) of the bearing shell are bolted and
doweled at the horizontal joint by means of 4 taper pins and 4
stocker-head screws.
Section A-A
1 Bearing pedestal, upper 7 bearing liner
2 Cap 8 Turbine shaft
3 Key 9 Brg. pedestals
4 Bearing shell upper lower
5 Cowling with all baffle 10 Key
6 Thrust pad 11 Oil line
bearing. The bearing liners are provided with a
machined babbit face; additional scraping is neither
necessary nor allowable.
In order to prevent the bearing from exerting a bending
moment on the shaft, it is pivot-mounted on spherical
support (16). The spherical block (14) with shims (13,
15), is bolted to the lower bearing shell (12). A
transverse projection in the upper part of the cap (2)
and the fitted key (3) prevent the bearing shells from
rising.
The bearing shells are located laterally by keys (10).
The bearing is supported axially against the bearing
pedestal (1, 9) by means of keys (17, 18) (Section H-
H). This fixing is of great importance for axial clearance
in the whole Turbine.
Located at each end of the bearing shell, babbitted
thrust pads (6) form two annular surfaces on which the
integralily machined shaft
Collars run.
Section B-B
12 Bearing shell lower
13 Shim
14 Spherical blocks
15 Shim
16 Spherical supports
25 Key
“a” Shaft jacking oil

BHEL, Hardwar 6.1-0260-01/1

These collars and thrust pads permit equal loading of the
19 Thermocouple
thrust bearing in either direction. As shown in section N-N,
20 Thermocouple
the thrust pads are of the tilting type, secured in place by pins
(23) and flexible mounted on split spring element (21). Oil Supply
Temperature Measurement Lubricating oil is admitted to the bearing shells from
one side via oil line (11) from where it flows to the oil
Metal temperature of the journal bearing and thrust pads is
spaces milled into the upper and lower bearing shells
monitored by the thermocouples (19, 20) (Section E-E and G-
at the horizontal joint.
G).

Oil leaving the journal bearing flows to the two annular

grooves adjacent to the bearing surface and then to
the thrust pads (6). Through the two oil return cowlings
(5), oil is discharged into the drain area in the pedestal
(9)
Jacking Oil
Passages are located at the lowest point in the lower
bearing shell through which high pressure jacking oil is
supplied under the journal at low speed of the turbine
rotor (on start up or shutdown). Thus dry friction is
prevented and the breakaway torque on start-up with
turning gear is reduced.
High pressure oil “a” flows under the journals
via0the oil line and via openings in the lower bearing
shell (12). O-ring (24) located between the bearing
liner (7) and the lower bearing shell (12) prevents any
oil from penetrating between the two elements (Detail
“C”).
Any leakage passing the seal will drain off to the
bearing pedestal through a groove in the lower bearing
4 Bearing shell upper 21 Spring element shell. This arrangement ensures that no oil penetrates
6 Thrust pad 22 Key between the bearing liner and the bearing shell.
12 Bearing shell lower 23 Dowel pin

BHEL, Hardwar 6.1-0260-01/2

 Steam Turbine Journal Bearing
Description HP front

Construction Keys (8) are fitted on both sides of the projection.

The function of the journal bearing is to support the turbine
rotor. Essentially the journal bearing consists of the upper
and lower shells (3, 6); bearing cap (1), spherical block (7),
spherical support (14) and the key (11) .The bearing shells
are provided with a babbit face. The babbit surface of the
bearing is precision machined and additional scraping is
neither necessary nor permissible. Both bearing shells are
fixed by means of taper pins and bolted together.
In order to prevent the bearing from exerting a bending
moment on the rotor (5), it is pivot-mounted in the spherical
support (14). For this purpose the spherical block (7) with
shims (12, 13) is bolted to the bearing shell (6). A projection
in cap (1) with shims (9) fits into a corresponding groove in
the bearing shell (3) and prevents vertical movement of the
bearing shells.
The bearing shells are fixed laterally by key (11) which
are bolted to each other. Each key is held in position in
the bearing pedestal (10) by two lateral collars. The
temperature of the bearing bodies is monitored by
thermocouples (19) as shown in section c-c.
Oil Supply
Lubricating oil is admitted to the bearing shells from
one side and flows to oil spaces that are milled into the
upper shell at the horizontal joint and are open to the
rotor. The rotor (5) picks up oil from oil pocket
machined into the babbitting .The oil emerges from the
bearing shell where it is collected in the oil return
cowling (4) and drained into the bearing pedestal (10).

1 Cap 6 Lower bearing shell 11 Key

2 Tab Washer 7 Spherical blocks 12 Shim
3 Upper bearing shell 8 Key 13 Shim
4 Oil return Cowling 9 Shim 14 Spherical supports
5 Turbine Rotor 10 Bearing pedestal 15 Shim

BHEL, Hardwar 6.1-0270-01/1

Jacking oil
As shown in Detail B, a threaded nozzle (17) is arranged
at the lowest point of the lower bearing shell (6) through
which high pressure lift oil is supplied to the space below the
journals when the rotor is turning at low speed (on start-up
and shutdown).This high pressure oil floats the shaft to
prevent dry friction and overcome break way torque during
start-up on the hydraulic turning gear.
A seal (18) prevent high pressure oil from penetrating the
space between threaded nozzle and ring (16) and thus from
lifting the babbit. Any leakage oil can drain through passages
in the bearing shell below the ring.
Removal of Bearing Shells
Not only the upper shell (3) but also the lower bearing
shell (6) can be removed without the removal of rotor (5). To 16 Rings
enable this to be done the shaft is lifted slightly by means of 17 Threaded nozzles
jacking device but within the clearance of the shaft seals. The 18 Sealing ring
19 Thermocouple
lower bearing shell can then be turned upwards to the top
position and removed.

BHEL, Hardwar 6.1-0270-01/2

 Steam Turbine HP Turbine
Description Casing Supports and Guides

Supports
The turbine casing is supported on the support horns such
as to make allowance for the thermal expansion. It is
essential for the casing to retain concentric alignment with
the rotor, which is supported independently.
The turbine casing (2) is supported with its two front
and two rear support horns on the horn supports of the
bearing pedestal (1, 3) at the turbine centerline level.
This arrangement determines the height of the casing
and also allows thermal expansion to take place in the
horizontal plane by the support horns

1 Front bearing pedestal

2 HP turbine
3 Rear bearing pedestal

Fig.1 Connection between Turbine Casing

and Bearing Pedestals

BHEL, Hardwar 6.1-0280-01/1

Sliding on the sliding pieces (6) of the bearing pedestals (1;
3). To prevent lift-off of the turbine casing (2), holders (4) hold
down projections of the support horns which engage in
mating recesses in the bearing pedestal.
When the turbine is being erected, a clearance’s’ is
maintained between the thrust bar (5) and the turbine casing
support horn projection.
Guides
The central location of the turbine casing at right angle
To the turbine centerline is provided by the guides
shown in section B-B and E-E. These guides allow the
turbine casing to expand freely.
Fixed Point
The fixed point for the turbine casing (2) is located at
the horn support on HP-IP pedestal at the turbine
centerline level and is formed by the parallel keys (16).
Axial expansion of the turbine casing (2) originates
from this point.

1 Front bearing pedestal 10 Sliding piece

2 HP turbines 11 Plates
4 Holders 12 Parallel key
5 thrust bar 13 Scale indicating casing expansion
6 sliding piece 14 Sliding piece
7 Plates 15 Plates
8 parallel key 16 Parallel key
9 plates
Fig. 2 Details of Casing Supports and Guides

BHEL, Hardwar 6.1-0280-01/2

 Steam Turbine
Description
Double Shell Construction
The casing of the IP turbine is split horizontally and is
of double shell construction.
A double-flow inner casing (3,4) is supported in the
outer casing (2,5) (Fig.1) Steam from the HP turbine after
reheating enters the inner casing from top and bottom
through two admission branches which are integral with
the mid section of the outer casing.
This arrangement provides opposed double flow in the
two blade sections and compensates axial thrust.
The centre flow prevents the steam inlet temperature
from affecting the support horns and bearing sections.
BHEL, Hardwar
IP Turbine
Casing
The provision of an inner casing confines the
steam inlet conditions to the admission section of
this casing.
While the joint flange of the outer casing is
subjected only to the lower pressure and
temperature effective at the exhaust from the inner
casing.
This means that the joint flange can be kept
small and material concentrations in the area of the
flange reduced to a minimum.
In this way, difficulties arising from deformation
of a casing with flange joint due to non uniform
temperature raise e.g. on start-up and shut down,
are avoided.
The joint of the inner casing is relieved by the
pressure in the outer casing so that this joint has to
be sealed only against the resulting differential
pressure.
6.1-0310-01/1

Steam Inlet and Extraction Connection
The angle rings (9) are provided at the connection
of admission and extraction branches with the inner
casing (3, 4) (Detail ‘D’ Fig. 2 & 3).
One leg of the angle ring (9) at such a connection
bears against the back of the collar of the threaded
ring (7) in the outer casing while the other fits into an
annular groove in the inner casing.
The threaded ring (7) is fitted in such a way that the
short leg of the angle ring can slide freely between the
collar of the threaded ring and the outer casing.
The steam pressure prevailing on the inside, forces
the angle ring against the face of the outer casing.
The tolerances of the annular grooves in the inner
casing are dimensioned to allow the long legs of the
angle ring (9) to slide in the groove.
BHEL, Hardwar
The angle rings are flexibly expanded by the
pressure on the inside and their outer areas forced
against the annular grooves to provide the desired
sealing effect while providing a tight seal, this
arrangement permits the inner casing to move freely in
all directions.
Attachment of Inner Casing
Due to the different temperatures of the inner
casing relative to the outer casing, the inner casing is
attached to the outer casing in such a manner as to be
free to expand axially from a fixed point and radially in
all directions, while maintaining the concentricity of the
inner casing relative to the shaft.
The steam admission connections and the
extraction connections are designed to avoid any
restrictions due to thermal expansion.
The inner casing is attached to the outer casing in
the horizontal and vertical plane.
6.1-0310-01/2
 In the horizontal plane, as shown in details E and F Shoulders on the bottom half outer casing (5)
(Fig. 4 & 5) the four support horns of the top half inner project into corresponding recesses in the bottom half
casing (3) rest on plates (13) which are supported by inner casing (4) and together with the fitted keys (14)
the joint surface of the bottom half outer casing (5). provide a centering system for the inner casing (3, 4) in
the transverse plane.
The shoulder screws (12) are provided with
sufficient clearance to permit the inner casing to This arrangement allows axial and radial expansion
expand freely in all directions in the horizontal plane. of the inner casing relative to the outer casing while the
fitted keys (14) maintain transverse alignment.
Thermal expansion in the vertical direction
originates from the point of support at the joint.
This ensures concentricity of the inner casing
relative to the rotor (1) in this plane.
The support horns provided at the bottom half inner
casing (4), project into the recesses in bottom half
outer casing (5) with clearance on all sides.
Located on top of each support horn is a spacer
disc (11) whose upper surface has a clearance’s’ to
the flange face of the top half outer casing (2).
This clearance thus determines the lift of the inner
casing.
As shown in details E, the inner casing is located
axially by the fitted keys (10) arranged on both sides of
the support horns of the bottom half inner casing (4).
Thermal expansion in the axial direction originates
from these points.
Radial expansion is not prevented by these fitted
keys, as they are free to slide in the recesses of the
bottom half outer casing.

BHEL, Hardwar 6.1-0310-01/3

 Steam Turbine
Description IP Turbine
Blading

Moving and Stationary Blades

The IP turbine with advance blading consists of 2x10
(double flow) drum stages. All stages are reaction stages
with 50% reaction.
The stationary and moving blades of all stages are provided
with inverted T -roots in moving blade and hook type roots
in Guide blade which also determine the distance between
the blades.
All these blades are provided with integral shrouds, which
after installation form a continuous shroud.
The moving and stationary blades are inserted into
Appropriately shaped grooves in the rotor (4) and in the
inner casing (1) and are bottom caulked with caulking
material (5).
The insertion slot in the rotor is closed by a locking blade
which is fixed by grub screws.
End blades, which lock with the horizontal joint, are used at
the horizontal joint of the inner casing (1).
Gap Sealing
Sealing strips (7) are caulked into the inner casing
(1) and the rotor (4) to reduce leakage losses at the
blade tips.
Cylindrically machined surfaces on the blade
shrouds are opposite the sealing strips.
These surfaces have stepped diameters in order to
increase the turbulence of the steam and thus the
sealing effect.
In case of an operation disturbance, causing the
sealing strips to come into contact with opposite
surfaces, they are rubbed away without any
considerable amount of heat being generated.
They can then easily be renewed at a later date to
provide the specified clearances.
1

1 Inner Casing
2 Guide Blades 5
3 Moving Blade
4 Turbine Shaft
5 Caulking piece 2
6 Sealing strip
7 Caulking wire

7
5

BHEL, Hardwar
6.1-0320-02
 Steam Turbine
Description
Function
The function of the shaft seals is to seal the interior of the
turbine casing against the atmosphere at the front (thrust
bearing end) and rear shaft penetrations of the IP turbine.
The shaft seals are axial-steam-flow non-contacting seals.
In the region subject to low relative expansion in the
vicinity of the combined journal and thrust bearing, the seal
strips are caulked alternatively into the shaft and into spring-
supported segmented rings in the casing, forming a labyrinth
to impede the outflow of steam.
In the region subject to greater relative expansion at the
exhaust end, see-through seals are used, in which the seal
strips are located opposite each other, caulked into the shaft
and into seal rings centered in the outer casing.
BHEL, Hardwar
IP Turbine
Shaft Seals
The outer seal rings can be removed for inspection
and if necessary seal strips can be replaced during a
short turbine shut down keeping module in place.
Gap Sealing
Sealing between the rotating and stationary
elements of the turbine is achieved by means of seal
strip (9), caulked into seal rings (3; 5) and into the rotor
(4) (details A and C).
The pressure gradient across the seal is reduced by
conversion of pressure energy into velocity energy
which is then dissipated as turbulence as the steam
passes through the numerous compartments according
to the labyrinth principle.
6.1-0330-01/1
Seal Rings
The seal rings (3), the number of which depends on the
pressure gradient to be sealed are divided into several
segments as shown in Section BB and mounted in grooves in
the rings such that they are free to move radically.
Each segment is held in position against a shoulder by
helical springs (6) and by the steam pressure above the seal
rings (3).
This provides the proper clearance for the seal gaps.
Should rubbing occur the segments concerned can retreat?
The heat developed by light rubbing of the thin seal strips
(9) is so slight that it cannot cause deformation of the rotor
(4).
BHEL, Hardwar
When the turbine is started from the cold or warm
state, the seal rings naturally heat up faster than the
mounting rings however.
They can expand freely in the radial direction
against the centering force of the helical springs (6).
Steam Spaces
Steam spaces are provided within the shaft seals.
From space ‘P’ leakage is drawn off to the steam seal
header.
The slight amounts of leakage steam which are still
able to pass the seal ring are conducted from the
space ‘R’ into the seal steam condenser.
6.1-0330-01/2
 Steam Turbine
Description IP Turbine
Rear Bearing Pedestal

Arrangement
The bearing pedestal is located between the IP and LP
turbines.
Its function is to support the turbine casing and bear the
weight of IP and LP rotors.
The bearing pedestal houses the following turbine
components:
• Journal bearing
• Shaft vibration pick-up
• Bearing pedestal vibration pick-up
• Hand barring arrangement
Connection of Bearing Pedestal and Foundation
The bearing pedestal is aligned on the foundation by
means of hexagon head screws that are screwed into it at
several points.
On completion of alignment the space beneath the
bearing pedestal is filled with special non shrinking grout.
The bearing pedestal is anchored to the foundation by
means of anchor bolts.
The anchor bolt holes are filled with gravel which gives a
considerable vibration damping effect.

BHEL, Hardwar 6.1-0340-02

 Steam Turbine
Description
Construction
The function of the journal bearing is to support the turbine
rotor.
Essentially, the journal bearing consists of the upper and
lower shells (3, 6), bearing cap (1), torus piece (7),
cylindrical support (14) and the keys (10).
The bearing shells are provided with a Babbitt face which is
precision machined.
Additional scraping is neither necessary nor permissible.
Both bearing shells are fixed by means of taper pins and
bolted together.
In order to prevent the bearing from exerting a bending
moment on the rotor (5), it is pivot-mounted in the cylindrical
support (14).
For this purpose, the torus piece (7) with shims (12, 13) is
bolted to the bearing shell (6).
A projection in cap (1) with key (9) fits into a corresponding
groove in the bearing shell (3) and prevents vertical
movement of the bearing shells.
Centering of the bearing shells in the vertical plane is
achieved by means of keys (8).
BHEL, Hardwar
IP Rear Journal Bearing
The bearing shells are fixed laterally by spacers (10)
who are bolted to each other.
Each spacer is held in position in the bearing
pedestal (11) by two lateral collars.
The temperature of the bearing bodies is monitored
by thermocouples (15) as shown in section C-C.
Oil Supply
Lubricating oil is admitted to the bearing shells from
both sides, from where it flows to oil spaces milled
into the upper and lower shells at the horizontal joint
that are open to the rotor end.
Oil from the oil space machined in the babbitting is
carried through the rotor (5) and emerges from the
bearing shell from where it is collected in the oil
return cowling (4) and drained into the bearing
pedestal (11).
6.1-0345-01/1
 Jacking Oil

As shown in section B-B, two threaded nozzles (17) are

arranged at the lowest point of the lower bearing shell (6)
through which high pressure oil is supplied to the space
below the journal when the rotor is turning at low speed (on
start-up and shutdown).

This high pressure oil floats the shaft to prevent dry

friction and overcome breakaway torque during startup, thus
reducing torque requirements of the hydraulic turning gear.

A seal (18) prevents high pressure oil from penetrating

the space between threaded nozzle and ring (16) and thus
from lifting the Babbitt.

Any leakage oil can drain through passages in the

bearing shell below the ring.

Removal of Bearing Shells

Not only the upper shell (3) but also the lower bearing
shell (6) can be removed without the removal of rotor (5).

To enable this to be done, the shaft is lifted slightly by

means of jacking device but with in the clearance of the
shaft seals.

The lower bearing shell can then be turned upwards to

the top position and removed.

BHEL, Hardwar
6.1-0345-01/2
 Steam Turbine IP Turbine
Description Casing Supports and Guides

The turbine casing is supported on the support horns such
as to make allowance for the thermal expansion.
It is essential for the casing to retain concentric
alignment with the rotor which is supported
independently the turbine casing (2) is supported with
its two front and two rear support horns on the
bearing pedestals (1, 3) at the turbine centerline
level.

1 HP Turbine rear bearing pedestal

2 IP turbines Fig.1 Connection between turbine casing and
3 IP turbine rear bearing pedestal bearing pedestal

BHEL, Hardwar 6.1-0350-01/1

 The turbine casing (2) is supported with its two front and
two rear support horns on the bearing pedestals (1, 3) at the
turbine centerline level.
This arrangement determines the height of the casing
and also allows thermal expansion to take place in the
horizontal plane by the support horns sliding on the sliding
pieces (6; 16) of the bearing pedestals (1, 3).
To prevent lift off the turbine casing (2), holders (4; 15)
hold down projections of the support horns which engage in
mating recesses in the bearing pedestal.
When the turbine is being erected, a clearance’s’ is
established between the thrust bars (5; 14) and the turbine
casing (2) support horn projection.

Guides
The central location of the turbine casing at right angles to
the turbine centerline is provided by the guides shown in
section B.B.
These guides allow the turbine casing to expand freely.
Fixed Point
The fixed point for the turbine casing (2) is located at
the front horn support at the turbine centerline level
and is formed by the parallel keys ((7; 10).
Axial expansion of turbine casing (2) originates from
this point.

BHEL, Hardwar 6.1-0350-01/2

 Steam Turbine
Description Hydraulic Turing Gear

Arrangement
The hydraulic turning gear is situated between the main oil
pump and the journal bearing in the HP turbine front bearing
pedestal.
Function
The function of the hydraulic turning gear is to
rotate the shaft system at sufficient speed before start-
up and after shut-down in order to avoid irregular
heating up or cooling down and thus avoid any
distortion of the turbine rotors. The air flow set up by
the blades along the inner wall of the casing during
turning operation provides good heat transfer
conducive to temperature equalization between upper
and lower casing halves.
Operation
During turning gear operation, the shaft system is
rotated by a blade wheel which is driven by oil supplied
by the auxiliary oil pump. This oil passes via a check
valve into the nozzle box (1) and from there into the
nozzles (2) which direct the oil jet in front of the
blading.
Return Oil Flow
After passing the blading, the oil drains into
the bearing pedestal and flows with the bearing
oil into the return flow line.
Manual Turning Gear
A manual turning gear is provided in addition
to the hydraulic turning gear to enable the
combined shaft system to be rotated manually.
Lifting of Shaft
To overcome the initial break-away torque on start-
up and to prevent dry friction, the bearings are relieved
during turning gear operation by lifting oil supplied from
below i.e. the shafts are lifted slightly.

BHEL, Hardwar 6.1-0510-01

 Steam Turbine
Description
Function
The turbine generator is equipped with a mechanical
barring gear, which enables the combined shaft system to
be rotated manually in the event of a failure of the normal
hydraulic turning gear.
It is located at IP - LP pedestal Construction
The barring gear consists of a gear machined on the
rim of the turning gear wheel (10) and pawl (6). This pawl
engages the ring gear and turns the shaft system when
operated by means of a bar attached to laver (1). The pawl
(6) is shown disengaged and the lever (1) resting against a
stop. The lever (1) is held in position by latch (7).
BHEL, Hardwar
Mechanical Barring Gear
Operation Take the following steps to make the barring
gear ready for operation: Remove cover (2) unlatches at
(7) and attach a bar to lever (1).
Barring of lever (1) will rotate the combined
turbine generator shaft system.
After barring has been completed, return lever
(1) and pawl (6) to the position shown in figure and
secure lever (1) by means of latch (7) Replace cover
(2).
The barring gear may only be operated after the
shaft system has been lifted with high-pressure lift
oil. If it is hard to start turning by means of the
mechanical barring gear, this may be due to incorrect
adjustment of the jacking oil system or due to a
rubbing shaft. Before steam is admitted to the
turbine. Corrective action must be taken
6.1-0520-01
 Steam Turbine
Description
Function
When the turbine is started up or shut down, the
hydraulic jacking device is used to maintain the oil film
between rotor and bearings. The high-pressure oil is forced
under the individual bearing, thus raising the rotor. The
necessary torque from the hydraulic turning device or from
the manual turning device is reduced in this way. The high-
pressure oil also provides motive force to hydraulic turning
gear motor installed in front bearing pedestal.
Speed Limit Values
In order to avoid damage to the bearings, the jacking oil
pump must be switched on below a certain speed. The
exact speeds for switching on and off can be seen in the
Technical data 2-0103.
Jacking Oil Pump
The jacking oil pumps, one number AC (13) and one
number DC (14) are jack-screw immersion pumps situated
on the tank (10) supply the high pressure oil for the lifting
device. The oil is drawn off directly by one of the two
pumps. The pressure oil piping of the jacking oil pump that
is not in operation is closed by the check valve (12). In
order
1 HP turbine 6 Check Valve
2 IP turbine 7 Fine control valve
3 LP turbine 8 Pressure Limiting Device
4 Generator 9 Bypass Valve
5 Exciter 10 Main Oil Tank
BHEL, Haridwar
Hydraulic Jacking Device
To protect the jacking oil system from damage due to
improper switching ON of the jacking oil pump when
the check valve (12) is closed, a spring-loaded safety
valve (11) is situated in the piping between the
jacking oil pump (13) and the check valve (12). The
necessary pressure in the system is kept constant by
means of the pressure-limiting valve (8). The
pressure-limiting valve can be relieved by the bypass
valve (9). The superfluous flow from the pump is
conducted into the main oil tank.
The necessary jacking oil pressures are set for
each bearing by the fine control valves (7) in the oil
pipes. Check valve (6) in the jacking oil pipes prevent
oil from flowing out of the bearings into the header
during turbine operation when the jacking oil system
is naturally switched off.
Valve Arrangement
The fine control valve (7) of the turbine bearings,
the check valves (6) and the pressure gauges are
arranged in boxes, which are connected laterally to
the bearing pedestals.
11 AC Motor driven lifting oil pump 16 Valve
12 DC Motor driven lifting oil pump c Drain
13 spring loaded safety valve
14 Check valve
15 Duplex filters
6.1-0530-96/1
BHEL, Haridwar 6.1-0530-96/2
 Steam Turbine
Description
The turbine control system description for 600 MW steam
turbine comprises the following:
General Description
Start-up Procedure
Speed Control
Electrical Speed Measuring
Protective Devices
Over speeds Trip Test
Testing of Stop Valves
LP Bypass System (General)
Extraction Check Valve
Swing Check Valve in CRH line
Testing of Swing Check Valves in the Cold Reheat Line
Automatic Turbine Tester, General
Automatic Turbine Tester, Protective Devices
Automatic Turbine Tester, Stop Valves
HP Actuator
Electro-hydraulic Gland Steam Pressure Control
Control System Diagram
List of Parts
Lubrication Chart
Lubrication Chart, Index
Turbine generator unit MAA50HA001 MAB50HA001
MAC10HA001 and MAC20HA001 comprises four-
cylinder reheat condensing turbine with condensers
MAG10BC001 and MAG20BC001 and a direct-driven
three-phase a.c. generator.
The turbine has a hydraulic speed governor
MAX46BY001 and an electric turbine controller.
The hydraulic speed governor adjusts control valves
MAA10+20AA002 and MAB10+20AA002 by way of
hydraulic amplifier MAX45BY011 whilst the electric
turbine controller acts on these control valves by way of
electro-hydraulic converter MAX45BY001.
Hydraulic amplifier MAX45BY011 and electro-hydraulic
converter MAX45BY001 are switched in parallel to form a
minimum gate.
The system not exercising control is in its maximum
position.
The special operating conditions existing in reheat
condensing turbines necessitate additional control
elements.
On start-up of the high-pressure boiler it is necessary to
start up the turbine straight away with a considerable
steam rate and, due to the high temperature in the
reheated to admit steam to the reheated immediately.
BHEL Hardwar
General Description
As long as the HP section of the turbine is unable to
accommodate all the steam supplied by the boiler, the
rejected steam is routed directly to the reheated via HP
bypass valve.
The steam from the reheated which cannot be
accommodated by the IP section with its control valves
MAB10+20AA002 and reheat stop valves
MAB10+20AA001 is routed into condensers
MAG10BC001 and MAG20BC001 by way of LP bypass
stop & control valves.
The IP turbine must be fitted with its own control valves to
prevent steam remaining in the reheated from entering
the turbine via the IP and LP section and causing further
acceleration of the turbine after the main steam control
valves have been closed in the event of load rejection or
trip.
In addition, the steam pressure in the main steam line
would increase after sudden closure of the main stream
control valves, thus causing the HP by pass valve to
open, with the result that even more steam would flow
into the IP section of the turbine.
It is the function of main oil pump MAV21 AP001, driven
directly by the turbine shaft, to supply oil for bearing
lubrication, for the oil circuit for the over speed trip test,
and for the primary oil circuit, pressure in which is
generated by hydraulic speed transmitter MAX44AP001.
Two Electrically driven auxiliary oil pumps are provided
for auxiliary oil supply.
The LP control fluid circuit (8 bar) and HP actuators of the
main stream control valves, reheat control valves (32
bars) are supplied by two full-load control fluid pumps
installed in the control fluid tank.
The turbine is equipped with an electro-hydraulic seal
steam control system, LP bypass (EHA Type), an
automatic turbine tester for the protective devices, main
and reheat “Stop & Control Valves” and an automatic
functional group control.
6.1-0600-01
 Steam Turbine
Description
Mode of Operation
The turbine is started up and brought up to speed with
the assistance of the control valves MAA10+20AA002
and MAB10+20 AA002.
If the hydraulic controller is to govern start-up, the
reference speed setter MAX46BY001 must be set to
minimum speed during this process.
In this case the speed reference from the electric
controller is at maximum.
If conversely, start-up is to be governed by the electric
controller, reference speed setter MAX46 BY001 is set to
maximum and the speed reference from the electric
controller to minimum.
The combined stop and control valves are closed
because the trip fluid circuit is not yet pressurized.
Turning hand-wheel KA01 clockwise or operating motor
MAX47BY001M of start-up and load limiting device
MAX47BY001 in the close direction releases spring KA06
in auxiliary follow up piston KA08 via the linkage, thereby
preventing a buildup of auxiliary secondary fluid pressure.
The hydraulic amplifier MAX45BY011 with follow-up
pistons KA01 and KA02 is now in the control valves
closed position so that a buildup of secondary fluid
pressure is prevented when main trip valves
MAX51AA005 and MAX51M006 are latched in.
Further turning of hand-wheel KA01 moves pilot valve
KA02 of start-up and load limiting device MAX47BY001
further downwards, admitting control fluid first into the
start-up fluid circuit and then into the auxiliary start up
fluid circuit.
The start-up fluid flows to the space above the pilot valve
of test valves MAX47AA011+012 and MAX47AA021+
022, forcing them down against the action of the springs.
The auxiliary start-up fluid raises the pilot valves of main
trip valves MAX51AA005 and MAX51AA006, thereby
moving them into their normal operating position and
permitting trip fluid to flow to test valves
MAX47AA011+012 and MAX47AA021+022 of the main
stop valves and reheat stop valves.
At the same time, over speed trip release devices
MAY10AA001 and 002 are latched in if they have been
tripped.
BHEL, Hardwar
Start-up Procedure
The function of non return valve MAX42AA011 is to
interrupt transiently the fluid supply to solenoid valve
MAX48AA202 from the connection downstream of filters
MAX42BT001 and MAX42BT 002 during latching in of
main trip Valves MAX51AA005 and MAX51AA006 by
means of start-up and load limiting device MAX47BY001,
because the pressure drops in this line considerably for a
short time as a result of the high flow of fluid required to
fill the drained trip fluid system during this latching in-
period.
The pressure upstream of solenoid valve MAX48AA202
is maintained via orifice MAX42BP022 during this period.
This ensures that the solenoid valve remains in the
position shown.
The auxiliary start-up fluid circuit at the start-up and load-
limiting device MAX47BY001 is fed from the system down
stream of filter MAX42BT003 (fluid supply during testing),
since the pressure
In the system is subject to no significant change during
start-up.
It is not possible to supply the hydraulic fluid connection
of solenoid valve MAX48AA202 from this system, as this
would have an in admissible effect on the trip fluid system
while the latching operation with the solenoid valves
MAX48AA201 and MAX48AA202 during testing is taking
place.
After latching in, the trip fluid circuit is closed.
The trip fluid now flows to the space above servomotor
piston KA01 of stop valves MAA10+20AA001 and
MAB10+20 AA001 forcing it down against piston discs
KA002.
Operation of the start-up and load-limiting device is
continued until their lower limit position is reached.
When hand-wheel KA01 is turned back or motor
MAX47BY001M of start-up and load limiting device
MAX47BY001 is operated in the open direction, the
control fluid is allowed to drain first from the auxiliary
start-up fluid circuit and then from the start-up fluid circuit.
The pilot valve of test valves MAX47AA011+012 and
MAX47 AA021+022 are forced upwards by the springs,
whereupon the trip fluid above servomotor piston KA01
slowly drains off.
6.1-0610-01/1
The pressure difference thus created lifts both pistons
together into their upper limit position, thus causing main
stop valves MAA10+20 AA001 and reheat stop valves
MAB10+20 AA001 to open.
Main trip valves MAX51AA005 and MAX51AA006 are
now held in their operating position by the fluid pressure
beneath the differential piston.
Once the main & reheat stop valves are open, further
turning of hand-wheel KA01 or operation of motor
MAX47BY001M of the start -up and load limiting device in
the open direction will after passing through a certain
dead range, cause lever KA03 and sleeve KA04 to move
further downwards, as a result of which the auxiliary
secondary fluid pressure begins to increase and acts via
hydraulic amplifier MAX45 BY011 and follow up pistons
KA01 and KA02 to gradually open control valves
MAA10+20AA002 and MAB10+20AA002.
This brings the turbine up to about 85 to 90% rated
speed.
Speed controller MAX46BY001 now cuts in to maintain
turbine speed.
Start-up and load limiting device MAX47BY001 is then
brought into the fully open position.
A pressure gauge MAX44CP501 and electric speed
transducer MYA001CS011-013 are used to measure
speed.
Reference speed setter MAX46BY001 is used for further
speed run-up for connecting the turbine-generator unit in
parallel and for bringing it on load.
Turning hand-wheel KA01 of the reference speed setter
or operation of motor MAX46BY001M increase the
tension of speed setting spring KA02 to increase speed.
BHEL, Hardwar
Since in interconnected operation speed is determined by
grid conditions, Actuation of the reference speed setter
has the effect of changing turbine output.
Load Limitation
Start-up and load limiting device MAX47BY001 engages
mechanically in controller bellow KA09 of hydraulic speed
governor/controller MAX46BY001 so that it can serve
simultaneously as a load-limiting device.
This means that opening of the control valves
MAA10+20AA002 and MAB10+20 AA002 is limited to an
adjustable setting.
This setting is made manually or from the control room
via motor MAX47BY001M.
Electro-hydraulic Turbine Controller
If the turbine is to be started up with the electro-hydraulic
turbine controller, the reference signal from the electric
speed controller must first be set to minimum so that this
takes over running up the turbine-generator unit from
turning speed.
Start-up and load limiting device MAX47BY001 is brought
into its open position once the stop valves have been
opened.
Slowly raising the speed reference from the electric
controller cuts in the electric speed control system, and
the turbine-generator unit is brought up to rated speed
and synchronized.
Further loading is governed by the electric power
controller by increasing the load reference within the
admissible rate of load change.
6.1-0610-01/2
 Steam Turbine
Description
Speed control may be exercised either hydraulically or
electro-hydraulically.
Hydraulic Control
Main oil pump MAV21AP001 supplies the bearing and
primary oil circuits with control oil whilst hydraulic speed
transmitter MAX44AP001 acts as a pulse generator for
the control circuit, providing a primary oil pressure
proportional to the speed.
This oil pressure can also be read directly from speed
indicator pressure gauge MAX44CP501.
This primary oil pressure acts on diaphragm KA09 of
hydraulic speed governor MAX46BY001 against the
force of speed setting spring KA02 which is tensioned by
reference speed setter MAX46BY001.
The travel of diaphragm KA09, which can be limited by
starting and load limit device MAX47BY001, is
transmitted by linkage KA03 to sleeves KA04 of auxiliary
follow-up pistons KA08, the pistons KA05 of which are
held against the medium pressure by spring KA06.
Medium drains off according to the amount of port
overlap between piston and sleeve and a medium
pressure corresponding to the tension of spring KA06 is
built up.
This auxiliary secondary medium pressure acts as a
pulse signal via pilot valve KA07 of hydraulic amplifier
MAX45 BY011.
Piston KA08 of this hydraulic amplifier assumes a
position corresponding to the auxiliary secondary
medium pressure and operates the sleeves of follow-up
piston KA01and KA02 via a linkage system.
A feedback system stabilizes the position of pilot valve
KA07 and piston KA08 of hydraulic amplifier
MAX45BY011.
As already described for auxiliary follow-up piston KA08,
a secondary medium pressure corresponding to the
position of the sleeves and to the related spring tension
builds up in the follow up pistons of hydraulic amplifier
MAX45BY011.
Any change in the position of linkage KA03 results in a
proportional change of the secondary medium pressures
in the follow-up pistons of the hydraulic amplifier.
The secondary medium circuits and the auxiliary
secondary medium circuits are supplied from the trip
medium circuit by way of orifices.
The varying secondary medium pressure in the follow-up
pistons of the hydraulic amplifier in turn effects changes
in the positions of their associated control valves or
other control devices.
BHEL Hardwar
Speed Control
Electro-hydraulic Control
The speed of the turbine is measured digitally. For this
purpose electrical speed transducers MYA01CS011 to 013
are mounted on the high-pressure end of the turbine shaft.
The electro-hydraulic converter constitutes the link
between the electrical and hydraulic parts of the governing
system.
The electro-hydraulic converter consists of the speed
control converter MAX45BY001 and a proportional valve.
The signal from the electro-hydraulic controller actuates
the control sleeve via the proportional valve.
The control sleeve determines the position of pilot valve
KA07 in the manner of a follow-up piston.
The further mode of action is the same as that of the
hydraulic speed governor.
Two differential transmitters CG001A and CG001K are
located at piston KA08 of electro-hydraulic converter
MAX45 BY001 as feedback transmitters to the electro-
hydraulic controller.
This stabilizes the control process.
Change-over from Hydraulic to Electro-hydraulic
Control
As already mentioned, Change-over from one control
system to the other is possible even during operation as
the two controllers are connected in parallel downstream
of the associated follow up piston batteries, which form a
minimum value gate.
This means that it is always the controller with the lower
set point, which leads.
If the turbine is operated with the hydraulic governor, the
speed set point of the electro-hydraulic controller is set at
“maximum speed” which prevents the electro-hydraulic
control system from coming into action.
To bring in the electro-hydraulic control system, the speed
set point of the electro-hydraulic controller must be
reduced slowly until the secondary medium pressures
drop slightly.
When this occurs, the electro-hydraulic controller has
taken over.
Then the reference speed setter of hydraulic governor
speed MAX46BY001 is set to “maximum speed”.
The electro-hydraulic controller is then fully effective and
can operate over the entire load range.
The hydraulic speed governor also acts as a speed limiter
in the event of failure of the electro-hydraulic controller.
6.1-0620-01/1
In this case, operation of the turbine may immediately be
continued by means of the hydraulic speed governor.
Change-over from Electro-hydraulic to Hydraulic
Control
Change-over is performed in the reverse sequence.
First reduce the set point at reference speed setter
MAX46BY001 until the secondary medium pressures
drop slightly.
This indicates that the hydraulic speed governor has
taken over.
Then set the set point of the electro-hydraulic controller
to maximum.
The hydraulic speed governor is then completely
effective and can operate over the entire load range.
Adjusting Device for Valves
An adjusting device, which makes it possible to change
the setting response of the HP and IP control valves, is
provided for limiting the HP exhaust steam temperature.
In normal operation, control medium is admitted to the
space below the pistons of regulating cylinders
MAX45BY001 KA10 and MAX45BY011 KA10 by way of
energizing solenoid valve MAX42AA051, whereby the
pistons move into their upper end positions against the
force of the spring and, via a linkage, tension the springs
of follow-up pistons KA02 of the control valves in such a
way that this produces the desired setting response of
the IP control valves in relation to the HP control valves.
BHEL Hardwar
If the condition “Turbine load less than set minimum
load and the ratio of HP exhaust steam pressure to
main stream pressure greater than a set value is
fulfilled”, e.g. after a load rejection, solenoid valve
MAX42AA051 is de-energized, thereby cutting off the flow
of control medium to the regulating cylinders and allowing
the control medium under the pistons to drain off.
The pistons are moved into their lower end position by the
restoring springs and the springs of follow-up pistons
KA02 are adjusted so that the IP control valves do not
begin to open until the HP control valves have opened to a
greater extent, with the result that the HP exhaust steam
temperature is lowered.
For operation of the plant without the HP and LP bypass
stations, a manual adjusting mechanism KA11 is also
provided for adjusting the relationship between the valves
such that the reheat valves open before the main stream
valves.
Under these operating conditions, solenoid valve
MAX42AA051 is energized and an interlock is provided to
prevent de-energisation.
This adjustment may only be performed manually and
must always be performed on both follow-up piston
batteries MAX45BY001 and MAX45BY011, to ensure that
change-over from hydraulic to electro-hydraulic control
and vice versa is possible at all times.
This manual adjustment must always be reversed before
the HP or LP bypass station is brought into operation.
6.1-0620-01/2
 Steam Turbine
Description
The electrical speed signals originate from the electrical
speed transducers which consist of four ferromagnetic
type speed probes, MAY01CS011 to 014 (one as spare)
and a toothed wheel with 60 teeth made around its
circumference located on the main oil pump shaft.
The teeth of the wheel act upon the four stationary speed
probes.
When turbine rotates, square wave signals are generated
in the probes.
The frequency of these voltages is proportional to the
rotational speed of the turbine.
The output of these speed probes are fed to the input
modules which provide digital output signals.
The three values for the rotational speed obtained by this
process are continuously monitored for failures.
If one of the speed probes fails, the control circuit
continues to operate without interruption, using two
remaining speed probes.
BHEL, Hardwar
Control System
Electrical Speed Measuring
The output is then fed to the speed measuring unit,
electro-hydraulic controller and speed target unit.
The speed-measuring unit incorporates two speed
ranges.
The lower range covers 0-360 rpm and the upper range
0-3600 rpm.
The changeover from one range to the other is
completely automatic.
A speed indicator mounted on the hydraulic control
equipment rack provides local speed-readings.
Indicating lights located near the speed indicator show
which range is engaged.
From the speed-measuring unit, speed signals are also
provided to the turbine stress evaluator/controller,
automatic turbine tester and recorders.
Output signals are available for purchaser’s remote
speed indicators and functional group automatic (FGA).
6.1-0621-02
 Steam Turbine
Description
Over Speed Trip
Two over speed trips MAY10 AA001 and 002 are
provided to trip/shut down the turbine in the event of over
speed.
Each trip device consists of an eccentric bolt/striker fitted
in the emergency governor shaft with its center of gravity
displaced from the axis of rotation and held in position
against centrifugal force by a spring up to an adjustable
preset speed of 10 to 12 % above the normal turbine
operating speed.
At the preset over speed, centrifugal force overcomes the
spring force and the eccentric bolt/striker flies outwards
into its extended position.
In doing so it strikes the pawl which releases the piston of
the over speed trip release device KA01.
Through combined spring force and fluid pressure, the
piston opens the auxiliary trip fluid circuit to the main trip
valves MAX51 AA005 and MAX51AA006.
Thrust-Bearing Trip
Thrust bearing trips MAD12CY011/012/013 are tripped
electrically in the event of excessive axial displacement of
the turbine shaft.
Pressure Switch
Installed in the trip fluid circuit are two pressure switches
MAX51CP011 and MAX51CP012 which bridge the
longtime delayed relays of the reverse-power protection
system in such a way that the generator is shut down by
response of the short-time delayed relays as soon as it
begins to motor.
The annunciation Turbine trip initiated is transmitted
simultaneously to the control room.
Remote Solenoid Trip
Remote solenoid trip is activated via solenoid valves
MAX52 AA001 and MAX52 AA002.
The remote solenoid trip may be initiated manually from
the control room by push button, by the electrical low-
vacuum trip or the thrust bearing trip or other protective
devices.
Solenoid Valves for Load Shedding Relay
Solenoid valves MAX45 AA001 and MAX46 AA011 are
provided to prevent the turbine from reaching trip-out
speed in the event of a sudden load rejection.
These solenoid valves are actuated by the load shedding
relay if the rate of load drop relative to time exceeds a
predetermined value.
Solenoid valve MAX45AA001 opens the IP secondary
fluid circuit directly.
Solenoid valve MAX46 AA011 opens the auxiliary
secondary fluid circuit.
BHEL Hardwar
Protective Devices
Pilot valve KA07 of hydraulic converter MAX45BY011
moves upward and allows the control fluid to flow to the
area below piston KA08 of the converter.
Piston KA08 moves to its upper end position, thereby
depressurizing all secondary fluid circuits.
Since the reheat IP secondary fluid circuit opens directly,
the IP control valves (which control the major portion of
the power output) close without any appreciable delay.
A small delay is involved in closing all other control valves
by depressurizing the auxiliary secondary fluid circuit, but
his action is still performed before an increase in turbine
speed causes the speed controller to respond.
At the same time, the extraction check valves, which are
dependent on secondary fluid via extraction valve, relay
MAX51AA011, close?
After an adjustable interval, the solenoid valves are
reclosed, permitting secondary fluid pressures
corresponding to the reduced load to build up again.
Turbine Trip Gear
The trip fluid is taken from the control fluid via main trip
valve MAX51AA005 and MAX51AA006 and flows both to
the secondary fluid circuits and to the stop valves
MAA10+20AA001 and MAB10+20AA001.
The main trip valves serve to rapidly reduce the fluid
pressure in the trip fluid circuit. If the pressure below the
differential piston of main trip valves MAX51 AA005 and
MAX51AA006 drops below a preset adjustable value, the
piston in each valve is forced downwards by the spring,
opening the drain passage for the trip fluid and closing
the control fluid inlet.
If the pressure in the trip fluid circuit drops below a
predetermined value, spring loading separates the upper
and lower pistons of main stop valves MAA10+20 AA001
and reheat stop valves MAB10+20 AA001, and all the
stop valves close very rapidly.
At the same time, the control valves and extraction check
valves also close, as the secondary fluid circuits are fed
from the trip fluid circuit.
Thus on trip initiation, all turbine stop and control valves
close.
Manual local Trip Method of Initiating Turbine Trip
Manual local initiation of turbine trip is performed by way
of local trip valve MAX52 AA005.
The valve must be pressed downwards manually, thus
opening the drain passage for the auxiliary trip fluid.
The two limit switches MAX52CG005C and MAX52
CG005E indicate in the control room that trip has been
initiated locally by hand.
6.1-0630-01
 Steam Turbine
Description
Overspeed Trip
Two overspeed trips MAY10 AA001 and 002
are provided to trip/shut down the turbine in
the event of overspeed. Each trip device
consists of an eccentric bolt/striker fitted in
the emergency governor shaft with its center
of gravity displaced from the axis of rotation
and held In position against centrifugal force
by a spring up to an adjustable preset speed
of 10 to 12 % above the normal turbine
operating speed. At the preset overspeed,
centrifugal force overcomes the spring force
and the eccentric bolt/striker flies outwards
into its extended position. In doing so it
strikes the pawl which releases the piston of
the overspeed trip release device KA01.
Through combined spring force and fluid
pressure, the piston opens the auxiliary trip
fluid circuit to the main trip valves MAX51
AA005 and MAX51AA006.
Thrust-Bearing Trip
Thrust bearing trips MAD12CY011/012/013
are tripped electrically in the event of
excessive axial displacement of the turbine
shaft.
Pressure Switch
Installed in the trip fluid circuit are two
pressure switches MAX51CP011 and
MAX51CP012 which bridge the longtime
delayed relays of the reverse-power
protection system in such a way that the
generator is shut down by response of the
short-time delayed relays as soon as it
begins to motor. The annunciation Turbine
trip initiated is transmitted simultaneously to
the control room.
Remote Solenoid Trip
Remote solenoid trip is activated via
solenoid valves MAX52 AA001 and MAX52
AA002. The remote solenoid trip may be
initiated manually from the control room by
push button, by the electrical low-vacuum
trip or the thrust bearing trip or other
protective devices.
BHEL Hardwar
Protective Devices
Solenoid Valves for Load Shedding Relay
Solenoid valves MAX45 AA001 and MAX46
AA011 are provided to prevent the turbine
from reaching trip-out speed in the event of
a sudden load rejection. These solenoid
valves are actuated by the load shedding
relay if the rate of load drop relative to time
exceeds a predetermined value. Solenoid
valve MAX45AA001 opens the IP secondary
fluid circuit directly. Solenoid valve MAX46
AA011 opens the auxiliary secondary fluid
circuit. Pilot valve KA07 of hydraulic
converter MAX45BY011 moves upward and
allows the control fluid to flow to the area
below piston KA08 of the converter. Piston
KA08 moves to its upper end position,
thereby depressurizing all secondary fluid
circuits.
Since the reheat IP secondary fluid circuit
opens directly, the IP control valves (which
control the major portion of the power
output) close without any appreciable delay.
A small delay is involved in closing all other
control valves by depressurizing the
auxiliary secondary fluid circuit, but his
action is still performed before an increase
in turbine speed causes the speed controller
to respond. At the same time, the extraction
check valves, which are dependent on
secondary fluid via extraction valve relay
MAX51AA011, close.
After an adjustable interval, the solenoid
valves are reclosed, permitting secondary
fluid pressures corresponding to the reduced
load to build up again.
Turbine Trip Gear
The trip fluid is taken from the control fluid
via main trip valve MAX51AA005 and
MAX51AA006 and flows both to the
secondary fluid circuits and to the stop
valves MAA10+20AA001 and
MAB10+20AA001. The main trip valves
serve to rapidly reduce the fluid pressure in
the trip fluid circuit. If the pressure below the
differential piston of main trip valves MAX51
AA005 and MAX51AA006 drops below a
preset adjustable value, the piston in each
6.1-0630-01/1
valve is forced downwards by the spring,
opening the drain passage for the trip fluid
and closing the control fluid inlet.
If the pressure in the trip fluid circuit drops
below a predetermined value, spring loading
separates the upper and lower pistons of
main stop valves MAA10+20 AA001 and
reheat stop valves MAB10+20 AA001, and
all the stop valves close very rapidly. At the
same time, the control valves and extraction
check valves also close, as the secondary
fluid circuits are fed from the trip fluid circuit.
BHEL Hardwar
Thus on trip initiation, all turbine stop and
control valves close.
Manual local Trip Method of Initiating
Turbine Trip
Manual local initiation of turbine trip is
performed by way of local trip valve MAX52
AA005. The valve must be pressed
downwards manually, thus opening the drain
passage for the auxiliary trip fluid. The two
limit switches MAX52CG005C and MAX52
CG005E indicate in the control room that trip
has been initiated locally by hand.
6.1-0630-01/2
 Steam Turbine
Description
Testing with Turbine under Load Condition
Over speed trips MAY10 AA001 and 002 can be tested
using test device MAX62AA001 with the turbine running
under load or no-load conditions.
To operate the test device, pilot valve KA03 is first
pushed downwards and held in this position.
This isolates the auxiliary trip medium circuit from the
overspeed trips and prevents the main trip being initiated
by the over speed trips.
Subsequent operation of hand-wheel KA01 moves the
center pilot valve downwards.
This action blocks the drain and allows the control oil to
flow through the center bore of the pump shaft into over
speed trips.
The control oil pressure thus builds up and moves the
eccentric bolts/strikers outwards against the spring force,
releasing the pawls of the over speed trip releasing
device, as a results of which the pilot valve moves rapidly
inwards.
The pressure in the auxiliary rip medium circuit, up to the
over speed trip test device, then collapses.
Operation is followed by observing the reading at
pressure gauge MAX52CP501.
The trip pressure is read off at pressure gauge
MAX62CP501.
If during operation at rated speed, this pressure should
deviate from the baseline value as recorded in the test
report, a defect in the over speed trip may be assumed.
If the trip pressure is too high, the bolt may be made to
move freely by rapidly operating the pilot valve by means
of hand-wheel KA01 several times in succession.
If this measure does not have the desired result, the
turbine must be shut down and the emergency governor
to be inspected.
As soon as the auxiliary trip medium pressure drops to 0
at pressure gauge MAX52CP501, the center pilot valve
must be returned to its original position using hand-wheel
KA01.
The pressure in the test line should then return to 0, as
can be read off at pressure gauge MAX62CP501.
The bolts/strikers of the overspeed trips should return to
their original position.
BHEL, Hardwar
Over Speed Trip Test
When this happened, pilot valve KA02 must be pushed
downwards to admit control medium into the auxiliary
start-up medium circuit to the differential pilot valve of the
over speed trip device.
The pilot valve moves towards the right and latches the
overspeed trip device in again.
The buildup of pressure in the auxiliary start-up medium
circuit between the over seed trip test device and the over
speed trip release device can be followed at pressure
gauge MAX48CP501.
When pilot valve KA02 is then released, the auxiliary
start-up medium pressure returns to 0 pressures.
The auxiliary trip medium pressure must then remain at
its full value (readable at pressure gauge MAX52CP501).
If this is the case, pilot valve KA03 may be released.
The test is completed. If, when valve KA02 is released,
the auxiliary trip medium pressure collapses, pilot valve
KA02 must be pushed downwards again and must be
held in this position a little longer.
It is essential that the auxiliary trip medium pressure must
remain steady before valve KA03 is released.
Testing with Turbine under No-Load Condition
Over speed trips MAY10AA001 and 002 must be tested
at regular intervals by running the unloaded turbine up to
trip speed.
This is done by operating lever KA07 of hydraulic speed
governor MAX46BY001, which presses linkage KA03
downwards, thus increasing the secondary medium
pressures.
This causes the control valves to open and the turbine
starts to over speed.
The actual speed at which trip occurs can be read off at
pressure gauge MAX44CP501.
Limit switches MAY10CG001&002C of over speed trip
release device MAY10 AA001 and 002 indicate in the
control room that main trip valves MAX51AA005 and
MAX51AA006 have been actuated by over speed
protective device.
6.1-0631-01
 Steam Turbine
Description
Main Steam Stop Valves
The stop valves can be tested for freedom of movement
independently of each other even during operation with
the aid of the test valves MAX47AA011 to 012 attached
to each of them.
The main stop valves MAA10 and 20AA001 may only be
tested at a load that is less than 80% of the maximum
output.
If the test is conducted with the initial pressure controller
out of operation, the main stop valves may only travel out
of the open position to about 50% closed at the most and
are to be reopened immediately.
If the initial pressure controller is in operation complete
closure of a main stop valve may be performed.
This, however, is conditional upon the response time of
the initial pressure controller being high enough to keep
the initial pressure constant even during the testing
procedure.
First the main control valve concerned MAA10 or
20AA002, is to be closed by pressing of pushbutton in the
supply unit.
If in operation, the initial pressure controller opens the
other main control valve accordingly.
Once the control valve has been closed the stop valve
can be closed. It is to be reopened immediately.
BHEL, Hardwar
Testing of Stop Valves
The main control valves may be closed for testing
purposes for not longer than 4 to 5 minutes so that the
unbalanced steam flow is only present for a short period
to avoid significant effects on the HP turbine casing.
It is a precondition for testing the main stop valves that
there should be a mixing header in the steam leads
between the boiler and the stop valves.
Reheat Stop Valves
Testing of a reheat stop valve must be conducted at a
power output at which the reheat control valves MAB10
and 20 AA002 are fully open.
First the associated reheat control valve is to be closed
by pressing of pushbutton in the supply unit.
Then the reheat stop valve MAB10 or 20 AA001 is closed
by actuating test valve MAX47AA021 and 022 and
reopened.
On completion of the test the reheat control valve is to be
reopened.
As for the main steam stop valves it is a precondition for
testing the reheat stop valves that there should be a
mixing header in the steam leads between the boiler and
the stop valves.
6.1-0632-01
 Steam Turbine LP Bypass System
Description (General)

Function
The function of the LP bypass control system (EHA Type) Electro-hydraulic Actuator for LP Bypass Control
is to monitor the pressure in the reheat system and to Valve
control it under certain operating conditions.
The LP bypass control valve actuator is an electro-
During start-up and shutdown, and at operation below hydraulic actuator with an external control fluid supply
minimum boiler load, the volume of steam not utilized by from centralized Hydraulic Power Unit (HPSU).
the IP and LP cylinders of the turbine must be bypassed
The control block converts the electrical signal from the
to the condenser via the LP bypass valves.
controller into flow of hydraulic fluid.
This requires the bypass control system to maintain the
It controls the intake and discharge of hydraulic fluid to
pressure in the reheater constant in accordance with the
and from the piston chambers of the actuator in a
preset reference value.
continuous mode, thus permitting very precise positioning
In the event of disturbances, e.g. load shedding or trip of the actuator.
out, the amount of excess reheat steam bypassed to the
The control block will position the valve as well as block
condenser.
the cylinder in case of hydraulic fluid failure.
Hydraulic Power Supply Unit (HPSU)
Water Injection System
The hydraulic unit serves to supply the necessary
During LP Bypass operation a part or entire steam flow
pressurized fluid to the actuators.
produced by boiler is routed to the condenser.
The hydraulic power unit has two pumps. One pump is
In order that the condensate pumps do not have to supply
always in operation and the other is stand-by.
the injection water flow required for the full boiler capacity
Two nos. filtration circuits are provided in order to and to prevent the amount of excess water flow becoming
maintain the cleanliness of system for proper functioning too high, under normal start-up and shut down conditions,
of hydraulic system. a regulating type water injection system to optimize the
Hydraulic fluid, a phosphate ester is chosen for high water quantity to be mixed with LP Bypass steam is
pressure hydraulic system, which ensures good fire provided.
protection. Actuator for water injection valve may be hydraulic or
The fluid has good lubricating properties and allows a pneumatic type.
comparatively easy maintenance. A separate flow controller is provided to regulate the
A regeneration unit for hydraulic fluid is provided to spray water valve.
maintain its properties/quality. Note: - This is a general description of LP Bypass
Electro-hydraulic Actuator for LP Bypass Stop Valve System (EHA Type). Refer O&M manual supplied
alongwith equipments by vendor for detail
The LP bypass stop valve actuator is an electro-hydraulic description.
actuator with an external control fluid supply from
centralized Hydraulic Power Supply Unit (HPSU).
The unit is designed to operate a single acting cylinder
with a spring in closing direction.
The unit has a solenoid valve for opening & closing of
stop valve and two trip solenoid valves for fail
close/positive close function.
Operation of any one trip solenoid valve is sufficient to
close the stop valve.

BHEL, Hardwar 6.1-0640-01

 Steam Turbine
Description
The function of extraction check valves LBQ71, LBQ50,
LBS41, LBS42, LBS31, LBS32, LBS21 and LBS22
AA001 and 002 is to prevent the backflow of steam into
the turbine from the extraction lines and the feed water
heaters.
Two free-swinging check valves are installed in each
extraction lines A2, A3, A4 A5 and A7.
In the event of flow reversal in the extraction lines, the
valves close automatically, whereby actuator KA01
assists the closing movement of the disc.
The mechanical design of the swing check valves is such
that they are brought into the free -swinging position by
means of trip fluid pressure via actuator KA01 and the
disc is moved into the steam flow by means of spring
force acting via the lever, shaft and disc lever and closes
if differential pressure is either lowered or reversed.
The trip supply to actuator KA01 is controlled by
changeover valves MAX51AA028, MAX51AA031 etc.
BHEL Hardwar
Extraction Check Valve
The swing check valves are released for opening or
assisted in closing through solenoid valves MAX51AA048,
MAX51AA051 etc at adjustable IP secondary oil pressure.
The release setting for opening cannot be arbitrarily
adjusted towards higher turbine output, as the swing
check valve will open even without the release action if
the steam pressure difference exerts a greater force than
the closing spring.
Turning the hand wheel on the changeover valves
MAX51AA048, MAX51AA051 etc. close the associated
swing check valves within the bounds of the effectiveness
of the spring.
The swing check valve in extraction lines A4 can also be
triggered by differential pressure switch LBS42CP002.
This differential pressure switches energizes solenoid
valves MAX51AA028 and MAX51AA031 if the steam flow
drops below a preset rate (differential pressure), thereby
further assisting the closing action of the swing check
valve.
The position of all swing check valves is indicated via
position transmitters-CG001A and CG002A.
6.1-0650-01
 Steam Turbine
Description
In order that the turbine may be completely separated
from the steam when it is stationary, an additional check
valve LBC10 AA001 is fitted in the line between the HP
cylinder and the reheater and operating through pilot
valve MAX42AA001 +002 and the rotary actuator KA01
depending on the pressure in the associated secondary
medium circuit.
The swing check valve opens fully when the control
valves reached approx. 5 to 10% of their full-power
travel.
Only when the control valves reach this point again as
they are being closed, the swing check valve brought
into steam flow again by the hydraulic actuator.
BHEL, Hardwar
Swing Check Valve
Cold Reheat Steam Line
Thus when the steam flow in the normal direction ceases,
the check valve is closed by the actuator KA01 and
prevents the steam in the cold reheat line from returning to
the turbine.
By removing the valve from the steam flow during
operation above 5 to 10% of maximum power, additional
pressure losses during normal operation are avoided.
If, during start-up, the steam pressure on the inlet side of
the valve and at the same time the secondary medium
pressure is not yet sufficient to open the valve, the steam
pressure will open the swing check valve against the
medium pressure in the manner of a safety valve.
The Open and Control position of the swing check valve
are indicated in the control room via the limit switches.
6.1-0651-01
 Steam Turbine
Description
The check valve LBC10AA001 in cold reheat line is wide
open during normal operation by its associated rotary
servomotor KA01.
For testing the immovability, the check valve can be
moved in closing direction by interrupting the connection
between pilot valve MAX42 AA002 and HP secondary
fluid line with closing of shut-off valve MAX45AA566 (pilot
valve and shut-off valve are installed in the turbine
hydraulic control rack).
By closing the shut-off valve the pilot valve MAX42AA002
is reversing and rotary servomotor is moving the check
valves in closing direction.
Because the torque of this servomotor is limited, the
check valves cannot be closed completely.
BHEL, Hardwar
Testing of Check Valves
in Cold Reheat Line
This can be brought only in an intern position.
When the check valve starts moving, the open position
limit switch will change position, which is indicated in the
control room.
With this indicator the regular movement of the check
valve can be checked after closing shut-off valve
MAX45AA566 nearby up to this value.
After this check the shut-off valve has to be reopened.
The check valve is moved then in its wide-open position.
At the position indicator in the control room it can be
checked if the check valve has reached again its wide-
open position.
6.1-0652-01
 Steam Turbine
Description
Function
Healthiness of the protective devices and the stop and
control valves is vitally important for the operational
reliability and availability of the turbine.
Hence, it is essential that these equipments are always
kept in a fully serviceable condition.
Economy has dictated longer intervals between turbine
overhauls, with the result that testing of the equipments
and devices is now necessary at regular intervals during
normal operation.
There are manually operated devices for testing the free
operation of the stop and control valves.
However, these tests do not cover all components
involved in an automatic trip with the result that the
conditions only party corresponds to those prevailing
during a real trip.
The system
Any possible mal-operation associated with manually
operated devices is avoided with fully automatic tests by
means of the automatic turbine tester.
Full protection for the turbine during testing is also
assured by suitable circuit arrangements.
This increases the operational reliability and availability of
the plant.
The automatic turbine tester is realized in digital
technology.
System adaptation
The system is subdivided into functional groups for each
device.
Each group contains the device itself and all necessary
transmission elements for initiation of a normal trip.
BHEL, Hardwar
Automatic Turbine Tester
(General)
The automatic turbine tester is divided into the following
2 subgroups:
1. Protective devices
Description: “Automatic Turbine Tester, Protective
device”.
2. Main stops and control valves
Description: “Automatic Turbine tester, stop and
control valves”.
The complete testing of all components which must
operate when an automatic trip becomes necessary is
assured, despite the subdivision into two testing groups
(protective devices, stop and control valves), because
the main trip valves which store the trip signal by
mechanical hydraulic means are operated together with
each protective device and subsequent satisfactory
reduction of the trip oil pressure after the valves are
monitored.
Nature of the description
The descriptions mentioned above contain the practical
sequence of the tests on the individual devices and gives
details of possible irregularities.
The description of equipment contained in the automatic
control cubicle (stepping switches, interlock modules,
etc), the control panel in the control room and schematic
circuit diagrams are contained in the separate electrical
section of the “Operating Manual” for the automatic
turbine tester.
For the understanding of the automatic turbine tester
from these descriptions it is assumed that the reader is
fully conversant with the functioning of the individual
protective devices and valves within the overall turbine
governing and protection system.
6.1-0660-00
 Steam Turbine
Description
Scope of Testing
The Automatic turbine tester (ATT) subgroup for the
protective devices is divided into a preliminary test and
the following three individual testing systems.
ƒ Remote trip solenoid MAX52AA001
ƒ Remote trip solenoid MAX52AA002
ƒ Over speed trips MAY10AA001/MAY10 AA002
One or more systems can be selected for testing at the
control panel and the selection is stored.
The start of the test program automatically causes a
preliminary test to be carried out on the protective
channels which are to be effective during actual testing
and then establishes the test circuit.
Once the first test selected has been completed and the
protective device has latched in again, the test circuit is
restored to its normal operational configuration.
Further selected tests must be started individually by
pressing the Test push-button to start the program.
General
During normal operation, the protective devices act via
main trip valves MAX51 AA005 and MAX 51AA006 on
the stop and control valves and extraction swing check
valves.
The remote trip solenoids MAX52 AA001 and MAX52
AA002, over speed trips MAY10AA001/MAY10AA002
actuate main trip valves MAX51AA005 and MAX51AA006
by opening the auxiliary trip fluid circuit.
For the duration of testing of the protective devices, a test
circuit is established .In order to keep the trip fluid circuit
effective, it is isolated from main trip valves MAX51
AA005 and MAX51AA006 by means of change-over
valve MAX51AA211 and supplied with fluid via solenoid
valves MAX51AA201 and MAX51AA202 (remote trip
during testing).
Setting Data
The setting data for the pressure switches are listed in
the setting record Measuring Point List.
The actually set values are logged in the Commissioning
Test Record.
The test running times, etc. is entered in the functional
diagrams.
Test Sequence
Start of Testing
The test begins with the selection of the protective
devices subgroup.
This is performed by pressing the subgroup On/Off push
button.
BHEL Hardwar
Automatic Turbine Tester
for Protective Device
Trip Initiation during Testing
To provide normal protection for the turbine during
testing, any trip initiation signals from the protective
devices will de-energize the solenoid valves for remote
trip during testing and the same time initiate the reset
program.
This also applies to all normal electrical remote trips such
as generator protection, etc.
For the duration of testing, two electrical speed signals
are formed to provide protection against turbine
overspend.
During all electrical testing of the protective devices, the
electric trip action is prevented however; all annunciations
are activated as for actual trip.
The appropriate section of the alarm annunciation system
is thus also tested.
Features of the Automatic Turbine Tester
The automatic turbine tester is distinguished by the
following features:
ƒ Individual testing of each turbine
protective device.
ƒ Automatic testing, upon selection of a test, of the
devices that protect the turbine during that test.
Testing of the protective devices for normal turbine
operation can only be performed if the preliminary
test has run without fault and the protection of the
turbine during testing is assured.
ƒ Monitoring of all program steps for execution within a
certain time.
ƒ Interruption if the running time of any program step is
exceeded or if trip is initiated.
ƒ Automatic reset of the test program after a fault.
ƒ Protection of the turbine during testing provided by
special test protective devices.
The subgroup remains on until switched off when the
program has been completed. While the protective
devices subgroup program is running, the other
subgroups are blocked.
The On/Off push-button is also used to acknowledge
alarms.
Selection
After the subgroup has been switched on, the protective
device to be tested is selected by pressing the selection
push button for the individual device.
A separate selection push-button is provided for each
protective device.
Only one selection may be made at a time.
6.1-0661-00/1
Selection of a further test is possible only once all other
programs have ended
Test Push-Button
The automatic test program is started by pressing the
Test push-button
Cancel Push-Button
This push-button can be used to terminate the test
program running at any time and to initiate the reset
program.
The reset program has priority over the test program.
Lamp Test Push-Button
All the signal lamps on the control panel can be tested by
pressing the Lamp Test Push-Button.
Individual Tests
The individual test is performed after completion of the
preliminary test and after the test circuit has been
established.
Successful completion of each individual test is
annunciated by the limit switches on main trip valves
MAX51AA005 and MAX51 AA006, pressure switch
MAX52CP211 in the auxiliary trip fluid circuit and
pressure switch MAX 51CP209 in the trip fluid circuit
between change-over valve MAX51AA211 and the main
trip valve MAX51AA006.
The associated limit switch also annunciates when a
protective device (except for the remote trip solenoids)
has been activated.
On completion of each individual test, all activated
protective devices are returned to their normal operating
position by reset solenoid valves MAX48AA201 and
MAX48 AA202 and the test circuit is deactivated.
BHEL Hardwar
Whenever several of the same types of protective device
are provided, only one will be described in the following,
as the test procedure is the same for all.
Preliminary Test
Pressing the Test push-button automatically initiates a
test of the protective circuits to be effective during testing.
Function
The function of the preliminary test is to detect any faults
in the protective circuits to be used during testing, and, if
any are detected, to inhibit testing of the protective
device, as this would leave the turbine without protection.
Test Sequence
In the course of the preliminary test, solenoid valves
MAX51AA201 and MAX51 AA202 (remote trip during
testing) are automatically tested before the test circuit is
established.
These valves (MAX51AA201 and MAX51AA202) are first
energized, resulting in a buildup of control fluid upstream
of changeover valve MAX51AA 211.
Initiation of Schmitt triggers (in the speed measuring unit)
de-energizes solenoid valve MAX51AA201 and the
control fluid up stream of changeover valve MAX51
AA211 is drained.
6.1-0661-00/2
Successful completion of testing is annunciated by
pressure switch MAX51CP207 between solenoid valve
MAX 51AA201 and changeover valve MAX51AA 211.
Subsequently, solenoid valve MAX51 AA202 is de-
energized via the second channel of its Schmitt trigger,
thereby depressurizing the control fluid still present
between solenoid valves MAX51AA201 and
MAX51AA202.
This process is monitored by pressure switch
MAX51CP205.
On successful completion of the preliminary test, the test
circuit is automatically established which permits realistic
testing of the protective devices without initiating turbine
trip.
Solenoid valves MAX51AA201 and MAX51 AA202 (for
remote trip during testing) are again energized
whereupon control fluid is supplied to change over valve
MAX51 AA211.
Then solenoid valve MAX61AA201 is energized, effecting
changeover from trip fluid to control fluid.
The control fluid in this line drains off, and the pressure
difference drives changeover valve MAX51AA211 into its
test position (lower end position), thereby actuating limit
switch MAX51CG211C which annunciates this status.
De-activating the Test Circuit
The test circuit is deactivated in the reverse order on
completion of the selected test and after automatic
latching of the protective device concerned in its normal
operating position.
Hydraulic Test Signal Transmitters
The function of the hydraulic test signal transmitters is to
activate the related protective device (with the exception
of the remote trip solenoids).
Each protective device has an associated test signal
transmitter.
For testing the over speed trip device, the associated test
signal transmitter builds up a test pressure relatively
slowly and passes it to the over speed trips.
The testing signals to remote trip solenoids MAX52AA001
and MAX52AA002 are formed within the automatic
turbine tester itself and not by a test signal transmitter.

BHEL Hardwar 6.1-0661-00/3

Main Trip Valves
MAX 51 AA005 and MAX 51 AA006
Only one of the two main trip valves is described in the
following, as they are constructional and functionally
identical.
Function
The function of the main trip valve is to amplify and store
the hydraulic or mechanical (manually initiated local) trip
signal. It must respond in the course of every successful
protective device test.
Operation
Each main trip valve is kept in its position by auxiliary trip
fluid pressure.
If a protective device is actuated, the auxiliary trip fluid
circuit is depressurized and the main trip valve is
activated.
This connects the trip fluid and auxiliary trip circuits to
drain and shuts off the control fluid supply to the turbine
valves.
At the same time, limit switch 1 is actuated.
Auxiliary start-up fluid pressure forces differential piston
(3) into its normal operating position.
Control fluid IV is then free to pass through to build up the
pressure in the trip fluid and auxiliary trip fluid circuits.
Pressure switches MAX48CP201 and MAX48CP202
monitor the orderly pressure collapse of auxiliary start-up
fluid circuit after latching-in of main trip valves.
BHEL Hardwar
Attention: The lever for manual actuation of the main trip
valve must not be test operated during turbine automatic
testing operation, as the electrical trip action is always
initiated via the manual trip-out limit switch.
Remote Trip Solenoids
MAX52 AA001 and MAX52 AA002
The twin electrical remote trip feature consists of the two
remote trip solenoid valves MAX52AA001 and
MAX52AA002.
One trip channel is described here, as the test procedure
is the same for both.
Function
The function of the remote trip solenoids is to
depressurize the auxiliary trip fluid circuit in the shortest
possible time, thereby bringing main trip valves
MAX51AA005 and MAX51AA006 into their trip positions,
in the event of a malfunction requiring electrical trip
initiation.
During normal operation, the remote trip solenoid isolates
the auxiliary trip fluid circuit from the drain.
For testing, the automatic turbine tester switches over the
solenoid valve so that the auxiliary trip fluid circuit is
connected to drain.
6.1-0661-00/4
Trip initiation is monitored downstream of the main trip
valves by pressure switches MAX51CP209 and
MAX52CP211 in the auxiliary trip fluid circuit. In addition,
the limit switch of each main trip valve must annunciate
successful completion of the test.
Latching -in
On successful completion of testing, remote trip solenoids
MAX52AA001 and MAX52 AA002 are de-energized.
The reset program is then started.
Over Speed Trips
MAY10AA001/MAY10AA002
Function
The two over speed trips are provided to protect the
turbine against over speeding in the event of load
rejection coincident with failure of the speed controller.
As they are particularly important to the protection of the
turbine, they can also be locally tested by manually with
the aid of the over speed trip test device MAX62AA001
(hydraulic test signal transmitter) during turbine operation
at rated speed. (For description see Over Speed Trip
Test).
Operation
When the preset over speed is reached, the eccentric fly
bolt/striker (2) of each over speed trip activates piston (5)
and limit switch (6) annunciate via pawl (4).
This connects the auxiliary trip fluid circuit to drain,
thereby depressurizing it.
The loss of auxiliary trip fluid pressure causes the main
trip valve to drop which in turn causes the trip fluid
pressure to collapse.
BHEL Hardwar
To activate the over speed trip at rated speed, as the test
routine performed by the automatic turbine tester
requires, a specific force, equivalent to the increase in
centrifugal force between rated speed and preset trip
over speed, is needed.
For testing, this force is exerted by the test oil pressure,
acting on the fly bolt /striker (2) .On the basic of the
existing defined geometry, the test oil is reproducible
measure for the trip speed, and can therefore be used to
check whether the over speed trip responds at the
desired setting.
Test Sequence
The test oil pressure is produced using the hydraulic test
signal transmitter, which is also used for manual testing.
First the command is given to the actuator motor to go
into the trip position (down).
After a certain idling time, the test oil pressure builds up
to act on the two over speed trip fly bolts/strikers (2).
If the two bolts are functioning correctly, they will fly
outwards into the trip position when the defined pressure
is reached, thereby activating the main trip valve via pawl
(4), piston (5) and the auxiliary trip fluid circuit.
The two over speed trips are monitored for activation at
the given test oil pressure by the two pressure switches
MAX62CP211 and MAX62CP212 in the test oil line, and
the limit switch (6).
Pressure switches MAX 62CP211 and MAX62CP212 are
preset to respond at a certain level (approx.O.15 bar)
below and above the test oil reference pressure
respectively.
6.1-0661-00/5
This test oil reference pressure is determined during
commissioning and entered in the commissioning test
record.
Limit switch (6) must respond within the pressure range
between the settings of pressure switches MAX62CP211
and MAX62CP212.
A slow buildup of pressure is required for this operation
that is why a relatively long monitoring period equivalent
to the running time of the actuator, has to be selected.
This double check-back of the hydraulic test signal
transmitter having returned to normal position ensures
that, after completion of testing, the over speed at which
the turbine will trip is not reduced due to test oil pressure
remaining effective and that the over speed trip will not be
set off prematurely in the event of load reduction.
While test oil pressure is decreased, the two over speed
fly bolts/strikers spring back into their normal positions at
a pressure well above 0.5 bars.

Premature response of the over speed trips is Subsequently, piston (5) is brought back into its normal
position by the pressure of auxiliary start-up fluid II and
annunciated.
latched-in with pawl (4).
Latching-in
At the same time, piston (5) shuts off drain channel IV, so
Once the trip has been initiated, the actuator of the auxiliary trip fluid III can build up pressure.
hydraulic test signal transmitter is driven back until the
Once this has been done, the auxiliary start-up fluid can
limit switch annunciates that normal position has been
reached. be depressurized.

Monitoring must be continued until the test oil pressure at

pressure switch MAX62 CP213 is less than 0.1 bars.

BHEL Hardwar 6.1-0661-00/6

Reset Solenoids
MAX48 AA201 and MAX48 AA202
Function
The function of the reset solenoids is to restore the
tripped protective devices to their normal operating
positions during the ATT reset program.
Operation
The reset solenoids are two 2/3-way solenoid valves,
fitted in the auxiliary start-up fluid line.
Both solenoid valves are energized in the course of the
reset program conducted after each subtest, so that
auxiliary start-up fluid II is supplied with control fluid III.
The control fluid pressure forces all protective devices
back into their normal operating positions and the trip
fluid and auxiliary trip fluid pressure can build up again.
When the protective devices have latched-in again, reset
solenoid MAX48AA021 is de-energized first to shut of the
control fluid supply through this value.
Dispersion of the auxiliary start-up fluid pressure is
monitored by pressure switch MAX48CP201.
The second reset solenoid MAX48 AA202 is then de-
energized to disperse the pressure between the two- 1 Compression I Aux. start-up fluid
Spring II Aux. start-up fluid
solenoid valves.
2 Coil to protective devices
This is monitored by pressure switch MAX48 CP202. 3 Valve disc III Control fluid
The use of two reset solenoids ensures that main trip Fig. 7 –Reset Solenoid
valve MAX51AA005 and MAX51AA006 and over speed
trip will always be sure to be actuated if either one of the
two reset solenoids is de-energized.

BHEL Hardwar 6.1-0661-00/7

 Steam Turbine
Description
The following description refers to a standard stop and
control valve assembly.
The same text applies analogously to both the main
stop and control valves and the reheat stop and control
valves.
The valve assembly described is drawn in the closed
position (ready for start-up).
General
The stop and control valves of the turbine are the final
control elements actuated by the protective devices arid
it is, therefore, equally important that these, as well as
the protective devices, should function reliably.
The testing of these valves in conjunction with testing of
the protective devices, as already described in
Automatic Turbine Tester, General ensures that all
elements which must respond on turbine trip are tested
for their ability to function reliably.
Each stop valve is tested together with its associated
control valve.
The automatic turbine tester is designed so that only
one valve assembly may be selected and tested at any
time.
Test Requirements
To avoid turbine output changes and initial pressure
variations due to the closing of the control valve under
test during ATT, the electro-hydraulic turbine controller
must be in operation prior to testing.
To facilitate compensation by the controller, the closing
time of the control valves is relatively long, and to
enable initial pressure to be maintained constant,
testing is only permissible when the turbine output is
below a certain value.
Special Conditions during Testing
The main stop and control valves may only be tested if
no other ATT subgroup is running.
During testing the selected control valve
(MAA10+20AA002) is closed completely by means of a
motor operated actuator (-AA002M) acting on pilot
ƒ Time-related monitoring of all program steps, and
their implementation.
ƒ Interruption due to running time exceeded or
turbine trip.
ƒ Automatic reset of test program after a fault.
ƒ Protection of the turbine during testing provided by
special test protective circuit’s piston (KA06) parallel to
pilot value (KA05).
BHEL, Hardwar
Automatic Turbine Tester
Stop and Control Valves
This result in a closing movement simulating that which
occurs when the associated secondary fluid pressure
drops.
The resultant, constant slow closing movement is
necessary in order to keep the output constant.
Thus the conditions for actuation of the valve are the same
during testing as during normal actuation by the controller.
The stop valves, which are held in the open position by trip
fluid pressure during normal operation, are subjected to
exactly the same hydraulic conditions during testing as
would be the case in the event of actual turbine trip, as the
action of the protective devices is simulated by the
solenoid valve (MAX61AA211 and 212).
The steam side conditions during testing are somewhat
more severe than during actual trip, as the pressure
downstream of the stop valve can not drop off during
closure because the control valve is closed.
This means that the steam pressure acting against the
spring closure force is greater than in the event of normal
trip.
The automatic turbine tester intervenes only in the fluid
circuits normally used to control the valves and uses only
trip fluid to actuate the test valves (MAX47AA011 and 012)
and to reset and open the stop valves.
Thus closure of the valves cannot be impeded in the event
of a genuine trip during testing, regardless of the stage,
which the test has reached.
This also applies to the control valves, as the ATT does not
interrupt the secondary fluid circuit and secondary fluid can
thus be depressurized in the normal manner in the event of
a trip.
Features of Automatic Turbine Tester
The ATT has the following features:
ƒ Separate part-testing of each valve assembly.
6.1-0662-01/1
Setting Data
The setting data for the pressure switches used to
monitor the individual valve movements are listed in the
setting record Pressure Switch settings.
The actual set values are logged in the
Commissioning Test Record. The test running times,
etc., are entered in the functional diagram.
Test Selection Units
There are two nos. of combined main steam and control
valves” and two no’s of combined reheat stop and
control valves, each of which is tested as a separate
unit and has a separate selection push-button on the
ATT control panel.
They are as follows:
Selection1:
Main stop and control valve (LHS)
Selection 2:
Main stop and control valve (RHS)
Selection 3:
Reheat stop and control valve (LHS)
Selection 4:
Reheat stop and control valve (RHS)
Test Procedure
Start of Test
The test starts with the selection of subgroups by
pressing the On/Off push-button.
The subgroup remains on until it is switched off after
the programmed is concluded.
When one subgroup program is running, the other
subgroup is blocked.
The On/Off push button also acknowledges signals:
During this time, the turbine output controller
compensates for the effects of closure of the valve
being tested on the turbine output by opening the
remaining control valves.
The running time for closure of the control valve is
monitored. If the control valve is functioning properly, it
will close within the preset running time.
BHEL, Hardwar
Selection
If the test requirements have been fulfilled, the valve,
assembly (e.g. main stop and control valve (LHS)) to be
tested is selected by switching in the subgroup by pressing
title selection push-button.
A separate selection push-button is provided for each
combination of stop and control valve assembly.
Only one selection may be made at a time.
Selection of a further test is not possible until the
programme already selected has ended.
Operation Push-button
The test run is started by pressing the Operation push-
button in the Stop and Control valves tile.
Shutdown Push-button
This push-button can abort the current unit test and
introduce the reset program, which has priority over the
test program me.
Lamp Test Push-button
All lamps on the panel are tested by pressing the Test
push-button.
Closure of Control Valve
If all the test requirements have been fulfilled and the
selection and operation push buttons pressed, the control
valve (MAA10 and 20AA002) is closed by means of the
associated actuator (test motor –AA002M).
Operation of the actuator (KA01) is continued until limit
switch (-CG002C) and limit switch (-AA002M S72, S73) on
the actuator is tripped to annunciate that the control valve
being tested is in closed position.
Closure of Stop Valve
Then the solenoid valve (MAX61AA211 and 212)
energized.
This allows trip fluid to flow to the space below changeover
slide valve (MAX61AA011 and 012), which moves into its
upper end position and connects the space below piston
disc (KA02) with the drain.
The pressure in this space drops rapidly and is monitored
by pressure switch (MAX51CP223, 228).
When the pressure at this pressure switch has dropped
slightly below the breakaway pressure of piston disc
(KA02), monitoring of the stop valve closure time starts.
The associated limit switch (-CG001E) annunciates entry
of the valve into its closed position, thus making it possible
to monitor the valve closing action for completion within the
maximum permissible running time.
6.1-0662-01/2
Opening of Stop Valve
Next, solenoid valve MAX47AA211 and 212 is
energized (test position) and trip medium is admitted to
the control surface of the piston in the test valve MAX47
AA011 and 012.
The pilot moves into its lower end position against the
spring force, thus permitting trip medium to flow to the
space above piston KA01 of the stop valve.
This piston is forced downwards by pressure of the
medium, thereby tensioning the spring between piston
KA01 and piston disc KA02 and finally pressing against
piston disc KA02.
Up to this point the medium pressure above piston
KA01 is relatively low, being equal to the spring force
acting against it.
The spontaneous pressure rise when piston KA01 has
made contact with piston disc KA02, and thus on
completion of the spring tensioning action, is detected
by pressure switch MAX51CP222, 227.
If all conditions are fulfilled within this relatively long
monitoring period, solenoid valve MAX61AA211 and
212 is de-energized (operating position), so that trip
medium is once again able to flow to test valve
MAX47AA011 and 012 and the drain is blocked off
again.
The buildup of trip medium pressure is monitored by
pressure switch MAX51CP221, 226.
When the pressure is sufficiently high, the stop valve is
opened by de-energizing solenoid valve MAX47AA211
and 212 (operating position).
Test valve MAX47 AA011 and 012 switches over,
admitting trip medium to the underside of the piston
disc KA02 and after a certain amount of further travel,
slowly connects the space above piston KA01 with the
drain.
The resultant pressure difference causes the tensioned
piston relay to open the stop valve.
As soon as the open position is reached, the full trip
medium pressure builds up.
This is monitored by pressure switch MAX51CP221,
228 and by limit switch –CG001D.
Testing of the stop valve is now completed.
Re-Opening of Control Valve
If the conditions are fulfilled within the specified
monitoring period, the control valve is reopened.
BHEL, Hardwar
The motor of positioned–AA002M is operated in the
opening direction.
Positioned–AA002M moves the control valve into its
original position in the reverse sequence to the closing
action.
Again the initial pressure and output are kept constant by
the appropriate controller.
Operation of positioned -AA002M is continued until, after a
certain amount of over travel, it has positively ceased to
influence the controller.
This position is detected by limit switch –AA002 MS61 or –
AA002 MS62.
If the control valve is functioning properly, it will open within
the preset running time.
Cancellation of Selection
On conclusion of testing of each combination of valve
assembly, the selection is automatically cancelled and the
programme is shut down.
Interruption due to Running Time Exceeded
The reset program is automatically initiated if the running
time for any step in the test program is exceeded.
If any running time is exceeded during the reset program,
the program halts.
In either case, the alarms Fails signal and Time overrun
generated.
If the Faults in ATT alarm is displayed, the fault lies in the
automatic tester itself.
Interruption due to Turbine Trip
If electrical turbine trip is initiated during testing, all
solenoid valves are de-energized and positioner –AA002M
is returned to its extreme position and the programmed
cancelled.
All equipments associated with the automatic turbine tester
are automatically returned to their normal position.
6.1-0662-01/3
 Steam Turbine
Description
The actuator is of the two-stage amplification type, i.e. it
incorporates pilot and main control mechanisms.
The actuating forces for movement of the HP control
valve are generated, in the opening direction, by main
actuator piston KA02 under the force of the control fluid
and, in the closing direction, by the disc spring column.
During actuation main pilot valve KA07 acts as a 3-way
valve to allow the control fluid to flow to the space behind
main actuator piston KA02.
Main pilot valve KA07 is actuated via the resetting linkage
by means of auxiliary pilot piston KA06 which is subject to
control fluid pressure on both sides.
The actuating signal given by the signal fluid pressure
acts on the face of pilot valve KA05 pressing it against
the resetting spring on the opposite side.
Acting as a 4-way valve, the pilot valve allows fluid to
flow to both sides of auxiliary pilot piston KA06.
BHEL, Hardwar
HP Actuator
When the signal fluid pressure changes, pilot valve KA05
is displaced which results in movement of auxiliary pilot
piston KA06.
The movement of piston KA06 is transmitted via the
resetting linkage of the pilot mechanism to the resetting
spring, causing spool valve KA05 to return to the central
position which establishes proportionality between the
signal fluid pressure and the travel of auxiliary pilot piston
KA06.
At the same time, main pilot valve KA07 displaced via the
resetting linkage system by auxiliary pilot piston KA06,
effects displacement of main actuator piston KA02 whose
movement returns main pilot valve KA07 to the central
position via the resetting mechanism.
Consequently the position of the pilot and main actuator
pistons is proportional to the secondary fluid pressure in
the steady state (on completion of the control action).
6.1-0665-00
 Steam Turbine
Description
Function
With all shaft seals subject to a positive pressure
difference, the escaping steam is throttled to a low
pressure and fed into a header 1.1, which is common to
all shaft seals.
Those seals, which are under vacuum, must be
supplied with seal steam to prevent the ingress of air.
The supply of steam is taken from the header 1.1.
The amount of leakage steam and seal steam required
depends on the pressure at the seals, which, in turn, is
primarily dependent on the turbine load.
The function of the control system is to maintain the
pressure at the bleed-off points of all seals at the same
preset pressure.
This is effected by exhausting steam from the header
(e.g. to the condenser) or supplying extra steam to the
header 1.1, according to operating conditions.
Arrangement
Leak-off control valve 1.3 is used for discharging
surplus steam from the header 1.1 and seal steam
supply control valve 1.4 for admitting extra steam to it.
All valves are actuated by type HSA-1-K electro
hydraulic actuators.
The actuators 1.11 are under the continuous control of
an electric controller 1.9 each via an electro hydraulic
converter.
BHEL, Hardwar
Electro-hydraulic Seal
Steam Pressure Control
The electro hydraulic converter comprises a control coil,
which adjusts the position of the impingement plate of
the hydraulic preamplifier.
Controller
The function of the electric controller 1.9 in conjunction
with the transducer 1.6 and the actuating elements
(control valves) is to maintain a controlled variable at a
preset valve by adjusting the final controlling elements.
The actual valve of the control system is acquired
continuously by the transducer 1.6 and compared
against the set value in the electric controller 1.9.
If the actual value deviates from the set value, one of
the final controlling elements (either the leak-off or
steam supply control valve) is adjusted until the actual
value again agrees with the set value.
Only if there is a large control deviation, e.g. during a
full-load trip, are all valves operated simultaneously.
The electric controller is realized in digital technology.
Mode of Operation
The input signal coming from the controller flows
through the solenoid (31).
The magnetic field of the solenoid together with the
magnetic field of the permanent magnet system (42)
exercises a force on the freely pivoted armature (30).
This force reacts against the force generated by the
tension of the return spring.
6.1-0670-01/1
If the input signal is changed, the equilibrium will be
disturbed and, therefore, there will be a deflection of the
armature retained by the spring (32) and return spring
(36).
The baffle plate (29) then covers the two-rebound
nozzle tips (15) to an unequal extent. In the oil flow that
flows through two-choke valves (21) to the rebound
nozzles (16), a pressure differential is created.
The oil pressure existing in the rebound nozzles is
applied to the face of the slide gate (1a).
The slide gate is deflected and releases the oil flow to
or from the hydraulic cylinder (5.1).
The deflection of the slide gate is dependent upon the
magnitude of an input signal change.
The greatest amount of deflection and, therefore, the
fastest change in the Hydraulic cylinder’s position is
already achieved with an input signal change of delta I
≥ 3 mA.
BHEL, Hardwar
Following smaller changes in signal, the hydraulic
cylinder operation is correspondingly slower.
The servo-valve enables an extremely sensitive control
by virtue of its special construction.
The main cylinder piston moves and in so doing
changes the position of the coupled actuator.
At the same time, the tension in the return spring (36)
changes via the return rod (44) and the adjustment.
Lever (39), until the tension of the springs and magnetic
forces reach a state of equilibrium.
The armature returns to its mid position, the pressures
on the faces of the slide gates (1a) are of equal
magnitude.
The slide gate moves to its mid position, the oil flow to
the cylinder is initially reduced and, when the slide gate
(1a) reaches its middle setting it is completely shut off
and the main piston of the hydraulic cylinder is in its set
position.
6.1-0670-01/2
The position of the main piston or rather the actuator is
directly proportional to the input signal on the servo
valve.
Double Blocking Valve
A double blocking valve is connected to the outlet side
of the servo-valve.
The pump pressure opens the hydraulically operated
check valve (8).
The connections to the hydraulic cylinder (5.1) are free.
If the oil supply fails, both hydraulically operated check
valve close.
The hydraulic cylinders piston will be retained in its last
position.
Display of control deviation /Adjusting the set value
The control deviation is displayed on each of the two
desk tiles for the valves.
The two instruments are connected in parallel.
The set value for steam pressure in the header can be
adjusted between 0 and 22 mbar at the controller by
means of the set value push-button.
Electric manual control
The controller can be switched off by the push button
“Controller on/off”.
BHEL, Hardwar
Then the valves can be controlled directly by hand by
means of the push-button “Higher/Lower” below the
valve position display with the aid of the remote-control
manual control setter of the electrical equipment.
The inscription “Higher/Lower” refers to the change in
pressure when the push-button is operated, e.g.
“Higher” means increasing the pressure (the leak-off
steam control valve closes or the seal steam control
valve opens).
Manual control is disconnected during automatic
control; the manual control setter is then automatically
tracked to the controller output voltage by the
equalizing controller so that when changing over from
automatic control to manual control the manual control
setter is already in the correct position.
Under manual control the equalizing controller
automatically tracks the output voltage of the
disconnected controller 1.9 to the manual control
voltage.
If the control deviation has been reduced to zero by
positioning the valves before the controller is switched
on, the change-over from manual control to automatic
control will be bump less; otherwise the controller
regulates the pressure to the preset value after it has
been switched on.
Thus, it is quite easy to switch the controller on and off
during operation.
6.1-0670-01/3
BHEL, Hardwar 6.1-0670-01/4
BHEL, Hardwar 6.1-0680-02
 Steam Turbine Control System
Description Diagram Legend

Power Plant iden- Title Coor-

Power Plant iden- Title Coor-
tification System dinete
tification System dinete
LBQ71AA001 Extraction Check Valve A7 E6
KA01 Servomotor E6
LBC10 AA001 Swing Check Valve of CRH E7
LBQ71CG001 A Remote Position Indicator E6
KA01 Rotary Servomotor E7
LBC10 CG001 B Limit Switch, Open Position E7
LBQ71AA002 Extraction Check Valve A7 E6
C Limit Switch, Closed Position E7
KA01 Servomotor E6
D Limit Switch, Open Position E7
LBQ71CG002 A Remote Position Indicator E6
E Limit Switch, Closed Position E7
MAA10 + 20
LBS21 AA001 Extraction Check Valve A2 E12,13
AA001 Main Stop Valve ABC7
KA01 Servomotor E12,13
KA01 Piston AB7
LBS21 CG001A Remote Position Indicator E12,13
KA02 Piston Disc B7
LBS21 AA002 Extraction Check Valve A2 E13
MAA10 + 20
LBS21 CG002 A Remote Position indicator E13
CG001 B,F,H Limit Switch, Open Valve Position B7
C,G,J Limit Switch, Closed Valve Position B7
LBS22 AA001 Extraction Check Valve A2 E12,13
D Limit Switch, Open Valve PositionATT B7
KA01 Servomotor E12,13
E Limit Switch, Closed Valve PositionATTB7
LBS22 CG001A Remote Position Indicator E12,13
MAA10+ 20
LBS22 AA002 Extraction Check Valve A2 E13
AA002 Main Control Valve BC7,8
LBS22 CG002 A Remote Position indicator E13
KA01 Servomotor C7,8
KA02 Piston C7
LBS31 AA001 Extraction Check Valve A3 E13
KA05 Pre Control Pilot Valve C7
KA01 Servomotor E13
KA06 Relay Piston for Pre Control Pilot ValveC7
LBS31 CG001A Remote Position Indicator E13
KA07 Main Pilot Valve C7
KA09 Hand wheel for Testing Device B7
LBS31 AA002 Extraction Check Valve A3 E13
M Electrical Motor for Testing Device B7
LBS31 CG002 A Remote Position indicator E13
AA002 MS61 Torque limit Switch,
Testing Device 100% ATT B7
LBS32 AA001 Extraction Check Valve A3 E13
MS62 Travel Limit Switch,
KA01 Servomotor E13
Testing Device 100% ATT B7
LBS32 CG001A Remote Position Indicator E13
MS72 Torque Limit Switch,
Testing Device 0% A TT B7
LBS32 AA002 Extraction Check Valve A3 E13
MS73 Travel Limit Switch, B7
LBS32 CG002 A Remote Position indicator E13
Testing Device 0% ATT
LBS41 AA001 Extraction Check Valve A4 C10
MAA10 + 20
KA01 Servomotor C10
CG002 A Remote Position Indicator C7
LBS41 CG00 1A Remote Position Indicator C10
C Limit Switch, Closed Valve Position ATT C7
LBS41 AA002 Extraction Check Valve A4 C10
MAB10 +20
KA01 Servomotor C10
AA001 Reheat Stop Valve ABC9
LBS41 CG002A Remote Position Indicator C10
KA01 Piston A9
KA02 Piston Disc A9
LBS42 AA001 Extraction Check Valve A4 AB11
KA01 Servomotor A 11
MAB10 + 20
LBS42 CG001A Remote Position Indicator B 11
CG001 B,F,H, Limit Switch, Open Valve Position A9
C,G,J Limit Switch, Closed Valve Position A9
LBS42 AA002 Extraction Check Valve A4 AB1 1,12
D Limit Switch, Open Valve Position ATT A9
KA01 Servomotor A12
E Unlit Switch,Closed Valve Position ATT A9
LBS42 CG002A Remote Position Indicator B12

LBQ50AA001 Extraction Check Valve A5 E9

KA01 Servomotor E9
LBQ50CG001 A Remote Position Indicator E9

LBQ5OAA002 Extraction Check Valve A5 E9

LBQ50 CG002A Remote Position Indicator E9

BHEL Hardwar 6.1-0681-02/1

Power Plant iden- Title Coor-
tification
Power System
Plant iden- Title dinete
Coor-
tification Power Plant iden- Title Coor-
PowerSystem
Plant iden- Title dinete
Coor-
tification System dinete
tification System dinete
MAD12
MAB10+ 20 Main Control Valve BC9,10
CY011,012,013
AA002 Electrical Thrust Bearing Trip D8
MAB10+ 20 Main Control Valve BC9,10
AA002 MAX44AP001 Hydraulic Speed Transmitter E1
MAV21 AP001KA01 Main Oil Pump
Servomotor E1
C10
KA02 Piston C10C10 MAX44CP501 Pressure Gauge, Primary Oil A5
MAV21BT001KA01 Servomotor
Oil Filter
KA05 PrePiston
KA02 Control
(Hydraulic Pilot Valve
Control Equipment Rack) C10 D4C10
KA06 Relay
KA05 PrePiston
ControlforPilot
Precontrol
Valve Pilot ValveC10
C10 MAX45BB001 Accumulator for Extraction Valve
MAX31 KA07 Main
KA06 PilotPiston
Relay Valve for Precontrol Pilot ValveC10
C10 Relay E4
BB011, 016KA09 Hand wheel
Accumulator
KA07 Main Pilotfor Testing
HP
Valve Device
Servomotor, B10C10
M Electrical
Main
KA09 Control
Hand Motor for Testing
Valves
wheel for Testing Device
Device B10B7B10 MAX45BY001 Electro-Hydraulic Converter F4
MS61 MTorque Limit Switch,
Electrical Motor for Testing Device B10 KA01 Follow-Up Piston for Main
MAX31 Accumulator
Testing
MS61 TorqueDevicefor 100%
Limit HP Servomotor,
ATT
Switch, B10 Control Valves F5
BB21, 26 MS62 Reheat
Travel Control
Limit
Testing Valves
Switch,
Device 100% ATT B9B10 KA02 Follow Up Piston for Reheat
MS62 Testing Device 100%
Travel Limit Switch, ATT B10 Control Valv8S F5
MAX31 BB021
MS72 Accumulator
Torque for HP Servomotor,
LimitDevice
Switch,
BB041,049 Testing
Bypass Control 100% ATT
Valves C11B10 KA04 Sleeve F4
MS72 Testing
TorqueDevice
Limit0% ATT
Switch, B10 KA05 Piston F4
MS73 Travel LimitDevice
Testing Switch,0% ATT B10B10 KA06 Helical Spring F4
MAX32
Testing
BT011 +012 MS73 FluidTravelDevice
Filter Limit
for Pre0% ATT
Switch,
Control. B10 KA08 Piston F4
MainTesting
ControlDevice
Valves0% ATT A7 KA10 Adjusting Device Control Valves F5
MAB10 + 20 KA11 Manual Adjusting Device F5
CG002 A
MAB10 + 20 Remote Position Indicator C10
CG002 C A Limit Switch,Position
Remote Closed Indicator
Valve Position C10C10
C ATTLimit Switch, Closed Valve Position C10
ATT

MAX32BT021
MAV21 AP001 Fluid Filter
Main Oilfor Pre Control,
Pump E1
Reheat Control Valves A10
MAV21BT001 Oil Filter
MAX32BT081 (Hydraulic
Fluid Filter for Control Equipment Rack) D4
Pre Control,
Bypass Control Valves C11
MAX31
BB011, 016 Accumulator for HP Servomotor,
MAX41 CP50l Pressure Gauge.Valves
Main Control Control Fluid B7
(Hydraulic Control Equipment Rack) C2
MAX31 Accumulator for HP Servomotor,
BB21, 26
MAX42AA001 Reheat
Slide Valve Control Valves
for Swing Check Valve B9
Cold Reheat D7
MAX31 BB021 Accumulator for HP Servomotor,
BB041,049
MAX42AA002 Bypass
Slide Valve Control Valves
for Swing Check Valve C11
Cold Reheat D8
MAX32
BT011 +012 Fluid Filter for Pre Control.
MAX42AA011 Non-Return Valve
Main Control Valves B1 A7

MAX42BT001 Fluid Filter

MAX32BT021 (Hydraulic Control
Fluid Filter Equipment
for Pre Control, Rack) C1
Reheat Control Valves A10
MAX42BT002 Fluid Filter
MAX32BT081 (Hydraulic Control
Fluid Filter Equipment
for Pre Control, Rack) C2
Bypass Control Valves C11
MAX42BT003 Fluid Filter
MAX41 CP50l (Hydraulic
Pressure Control
Gauge.Equipment Rack)
Control Fluid B4
(Hydraulic Control Equipment Rack) C2
MAX44AP001 Hydraulic Speed Transmitter E1
MAX42AA001 Slide Valve for Swing Check Valve
MAX44CP501 Pressure Gauge, Primary Oil
Cold Reheat A5 D7

MAX45BB001
MAX42AA002 Accumulator forfor
Slide Valve Extraction ValveValve
Swing Check
Relay
Cold Reheat E4 D8

MAX45BY001
MAX42AA011 Electro-Hydraulic Converter
Non-Return Valve F4 B1
KA01 Follow-Up Piston for Main
MAX42BT001 Control
FluidValves
Filter F5
KA02 Follow Up Piston
(Hydraulic for Reheat
Control Equipment Rack) C1
Control Valv8S F5
KA04
MAX42BT002 Sleeve
Fluid Filter F4
(Hydraulic Control Equipment Rack) C2

MAX42BT003 Fluid Filter

Power Pl (Hydraulic Control Equipment Rack) B4

BHEL Hardwar 6.1-0681-02/2

 Powr Plant iden- Title Coor-
tification System dinete Power Plant iden- Title Coor-
tification System dinete
MAX45
MAX47CG001F Limit Switch, 56% G1
CG001 A Remote Position Indicator F4
MAX47CP501 Pressure Gauge, Start-up Fluid G1
K Remote Position Indicator F4
MAX48 CP501 Pressure Gauge,
T Solenoid F4 Auxiliary start-up fluid E3
B Limit Switch Operating Without Bypass
Valves and Adjusting Device Blocked F5 MAX51
C Limit Switch, Displacement of AA005 +006 Main Trip Valve B2
Control Valves F5
MAX 51
MAX45BY011 Hydraulic Converter F2 CG005+006 C Limit Switch, Alarm B2
KA01 Follow-up Piston for Main Control Valves F3 E Limit Switch, Alarm, ATT B2
KA02 Follow-Up Piston for Reheat Control F3
valve MAX51AA041 Slide Valve for Extraction
KA04 Sleeve G3 Check Valve A2 E12
KA05 Piston G3
KA06 Helical Spring F3 MAX51 AA044 Slide Valve for Extraction
KA07 Pilot Valve G2 Check Valve A3 E13
KA08 Piston G3 MAX51 AA047 Slide Valve for Extraction
KA09 Proportional Band Adjustment G2 Check Valve A4 C12
KA10 Adjusting Device Control Valves F4
MAX51 AA048 Slide Valve for Extraction
KA11 Manual Adjusting Device F4
Check Valve A4 A 11
MAX45CG011 B Limit Switch, Operation without Bypass
Valves and Adjusting Device Blocked F3 MAX 51 AA 050 Slide Valve for Extraction
C Limit Switch, Displacement of control Check Valve A4 C12
valves F4
MAX 51 AA051 Slide Valve for Extraction
MAX45CP501 Pressure Gauge Secondary Fluid Check Valve A4 A11
Main Control valves F2
MAX 51 AA056 Slide Valve for Extraction
MAX45CP511 Pressure Gauge, Secondary Fluid Check Valve A5 E9
Reheat Control Valves E2
MAX 51 AA059 Slide Valve for Extraction
MAX46BY001 Hydraulic Speed Governor G1 Check Valve A7 E6
KA01 Hand wheel F2
KA02 Speed Setting Spring F1 MAX 51 AA060 Slide Valve for Extraction
KA03 Link F1 Check Valve A7 E6
KA04 Sleeve F2
MAX51AA211 Changeover Valve B3
KA05 Piston F2
KA06 Helical Spring F2
MAX51 CG211B Limit Switch, up Normal Position ATT B3
KA07 Overspeed Tester Lever F2 C Limit Switch, Down- Test Position ATT B3
KA08 Auxiliary Follow-up Piston F2
KA09 Governor Bellows G1 MAX51CP501 Pressure Gauge, Trip Fluid A3
M Electrical Motor F1
MAX51 CP522 Pressure Gauge, Trip Fluid above piston
MAX46CG001 A Remote Position Indicator F2 527 Main Stop Valve A6
B Limit Switch 100%
(Start-Up Automatic) F2 MAX 51 CP523 Pressure Gauge, Trip Fluid below piston
528 Disc Main Stop Valve B6
MAX46CP501 Pressure Gauge.
Auxiliary Secondary Fluid F2 MAX51 CP542 Pressure Gauge, Trip Fluid above Piston
547 Reheat Stop Valve A9
MAX47
AA011 +012 Test Valve for Main Stop Valves B6 MAX51 CP543 Pressure Gauge, Trip Fluid below Piston
548 Disc Reheat Stop valve B9
MAX47
MAX52AA005 Local/Manual Trip Valve B2
AA021 +022 Test Valve for Reheat Stop Valves A9
MAX52 CG005 C Limit Switch, Alarm B2
E Limit Switch, Alarm ATT B2
MAX47BY001 Starting and Load Limit Device F1
KA01 Hand wheel F1 MAX 52 CP501 Pressure Gauge, Aux, Trip Fluid D3
KA02 Valve F1
M Electrical Motor F1

MAX47CG001 A Remote Position Indicator F1

B Limit Switch, 100% G1
C Limit Switch, 0% G1
D Limit Switch, 42% G1

BHEL Hardwar 6.1-0681-02/3

Power Plant Iden- Title Coor- Power Plant Iden- Title Coor-
tification System dinate tification System dinate

MYA01
CS011-013 Electrical Speed Transmitter E1

MAX42AA001 Solenoid Valve, Adjustment of

Control Valves F5

MAX45AA001 Solenoid Valve for Load Shedding Relay

in Secondary Fluid to Reheat
Control Valves E5

MAX46AA011 Solenoid Valve for Load Shedding Relay

in Auxiliary Secondary Fluid G2

MAX47
AA211 +212 Solenoid Valve for start -up Fluid,
Main Stop Valve B5
MAX 47
AA221 +222 Solenoid Valve for Start-up Fluid,
Reheat Stop Valves B8

MAX48
AA201 +202 Solenoid Valve for Auxiliary
Start-Up Fluid B1,2

MAX51AA021 Solenoid Valve for Extraction

Check Valve E12

MAX51AA022 Solenoid Valve for Extraction

Check Valve E12

MAX51AA024 Solenoid Valve for Extraction

Check Valve E13

MAX51AA025 Solenoid Valve for Extraction

Check Valve E13

MAX51AA027 Solenoid Valve for Extraction

Check Valve A4.1 C 12

MAX51 AA028 Solenoid Valve for Extraction

Check Valve A4.2 A10

MAX51 AA030 Solenoid Valve for Extraction

Check Valve A4.1 C12

MAX51AA031 Solenoid Valve For Extraction

MAX61 Check Valve A4.2 A11
AA011 +012 Test Valve for Main Stop Valves B6
MAX51 AA036 Solenoid Valve for Extraction
MAX61 Check Valve A5 E9
AA021 +022 Test Valve for Reheat Stop Valves B8
MAX51 AA040 Solenoid Valve for Extraction
Check Valve A7 E6

MAX51 AA041 Solenoid Valve for Extraction

Check Valve A7 E6

MAX51 AA201 Solenoid Valve for Control Fluid

MAX62AA001 Overspeed Trip Test Device C4 Supply during Test B3
KA01 Valve for Test oil C4
KA02 Valve for Auxiliary Start-up Fluid C4 MAX51AA202 Solenoid Valve for Control Fluid
KA03 Valve For Auxiliary Trip Fluid C4 Supply During Test B4
KA001M Electrical Motor C4
MAX52AA001 Remote Trip Solenoid C2
MAX62CG001 B Limit Switch, up-Normal position ATT C4
C Limit Switch, Down- Test Position ATT C4 MAX52AA002 Remote Trip Solenoid C2

MAX62CP501 Pressure Gauge, Test Oil Overspeed D1 MAX53AA051 Solenoid Valve for Sequential
Trip Water Injection C13
MAY10
AA001 +002 Overspeed Trip E2 MAX61AA201 Solenoid Valve for Changeover from
KA01 Releasing Device E2 Trip Fluid to Control Fluid C3

MAY10
CG001 +002 C Limit Switch, Alarm E3
E Limit Switch Alarm ATT E3

BHEL Hardwar 6.1-0681-02/4

 Power Plant iden- Title Coor-
Power Plant iden- Title Coor-
tification System dinete
tification System dinete
MAX48 CP202 Pressure Switch for Auxiliary
MAX61 Start-up Fluid Between Solenoid
AA211 +212 Solenoid Valve for Testing of
Valves MAX48AA201 and202 B1
Main Stop Valves C5,6
MAX51
MAX61
CP001 +002 Pressure transmitter for Trip fluid A1
AA221 +222 Solenoid Valve for Testing of
Reheat Stop Valves C8 MAX51
CP205 +206 Pressure Switch for Trip Fluid Between
Solenoid Valves MAX51 AA201
and 202 B3
LBS42 CP002 Differential Pressure Monitor for
Extraction Check Valve-A4
MAX51
(Batron -Cell) B11
CP207 +208 Pressure Switch for Trip Fluid Ahead of
Changeover Valve MAX51 A211 B3

MAX51
CP209 +210 Pressure Switch for Trip Fluid Ahead of
Changeover Valve MAX51 AA211 B2,3
MAG10CP001 Pressure Transmitter, Electrical Low MAX51CP 221 Pressure Switch for Trip Fluid ahead of
Vacuum Trip.
+226 Main Stop Valve, Test Valve B6
Signal Pressure to high E13
MAX51CP222 Pressure Switch for Pressure above
MAG 10CP002 Pressure Transmitter, Electrical low
+227 Piston of Main Stop Vale B7
Vacuum Trip, Alarm E13
MAX51 CP223 Pressure Switch for Pressure below
MAG10CP003 Pressure Transmitter Electrical low Vacuum
+228 Piston Disc of Main Stop Vale A7
Trip Interlocking MAG10CPO12 E14
MAX51CP242 Pressure Switch for Trip Fluid above
MAG10CP004 Pressure Transmitter for Energizing of
+247 Piston of Reheat Stop Valve A9
Vacuum Breaker E13
MAX51 CP243 Pressure Switch for Trip Fluid Below
MAX45 CP211 Pressure Switch For Reheat Control
+248 Piston Disc of Reheat Stop Valve B9
Valves Secondary Fluid E2
MAX52CP211 Pressure Switch for Auxiliary
MAX48 CP201 Pressure Switch For Auxiliary C2
Trip Fluid B3
Start-up Fluid
MAX62 CP 211 Pressure Switch for Test oil of
overspeed Trip max D1

MAX62 CP 212 Pressure Switch for Test oil of

overspeed Trip max. D1

MAX62 CP 213 Pressure Switch for Test oil of

overspeed Trip Pressure Collapsed D2

MAX45 AA031 Pressure Converter for IP secondary

Oil E4

BHEL Hardwar 6.1-0681-02/5

 Steam Turbine Lubrication Chart
Description

No. Lubrication Filling Lubricant Lubrication Top-up Remarks

Point Quantity Interval Quantity

1. Overspeed test Turbine oil* Every 1 to 2

device months
2. Reduction gear of 200g Grease Every 1 to 2 ≈ 10g
overspeed trip Servogem-2 months
test device
3. Main control valve Molykote U After every Use no oil
stem dismantling or grease
4. Main stop valve Molykote U After every Use no oil
stem dismantling or grease
5. Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main stop valve
6. Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main control valve
7. Hinge of main Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
8. LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of main SF7-026 Operating
control valve hours
9. Reheat control Molykote U After every Use no oil
valve stem dismantling or grease
10. Reheat stop valve Molykote U After every Use no oil
stem dismantling or grease
11. Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat stop valve
12. LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of reheat SF7-026 Operating
control valve hours
13. Hinge of reheat Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
14. Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat control
valve
15. Hinge of Molykote U After every Use no oil
extraction swing dismantling or grease
check valve
16. Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
starting and load Servogem-2 months
limit device

BHEL Hardwar 6.1-0690-02/1

 No. Lubrication Filling Lubricant Lubrication Top-up Remarks
Point Quantity Interval Quantity

17. Journal for Turbine oil* Every 1 to 2

hydraulic speed months
governor
18. Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
reference speed Servogem-2 months
setter
19. Bearing of Turbine oil* Every 1 to 2
trimming device months
20. Hinge of cold Molykote U After every Use no oil
reheat swing dismantling or grease
check valve
21. Stem guides of Molykote U After every Use no oil
shaft seal steam dismantling or grease.
valve Lubrication
point not
shown
22. Shaft seal steam 7 to 9 kg Hydraulic oil 1stoil change 7 to 9 kg Lubrication
valve actuators to DIN 51517 after 6 point not
and VDMA months, shown
24318 H-LP thereafter
oils** every12
months.

* Turbine oil 46/Servoprime 46 of IOC, Turbinol 47 of HPCL or equivalent

** HLP 46 (VG) ISO of IOC

BHEL Hardwar 6.1-0690-02/2

BHEL, Hardwar 6.1-0690-02/3
 Steam Turbine
Description
Function
The function of the hydraulic speed governor is to operate
the control valves to give the appropriate turbine steam
throughput for the particular load condition. The
arrangement and functioning of the governor within the
overall governing system is described in the section on
governing.
Construction
The principal components of the speed governor are the
bellows (8), the link (11), the speed setting spring (13),
the sleeve (5) and the follow-up piston (4). The primary oil
supply from the hydraulic speed transmitter is available at
connection ‘a1‘. A fire resistant fluid is used as the
hydraulic fluid in the governing system. An additional
bellows (9) prevents primary oil getting into the control
fluid circuit if there be a leakage in the governor bellows
(8). In this case, the leakage oil can be drained off via
connection ‘c1 ‘. In case a leak in the bellows (9) occurs,
the control fluid that has leaked in will also be drained off
via connection ‘c1’.
The primary oil pressure (connection ‘a1‘) is dependent
on the speed and determines the position of the link (11)
via the bellows (8) and the push rod (10). The speed
setting spring (13) opposes the primary oil pressure. Its
pre-compression can be varied either by hand or
remotely by the motor (16). The sleeve (5) which can
slide on the bottom end of the follow-up piston (4) is
attached to the link (11). The follow-up piston is held
against the auxiliary secondary fluid pressure (connection
‘b’) by the tension spring (3). The follow-up piston and the
sleeve have ports, which at normal overlap allow
sufficient fluid to escape to produce equilibrium between
the auxiliary secondary fluid pressure and the force of the
tension spring (3).
Each steady-state position of the link (11) and hence of
the sleeve (5) corresponds to a specific force from the
tension spring (3) and hence to a specific secondary fluid
pressure which in turn determines the position of the
control valves.
BHEL, Hardwar
Hydraulic Speed Governor
Limiting Device
with Starting and Load
Mode of Operation
If the primary oil pressure falls (as a result of increasing
load and the resulting drop in speed), the link (11) and
the sleeve (5) sliding on the follow-up piston (4) are
moved downwards by the speed setting spring (13) so
that the overlap of the ports in the sleeve and the follow-
up piston is reduced. This causes the pressure in the
auxiliary secondary fluid circuit to rise and the follow-up
piston follows the movement of the sleeve against the
increasing force of the tension spring (3) until normal
overlap of the ports and equilibrium are restored. The lift
of the control valves is increased in this manner by the
increased secondary fluid pressure.
Conversely, a rise in primary oil pressure causes the lift
of the control valves to be reduced.
When the pre-compression of the speed setting spring
(13) is varied with the reference speed setter it changes
the relationship between the primary oil pressure and the
secondary fluid pressure and hence the relationship
between speed and power output.
Lever (12) allows the link (11) to be depressed by hand to
give a lift signal to the governor, e.g. to provide a second
means of overspeeding the machine for testing the
overspeed trips in addition to the over speed trip tester.
Starting and load limiting device
Before start-up, the pilot valve (21) is brought to its
bottom limit position either by hand or remotely by the
motor (20). This causes the bellows to be compressed via
the lever (6) and the pin (7) until the governor assumes
the position “Control valves closed”. With the pilot valve
(21) in the bottom limit position, control fluid from
connection ‘a’ can flow simultaneously to the auxiliary
start-up fluid circuit (connection ‘u1‘) and as start-up fluid
via connection ‘u’ to the stop valve to prepare these for
opening. When the pilot valve (21) is moved back the
auxiliary start-up fluid circuit is depressurized and
subsequently the start-up fluid connection ‘u’ is opened to
the return ‘c’. This opens the stop valves. Further upward
movement of the pilot valve (21) causes the pin (7) to
release the bellows as with falling primary oil pressure
and the control valves are opened. The release of the
bellows can be limited by the pin (7) so that the control
valves do not open any further despite a further reduction
in primary oil pressure.
6.1-0710-00/1
BHEL, Hardwar 6.1-0710-00/2
 Steam Turbine
Description
Function
The adjusting gear is used for manual or motor operation
of the reference speed setter and the starting and load
limiting device.
Mode of Operation
The speed/load adjusting gear is operated either
manually or by means of motor (28). The rotary
movement of the motor shaft is transmitted to worm
wheel (15) via worm wheel (9) and the worm attached to
it. Worm wheel (15) is located axially on the threaded
portion of the hand wheel spindle (16) by insert (5) and
the gear casing (11). The spindle (16) is connected with
bushing (4) by a feather key so as to permit the
BHEL Hardwar
Adjusting Gear
Spindle to slide axially in the bushing (4), which can
rotate in cover (19). Spring (6) Forces the thrust rings
(18) against bushing (4) which prevents bushing (4) and
spindle (16) from turning. Spindle (16) however, can be
moved axially by turning the worm wheel (15). Spindle
(16) can be moved up or down depending on which
direction worm- wheel (15) turns. The limit of travel is set
by limit rings (14 and 17). If either stop has been reached
the thrust rings operates as a slip coupling. The thrust
rings also protect the motor (28) from overload in the
event of restrictive movement within the adjusting gear.
6.1-0720-00
 Steam Turbine
Description
Function
The electro-hydraulic converter is the connecting element
between the electrical and hydraulic parts of the turbine
control system. It converts the signals from the electric
controller into the hydraulic signals and amplifies them
before transmitting them to the actuating devices.
Construction
The principal components of the converter are
proportional valve (1), Manifold plate (12), EHC Piston
(7), Casing (4), position transmitter (2), follow-up pistons
(21) and actuator (17). Bushings and follow-up pistons ‘A’
are connected to each other via the adjusting screws
(24), spring end pieces and the springs (22). The control
signals from the electro-hydraulic controller operate on
proportional valve (1) through a matching amplifier
module. The control fluid from connection ‘a’ is admitted
to the space above or below the piston (7) with the
opposite side of the piston opened to the fluid drain. The
resulting motion of the piston (7) is transmitted via lever
(13) to the sleeves (20) which in turn can slide on the
follow-up pistons (21).
BHEL Hardwar
Electro-hydraulic Converter
for Turbine Control System
The secondary fluid circuits, which are fed from the trip
fluid circuit via throttles and supply the various actuating
devices, are connected at point ‘b’. The secondary fluid
pressures are determined by the tension of springs (22)
which counter balance the fluid pressure acting on the
follow-up pistons (21). Each follow-up piston and sleeve
(20) has ports, which control the secondary fluid flow
according to their overlap. When the throttling area is
changed by the movement of the sleeve (20), it also
changes the pressure in the follow-up piston causing it to
follow the movement of the sleeve. This varies the
tension of springs (22) until equilibrium is regained
between the spring force and the new secondary fluid
pressure. Each position of the EHC piston (7) thus
corresponds to a specific position of the sleeves (20) and,
therefore, the follow-up pistons (21). The position of the
follow-up piston is the determining factor for the
secondary fluid pressure at point ‘b’.
The initial tension of the follow-up piston springs can be
varied by means of the setscrews (24).
6.1-0730-03/1
Controlling action with the Elctro-hydraulic Converter
When the electric controller gives a command to open the
turbine control valves, the proportional valve enables the
control fluid to flow through port ‘B’. The fluid flows to the
space below the piston (7) via manifold plate (12). This
moves the piston (7) upwards.
The following movement of the piston (7) then slides the
sleeves (20) downwards over the levers (13, 19) reducing
the drain area between the sleeves and the follow-up
pistons (21), causing the pressure in the follow-up pistons
and secondary fluid circuits to rise.
The motion of the piston (7) produces a simultaneous
feedback action on the proportional valve (1) via the
position transmitter (2). The control command gets
modified and in the equilibrium position there is no flow
through the proportional valve neither to port ‘B’ nor to
port ‘A’. When a command is given to close the control
valves, the controlling action is similar but in the reverse
sequence.

BHEL, Hardwar 6.1-0730-03/2

Adjusting Device for Valves

The follow-up pistons ‘B’ and the lever (14) of the rotary
shaft (15) situated above it are connected by the springs
(22) of follow-up pistons ‘B’, the guide pin (16) and the
setscrews (30). During normal operation an energized
solenoid valve allows control fluid ‘a1’ to flow under the
piston (25) of the actuator (17). The piston (25) is moved
upwards against the forces of the spring (26). Stop (34)
locked in normal position by pin and the initial tension of
the tension springs (22) of the follow-up pistons ‘B’ is
adjusted by means of the lever (28, 14) which results in
the IP control valves opening in relation to the HP control
valves as intended for this operation. If the condition
turbine load less than a set minimum load and the
ratio of HP exhaust steam pressure to main steam
pressure greater than the set pressure ratio is fulfilled,
for example after load shedding, the solenoid valve will
be de-energized. This blocks the flow of control fluid to
the actuator (17) and allows control fluid under the piston
(25) to flow into the return pipe. The force of the spring
(26) moves the piston into the lower end position and the
tension springs (22) of the follow-up pistons ‘B’ are
adjusted so that the IP control valves do not begin to
open until the HP control valves are wider open. The
lever (28) then rests on the precisely set stop (34). Limit
switch (29) indicates: Setting device engaged.

Setting Device for start-up without Bypass Valves

If the plant is started up without bypass system, the
IP/reheat stop and control valves must open before the
main steam stop and control valves. For this purpose, the
hand wheel (32) is set in the upper end position. Signal
from limit switch (33): Setting device in operation
without bypass system position.

BHEL, Hardwar 6.1-0730-03/3

 Steam Turbine
Description
Function
The function of the hydraulic amplifier is to amplify the
signals from the hydraulic speed governor (connection
‘b1’) so that they are sufficient for the actuating devices.
Construction
The principal components of the amplifier are amplifier
piston (1), pilot valve (7), follow-up piston (2) with sleeves
(3), mechanical feedback system (6) and actuator (21).
Bushings and follow-up pistons ‘A’ are connected to each
other via the setscrews (10), spring end pieces and
springs (11). Auxiliary secondary fluid flows over the pilot
valve (7) via connection ‘b1’. In the steady-state
condition, the pilot valve is in its center position and the
pressure in the Auxiliary secondary circuit and the force
of spring (8) are in equilibrium. The pilot valve is kept in
rotation by control fluid flowing from tangential holes in an
integral collar to give greater freedom of reciprocal motion
and high response sensitivity.
BHEL Hardwar
Hydraulic Amplifier
for Turbine Control System
When the pilot valve is deflected from its center position
control fluid from connection ‘a’ is, admitted to the space
above or below the amplifier piston (1) with the opposite
side of the piston opened to the fluid drain. The resulting
motion of the amplifier piston is transmitted via lever (5)
to the sleeves (3) which in turn, slide on the follow-up
piston (2). The secondary fluid circuits, which are fed
from the trip fluid circuit via throttles and supply the
various actuating devices, are connected at point ‘b’. The
secondary fluid pressures are determined by the tension
of springs (11), which counterbalance the fluid pressures
acting upon the follow-up pistons. Each follow-up piston
(2) and sleeve (3) has ports, which control the secondary
fluid flow according to their overlap. When the throttling
area is changed by movement of the sleeve (3), it also
changes the pressure in the follow-up piston causing it to
follow the movement of the sleeve; this varies the tension
of spring until equilibrium is regained between the spring
force and the new secondary fluid pressure. Each
position of the amplifier piston (1) corresponds to a
specific position of the sleeve (3) and the follow-up piston
(2). The position of the follow-up piston is the determining
factor for the secondary fluid pressure at point ‘b’.
6.1-0740-02/1
The initial tension of the follow-up piston springs can be
varied by means of the adjusting screws (10, 14), and the
levers (15, 16).
Controlling action with the Hydraulic Governor
The pressure above the pilot valve (7) is varied by the
hydraulic governor via varying the auxiliary secondary
fluid pressure connected at ‘b1’. An increasing auxiliary
secondary fluid pressure causes the secondary fluid
pressure at the connection ‘b’ to rise and open the
actuating devices; a Reduction in the secondary fluid
pressure causes the actuating device to close. The
motion of the amplifier piston produces a simultaneous
feedback via lever (6) and causes the pilot valve to
assume its center position when the new position of the
amplifier piston is reached. Each auxiliary secondary fluid
pressure corresponds to a certain position of the piston
(1) which, in turn, results in a certain secondary fluid
pressure at connection ‘b’ with each auxiliary fluid
pressure. The degree of proportionality of the hydraulic
governor can be adjusted by varying the position of lever
Pivot (6) with the setscrew (9).
BHEL, Hardwar
The follow-up piston ‘B’ and the lever (15) of the rotary
shaft (12) situated above it are connected by the springs
(11) of follow-up pistons ‘B’, the guide bolts (13) and the
setscrews (14). During normal operation, an energized
solenoid valve allows control fluid ‘a1’ to flow under the
piston (20) of the actuator (21). The piston (20) is moved
upwards against the force of the spring (19). Stop (25)
locked in normal position by pin and the initial tension of
the tension spring (11) of the follow-up piston ‘B’ is
adjusted by means of the lever (15, 16) which result in
the IP control valves opening in relation to the HP control
valves as intended for this operation.
If the condition Turbine load less than a set minimum
load and the ratio of HP exhaust steam pressure to
main steam pressure greater than the set pressure
ratio is fulfilled, for example after load shedding, the
solenoid valve will be de de-energized. This blocks the
flow of control fluid to the actuator (21) and allows control
fluid under the piston (20) to flow into the return pipe. The
force of the spring (19) moves the piston into the lower
end position and the tension springs (11) of the follow-up
pistons ‘B’ are adjusted so that the IP control valves do
6.1-0740-02/2
Not begin to open until the HP control valves are open.
The lever (16) then rests on the precisely set stop (25).
Limit switch (17) indicates: Setting device engaged.
Setting Device for Start-up without bypass valves
BHEL, Hardwar
If the plant is started up without bypass system, the
IP/reheat control valves must open before the main
steam control valves. For this purpose, the hand wheel
(24) is set in the upper end position.
Signal from limit switch (23): Setting device in operation
without bypass system position.
6.1-0740-02/3
 Steam Turbine Damping Device
Description

Function
The damping device is located in the bypass control
injection water line and serves to damp out any
pressure surges and pulsations.
Mode of Operation
When the pressure at the Inlet ‘a’ increases, the ball (6)
is held firmly against the lower seat and the rising
pressure can be propagated to the outlet ‘b’ only slowly
through the throttling passage in grub screw
(2).Conversely, if the pressure in inlet ‘a’ falls suddenly,
the higher pressure in outlet ‘b’ lifts the ball (6) from the
lower seat, closing the throttling passage.

BHEL, Hardwar 6.1-0750-00

 Steam Turbine
Description
Construction and Mode of Operation
The electrical speed pick-up located in the front bearing
pedestal indicates the exact speed through all speed
ranges of the turbine. The measuring procedure
functions as follows: -A toothed wheel (1) is mounted
on shaft (2) of main oil pump. The speed probes are
installed around the periphery of the
BHEL, Hardwar
Electrical Speed Pick-Up
Toothed wheel, which rotates, with the rotation of the
turbine shaft. On rotation of the toothed wheel (1),
electrical impulses are generated as a result of alternating
effect between the speed probe (3) and the toothed wheel
(1). The output frequency is conducted to the speed-
Measuring unit.
6.1-0760-01
 Steam Turbine Pressure Converter
Description

Function
The pressure converter is installed in the IP secondary oil
circuit. It does not permit to raise the IP secondary oil
pressure beyond certain value.
Construction
The pressure converter is provided with a follow up piston
(3), which slides in the bushing (6) at the top, and in the
sleeve (2) at the bottom. The bushing and follow up
piston are connected to each other via the set screw (9,
10) and the spring (4). There are drainage slots in the
follow up piston (3) and sleeve (2), through which a larger
or smaller amount of fluid can flow into the fluid return line
‘c’ depending on how much they overlap. The fluid
pressure prevailing in the follow up piston (3) is
connected to the reheat control valves for speed control
via connection ‘x’.
Mode of Operation
When the setscrew (9) of the pressure converter has
been appropriately set, IP secondary fluid pressure is
permitted to increase to certain value.

1 Ring 8 Cap
2 Sleeve 9 Set Screws
3 Follow up piston 10 Set Screw
4 springs
5 Casing
6 Bushing c return flow
7Cover x IP secondary fluid

BHEL, Hardwar 6.1-0761-00

 Steam Turbine
Description
Function and Arrangement
One stop and one control valve are combined in a
common body.
The main stop valve provides a means of isolating the
turbine from the main steam line and can rapidly interrupt
the supply of steam to the turbine.
The function of the control valve is to regulate the flow of
steam to the turbine according to the prevailing load.
BHEL Hardwar
Combined Main Stop
and Control Valves
Stop Valve
The steam enters the valve casing (13) via the Inlet
connection and remains above the Stop disc (1).
The main valve disc incorporates a pilot disc formed from
the end of the valve steam (3).
The valve stem is sealed by packing rings (6).
On the back of the valve disc is a raised seat which
comes into contact with a neck bush (4) when the valve is
fully open and so provides extra sealing at this point for
the stem.
6.1-0810-01/1
Both stem and disc are secured against torsion.
The valve body cover (2) is held in the valve casing (13)
by a threaded ring (8).
There is a U-shaped gasket (5) between cover and
casing.
The two legs of the gasket are pressed against the
sealing face to give a tight joint.
The stop valve is opened hydraulically and closed by
spring force.
Testing Main Stop Valve
Each stop valve must be tested at regular intervals to
ensure proper functioning.
A testing valve is provided for this purpose.
BHEL, Hardwar
Control Valves
The stem and disc (16) of the control valve are in one
piece.
Balancing holes in the valve disc reduce the operating
force required.
The valve stem and disc (16) are guided in the cover (17)
and the stem is sealed by packing rings (20).
When the valve is fully opened, the raised seat of the
valve disc rests against the neck bushing (18) and
provides additional sealing.
As with the stop valve, the valve body cover (17) is held
in the casing by a threaded ring (21) and is sealed by U-
shaped gasket (19).
The control valve is actuated by the piston of the
servomotor (26) that is operated by a cup spring in the
closing direction and hydraulically in the opening
direction.
6.1-0810-01/2
 Steam Turbine Servomotor for Main
Description and Reheat Stop Valves

Just before the valve disc seats, the piston disc enters a
The operative part of the servomotor consists of a two-
part of the cylinder where the diametric clearance is
part piston, the lower disc-shaped part of which is
reduced.
connected via piston rod to the valve stem.
This arrangement restricts the flow of fluid past the piston
The other part of the piston is bell-shaped and moves
disc and so produces a braking action, which causes the
within the housing, which is in the form of a cylinder.
valve disc to seat gently.
Two spiral springs are placed between the two halves of
All fluid connections are routed through a test valve.
the piston at the lower end a spring plate is interposed
between the springs and the piston disc. All operations can be controlled by means of the test
valve and the starting & load limiting device and main trip
When trip fluid is admitted to the space above the bell-
valve.
shaped part of the piston, it moves this half of the piston
downwards, compressing the springs, until it seats
against the piston disc.
After the main stop valves have been opened, the turbine
is started by the control valves.
Before the main stop valves can be opened, however,
they must be “pressurized”, i.e. prepared for opening, by
admitting trip fluid from the trip fluid circuit to the space
above the piston to press it down against the piston disc
after overcoming the resistance of the springs.
The edge of the bell-shaped half of the piston is designed
to produce a fluid tight seal with the piston disc.
To open the valve, fluid from the trip fluid circuit is
admitted to the space below the piston disc and,
simultaneously, the space above the bell-shaped half of
the piston is opened to drain.
This causes both halves of the piston to move together in
the direction, which opens the valve. In order to reduce
fluid leakage past the bell-shaped part of the piston when
the valve is open, a back seat is provided in the housing
against which the collar of the piston can seat.
When the valve is tripped, the pressure in the trip fluid
circuit, and hence in the space below the piston disc,
falls, with the result that the springs separate the two
halves of the piston and the piston disc connected to the
valve stem moves to close the valve.

BHEL Hardwar 6.1-0811-00

 Steam Turbine
Description
The flow of steam to the turbine is regulated by varying
the lift of the control vale by means of its servomotor.
The control valve is actually moved by the piston (9),
which is loaded, on one side by the disc springs (10) and
on the other side by hydraulic pressure.
The position of the valve is determined by the secondary
fluid pressure, which is controlled by the governor.
Since large operating forces are required, the servomotor
is of the high-pressure type (approx. 32 bars) and has a
pilot control system.
The supply of secondary fluid (connection ‘b’) controls the
auxiliary pilot valve (14) which directs control fluid from
connection ‘a1’ to the appropriate side of the pilot piston
(4).
The pilot piston operates the main pilot valve (3) through
lever (5) so that when the valve is being opened, control
fluid from connection ‘a’ is directed to the underside of
piston (9).
When the valve is being closed, fluid drains through the
main pilot valve.
Pilot Control System
When the turbine is running and the valve is steady at
any particular value of lift, the auxiliary pilot valve (14) will
be in the center position shown in the drawing. In this
position the force exerted by the spring (13) and the
secondary fluid pressure acting on the auxiliary pilot valve
are in equilibrium.
When the governor varies the secondary fluid pressure to
open or close the control valve, the auxiliary pilot valve is
deflected from this center position.
This allows control fluid (connection’ a1 ‘) to flow to one
side of the pilot piston (4) while the other side of the
piston is opened to drain.
The movement of the pilot piston returns the auxiliary
pilot valve to its center position by means of the feedback
linkage (12) thus giving proportionality between
secondary fluid pressure and pilot piston travel.
The degree of proportionality of the pilot control system
can be adjusted by varying the position of the feedback
lever pivot (12).
The auxiliary pilot valve is continuously rotated by the
action of fluid issuing from tangential drillings in a disc
mounted on its spindle in order to ensure that the valve
moves freely at all times.
BHEL Hardwar
Hydraulic Servomotor for
Main and Reheat Control Valves
Main Control System
The movement of the pilot piston (4) deflects the main
pilot valve (3) from its center position by means of lever
(5) so that either, control fluid from connection ‘a’ is
directed to the underside of piston (9) and the control
valve opens, or the underside of piston is opened to drain
so that the disc springs can close the control vale.
Shortly before the main valve disc actually comes into
contact with the seat, the servomotor piston (9) enters a
recess turned in the body and throttles the flow of fluid
draining from the underside of the piston.
This slows down the valve closing motion and the disc
seats gently.
The spring (1) pre-loads the linkage and prevents any
slackness or lost motion at the pivots.
The straight feedback cam (7) mounted on the end of the
servomotor piston rod (8) returns the main pilot vale (3) to
its center position by means of a lever system.
The slope of the feedback cam is in two stages to give
two degrees of proportionality, which produce good
linearity of the steam flow characteristics.
Testing Device
The control valve can be operated either by hand or
under power independently of the governor by means of
the testing device (11) in order to check the free
movement of the valve.
The testing device acts on the lever (5) in the same
manner as the pilot piston (4); the system demanding the
smaller valve lift being in control,
Damping Device
Fig.2 illustrates the auxiliary pilot valve (14) and the
damping device in the secondary fluid circuit.
Any signals in the secondary fluid circuit are damped out
by passing the secondary fluid through capillary tube (16)
before it enters the auxiliary pilot vale (14).
Any air carried by the secondary fluid is conducted to the
free space in the actuator via the screw plug (18) and
holes in the casing of the damping device and pilot valve.
6.1-0812-00/1
BHEL, Hardwar 6.1-0812-00/2
 Steam Turbine
Description
Function
The function of the test valve is to open and close the
emergency stop valve, either by start-up fluid circuit or
manual operation especially when the emergency stop
valve is being checked for easy movement.
Arrangement
Each test vale (6) and auxiliary valve (5) is arranged in
series behind a solenoid valve (1, 2).
Each emergency stop valve is served by one test valve,
whereby a test valve (6) is combined with an auxiliary
valve (5) in a common casing.
These blocks of test valves are arranged in frames
immediately next to the relative emergency valve groups.
Opening of the Emergency Stop Valve
In order to open the emergency stop valve, the valve (6)
must first be forced downwards against the force of the
spring (7).
This can either be done by start-up fluid (connection ‘u’)
or manually with the hand wheel (3).
Trip fluid (connection ‘x’) can then flow to connection ‘x1’
and on over the piston in the be returned to the upper
position, either by lowering the pressure in the start-up
fluid circuit or by manually turning the hand wheel (3).
BHEL Hardwar
Test Valve
for Emergency Stop Valve
The trip fluid can now flow from connection ‘x’ to
connection ‘x2’ via the auxiliary valve (5) and ducts in the
casing, and thus under the piston disc.
Testing the Emergency Stop Valves
Emergency stop valve the valve must then for testing the
emergency stop valve, the valve (6) is moved slowly
downwards by means of the hand wheel (3).
In this way, trip fluid is admitted to connection x 1 and
then connection x 2 Iinked to drain c, which closes the
emergency stop valve.
After this, the hand wheel (3) is slowly turned back and
the emergency stop valve opens again.
This procedure is accordingly the reverse of the closing
procedure.
Closing the Emergency Stop Valve by Automatic
Testing Device
When trip fluid is admitted under the auxiliary valve (5)
via connection v, this will be forced upwards against the
force of the spring (4).
This links connection x2 with drain ‘c’ via valve (5).
Fluid thus drains under the piston disc in the emergency
stop valve and the valve closes suddenly.
6.1-0813-00
 Steam Turbine Combined Reheat Stop
Description and Control Valves

Function and Construction A pilot valve, integral with the valve stem (6) is provided for
One stop and one control valve are combined in a relieving, thereby reducing the force necessary for opening.
common body with their stems arranged at right angles The valve disc (7) slides in the bushing of the valve cover
to each other. (4) and have a bead on the back which lies against the
base bushing (5) and provides additional sealing at this
The stop valve can interrupt the supply of steam from
the reheater to the IP and LP turbines extremely point. Metal packing rings (3) seal the valve stem.
quickly. The stop valve is opened hydraulically and closed by spring
force.
The control valve controls the steam flow to the IP and
LP turbines on load rejection, start-up & shutdown and Testing Stop Valves
remains fully open in the upper load range to eliminate Each stop valve must be checked for correct operation at
any throttling losses. regular intervals.
Further details of the arrangement of the valve A test valve is provided for this purpose. The checking
combination in the control system can be seen under
procedure is described in section “Test valve”.
section “Governing system”.
Reheat Stop Valve
The stop valve is a single seat valve with integral pilot
valve. Steam enters via the inlet of the valve body (2)
and remains above the valve disc (7) when the stop
valve is closed.

BHEL Hardwar 6.1-0814-00/1

Control Valve
The control valve has a pipe-shaped valve disc (14)
that is bolted to the valve stem (13) and slides in the
bushing in the valve cover (11).
The valve disc is provided with relieving holes to
reduce the necessary controlling force.
A ring fixed in the bushing of the valve cover prevents
the valve disc from rotating.
BHEL, Hardwar
This valve disc also has a back sealing that operates when
the valve is fully open.
Asbestos/graphite packing rings (10) seal the valve stem
(13) in the valve cover (11).
The control valve is operated by the piston of the
servomotor (9) i.e. is opened hydraulically and closed by
disc springs.
In the event of a disturbance in the system or on trip-out,
both stop valve and control valve close rapidly.
6.1-0814-00/2
 Steam Turbine Hangers for Reheat Stop
Description and Control Valves

Tensile forces are taken up via the disk spring (8) and tie
The reheat stop and control valves arranged beneath the
rod (6) by girders (1) that rest horizontally on shims in a
turbine operating floor in front of the turbine-generator
recess in the foundation and are connected to the
unit are suspended at three points from girders in the
foundation via clamping plates.
upper foundation plate in such a way that they can follow
thermal expansion of the steam lines. Tie rod (6) is screwed into rod cap (5) and when the
correct elevation of the reheat stop and control valve (3)
The ball-and-socket design of the tie caps (5) and spring
has been established, is secured to prevent turning.
body (9) and the disk spring stack (8) arrangement permit
free movement of the reheat stop and control valve (3) in
all directions.

BHEL Hardwar 6.1-0815-01

 Steam Turbine
Description
Function
Steam Strainers are installed in the main steam lines and
in the hot reheat lines from the boiler.
They protect the admission elements of the HP and IP
turbines from foreign objects, which could be picked up in
the boiler or associated piping.
Construction
The strainer screen (2) is made of corrugated strip wound
on a frame.
This Design offers a high degree of resistance, even to
particles impinging at high velocity.
The frame consists of two rings (1, 6) and a number of
rods (5) welded between the rings.
The rods are additionally held by reinforcing rings (4)
welded inside them.
BHEL, Hardwar
Steam Strainer
The strainer is designed for a single direction of flow from
the outside inwards.
For longer strainers, the screen is made up of several
parts.
The end turns of the corrugated strip are then tacked to
the T -section intermediate rings (3).
The maximum mesh size of the strainer, which inner
diameter determined by the height of the corrugations, is
1.6 mm.
The effective area is made atleast three times the cross-
sectional area of the pipe.
The strainer is used for both initial commissioning of the
turbine and for regular operation.
Fig. 3 Corrugated Metallic` Strip
6.1-0816-00
 Steam Turbine Changeover Valve
Description for Bleeder Check Valve

Function
The function of the changeover valve is to manually
operate the actuator of the bleeder check valve.
Mode of Operation
The trip fluid (connection x) holds the valve (10) in the
upper end position (illustrated) against the force of the
spring (8).
The trip fluid flows via the holes in the valve to
connection x 1 and then on to the actuator of the bleeder
check valve.
The valve can be moved downwards by means of hand
wheel (1).
In this way connection x1 is connected to the fluid drain
‘c’ and the fluid drains away from the actuator of the
bleeder check valve.
The spring of the actuator can then initiate the closing of
the check valve.
If the pressure drops at the trip fluid connection x, the
spring (8) pushes the valve (10) downwards.
In this way the fluid drain of the actuator is also freed.

1 Hand wheel 6 Cover

2 Spindle 7 Bush
3 Cap nut 8 springs
4 Bush 9 Ball
5 Lip ring 10 Valve
11 Cover c Drain fluid
x Trip fluid
x1 Trip fluid to actuator

BHEL Hardwar 6.1-0840-00

 Steam Turbine
Description
Function
The auxiliary valve controls the fluid supply to the
extraction check valve actuators and its function is to
give the check valves a signal to close in the case of a
drop in load or trip-out so that steam can not flow out of
bleeder lines back to the turbine.
The auxiliary valve serves several check valves.
Mode of Operation
Trip fluid is admitted through connection ‘x’ on the body
(10) (section A-B).
Secondary fluid from follow-up pistons of main control
valves is admitted to the spaces above and below the
valve (11) through connection ‘b2’.
As the pressure above and below the valve (11) are
equal under normal conditions, the valve is held in the
lowest position by the force of the spring (7).
BHEL, Hardwar
Auxiliary Valve
of Extraction Check Valve
With this position of the valve, the trip oil ‘x’ can flow to
the other valves and as soon as these valves have been
switched to the upper position by secondary fluid from
follow-up piston of reheat control valves-on to the
change-over valves of the extraction check valves
(connection ‘x1‘).
The check valves are then free to open.
On a reduction in load, as mentioned above, the pressure
above the valve (11) is reduced accordingly while the
pressure below the valve is retained for a while.
This is made possible by the fact that the pressure
reduction below the valve is retarded by the ball (15) and
the pressure in the accumulator (connection ‘b’) until the
equilibrium is re-established between the pressure in the
accumulator and the new pulse fluid pressure (connection
‘b2’) via the equalizing passage in the cover (12).
6.1-0841-00/1
Owing to the brief differential surge, the valve (11) is
forced upwards against the action of the spring (7), thus
cutting off the trip fluid supply to the check valves and
opening the fluid return.
As a result of this, the check valves receive a closing
impulse and close at reduced or reversed differential
steam pressure.
The valves (16), (section C-D) are acted upon from below
(connection ‘b1’) by the load -dependent secondary fluid
pressure of the control valves.
If the secondary fluid pressure exceeds the value set by
adjusting the springs, these valves are forced upwards
against the action of the springs and open the path for the
trip fluid to the changeover valves of the extraction check
valves.
BHEL, Hardwar
The lift of the valves is limited by a collar at their lower
end.
By appropriately setting the springs (14) to the valves, it
can be ascertained at which secondary fluid pressure i.e.,
at which turbine load, the check valves open or receive
an impulse to close.
If the pressure in the secondary fluid circuit drops, the
valves are pushed downwards by the force of the springs
and the inlet ports from the trip fluid circuit are cut off, the
bleed valves thus receiving an impulse to close.
The fluid in the line to the changeover valves can drain off
through the opened fluid return ‘c’.
6.1-0841-00/2
 Steam Turbine
Description
Function
The function of the rotary vane actuator flanged to the
swing-check valve is to open or close the swing-check
valve fitted in the cold reheat line.
Operation
When the pilot valve operated by the transformer of the
speed controller passes control fluid via connections‘d’
to the interior of the actuator, the adjacent connection
‘d1’ is depressurized.
The control fluid then flows through bores in the body
into the two diametrically opposite chambers turning
rotary vane (2) on actuator shaft (8) into contact with
the Segments (1).
BHEL, Hardwar
Rotary Vane Actuator
for Reheat Swing-Check Valve
This rotary movement, transmitted by actuator shaft (8) to
shaft (3) of the swing-check valve via coupling (5; 6) closes
the swing-check valve.
Conversely, the swing-check valve is opened when control
fluid is admitted through connections ‘d1’
Seals, Fixing
Actuator shaft (8) is guided in bushings (11) at both ends of
the segments (1) and is sealed off by seal ring (10).
The segments (1) are fixed in body (12) and in cover (13)
by means of fitted pins. Leaking fluid ‘c’ is drained to the
header.
6.1-0853-01
 Steam Turbine Pilot Valve for Rotary Vane
Description Actuator of Swing-Check Valve

Function
The function of the pilot valve is to control the admission
of control fluid to the moving vane actuator in such a way
that the swing-check valve is operated in accordance with
the pressure in the secondary fluid circuit.
Mode of operation
The swing-check valve is kept open as long as the
pressure in the secondary fluid circuit does not drop
below a definite limit value.
If signal fluid enters the body via connection ‘b’, the valve
(10) is lifted against the action of the spring (5).
The initial tension of this spring and thus the point at
which the swing-check valve opens can be adjusted.
If the valve (10) is lifted beyond the center position
illustrated, the control fluid entering at connection ‘a’ flows
on to a chamber of the actuator via connection ‘a2’ to
open the swing-check valve.
Connection ‘a1’ then communicates with the fluid return
‘c’ via passages in the body, permitting the fluid to drain
away from the actuator chambers not supplied with
control fluid.
If the valve (10) drops below the center position
illustrated, the control fluid will then be conversely
admitted to the actuator chambers in such a way that the
swing-check valve closes.
To prevent the valve (10) from seizing in its sleeve (9)
during operation control fluid is passed through the center
bore and out through the tangential bores at the wheel
disc (8) to impart rotary movement to the valve (10).
For this reason, a thrust ball bearing (7) and a ball (13)
are fitted for this purpose.

1 Throttle capillary tube 12 Slotted nut

2 Cap nut 13 Ball
3 Setscrews
4 Hood
5 Compression spring
6 spring disc
7 Thrust ball bearings
8 Wheel disc
9 Valve bush
10 Valves
11 Bush c Returns
a Control fluid b Signal fluid
a1 Control fluid (closes swing check valve)
a2 Control fluid (opens swing check valve)

BHEL, Hardwar 6.1-0854-00

 Steam Turbine Auxiliary Pilot Valve
Description for Rotary Vane Actuator
For Reheat Swing-Check Valve

Function
The function of the auxiliary pilot valve for the pilot valve
for the reheat check valve actuator is to control the
admission of control fluid to the pilot valve in such a way
that the swing-check valve is actuated in accordance with
the pressure in the secondary fluid circuit.
Operation
The swing-check valve is kept open as long as the
pressure in the secondary fluid circuit does not drop
below a definite limit value.
Secondary fluid entering body (9) via connection ‘b’ lifts
spool (7) against the action of the spring (3).
The initial tension of this spring and thus the point at
which the swing-check valve opens can be adjusted.
If spool (7) is lifted beyond its central position as
illustrated, the control fluid entering at connection ‘a’ flows
on via connection ‘a1” to connection ‘b’ of the pilot valve
to open the swing-check valve via the rotary actuator.
If spool (7) drops below its central position as illustrated,
control fluid is admitted to the opposite chambers of the
rotary actuator, so that the swing-check valve closes.
To prevent spool (7) from seizing in its sleeve (6) control
fluid is passed through the center bore in the spool during
turbine operation and out through tangential bores in the
upper part of spool (7) to impart rotary motion to the
spool.
A deep-groove ball bearing (5) between spool (7) and
spring retainer (4) reduces friction from the rotary motion.

BHEL, Hardwar 6.1-0855-00

 Steam Turbine Gland Steam Control Valve
Description along with Actuator

Function Supplier’s catalogue may be referred for complete details.

One function of the gland steam control valve, which is Valve along with actuator is supplied by M/S Samson
situated in the grand steam pipe of the seal steam Controls Pvt. Ltd. B-43, Wagle Industrial Estate, Road
system, is to supply the shaft seals with seal steam No. 27, Thane (Maharashtra)
during start-up and in the lower load range.
A further function is to keep the set pressure in the
header constant in order to prevent air penetrating the
vacuum of the shaft seals.
Construction and Mode of Operation
The gland steam control valve is operated by the
pneumatic actuator which is moved in the open direction
by air pressure and in closed direction by the spring
force.
The gland steam pressure controller feeds 4 to 20 mA
control signal to the positioner which in turn gives the
corresponding air pressure to the actuator for the
operation of gland steam control valve.
The cross section view of gland steam control valve
alongwith actuator of gland steam system is also given
here.

1-Body 26-Bonnet Bush

2-Seat 27-Extended Bonnet
3-Plug 28-1½ “-6UNC-2B Nut
4-Bush 29-1½ “-6UNC-2A Stud
5-Packing 30-Flow Divider
6-Spring
7-Washer
8-Threaded Bush
9-Washer
10-Body Gasket
11-Adaptor
12-Nut
13-Yoke Bonnet
14-Travel Indicator
15-Wiper Ring
16-Oil Seal
17-Coupling
18-Diaphragm Plate
19-Diaphragm
20-Actuator
21-Spring
22-Actator Nut
23-Bush
24-Hand Wheel Position Indicator
25-Needle Roller Bearing

BHEL Hardwar 6.1-0860-02

 Steam Turbine Leakage Steam Control Valve
Description along with Actuator

Function Supplier’s catalogue may be referred for complete details.

The function of the leakage steam control valve, which is Valve along with actuator is supplied by M/S Samson
situated in the leakage steam pipe of the seal steam Controls Pvt. Ltd. B-43, Wagle Industrial Estate, Road
system, is to drain excessive steam from the header in No. 27, Thane (Maharashtra)
order to keep the set pressure in the seal steam header.
Construction and Mode of Operation
The leakage steam control valve is operated by the
pneumatic actuator.
Valve is moved in the open direction by the air pressure
and moved in closed direction by spring force.
The gland steam pressure controller feeds 4 to 20 mA
control signal to the positioner which in turn gives the
corresponding air pressure to the actuator for the
operation of leakage steam control valve.
The cross sectional view of leakage steam control valve
alongwith actuator of gland steam system is given here.

1-Body
2-Seat
3-Plug
4-Bush
5-Packing
6-Plug stem
7-Lock Nut
8-Threaded bush
9-Retainer Ring
10-Body Gasket
11-Adaptor
12-Ext. Bonnet
13-Yoke
14-Travel Indicator
15-Coupling (Clamp)
16-Diaphragm plate
17-Diaphragm
18-Actuator casing
19-Spring
20-Actuator nut
21-1 ½ “– 6UNC-2B Nut
22-1 ½ “– 6UNC-2A Stud

BHEL, Hardwar 6.1-0870-02

 Steam Turbine
Description
Function:
The Function of the main trip valve is to open the trip fluid
circuit in the event of abnormal conditions, thereby
closing the valves and thus shutting off admission of
steam to the turbine.
Construction the main trip valve consists of mainly two
valves (12) that slide in the casing (11) and are loaded by
the springs (5, 6).
The valves (12) are designed as differential pistons being
forced tightly against the body assemblies (10) by the
rising pressure of the fluid.
Control fluid flows into the casing (11) via connection ‘a’
and with a tripping device latched in (in the position
shown).
Into the trip fluid circuit via connection ‘x’. The trip
Operation:
When starting the unit, the valves (12) are lifted by the
aux. start up fluid (connection ‘u1 ‘) against the force of
the springs (5, 6) and forced tightly against the
assemblies (10).
In this way pressure is build up in the trip fluid circuit (x)
and the auxiliary trip fluid circuit (x1).
BHEL, Hardwar
Main Trip Valve
The pressure in the auxiliary trip fluid circuit keeps the
valve in the position shown while the aux. start up fluid
drains through the start up device.
Fluid circuit leads to the stop valves and the secondary
fluid circuits.
Via passage drilled in the body (11) (Section A-A) fluid
flows to the auxiliary trip fluid circuit, which leads to the
hydraulic protection devices.
Should the fluid in the pressure in the auxiliary trip fluid
circuit drop below a specific value for any reason (e.g. by
tripping of a protection device) the valves?(12) move
downwards due to the spring force and their own weight,
thus connecting connections ‘x’ and ‘x1’ with the fluid
back flow ‘c’.
This depressurizes the trip fluid circuit which causes the
main and reheats stop valves to close.
The fluid supply to the secondary fluid circuits is also shut
off, thus causing the control valves to close.
The two valves (12) work independently of each other so
that even if one valve fails the function of the tripping
device is not impaired.
The limit switches (1) transmit electrical signals to the
control room.
6.1-0910-00
 Steam Turbine Emergency Trip Valve
Description for Manual trip out

The emergency trip valve enables the machine to be

manually tripped out.
The valve consists of the valve cone (8), which
slides in the bushing (9) and is loaded by the spring (7),
and the ball head (1) with the spindle (4).
During normal operation the valve (8) is forced
tightly against the bushing (6) by the pressure of the
auxiliary trip fluid arising at connection ‘x1 ‘.
To actuate the trip, the ball head (1) is pushed
downwards.
This opens the valve and connects the auxiliary trip
fluid circuit (connection ‘x1 ‘) with the fluid back flow ‘c’,
The drop in pressure in the auxiliary trip fluid circuit
actuates the emergency tripping device.
The limit switch (2) shows the tripping of the valve.
On start-up, before the auxiliary trip fluid is
pressurized, the valve (8) is forced upwards against the
bushing by the auxiliary start-up fluid (connection ‘u1‘).

1 Ball head
2 Limit switch
3 Cover
4 Spindle
5 Springs
6 Bushing
7 Spring
8 Valve cone
9 Bushing
10 Casing
11 Cover
x1 Auxiliary trip fluid
u1 Auxiliary start-up fluid
c Return fluid

BHEL, Hardwar 6.1-0911-00

 Steam Turbine Solenoid Valve for
Description Remote Trip-out

Function:
The solenoid valve is installed in the auxiliary trip fluid line
to the automatic trip gear and, when operated, causes the
auxiliary trip fluid circuit to be opened and the turbine
stopped,
The solenoid valve is remote-controlled electrically, e.g.
from the control room or from a protective device.
Construction:
The directions of flow are indicated by arrows on the
body.
The solenoid sleeve (4) is bolted to the casing (6) and is
inserted in the magnet casing (1) with the armature (3).
The complete valve element is placed in the body (6) and
held by the plug (11).
The two valve discs (8) seal the valve seats (9).
The solenoid valve and the line to the automatic trip gear
are ventilated by means of the screw (12).
Mode of Operation
When the solenoid (1) is not energized, the armature (3)
is moved downwards by the spring (2) so that the valve
disc (8) is pressed against the valves seats (9) to provide
sealing.
The solenoid valve is operated by energizing the solenoid
(1).
The armature and the valve discs are drawn upwards
against the force of the spring (2) so that the auxiliary trip
fluid ‘a’ is linked with the drain ‘c’ and the pressure in the
line to the automatic trip gear collapses.

1 Magnet casing
2 Spring
3 Armature
4 Solenoid sleeve
5 Hexagonal nut
6 Casing
7 Ring
8 Stem with two valve discs
9 Valve seat
10 O-ring
11 Plug
12 Ventilation screw
a Auxiliary trip fluid to automatic trip gear
c Drain

BHEL, Hardwar 6.1-0912-00

 Steam Turbine Over Speed Trip
Description

Function and Construction:

The function of the over speed trip is to stop the turbine

when the permissible speed is exceeded.

It is fitted in the turbine rotor (7) and consists of the

eccentric bolt/striker (4), adjusting screw (6), spring (5)
and the screw plug (1).

Mode of Operation:

The over speed trip mechanism is set by the adjusting

screw (6).

By appropriate adjustment of the screw, the center of

gravity of bolt/striker (4) is positioned eccentrically to the
turbine shaft so that below the tripping speed the bolt is
held in the position shown by the spring (5) against the
centrifugal force.

In this position, the bolt bears against the screw plug (1).
1 Screw Plug 5 Springs
If the turbine rotational speed exceeds the over speed 2 Guides Bushing 6 Adjusting Screw
setting, the centrifugal force overcomes the force of the 3 Guiding Foil 7 Turbine Rotors
spring (5) and forces the bolt/striker (4) out of the turbine 4 Bolt/Striker 8 Guide Ring
rotor (7).
Fig. 1 Arrangement of Over Speed Trip in Turbine Rotor
This activates the turbine automatic stop mechanism.

BHEL, Hardwar 6.1-0920-00

 Steam Turbine
Description
Function:
The function of the over speed trip releasing device is to
open the auxiliary trip fluid circuit and thereby shut down
the turbine when an over speed is reached which would
subject the rotor to high centrifugal force.
Construction:
The over speed trip releasing device located in the
bearing pedestal consists of valve bodies (4, 10), pilot
valve and rods (3, 5, 7, 8), pawls (12) and limit switch (1).
The bellows 16) on the pilot valves and rods prevent
hydraulic control fluid from entering bearing pedestals
and lubrication system.
When the turbine is started up, the pilot valve, rods and
pawls are latched by auxiliary start-up fluid ‘u1 ‘.
Turbine Trip by over speed Trip Device.
When the over speed trip operates, the eccentric
bolts/striker fly out radially and strike pawls (12).
The impact of the bolt/striker rotates the pawls outwards
against the force of torsion springs (11).
BHEL, Hardwar
Over Speed Trip Releasing Device
The latches of the pawls release rod (8) which, in turn,
moves towards the shaft (13) due to the force of spring-
loaded pilot valve (3) and force of the auxiliary trip fluid
‘x1’.
This Movement opens fluid drain ‘c’ to the auxiliary trip
fluid and the resulting loss in pressure and trips the
turbine.
The electrical trip signal is transmitted to the control room
by the limit switches (1).
Testing the Over Speed Trips for Free Movement:
Proper functioning of the over speed trips is important
since severe damage may result from excessive over
speeds.
The over speed trip test device makes it possible to
check the bolts/strikers as well as pilot valves and rods
(3, 5, 7, 8) without interrupting operation of the turbine.
Start-up before restarting the turbine following a trip, latch
in the over speed trip.
This is done by admitting auxiliary startup fluid ‘u1’ into
pilot valve body (4) and forcing the respective pilot valve
(3) outwards until rod (8) engages the latch of the pawl.
The auxiliary start-up fluid flow is interrupted and auxiliary
start-up fluid flows via a hole to fluid drain ‘c’.
6.1-0921-00
 Steam Turbine
Description
Function
The function of the over speed trip test device is to test
and exercise the over speed trip.
The over speed trip consists of bolts/strikers which
protrude against the force of a spring under the effect of
centrifugal force during an over speed condition.
The bolt/striker strikes a pawl and thus opens the
auxiliary trip fluid circuit and in turn trip fluid circuit so that
the stop and control valves immediately interrupt the
admission of steam to the turbine.
Perfect functioning of the over speed trip is of the utmost
importance.
BHEL, Hardwar
Over Speed Trip Test Device
Construction
The over speed trip test device consists of three pilot
valves (4, 10, 11) combined in valve block (12).
Pilot valve (11) is held in the position by spring (9), which
bears against guide piece (15) and rod (7).
In this position auxiliary trip fluid can pass to the over
speed trip release device via connection ‘x’ and ‘x1‘.
If the pilot valve (11) is pushed inwards and held by
means of the knob (6), the auxiliary trip fluid circuit
(connection ‘x’ and ‘x1’) is separated from the over speed
trip release apart from a small quantity of fluid which is
permitted to pass to fill up the empty pipe after the test
operation.
6.1-0922-00/1
This prevents the emergency trip from being actuated by
the over speed trip.
Pilot valve (10) performs the function of admitting test oil
to the eccentric bolts/strikers of the over speed trips,
causing them to protrude from the turbine shaft during
the over speed trip test operation.
Pilot valve (10) is guided in guide bushings (13, 14).
A center bore with radial openings is provided in the pilot
valve.
An annular chamber in the bushing (13) is connected to
test oil connection ‘a1’.
In the position shown oil is prevented from entering the
bore of the pilot valve.
By means of hand wheel (5), the pilot valve (10) can be
moved inwards so that the passage from connection ‘a2’
is blocked from drain ‘c1’.
BHEL, Hardwar
Control oil can now flow from connection ‘a1’ via the
bushing (13) and the pilot valve (10) to connection ‘a2’
and the bolts/strikers of the over speed trip.
Pilot valve (4) is used for resetting the over speed trip
release device after the test operation.
When pilot valve (4) is pushed inwards against the force
of spring (3), control fluid can flow from connection ‘a’ to
‘u1, thus latching in the over speed trip device.
During start-up, connections ‘u’ and ‘u1’ provide a
passage for auxiliary start-up fluid for latching in the over
speed trip release device.
After the test operation, the pilot valves (4, 11) are
blocked.
6.1-0922-00/2
 Steam Turbine
Description
Function: The purpose of the low vacuum trip is to
operate the main trip valve when a failure of vacuum
occurs in the condenser, thus tripping out the main and
reheat stop and control valves and shutting off the
supply of steam to the turbine within the shortest
possible time.OperationThe condenser vacuum is
connected via ‘I’ (connection to condenser) to the top
side of the diaphragm (8). The space below the
diaphragm is at atmospheric pressure. Upon failure of
the condenser to maintain proper vacuum, diaphragm
(8) is forced downwards by the increase in pressure
and the force of the spring (7) against the force of
spring (10), thus moving valve (9) downwards. This
establishes a connection between ‘x1’ (control fluid) and
drain ‘c’ so that the auxiliary trip fluid circuit is
Depressurized and the main trip valve operates.
Concurrently, valve (11)
BHEL, Hardwar
Low Vacuum Trip
Actuates the limit switches (15), which initiate an alarm
contact. The range in which the vacuum safety device
operates can be varied by adjusting the initial tension of
the spring (7) by means of the adjusting screw (5).In order
to isolate the auxiliary trip fluid circuit during starting,
auxiliary pilot valve (9) is lifted by means of the spring (10)
so that drain ‘c’ is shut off, thereby establishing pressure in
the auxiliary trip fluid circuit when no vacuum exists. As
primary oil pressure builds up with the increase in turbine
speed, piston (2) is forced into the lower position. This
lower position is reached when the speed is still far below
the rated value at which time the low vacuum trip safety
device is ready to operate.
6.1-0935-00
 STEAM TURBINE CONDENSER SAFETY DEVICE                                 
Description  
 

Function:  
The function of the condenser safety device situated in
the control fluid circuit of the bypass control system is to
protect the condenser, when there is an excessive
increase in pressure in the condenser, by opening the
control fluid Lines so that the resulting drop in pressure
causes the bypass valves to close Mode of Operation the
steam space in the condenser is connected with the
spring space above the diaphragm (5) via connection ‘I’.
The space below the diaphragm is at atmospheric
pressure. If the pressure in the condenser increases
excessively, the diaphragm (5), and thus the valve (6), is
forced downwards out of the upper end position by the
increasing pressure and the force of the spring (4). This
shuts off the connection ‘a1” to the bypass valve from
connection. ‘a’ which is from the converter and connects
it to drain ’c’.The pressure range in which the vacuum
safety device operates can be varied by adjusting the
initial tension of the spring (4) by means of the adjusting
screw (2). During commissioning the valve (6) is
automatically moved into the upper end position, where it
keeps the control fluid circuit closed, as soon as the
negative pressure in the condenser falls below the
present value. In order to be able to close the control
fluid circuit when there is still insufficient vacuum in the
condenser, the valve is lifted via the lever (10) and cam
(9) but is not yet brought into its upper end position. As
already mentioned, this end position is not reached until
there is sufficient vacuum. After this, the lever (10) and
cam (9) drop down and do not impair the functioning of
the vacuum safety device. Any leakage fluid can drain off
through passages in the valve sleeve (7) and the casing
(8). 

BHEL, Hardwar 6.1-0940-00

 Steam Turbine Solenoid Valve for Temperature
Description Controlled Interlock

Function:-
When there is an unallowable rise in condenser
temperature due to lack of injection water a temperature
sensor situated in the condenser dome sends electric
signals to the solenoid valve which open the signal fluid
circuit of the bypass valve actuators, thereby closing the
bypass valves so that the steam flow to the condenser is
interrupted. Mode of Operation During normal operation,
the control fluid ‘a’ holds the main control valve (7)
against the force of the compression spring (8) in the
center position as shown here, This provides the
connection between the signal fluid from pressure switch
for injection water ‘b’ and the stop and control valve
operator of the bypass stop valve ‘b1 “, If the temperature
in the condenser rises to an unallowable value, the
solenoid valve (3) is moved downwards against the force
of the compression spring (4) so that the control fluid ‘a’
arising before the main control valve (7) is connected with
the drain ‘c’. Simultaneously, the control fluid ‘a’ can flow
behind the main valve (7) so that the main valve moves
forwards against the force of the compression spring (6)
and the signal fluid circuit ‘b1’ is opened and connected
to the drain ‘c’ and the bypass stop and control valve
closed’.

BHEL, Hardwar 6.1-0950-00

 Steam Turbine Vacuum Breaker for Reducing the
Description Running Down Time of the Turbine

Function:-
With normal shut down or tripping of the machine, the
function of the vacuum breakers is to cause an increase
in condenser pressure by conducting atmospheric air into
the condenser together with bypass steam flowing into
the condenser from the bypass station.
When the pressure in the condenser increases, the
ventilation of the turbine blading is increased, which
causes the turbo set to slow down so that the running
down time of the turbo set and the time needed for
passing through critical speeds are shortened?
Total Vacuum Breakers
In special cases requiring a rapid shut down of the turbo
set, the total vacuum breaker is employed.
Electrical Control of Total Vacuum Breaker
So that the vacuum can also be broken without limitation
due to condenser pressure, a manual key is provided.
This key opens the vacuum breaker valve.
However, it cannot go into the closing position until the
close key provided for closing is used.
This control enables a complete equalization of
condenser and ambient pressure.
Automatic Control
The vacuum breaker is also actuated automatically by the
turbine fire protection system to shut the turbo set down
more quickly.
It is switched back manually using the close key in this
case.
Mode of Operation of Vacuum Breaker
When the magnet is not excited, the solenoid valve is
switched to open.
The control medium arising holds the vacuum breaker
valve in the closed position by means of the power piston.
When the pressure drops the vacuum breaker is opened
by spring force.
The piston (3) and thus the valve disc (19) are moved
Opening Process upwards by the force of the spring (5) (Fig. 2).
When the magnet is excited the control medium is without Closing Process
pressure so that the control medium in front of the
solenoid valve is connected with the drain ‘c’. When the magnet is not excited the valve is closed by the
control medium arising.
The pressure of the control medium ‘a’ via the piston (3)
presses seal ring (17) arranged in the valve disc (19) on to
the valve seat (20) against the force of the compression
spring (5).

BHEL, Hardwar 6.1-0960-00/1

 1 Piston cover
2 Stop
3 Piston
4 Valve stem
5 Compression spring
6 Piston bottom
7 Limit switch
8 Spacer column
9 Cap nut
10 Gland seal
11 Pecking
12 Valve cover
13 Bushing
14 Valve calling
15 Screw coupling
16 Divided ring
17 Seal ring
18 Disc guide
19 Valve disc
20 Valve seat

a Control medium
I Inlet for atmospheric air
I1 Atmospheric air flowing into condenser

Fig. 2 Drawing Showing Function of Vacuum Breaker

BHEL, Hardwar 6.1-0960-00/2

 Steam Turbine Changeover Valve
Description for Testing Device

Function:-
The function of the changeover valve is to shut off the
flow of trip fluid into the trip fluid circuit while the
protective devices are being tested for proper
operation by means of the Automatic Turbine Tester
(ATT) and to allow control fluid ‘a’ to flow in so that the
stop valves do not close when the safety devices
respond.
Mode of Operation
During normal operation, the control fluid ‘a1’ in the
space under the lower piston (8) of the changeover
valve keeps the valve in the upper end position shown
here.
In this way, connection ‘x’ is connected with connection
‘x1’ and trip fluid can flow into the trip fluid circuit.
The space above the piston (6) (connection ‘a’)
remains depressurized during normal operation.
When safety devices are checked for proper operation,
the space below the lower piston (8) is depressurized
by means of a solenoid valve and control fluid ‘a’
enters the space above the upper piston, which moves
the valve into the lower position.
Due to the connection now made between connections
‘a’ and ‘x1’, control fluid ‘a’ can flow freely into the trip
fluid circuit, which keeps the stop valves open for the
duration of the test.
Two limit switches (1) transmit the position of the valve
to the control room.

1 Limit Switch 9 Body

2 Piston Rod 10 Cover
3 Seal
4 Bushing a Control Fluid
5 Inset a1 Control Fluid
6 Upper Piston c Fluid Drain
7 Sliding Bushing x Trip Fluid from
8 Lower Piston Tripping Device
x1 Trip Fluid to Trip
Fluid Circuit

BHEL, Hardwar 6.1-0980-00

 Steam Turbine Oil Supply System MAV
Description System Description

Accompanying system diagram

Description and function of components of the
(Drawing No. 2-13100-Q8101 on Sheet No. hydraulic and lubricating oil system
On Sheet No.6.1-1000-96/4) The components of the hydraulic and lubricating oil system
Process engineering functions of the
and their function are described below:
Hydraulic and lubricating oil system
ƒ Main oil tank
The hydraulic and lubricating oil system has the
The oil necessary for operation is stored in the main oil
following process engineering functions: tank. The oil pumps draw the turbine oil from the main oil
• Lubrication and cooling of the turbine and generator tank and forward it to where it is needed. The strainers in
bearings with turbine oil drawn from the main oil tank the main oil tank remove large solid contaminants in the
by the oil pumps and forwarded via cooler and filter to returning oil before the oil reaches the suction section of the
the bearings; pressures and flow rates are set with main oil tank.
throttle valves. Air and oil vapour are drawn out of the main oil tank by the
ƒ Supplying motive oil to turning gear. oil vapour extractor.
ƒ Backflow of the turbine oil to main oil tank. The main oil tank level is monitored.
The turbine oil can be drained from the main oil tank.
Components of the hydraulic and lubricating • Injector MAV21 BN001
MAV21 BN002
oil system
Injector is located upstream of the main oil pump, which is
In addition to piping, manually operated valves, and
driven by the turbine shaft. The injector is a submersible
monitoring equipment, the following tanks, pumps,
pump, which draws the turbine oil directly from the main oil
drives, coolers, filters and valves are necessary for
tank using turbine oil and forwards it to the main oil pump
operation of the hydraulic and lubricating oil system:
under positive pressure.
• Main oil pump MAV21 AP00I
• Main oil tank and oil pumps The main oil pump is driven by the turbine shaft and
Main oil tank assumes the function of oil supply just before the turbine
Injector feeder pump MAV 21 BN001 generator unit reaches rated speed.
Injector feeder pump MAV 21 BN002 • Auxiliary oil pumps
Main oil pump driven by MAV 21 AP001 Auxiliary oil pump 1 MAV22 AP001
The turbine shaft Auxiliary oil pump 2 MAV23 AP001
Auxiliary oil pump 1 MAV22 AP001 The auxiliary oil pumps are submersible pumps, which draw
Auxiliary oil pump 2 MAV23 AP001 oil directly from the main oil tank. One of the two auxiliary oil
Emergency oil pump MAV24 AP001 pumps supplies the hydraulic and lubricating oil system with
• Turning gear oil supply valve MAV51 AA001 turbine oil as long as the main oil pump is unavailable when
ƒ Oil coolers and oil filters turbine generator speed is too low for supplying oil, e.g.,
.Oil cooler 1 MAV41 BC001 during start-up or shutdown of the turbine. Generator or
Oil cooler 2 MAV41 BC002 during turning gear operation
Double multiport butterfly MAV41 AA521 ƒ Emergency oil pump MAV24 AP001
Valve The emergency oil pump is a submersible pump, which
Oil temperature control valve MAV41 AA001 draws oil directly from the main 'oil tank. The turbine oil is
Lubricating oil filter MAV42 BT001 forwarded by the emergency oil pump while bypassing the
ƒ Lubricating oil supply to bearings oil cooler and oil filter in the lubricating oil system when the
Lubricating oil valve MAV42 AA502 auxiliary oil pumps are unavailable for turbine oil supply due
Upstream of turbine bearing 1 to a fault in three-phase power supply.
Lubricating oil valve see below
Upstream of turbine bearing n
Lubricating oil valve see below
Upstream of generator bearing n
There is a lubricating oil throttle valve (coded
according to the system diagram) in the lubricating oil
line upstream of every turbine or generator bearing.

BHEL, Hardwar 6.1-1000-96-1

 • Motive oil valve of the MAV51 AA001
turning gear
The motive oil valve of the turning gear is actuated
by the associated motor.
• Oil coolers
Oil cooler 1 MAV41 BC001
Oil cooler 2 MAV41 BC002
One oil cooler is always in operation to remove the
heat generated by the turbine and generator
bearings from the turbine oil. The second oil cooler
is on standby. Changeover to the standby oil cooler
must be made when the oil cooler in operation clogs
or leaks.
The maximum flow rate of the cooling water
.through the oil cooler in operation must be
maintained for good heat transfer and preventing
deposits in the cooler tubes.
ƒ Double multiport butterfly MAV41 AA521
Valve
The double multiport butterfly valve is the
changeover valve for the oil coolers.
ƒ Oil temperature control MAV41 AA001
Valve
The lubricating oil temperature upstream of the
turbine and generator bearings is maintained by the
oil temperature control valve.
The oil temperature control valve is a multiport valve
in which hot and cold turbine oil is mixed to obtain
the desired lubricating oil temperature of approx.
45-degree C downstream of the control valve.
ƒ Duplex lubricating oil filters
Lubricating oil filter MAV42 BT001
One element of the switchable duplex lubricating oil
filter is always in operation to protect the turbine
and generator bearings against solid contaminants.
The differential pressure across the lubricating oil
filter in operation is a measure of filter clogging.
- set point and limit values of the lubricating oil
ƒ Double multiport butterfly valve
The double multiport butterfly valve is the
changeover valve for the lubricating oil filters.
ƒ Lubricating oil throttle valves upstream of
turbine and generator bearings
BHEL, Hardwar
The bearing-specific oil flow rates are set with the
throttle valves in the lubricating oil lines upstream of the
turbine and generator bearings.
ƒ Piping and valves
The turbine oil is supplied to where it is needed through
piping. The dimensions of the oil lines are a function of oil
velocity and the oil pressure during operation.
Piping, oil coolers, and oil filters are equipped with drain
valves. Oil coolers and oil filters can be filled and vented.
Air and oil vapour is extracted from the return lines.
Sampling valves are provided for taking oil samples.
Passive turbine fire protection
The main oil tanks, oil pumps, oil coolers, oil filters, and
important oil system valves are installed in separate
compartment of the turbine building. This compartment is
designed with a sump for catching leak oil. The sump
volume is the same as that of the main oil tank.
The oil lines are laid in ducts, which can collect leak oil and
prevent it from contacting machine parts on which it can
ignite.
Information for operation and maintenance
ƒ Technical Data
The Technical Data contain the following information:
- Nominal capacity of the main oil tank
- reference values for the capacity of the lubricating oil
system including the oil-side volume of the system tanks,
coolers, filters, and piping, which are filled during operation
- Highest and lowest oil level in the main oil tank during
turbine generator operation at rated, s-.peed
- Reference values for the amount of oil which must be filled
into the main oil tank for operation of the hydraulic and
lubricating oil system and for the amount of oil necessary for
flushing the oil system during commissioning or inspection
and overhaul
- Manufacturer, type designation, and design data of oil pump
motors
temperature for operation and shutdown of the turbine
generator unit
6.1-1000-96/2
 - Manufacturer, type designation , and Auxiliary oil pump must be switched off.
fineness of the lubricating oil system filter Extended parallel operation of the main and auxiliary oil
- reference values for oil heat up in the pumps shall be avoided.
bearings and bearing-specific oil requirement ƒ Sub-loop controls of the hydraulic and
ƒ Dimensioning of the main oil tank lubricating oil system.
The main oil tank is dimensioned so that the total oil - Sub-loop controls for the oil Pumps
in the tank is not recalculated more than 8-10 times All oil pumps of the hydraulic and lubricating oil system
per hour. The turbine oil in the system takes up air driven by electric motors are controlled by the switching
during every recirculation. This air is released from commands of the associated sub-loop controls. The oil
the turbine oil in the course of the dwell time in the pumps should always be switched on in a certain sequence
main oil tank. Large amounts of air in the turbine oil to ensure the lubricating oil supply to the turbine and
generator bearings in the event of a drop in oil pressure in
are either due to an excessive turbine oil recirculation
the hydraulic or lubricating oil system. The sub-loop controls
rate or due to an inadequate air release property of
of the oil pumps must be in AUTO mode as long as the line
the turbine oil. of shafting is driven by steam or the turning gear.
ƒ Setting of the throttle valves of the hydraulic ƒ Changeover of oil coolers and filters
and lubricating oil system Standby oil coolers and standby lubricating oil filters must
The throttle valve settings for the hydraulic and be filled and vented before changeover.
lubricating system are optimised during initial start- ƒ Venting of the oil coolers
up when the turbine generator unit is running at
rated speed: The oil-side vent of the oil cooler in operation must be
- The INJECTOR (MAV21BN001 / open.
MAV21BN002) ensure a positive pressure of approx.
0.2 bars in the suction line immediately upstream of
the main oil pump.
- Lubricating oil throttle valves upstream of the
turbine and generator bearings, e.g., lubricating oil
throttle valve upstream of the first turbine bearing
MAV42 AA501.
The mass flows of the oil necessary for lubricating
and cooling are set using the lubricating oil throttle
valves upstream of the turbine and generator
bearings in accordance with the reference values
given in the Technical data. The lubricating oil throttle
valve upstream of every bearing should be adjusted
so that the turbine oil in the bearing heats up to
approx. 20 K.
ƒ Characteristics of the main and auxiliary oil
pumps are designed with respect to one another so
that the main oil pump assumes the oil supply just
before the turbine generator unit reaches rated
speed. If the auxiliary oil pump is still in operation
when the takeover criteria of the main oil pump are
fulfilled, the

BHEL, Hardwar 6.1-1000-96/3

BHEL, Hardwar 6.1-1000-96/4
 Steam Turbine Oil System MAY
Description Oil Vapour Extraction System

Oil vapour extractors

Accompanying system diagram Oil vapours extractor 1 MAV82 AN001
(Drawing No. 2-13100-Q8103 on Sheet No. Oil vapours extractor 2 MAV82 AN002
6.1-1001-96/2) Check valve of MAV82 AA001
Oil vapours extractor 1
Process engineering function of the oil vapour Check valve of MAV82 AA002
extraction system Oil vapour extractor 2
Oil vapour forming, for example, due to turbulent flow One of the two single-stage oil extractors, whose
of turbine oil in the bearing pedestals and due to release characteristic is matched to volumetric flow of oil-
of entrained air in the oil return lines and main oil tank is enriched air, must be in operation as long as the
removed by one of the two extractors of the oil vapour generator is filled with hydrogen.
extraction system. The check valves downstream of the oil vapour
The negative pressures above the oil surface in the extractors prevent the extractor in operation from
bearing pedestals, oil return lines, and main oil tank drawing in air tough the standby extractor.
prevent turbine oil or vapour from escaping into the ƒ Oil separator MAV82 BT001
atmosphere. Virtually all of the turbine oil in the vapour phase is
Turbine oil and oil vapour are separated in the oil removed by the oil separator. Inadequate oil
separator of the oil vapour extractors so that the air separation is usually caused by excessive
released into the atmosphere is virtually free of oil. volumetric flow of oil vapour. Consequently, the
throttle valves in the oil vapour extraction lines
must not be opened too far and the lid of the main
Components of the oil vapour extraction system
oil tank must be airtight.
In addition to piping the following equipment is necessary
for operation of the oil vapour extraction system: ƒ Adjustable throttle valves in the oil vapour
extraction lines
Volumetric flow in the oil vapour extraction lines is
adjusted with throttle valves so that negative
ƒ Oil vapour extractors and oil separator pressures in the bearing pedestals equal the
Oil vapours extractor1 MAV82 AN001 reference value of approx. 5-10 mm of water column.
Oil vapours extractor2 MAV82 AN002 The negative pressures in the oil return lines and
Throttle valve upstream of MAV82 AA511 main oil tank must be matched to this reference value
Oil vapour extractor1 without degrading oil separation in the oil separator
Throttle valve upstream of MAV82 AA512 due to excessive volumetric flow.
Oil vapour extractor2 If the pressure in one bearing pedestal or in the main
Check valve of MAV82 AA001 oil tank is considerably lower than the reference
Oil vapour extractor1 value, there is a risk of dust, moisture, or leak off
Check valve of MAV82 AA002 steam from the immediate atmosphere being drawn
Oil vapour extractor2 into the oil system.
Oil separator MAV82 BT001
ƒ Throttle valves downstream of bearing
pedestals Notes on operation of the
Bearing pedestal 1 MAV81 AA501 Oil vapour extraction system
Bearing pedestal 2 MAV81 AA503 During extended shutdowns the oil system fills with
Bearing pedestal 3 MAV81 AA505 air as the oil slowly flows back into the main tank. When
Gen. Brg. pedestal MAV81 AA507 the system is started up again by activating the pump,
Exciter bearing pedestal MAV81 AA511 resuming oil flow, the air is driven out and accumulates in
ƒ Throttle valves of oil return lines the bearing pedestals. Pressure build-up in the bearing
Throttle valve MAV81 AA521 pedestals and discharge of oil through the seal rings can
Throttle valve MAV81 AA522 be prevented by filling the system using the emergency
oil pump.

Description and function of components of the oil

vapour extraction system
The components of the oil vapour extraction system
and their function are described in the following:

BHEL, Hardwar 6.1-1001-96/1

6.1-1001-96-2
 Steam Turbine
Description
Accompanying system diagram:
(Drawing No. 2-13100-Q8103 On sheet 6.1-1001-96/2)
Process engineering functions of the oil discharge
and vent system
The valves and pipes of the oil discharge and vent system
are used to discharge the turbine oil from the components
of the oil system, and to vent certain components.
The discharged turbine oil is temporarily stored and then
refilled into the main oil tank. The turbine oil is purified
either before or during the refill process.
Components of the oil discharge and vent system
The oil discharge and vent system contains valves with ID
codes as shown on the system diagram, and the piping
required for discharging the turbine oil and venting the oil
system components.
Description and function of components of the oil
discharge and vent system
ƒ Oil drain valves
The oil drain valves, the ID codes of which are given in
the system diagram, are used to drain the following oil
system components:
- Main oil tank MAV10 BBOO1
The main oil tank is drained if the entire turbine oil fill
is to be discharged, or if the main oil tank is to be cleaned
during inspection and overhaul.
The entire oil fill is discharged if the oil system,
including all components thereof, is to be cleaned or if the
turbine oil is to be reconditioned or replaced.
-Oil cooler 1 MAV41 BC001
-Oil cooler 2 MAV41 BC002
The turbine oil must be discharged from one of the oil
coolers if a check on leak tightness or condition is to be
performed or if the oil cooler is to be cleaned.
- lubricating oil filter 1 MAV42 BT001
- Jacking oil filter MAV35 AT001
Oil filters must be drained on each cleaning operation or
whenever the filter elements are changed.
-Oil piping systems
The turbine oil in the oil piping systems is discharged
when the oil system is drained completely, or before
corrective action is undertaken to eliminate leaks. The
turbine oil must be discharged into a clean oil tank or into
clean oil drums.
If the entire turbine oil fill is to be discharged, an
appropriately sized stationary or mobile oil tank must be
provided. An oil pump is used to return
BELL, Hardwar
Oil System MAV
Oil Discharge and Vent System
System Description
Turbine oil to the main oil tank. Under normal operating
conditions, all oil drain valves must be closed in order
to avoid interruption of the oil supply.
Oil drain valves of the oil tank, the oil coolers and the
oil piping system are to be locked against unauthorised
or accidental opening.
ƒ Draining the jacking oil system
Note that the jacking oil filter system is drained using
the drain line of the jacking oil filter. The appropriate
valves must be aligned to route oil flow to the jacking
oil filter used for drainage.
ƒ Vent valves
The vent valves, the ID codes of which are given in the
system diagram, must be used to vent the following oil
system components:
- Oil cooler 1 MAV41 BC001
- Oil cooler 2 MAV41 BC002
The valves in the vent lines of the oil coolers
Must be open at all times.
-Lubricating oil filter MAV42 BT001
- Jacking oil filter MAV35 AT001
The filter housing of the switchable duplex filters of the
operating oil systems must be filled and vented after
the filter elements have been cleaned.
The vent lines feed into the oil return line or into the oil
tank of the oil discharge system, to avoid oil loss during
venting.
Information for operation and maintenance
Incorrect valve positions, inadequate protection
of valves against unauthorized actuation,
incorrect turbine oil fill and discharge
procedures, and failure to isolate valves can
result in faulty operation, damage, contamination
of waste water or buildings, and loss of turbine
oil. For this reason, all information on this subject
in this system description must be observed. In
particular, the following information must also be
complied with:
ƒ Complete drainage of the oil system before
changing the turbine oil fill when changing the
turbine oil fill, the used oil must be fully removed
from the system so that the properties of the new
turbine oil are not adversely affected.
If necessary, flanges and threaded joints must be
disconnected and valve bonnets removed, so
that the used oil can be completely removed.
Once discharged, the used oil must be disposed
of properly.
ƒ Isolation of oil system components
Before an oil drain valve is opened, there must
be oil-side isolation of the component to be
drained.
Before the main oil tank is drained, the operating
6.1-1002-96/1
 Steam Turbine
Description
Oil pumps which draw the turbine oil from the main oil
tank must be deactivated to prevent the oil pumps
from running dry.
ƒ Discharging the turbine oil into drums
To allow rouse of the turbine oil, drums into which the
oil is discharged must be free of contaminants of any
kind.
Drums must not overflow when being filled with the
discharged oil, nor must they be damaged during
transportation.
Due to the amount of time and the large
BHEL, Hardwar
Oil System MAV
Oil Discharge and Vent System
System Description
Transportation effort involved, turbine oil should only be
discharged into drums if neither stationary nor mobile oil
tanks are available.
ƒ Oil level in the main oil tank
The oil level in the main oil tank must be topped up
while the turbine generator unit is operating at rated
speed, since this operating condition is used as the
basis for defining the reference operating level for the
oil.
Care should be taken that the reference operating level
is not exceeded.
6.1-1002-96/2
 Steam Turbine
Description
Accompanying system diagram:
(Drawing No. 2-13100-Q8103 On sheet 6.1-1001-96/2)
Process engineering function of the oil conditioning
system
Turbine oil is subjected to stringent requirements in terms
of purity, since the properties of the turbine oil and the
condition and proper functioning of the turbine generator
components which come into contact with that oil can be
adversely affected by solid or liquid contaminants.
The function of the oil conditioning system, which can be
kept in continual operation independently of the operating
oil systems, is to either maintain or restore the purity of the
turbine oil.
ID codes of the oil conditioning system components
ƒ Multipurpose oil conditioning station
BHEL, Hardwar
Oil System MAY
Oil Conditioning (Purification)
System Description
Description of the oil conditioning system
arrangement
A multipurpose oil conditioning station is available for
turbine oil conditioning.
Information for operation and maintenance
• Valve positioning during normal operation
The positions of the manually operated valves of the
oil conditioning system during normal operation are
given in the position list for manually operated
valves appended to the operating instructions.
ƒ Operation and maintenance of the oil
conditioning system.
For all questions regarding the operation and
maintenance of the oil conditioning station, please
refer to the manufacturer's instructions..
6.1-1003-96
 Steam Turbine
Description
Function
The main oil tank contains the oil necessary for the
lubrication and cooling of the bearings, for the jacking
system and for the hydraulic turning gear. It not only
serves as a storage tank also for deaerating the oil.
The capacity of the tank is such that the full quantity of
oil is circulated not more than 8 times per hour. This
results in a retention time of approx. 7 to 8 minutes from
entry into the tank to suction by the pumps. This time
allows sedimentation and detrainment of the oil.
1 Suction pipe (injector) 8 Oil inlet
2 A.C. auxiliary oil pump 9 Riser section inlet
3 D.C emergency oil pump 10 Inspection port
4 Jacking oil pump 11 Oil vapors exhausters
5 Oil level indicator 12 Level switch
6 Riser section drain 13 Oil strainer
7 Main section drain.
BHEL, Hardwar
Main Oil Tank
Oil Flow in Tank
Oil returning to the tank from the oil supply system first
flows through a submerged inlet (8) into the riser
section “of the tank where the first stage of deaeration
takes place as the oil rises to the top of the tank. Oil
overflows from the riser section through the oil strainer
(13) into the adjacent section of the tank where it is then
drawn off on the opposite side by the suction pipe or the
oil pumps.
Oil pumps
The main oil pumps draws the oil through a suction
pipe (1) situated at the flow end of the tank (1). This
suction pipe is constructed as an injector to aid the
suction of the main oil pump which has to overcome
a certain suction head. Power oil is conducted to the
injector via an injection pipe.
6.1-1010-01/1
This injection pipe also fills the suction pipe of the main
oil pump when the plant is being started up.
The auxiliary oil pumps (2, 3) arranged on the tank are
electrically driven rotary oil pumps (2). The jacking oil
pumps (4) also situated on the tank, are electrically
driven jack-screw immersion pumps (3). All pumps
immerse in the oil contained in the tank and draw oil
from the deepest point in order to obtain oil as free of
air as possible. The driving elements of the pumps are
fixed to the base plates of the tank covet.
Oil Strainer
The basket type oil strainers (13) are mounted in the
tank. They are of brass wire mesh of 0.25 mm filtration
particle size and can be exchanged by opening the tank
cover.
BHEL, Hardwar
Oil Vapors Exhaust
The whole tank is made as airtight as possible. Oil
vapors exhausters (11) produce a slight negative
pressure in the tank, in the return drain lines and in the
spaces in the bearing pedestals so that oil vapors
arising is drawn off.
Oil Level Indicator
The main oil tank has a direct reading oil level indicator
and a fluid limit switch. This permits signals to be
transmitted when maximum and minimum levels have
been reached. Extra tank volume is provided between
the normal operating level and the tank cover to accept
oil from the entire oil supply system when the turbine is
shut down; the tank is constructed with a sloping bottom
with drain connections at the lowest point (6, 7).
Also refer to the following sections
(1) 6.1-1020 Main oil Pump
(2) 6.1-1030 Auxiliary oil Pump
(3) 6.1-1040 D.C Emergency oil pump
(4) 6.1-1050 jacking oil pump
6.1-1010-01/2
 Steam Turbine
Description
Function
The main oil pump is situated in the font bearing
pedestal and supplies the entire turbine with oil that is
used for bearing lubrication, cooling the shaft journals
and as primary and test oil. The main oil pump is driven
direct from the turbine shaft via the coupling (11). If the
turbo-set is out of operation or the main oil pump fails,
auxiliary oil pumps take over the necessary oil supply.
These pumps also convey oil into the suction branch of
the main oil pump until the main oil pump has started to
draw from the main oil tank which is situated at a lower
level [1].
Construction
The double flow impeller (5) is an integral part of the
pump shaft. The pressure and suction chambers are
sealed off from each other by seal rings (4) which are
split and secured against turning at the joint. The
BHEL, Hardwar
Main Oil Pump with
Hydraulic Speed Transmitter
Pump shaft (5) runs in the journal bearing (1) and the
combined journal and thrust bearing (7). Both bearings are
lubricated with filtered 011. If the over speed trip test
device, which is described separately [2] is actuated, over
speed trip test oil ‘a’ flows to the over speed trip devices
via the oil tube (16) built into the pump shaft (5).
Hydraulic Speed Transmitter
The pump shaft (5) also carries the hydraulic speed
transmitter (14) which runs in the bearing (7) and in rings
(13). The hydraulic speed transmitter operates on the
same principle as a centrifugal pump impeller. Any change
in speed gives rise to a pressure change in primary oil
circuit ‘a1’ which serves as a control impulse for the
hydraulic speed controller. The hydraulic speed transmitter
(14) is supplied with control oil from the hydraulic control
equipment rack
6.1-1020-01/1
Via the oil supply reservoir (9). ! \n annular bead in the
speed transmitter ensures that its interior is at ways
covered with a thin layer of oil to maintain a uniform
initial pressure. Excess oil drains into the bearing
pedestal.
Electrical Speed Plck-up
The pick-up for the electrical speed transmitter (12) is a
nonmagnetic disc into which small magnets are inser1ed
around the circumference. When the disc rotates as the
pump runs, ~h8 alternating effect between the magnets
and the Hall generators, not shown here, gives rise to a
voltage signal which is forwarded to the electrical speed
display [3].

Fig. 2 Hydraulic Speed Transmitter, Cross Section

BHEL, Hardwar 6.1-1020-01/2

 Steam Turbine
Description
Description
The auxiliary oil pump is a vertical one-stage rotary
pump with a radial impeller and spiral casing. It is fixed to
the cover of the oil tank and submerges into the oil with
the pump body. It is driven by an electric motor that is
bolted to the cover plate (1). The oil enters the suction
connection from underneath and is supplied to the oil
system via the pressure pipe (18). The pump shaft has:
a sleeve bearing (12) in the pump casing and a grooved
ball bearing (7) in the bearing yoke. The bearings are
lubricated from the pressure chamber of the pump; the
sleeve bearing via a bore in the casing; the grooved ball
bearing ‘, IA a lube line.
Assembly
The pump is assembled before dispatch and can be
mounted on and bolted to the oil tank as a complete unit.
When connecting, care must be taken the piping is not
stressed when bolted.
Dismounting Exchanging the Impeller
After the motor has been disassembled and the pressure
pipe disconnected. The pump must be removed from the
tank as a complete unit.
BHEL, Hardwar
Auxiliary Oil Pump
After the suction casing (14) has been removed and the
shaft nut (16) loosened. The impeller can be extracted. It
is advisable to renew the split rings (17) when exchanging
the impeller. The now clearance between split ring and
impeller neck is 0.3 mm in diameter.
Exchanging the Bearings
When dismantling the pump must be removed as above.
Loosen the pump casing from the pressure line and
suspension pipe from cover plate. Remove coupling
halves from the shaft by means of an appropriate device.
Remove retaining ring (6), loosen bearing nut (6) and
detach grooved ball bearing. Extract pump shaft after the
unscrewing of impeller. The pump is reassembled in
reverse order.
Adjusting Pump Rotor
During assembly, the rotor rests on the sealing ring of the
suction casing. Lift the rotor by means of the bearing nut
(5) until the rotor sits firmly with the shoulder of the shaft
and the distance ring (8) at the inner ring of the grooved
ball bearing. Secure the bearing nut with threaded pin.
6.1-1030-01
 Steam Turbine
Description
Function
The emergency oil pump is of the vertical, centrifugal,
submerged type and serves for lubrication and cooling
of the bearings during emergency conditions.
Location
The unit is located on top of the main oil tank and
driven by a D.C. motor. The complete pump -motor
assembly is attached to mounting plate (1) which is
bolted to the top of the main oil tank.
Construction
Oil is delivered by impeller (15) via the intake (141 to
volute (13) from where the oil flows through discharge
pipe (18) to the oil supply system.
BHEL, Hardwar
D.C. Emergency Oil Pump
The vertical pump shaft (9) is connected to the motor
shaft by a flexible coupling equipped with rubber -
sleeved coupling studs. The radial ball bearing (7)
carries the downward thrust load of the pump and with
the lower babbitted sleeve bearing 112) guides the
shaft. The lower sleeve bearing is mounted in volute
113). Pressure lubrication is provided to both bearings.
The lower bearing is supplied with oil through a drilled
oil passage from the discharge side of the pump. The
upper bearing is oil fed by pipe (10) which connects to
the pump discharge. Seal rings (17) form a seal
between the impeller suction and the pump discharge.
6.1-1040-01
 Steam Turbine
Description
Function
The jacking oil pump is a self-priming screw-spindle
pump with three spindles and internal bearings the
pump supplies the jacking oil that is needed for lifting
the shafting at low speeds [1].
Construction, Mode of Operation
The screw-spindle pump is connected vertically to the
cover plate (2) of the main oil tank via a support (5) and
immerses with the suction casing (15) into the oil, the
drive is an electric motor that is bolted to the cover plate
(2). The oil now into the suction branch of the suction
casing (15) from underneath and is supplied to the
lifting oil system by the pump via the pressure pipe (3).
The driving spindle (16) and the two moving spindles
(20) run in the inner casing (13). The fluid pressure to
which the spindle thread is subjected on the pressure
side is compensated by the driving spindle by means of
the balancing piston (shrunk-on sleeve) running in the
throttle bushing (11).
BHEL, Hardwar
Jacking Oil Pump
With the hollow moving spindles, the axial thrust is
compensated by the balancing pistons arranged on the
suction side which run in the balancing bushings (21).
The throttle bushing (11) and the driving spindle (16)
form a throttling gap that separates the pressure area
from the following area. The oil that leaves the throttle
gap. Flows via the grooved ball bearing (7) into the
support and from there back into the main oil tank. The
grooved ball bearing is lubricated with this oil. The
driving spindle is fixed by means of the grooved ball
bearing in the bearing carrier (9) that is bolted to the
pressure casing (12) of the pump.
Due to the special profile given by the sides of the
threads the three spindles form sealed chambers, the
contents of which are continuously being moved axially
from the suction side to the pressure side of the pump
as the spindles rotate.
Also refer to the following sections
[1] 6.1-0100 Technical Data
[2] 6.1-0510 Hydraulic Turning Gear
[3] 6.1-0530 Hydraulic Lifting Device
6.1-1050-00
 Steam Turbine Oil Throttle
Description

Arrangement
The oil throttles arranged immediately before the bearing
in the lubricating lines serve for adjusting the necessary
amount of oil for the bearings. While the left half of the
sectional view represents the oil throttle during oil
flushing, the right half shows the oil throttle in normal
operation.
Construction
The main parts of the oil throttle are the body (8), in
which either the oil strainer (7) which is held in place by
the screw plug (6), for the flushing process or the
adjustable throttle piece (5) with parts (1, 2, 3) for normal
operation are inserted.
Operation
The flushing process is carried out before the turbine is
taken into service. After the flushing, the oil strainer (7)
as well as the screw plug (6) is to be exchanged with the
throttle piece (5) and the screw plug (3) with the capped
nut (11. By means of the adjustable throttle piece, the
cross section of the passage is then adjusted for normal
operation, according to the necessary amount of the
lubricating oil and consequently the lubricating oil flow
adapted to the required oil exit temperature of the
bearing.

BHEL, Hardwar 6.1-1080-00

 Steam Turbine
Description
Arrangement
The oil throttles arranged immediately before the
bearings in the lubricating lines inside the bearing
pedestals serve for adjusting the necessary amount of
oil for the bearings. While the Fig. 1 represents the oil
throttle during normal operation, Fig. 2 shows the oil
throttle during final stage of oil flushing.
Operation
BHEL, Hardwar
Oil Throttle
The flushing process is carried out before the turbine is
taken into service. The strainer (7) is installed in final
stage of flushing. The oil strainer (7) as well as the
blind cover (6) is to be exchanged with the throttle
spindle (1), cap nut (2), nut (3) and cover (4). By means
of adjustable throttle, the cross section of the oil
passage is then adjusted for normal operation.
According to the necessary amount of the lubricating oil
and consequently the lubricating oil flow adapted to the
required oil exit temperature of the bearing.
6.1-1081-00
 Steam Turbine Three-way Control Valve
Description for Lubricating Oil Temp. Control

Description
The three way temperature control valve has the function of
regulating the lubricating oil temperature at 45 °C. Possible oil
flow paths for regulating the oil temperature are:
All lubricating oil flows through oil cooler.
Lubricating oil flows through oil cooler and bypass piping.
All lubricating oil flows through bypass piping.
Valve Type
Three ways Angle Valve with Electric Actuator.

BHEL, Hardwar 6.1-1090-01

 Steam Turbine H.P. Control Fluid Pump
Description With LP Extraction

Description:
The extraction or dual pressure pump is a vertical rotary
pump in multiple stages. It is attached to the cover of the
fluid tank and submerges in the control fluid. Drive is
provided by an electric motor located on the cover plate (1).
Control fluid enters the suction casing (10) from below and
is conducted into the LP control fluid circuit via the pressure
pipe (19) and into the HP control fluid circuit via pressure
pipe (23). The pump shaft is guided by a sleeve bearing
(11) in the suction casing and by ball bearings (25) in the
bearing support (4). The ball bearings and the bevel gear
coupling are lubricated by oil from the 1st stage pressure
chamber via lubricating pipe (22).The sleeve bearing is
lubricated via a passage in the casing.
Assembly:
The pump is delivered in assembled state and can be
placed as a unit on the tank and bolted to it. When
connecting the pressure pipe care must be taken that the
piping is not stressed when bolted.
Exchanging the Rotors:
When the motor has been dismantled and the pressure
piping removed. The pump must be extracted as a unit from
the tank. After the suction casing has been removed and
the rotating wheel nut loosened, the 1 st stage rotating
wheel can be extracted. In order to dismantle the other
stages, the baffle ring and then the stage casing are
removed. It is expedient to renew the seal rings when
exchanging the rotating wheels. The new clearance
between seal ring and the neck of the rotating wheel is 0.3
mm in diameter. The pump is assembled in the reversed
sequence.
Exchanging the Bearings (11 and 25):
The pump is first taken apart; loosen pump casing from
pressure piping and bearing support from the cover plate;
remove coupling half from the shaft by means of special
device; remove bearing securing device; loosen nut (2) and
ball bearings (25). The pump is assembled in the reversed
sequence.
Adjusting Pump Rotor:
During assembly the shaft is supported by the sealing ring
of the suction casing. The shaft is lifted by means of the nut
(2) until the rotor with shaft shoulder and distance ring (24)
sits firmly on the inner ring of the ball bearing. Bearing nut is
then secured with threaded pin.

BHEL, Hardwar 6.1.1110-00

 Steam Turbine Plate-type Filter
Description

The plate type filter cleans the oil or fluid used in the
governing system.
Construction:
The plate type filters are installed in Governing and LP
Bypass racks. Single stage plate type filters are used in
LP Bypass racks while in Governing rack the filter has
three stages. The filtering elements are arranged in
parallel inside the casing. The main components of the
filter are: hand wheel (1), filter top (2), filter element (3),
body (4) and sludge drain plug (5).
Mode of Operation:
The control fluid enters the body at the right hand arrow
and passes through the filter element (3). The sludge gets
arrested on the surface to the cartridges. The clean fluid
flows out to the machine.
Operation and Maintenance:
To clean the plate type filter, use the hand wheel (1) to
turn the filter cartridges. The sludge and dirt removed
collect at the bottom of the body (4) in the sludge
collection chamber. The hand wheel (1) should be turned
2 or 3 revolutions daily. Accumulated sludge is to be
removed at fairly long intervals when the plant is shut
down by removing the screw plug (5). The filter cartridges
need not be removed.
Disturbance:
If the filter is not given due attention and the hand wheel
not turned regularly, it may happen that the cartridges
become so clogged that it is impossible to turn the main
spindle, and there is only a very slight flow of fluid through
the filter. In such cases no force should be applied under
any circumstances. It is relatively easy to correct this kind
of trouble when the machine is shutdown: Remove the
element from the body carefully. The cartridges can now
be cleaned thoroughly by using a noncorrosive cleaning
fluid and with the aid of a brush. Do not take the cartridges
apart. After the filter element has been cleaned, place it
back in the position. It is possible that the gland in the filter
top may become loose or sticky. In such cases tighten the
gland nut or replace the packing. Be sure not to tighten
the nut too much so as to prevent the cartridges from
being turned.

BHEL, Hardwar 6.1-1120-00


Steam Turbine Description
Function:
Duplex filters permit the dirty fitter elements to be cleaned
during operation.
Construction:
The Duplex filter consists of two filter bodies and is fitted
with a change-over device which enables the filter to be
switched as desired. The filter bodies are designed
according to the pressure stage and the relevant codes and
the filter itself is designed to provide safety taking into
account the differential pressures.
Installation of Duplex Filters:
When the filter is being bolted to the foundation, the casing
must not be subjected to any external stresses. This also
applies when the piping is being connected .Care must be
taken that the fluid flows through in the correct direction.
The directing of flow is normally marked on the flanges of
the filter bodies.
Differential Pressure Gauge:
The function of the device is to measure and give a visual
indication of’ the variation in the differential pressure
Fig.2 Cylindrical Filter
BHEL, Hardwar
Duplex Filter
For Pilot Control of Control Valves
Mode of Operation of Differential pressure Gauge:
The casing is divided into two pressure chambers by a diaphragm
sealed piston. The first chamber is connected with the filter
entrance and the other with the exit. In the normal case ( p = O),
the piston is held in the zero position by a tension spring. On an
increase in the differential pressure, the piston is pushed against
the tension spring. Each alteration in pressure corresponds to
a certain piston setting. This position is transferred
magnetically i.e. with low friction,
To the indicating disc and the two contacts outside the pressurized
area. At certain red portion of the two viewing windows of the
indicating disc which occurs for example when filter contamination
increases and at specified switching points a particular contact,
thus correspond to the prevailing differential pressure.
Fig.3 Differential Pressure Gauge
Valve Changeover Device:
The changeover device consists of two changeover valves
arranged one above the other. Valve discs (4) that control the path
of flow in the valve casing are moved by means of a star-wheel via
spindle that has a left and right hand thread. This construction
guarantees synchronized movement of the two valves discs
whereby one filter chamber is switched on before the other
chamber is switched off, Without causing the flow to be
interrupted .A visual indicator on the upper valve casing
shows the prevailing direction of flow and switching.
6.1-1130-00/1
Operating the Changeover Valve:
The large arrow on the switching gauge (1) gives the
direction of flow and the small arrow the switching direction.
Before operating the changeover device, the pressure
equalizing coak (2) must be open. The duplex filter is
switched to the other filter chamber by turning the star-
wheel (3) in the given direction. By means of a turning lever,
the valve discs can be easily loosened. The star-wheel (3)
is also tightened to the end position by means of this turning
lever. The valve discs (4) open in the appropriate direction
of flow and the change-over process is then completed. The
cock of the pressure equalizing pipe must then be closed so
that one filter chamber is hermetically sealed.
Start-up and Cleaning:
Change-over device in intermediate position; both filter
chambers in operation
Open vents in both chambers
Start-up plant slowly
Close vents when air has escaped and fluid begins to
come out
Block one filter chamber by opening changeover device.
While the first filter chamber is filtering, the shut off
chamber is in reserve until the permissible differential
pressure has been reached due to contamination. When
the permissible differential pressure has been reached,
one must switch over to the clean filter chamber as
follows:
Open pressure equalizing cock and check whether the
reserve chamber is full by opening the vents for a short
time
Change over
Close pressure equalizing cock.
Open vent in shut-off half; this relieves the control fluid
and gives the possibility of checking whether the
changeover device has blocked the flow to the filter
chamber.
Disassemble the casing cover of the shutoff filter
chamber.
Remove filter element vertically in an upwards direction,
Clean mesh of filter element with appropriate cleaning
material and by blowing through the mesh from the
clean side (see filter cleaning instructions). Fig.4 Changeover Valve
Re-insert cleaned filter element.
Close casing through cover; vent is still open. Before 1 Switching position indicator
replacing cover take care that condition and position of 2 Pressure equalizing cock
seal are perfect. If necessary change seal. 3 Star-wheel
Open pressure equalizing cock until filter half is 4 Valve disc
deaerated. Unscrew switching gauge.
Close vent. Filter half is ready as reserve again. Loosen valve discs by turning star-wheel
Disassemble upper cover.
Removal and Installation of Changeover Valve: Unscrew valve stem with valve disc (4).
Be lore removing the changeover valve, care must be taken Check sealing rings and renew if necessary.
Screw valve stem with valve disc (4) back again.
that the fluid in the casings is not under pressure.
Close casing with cover.
Assemble switching gauge.
Disassemble lower cover.
Unscrew Valve stem with valve disc.

BHEL, Hardwar 6.1-1130-00/2

 Cleaning the Filters:-
1. Normal Cleaning
1.1 With multi-part filters, each element is cleaned in
dividedly.
1.2 Brush the individual elements with a not too hard
brush and suitable cleaning agent over a bath or
container and rinse.
1.3 Blow compressed air from the clean side through the
filter that has been cleaned in this way in order to
remove any dirt particles caught in the filter mesh.
The cleaning process can be carried out with filter
cleaning apparatus (Fig. 5).
Application according to Item 2.3
2. Cleaning Obstinate Dirt:
2.1 Place complete filter in a container with a cleaning
agent for several hours or spray repeatedly at short
intervals.
2.2 Treat filter elements as described under 1.2 and 1.3.
2.3 Using filter cleaning apparatus (Fig.5) and suitable
agent, blow through filter thoroughly from clean side.
3. Cleaning Disassembled Filter Elements:
Fig. 5 cleaning device for filter element
(Only with bolted construction)
Only when absolutely necessary to be performed 4. Cleaning Agents:
with great care. Suitable cleaning agents are e.g. air, water, steam, Tri-
3.1 loosen all nuts (a) on respective filter element and
Perchlorethylene, petrol, benzene, diesel oil, etc.
remove.
3.2 Detach lower filter plate (b)
The application depends on their cleaning capacity and their
3.3 Detach filter casing (c) compatibility with the media to be filtered.
3.4 Remove support pipe (d)
3.5 Clean strainer basket as in Item 2
3.6 Clean all parts. Also upper filter plate (g) and stay
rod (e)
3.7 Check all seals (f) and strainer basket for damage
and renew if necessary
3.8 Assemble filter elements and bolt firmly. Care must
be taken here that strainer basket and seals sit
properly.

BHEL, Hardwar 6.1-1130-00/3

 Steam Turbine
Regenerating Plant
Description

General: The Fuller’s earth needed for regenerating the fire

resistant fluid must be dry with a residual water content
Of the various types of fire resistant fluid, the only ones
of not more than 1% of the weight. If required Fuller’s
suitable for use with our turbines are phosphoric esters of the
earth must be dried at a temperature not exceeding
group HS-D which have a low water and chlorine content.
105 C.
Their chemical composition and structure necessitate certain
The US strainer number 30/60 mesh is the granular
measures and alterations compared with an oil system.
size to be used (or this must correspond to the details
Fire resistant fluid systems for our turbines are provided with
from the fluid manufacturer). The dust proportion of the
a bypass regenerating plant. The design of this plant is made
granulate must not be used. The amount of earth must
to the specifications of the fluid manufacturer. Any acids and
not be too little and must be stamped or shaken to
ageing products are removed during operation by continuous
avoid the formation of gaps and channels which would
filtering through Fuller’s-earth and mechanical filters.
reduce the effectiveness of the Fuller’s earth.
The mode of operation of this natural earth treatment is
The efficiency of the regenerating plant is to be
based on a ion-exchange reaction. In addition to the
controlled by an exact record of the neutralization
precautions against acidifying of the fluid, continuous care is
value and the degree of purity.
taken that any solid particles are separated by the fine filter
so that they can not speed up the reaction. The fine filter of Construction of Regenerating Plant:
this plant retains particles of Fuller’s earth as well as The filter group consists of one dry filter (10), 2 Fuller’s
providing the essential cleanliness of the whole system and earth filters (6) and a mechanical Filter (7).The
increasing the life of the filters. cleaning and deacidifying takes place in a separate
circuit. A pump (4) conducts a constant amount of fluid
through the filter group and back into the tank (1).

BHEL, Hardwar 6.1-1140-00/1

When the filter is contaminated there is an increase in the
fluid pressure. A spring safety valve (3) is installed to protect
the system against an excessively high increase in pressure.
Dry Filter:
Fluid first enters the dry filter. The cartridges inside the filter
remove dirt and water from the fluid. The outer media layer
filters out silt, rust and other particular contaminants. The
inner layers absorb water and will chemically bond it so that
no water will release downstream. When the cartridge
reaches its water holding limit, the media swells and the
differential pressure rapidly increases. The differential
pressure indicator reaches the all-red range. This signals the
operator that the cartridge must be changed.
Fuller’s earth Filter (Fig. 2):
The Fuller’s earth filter contains three sections with a special
granulate which binds any acid present in the fluid. Two filters
work in parallel and cannot be switched over.
Mechanical Fine Filter (Fig. 3):
Following the Fuller’s earth filters is a fine filter with textile
inserts of finest mesh. These inserts retain the finest particles
of dirt, both metallic and nonmetallic impurities. In this way
the fine filter also serves the safety of the control fluid system
by trapping any particles of granulate that may be circulating.
Fig. 2 Fuller’s Earth Filter
The fine filter also separates water particles and other ageing
1 Connection for pressure gauge
materials which would make it necessary so renew the 2 Connection for air exhaust
control fluid too soon. 3 Connection for safety valve
Commissioning and Maintenance of the Filter Plants: 4 Control fluid Inlet
5 Control fluid outlet
„ The filters are to be continuously desecrated by slightly 6 Connection to drain tank
opening the vent valve. 7 Filter basket with gauge
„ Observe pressure increase on pressure gauge „ Lift cover taking care not to damage seal
„ The acid content must be checked by examining the fluid „ Loosen drain pipe screws and lift basket cover
in the laboratory at certain intervals. „ Extract filter basket (7) carefully and centrally
„ If there is a constant increase in the acid value. „ Clean inside of filter casing
The granulate is exhausted and must be replaced earlier than „ Clean filter basket (7)
originally intended. „ After cleaning care must be taken that the parts are
„ The increasing contamination of the filter can be completely dry
measured by the constant increase in pressure. The Fill filter basket and Insert. The earth must be carefully
differential pressure indicators installed in the system show pressed down without use of excessive force so that
optically the degree of contamination. When the white-red the sections are filled compactly in order to prevent
segments are only showing red, the filter material must be later settling of the earth and the possible formation of
changed. channels
„ Insert clean basket covers and tightens well
Exchanging the Earth Filling (Fig. 2):
„ Switch off pump with screw so that no Fuller’s earth can escape
„ Close drain (6).
„ Open filter drain (6). Drain Filter (Flg.2)
„ Replace cover carefully and tighten uniformly by
„ Loosen cover bolts
means of screws (pay attention to seal)
„ Switch on pump (4).

BHEL, Hardwar 6.1-1140-00/2

Instructions for Installation of Filter Cartridges of Fine
Filter (Fig.3):
The filter cartridges (8) are to be immersed in the control fluid
before the first commissioning and installed in the filter. The
cartridges must be placed above the standpipes such that the
large opening of the filter cartridge faces downwards. By
inserting the rubber and metal discs and the clamping springs
in this sequence, the filter cartridges are stressed by means
of the clamping screws to equalize an alteration in the length
of the filter cartridge column.
Means of Cleaning:
The following are to be used for cleaning:
Textile and paper cloths without threads, benzene, white
spirit, trichloroethylene, perchloroethylene and compressed
air.
When using these, the respective accident prevention rules
are to be observed.
Remains of cleaning materials are to be carefully removed
(when chlorinated hydrocarbon is used there must be no
increase in the chlorine content of the FRF).
Each newly cleaned surface is susceptible to corrosion. In
order to protect the surfaces, therefore, they must be
moistened with FRF or a corrosion protection medium
compatible with FRF immediately after cleaning.

1 Connection for pressure gauge

2 Connection for air exhaust
3 Connection for safety valve
4 Control fluid inlet
5 Connection for thermometer
6 Control fluid outlet with flow gauge
7 Connection for sludge outlet and drainage
8 Filter cartridges

Fig. 3 Mechanical Fine Filter

BHEL, Hardwar 6.1-1140-00/3

 Steam Turbine Drain System MAL
Description

System Diagram

MAL Turbine Drains System Drawing No. 1-13100-Q8131 on sheet No. 6.1-1210-96/2

MAG Turbine Drains System Drawing No. 1-13100-Q8131 on sheet No. 6.1-1210-96/2

BHEL, Hardwar 6.1-1210-96/1

6.1-1210-96-2
 Steam Turbine System Diagram
Description Index

System Diagram

MAA HP-IP-LP Scheme Drawing No. 1-13100-Q8142 on sheet 6.1-1220-96/2

MAB HP-IP-LP Scheme Drawing No. 1-13100- Q8142 on sheet 6.1-1220-96/2
MAC HP-IP-LP Scheme Drawing No. 1-13100- Q8142 on sheet 6.1-1220-95/2
MAN Condenser Spray System Drawing No. 2-13100- Q8141On sheet 6.1-1220-96/3
LCE Condenser Spray System Drawing No. 2-13100- Q8141On sheet 6.1-1220-96/3

BHEL, Hardwar 6.1-1220-96/1

6.1-1220-96-2
6.1-1220-96-3
 Steam Turbine Component Diagram
Description Index

Component Diagram

MAA HP Stop & Control Valves Drawing no. 4-18000-84022 on sheet 6.1-1230-96/3

MAB IP Stop & Control Valves Drawing no. 4-18000-84022 on sheet 6.1-1230-96/4

MAN LP Bypass Valve (ETA Type) Drawing no. 4-18000-84022 on sheet 6.1-1230-96/5

MAW Seal Steam /Leak off Steam Valve Drawing no. 4-18000-84022 on sheet 6.1-1230-96/6

MAD Measuring Points on Turbine – Generator Drawing no. 4-18000-84021 on sheet 6.1-1230-96/7
Bearings

BHEL, Hardwar 6.1-1230-96/1

BHEL, Hardwar 6.1-1230-96/2
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BHEL, Hardwar 6.1-1230-96/4
BHEL, Hardwar 6.1-1230-96/5
BHEL, Hardwar 6.1-1230-96/6
BHEL, Hardwar 6.1-1230-96/7
BHEL, Hardwar 6.1-1230-96/8
BHEL, Hardwar 6.1-1230-96/9
BHEL, Hardwar 6.1-1230-96/10
 Steam Turbine Shaft Seal Steam System MAW
Description System Description
ACOMPANYING SYSTEM DIAGRAMS ƒ Leakage steam system
Dwg nos. 1-13100-Q8121 & 3-13100-Q8122 on Sheet nos. 6.1- Butterfly valves in the leakage steam lines of the shaft
1240-96/4 & 6.1-1240-96/5 Process seals
Engineering function of the shaft seal steam system - 1st casing front MAW82 AA501
st
The process engineering function of the shaft seal steam - 1 casing rear MAW81 AA501
nd
system is to prevent the escape of shaft seal steam from the - 2 casing front MAW83 AA501
turbine to the atmosphere and the ingress of air into the turbine - 2nd casing rear MAW84 AA501
rd
and the condenser. The provision also made for drawing the leak - 3 casing front MAW85AA501
off steam from U-Ring, in case of failure, the spindles of Main - 3rd casing rear MAW86AA501
Steam Stop & Control valves, HRH Steam Stop & Control Valves Isolation valve upstream of the MAW80AA001
and LPBP Stop & Control Valves under leak off steam system. Seal steam condenser MAW80AC001
The subsystems of the shaft seal steam system have the Isolation valve upstream of MAW80AA011
following functions: leak off steam condenser exhauster 1
Leak off steam condenser MAW80AN001
exhauster 1
ƒ Seal and leak off steam system Isolation valve upstream of MAW80AA012
- Exhausting of leadoff steam from shaft seals having a Leak off steam condenser exhauster 2
positive internal pressure and from valve stem seals. Leak off steam condenser MAW80AN002
- Supplying the shaft seals having a sub-atmospheric exhauster 2
internal pressure with seal steam. Valve upstream of seal steam MAW10AA011
- Admission of excess leak off steam to the condenser. Supply control valve
ƒ Leakage steam system The control of this valve is temperature dependent
and the valve is open as long as the temperature of
- Exhausting of leakage steam from the leakage steam
steam before this valve is more than pre-set value.
chambers of the shaft seals.
Description and function of the components of
- Condensing of leakage steam in the seal steam
the shaft seal steam system
condenser.
The components of the shaft seal steam system
- Exhausting of leakage steam to atmosphere during
and their function described in the following.
faulted seal steam condenser operation.
- Extraction of air from the seal steam condenser using ƒ Valve upstream of the seal steam control valve
one of the leaks off steam condenser exhausters. MAW10AA011
ƒ Leakage steam condensate system The control of this valve is temperature dependent
- Exhausting of leakage steam condensate to the waste and the valve is open as long as the temperature of
water system. steam before this valve is more than pre-set value.
ƒ Seal steam control valve
Components of the shaft seal steam system MAW10AA001
In addition to piping, monitoring equipment and manually
The seal steam control valve positioned by the shaft
operated valves, the following equipment and valves are seal steam controller. The valve opens if the amount
necessary for operation of the shaft seal steam system: of leak-off steam is not sufficient to satisfy seal
steam requirements. During start up & shut down
ƒ Seal steam supply System and at low load operation range up-to 35%, steam
Seal steam control valve MAW10AA001 from auxiliary source supplied to system through seal
Motor-operated bypass valve MAW15AA001 steam control valve. The pressure in the header is
Valve upstream/downstream of seal steam control valve maintained at slightly higher than the atmospheric
-upstream of seal steam MAW10AA010 pressure at a pre-set value (1.023 ate) by seal steam
Control valve pressure controller. An electrical pressure controller
-downstream of seal steam MAW10AA512 connected to a valve lifts controller acts on the
Control valve actuator of the seal steam leak-off and supply valves.
ƒ Leak off steam discharge system Each valve is equipped with an electro-hydraulic
Leak off steam control valve MAW50AA001 actuator. If the electro hydraulic actuating fails, the
Motor-operated bypass valve MAW55AA001 seal steam leak-off and supply valves may be moved
Valve upstream/downstream of leak off control valve to required position with the help of built-in manual
- Upstream of leak off steam MAW50AA010 of control pump.
valve ƒ Motor-operated bypass valve MAW15AA001
- Downstream of leak off steam MAW50 AA512 The bypass valve can be opened from the control
control valve room if the seal steam control valve is not able to
satisfy seal steam requirements, e.g., as a result of
faulted seal steam control valve operation, or if the
steam pressure upstream of seal steam inlet valves

BHEL, Hardwar 6.1-1240-96/1

BHEL, Hardwar 6.1-1240-96/2
 ƒ Keeping the seal steam line upstream of the
seal steam control valve warm

The warm-up valve used to keep the seal steam line

upstream of the seal steam control valve warm.
Opening and closure of the warm-up valve is
dependent on the steam temperature upstream of the
seal steam control valve.
ƒ Exhausting the leakage steam to
atmosphere
Under normal operating conditions, the leakage
steam condensed in the seal steam condenser.
If the seal steam condenser is not available, the
leakage steam must be exhausted to
atmosphere.

BHEL, Hardwar 6.1-1240-96/3

6.1-1240-96-4
6.1-1240-96-5
 Steam Turbine
Description
Construction
The LP turbine casing consists of a double-flow unit and
has a triple shell welded casing.
The outer casing consists of the front and rear walls, the
two lateral longitudinal support beams and the upper part.
The front and rear walls as well as the connection areas of
the upper part are reinforced by means of circular box
beams.
The outer casing is supported by the ends of the
longitudinal beams on the base plates of the foundation.
BHEL Hardwar
LP Turbine
Casing
Steam Admission
Steam admitted to the LP turbine from the IP
turbine flows into the inner casing (3; 4) from both
sides through steam inlet connection before the LP
blading.
Expansion joints are installed in the steam piping to
prevent any undesirable deformation of the casings
due to thermal expansion of the steam piping.
6.1-1310-01/1

Inner Casing
The double-flow inner casing which is of double-shell
construction consists of the outer shell (2; 5) and the inner
shell (3; 4).
The inner shell is attached in the outer shell with provision
for free thermal movement.
Stationary blading is carried by the inner shell.
The stationary blade row segments of the LP stages are
bolted to the outer shell of the inner casing.
The complete inner casing is supported by the longitudinal
support members of the outer casing lower half, in a
manner permitting free radial expansion concentric with the
shaft and axially from a fixed point (Fig, 2).
Support and Centering of the Outer Casing
The outer casing of the turbine is carried on the side
members who rest on plates grouted into the foundation
alongside the turbine.
BHEL Hardwar
Two guides are attached to the longitudinal beams
of the outer casing lower part (7) below the center
inlet as shown in detail F (see Figs. 2; 3) to prevent
axial displacement of the outer casing.
The outer casing (1; 7) expands axially in both
directions from this point with the longitudinal
beams.
The keys (12) in the casing guides allow radial
expansion.
The vertical center plane guides for the casing are
at the lowest point of the circular box beams, which
stiffen the front and rear end walls (See detail A Figs.
1; 4).
This location allows for radial and axial expansion of
the casing.
Two rectangular plates (16) are welded at right
angles to the inner surface of each box beam.
A guide block (15) rigidly attached to the foundation,
fits between these plates to locate the casing.
Keys (14) are provided between the block (15) and
the plates (16) to facilitate accurate vertical alignment
of the casing.
6.1-1310-01/2
Attachment of Inner Casing in LP-Outer Casing
In the horizontal plane the four brackets of the complete
inner casing are supported by shims (19) placed in the
plates (22) bolted to the longitudinal support beam of the
outer casing.
The two brackets (Fig. 6) towards the IP turbine end are
fixed in the axial direction by fitted keys (20) as compared
to the brackets at the generator end (Fig.7) which are free
to move due to thermal expansion.
The spacer bolts (23) prevent lifting of the inner casing.

In the horizontal plane, the upper half on the inner

Spacer bolt hole clearance is provided to permit the inner
casing to expand horizontally on shims (19) of the fixed
support in the transverse direction relative to the axis of the
machine and on the shims of the non-fixed support in the
transverse and longitudinal direction relative to the machine
axis.
Since vertical thermal expansions originate at about the
level of the horizontal joint, concentricity of the inner casing
with the shaft is ensured in this plane.
As shown in Fig. 5 two casing guides are located at the
lower half (5) of the outer shell to prevent any transverse
displacement of the inner casing from the centerline of the
turbine.
Radial and axial expansion is permitted by fitted keys (18)
in these casing guides
Attachment of Inner Shell
The inner shell (3; 4) is attached to the outer shell (2; 5) in
the horizontal plane and is guided axially in the vertical
plane (Figs. 11; 12).
shell is supported by four brackets resting on support
plates (26;27) located at N and 0 of the joint face of
the lower half of the outer shell (Figs. 8;9).
Four brackets of the inner shell lower half that are
covered by the joint face of the outer shell prevent
lifting of the inner shell.
Small clearance between covers plates (25; 28) and
joint face of the outer shell permits the inner shell to
freely expand in the horizontal direction at the
support points.
Thermal expansion in the vertical plane originates at
the joint face.
This ensures concentricity of the inner shell with the
shaft in the vertical plane.

BHEL Hardwar 6.1-1310-01/3

The brackets of the inner shell, lower half (4) project into
recesses of the outer shell lower half (5).
These brackets are provided with clearance on all sides
and serve to align the inner shell lower half in the outer
shell lower half by the use of lifting bolts during erection.
Fitted keys (24) are located on each side of the brackets at
the IP turbine end of the LP casing.

As shown in Fig. 8 these keys locate the inner shell in the

axial direction as thermal expansion in the axial direction
originates from these two points.
In the vertical plane there are four centering pins (31) which
are guided in bushings (30) Fig. 10

The ends of the centering pins are fitted in keys (32) which
slide in axial grooves of the inner shell.
This arrangement permits axial displacement of the inner
shell relative to keys (32) and vertical displacement along
the axis of the centering pins (31).
The transverse displacement relative to the axis of the
turbine is prevented by the keys.
Transverse thermal expansion relative to the axis of the
turbine originates from these keys so that concentricity of
the inner shell with the shaft is also maintained in this
plane.
Bushings (30) have an eccentric bore and by turning those
during erection transverse alignment of the inner casing are
adjusted. Grub screws lock the bushings in place after
alignment has been completed.

BHEL Hardwar 6.1-1310-01/4

 Steam Turbine
Description
Atmospheric relief diaphragms are provided in the upper
half of each LP exhaust end section to protect the turbine
against excessive pressure.
In the event of failure of the low vacuum trips the pressure
in the LP turbine exhaust rises to an excessively high level
until the force acting on the rupturing disc (1) ruptures the
breakable diaphragm (2) thus providing a discharge path for
the steam.
The diaphragm consists of a thin rolled lead plate.
BHEL Hardwar
Atmospheric Relief Diaphragm
To insure that the remnants of the diaphragm and
rupturing disc are not carried along by the blow-off
steam a cage with brackets (5) is provided.
As long as there is a vacuum in the condenser the
atmospheric pressure forces the breakable
diaphragm and the rupturing disc against the
supporting flange (3).
6.1-1320-00
 Steam Turbine
Description
The drum blading stages 1 to 5 of the double flow LP
turbine are of advanced type with 50% reaction.
The stationary blades are located in the inner shell of the
inner casing and form the inlet group of blading of the LP
turbine.
The LP exhaust stages following these blades are
described in detail in a separate section.
The stationary blades (4) have T -roots.
They are fitted in the inner casing (1) in grooves of
corresponding design where they are secured by caulking
material.
Special locking blades are used at the horizontal joint.
BHEL Hardwar
LP Turbine
Drum Blading
Secured by means of grub screws the moving blades
(3) have T -roots which are inserted into the
corresponding grooves in the LP rotor (6) and
secured by caulking material (5).
The insertion slot is closed by means of a locking
blade which is fixed by means of grub screws.
All T -root blades have integral shrouds which upon
installation form a continuous shroud.
In order to keep the blade tip losses low, replaceable
sealing strips (2) are caulked into the inner casing (1)
and the turbine rotor (6).
6.1-1330-02
 Steam Turbine LP Turbine
Description LP Stages

The last three stages of the LP turbine blading are

designed as reaction stages.
The stationary blade rows are made into a semicircular
segment by welding the inner rings, blades, and outer rings
together and bolting them to the inner casing (12).
The last two stationary rows consist of hollow blades.
Slots are provided in the blade surface of the last
stationary row.
Through these slots any water passing over the surface
of the blades may be drawn away to the condenser.
The inner rings form a continuous shrouding strip after
assembly with the stationary blade segment.
Moving blades (3, 5, and 9) with curved fir-tree roots
(view “X”) are fixed in the axial grooves of the turbine shaft
(10) by means of clamping piece (6).
These blades are secured against axial movement by
locking strips (7), which are inserted into a circular groove
milled in the shaft.

In order to reduce blade-tip losses at the stationary

blades (4, 8, 11), sealing strips (1) are caulked into the
turbine shaft (10).
Opposite the sealing strips, shroud rings of the
stationary blades have cylindrically turned surfaces.
This arrangement permits favorable radial clearance to
be attained.

Note:
During erection or overhaul, don’t try to rotate the rotor
by applying force on moving blades having fir tree
roots. It can loosen the blades.

BHEL Hardwar 6.1-1340-01

 Steam Turbine LP Turbine
Description Shaft Seals

Function
The function of the axial shaft seals situated between the
bearing casings and the LP exhaust casing is to seal the
inner space of the LP exhaust casing against atmospheric
pressure at the passages through the shaft.
Gap Sealing
The sealing effect between the moving and stationary
parts of the turbine is achieved by means of sealing strips
(4) which are caulked into the individual seal rings (2),
The prevailing pressure is reduced according to the
labyrinth principle by conversion into velocity with
subsequent turbulence in many sections.

When the turbine is started from the cold or semi-

warm state, the sealing rings naturally heat up more
quickly than the steam seal casings.
They can then expand radially without hindrance
against the centering force of the helical springs.
Steam Spaces
Steam spaces are provided within the shaft seal.
When the plant is started up and in operation, sealing
steam enters space “Q” to prevent air penetrating the
space, which is under a vacuum.
The slight amount of steam that passes the center
seal ring is drawn off from space “R” into the seal
steam condenser.

Sealing Rings
The sealing rings (2), the number of which depends on the
pressure existing in the turbine, are split into several
segments as shown in section A-A and arranged in T-
shaped annular grooves in the steam seal casing (1) so that
they can move radically.
Several helical sprir1gs (3) force each segment against a
shoulder and hold it in this position.
This permits the correct clearance in the sealing gaps.
Should rubbing occur, the segments concerned retreat?
The frictional heat developed by the thin strips (4) due to
this light pressure is so slight that it cannot cause
deformation of the rotor (5).

BHEL Hardwar 6.1-1350-00

 Steam Turbine LP Turbine
Description Rear Bearing Pedestal

Arrangement

The bearing pedestal is situated between the LP turbine

and generator. Its function is to bear the weight of LP rotor.

The bearing pedestal contains the following turbine

components:

Bearing pedestal vibration pick-up

Journal bearing
Shaft position measuring device
Shaft vibration pick-up

Connection of Bearing Pedestal and Foundation

The bearing pedestal is aligned on the foundation by

hexagonal screws that are bolted into the bearing pedestal.

To overcome friction resistance, balls are arranged under

the heads of these hexagonal screws.

After alignment the space under the bearing pedestal is

filled in with special nonshrink grout, resistant to expansion
and contraction.

The bearing pedestal is also connected to the foundation by

means of anchor bolts.

BHEL, Hardwar 6.1-1360-01

 Steam Turbine Journal Bearing
Description

Construction
The function of the journal bearing is to support the
turbine rotor.
Essentially, the journal bearing consists of the upper
and lower shells (3, 6), bearing cap (1) torus piece (7), and
cylindrical support (14) and the spacers (10, 19).
The bearing shells are provided with a babbitt face.
Babbitt surface of the lower bearing shell has been
specially machined to improve the stability of the bearing.
Any additional scraping on the babbitt surface is neither
necessary nor permissible. Both bearing shells are fixed by
means of taper pins and bolted together.
In order to prevent the bearing from exerting a bending
moment on the rotor (5).
It is pivot -mounted in the cylindrical support (14).
For this purpose, the torus piece (7) with shims (12, 13)
is firmly bolted to the bearing shell (6).
A projection in cap (1) with key (9) fits into a
corresponding groove in the bearing shell (3) and prevents
vertical movement of the bearing shells.
Centering of the bearing shells in the vertical plane is
achieved by means of keys (8).
The bearing shells are fixed laterally by the
spacers (10, 15).
Each spacer is held in position in the bearing
pedestal (11) by two lateral collars.
The temperature of the bearing bodies is
monitored by the thermocouples (15) as shown in
section C-C
Oil Supply
Lubrication oil is admitted to the bearing shell
from one side.
From where it flows to the oil spaces milled into
the upper and lower shells at the horizontal joint that
are open to the rotor end.
Oil from the oil space machined in the babbitting
is carried through the rotor (5) and emerges from the
bearing shell from where it is collected in the oil
return cowling (4) and drained into the bearing
pedestal (11).

1 CAP 5 TURBINE SHAFT 9 KEY 13 SHIM

2 TAB WASHER 6 LOWER BEARING SHELL 10 SPACER 14 CYLINDRICAL
3 UPPER BEARING SHELL 7 TOROUS PIECE 11 BEARING PEDESTAL SUPPORT
4 OIL RETURN COWLING 8 KEY 12 SHIM 19 SPACER

BHEL Hardwar 6.1-1370-04/1

Jacking Oil

As shown in section B-B threaded nozzles (17) are

arranged at the lowest point of the lower bearing shell (6)
through which high pressure oil is supplied during start-up.

This high-pressure oil relieves the bearing to overcome

breakaway torque and prevent dry friction, thus reducing
the torque requirements of the hydraulic turning gear.

The lift oil flows into the above mentioned threaded

nozzles (17) through passages in the lower bearing shell
(6).

A seal (18) prevents high-pressure oil from penetrating

the space between threaded nozzle and ring (16) and thus
from lifting the babbitt.

Any leakage oil can drain through passages in the

bearing shell below the ring.

Removal of bearing shells

Not only the upper (3) but also the lower bearing shell
(6) can be removed without the removal of the shaft (5).

To enable this to be done, the shaft is lifted slightly by

means of the lifting device but within the clearance of the
shaft seals.

The lower bearing shell can then be rotated to the top

position and removed.

BHEL Hardwar 6.1-1370-04/2

 Steam Turbine Operation of the Turbine
Description Introduction

In the Operation section of the manual the steps of

startup, power operation and shutdown of the turbine
are given.
Also, the activities that must be performed during
shutdown to maintain operability are described.
Temperature margins are indicated on CRT during all
Basic knowledge of operation and monitoring of
turbines are taken for granted. Further knowledge operating conditions.
The turbine can be operated in line with three different
gained during the commissioning period gives the
operating staff a more complete understanding of stress limits or operating modes viz. Fast, Normal and
turbine generator operation. Slow, which are selected by operator action. To
safeguard shaft material, switch over from slow to
Role of Turbine Stress Controller (TSC):- normal or fast mode is not permitted until the
temperature in shaft center line exceeds 100 °C.
The function of TSC is to continuously monitor and
Beyond this point, it is possible to switch over from S
evaluate the main components of turbine viz. Main
(slow) to N (normal) mode or from N to F (fast) mode
steam stop and control valve, HP rotor, HP casing and
at any time. However. Before the TSC enables switch
IP rotor in respect of their material limits and fatigue
over from F mode to back to N mode or from N to S
life. It monitors the operational non steady state
mode, it automatically checks whether there will still be
thermal stresses affecting the steam admission area,
a positive temperature margin of 15 °C in the new
and the turbine dedicated computing channels perform
mode once this change over has been affected.
on going calculations of material fatigue. This allows
turbine operation within a set envelope against various
permitted stress types or loading combinations.

BHEL, Hardwar 6.2-0001-01

 Steam Turbine
Operation Control
The efficiency of turbine and functioning of its
components depend, among other things, on whether
the steam quality and the properties of the operating
fluids fulfil the requirements listed in the Description
section of this manual. Particular care should always
be taken during startup that the purity and the physical
& chemical properties comply with the turbine
manufacturer’s guidelines.
Steam Purity:
The steam purity must comply with the guideline on
‘Steam Purity’ (1) before startup and power operation
is begun.
Blade deposits reduce the efficiency. Deposits can
only be removed by time-consuming processes [2] and
occur during power operation when normal values are
exceeded.
Immediate corrective action must be taken to restore
the required steam Quality specified in the guideline
[1].
BHEL, Hardwar
Specification of Steam, Oil and
Fluid
Turbine Oil:
Oil Specifications guideline [3] lists the
requirements for the operating fluid. Also
maintenance instruction on Oil Care [4] should be
followed. Regular sampling and laboratory checks
will indicate that the turbine oil complies with the
specifications.
The purity (freedom from liquid and solid impurities),
air-release properties and foaming characteristics of
the oil are important to the functioning of the turbine
generator unit’s components.
Control Fluid:
The guideline ‘Control Fluid’ [5] has the requirements
for this operating fluid. The maintenance instruction
‘Care of Control Fluid’ [6] should also be followed.
Regular sampling and laboratory checks will indicate
that the control fluid complies with the specifications.
The purity (freedom from liquid and solid impurities),
neutralization coefficient as a characteristic for aging,
air-release properties and foaming characteristics of
the fluid are important to the functioning of the turbine
generator unit’s components.
Also refer to the following sections
[1] 6.1-0120 Steam Purity Required Values
[2] 6.3-0070 Steam Washing of Turbine
[3] 6.1-0310 Oil Specification
[4] 6.3-0080 Oil Care
[5] 6.1-0140 Fire Resistant Fluid
[6] 6.3-0082 Care of Control Fluid
6.2-0002-00
 Steam Turbine Testing of Turbine Components
Operation General

Introduction:- Countermeasures for Abnormal

The operational reliability and availability of a
turbine is assured only if all the vital components and
monitoring equipment for operation are in the specified
condition at all times.
This applies particularly to:
„ Controllers
„ Protective devices
„ Safety devices
„ stop and control valves and other important turbine
valves
„ monitoring equipment
The unit’s operating parameters can provide
important information on the condition and reliability of
the turbine unit and its systems,
Testing Intervals:-
The following recommendations, for time Intervals
between tests have been compiled, on the basis of
experience gained by the turbine manufacturer and the
operators.
Conditions:-
It is recommended that all abnormal conditions
detected in the course of testing be eliminated by the
countermeasures specified in the remedial action and
maintenance instructions in the turbine manual.
In some cases the desired condition may be
restored sooner or prevented from deteriorating if the
testing intervals are shortened. Use of this opportunity
is recommended. Shorter testing intervals also make it
easier to detect and monitor any progressive
deterioration in the condition of component.
On this basis, the optimum timing for the necessary
remedial actions may be determined in the light of
other factors, requiring consideration.
Performance of Tests:-
Tests are generally performed by the operator’s
properly qualified plant personnel.
As a rule the performance testing should be
executed immediately after maintenance or overhaul
activities, such as major inspection, in the presence of
concerned qualified personnel form BHEL.

BHEL, Hardwar 6.2-0020-00

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals - Controllers

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Turbine Governor
- Function 1 X X X
- Setting X X

Load Shedding Relay

- Function X X
- Setting X X

Bypass Controller
- Function 3 X X X
- Setting X X

Seal Steam Controller

- Function X X

Fluid Temperature
Controller
- Function
X X
Oil Temperature
Controller
- Function X X

BHEL, Hardwar 6.2-0021-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals –
Automatic Turbine Tester

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Automatic Turbine
Tester for Protective
Devices

- Functioning of remote 2 X X X
trip solenoid
- Functioning & setting
of over speed trips
- Functioning & setting
of hydraulic low
vacuum trip

BHEL, Hardwar 6.2-0022-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals –
Automatic Turbine Tester

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Automatic Turbine
Tester for Stop & Control 2 X X X
valves
- Free movement of
stop valves
- Free movement of
control valves

BHEL, Hardwar 6.2-0023-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals- Protective Devices

Component Test Cycle Plant

- Type of test after start -Up Status

After shutdown>1month

During or after overhaul

shutdown
Monthly

running
Weekly

Yearly
Main Trip Valves
- Functioning and breakaway pressure x x x

Overspeed Trips
- Functioning and setting during testing with x x x
Hydraulic test signal transmitter
- Functioning and setting during testing by Overspeed 1 x x

Thrust Bearing Trips

- Functioning x x

Hydraulic Low Vacuum Trip

- Functioning and setting x x

Electrical Low Vacuum Trip

- Functioning and setting 6 x x

Bypass Mode Low Vacuum Trip

- Functioning and setting x x

Reverse Power Protection

- Functioning at each shutdown 1 x x x
- Functioning and setting x x

Oil Starvation Trip

- Functioning and setting 1 x x

Turbine Fire Control System

- Functioning 1 x x x
- alarms 1 x x x

Alarms from Protective Devices

.Functioning and setting of binary signal transmitters 3 x x

BHEL, Hardwar 6.2-0024-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals-Safety Devices

Component Test Cycle Plant

- Type of test after start Up Status

After shutdown>1 month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Safety Valves
- Functioning and set pressure x

Rotary Pump Relief Valves.

- Functioning and set pressure x x

Sub loop Control for Auxiliary and Emergency Oil Pumps

- Functioning 3 X* x x
- Setting of pressure switches x x

Automatic Changeover Units for Control Fluid Pumps

- Functioning 3 X* x x
- Setting of pressure switches x x

Extraction NRV Checks

- Functioning 1 x x
- Setting of differential pressure switches x x x

* At each shut-down and startup

BHEL, Hardwar 6.2-0025-01

 Steam Turbine Turbine Systems Testing
Operation Testing Intervals- Valves

Component Test Cycle Plant

- Type of test after start -Up Status

After shutdown>1month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Stop Valve
- Free movement x x x
Using starting and load limiting device.
Test valve or trip actuation
- Breakaway pressure x x
- Leak tightness at each startup x x x

Control Valve
- Free movement x x
Using starting and load limiting device.
Test gear or trip actuation
- Leak tightness 1 x x
(In conjunction with test of reverse power protection at
Each shutdown)
- Free movement x x
(Observe control valves lift at each load change) 1 x

Extraction Valves
- Free movement 2-4 x x x
By observation of position indicators

Vacuum Breaker
- Functioning at each shutdown 1 x x x

CRH NRV
- Free movement 2 x x x
By operating pushbutton on desk

BHEL, Hardwar 6.2-0026-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals – Monitoring Devices

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly
Alarms
- functioning X X

Binary Signal
Transmitters X X
- functioning and setting

Speed Indicators
Temperature Gauges
Expansion Measuring
Devices
Vibration Measuring
Devices
liquid Level Measuring
Devices
Valve lift Transducers
- accuracy of indication 3 X X X

BHEL, Hardwar 6.2-0027-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals- Operating Parameters

Component Test Cycle Plant

- Type of test after start -Up Status

After shutdown>1 month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Steam Pressures
Steam Temperatures
Steam Mass Flow Rates
Casing Temperatures
Bearing Metal Temperatures
Expansion
Vibration
Liquid Levels
Oil Pressures
Oil Temperatures
Control Fluid Pressures
Control Fluid Temperatures
- Recording of operating values for long term monitoring 3 x x
Purposes

BHEL, Hardwar 6.2-0028-01

 Steam Turbine
Operation
Introduction:-
Startup of the turbine and auxiliary systems must
always be performed to ensure operational reliability
and economy.
Startup is a phase where almost all operating values
are subject to change. Monitoring of transient
operating state by monitoring instrumentation
demands close attention.
It is very important that all control operations are
always performed in the recommended sequence.
To fulfill these requirements, startup schematics are
prepared to show all control operations and monitoring
criteria for the turbine and its auxiliary systems.
BHEL, Hardwar
Starting the Turbine
The startup schematics of the turbine manual are
compiled so that with their help the turbine generator
unit can be started up from the control room by
operating the control devices by watching the analog
displays.
The schematics have added instructions that must be
followed during startup or operation of the system.
Instrumentation and control functions are given in
ATRS functional schematics. To maintain operational
reliability and economy, certain tests must be
performed during all phases of turbine operation. This
furnishes information on the condition of turbine
generator components.
Since some tests must be carried out before or during
the startup phase, a list of the tests and their intervals
[1] given at the beginning of the system- startup
schematics.
6.2-0110-01
 Steam Turbine Startup and Shutdown Diagrams
Operation Symbols

The symbols commonly used in other operating Values recorded in the logs and from the actual
documents are used for the startup and shutdown settings of the binary signal transmitters.
schematics.
Insofar as symbols with indices are used instead of
Normally, the check back from the execution of a values, only the values recorded in the logs shall be
switching or control operation also constitutes the used.
enabling criterion for the following switching or operating
step.
Symbols used:-
If there are other criteria to be fulfilled before a step can
be enabled, these criteria are listed prior to the first or + Interrogation from the control room
next step, as the case may be. = interrogation from the local control
station
Unless otherwise stipulated. The criteria are “and” gated,
– Interrogation at equipment
i.e. all criteria must be fulfilled.
(N) + manual switching operation from
An “or” gate between two or more criteria indicates that control room
one of several criteria must be fulfilled. (N) = manual switching operation from
local control station
The symbols and rules apply to all schematic (N) - manual switching operation at
representations of control operations contained in the equipment
turbine manual. ** switching operation triggered
automatically (can, however, also be
References to further explanations are identified in the performed manually from control
schematics by the number of the instruction concerned. room)
The operating values given in the schematics are nominal * switching operation triggered
values and may deviate from the actual automatically (can, however. also be
performed manually from local
control station)
* switching operation triggered
automatically (manual actuation not
possible)

BHEL, Hardwar 6.2-0111-00

 Steam Turbine Start of Turbine/Generator
Operation Startup Diagram (General)

(01) + TURBINE/GENERATOR START UP PREPARE REF. TO 6.2-0133

+ PREPARATION FOR START UP COMPLETED
(02) + EXTERNAL SYSTEMS READY FOR OPERATION CHECK
CIRCULATING WATER FOR CONDENSER AVAILABLE
COOLING WATER FOR COOLERS AVAILABLE
AUXILIARY STEAM AVAILABLE
DEMINERALIZED WATER SUPPLY AVAILABLE
CONDENSATE SYSTEM READY FOR OPRN.
VACUUM PUMP READY FOR OPRN.
THE EXTERNAL SYSTEMS DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAMS OF SYSTEMS.
INSTRUCTIONS OF EXTERNAL SYSTEMS MUST
COMPLY WITH TURBINE OPERATION.
+ EXTERNAL SYSTEMS READY FOR OPRN.
(03) + OIL SYSTEM AND TURNING GEAR START REF. TO 6.2-0130
START OF OIL SYSTEM APPROX.6 HOURS
PRIOR TO TURBINE START.EXTEND
TIME IN ADVANCE OF TURBINE START IF
OIL TEMPERATURES ARE EXTREMELY LOW.
WITH FGA (OIL SUPPLY)
OR
MANUAL OPERATION AT OPER. CONSOLE
FGA=FUNCTIONAL GROUP AUTOMATIC
+ SHAFT TURNS
– CF-RECONDITIONING-PLANT AND HEATERS IN OPERATION
PRIOR TO CONTROL FL PUMP OPERATION THE
CONTROL FLUID TEMPERATURE SHOULD BE > 20°C
TEMP. RATE DURING HEATER OPERATION 1-2° K / HOUR
START OF OPERATION OF RECONDITIONING
AND HEATERS IN ACCORDANCE WITH INITIAL
TEMPERATURE AND HEATING RATE.
OPERATE RECONDITIONING PLANT CONTINUOUSLY
IF NEUTRALISATION NUMBER TENDS TO INCREASE
+ TEMPERATURE IN CONTROL FLUID TANK > 20°C
(04) + CONTROL FLUID SYSTEM START REF. TO 6.2-0135
WITH FGA (CONTROL FLUID SYSTEM)
OR
MANUAL OPER.AT OPER.CONSQLE
+ CONTROL FLUID SYSTEM IN OPERATION
(05) + CONDENSING PLANT START REF.TO 6.2-0140
TIMING OF CONDESING-PLANT START MUST
AGREE WITH TIMING OF FIRST STEAM ENTERING
THE CONDENSING PLANT
THE CONDENSING PLANT DOES NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAM OF SYSTEMS.
INSTRUCTIONS OF THE MANUFACTURER OF THE
CONDENSING PLANT MUST AGREE WITH TURBINE
OPERATION.
+ CONDENSATE PUMPS ON
WITH FGA (CONDENSING PLANT)
OR
MANUAL OPER.AT OPER.CONSOLE

BHEL, Hardwar 6.2-0112-00/1

 Steam Turbine Start of Turbine/Generator
Operation Startup Diagram (General)

+ VACUUM PUMPS ON

WITH FGA (CONDENSING PLANT):

OR
WITH SLC (AIR REMOVAL)
OR
MANUAL OPER, AT OPER, CONSOLE

+ SEAL SYSTEM SUPPLY ON

WITH SLC (SEAL STEAM)
OR
MANUAL OPER, AT OPER, CONSOLE
+ VACUUM < P AMB
+ SEAL STEAM PRESSURE > P AMB
(06) + STATE OF OPERATION OF STEAM GENERATOR CHECK
+ STEAM GENERATOR IN OPERATION
+ CRITERIA FOR BYPASS OPERATION FULFILLED

(07) + START OF BYPASS OPERATION OBSERVE REF. TO 6.2-0150

(08) + MAIN STEAM (MS) LINE WARM UP REF. TO 6.2-0160
WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ MAIN STEAM (MS) LINE WARMED UP
(09) + CRITERIA FOR WARMING UP TURBINE CHECK

(10) + TURBINE WARM UP REF. TO 6.2-0160

WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ TURBINE WARMED UP
+ CRITERIA FOR SPEEDING UP TURBINE/ FULFILLED
GENERATOR

(11) + TURBINE/GENERATOR TO RATED SPEED SPEED UP REF. TO 6.2-0160

WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ TURBINE/GENERATOR SPEED 3000 RPM
+ CRITERIA FOR SYNCHRONISING FULFILLED

(12) + GENERATOR BREAKER ON REF. TO 6.2-0210

WITH FGA (TURBINE CONTROL)
OR
AUTOMATIC SYNCHRONISER
+ GENARATOR SYNCHRONISED

+ LOADING CRITERIA FULFILLED

(13) + TURBINE/GENERATOR LOAD REF. TO 6.2-0210

BHEL, Hardwar 6.2-0112-00/2

 Steam Turbine Preparation for Startup
Operation Startup Diagram

(01) - PRESERVATION DEVICES REMOVE

- AIR DRYER REMOVED
- CONNECTING FLANGES CLOSED
- AIR OUTLET SOCKETS CLOSED

(02) - INSPECTION OPENINGS CLOSE

MAN-OR HANDHOLES IN
- LP TURBINE
- CROSS AROUND PIPES
- CONDENSER

(03) + VOLTAGE SUPPLY SWITCH ON

+ DRIVES ENERGISED
+ REMOTE CONTROLS ENERGISED
+ CONTROLS ENERGISED
+ MEASURING DEVICES ENERGISED
+ ALARM DEVICES ENERGISED
+ SUPERVISORY EQUIPMENT ENERGISED
+ PROTECTIVE DEVICES ENERGISED
+ TESTING DEVICES ENERGISED

(04) + LIGHT BULBS FOR PANEL AND ALARMS CHECK

+ DEFECTIVE LIGHT BULBS REPLACED

(05) + MEASURING EQUIPMENT READY FOR OPERATION CHECK

+ CHECK OF O-SETTING CARRIED OUT
+ RECORDERS SWITCHED ON
+ RECORDERS TIME ADJUSTED

(06) + LIQUID LEVELS CHECK

+ LEVEL OF CONDENSER NORMAL
+ LEVEL. IN U-LOOPS NORMAL
+ LEVEL OF OIL TANK NORMAL
+ LEVEL OF CONTROL FIUID TANK NORMAL

(07) - FILTERS CLEAN

(08) + TEST PROGRAM (STANDSTILL) CARRY OUT REFER TO 6.3-0061

TESTING INTERVALS OBSERVE REFER TO 6.2-0020

(09) + TEST PROGRAM (STARTUP) CARRY OUT REFER TO 6.3-0030

TESTING INTERVALS OBSERVE REFER TO 6.2-0020

(10) + GENERATOR READY FOR OPERATION CHECK

+ GENERATOR HYDROGEN FILLED
+ SEAL OIL SYSTEM IN OPERATION
+ PRIMARY WATER SYSTEM IN OPERATION
+ OIL VAPOUN EXTRACTION IN OPERATION
+ SUBLOOP CONTROL OIL PL/MPS AND FANS ON
+ IMPORTANT OPER. VALUES GENERATOR NO ALARM
+ LIQUID IN GENERATOR NO ALARM

BHEL, Hardwar 6.2-0113-00

 Steam Turbine Operating Position of
Operation Manually Operated Valves

Introduction:- + Manually in the control room”

* For remote controlled valves only
Most of the manually operated valves in a turbine
generator unit have to be in a defined position prior to • Operating positions:-
startup, and this position must be checked before the unit
goes into operation. Open
Lead Sealing of Valves:- Closed
Mode-Dep. = Mode-dependent (position varies
It is recommended that all valves, the position of which with mode of operation, cannot be
remains unchanged during operation be secured in classed as open or closed).
position with lead seals. All that need then be checked is Perm set = permanently set
that the seals are undamaged. Operational = ready to operate (e, g, control
The valves which are secured with lead seals must be valves)
identified in the check list. /FG = Position cannot be controlled
Symbols and definitions:- manually (controlled by automatic
functional group controls or by
• Measures for the setting of valves medium carried)
- Manually on location
= Manually on the local control console”

BHEL, Hardwar 6.2-0120-00

 Steam Turbine Oil System and Turning Gear
Operation Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES) GENERAL) CHECKED
AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
VALVES BEFORE / AFTER PUMPS OPEN

PERMANENT VENTS OPEN

VENTS OF COOLERS OPEN
VALVES IN FILLING LINES (PERMANENT) OPEN
VALVES BEFORE / AFTER FANS IN SERVICE OPEN
VALVES BEFORE/AFTER STAND BY FANS CLOSED
DRAIN VALVES OF COOLERS CLOSED
DRAIN V ALVES OF TANKS CLOSED
DRAIN VALVES OF FILTERS CLOSED

VALVES IN TEMPORARY V~NTS CLOSED

VENTS OF COOLERS (WATER SIDE) CLOSED
VENTS OF FILTERS CLOSED
VALVES IN TEMPORARY FILLING LINES CLOSED
V ALVES OF PRESSURE TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE PIPES FOR TESTING CLOSED
MULTI WAY VALVES OF COOLERS IN SERVICE
MULTI WAY VALVES OF FILTERS IN SERVICE
THROTTLE VALVES IN VAPOUR LINES ADJUSTED
SPEC. MAN. OPER. VALVES OF SYSTEM CHECKED

AND IN POSITION
THROTTLE VALVES IN JACKING Oil LINES ADJUSTED
RELIEF VALVE OF JACKING Oil SYSTEM ADJUSTED
COOLING WATER VALVES OF STANDBY CLOSED
OIL COLER
DRAIN OF OIL COOLER WATER SIDE OPEN
FILLING LINE OF STANDBY OIL COOLER OIL SIDE OPEN
VALVE POSITION OIL PURIFYING PL! ANT ADJUSTED

+ OIL PUMPS READY FOR OPRN MAV22 AP0 01

MAV23 AP0 01
MAV24 AP0 01
MAV31 AP0 01
MAV32 AP0 01
MAV33 AP0 01
OIL PUMPS ON MANUAL CONTROL SWITCH ON
OR
OIL PUMPS ON SUBLOOP CONTROL SWITCH ON
OIL PRESSURES NORMAL

+ OIL VAPOUR FAN (TURBINE) ON MAV82 AN0 01

OR MAV82 AN002
OR READY FOR OPRN MAV82 AN002
OR MAV82AN-0 01
+ OIL VAPOUR FAN (GENERATOR) ON MKO31 AN0 01
OR MKO32 AN0 01
OR READY FOR OPRN MKO32 AN0 01
OR MKO31 AN0 01
+ SUBLOOP CONTROL OIL VAPOUR FAN GEN. ON ----------------------

BHEL, Hardwar 6.2-0130-02/1

ONE OUT OF TWO VAPOUR FANS OF THE
TURBINE OIL TANK AND THE GENERATOR

MUST BE IN OPERATION AS LONG AS THE

GENERATOR IS FILLED WITH HYDROGEN.

ONE OIL COOLER OIL SIDE IN SERVICE MAV41 BC0 01

OR MAV41 BC002

CHECK OIL COOLER(S) IN SERVICE AT THE

INDICATOR AT THE CHANGE-OVER VALVE(S).
DO NOT ADJUST ANY INTERMEDIATE POSITION
OF CHANGE-OVERVALVE.
 COOLING WATER”’FOR OIL: COOLER(S) AVAILABLE
OPERATION OF THE COOLING WATER SYSTEM
ACCORDING TO SEPARATE INSTRUCTIONS NOT
INCLUDED IN THE TURBINE MANUAL
 SERVICE OIL COOLER (WATER SIDE) FILLED MAV41 BC0 01
AND VENTED OR MAV41 BC002
 COOLING WATER PIPE VENTED
 STAND BY OIL COOLER WATER SIDE DRAINED MAV41 BC0 01
IF THE OIL COOLER IN STANDBY CAN NOT BE AND DRIED OR MAV41 BC002
DRIED BY OIL FLOWING VIA THE FILLING
AND THE VENT LINE, THE OIL COOLER IN STAND
BY MUST BE EXPOSED TO THE FULL FLOW OF
THE COOLING WATER ONCE WEEKLY TO
PREVENT DEPOSITS CAUSING CORROSIVE
ATTACKS TO THE MATERIAL
+ SLC OIL TEMPERATURE CONTROL ON
THE OIL TEMPERATURE CONTROLLER CAN BE
SWITCHED DN/OFF MANUALLY. IT ALSO GETS
ON/OFF COMMANDS FROM FGA ON FULFILLMENT
OF CERTAIN CRITERIA
 OIL LEVEL IN TANK NORMAL MAV10 CL521
COMPARE ACTUAL VALUES WITH STAND-
STILL CONDITION VALUES OF OIL PUMPS.
 OIL FILTERS INCLUDING STANDBY FILTERS READY FOR OPRN
FILTER ELEMENTS CLEANED OR REPLACED
OIL PROPERTIES NORMAL
OIL CLEAR.
NO COLLECTION OF WATER AT THE BOTTOM
OF THE OIL TANK.

(02) + GENERATOR READY FOR OPERATION CHECK

+ MANUAL OPERATED VALVES GENERATOR ADJUSTED
REFER TO GENERATOR MANUAL
+ GENERATOR HYDROGEN FILLED
+ HYDROGEN PURITY > 95% MKG25 CQ0 01
+ SEALL OIL PUMP AIR SIDE ON MKW11 AP0 01
OR MKW21 AP0 01
+ STANDBY SEAL OIL PUMP AIRSIDE OFF MKW21 AP0 01
OR MKW11 AP0 01
AND MKW31 AP0 01
+ SEAL OIL PUMP GAS SIDE ON MKW13 AP0 01
THE DC SEAL OIL PUMP WILL ONLY BE
OPERA TED IF THE AC POWER SUPPLY
IS FAULTY
+ SUBLOOP CONTRSCOF SEAL OIL PPS. ON --------------------

THE SEAL OIL PLANT MUST ALSO BE IN AND -------------------

OPERATION IF THE TURNING GEAR
WILL BE OPERATED EVEN THE GENERATOR
IS NOT FILLED WITH HYDROGEN.

BHEL, Hardwar 6.2-0130-02/2

+ SEAL OIL SYSTEM NO ALARM
+ LIQUID IN GENERATOR NO ALARM -----------------
AND MKA22 CL0 01
AND MKA23 CL0 01
AND MKA23 CL 011

(O3) + CRITERIA FOR BEGIN OF START UP CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE STARTED UP FROM
STANDSTILL
+ AUXILIARY OIL PUMP OFF MAV22 AP0 01
AND MAV23 AP0 01
+ EMERGENCY OIL PUMP OFF MAV24 AP0 01
THE DC EMERGENCY OIL PUMP WILL OPERATE
IF AC POWER SUPPLY FAILS
+ TURNING GEAR OIL VALVE CLOSED MAV51 AA0 01
AND
+ SUBLOOP CONTROL TURNING GEAR OFF MAV51 EE0 01
+ SUBLOOP CONTROL OF AUX OIL PUMPS OFF MAV22 EE0 01
AND
+ SUBLOOP CONTROL EMERGENCY OIL PUMPS OFF MAV24 EE0 01
+ JACKING OIL PUMPS OFF MAV31AP0 01
AND MAV32 AP0 01
AND MAV33 AP0 01
AND
+ SBULOOP CONTROL JACKING OIL PUMPS OFF MAV30 EE0 01
AND MAV33 EE0 01

(04) + FGA OIL SYSTEM START

FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THE FGA
OR
+ OIL SYSTEM MANUAL OPERATED START
.
(05) + AUXILIARY OIL PUMP SWITCH ON MAV22 AP0 01
OR MAV23 AP0 01
+ AUXILIARY OIL PUMP ON MAV22 AP0 01
OR MAV23 AP0 01
WITH FGA OIL SUPPLY

(05/S) + AUXILIARY OIL PUMP 1 ON MAV22 AP0 01

OR AUXILIARY OIL PUMP 1 FAULTED MAV22 AP0 01
+ AUXILIARY OIL PUMP 2 MANUAL OPERATION ON MAV23 AP0 01
+ OIL PRESSURE > 5 KG/CM2 MAV21 CP0 01
+ LUB OIL PRESSURE >1.2 KG/CM2 MAV42 CP0 01
+ OIL LEVEL IN TANK NOALARM MAV1O CL0 01
+ FILTER LUB OIL SYSTEM NO ALARM
DIFERENTIAL PRESSURE ACROSS FILTER NOT HIGH MAV42 CP013
PRESSURE BEHIND FILTER NOT LOW MAV42 CP014
LOCAL INDICATOR NOT INITIATED MAV42 B1001
CHECK STAND BY FILTER BY LOCAL
CHANGE OVER

(06) + TURNING GEAR OIL VALVE OPEN MAV51 AA0 01

+ TURNING GEAR OIL VALVE OPEN MAV51 AA0 01
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL TURNING GEAR SWITCH ON MAV51 EE0 01
+ SUBLOOP CONTROL TURNING GEAR ON MAV51 EE0 01
+ ORWITH FGA (OIL SUPPLY)

BHEL, Hardwar 6.2-0130-02/3

(06/S) + SUBLOOP CONTROL TURNING GEAR ON MAV51 EE0 01
SUBLOOP CONTROL OPENS AND CLOSES THE
TURNING GEAR OIL VALVE DEPENDING ON
TURBINE/GENERATOR SPEED.
TURNING GEAR OIL VALVE (OPEN) < 210 RPM
TURNING GEAR OIL VALVE (CLOSED) > 240 RPM
TURNING GEAR OIL VALVE CLOSES DURING
STARTUP AND OPENS WHEN THE TURBINE
IS COASTING DOWN AFTER SHUTDOWN.
DO NOT SWITCH OFF SUBLOOP CONTROL
AS LONG AS TURBINE IS IN OPERATION TO
MAKE SURE TURNING GEAR CUTS IN IF
TURBINE WILL BE SHUTDOWN.

+ TURNING GEAR OIL VALVE OPEN MAV51 AA0 01

+ OIL LEVEL IN TANK NO ALARM MAV10 CL0 01

(7) + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS SWITCH ON

AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH ON
+ SUBLOOP CONTROL OF AUXILIARY Oil PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY Oil PUMPS ON
OR WITH FGA (OIL SUPPLY)

(07/S) *+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON

AND

+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON

THE SUBLOOP CONTROLS START THE AUXILIARY
OIL PUMPS AND THE DC EMERGENCY OIL PUMPS
DEPENDING ON PRESSURE.
AUXILIARY Oil PUMP 1 < 4.8 KG/CM2 MAV21 CP011
AUXILIARY Oil PUMP 2 < 4.5 KG/CM2 MAV21 CP012
AC EMERGENCY Oil PUMP < 1.1 KG/CM2 MAV42 CP011
DC EMERGENCY Oil PUMP < 1.1 KG/CM2 OR MAV42 CP0 12
SIMULTANEOUSLY ALARMS WILL BE ACTUATED.
LUBRICATING OIL PRESSURE MAV21 CP011
AND/OR
LUBRICATING OIL MAV42 CP011
THE SUBLOOP CONTROLS OF EMERGENCY OIL PUMPS
AND JACKING OIL PUMPS MUST NOT BE SWITCHED
OFF UNTIL THE SHAFT STOPS COMPLETELY.

(08) + SEAL OIL PRESSURE GENERATOR END CHECK

+ SEAL OIL PRESSURE AIR SIDE TURBINE END > P MIN MKW71 CP511
+ SEAL OIL PRESSURE AIR SIDE EXCITER END > P MIN MKW71 CP521
+ SEAL OIL PRESSURE GAS SIDE TURBINE END > P MIN MKW73 CP511
+ SEAL OIL PRESSURE GAS SIDE EXCITER END < P MIN MKW73 CP521
= SUBLOOP CONTROL OF SEAL OIL PUMPS ON
THE SUBLOOP CONTROL OF THE SEAL OIL PUMPS
START THE PUMPS DEPENDING ON SEL OIL PRESSURE.
P MIN ACCORDING TO ACTUAL H2 PRESSURE.

(09) + JACKING OIL PUMP SWITCH ON MAV31 AP0 01

OR MAV32 AP0 01
+ JACKING OIL PUMP ON MAV31 AP0 01
OR MAV32 AP0 01
WITH SUBLOOP CONTROL

BHEL, Hardwar 6.2-0130-02/4

+ SUBLOOP CONTROL OF JACK1NG OIL PUMP SWITCH ON MAV30 EE0 01
AND MAV33 EE0 01
+ SUBLOOP CONTROL OF JACKING OIL PUMP ON MAV30 EE0 01
AND MAV33 EE0 01
OR WITH FGA (OIL SUPPLY)
(09/S)*+ SUBLOOP CO~TROL OF JACKING OIL PUMP ON MAV30 EE0 01
AND MAV33 EE0 01
+ JACKING OIL PUMP ON MAV31 AP0 01
OR JACKING OIL PUMP FAULTED MAV31 AP0 01
+ JACKING OIL PUMP MANUAL OPERATION ON MAV32 AP0 01
OR MAV33 AP0 01
SUBLOOP CONTROL STARTS AND STOPS THE
JACKING Oil PUMP 1 DEPENDING ON
TURBINE/GENERATOR SPEED CRITERIA.
JACKING OIL PUMP 1 ON < 510 RPM
JACKING OIL PUMP 1 OFF > 540 RPM

AND
SUBLOOP CONTROL STARTS THE JACKING OIL
PUMP 2 DEPENDING ON JACKING OIL PRESSURE

BHEL, Hardwar 6.2-0130-02/5

 Steam Turbine Control Fluid System
Description Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES (GENERAL) CHECKED CHECKED

AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
PERMANENT VENTS OPEN
ISOLATING VALVES BEF/BEH CON- OPEN
TROL VALVES
ISOLATING VALVE IN CONTROL FLUID LINES OPEN
VALVES AHEAD OF HYDRAULIC ACCUMULATORS OPEN
VENTS OF COOLERS OPEN
DRAIN VALVES OF COOLERS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN DRAINS OF PIPING CLOSED
VALVES OF PRESSURE-TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VENTS OF COOLERS (WATERSIDE) CLOSED
VENTS OF FILTERS CLOSED
MULTI-WAY VALVES OF COOLERS ADJUSTED
MULTI-WAY VALVES OF FILTERS ADJUSTED

- SPEC.MAN.OPER. .OF SYSTEM CHECKED

AND IN POSITION
COOLlNG WATER VALVES OF CLOSED
STANDBY CONTROL.FLUID COOLER
DRAIN OF STANDBY CF- COOLER OPEN
WATERSIDE

VALVES IN RECONDITIONING PLANT ADJUSTED

+ CF-RECIRCULATION PUMP READY FOR OPERATION MAX91AP001

CF-PUMPS MANUALLY SWITCH ON

OR CF-PUMPS WITH SUBLOOP CONTROL SWITCH ON
CONTROL FLUID PRESSURESS NORMAL

CF-COOLER CF-SIDE IN SERVICE MAX41 BC001

OR MAX41 BC002
CHECK CF-COOLER IN OPERATION
AT LOCAL INDICATOR OF CHANGE
OVER VALVE.
DO NOT ADJUST ANY INTERMEDIATE
POSITION OF CHANGE OVER VALVE

- COOLING WATER FOR CF-COOLER AVAILABLE

- CF COOLER IN OPER. WATERSIDE FILLED MAX41 BC001

AND VENTED OR MAX41 BC002

- COOLING -WATER PIPE VENTED

BHEL, Hardwar 6.2-0135-02/1

 STANDBY CF-COOLER WATER SIDE DRAIND MAX41 BC001
AND DRIED OR MAX41 BC002
IF THE CF-COOLER IN STANDBY
CANNOT BE DRIED BY WARM
CONTROL FLUID FLOWING VIA
THE FILLING AND VENT-LINES
THE CONTROL-FLUID COOLER
IN STANDBY MUST BE FLUSHED
BY FULL WATER FLOW ONCE
WEEKLY TO WASH OUT-DEPOSITS
TO AVOID CORROSION ATTACK
OFTHETUBES.

+ CF- TEMPERATURE -CONTROL ON MAX01 DT001

THE CF- TEMPERATURE CONTROL
CAN ALWAYS BE SWITCHED ON.
IF THE FUNCTIONAL GROUP
AUTOMATIC WILL RECHECK THE
MODE OF OPERATION OFTHE
CONTROLLER OR THE COMMAND
<ON> WILL BE GIVEN THE
CRITERIUM IS FULFILLLED AND
THE PROGRAM CONTINUES.

+ SETPOINT CF- TEMPERATURE CONTROL 50±2º CEL MAX11 CTO01/2

FIX SETPO1NT

+ CF-TEMPERATURE CONTROL VALVE CLOSED MAX41AA001

CF- TEMPERATURE IN TANK <50 º CEL

+ LEVEL IN CONTROL FLUID TANK NORMAL MAX11 CL521

COMPARE ACTUAL VALUES WITH
TEST REPORT VALVES DURING
STAND STILL OF CF-PUMPS

+ CF-FILTERS IN SERV.AND STANDBY

FILTER-INSERT CEANED READY FOR OPERATION
OR
FILTER REPLACED.
FILTER CODE NO REFER TO
SINGLE LINE DIAGRAM.

- CF-RECONDITIONING PLANT READY FOR OPERATION

FILTER EARTH NOT EXHAUSTED.
SAMPLES OF THE CONTROL FLUID
MUST BE TAKEN AND ANALYSED
FOR PROPERTIES OF FLUID.
THE FILTER EARTH MUST BE
REPLACED IN REGULAR INTERVALVES
GIVEN IN INSTRUCTION
6.3-0082 OR IN SPECIFICATION.
MECHANICAL FINE MESH FILTER
NOT EXHAUSED OBSERVE DIFFERENTIAL
PRESSURE WHEN OPERATING
RECONDITIONING PUMP,
EARTH-AND MECHANICAL FILTER
FILLED AND VENTED

BHEL, Hardwar 6.2-0135-02/2

 -START RECONDITIONING PUMP
-VENT FILTERS
-SHUT-DOWN RECONDITIONING PP
- DEAERATION OF CF- TANK READY FOR OPERATION
AIR-FILTER: NO CHANGE IN
COLOUR.
EXHAUSTER FAN <ON>
- CONTROL FLUID PROPERTIES NORMAL
REFER TO 6.3-0082
- CONTROL FLUID HEATER READY FOR OPERATION
(02) + CRITERIA FOR BEGIN OF STARTUP CHECK
IF THE FOLLOWING CRITERIA
ARE FULFILLED THE SYSTEM
WILL BE STARTED-UP FROM
< STANDSTILL>.
+ CONTROL FLUID PUMPS (CF-PUMPS) OFF MAX16AP001
AND MAX16AP002

+ SUBLOOP CONTROL OF CF-PUMPS OFF MAX16EE001

+ SUBLOOP CONTROL CF-HEATERS OFF MAX91EE001

+ CF-RECONDITIONING PUMP OFF MAX91 AP001

+ CF-TEMPERATURE IN TANK < 20 CEL MAX11CTO01A

(03) + SUBLOOP CONTROL CF-HEATERS SWITCH ON MAX91EE001

AND
+ CF-RECONDITIONING PUMP SWITCH ON MAX91AP001
+ CONTROL FLUID HEATER ON MAX91AH001
AND
+ CF-RECONDITIONING PUMP ON MAX91 AP001
THIS STEP HAS TO BE CARRIED
OUT IN DEVIATION FROM THE
FGA-PROGRAM TO SATISFY THE
CRITERION
CF-TEMPERATURE IN TANK > 20 CEL MAX11CT001A
TO START CF. PUMPS
(04) + CF-PUMP. FOR OPERATION PRESELECT MAX16AP001
OR MAX 16AP002
+ CF-PUMP. FOR OPERATION PRESELECTED MAX16AP001
OR MAX16AP002
(05) + CONTROL. FLUID SYSTEM MANUAL START

OR WITH FGA < CONTROL. FLUID SYSTEM>

+ FGA < CONTROL-FLUID SYSTEM> START

OPERATION OF PUSH BUTTONS

REFER TO MANUAL FOR THE FGA-
FGA = FUNCTIONAL GROUP AUTOMATIC

+ CF-TEMPERATURE IN TANK >20CEL MAX11CTO01A

(06) + ONE CONTROL FLUID PUMP SWITCH ON MAX16AP001

OR MAX 16AP002
+ ONE CONTROL FLUID PUMP ON MAX 16AP001
OR MAX16AP002
OR WITH FGA < CONTROL FLUID SYSTEM>

BHEL, Hardwar 6.2-0135-02/3

 (06/S)* + ONE CONTROL FLUID PUMP ON MAX16AP001
OR MAX16AP002

+ CONTROL FLUID PRESSURE > 28 BAR MAX31CP001

+ CONTROL FLUID PRESSURE > 5 BAR MAX41CP001

+ FILTER SUPERVISORY EQUIPMENT NO ALARM

+ LEAKAGE SUPERVISORY EQUIPMENT NO ALARM

- LEVEL IN CONTROL FLUID TANK NORMAL MAX 11 CL621

(07) + SUBLOOP CONTROL OF CF-PUMPS SWITCH ON MAX16EE001

+ SUBLOOP CONTROL OF CF-PUMPS ON MAX16EE001

SUB LOOP CONTROL OF CF-PUMPS
STARTS THE STANDBY PUMP IF
THE CF-PRESSURE BEHIND PUMP
DROPS TO < 28 BAR

(08) + SUBLOOP CONTROL CF-HEATER SWITCH ON MAX91AH001

+ SUBLOOP CONTROL CF-HEATERS ON MAX91AH001
THE SUBLOOP, CONTROL OPERATES
THE HEATER DEPENDENT ON THE
FOLLOWING CRITERIA:
<ON> AT CF-TEMP. IN TANK < 48 CEL MAX1 1CT001
<OFF> AT CF-TEMP. IN TANK > 52 CEL MAX1 1CT001
OR
< ON> AT THE HEATER < 50 CEL MAX91 CT001
<OFF> AT THE HEATER > 65 CEL MAX91CT001
THE HEA TER- TEMPERA TURE-PRO-
TECTION WILL BE INITIATED
AT A TEMPERATURE AT HEATER > 75 CEL MAX91CT002
THE SUBLOOP CONTROL INTER-
LOCKS THE HEATER, IF THE
CF- TEMPERATURE CONTROL VALVE
IS NOT CLOSED.
OR WITH FGA < CONTROL. FLUID SYSTEM>

(08/5)* + SUBLOOP CONTROL CF-HEA TERS ON MAX91 AH001

(09) + CF-RECONDITIONING PUMP SWITCH ON MAX91 AP001

+ CF-RECONDITIONINGPUMP ON MAX91 AP001

OR WITH FGA < CONTROL. FLUID SYSTEM>

(09/5)* + CF-RECONDITIONING PUMP ON MAX91AP001

(10) - FILTER OF RECONDITIONING PLANT VENT

THE STEPS (08) AND (09) MUST NOT

BE CARRIED OUT IF THE CF-
HEATER AND/OR THE RECONDITIONING
PLANT OPERATES PRIOR TO CONTROL
FLUID PUMP OPERATION.

BHEL, Hardwar 6.2-0135-02/4

 Steam Turbine Condensing Plant
Operation Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

MANUAL OPERATED VALVES (GENERAL) CHECKED
AND IN POSITION

ROOT VALVES IN IMPULSE PIPES OPEN

VALVES AHEAD OF TRANSMITTERS OPEN
PERMANENT VENTS OPEN
VALVES IN FILING-LINES OPEN
(PERMANENT)
VALVES BEF/BEH FANS IN SERVICE OPEN
VALVES BEF/BEH STANDBY FANS CLOSED
ISOLATING VALVES BEF/BEH CONTROL VALVES OPEN
VALVES IN TEMPERARY VENTS CLOSED
VALVES IN TEMPERARY FILING LINES CLOSED
VALVES IN BYPASS LINES CLOSED
VALVES OF PRESSURE-TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE-PIPES FOR TESTING CLOSED
VALVES IN DRAIN-LINES CLOSED

- SPEC.MAN.OPER.VVLS .OF SYSTEM CHECKED

AND IN POSITION
VALVE AHEAD OF SEAL-STEAM CONDENSER OPEN
VALVE IN SEAL STEAM LINE TO ATMOSPHERE CLOSED
ISOLATING VALVES BEF/BEH SEAL STEAM SUPPLY LINE OPEN
BYPASS VALVE OF SEAL STEAM SUPPLY LINE CLOSED
BYPASS VALVE OF SEAL STEAM LEAK-OFF VALVE CLOSED
THROTTLE VALVES IN VAPOUR LINES ADJUSTED
VALVES IN AIR SUCTION LINES OPEN
ISOLATING VALVES IN AIR SUCTION LINES CLOSED
VALVES IN AIR SUCTION LINES OPEN
FROM AIRCOOLER OF CONDENSER
VALVES IN SEALING WATER-LINES OPEN
FOR VACUUM VALVES
VALVES IN SEALING WATER-LINES OPEN
FOR VACUUM BREAKER
VALVES IN SPRAY-WATER-LINES OPEN
FOR STAND- PIPES OPEN
VALVES BEHIND VACUUM BREAKER OPEN
LEVEL OF CONDENSER NORMAL
- LEVEL IN U-LOOPS NORMAL
U-LOOPS FILLED BY MEANS OF
+ FILLING VALVES
SET-POINT SEAL STEAM CONTROLLER >P AMB
FIX SETTING

(02) + EXT SYSTEMS READY FOR OPERATION CHECK

+ CIRCULATING WATER OF CONDENSER AVAILABLE

CIRCULATING WATER SYSTEM

DOES NOT BELONG TO THE SCOPE OF

BHEL, HARDWAR 6.2-0140-02/1

 SUPPLY<TURBINE/GENERATOR>
SPECIAL INSTRUCTION FOR
- CIRCULATING WATER PUMPS
- VENTING OF THE CIRCULATING
WATER SYSTEM MUST AGREE WITH TURBINE-
OPERATING AND HAVE TO BE FOLLOWED
NOTE-
MAXIMUM CIRCULATING WATER
SPEED IN CONDENSER TUBES
MUST NOT BE EXCEEDED
+ CONDENSING SYSTEM IN OPERATION
THE CONDENSATE SYSTEM
DOES NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
SPECIAL INSTRUCTION FOR CONDENSING PUMPS
- CONDENSER LEVEL CONTROL
- MINIMUM FLOW CONTROL
- HEATER
MUST AGREE WITH TURBINE-
OPERATING AND HAVE TO BE FOLLOWED
+ VACUUM PUMPS READY FOR OPERATION
THE VACUUM PUMPS
DO NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
OPERATIONAL READINESS ACC.
TO SPECIAL INSTRUCTIONS
+ AUX. SYSTEM FOR SHAFT SEALS AVAILABLE
THE AUX. SYSTEM
DO NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
POSITION OF VALVES AHEAD OF
- SEAL STEAM SUPPLY VALVE
ACCORDING TO SINGLE LINE DIAGRAM
IF APPLICABLE REFER TO
SPECIAL INSTRUCTIONS

(03) + CRITERIA FOR BEGIN OF START UP CHECK

IF THE FOLLOWING CRITERIA
ARE FULFILLED THE SYSTEM
WILL BE STARTED-UP FROM
< STANDSTILL>.
+ TURNING GEAR IN OPERATION REF TO 6.2.0130
+ CONTROL FLUID SYSTEM IN OPERATION REF TO 6.2.0135

+ DRAIN OF SEAL STEAM HEADER CLOSED MAL81AA001

+ SEAL STEAM CONTROL AND OFF
+ WARM UP VALVE SEAL STEAM CLOSED MAW11AA001
AND VACUUM BREAKER CLOSED MAW10AA001
AND SEAL STEAM EXHAUST FAN OFF MAW80AN002
+ VACUUM PUMPS AND OFF
+ AIR SUCT-VALVE PUMP CLOSED

BHEL, HARDWAR 6.2-0140-02/2

 (04) + DRAIN OF SEAL STEAM HEADER OPEN MALe-1AA011
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL DRAINS SWITCH ON MALOOEE001
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
POSITION OF DRAIN VALVE(S)
DEPENDING ON TEMPERATURE
CRITERIA IN HEADER
VALVE(S) <OPEN> STEAM-TEMP. < 120 CEL
VALVE(S) <CLOSEQ> STEAM-TEMP. >150 CEL

(05) + AIR SUCTION EQUIPMENT START

AND
+ SHAFT SEAL STEAM SUPPLY START
OR WITH FGA <CONDENSING PLANT>
+ FGA <CONDENSING PLANT> START
OPERATION OF PUSH BUTTONS
REFER TO MANUAL FOR THE FGA.
FGA=FUNCTIONAL GROUP AUTOMATIC

(06) + SEAL STEAM EXHAUST FAN SWITCH ON MAW80AN001

OR MAW80AN001
+ SEAL STEAM EXHAUST FAN ON MAW80AN001
OR MAW80AN002
AND
+ SEAL-STEAM CONTROL SWITCH ON
+ SEAL-STEAM CONTROL ON
AND
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP CONTR. <SEAL-STEAM> SWITCH ON
+ WARM-UP CONTR. <SEAL-STEAM> ON
SLC <SEAL-STEAM
SLC=SUBLOOP CONTROL
(06/S)* + SEAL STEAM EXHAUST FAN ON MAW80AN001
OR MAW80AN002
AND
(06/S)* + SEAL-STEAM CONTROL ON
AND
(06/S)* + WARM-UP CONTR. <SEAL-STEAM> ON
BY STEAM FLOW THROUGH THE
WARM-UP VALVE THE STEAM-
TEMPERATURE UPSTREAM OFTHE
SEAL-STEAM SUPPLY VALVE
WILL BE INCREASED UNTIL THE
REQUIRED TEMPERATURE WILL
BE REACHED.
THE SEAL STEAM SUPPLY VALVE
MUST NOT BE OPENED UNTIL
THE TEMPERATURE CRITERIA
IS FULFILLED AND A MINIMUM
VACUUM IS REACHED IN THE
CONDENSER.
CRITERIA FOR OPENING THE
SEAL STEAM SUPPLY VALVE
STEAM-TEMPERATURE > 220 CEL
VACUUM < 0.7 BAR

BHEL, HARDWAR 6.2-0140-02/3

 07) + VACUUM-PUMPS SWITCH ON
THE VACUUM PUMPS DO NOT BELONG
TO THE SCOPE OF SUPPLY OF THE
<TURBINE/GENERA TOR>.

OPERATION OF PUMPS AND VALVES ‘.

FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION, \CCORDING
TO SPECIAL INSTRUCTIONS. .
IOPERATION OF PUMPS AND VALVES
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION REFER

TO PLANT-MANUAL

+ VACUUM-PUMPS ON MAJ60AN001
AND MAJ70AN001

(08) + AIR-SUCT -VALVE VACUUM PUMP OPEN

+ AIR-SUCT-VALVE VACUUM PUMP OPEN

(08/S)*+ VACUUM PUMP ON MAJ60AN001

AND MAJ70AN001
+ VACUUM < 0.7 BAR MAG10CP001

+ TEMP. AHEAD OF SEAL-ST. SUPPLY VLV > 220 CEL MAW10CT001

(09) * + OPENINGOFSEAL-STEAMSUPPLYVLV OBSERVE MAW11AA001

+ SEAL STEAM PRESSURE >P AMB MAW20CP001

+ VACUUM < 0.15 BAR

(10) + VACUUM PUMP OPERATION CHANGEOVER

CHANGE IN OPERATION OF VACUUM-
PUMPS SERVES THE PURPOSE TO
HAVE ALL VACUUM PUMPS IN OPER-
ATION WHICH ARE NECESSARY
TO REMOVE AIR AND GAS FROM
THE CONDENSER DURINGOPER-
ATION. OBSERVE ALL CRITERIA -
INVOLVING VACUUM PUMP-OPER-
ATION.

GENERAL OUTLINE:

+ SERVICE VACUUM PUMP ON

AND
+ STARTUP A. STANDBY VACUUM PUMPS CFF

BHEL, HARDWAR 6.2-0140-02/4

 Steam Turbine Bypass-System
Description Start of Operation

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES CHECKED
ACCORD. TO LIST OF
VALVE-POSITION
AND IN POSITION
+ BYPASS-CONTROLLER ON
+ BYPASS-CONTROLLER NOT FAULTED

+ FIXPRESSUREREFERENCEVALUE KG/CM2
THE SETTING OF THE FIX
PRESSURE REFERENCE VALUE
DEPENDS ON THE REQUIREMENTS
OF THE STEAM-GENERATOR
F.E. THE SYSTEM FLOW THROUGH
THEREHEATER.
THE SETPOINT HAS TO BE
RAISED DURING STARTUP TO
MEETTHE DESIGN-VALUE FOR
MINIMUM LOAD OF THE STEAM-
GENERATOR.
FIX PRESSURE REFERENCE
VALUE AS DESIGNED. ...KG/CM2

+ HYDRAULIC PRESSURE SWITCH DELOCKED

THE H’ (DRAULIC PRESSURE
SWITCH MUST ONLY BE
BLOCKED FOR THE PURPOSE
OF TESTING.

(02) + EXT. SYSTEM READY F. OPERATION CHECKS

EXTERNAL SYSTEMS = SYSTEMS
BEYOND THE SCOPE OF SUPPLY
OF THE TURBINE/GENERATOR

+ CIRCULATING WATER OF CONDENSER AVAILABLE

+ CONDENSATE PUMPS IN OPERATION

+ VACUUM-PUMPS IN OPERATION

+ VACUUM < 0, 6 KG/CM2

(03) + INT. SYSTEM READY FOR OPERATION CHECK

INTERNAL SYSTEMS = SYSTEMS
WITHIN THE SCOPE OF SUPPLY
OFTHETUR8JNE/GENERATOR.

BHEL, Hardwar 6.2-0150-00/1

 + Oil SYSTEM IN OPERATION

+ TURNING GEAR IN OPERATION

+ CONTROL FLUID SYSTEM IN OPERATION

+ VACUUM-PUMPS IN OPERATION

+ VACUUM < 0, 6 KG/CM2

(04) + STATE OF OPERAT. STEAM- CHECK

GENERATOR

+ STEAM-GENERATOR IN OPERATION

+ REHEAT PRESSURE/FIX PRESS. RELATION < 1

REF. VALUE

(05) + CRITERIA FOR BEGIN OF STARTUP CHECK

+ BYPASS STOP VALVE CLOSED MAN11AA001

AND MAN12AA001

+ BYPASS CONTROL VALVE CLOSED MAN11AA002

AND MAN12AA002

+ HYDR. SIGNAL OF BYPASS CONTROL < 1.0. KG/CM2

+ SP RAY WATER PRESSURE < 1.0 KG/CM2

+ REHEATPRESSURE/FIXPRESS. RELATION = 1
REF. VALUE

(06) + START OF BYPASS-OPERATION OBSERVE

BYPASS OPERATION STARTS IF
THE STEAM PRESSURE UPSTREAM
OF THE BYPASS VALVE MEETS
THE PRESS-REFERENCE VALUE.

* + BYPASS STOP VALVE OPENS MAN11AA001

AND MAN12AA001

* + SPRAY WATER VALVES (STAGE 1) OPEN

DESIGNATLON OF THE SPRAY.
WATER VALVES ACCORDING TO
SINGLE LINE DIAGRAM.

* + BYPASS CONTROL VALVE OPENS MAN11AA002

AND MAN12AA002

+ INTERLOCKS OF BYPASS-CONTROLS NOT INITIATED

THE BYPASS-CONTROL AND
STOP VALVES CLOSE IF THE
FOLLOWING CRITERIAARE
FULFILLED:
VACUUM > 0.6 KG/CM2
SPRAYWATERPRESSURE < 9, 5 KG/CM2

BHEL, HARDWAR 6.2-0150-00/2

 + LIMIT VALUE OF STEAM FLOW NOT INITIATED

THE LIFT OF THE BYPASS-

CONTROL VALVES WILL BE
LIMITED. IF THE LIMIT
PRESSURE IS REACHED
THE BYPASS-CONTROL VALVE
CLOSE. .

+ LIFT OF BYPASS-CONTROL-VALVES 100%

(07) + FIXPRESSURE REFERENCE VALUE SETHIGHER

+ FIXPRESSURE REFERENCE VALVE HIGHER

+ LIFT OF BYPASS-CONTROL-VALVES < 100%

THIS CASE CAN OCCUR IF
THE FIXPRESSURE REFERENCE
VALUE HAS BEEN REDUCED
BELOW THE DESIGN VALUE
DURING STARTUP.

BHEL, HARDWAR 6.2-0150-00/3

 Steam Turbine Warm up and Startup of Turbine
Operation Startup Diagram

(01) + TURBINE READY FOR STARTUP CHECK

AND
+ MAIN STEAM LINES READY FOR WARMUP CHECK
+ MANUAL OPERATED VALVES OPEN.
(POSITION ACCORDING TO LINE DIAGRAM)
TEST VALVES OF STOP VALVES OPEN
HYDRAULIC VALVES OF EXTRACTION NRV OPEN
+ ELECTROHYDRAULIC TURBINE CONTROL ON
+ ELECTROHYDRAULIC TURBINE CONTROL NOT FAULTED
+ SPEED REFERENCE VALUE < N TURN GEAR
NORMALLY THE TURBINE WILL BE CONTROLLED
BY THE ELECTROHYDRAULIC CONTROLLER.
REFER TO 6.2-0180 FOR CHANGE OVER TO AND
OPERATION OF HYDRAULIC GOVERNOR
+ STARTING AND LOAD LIMIT DEVICE 0% MAX47 BY001
+ SPEED SETTER HYDRAULIC GOVERNOR 100 % MAX46 BY001
+ TURBINE STRESS EVALUATOR/CONTROLLER (TSE/TSC) ON
+ TSE/TSC NOT FAULTED
TSE/TSC TEST POSITIVE
NO ALARM
.NO FAULT INDICATOR ILLUMINATED
NO UNREASONABLE POSITION OF DISCS
+ TSE/TSC INFLUENCE ALWAYS ON
EXEMPTION: TSE/TSC FAULTY
CHANGE OVER WHEN DISTURBED. REFER TO 6.2-0430
IF THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURE AT THE MEASURING POINTS
WHICH REPRESENT THE THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED. REFER TO 6.1-011
REF 6.2-0430 IF TSE/TSC ALLOWANCE IS REDUCED.
APPLIES TO ALL MODES OF OPERATION
+ TRIPPING DEVICE TURBINE PROTECTION NO ALARM
OVERSPEED TRIP MAY10 AA001
AND MAY10 AA002
IF STARTING AND LOAD LIMIT DEVICE > 20 %
+ ELECTRICAL TRIP NO ALARM
+ CASING DIFFERENTIAL TEMPERATURES NO ALARM
HP TURBINE CENTER TOP/BOTTOM < 90°C MAA50 CT051
AND MAA50 CT052
OR IP TURBINE FRONT TOP/BOTTOM < 30°C MAB50 CT043
AND MAB50 CT044
OR IP TURBINE REAR TOP/BOTTOM < 30°C MAB50 CT061
AND MAB50 CT062
CASING DIFFERENTIAL TEMPERATURES DETERMINE
THE DISTORTION OF THE TURBINE CASINGS

(02) + GENERATOR READY FOR OPERATION CHECK

ALL REQUIREMENTS AS PER GENERATOR MANUAL
FULFILLED BEFORE STARTUP
+ GENERATOR BREAKER OFF
+ EXCITATION BREAKER OFF
+ SEAL OIL PLANT IN OPERATION
+ H2 PRESSURE P DESIGN MKG25 CP003
+ HYDROGEN PURITY > 95% MKG25 CQ001
+ H2 TEMPEARTURE CONTROL ON

+ H2 TEMPERATURE CONTROL NOT FAULTED

BHEL, Hardwar 6.2-0160-02/1

 + PRIMARY WATER PUMP ON MKF12 AP001
OR MKF22 AP001
+ STANDBY PRIMARY WATER PUMP OFF MKF22 AP001
OR MKF12 AP001

+ PRIMARY WATER PRESSURE > P MIN MKF12 CP001

+ SUBLOOP CONTROL PRIMARY WATER PUMPS ON
+ PRIMARY WATER CONDUCTIVITY < 1, 5 MYS/CM MKF35 CO001
+ PRIMARY WATER TEMPERATATUREV CONTROL ON
+ PRIMARY WATER TEMPERATURE CONTROL NOT FAULTED
THE CRITERIA FOR THE GENERATOR HAVE TO
BE FULFILLED FOR ALL MODES OF OPERATION
WHICH CAN OCCURR,

+ DRAIN UPSTREAM OF MCV OPEN MAL11AA011

AND MAL AA011
+ DRAIN HP OUTER CASING OPEN MAL22 AA011
CRITERION: TEMPERATURE HP TURBINE < 300 °C
OR
+ DRAIN HP OUTER CASING CLOSED MAL22 AA011
CRITERION: TEMPERATURE HP TURBINE > 320 °C
+ DRAIN AHEAD OF SWING CHECK CRH NRV OPEN MAL65 AA011
CRITERION: CRH NRV CLOSED
+ DRAIN BEFORE IP CONTROL VALVE OPEN MAL26 AA011
AND MAL27 AA011
+ DRAIN DOWN STREAM IP CONTROL VALVE OPEN MAL31 AA011
AND MAL32 AA011
CRITERION: VALVE CASING TEMPERATURE
MINUS SATURATION TEMPERATURE OF STEAM <-20 °C
OR
+ DRAIN BEFORE IP CONTROL VALVE CLOSED MAL26 AA011
AND MAL27 AA011
+ DRAIN DOWN STREAM IP CONTROL VALVE CLOSED MAL31 AA011
AND MAL32 AA011
MINUS SATURATION TEMPERATURE OF STEAM > 50 °C ‘
CRITERION: EXTRACTION VALVE CLOSED

(05) + CRITERIA FOR BEGIN OF START UP CHECK

IF ALL CRITERIA AS LISTED BELOW ARE
FULFILLED THE TURBINE/GENERATOR WILL
BE STARTED FROM
-TURNING GEAR IN OPERATION
-STOP VALVES CLOSED
+ MAIN STEAM STOP VALVES CLOSED MAA10 AA001
AND MAA20 AA001
+ REHEAT STOP VALVES CLOSED MAB10 AA001
AND MAB20 AA001
+ HP CONTROL VALVES CLOSED MAA 10 AA002
AND MAA20 AA002
+ IP CONTROL VALVES CLOSED MAB 10 AA002
AND MAB20 AA002
+ SWING CHECK VALVE COLD REHEAT L4NE CLOSED LBC10 AA001

+ EXTRACTION VALVE CLOSED

(06) + DRAINS AHEAD OF MS/RH STOP VALVES CHECK

(07.) + PREWARMING OF TURBINE START

OR WITH FGA (TURBINE CONTROL)
PROGRAMME (STARTUP) START

BHEL, Hardwar 6.2-0160-02/2

 OPERATION OF PUSH BUTTONS
REFER TO MANUAL FOR THE FGA

(08) + SLC WARM-UP CONTROL SWITCH OFF.

+ SLC WARM-UP CONTROL OFF
OR WITH FGA (TURBINE CONTROL)
(08/S) + WARM-UP CONTROL OFF

(09) + DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL11 AA011

AND MAL AA011
+ DRAIN AHEAD OF HP CCNTROL VALVES CLOSED MAL11 AA011
AND MAL12 AA01 1
OR WITH FGA (TURBINE CONTROL)
(09/S)*+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL11 AA011
AND MAL12 AA01 1.

(10) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 6.2-0170
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 6.2.0170
OR
+ MAIN STEAM VALVE TEMPERATURE < 100 °C
RELEASE OF STEP (05) OF THE FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PROGRAMME
HA VE BEEN FULFILLED

(11) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION

(12) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BY001
OR WITH OF FGA (TURBINE CONTROL)

(12/S) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BY001
STARTING AND LOAD LIMIT DEVICE > 42% MAX47 BY001
+ MAIN STEAM STOP VALVES OPEN MAA10 AA001
MAA20 AA001

(13) + STEAM TEMPERATURE CRITERIA CHECK

+ STEAM TEMPERATURE CRITERIA FULFILLED
FOR CRITERIA REFER STEP (10)

(14) + SLC WARM.UP CONTROL SWITCH ON.

OR WITH FGA (TURBINE CONTROL)
(14/S) + SLC WARMUP CONTROL SWITCHED ON
TRACKING DEVICE SWITCHED, ON

(15) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX4B.Y001

OR WITH FGA (TURBINE CONTROL)
(15/S)+ STARTING AND LOAD LIMIT DEVICE RAISE MAX47 BY001
+ STARTING AND LOAQ. LIMIT DEVICE > 56 % MAX47 BY001
+ REHEAT STOP VALVES OPEN MAB10 AA001

(16) + WAIT
WARM UP PROCEDURE WILL BE GUlDED BY THE
WARM.UP CONTROL. LEADING PARAMETER IS THE
TEMPERATURE ALLOWANCE OF THE TSE/TSC CHANNEL
(ADMISSION). THE DRAINS OF THE CONTROL
VAL VES WILL BE OPENED AND CLOSED DEPENDING
ON THE MAGNITUDE OF TSC ALLOWANCE. IF THE
WARM.UP CONTROL IS DISTURBED OR NOT IN

BHEL, Hardwar 6.2-0160-02/3

 OPERATION OPERATE DRAIN VALVES OF THE HP
CONTROL VALVES MANUALLY. CLOSE ON DECREASING
TSE/TSC ALLOWANCE. OPEN ON INCREASING TSE/TSC
ALLOWANCE. IF THE TSE/TSC IS FAULTY OPERATE
DRAIN V ALVES ACCORDING TO WALL TEMP
AT THE TSE/TSC RECORDER. REFER TO TECHNICAL
DATA FOR LIMITS OF DIFFERENTIAL
TEMPERATURES OF THE TSE/TSC.

(17) + DRAINS MAIN STEAM LINE CLOSE

+ DRAINS MAII’J’STEAM LINE CLOSED
THE DRAINS OF MS LINE DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR)
CRITERION: STEAM IN MS LINE SUPER HEATED

(18) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REF. 6.2-0170 FIG.1, 4
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REF. 6.2-0170 FIG.L.5
THE RELEASE OF STEP (12) OF FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PRO (1RAMME
HAVE BEEN FULFILLED

(19) + LOAD REFERENCE VALUE CHECK MYA01 DU001

+ LOAD REFERENCE VALUE > 10 % MYAOL DUOOL

(20) + SPEED REFERENCE VALUE SET HIGHER

+ SPEED REFERENCE VALUE > 650 RPM
THE WARMUP SPEED’MUST NOT EXCEED THE
MINIMUM SPEED OF THE BARRED SPEED RANGE
IN ORDER TO AVOID OPERATION IN RANGES
WHERE NATURAL FREQUENCY OF FREE STANDING
LP BLADES IS TO BE EXPECTED,
OR WITH FGA (TURBINE)
(20/S)* + SPEED REFERENCE VALUE SET HIGHER
THE PREWARMING PROCEDURE IS GUIDED BY THE
TSE/TSC INFLUENCE TO THE ELECTRO HYDRAULIC
CONTROL, THE SPEED WILL BE REDUCED IF THE
TSE/TSC ALLOWANCE IS REDUCED TO ZERO, IF
THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE THERMAL STRESSES OF CASING
AND ROTOR MUST BE EVALUATED. REFER 6.2-0430
IF TSE/TSC ALLOWANCE IS REDUCED

+ SPEED OF TURBINE/GENERATOR > 240 APM

(21) + TURNING GEAR OIL VALVE CLOSE MAV51 AAOOL
OR WITH SUBLOOP CONTROL
(21/S)* + TURNING GEAR OIL VALVE CLOSED MAV51 AAOOL

+ SPEED OF TURBINE/GENERATOR > 540 RPM

22) + JACKING OIL PUMP SWITCH OFF MAV31 APOOL
OR MAV32 AP001
+ JACKING OIL PUMP OFF MAV31 AP001
AND MAV32 AP001

BHEL, Hardwar 6.2-0160-02/4

 OR WITH SUBLOOP CONTROL

(22/S)* + JACKING OIL PUMP OFF MAV31 AP001

AND MAV32 AP001

(23) + STEAM TEMPERATURE CRITERIA CHECK

AND
+ OPERATIONAL VALUES OF TURBINE CHECK
+ STEAM TEMPERATURE CRITERIA FULFILLED REF. 6.2-0170 FIG, 6
+ TURBINE STRESS MARGIN > 30 OK
+ BEARING VIBRATION NORMAL
+ SHAFT VIBRATION NORMAL
DEFINITION OF NORMAL VALUES OF VIBRATION:
VIBRATION PREVIOUSLY OBSERVED WHEN OPERATING
WITH SAME SPEED AND OTHER PARAMETERS

(24) + WARM-UP CONTROL SWITCH OFF

WARM-UP CONTROL OFF
OR WITH FGA (TURBINE CONTROL)
(24) + WARM-UP CONTROL OFF

(25) + SPEED REFERENCE VALUE SET HIGHER MYAO1 DU001

+ SPEED REFERENCE VALUE > 3000 RPM MYA01 DU001
OR WITH FGA (TURBINE)
(25/S)* + SPEED REFERENCE VALUE > 3000 RPM

(26) + WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITICAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCURS. THE TSE/TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC.
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSE/TSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED REFER TO 6.1-011
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.

+ SPEED REFERENCE VALUE 3000 RPM

(27) + OPERATIONAL VALUES OF TURBINE CHECK
+ BEARING VIBRATION NORMAL
+ SHAFT VIBRATION NORMAL
+ BEARING TEMPERATURES NORMAL

(28) + DRAIN AHEAD OF HP CONTROL VALVES CLOSE MAL 11 AA011

BHEL, Hardwar 6.2-0160-02/5

 AND MAL 12 AA011

+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL 11 AA011

AND MAL 12 AA011
OR WITH FGA (TURBINE CONTROL)
(28/S)* + DRAIN AHEAD OF HP CONTROLVALVES CLOSED MAL 11 AA011
AND MAL 12 AA011

(29) + AUXILIARY OIL PUMP SWITCH OFF MAV22 AP001

AND MAV23 AP001

OR WITH FGA (TURBINE CONTROL)

+ STEAM TEMPERATURE CRITERIA CHECK

+ GENERATOR SYNCHRONIZE REFER TO 6.2-0210

BHEL, Hardwar 6.2-0160-02/6

 Steam Turbine Warming-up and Starting theTurbine
Description Temperature Criteria

Warming-up and Starting the Turbine Des

The admission steam temperature should meet
the metal temperature as shown in the diagram
below in order to start and load the turbine in
shortest possible time.

Note: The following criteria represent

approximate values, which can be optimized by
operational experience.

Turbines with Automatic Turbine Runup System

(ATRS) should under go optimizing.

Criteria for the opening of stop valves

When opening the main stop valves the main

steam parameters should meet the following
recommended values.

Minimum main steam temperature

θms>θs Fig.1

θms = Main steam temperature

at steam generator outlet

θs = Temperature of saturated
steam (depending on
main steam pressure)
and
θms>f(θmcv50%) Fig.2

θms = Main steam temperature

at steam generator
outlet

θmcv50% = Middle wall temperature

of main control valve
casing

BHEL Hardwar 6.2-0170-01/1

 Maximum main steam saturation temperature
ahead of the turbine

θs>f (θmcv50%) Fig.3

θs = Maximum main steam saturation

temperature ahead of the turbines

θmcv 50% = Middle wall temperature of main

control valve

Starting Criteria

When the main control valves are opened the

main steam and reheat steam temperatures
should fulfill the following criteria:

Minimum main steam temperature

θms>θs Fig.1

θms = Main steam temperature ahead of the

turbine

θs = Temperature of saturated steam

(depending on main steam pressure)

And

θms>f (θHT50%) Fig.4

θms = Main steam temperature ahead of turbine

θHT 50% = Middle wall temperature of HP-

casing or simulated middle phase shaft
temperature

BHEL, Hardwar 6.2-0170-01/2

 Minimum reheat temperature

9Reh > f (9IT 50%)

Fig. 5

9Roh = Steam temperature in

the hot reheat line

9IT 50% = Simulated midwall

temperature of the IP-
shaft

Speeding up criteria

Before the turbine is brought to rated

speed the main steam temperature 9MS
ahead of the turbine should fulfill the
following criteria:

9MS < f (9HT 50%) Fig. 6(a) & (b)

9MS = Main steam temperature

ahead of the turbine

9HT 50% = Middle wall temperature

of the HP-turbine casing
or simulated midwall
temperature of HP shaft

BHEL, Hardwar 6.2-0170-01/3

 Loading criteria

Before the turbine is loaded the reheat

temperature, ahead of the turbine should fulfill
the following criteria

9Reh > f (9IT 50%) Fig. 7

9Reh = Steam temperature in the hot reheat line

9IT 50% = Simulated midwall temperature of the IP-

turbine shaft

BHEL, Hardwar 6.2-0170-01/4

 Steam Turbine Warming up and Starting the Turbine
Operation Controller

1 Operating modes of the control systems

The turbine generator Unit is accelerated and
and of the starting and load limit device
Maintained at constant warm-up speed
Electrical speed Control
Accelerate unit to rated speed
- Warm-up operation
Maintain unit at rated speed
- Running up the turbine I generator unit
- Rated speed operation
The turbine generator unit is accelerated and
Maintained at constant warm-up speed by manual
Hydraulic governor
Actuation of the starting and load limit device
- Warm-up operation
When the reference speed setter is in the 0% position,
the hydraulic governor takes over speed control at
- Running up the turbine generator unit
approx. 8O% rated speed
So, run -up of the turbine generator unit from
approx. 8O to 100% rated speed is controlled by
The hydraulic speed governor.

Maintain unit at rated speed

Acceleration to 107% of rated speed by the governor;
- Rated speed Operation
Speed is increased to trip speed using acceleration
Over speed trip test
Lever on casing of hydraulic governor;
During over speed trip test, the electrical speed
Controller must be disengaged and switched off.

The main trip valves are brought into operating

Position when the starting and load limit device is
Starting and load limit device
In the 0% position.
- setting operating configuration of main trip valve
When the starting and load limit device is in
- Opening the stop valves
Approx 4 0% open position, the stop valves should
Be open;
The test valves of the stop valves must be in the
Operating position for the opening procedure.

See Hydraulic speed governor

- Warm up operation
0-107% (limitation by hydraulic speed governor)
2 Electrical speed control
Control range in % rated speed
The actual set point follows the target set point
Set point control
Along preset gradients.
- Target set point /actual set point
The preset gradient is reduced according to a
Predeterminaned characteristic to confirm to the
- Limitation of set point by turbine, stress evaluator (TSE)
Margin generated by the TSE
The TSE signal must always be present if the TSE
- Application of the TSE signal
Is not faulted.
The actual set point no longer follows the target
- Operation with TSE faulted
Set point if the TSE is defaulted
The actual and target set point must be matched up
Before the TSE signal can be switched off. When the
Signal from TSE is not present, the thermal
Stress in the turbine components must be figured
Out by comparing. The actual temperature and their
Differences with the curves for permissible
Temperature margins as given in Technical Data 6.1-011

BHEL Hardwar 6.2-0180-00/1

 Limitation by higher-level or alternative
Controllers or other devices
- Minimum value selection
- Hydraulic speed governor
(Speed setting device approx.80%)
- Starting and load limit device
Operation
- Operating elements and monitoring
Instruments
- Operating logic sequences for changing
The operating mode
3 Hydraulic Speed Governor
Set point control
- Target set point factual set point
Limitation by higher-level or
Alternative controllers or other device
- Minimum Value selection
- Electro hydraulic controller
<100% value selection
- Starting and IQad limit device
Operation
- Operating elements and monitoring
Instruments
- Operating logic sequences for
Changing operating mode
BHEL Hardwar
Effective controller = controller with the lowest
Set point setting at any time (also applies to other
Devices influencing the opening characteristic)
Limit set point by hydraulic minimum
value selection;
Limit set point by hydraulic minimum
Valve selection;
Excessive control valve opening can be prevented
By using the starting and load limit device to
Limit valve travel.
see arrangement of control desk as described in
controller manual. Pay attention to notes on operation
Of release pushbuttons!
See Appendix (for changing the operating mode during
no-load operation sees
Power Operation, Controller 6.2-0180
the actual set point immediately follows the target
Set point (no influence from turbine stress evaluator),
During operation with the hydraulic speed governor,
The thermal stresses in the turbine components must
Be figured out on the basis of the TSE display or,
If the TSE is faulted, by comparing the actual
Temperatures and their differences with the curves
For permissible temperature margins as given in
Technical Data 6.1-011.
Effective controller = controller with lowest
Set point setting at any time (also applies to other
Devices influencing the control characteristic)
Limits set point by hydraulic minimum
Limits set point by hydraulic minimum
Value selection
see arrangement of control desk as described in
in controller manual
See next page
6.2-0180-00/2
 + Turbine generator unit speed = Turning gear speed
+ Stop valve position = 0%
+ Control Valve position = 0%
+ Main trip valves = depressurized
+ Starting and load limit device = 40% open
+ Reference speed setter = 0%
+ Electrical speed reference = 0%

(1) + Electrical speed reference rise

+ Electrical speed reference = 100%

(2) + Plunger coil deenergize

+ Plunger coil deenergize

(3) + Starting and load limit device lower

+ Starting and load limit device =0%
+ Main trip valves in operating configuration

(4) + Starting and load limit device rise

+ Starting and load limit device >40%
+ Stop valve position = 100%
+ Warm-up criteria for main steam lines fulfilled

(A) + Main Steam lines warm-Up

+ Criteria for admission of steam into turbine fulfilled
+ Steam generation adequate

(5) + Starting and load limit device rise

+ Control valves open
+ Turbine generator unit speed = warm-up speed

(6) + Using Starting and load limit device maintain constant speed

(B) + Turbine Warm-up

+ Run-up criteria fulfilled
+ Steam generator output adequate

(7) + Starting and load limit device rise

+ Control Valve open
+ Turbine generator unit speed > warm-up speed
+ Turbine generator unit speed = 75% rated speed

(8) + Starting and load limit device rise

+ Starting and load limit device = 100% open

(9) + Reference speed setter rise

+ Turbine generator unit speed = rated speed

Operating logic sequence 1: Starting up the turbine generator unit with the
Starting and load limit device and the hydraulic
Speed governor
A see warming up the Main Steam Line
B sees Warming up Starting up the Turbine

BHEL Hardwar 6.2-0180-00/3

 + Turbine generator unit speed > turning gear speed and
< 75% rated speed
+ Electrical speed reference = turbine generator unit speed
+ Reference speed setter = 100%

+ Starting and load limit device = 56 to 100%

(1) + Starting and load limit device lower

+ Starting and load limit device effective

(2) + Electrical speed reference rise

+ Electrical reference = 100%

(3) + Plunger coil deenergize

+ Plunger coil deenergize

(4) + using starting and load limit device maintain constant speed

(5) + Reference speed setter lower

+ Reference speed setter = 0%

Operating logic sequence 2: Transition from operating with electrical speed controller to
Operating with starting and load limit device
(Speed approx, 80% rated speed)

+ Turbine generator unit speed > Turning gear speed and

75% rated speed
+ Electrical speed reference = 100%
+ Plunger coil deenergize
+ Reference speed setter = 0%
+ Starting and load limit device effective

(1) + Plunger coil energize

+ Plunger coil energized

(2) + Electrical speed reference lower

+ Turbine generator unit speed = electrical speed reference

(3) + Starting and load limit device rise

+ Starting and load limit device 56 to 100 %

(4) + Reference speed setter rise

+ Reference speed setter = 100%

Operating logic sequence 3: Transition from operating with starting and load limit
Device to operation with electrical speed controller
(Speed approx, 80% rated speed)

BHEL Hardwar 6.2-0180-00/4

 Steam Turbine Load Operation
Operation Introduction

Power operation begins by synchronizing of the

generator. The turbine generator load may then be The operating staff must detect all operating conditions
raised or lowered according to the commands from the that are a danger to tile turbine generator and must
monitoring/controlling equipment, in particular the load immediately correct them.
margins from the turbine stress evaluator (TSE) /
Regular checking of protection equipment, long-term
turbine stress controller (TSC), to meet the grid power
monitoring of operating variables and operational
requirement. maintenance are very important for early detection and
During power operation, monitoring is essential for the
elimination of system faults.
economic operation of the turbine generator.
Neglecting this principle runs the risk of reductions in
availability and reliability.

BHEL, Hardwar 6.2-0200-00

 Steam Turbine Synchronization and Loading
Operation Startup Diagram

(01) + GENERATR READY TO BE CHECK

SYNCHRONIZED

+ SPEED OF TURBINE/GENERATOR 3000 RPM

+ DRAIN OF SEAL STEAM HEADER NORMAL

+ H2-SUPPL Y SYSTEM NO ALARM

+ SEAL-OIL PLANT NO ALARM

+ PRIMARY WATER SYSTEM NO ALARM

+ LIQUID IN GENERATOR NO ALARM

+ STEAM TEMPERATURE CRITERIA FULFILLED

(02) + EXCITATION BREAKER SWITCH ON

+ EXCIT ATION BREAKER SWITCHED ON

OR WITH FGA (TURBINE CONTROL)

(02/S)* + EXCITATION BREAKER SWITCHED ON

(03) + GENERATOR VOLTAGE SET HIGHER

+ GENERATOR VOLTAGE HIGHER

OR WITH FGA (TURBINE CONTROL)

(03/S)* + AUTOMATIC SYNCHRONIZER ON

(04) + GENERATOR VOLTAGE CONTROL CLOSED

+ GENERATOR VOLTAGE CONTROL SWITCHED ON

OR WITH (AUTOMATIC SYNCHRONIZER)

(04/S)* + GENERATOR VOLTAGE CONTROL SWITCHED ON

(05) + SYNCHRONOSCOPE SWITCHED ON

OR WITH (AUTOMATIC SYNCHRONIZER)

+ SYNCHRONOSCOPE SWITCHED ON

BHEL Hardwar 6.2-0210-00/1

 (07) + GENERATOR VOATAGE ADJUSTED
BY MEANS OF REFERENCE
VALUE OF VOLTAGE CONTROL

+ GENERATOR/LINE-VOLTAGE MET
OR WITH (AUTOMATIC SYNCHRONIZER)

(07/5)* + GENERATOR/LINE-VOLTAGE MET

(08) + GENERATOR FREQUENCY ADJUSTED

BY MEANS OF REFERENCE
VALUE OF SPEED CONTROL

+ GENERATOR/LINE-FREQUENCY MET

OR WITH (AUTOMATIC SYNCHRONIZER)

(08/5)* + GENERATOR / LINE-FREQUENCY MET

GENERATOR FREQUENCY MUST
BE ADJUSTED IN SUCH A WAY
THAT THE NEEDLE OF THE
SYNCHRONOSCOPE TURNS
SLOWLY IN THE DIRECTION
GENERATOR FREQUENCY HIGHER
THAN LINE FREQUENCY =
FAST SYNCHRONIZING.
FAST SYNCHRONIZING ENSURES
THAT THE GENERATOR Will
BE LOADED IMMEDIATELY
AFTER SYNCHRONIZING
THUS PREVENTING REVERSE
POWER RELAY TO BE ACTUATED.

(09) + SYNCHRONIZING DEVICE START

+ GENERATOR BREAKER SWITCHED ON

IF THE BREAKER WILL BE
SWITCHED ON MANUALLY
ADJUSTED PHASE ANGLE TO
NEEDLE OF SYNCHRONOSCOPE
MUST METT THE ZERO-ANGLE
MARK ON THE SCALE WHEN
SWITCHING IN BREAKER.

OR WITH (AUTOMATIC SYNCHRONIZER)

(09/5)* + GENERATOR BREAKER SWITCHED ON

(10) + SPEED REFERENCE VALUE SET HIGHER MYA01DU001

+ GENERATOR LOAD > 10%

BHEL, Hardwar 6.2-0210-00/2

 (11) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47BYO01

+ STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01

OR WITH FGA (TURSINE CONTROL)

(11/S)* + STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01

+ TURBINE STRESS EVALUATOR (TSE) CHECK

+ TURBINE STRESS EVALUATOR (TSE) CHANGED OVER

AT A PRESENT MINIMUM LOAD
THE TSE CHANGES OVER FROM
TEMPERATURE-TO LOAD SCALE

+ GENERATOR LOAD > 10%

LOAD CONTROLLER SWITCHED ON

THE LOAD CONTROL WILL BE
SWITCHED ON AT A PRESET
MINIMUM LOAD.

(12) + LOAD REFERENCE VALUE SET HIGHER MYA01 DUO01

+ LOAD REFERENCE VALUE TARGET LOAD MYA01 DUO01

(13) + WAIT

(13/S)* + LIMITED LOAD REFERENCE VALUE HIGHER MYA01DUO01

THE LIMITED LOAD REFERENCE
VALUE FOLLOWS THE TARGET
LOAD REFERENCE VALUE
WITH THE ADJUSTED
LOAD GRADIENT.
THE LOAD GRADIENT WILL
BE REDUCED, IF REDUCTION
OF THE TSE ALLOWANCE OCCUR.
THE TSE INFLUENCE WILL BE
EFFECTIVE VIA THE REFERENCE
LIMITER.

IF THE TSE IS FAULTED THE

DIFFERENTIAL- TEMPERATURES
AT THE MEASURING POINTS
WHICH REPRESENT THE
ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST
BE EVALUATED.

REFER TO 6.2-0430 IF
TSE-ALLOWANCE IS
REDUCED.

BHEL, Hardwar 6.2-0210-00/3

 (14) + DRAIN DOWNSTREAM RCV CLOSE

OR WITH SUBLOOP CONTROL (DRAINS)

POSITION OF DRAINS CHECK

+ DRAIN DOWNSTREAM OF HP-CONTR. CLOSED MAL 15AAO01

VLV AND MAL 16AAO01

CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATURATION
TEMPERATURE OF STEAM

+ DRAIN OUTER CASING CLOSED MAL 22AA011

CRETERIUM:
TEMP.HP-CASING TOP >320 CEL

+ DRAIN AHEAD OF SWING-CHECK CRH CLOSED MAL65AA011

CRITERIUM: LBC10AAO01
NON RET.CHECK VLV COLD REH. OPEN

+ DRAIN UPSTREAM RCV CLOSED MAL26AA011

AND MAL27 AA 11

CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATURATION
TEMPERATURE OF STEAM

+ DRAIN DOWNSTREAM RCV CLOSED MAL31AA011

AND MAL32AA011
CRITERIUM:
VALVE CASING TEMPERATURE > 50 CEL
MINUS SATURATION
TEMPERATURE OF STEAM

(15) + HEATER OPERATION CHECK

+ HEATERS IN OPERATION
+ EXTRACTION VALVE > 0% LBO50AAO01
AND LBS41AAO01
AND LBS42AAO01
AND LBS31AAO01
AND LBS21AAO01

(16) + DRAINS OF EXTRACTIONS CLOSE MAL47AA011

AND MAL51AA011
AND MAL54AA015
AND MAL55AA011

BHEL, Hardwar 6.2-0210-00/4

 + DRAINS OF EXTRACTIONS CLOSED MAL47AAO11
AND MAL51AAO11
AND MAL54AAO15
AND MAL 55AAO11

IF THE EXTRACTION STEAM

FLOW WILL BE REDUCED,
CAUSING THE EXTRACTION
VALVE TO CLOSE THE
RESPECTIVE DRAIN MUST
BE OPEN.

+ BOILER/TURBINE LOAD RELATION 1

(17) + BYPASS CONTROL VALVE CHECK

+ BYPASS CONTROL VALVE CLOSED MAN11AAOO2

AND MAN12AAOO2

+ BYPASS STOP VALVE CLOSED MAN11AAOO1

AND MAN12AAOO1

BHEL, Hardwar 6.2-0210-00/5

 Steam Turbine
Operation
1 Control System Operating Modes
Electrical speed control
- During synchronization of generator
- After synchronization of generator
(Normal operating mode)
- After synchronization of generator
(Operating mode if load controller defective)
- Load shedding
(Disconnection of generator from power grid)
Hydraulic control
(Operation if electrical control system defective)
- During synchronization of generator
- After synchronization of generator
- Load shedding
(Disconnection of generator from power grid)
Electrical load control of turbine generator
- Constant pressure operation without
Frequency influence
- Constant pressure operation with
Frequency influence as given by the
Proportional setting of the frequency
Control and by the thermal storage
Capacity of the steam generator
- Variable pressure operation without
Frequency influence
- Variable pressure operation with frequency
Influence as given by the proportional
Setting of the frequency control unit
And the thermal storage capacity of the
Steam generator by controlled throttling of
The control valves
Initial pressure control by the electrical
Load controller (alternative to limit initial
Pressure control)
- Constant pressure operation
(With or without frequency influence)
Limit initial pressure control by the electrical load controller
(Alternative to initial pressure control)
- Operation of load controller with or
Without frequency influence for stabilization
Of steam generator operation
In the event to pressure drops
BHEL Hardwar
Power Operation
Controllers
Setting and maintenance of constant synchronization
Speed.
Run-up to approx. 2x unit auxiliary power requirement
before changeover to load control.
Power operation up to Pmax or until control.
Valves full open.
Interception of turbine generator before it reaches
Trip speed;
Maintenance of constant speed at residual load
(Auxiliary power requirement);
Setting and maintenance of constant synchronization
Speed.
Power operation up to Pmax or until control valves full open.
Interception of turbine generator before it reaches trip
speed;
Back up by over speed anticipatory relay.
Maintenance of constant speed at residual load
(Auxiliary power requirement);
Maintenance of constant load up to Pmax by
Positioning control valves.
As above, turbine generator assists in grid frequency
Stabilization when frequency changes.
Maintenance of constant load ;{ steam generator con-
Troll system takes over control when max. Control
Valve lift reached).
Maintenance of constant load;
Turbine generator assists in grid frequency stabilization
when frequency changes.
Maintenance of constant pressure in steam generator
As given by proportional settings characteristics of”
Pressure reference value.
Maintenance of constant pressure in steam generator
As given by proportional setting characteristic of
Pressure reference value incorporating response
Reference value.
6.2-0220-00/1
2 Electrical Speed Control
Control range
- Speed (as % 9f rated speed)
- Valve lift
- Load at design pressure.
Reference limiter
- Target reference value/actual
Reference value
- Limitation of reference limiter by TSE
(Turbine stress evaluator) component
- Application of TSE signal
- Operation with TSE faulted
Limitation by priority or alternative
Controllers or other equipment
- Minimum value selection
- Hydraulic governor < 100%
- Starting and load limit device < 100%
Operation
- Control and monitoring devices
- Control logic for changing operating
Mode
Instructions for control and operational
Monitoring
- speed reference value after changeover
To load control
3 Hydraulic Governor
Control range
- Speed
- Valve travel at rated speed
- Load at design pressure
Reference limiter
- Target reference value/actual
Reference value
BHEL, Hardwar
0-170%
(Limited by hydraulic governor)
100%
100%
the actual reference value tracks the target
reference along a preset gradient.
the present gradient is reduced in accordance with
a predetermined characteristic to conform to the
Load margin generated by the TSE.
The TSE signal must always be present unless the
TSE is faulted. .
the actual reference value no longer tracks the
Target reference value if the TSE is faulted;
Actual and target reference value must be matched
Up before the TSE signal can be switched off.
The thermal stresses In the turbine components
Must be assessed by comparison of the actual tem-
Peratures and their differences with the curves for
Permissible temperature margins given in
Technical Date 6.1-011.
Controller in effect = controller with lowest
Set point;
(Also applicable to other equipment that affects
The controller output signal.
limits reference value by means of hydraulic minimum
Value selection.
limits reference value by means of hydraulic minimum
Value selection.
Control valve lift overshot can be prevented by
Means of starting and load limit device
see desk allocation diagram in controller manual.
Note instructions on use of release pushbuttons I
See appendix
after changeover to load control the speed
reference value is to be set such that speed will
Revert to approx. 0.6% above rated speed in the
Event of load shedding.
80-107%
100%
100%
Actual reference value tracks target reference
value directly (no TSE component).
During operation with the hydraulic governor in
Control, the thermal stresses in the turbine com-
Ponents must be assessed by referring to the TSE
Display or, if the TSE is faulted, by comparing
The actual temperatures and their differences with
The curves for permissible temperature margins as
Give in Technical Data 6.1-011.
6.2-0220-00/2
 Limitation by priority or alternative
Controllers or other equipment
- Minimum value selection
- Electro hydraulic controller < 100%
- Starting and load limit device < 100%
Operation
- Control and monitoring devices
- Control logic for changing operating
Mode
Instructions for control and operational
Monitoring
- Actual speed after load shedding
- Starting and load limit device
4 Load Control by the Electrical Controller
Control range
- Valve travel 100%
- Load at design pressure 100%
Reference limiter
- Target reference value/actual
- Limitation of reference limiter by TSE
- Application of TSE signal
- Operation with TSE faulted
Limitation by priority or alternative
Controllers or other equipment
- Minimum value selection
Absolute limit load reference value
BHEL, Hardwar
Controller in effect == controller with lowest
Reference value;
(Also applicable to other equipment that affects
The controller output signal).
Limits reference value by means of hydraulic
Minimum value selection.
Limits reference value by means of hydraulic
Minimum value selection.
see desk allocation diagram in controller manual.
See appendix
as dictated by setting of speed reference value
Before load shedding with allowance for droop,
After shedding, the actual speed must revert to
Rated speed.
during operation with the hydraulic governor in
Control, the turbine generator assists in grid
Frequency stabilization as governed by the droop
Of the controller;
The influence of the frequency component on the
Load reference value tending to raise power can
Be eliminated by switching in starting and load
Limit device
the actual reference value tracks the target
Reference value reference value along a preset gradient.
the present gradient is reduced in accordance with
A predetermined characteristic to conform to the
Load margin generated by the TSE.
The TSE signal must always be present unless the
TSE is faulted.
the actual reference value no longer tracks the
Target reference value if the TSE if faulted;
Actual and target reference value must be matched
Before the TSE signal can be switched off.
The thermal stresses in the turbine components
Must than be assessed by comparison of the actual
Temperatures and their differences with the curves
For permissible temperature margins given in
Technical Data 6.1-011.
Controller in effect = controller with lowest
Reference value;
(Also applicable to other equipment that affects
The controller output signal).
Limit reference values by means of electric minimum
Selection;
Active in the event of unit malfunctions.
6.2-0220-00/3
 - Hydraulic speed governor < 100%
- Starting and load limit device < 100%
Operation
- Control and monitoring devices
- Control logics for changing operating
Mode
Instructions for control and operational
Monitoring
- Changeover from speed to load and from
Load to speed control
- Switching off load controller in the
Event of load shedding
- Cut in of initial pressure controller
BHEL, Hardwar
Limits reference value by means of hydraulic
Minimum value selection
See above
see desk allocation diagram in controller manual.
Note instructions on use of release pushbuttons
see appendix
Valve lift reference value must be matched up prior
to changeover.
Changeover from load to speed control is effected
when the load falls below a preset value;
Changeover back to load control is effected if the
Actual load rises above the lower limit within
approx. 2s.
the pressure control deviation must be 0 before
The initial pressure can cut in.
6.2-0220-00/4
 APPENDIX

+ Turbine generator speed = rated speed

+ Turbine generator load = Zero MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = rated speed
+ Speed changer = 100%
+ Starting and load limit device = 100%

(1) + Speed changer lower

+ Speed changer reference value < electrical speed reference value

(2) + Electrical speed reference value rise

+ Electrical speed reference value = max. Speed
+ Valve position controller reference value > 100%

(3) + Plunger coil switch off

+ Plunger coil off
+ Required speed reference value higher or lower

(4) + Speed changer rise or lower

Control logics 1: Changeover from electrical to hydraulic speed control in idling mode, e.g. for exercising over speed trips.

+ Turbine generator speed =rated speed

+ Turbine generator load = Zero MW
+ Plunger Coil off
+ Electrical speed controller not in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = max. Speed
+ Speed Changer = % position for rated speed
+ Starting and load limit device = 100%

(1) + Plunger coil Switch on

+ Plunger coil on

(2) + Electrical speed reference value lower

+ Electrical speed reference value < speed setter reference value

(3) + Speed changer rise

+ Speed changer = 100%
+ Required speed higher or lower

(4) + Electrical speed reference rise or lower

Control logics 2: Changeover from hydraulic speed control in idling mode e.g. after exercising over speed trips.

BHEL, Hardwar 6.2-0220-00/5

 + Turbine generator load >0MW
+ Individual valve controller in operation
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller in operation
+ Electrical speed reference value = rated speed + load component
+ Speed Changer = 100%
+ Starting and load limit device = 100%

(1) + Speed changer lower

+ Speed changer reference valve < electrical speed reference value

(2) + Electrical speed reference value rise

+ Electrical speed reference value = max. Speed
+ Valve position controller reference value > 100%

(3) + Plunger coil switch off

+ Plunger coil off
+ Load reference value higher or lower

(4) + Speed changer rise or lower

+ Hydraulic frequency control not required

(5) + Starting and load limit device lower

+ Starting and load limit device in effect

(6) + Speed changer rise

+ Speed changer = 1 00%
+ Load higher or lower

(7) + Starting and load limit device rise or lower

Control logic 3: Changeover from electrical to hydraulic speed control during speed controlled Power operation
(Procedure (5) onwards: Switching off hydraulic frequency influence)

BHEL, Hardwar 6.2-0220-00/6

 + Turbine generator load > OMW
+ Plunger coil off
+ Electrical speed controller not in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = max. Speed
+ Speed changer = 100%
+ Starting and load limit device = in effect

(1) + Speed changer lower

+ Speed changer in effect

(2) + Starting and load limit device rise

+ Starting and load limit device = 100%

(3) + Plunger coil switch on

+ Plunger coil on

(4) + Electrical speed reference value < speed changer reference value

(5) + Speed changer rise

+ Speed changer = 100%
+ Load reference value higher or lower

(6) + Electrical speed reference value rise or lower

Control logics 4: Changeover from hydraulic to electrical speed control in power operation
(Up to procedure (2): switching on hydraulic frequency component)

BHEL, Hardwar 6.2-0220-00/7

 + Turbine generator load > a MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Pressure component on
+ Pressure controller in operation
+ Electrical load reference value = actual # pressure component
+ Electrical speed reference value = approx 1.005 x rated speed
+ Speed changer = 100%
+ Starting and load limit device = 100%

(1) + Electrical initial pressure controller switch off

+ Initial pressure controller off
+ Limit initial pressure controller on

(2) + Initial pressure component switch off

+ Initial pressure component off

(3) + Speed changer lower

+ Speed changer reference valve < electrical load reference value

(4) + Electrical speed and load reference values rise

+ Electrical speed reference value = max. Speed
+ Electrical load reference value = max. Load

(5) + Plunger coil switch off

+ Plunger coil off
+ Turbine generator load reference value higher or lower

(6) + Speed changer rise or lower

+ Hydraulic frequency control off

(7) + Starting and load limit device lower

+ Starting and load device in effect

(8) + Speed changer rise

+ Speed changer = 100%
+ Turbine generator load reference value higher or lower

(9) + Starting and load limit device rise or lower

Control logics 5: Changeover from electrical load control to hydraulic speed control
Procedure (5) + (6) switch off hydraulic frequency influence

BHEL, Hardwar 6.2-0220-00/8

 + Turbine generator load > 0 MW
+ Plunger coil A off
+ Electrical load controller not in operation
+ Electrical load reference value = max. Load
+ Electrical speed reference value = max. Speed
+ Speed Changer = 100%
+ Starting and load limit device in effect

(1) + Speed changer lower

+ Speed changer in effect

(2) + Starting and load limit device rise

+ Starting and load limit device = 100%

(3) + Plunger coil switch on

+ Plunger coil on

(4) + Electrical load controller switch on

+ Electrical load controller on

(5) + Electrical reference value lower

+ Electrical reference value = approx. 1.005 x rated speed

(6) + Electrical load reference value lower

+ Electrical load reference value < speed setter reference value

(7) + Speed changer rise

+ Speed changer = 100%
+ Load higher or lower

(8) + Electrical load reference value rise or lower

+ Load actual load higher or lower
+ Initial pressure controller reference value on
+ Limit initial pressure required

(9) + Initial pressure component switch on

(10) + Initial pressure controller control balance

+ Deviation
+ Initial pressure controller control balanced
Deviation

(11) + Initial pressure controller switch on

+ Initial pressure controller on
+ Load higher or lower

(12) + Steam generator output reference value rise or lower

Control logics 6: Changeover from hydraulic to electrical load control in power operation
Procedure (1) + (2) Switch off hydraulic frequency cornball
Procedure (9) + (10) Switching on pressure condoner

BHEL, Hardwar 6.2-0220-00/9

 Steam Turbine
Operation
Introduction
During startup and shut-downs, there can be iong
period during which Steam turbines are operated at very
low volumetric flows. This operating mode can result in
blade wind age in individual stages of multi-stage
turbines.
The direction of the energy conversion cycle at the
affected blade stages is reversed. The mechanical
energy transmitted by the turbine shaft is converted to
thermal energy, which in turn result in an increase in the
temperature of both the steam and the turbine
components.
Unallowably high temperatures can occur as a result
of blade wind age, leading to loosening of the blade
assembly of drum stages through plastic deformation.
Turbine casings can undergo deformation due to the
effects of high temperatures.
During steam turbine operation, the operating mode
and limiters and protective devices must be used to keep
heat up due to blade wind age within the prescribed
Limits.
Thermodynamic and operating factors affecting
blade wind age
The following factors can lead to blade wind age:
Volumetric flow Blade wind age can occur as a result of
insufficient volumetric flow through a multistage
expansion section of the steam turbine.
The lower the volumetric flow through a blade stage, the
lower the turbine efficiency will be in the case of very low
volumetric flows, steam flow through the stage is not
directed and the steam has to be accelerated up to the
average speed of the rotating blades, which creates a
deceleration effect.
As the volumetric flow decreases, and the turbine starts
to operate at zero load, blade wind age result in
transition from power transfer from the blades to power
transfer to the blades.
Blade wind age starts in the final blade stages of an
expansion section, and extends towards the first stages
as flow decreases.
Steam density, steam pressure and turbine generator
speed.
The degree of wind age-induced heat up which occurs
as a result of low volumetric flow through an expansion
section of the steam turbine depends on the wind age
power.
The higher the steam density and the turbine speed to
the third power, the greater will be wind age power, and
therefore the heat up, in one blade stage.
BHEL, Hardwar
Actions to Prevent Unallowable Heat up
Through Blade Wind age
Procedural Instruction
Owing to the proportional relationship between steam
density and steam pressure, the steam pressures in
expansion sections undergoing wind age can be used to
determine the degree of heat up due to wind age.
General actions to prevent unallowable heat up of
the steam turbine due to wind age
Limitation of the period of ‘motoring’ operation Blade
wind age can occur in expansion sections of a steam
turbine if volumetric flow drops to zero, resulting in the
turbine being driven by the generator which acts as a
motor driven by the public power system.
- Activation of short-time reverses power protection
following turbine trips
After turbine trip, which can be initiated during any
operating mode of the turbine generator unit? the
generator must be isolated from the public power system
after no more than four seconds through activation of the
short-time reverse power protection.
in order to prevent motoring of the generator at high
speed beyond this time period owing to the interruption
in volumetric flow and high steam pressure in one
expansion section.
Activation of long-time reverse power protection
during a (schedule) turbine generator shut-down, the
control valves of the turbine generator unit are closed, to
allow the generator to be isolated from the public power
system through activation of the long-time reverse power
protection.
The maximum time delay for activation of the long-
time reverse power protection specified in the Technical
Data must not be exceeded. The long-time reverse
power protection must be functionally tested in
conjunction with leak testing of the control valves each
time the turbine generator unit is shut down.
Turbine trip after limit values have been reached
Blade wind age causes temperature increases at certain
exhaust-steam or casing -temperature measuring points.
The limit values of the temperature at which turbine trip
is to be initiated are specified in the Technical Data. if,
under particularly unfavorable conditions, these
temperatures are reached, turbine trip must be initiated,
either manually from the control room, or automatically
by tripping of a protective device.
6.2-0230-00/1
 Blade wind age in the HP expansion section of a
steam turbine with reheat
At low volumetric flows, blade wind age can
occur towards the exhaust end of the HP expansion
section if the steam pressure in or downstream other HP
turbine section is high.
Blade wind age can occur during the following modes of
operation:
No-load or low-load operation during startup of the
tubine generator unit.
No-load or a auxiliary-power operation following load
rejection.
The risk of unallowable heat up due to wind age ,is
Particularly high following load rejection, since this may
coincide with a high reheat steam pressure, meaning
that turbine generator speed temporarily exceeds rated
speed.
Motoring operation prior to activation of the long- time
reverse power protection during shut-down of the turbine
generator unit
At over speed during over speed trip testing
Actions to be taken to prevent unallowable heat up
of the HP turbine due to wind age
Optimization of the volumetric flow through the HP
Turbine by staggered operation of the main steam and
Reheat control valves.
By Specifying a staggered control valve operating
sequence in which the main steam control valve open
before the reheat control valves, the volumetric flow
through the HP turbine during no-load or low-load
operation is optimized so that unallowable heat up due
to wind age can only occur under the most unfavorable
conditions e.g. if the pressure downstream of the HP
section is too high.
Optimization of the volumetric flow through the HP
turbine by means of trimming device
During turbine operation at low volumetric flow, the
trimming device adjusts the staggered operating
sequence of the main steam and reheats control valves
on the basis of HP turbine exhaust steam temperature,
thus ensuring that the largest possible volume of steam
flows through the HP turbine.
Proper observance of limit conditions for reheats steam
pressure
The steam pressure ration PMS / PRS as a function of
power ratio must not drop below that specified in Data
Sheet.
If the turbine generator unit at a volumetric flow
approaching zero e,g. during turbine generator shut-
down prior to activation of the long-time reverse power
protection or during operation at over speed for over
speed trip testing, the maximum reheat steam pressure
PRS MAN specified in Data Sheet [1] must not be
exceeded.
BHEL, Hardwar
The limit conditions for reheat steam pressure can be
established on the basis of set point values for the main
steam and IP/LP bypass controllers.
Draining the HP turbine by opening the drain valves in
the case of low volumetric flow combined with high
reheat steam pressure, the HP turbine must be drained
by opening the valves in the drain lines located
downstream of the HP control valves, at the turbine
outer casing and upstream of the non return valve(s)
downstream of the HP turbine.
These drain valves are actuated on the basis of a load
signal (p<approx. 5%) or the opening signal of the HP
turbine dump valve, which can be installed as an
additional limiter.
If necessary, the drains sub loop control must be
switched immediately the MANUAL mode and the drain
valves must be opened using a remote manual
command.
Back fitting an HP turbine dump valve
If under unfavorable conditions the cross sections of the
drains compared to the volume of the space
constituted by the HP turbine and the HP exhaust
steam lines up to the non return valve (s) is not a large
enough to ensure sufficiently fast drainage, the plant
operator can arrange with the turbine supplier for an HP
turbine a dump valve to be beck fitted (e.g. to reduce the
time required for pressure reduction).
Actions to be taken in the event of fault-induced closure
of the main steam stop and/or control valves
One particular fault which can arise occur during power
operation when the volumetric flow through the HP
turbine approaches zero as a result of fault-induced
closure of the main steam stop and/or control valves, but
the turbine generator unit continues to operate because
the reheat control valves are still open. In the event of
such a fault, further operation of the turbine generator
unit is not allowed, and must be stopped through remote
manual initiation of a turbine trip.
The occurrence of this type of fault is indicated by a load
surge, opening of the HP bypass station and an increase
in the HP exhaust steam temperature.
Actions to be taken in the event of backflow of steam
through the check valve(s) downstream of the HP
turbine. Blade wind age can occur as a result of non-
leak tightness or faulted operation of the check valve (s)
down stream of the HP turbine if pressure in the
reheated is high.
Non-leak tightness or faulted ‘operation’of1he check
valve(s) occurs if the steam pressure down steam of the
HP turbine cannot be reduced to less than the reheat
steam pressure down steam of the check valve (s) must
be subjected to regular checks for freedom of movement
and leak tightness, in order to
Prevent adverse effects in terms of blade wind age.
6.2-0230-00/2
 Actions to the taken in the event of a high steam
temperature downstream of the HP turbine
If blade wind age occurs in the HP turbine, there will be
an increase in steam temperature at1he measuring point
down steam of the HP turbine.
The limit value of maximum allowable exhaust steam
temperature specified In the Technical Data must not be
exceeded.
After the alarm “HP exhaust temperature high” has been
issued the following actions must be implemented
immediately to prevent unallowable heat up due to wind
age:
- establish a steam pressure ratio P MJP AS which lies
above the characteristic curve specified in Data Sheet
(1)
- reduce steam pressure in the HP turbine by
Lowering the constant-pressure set point for the IP/
LP bypass control system
- reduce the main steam temperature
- If the generator is connected to the public power
system, increase the turbine load
Blade wind age in IP turbines
Causes
In the case of IP turbines, blade wind age (which can
result in unallowable heat up of the blading) has a
number of causes, including excessively low. Volumetric
flow across the balding.
Actions
In the case of annunciation “IP exhaust steam
temperature high” is issued, or if the limit value for the
temperature downstream of the IP turbine specified for
prolonged operation (see Technical Data Sheet) is
exceeded, the load must be increased.
Blade wind age in LP turbine
In case of the LP turbine, blade wind age (which can
result in unallowable heat up of the blading and the
casing) is likewise caused by excessively low volumetric
flow across the blading.
Actions to be taken to prevent unallowable heat up of
LP turbine due to wind age
The following actions can be implemented to prevent the
unallowable heat up due to wind age:
Increase the turbine load.
Cooling by means of condensate injection.
After the alarm “LP casing temperature high” has been
initiated the spray valve of the LP condensate injection
system must be opened, either automatically or
manually, in order to prevent unallowable heat up due to
wind age.
Settings and Tests
Settings of the staggered operating sequences for
main steam & reheat steam control valves in accordance
with the relevant setting diagram.
BHEL, Hardwar
Settings of the settings for the staggered operation of
main steam & reheat steam control valves following
inspections and overhauls.
The control valve opening signals and lifts are recorded
as a function of a common opening signal and the
staggered operating sequence is checked on the basis
of the curve generated.
Functional testing of trimming device for main steam
and reheat control valves after inspections and
overhauls on the basis of the C&I functional diagrams.
On-line testing for freedom of movement of check
valve (s) downstream of HP turbine at six-weekly
intervals during turbine – generator unit operation.
Interruption of the control medium supply results in a
closure command being issued. The check valve (s)
should leave the fully opened position.
Leak testing of the check valve (s) downstream of
the HP turbine during each shut down of the turbine
generator unit.
The leak tightness of the check valve (s) downstream of
the HP turbine must be checked each time the turbine
generator unit is shut down. The check valve (s) must
close during shut down and, if the main steam stop
valves are closed, reclosure of the turbine drains must
not result in an increase in HP turbine steam pressure
while there is still positive steam pressure in the
reheater.
Testing of a activation of long time reverse power
protection in conjunction with leak testing of turbine
control valves during each shut down of the turbine
generator unit.
The turbine controller is used to reduce the steam
turbine load so far that the turbine control valve close
and the generator then acts as motor, driving the turbine.
This reverse power operation causes the reverse power
protection to be activated, which isolates the generator
from the public power system after a certain time delay
has elapsed.
Testing of activation of short time reverse power
protection during each shut down of the turbine
generator unit.
Isolation of the generator from the public power system
after 4 seconds must be monitored and recorded.
Testing and maintenance of protective device in the
event that a fault has resulted in a stricter changeover in
the protection circuit (annunciation: “protective device
faulted”).
6.2-0230-00/3
 Steam Turbine
Operation
The turbine-generator should be shutdown according to
operating instruction shown in the shutdown diagrams.
If an emergency occurs, the turbine generator unit may be
rapidly unloaded and/or be shutdown by operating the trip
push-button or trip valve from any operating condition.
During shutdown, all tests [1] for this must be performed. In
particular test the over speed protection by over speeding
after the recommended interval has elapsed. This test may
be performed when the turbine is at operating temperature,
particular attention is drawn to this test in this context.
If work has to be performed immediately after shutdown of
the turbine on hot parts or if the turning gear is to be
shutdown, instruction for accelerated cooling [2] must be
followed.
We recommend accelerated cooling to reduce cool down
time when shutting down the turbine-generator unit for
preventive maintenance or repairs.
BHEL, Hardwar
Startup and Shutdown Diagrams
Introduction
Short shutdowns should be used to perform minor
maintenance unless large-scale preventive
maintenance programs or repairs are to be performed.
It is a good idea to have a list ready of those jobs that
can be done during short shutdowns.
Operational readiness should be maintained during
maintenance and testing programs and/or should be
established after their completion to enable speedy
restart of the turbine-generator unit.
During long periods of shutdown the turbine and other
components may be exposed to corrosive attacks. So
care must be taken to ensure all components are
protected against corrosion as described in the
specific instructions.
6.2-0300-00
 Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram (General)

(01) + TURBINE/GENERATOR UNLOAD REF. TO 6.2-0320

OR
+ FGA (TURBINE -CONTROL STANDSTILL) START

(02) + START OF BYPASS OPERATION OBSERVE REF. TO 6.2-0320

(03) + GENERATOR BREAKER TO BE OPENED OBSERVE REF. TO 6.2-0320

REVERSE POWER PROTECTION INITIATED

(04) + TEST PROGRAM (SHUTDOWN) CARRY OUT REF. TO 6.3.0060

(05) + TURBINE TRIP INITIATE REF. TO 6.2-0320

OR WITH FGA (TURBINE-CONTROL)
*+ TURBINE TRIP INITIATED REF. TO 6.2-0320

(06) + START OF AUXILIARY OIL PUMP OBSERVE REF. TO 6.2-0320

(07) + TURNING GEAR OPERATION START REF. TO 6.2-0320

+ SHAFT LIFT OIL SUPPLY SYSTEM IN OPERATION
+ TURNING GEAR OIL SYSTEM IN OPERATION
OR WITH SUBLOOP CONTROL
*+ SHAFT LIFT OIL PUMP ON
*+ TURNING GEAR OIL VALVE OPEN

(08) + STEAM -GENERATOR NOT IN SERVICE

+ BYPASS -OPERATION COMPLETED
+ CONDENSING PLANT SHUT DOWN REF. TO 6.2-0330
+ VACUUM PUMPS OFF
+ SEAL -STEAM SUPPLY SHUT -DOWN
+ CONDENSATE PUMPS OFF
+ CIRCULATION WATER SUPPLY NOT IN SERVICE
OBSERVE

(09) + CONTROL FLUID PUMPS SHUT -DOWN REF. TO 6.2-0320

(10) + OIL SYSTEM WITH FGA (OIL SUPPLY) SHUT -DOWN REF. TO 6.2-0340
OR
MANUAL OPERATION AT OPER. CONSOLE
+ SHAFT STANDSTILL
+ OIL SYSTEM NOT IN SERVICE

BHEL, Hardwar 6.2-0310-01

 Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram

(01) + OPERATIONAL CONDITIONS CHECK

+ LOAD CONTROLLER ON
+ LOAD GRADIENT ADJUSTED
ADJUSTMENT ACCORDING TO
- REQUIREMENT OF LOAD DESPATCHER
- STEAM GENERATOR CONTROL
- THERMAL INFLUENCE ON TURBINE
+ BYPASS CONTROL ON
+ FIXED PRESSURE SET POINT BYPASS CONTROL ...KG/CM2
ADJUSTMENT IN AGREEMENT WITH
PRESSURE REQUIREMENTS -
- REHEAT PRESSURE DURING START-UP
AND SHUTDOWN
+ ELECTRO HYDRAULIC TURBINE CONTROL NOT FAULTED
+ BYPASS CONTROL NOT FAULTED
+ TSC -INFLUENCE ON
+ TURBINE STRESS CONTROLLER (TSC) NOT FAULTED
IF THE TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED.
REFER 6.2-0430 IF TSC ALLOWANCE IS REDUCED
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
+ SUBLOOP CONTROL TURNING GEAR OIL VALVE ON
+ SUBLOOP CONTROL DRAINS ON
THE SUBLOOP CONTROLS MUST ALWAYS BE
SWITCHED ON DURING OPERATION
+ TURBINE/GENERATOR LOAD > 0 MW
IT IS ASSUMED THAT THE TURBINE/GENERATOR
WILL BE UNLOADED FROM ANY LOAD TO 0 LOADS
WITHOUT DELAY

(02) + LOAD REFERENCE VALUE LOWER

+ LOAD TARGET VALUE 0 MW
OR WITH FGA (TURBINE -CONTROL)
+ FGA (TURBINE -CONTROL STANDSTILL) START

(02/S) * + LOAD TARGET VALUE 0 MW

(03) + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
THE LIMITED LOAD REFERENCE VALUE FOLLOWS
THE TARGET LOAD REFERENCE VALUE WITH THE
ADJUSTED LOAD GRADIENT. THE LOAD GRADIENT
WILL BE REDUCED IF REDUCTION OF TSC
ALLOWANCE OCCURS. THE TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.

+ TURBINE/GENERATOR LOAD: STEAM GENERATOR LOAD <1

(04) * + START OF BYPASS OPERATION OBSERVE
BYPASS VALVES OPEN IF LOAD OF STEAM
GENERATOR IS GREATER THAN
TURBINE/GENERATOR LOAD
*+ BYPASS STOP VALVES OPEN MAN41 AAO01
AND MAN51 AAO01
*+ BYPASS CONTROL VALVES OPEN MAN42 AAOO2
AND MAN 52 AAOO2

BHEL Hardwar 6.2-0320-02/1

 (05) + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
+ AUXILIARY POWER SUPPLY SECURED
CRITERION:
AFTER THE GENERATOR CIRCUIT BREAKER IS OPEN
THE UNIT AUX. POWER SUPPLY IS SECURED
OPERATION OF SWITCH GEARS MUST AGREE
WITH AUXILIARY POWER SUPPLY FACILITIES
*+ TURBINE LOAD CONTROLLER OFF
*+ TURBINE SPEED CONTROLLER ON
AFTER A FIX SET MINIMUM LOAD IS REACHED
THE TURBINE CONTROLLER CHANGES OVER FROM
LOAD TO SPEED CONTROL

(06) + SPEED REFERENCE VALUE LOWER

OR WITH FGA (TURBINE -CONTROL)
(06/S) *+ SPEED REFERENCE VALUE LOWER
+ SPEED REFERENCE VALUE < RATED SPEED
*+ MAIN STEAM CONTROL VALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 10 AAOO2
AND MAB20 AAO02
*+ REVERSE POWER PROTECTION INITIATED
*+ GENERATOR CIRCUIT BREAKER OPEN
MEASURES TO BE TAKEN ON FAILURE.
OF REVERSE POWER PROTECTION REF. TO 6.2-0410

(07) + TEST PROGRAM (SHUT DOWN I CARRY OUT REF, TO 6.3-0060

TESTING INTERVALS OBSERVE REF. TO 6.2-0020
FGA PROGRAM INTERRUPT

(08) + TURBINE TRIP INITIATE

OR WITH FGA
(08/S) *+ TURBINE TRIP INITIATED
+ BEGIN OF COASTING DOWN TIME NOTE
*+ TRIP FLUID PRESSURE 0 KG/CM2 MAX51 CPO 13
*+ MAIN STEAM STOP VALVES CLOSED MAA10 AAO01
AND MAA20 AAO01
*+ REHEAT STOP VALVES CLOSED MAB10 AAOO1
AND MAB20 AAO01
*+ MAIN STEAM CONTROL V ALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 1 0 AAO02
AND MAB20 AAO02
*+ SWING CHECK VALVE COLD REHEAT CLOSED LBC10 AAO01
*+ EXTRACTION NON RETURN VALVES CLOSED
CODE NO. OF EXTRACTION NON RETURN VALVES
REFER TO SINGLE LINE DIAGRAMS
*+ VACUUM BREAKER OPEN MAG10 AAO01
VACUUM BREAKER BRINGS VACUUM DOWN TO O.2KG/CM2 ABS
VACUUM BREAKER CLOSED AT VACUUM > 0.2 KG/CM2 ABS
IN CASE OF DANGER TO THE TURBINE/GENERATOR
THE VACUUM CAN BE REDUCED SO THAT COAST P AMB
DOWN TIME WILL BE REDUCED ACCORDINGLY.
*+ SPEED OF TURBINE/GENERATOR < 3000 RPM

(09) + STARTING AND LOAD LIMIT DEVICE LOWER MAX47BYO01

+ STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01
OR WITH FGA (TURBINE -CONTROL)
(09/s) + STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01

BHEL, Hardwar 6.2-0320-02/2

 (10) + DE-EXCITATION BREAKER OPEN
+ DE-EXCIT A TION BREAKER OPEN

(11) + VACUUM BREAKER CHECK

+ VACUUM > 0.2 KG/CM2 ABS
+ VACUUM BREAKER CLOSED

(12) + SPEED REFERENCE VALUE LOWER

+ SPEED REFERENCE VALUE 0%

(13) + WARM-UP CONTROL (SEAL STEAM) SWITCH CONTROL

+ WARM-UP CONTROL (SEAL STEAM) OFF

(14) + DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPEN MAL11 AA011
OR WITH FGA AND MAL12 AAO 11
+ DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPENS MAL 11 AA011
AND MAL12 AA011

(15) + START OF AUXILIARY OIL PUMP OBSERVE MAV22 APO01

OR
+ START OF EMERGENCY OIL PUMP OBSERVE MAV24 APO01
+ OIL PRESSURE < 4.8 KG/CM2 MAV21 CPO01
+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV22 APO01
OR
+ OIL PRESSURE < 4.5 KG/CM2 MAV21 CPO01
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
*+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV23 APO01
OR
+ LUBE OIL PRESSURE < 1.2 KG/CM2 MA V42 CPO 14
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
AND MAV23 APO01
*+ EMERGENCY OIL PUMP BY SUBLOOP CONTROL ON MAV24 APO01
+ OIL TEMPERATURE CONTROL VALVE CLOSE MAV41 AAO01
+ OIL TEMPERATURE CONTROL VALVE CLOSED MAV41 AAO01

+ SPEED OF TURBINE/GENERATOR < 510 RPM

(16) + JACKING OIL PUMP SWITCH ON MAV31 AP001

+ JACKING OIL PUMP ON MAV31 AP001

OR BY SURLOOP CONTROL JACKING OIL PUMP

*+ JACKING OIL PUMP ON MAV31 AP001

+ JACKING OIL PRESSURE IN HEADER > 100 KG/CM2 MAV35 CP012

OR
JACKING OIL PRESSURE IN HEADER < 100 KG/CM2 MAV35 CP012
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON
OR
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON MAV33 AP001
ON FAILURE OF AC POWER
+ END OF COASTING DOWN TIME NOTE
THE MEASUREMENT OF COASTING DOWN TIME
WILL GIVE VALUABLE INFORMATION ABOUT
INTERNAL CONDITIONS OF THE TURBINE, ESPECIALLY
WHEN SHUTDOWN OCCURS DUE TO DANGER

BHEL, Hardwar 6.2-0320-02/3

 + SPEED OF TURBINE/GENERATOR < 210 RPM
(17) + TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
+ TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
OR BY SUBLOOP CONTROL TURNING GEAR
*+ TURNING GEAR OIL VALVE OPEN MAV51 AAO01

(18) + DRAIN VALVES OPEN

+ DRAIN HP OUTER CASING OPEN MAL22 AA011
CRITERION:
TEMPERATURE HP OUTER CASING MIDDLE TOP < 300 °C
OR TURBINE LOAD <2%
+ DRAIN AHEAD OF CRH SWING CHECK VALVE OPEN MAL65 AA011
CRITERION: CRH NRV CLOSED
+ DRAIN UPSTREAM OF EXTRACTION VALVES OPEN
DESIGNATION OF DRAIN VALVES ACCORDING
TO SINGLE LINE DIAGRAM.
CRITERION: EXTRACTION CHECK VALVES CLOSED
+ DRAIN SEAL STEAM HEADER OPEN MAL81 AA011
CRITERION: TEMPERATURE IN SEAL STEAM HEADER < 120 °C
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL OF DRAINS NOT FAULTED
*+ DRAIN VALVES BY SUBLOOP CONTROL OPEN
CRJTERION: REFER TO MANUAL OPERATION

(19) + MODE OF OPERATION STEAM GENERATOR CHECK

AND
+ MODE OF OPERATION BYPASS CONTROLS CHECK
AND
+ MODE OF OPERATION CONDENSING PLANT CHECK
+ STEAM GENERATOR NOT IN SERVICE
+ BYPASS OPERATION COMPLETED
CRITERION:
BYPASS STOP VALVES CLOSED
BYPASS CONTROL VALVES CLOSED
THE BYPASS OPERATION IS COMPLETED IF THE
REHEATER OF THE STEAM GENERATOR IS
DEPRESSURIZED. THE REHEATER WILL BE
DEPRESSURIZED BY LEADING THE STEAM INTO
THE CONDENSER OR BY OPENING THE EXTERNAL
REHEATER DRAIN VALVES. THE BYPASS VALVE
WILL BE USED TO LEAD THE STEAM TO THE
CONDENSER. THE FIXED PRESSURE SET POINT
HAS TO BE LOWERED.
+ CONDENSING PLANT NOT IN SERVICE REF. TO 6.2-0330
VACUUM PUMPS OFF
CONDENSATE PUMP OFF
NOTE
IF THE CONTROL FLUID SYSTEM WILL BE SHUT
DOWN WITHOUT SHUTTING DOWN THE
CONDENSATE PUMP THE BYPASS SPRAY
WATER VALVES WILL OPEN. ON REF. TO 6.2-0330
OR OFF
+ SEAL STEAM PRESSURE P AMB
SEAL STEAM CONTROLLER OFF
SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
FAN OF SEAL STEAM CONDENSER OFF MAW80 ANOO1
AND MA W80 ANOO2

BHEL, Hardwar 6.2-0320-02/4

 + TEST PROGRAM (STANDSTILL) COMPLETED
+ CONTROL FLUID SUPPLIED DEVICES NOT IN SERVICE
(20) + CONTROL FLUID SYSTEM MANUAL OPERATION SHUTDOWN
OR WITH FGA (CONTROL FLUID SYSTEM)
+ FGA (CONTROL FLUID SYSTEM STANDSTILD START
OPERATION OF PUSH BUTTONS
REFER TO THE MANUAL FOR FGA.

(21) + SUBLOOP CONTROL HP .CONTROL FLUID PUMP SWITCH OFF

+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
+ HP -CONTROL FLUID PUMP OFF MAX16 AP001
OR MAX16 AP002
OR WITH FGA (CONTROL FLUID SYSTEM)
(21/S) *+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
(21/S) *+ HP -CONTROL FLUID PUMP OFF MAX 16 AP001
AND MAX 16 AP002

NEUTRALIZATION NO. NORMAL

NEUTRALIZATION NO. DOES NOT
TEND TO INCREASE
(22) + CF -RECONDITIONING PUMP SWITCH OFF MAX91 APOO1
+ CF -RECONDITIONING PUMP OFF MAX 91 APOO1
OR WITH FGA (CONTROL FLUID SYSTEM)

(22/S) *+ CF -RECONDITIONING PUMP OFF MAX91 APOO1

+ TEMPERATURE IN CONTROL FLUID TANK < 50 °C MAX11 CTO01

(23) + SUBLOOP CONTROL OF CONTROL FLUID HEATER SWITCH OFF
FLUID HEATER
SWITCH OFF SUBLOOP CONTROL OF CONTROL
FLUID HEA TEA ONLY IF THE CONTROL FLUID SYSTEM
MUST NOT BE OPERATED FOR AN EXTENDED PERIOD ~
OF TIME AND/OR THERE IS SUFFICIENT TIME TO C
HEAT-UP THE CONTROL FLUID IN THE TANK PRIOR
TO RESTART.

BHEL, Hardwar 6.2-0320-02/5

 Steam Turbine Condensing Plant
Operation Shutdown Diagram

(1) CRITERIA FOR SHUT DOWN CHECK

+ STEAM GENERATOR NOT IN SERVICE
+ BY PASS OPERATION COMPLETED
+ HP BYPASS VALVES CLOSED
+ EXTERNAL DRAINS OF STEAM LINES OPEN
BEFORE THE CONDENSING PLANT Will BE SHUT
DOWN ALL. ADMISSION STEAM SYSTEM HAVE
TO BE DEPRESSURIZED.

(2) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOLLOWING CRITERIA ARE FILLED
THE SYSTEM Will BE SHUT DOWN FROM OPERATION
+ AIR SUCTION VALVE OF VACUUM PUMPS OPEN
+ SERVICE VACUUM PUMP ON
+ VACUUM BREAKER CLOSED
+ SEAL STEAM CONTROL ON
AND
+ SEAL STEAM SUPPLY VALVE OPEN
+ SEAL STEAM EXHAUST FAN ON MAW11 AAO01
MAW80 ANO01
ORMAW80 AN02
+ CONDENSATE SYSTEM IN OPERATION
+ CIRCULATING WATER OF CONDENSER AVALABLE
+ VACUUM BREAKER OPEN
+ WARM-UP CONTROL (SEAL STEAM) ON

(3) + CONSENSING PLANT MANUAL OPERATION SHUT DOWN

OR WITH FGA (CONDENSING PLANT)
+ FGA (CONDENSING PLANT STANDSTILL) START
FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THE FGA

(4) + AIR SUCTION VALVE VACUUM PUMP CLOSE

+ AIR SUCTION VALVE VACUUM PUMP CLOSED

(5) + VACUUM PUMPS SWITCH OFF

+ VACUUM PUMPS OFF
THE VACUUM PUMPS DO NOT BELONG TO THE
SCOPE OF SUPPLY OF THE TURBINE/GENERATOR
OPERATION OF VACUUM PUMPS AND VALVES
ACCORDING TO SPECIAL INSTRUCTION.

(6) + VACUUM BREAKER OPEN MAG10 AAO01

+ VACUUM BREAKER OPEN MAG10 AAO01
OR WITH FGA, SUBGROUPS (SEAL STEAM SUPPLY
STANDSTILL)

(06/S) *+ VACUUM BREAKER OPEN MAG10 AAO01

+ VACUUM > 0.8KG/CM2

BHEL, Hardwar 6.2-0330-01/1

 + SEAL STEAM CONTROL SWITCH OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSE MAW11AAO01
+ SEAL STEAM CONTROL OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(07/S) *+ SEAL STEAM CONTROL OFF
AND
(07/S) *+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01

(08) + SEAL STEAM EXHAUST FAN SWITCH OFF MAW80 ANO01

ORMAW80 AN02
+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(08/S) *+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2

(9) + CONDENSATE SYSTEM SHUT DOWN

+ CONDENSTATE SYSTEM NOT IN SERVICE
THE CONDENSATE SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE-
GENERATOR). SPECIAL INSTRUCTIONS FOR
-CONDENSATE PUMPS
-CONDENSER LEVEL CONTROL
-MINIMUM FLOW CONTROL
-HEATERS
MUST AGREE WITH TURBINE OPERATION AND
HAVE TO BE FOLLOWED.
THE CONDENSATE SYSTEM CAN ALSO BE
SHUT DOWN AFTER STEP (12) IS CARRIED OUT.

(10) + CIRCULATING WATER SYSTEM SHUT DOWN

+ CIRCULATING WATER SYSTEM NOT IN SERVICE
CIRCULATING WATER SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE
GENERATOR).
THE CIRCULATING WATER SYSTEM SHOULD STAY
IN OPERATION DURING SHORT DOWNS TO
AVOID CORROSION OF THE CONDENSER TUBES,
THE CIRCULATING WATER’SYSTEM CAN£E SHUT
DOWN AFTER STEP (12) IS CARRIED OUT.

(11) + VACUUM BREAKER CLOSE MAG10 AAOO1

+ VACUUM BREAKER CLOSED MAG10 AAO01
OR WITH FGA (SEAL STEAM SUPPLY STANDSTILL)
(11/S) *+ VACUUM BREAKER CLOSED MAG10 AAO01

(12) + WARM-UP CONTROL (SEAL STEAM) SWITCH OFF

+ WARM-UP CONTROL (SEAL STEAM) OFF
OR WITH FGA (SEAL STEAM)
(12/S) +* WARM-UP CONTROL (SEAL STEAM) OFF

BHEL, Hardwar 6.2-0330-01/2

 Steam Turbine Oil System
Operation Shutdown Diagram

(01) + CRITERIA FOR STANDSTILL CHECK

+ CASING TEMPERATURE < 100 °C MAA50 CT053A
BEFORE THE TURBINE GEAR IS STOPPED, SHAFTS AND MAA50 CT054A
AND CASING MUST COQL DOWN TO 100 °C TO
PREVENT SHAFT DISTORTION DURING STANDSTILL
PERIOD FOLLOWING TURNING GEAR OPERATION.
THE TURNING GEAR MUST BE STOPPED IF ABOVE
TEMPERATURES ARE REACHED, EXCEPT IN CASES
WHERE EXTENDED TURNING GEAR OPERATION IS
REQUIRED e.g. IF THE TURBINE IS TO BE STARTED
IN SHORT TIME.

(02) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE SHUT DOWN FROM
TURNING GEAR OPERATION.
+ SUBLOOP CONTROL TURNING GEAR ON
AND
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
AND
+ AVXILIARY OIL PUMP ON MAV22 A Pool
OR MAV23 A Pool
+ WAITING TIME FOR COOLING DOWN (K4) EXPIRED
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
AND
+ JACKING OIL PUMP ON MAV31 A Pool
OR MAV32 A Pool

(03) + FGA (OIL SUPPLY STANDSTILL)

FOR OPERATION OF PUSH BUTTONS REFER
TO MANUAL FOR FGA.
OR
+ TURNING GEAR MANUALLY OPERATED SHUTDOWN

(04) + SUBLOOP CONTROL TURNING GEAR SWITCH OFF

AND
+ TURNING GEAR OIL VALVE CLOSE MAV51 AAOO1
+ SUBLOOP CONTROL TURNING GEAR OFF
AND
+ TURNING GEAR OIL VALVE CLOSED MAV51 AAOO1
OR WITH FGA (OIL SUPPLY)
(04/S) *+ SUBLOOP CONTROL TURNING GEAR OFF MAV51AAO12

(05) + WAIT
THE WAITING TIME IS EXPIRED WHEN THE
SHAFT COMES TO A COMPLETE STOP.
+ SHAFT STAND STILL

BHEL Hardwar 6.2-0340-01/1

 06) + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS SWITCH OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH OFF
AND
+ AUXILIARY OIL PUMP SWITCH OFF MAV22 A Pool
OR MAV23 A Pool
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
+ AUXILIARY OIL. PUMP OFF MAV22 A Pool
AND MAV23 A Pool
AND
+ EMERGENCY OIL PUMPS OFF MAV24 A Pool
OR WITH FGA (OIL SUPPLY)
(06/S) *+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
*+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
*+ AUXILIARY OIL PUMP OFF MAV22 A Pool
AND MAV23 A Pool
AND
*+ EMERCJENCY OIL PUMP OFF MAV24 A Pool

(07) + WAIT
WAIT FOR SHUTDOWN OF JACKING OIL PUMP UNTIL
THE RELATIVE EXPANSIONS ARE REDUCED AND NO
FURTHER MAJOR AXIAL SHIFTING OF THE JOURNALS
IN THE BEARINGS IS EXPECTED.

(08) + SUBLOOP CONTROL OF JACKING OIL PUMP SWITCH OFF

AND
+ JACKING OIL PUMP SWITCH OFF MAV31 A Pool
OR MAV32 A Pool
+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
+ JACKING OIL PUMP OFF MAV31 A Pool
OR WITH FGA (OIL SUPPLY) AND MAV32 A Pool
(08/S) *+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
*+ JACKING OIL PUMP OFF MAV31 A Pool
AND MAV32 A Pool

BHEL, Hardwar 6.2-0340-01/2

 Steam Turbine
Operation
Introduction
If service activities or repairs have to be carried out very
soon or immediately after shut down of the turbine, it is
advisable to reduce the cooling down time. Fast cooling
down is necessary especially if activities are to be executed
at turbine parts, which are exposed to high operational
temperatures.
Cooling down of the turbine during operation
The cooling down of the turbine is to be started during load
operation as follows:
Reduce unit power output to the boiler minimum load.
Slowly reduce admission temperatures to values, which
can be maintained steady by boiler control.
The HP exhaust temperature may not be reduced to
the saturation point corresponding to the HP exhaust
pressure.
Observe the TSE/TSC lower margin.
NOTE: Do not reduce load and temperature at the same
time because of the danger to exceed the permissible
relative expansion and the lower margin of the TSE/TSC
Load or temperature reduction have to be stopped or the
rate of ‘change to be reduced depending upon the limiting
values of relative expansion and the lower margins of the
TSE/TSC.
Operate the turbine with reduced load and steam
temperatures until the lower margin of TSE/TSC do not
change significantly any more.
BHEL, Hardwar
Fast Cooling Down of the Turbine
Shutdown the turbine in accordance with the
respective instructions after cooling down during
bypass operation has been completed.
Fast cooling down during stand still
During stand still air will be sucked through the
turbine by the vacuum pumps resulting in fast cooling
of casing and rotor.
Arrangement of the air Inlet sockets
HP turbine: Between main steam stop valves and
control valves.
IP turbine: At the admission pipes between control
valves and IP turbine,
During normal operation the air inlet sockets are
closed by blank flanges.
Procedure
Open air inlet sockets
Set test valve of all stop valves in the position stop
valve closed.
Operate vacuum pumps
Observe TSE/TSC lower margin and stop vacuum
pumps if limit values are exceeded.
The fast cooling down of turbine has to be
limited to those cases where this measure is
unavoidable with respect to the availability of the
turbine.
6.2-0350-01
 Steam Turbine Preventing Corrosion
Maintenance in Idle Turbines

Introduction The condensation produced when the temperature

If a turbine stands idle for a long period it is liable to
corrosion attack which if not prevented by appropriate
means, will cause deterioration of the components.
During long idle periods when the turbine has
cooled to the ambient temperatures, all components
which come into contact with steam vapour, water or
damp air are liable to corrosion attack.
The Effect of Corrosion
within the turbine falls below point (this is the
principal source of the water).
Fig.1 shows the effect of relative humidity on rusting
loss (VA) for a sample of carbon steel.
The rusting loss increase sharply when the relative
humidity is high therefore, to inhabit corrosion attack in
an idle turbine, the relative humidity of the enclosed air
should be maintain below 50% as far as possible.
FIg. 1 Enect of Relative Humidity on Hustling Loss
Vr

Seizure of sliding components due to increased Preventing Corrosion During Idle Periods
volume of the products of corrosion,
If complete effectiveness of the following method of
Heavier wear of corrosion-damaged surfaces,

Erosion of material reducing sections and producing

notch effects which weaken the components.

Leaks at valve and fittings,

Fouling of the systems which spreads the corrosion

to other areas.

Factors Contributing to Corrosion

Chemically corrosive gases and vapours are

seldom encountered in normal power stations in
sufficiently high concentrations to cause damage.
However, if a turbine is installed in or near a chemical
plant it would be possible for such gases and vapours
to increase the amount of corrosion.

On the other hand, water-which is responsible for a

high proportion of all corrosion -is found in all turbines
which have cooled down and been idle for some time.

The water originates from: corrosion prevention is to be achieved, it is essential

for no steam at all to enter the turbine while it is idle.
Residual water in inadequately drained spaces
Any auxiliary steam lines which will remain under
Steam leaking into the turbine and condensing steam pressure during a complete unit shut-down must
be isolated in a manner which ensures that no steam
can enter the turbine.

The turbine itself and its connecting pipe work must
be well drained through out the idle period. It is also
advisable to drain the condensate from the condenser.
There are basically two possible methods of
preventing corrosion attack caused by condensation
from the air inside the turbine:
The turbine components can be heated by means of
a hot air blower to a temperature above that of the
outside air.
The high relative humidity air inside the turbine can
be exchanged for dry air.
For large turbines, therefore, a method of
prevention is recommended employing an Air dryer to
exchange the high relative humidity air in the turbine
for dry air.

BHEL, Hardwar 6.2-0360-00/1

 Filtered air from the atmosphere is drawn into the Operation of the air -dryer must be executed in
Air dryer by a fan and moisture is removed from it In a accordance with the instructions of the dryer-
rotating drying wheel before it is delivered to the manufacturer.
turbine. The dying wheel which has absorbed the
moisture is dried by a reverse flow of hot air in the The air dryer does not belong to the scope of supply
regenerating sector which is separate from absorption
sector.
There will an obvious drop in the relative humidity
only a few hours after switching on the Air dryer. It

must be operated continuously while the turbine is idle.

The dryer’s relatively low power consumption does not
involve any great cost.

The filter of the Air dryer must be clean from time to

time depending on the dust content in the air supply. It
is inadvisable to operate the air dryer without the filter
because of the danger of blockage in the fine tubular
ducts of the absorption wheel. Two air dryers are
needed.
of BHEL.
Figure 3 shows the interconnection between air-
dryers and turbine.
Preservation of the Oil System
The wet air escapes at the drains behind HP
Turbine at flanges between IP valves and IP casing The turbine oil contains corrosion inhibitors
and the lowest point of the condensers. therefore it is unnecessary to adopt any special
measures to preserve oil carrying components except
Main steam control valves have to be opened and to operate one of the auxiliary oil pumps for an hour at
blocked in this position. intervals of two to three weeks.

BHEL, Hardwar 6.2-0360-00/2

 Steam Turbine Fault Tracing
Operation Introduction

The scope and content of the trouble shooting
instructions are limited to criteria or measures that can be
performed by the control panel operator or the turbine
operator without specialized help and avert events
detrimental to the operation and availability of the turbine
generator unit.
In the instruction Serious Faults [1], the remedial
measures are indicated against the faults that could have
severe consequences.
The operating staff must be trained to take proper action
should such fault occur.

Also refer to the following sections:

[1] 6.2-0410: Serious Faults

BHEL, Hardwar 6.2-0400-00

 Steam Turbine Serious Faults
Operation Fault Tracing

Introduction Many of the criteria refer not only extreme

Many operating faults require the monitoring
staff to take immediate appropriate action if
serious reductions in the availability,
operating reliability and service life of the
turbine are to be averted.
The following criteria and instruction must be
included in the intensive schooling and
training program for the monitoring staff.
conditions requiring immediate action but
also to the trends of the process transients,
which must also be taken into consideration.
The turbine is in danger not only when the
specified limits of a process parameter are
reached but also when the process
parameter deviates markedly or rapidly from
the normal values otherwise observed.

Fault Cause Remedy

ƒ Other symptoms
Load rejection
ƒ Turbine generator remains
in operation after short
time rise in speed.
ƒ Excess steam from steam
generator is dumped to the
condenser through the
bypass valves.
ƒ Prolonged operation at
rated speed with or without
residual load.
Load rejection with turbine
trip
ƒ Turbine speed reaches trip
speed of overspeed trip.
Breaker opens as a result of
an internal or external fault.
Normal procedure
Beaker opens as a result of an
internal or external fault.
Control valves and extraction
valves closed by the turbine
governor to stop the steam
flow through the turbine.
Manual intervention is not
possible as automatic shut
down is too fast.
Reduce steam generator to
minimum output immediately, if
this is not done automatically
by the unit control.
Operation may continue
indefinitely.
Limits specified in 6.1-0101
must not be exceeded.
Set reference speed setter to
rated speed.
Reduce main steam
temperature or load turbine if
HP turbine exhaust steam
temperature approaches to
limits.
General rule: determine cause
of shut-down. Synchronize
generator if permitted by
results of fault tracing.
See also Turbine Trip.
Refer 6.2-0450.

BHEL, Hardwar 6.2-0410-00/1

 Fault Cause
ƒ Other symptoms
Adverse condition during load
rejection
Control malfunction
Turbine trip
ƒ Turbine trip by protective
devices
ƒ Turbine-generator unit in
imminent danger
ƒ Excess steam from steam
generator is dumped to the
condenser through the
bypass valves
Overspeed after load rejection.
Shaft displacement in thrust
bearing due to damage to
bearing.
Condenser vacuum reduced
due to fault in condenser plant.
Remote trip by protective
devices in steam supply
system, turbine or generator.
BHEL, Hardwar
Remedy
Investigate conditions, e.g.
load and speed prior to load
rejection.
Check control and attend
malfunction.
Stop and control valves and
extraction valves close.
Generator disconnected from
system by reverse power
protection relay.
Speed drops;
Auxiliary oil pump cuts in due
to loss of pressure as speed
drops, turning gear operation
commences.
Reduce condenser vacuum to
shorten coast down.
− Open vacuum beaker
− Stop air extraction
− Allow air to condenser
plant.
Reduce steam generator to
minimum output immediately if
this is not done automatically
by the unit control.
General rule: determine cause
of trip. See also 6.2-0450.
See load rejection with turbine
trip.
Inspect thrust bearing and, if
necessary, repair, see also
6.2-0421. Refer to fault tracing
instructions and eliminate fault.
Refer to relevant fault tracing
instructions and eliminate fault.
Refer to relevant fault tracing
instructions and eliminate fault.
6.2-0410-00/2
 Fault
ƒ Other symptoms
Reverse power protection
relay fails to open generator
breaker
ƒ Turbine control valves
closed by control as load
removed
The following parameters
exceed the permissible
limits even though remedial
measures have been taken
as prescribed in the relevant
fault tracing instructions
ƒ Vibration high
BHEL, Hardwar
Cause Remedy
Suspected that steam is still Attention: do not open
entering the turbine. generator breaker manually
(danger of impermissible
overspeed).
Check position of control and
extraction valves (Desired
position: 0%).
Trip turbine.
Observe closing of stop
valves, check steam pressure
in turbine, check output
display, reduce condenser
vacuum:
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant
Open turbine drains
Open drains between stop and
control valves
Shut down steam generator;
reduce steam pressure in
steam supply lines.
Fault in reverse power If reverse power protection
protection relay relay is not actuated by all or
some of the above mentioned
measures, it is very probable
that there is a fault in the
reverse power protection relay.
In this case, disconnect the
generator from the supply
system by opening the
breaker.
Use load limiting device to
reduce load on turbine
generator unit from any
operating mode to no-load
and/or shut-down unit by
actuating main trip valve.
See 6.2-0420 Reduce condenser vacuum to
shorten coast down.
6.2-0410-00/3
 Fault
ƒ Other symptoms
ƒ Casing differential
temperatures high
ƒ Bearing metal
temperatures high
ƒ Temperature differences
between parallel steam
supply lines high
ƒ Rapid, large drop in inlet
stream temperature
ƒ Condensate level in
condenser very high
Cause Remedy
See 6.2-0423 Note: The decision whether
the load limiting device should
be used to further reduce load
See 6.2-0421
before the main trip valve is
actuated will depend both on
the seriousness of the danger
and on the amount by which
the limits are exceeded.

The following parameters

exceed the permissible
limits
ƒ Inlet steam pressure high, Steam generator output too Reduce steam generator
pressures and duration of high output or increase turbine load
exposure to excessive
pressures limited as
specified in 6.1-0100.
ƒ Inlet steam temperatures Fault in steam generator Change steam generator
high. Temperatures and operation, eliminate fault if
duration of exposure to necessary.
excessive temperature
limited is specified in
6.1-0100.
ƒ Steam pressure upstream Load too high Reduce turbine load
of blading and/or extraction
steam pressure high. Irregularities in the turbine e.g. Measure stage pressures and
Pressures and duration of blade choking. compare with normal values
under identical operating
exposure to excessive
pressure limited as conditions.
specified in 6.1-0100. Measure internal efficiency.
ƒ HP exhausts temperature Reduce main steam
high during no-load or low temperature or increase
load operation. turbine load.
If these measure do not
reduce the temperature,
initiate turbine trip.
ƒ LP turbine exhausts Ventilation heating through Start injection into LP turbine
temperature high during no blading. or increase load.
load or low load operation.
ƒ Bypass stream Condenser vacuum low. Check condensate pumps.
temperature high during Injection water pressure too Reduce steam generator
bypass operation low. Bypass steam flow rate output.
too high.

BHEL, Hardwar 6.2-0410-00/4

 Fault Cause Remedy
ƒ Other symptoms
Control valve or stop valve
fails to open again after
testing with automatic
turbine tester
ƒ All measures as Fault in valve or turbine tester. The turbine plant may be
prescribed in 6.2-0455 fail. operated with defective valve
for max.1 week.
If necessary, the output must
be reduced so that the limits
as prescribed in 6.1-0100 are
not exceeded.
Drain steam line upstream and
downstream of defective valve
thoroughly.
Observe limits for temperature
difference between parallel
steam supply lines.
Shaft assembly runs down
without lubricating oil
ƒ Fault in auxiliary and Check bearing metal
emergency oil pumps. temperatures, if impermissibly
Jacking oil pumps in high, inspect bearings.
operation
ƒ Fault in jacking oil Danger of bearing whipping.
pump(s). Check bearing metal
temperatures. Check bearings.
Fire or fire hazard during Set off fire alarm. Follow fire
operation protection rules. if
necessary, initiate fire
fighting measures.
At the same time:
ƒ Escape of control fluid Leakage in piping or other Press fire protection
turbine components pushbutton 1
or
Switch off sub-loop control for
the control fluid pumps
immediately and shut-down
(operating) pump (result:
turbine generator unit trips).
ƒ Escape of oil from the Leakage in piping or other Press fire protection
lubricating oil system turbine components pushbutton 2 (pressing fire
protection pushbutton 2
automatically initiate fire
protection 1 measures), result:
turbine generator unit trips.

BHEL, Hardwar 6.2-0410-00/5

 Fault Cause Remedy
ƒ Other symptoms
or
Shut down turbine generator
unit. Depressurize control fluid
system (measures as above).
Switch off sub loop control for
jacking oil pumps.
Start up jacking oil pumps.
Switch off subloop control for
auxiliary oil pump. If
necessary, shut down auxiliary
oil pump(s). Check to ensure
that subloop control cuts-in
emergency oil pump as oil
pressure drops. Close turning
gear oil valve. Reduce
condenser vacuum to shorten
coast down.
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant
ƒ Shaft comes to a standstill Shut down DC lubricating oil
when fire protection pump. Keep jacking oil pump
measures are initiated in operation if no leakage from
the jacking oil system.
Turn shaft through 180 degree
at intervals of approx. 10
minutes. For treatment of
turbine after complete
standstill shaft see 6.2-0460.
Eliminate leak and perform
hydrostatic pressure test.
Acknowledge initiation of fire
protection measures.
Restart lubricating and control
fluid system.
Commence turning gear
operation.
Replace insulating materials
soaked with escaped fluid.
Start up turbine generator unit.

BHEL, Hardwar 6.2-0410-00/6

 Fault
ƒ Other symptoms
Fire or fire hazard during
turning gear operation
ƒ Escape of control fluid
ƒ Escape of oil from the
lubricating oil system
ƒ Escape of oil from the
jacking oil system
Lubricating or control fluid
loss annunciated by level
monitoring circuit
ƒ Separate control fluid
system
Alarm: fluid level low or very
low (2-out-of-3)
ƒ Oil system
Alarm: oil level low
ƒ Oil system
Turbine trip due to oil level
very low (2-out-of-3)
BHEL, Hardwar
Cause Remedy
Set off fire alarm.
Follow fire protection rules.
If necessary, initiate fire
fighting measures.
Leakage in piping or other Measures as for fire or fire
turbine components hazard during operation.
Leakage in piping or other Jacking oil pump stays in
turbine components operation.
Close turning gear oil valve.
Switch off sub-loop control for
auxiliary oil pumps.
Shut down auxiliary oil pumps.
Check to ensure that, sub-loop
control cuts in the lubricating
oil pumps as oil pressure
drops. For further measures
see: Fire or fire hazard during
operation.
Leakage in piping or other Shut down jacking oil pump
turbine components (risk of bearing damage is
minor if turning gear stays in
operation).
Isolate and eliminate leak.
Start up jacking oil pump.
The system must be checked
immediately for leakage if this
alarm is generated in rapid
succession. A leak must be
assumed and appropriate fire
protection measures taken.
The system must be checked
immediately for leakage if this
alarm is generated.
Fire protection measures
initiated automatically.
Note: The trip system is
inoperative during turning gear
operation.
6.2-0410-00/7
 Fault Cause Remedy
ƒ Other symptoms
Escape of steam Leakage in piping or other Isolate steam leakage area
turbine components immediately and depressurize
system concerned, if possible.
If there is a rupture hazard
(pre-rupture leak), shut down
turbine generator unit
immediately.
Carefully consider risk of
erosion at sealing surfaces
and decide on time of shut
down.

Earthquake Unload and shut down turbine

generator unit rapidly.
Observe response on bearing
and shaft vibrations.
If necessary, check bearings
and alignment.
Check valve supports.
Check pipe hangers and tank
supports.

BHEL, Hardwar 6.2-0410-00/8

 Steam Turbine Vibration
Operation Fault Tracing

Despite all design, manufacturing and
erection measures to prevent it, excessive
vibration can occur and because the various
kinds of vibrations are intermingled, the
reasons for it are difficult to isolate.
If excessive vibration occurs, it is necessary
to carryout extensive tests together with the
manufacturer to determine its cause and
effective measures to be taken to combat it.
So, it is difficult to give a complete list of
possible causes and proper corrective action
to be taken, in this instruction.
The following data refers to the
characteristics, causes and remedial actions
pertaining to some typical type of vibration.

Fault Cause Remedy

ƒ Other symptoms
Rapid or instantaneous
increase in vibration over
the permissible limits or the
range of the measuring
system (alarm or instrument
display)
ƒ Loud noises and/or the Suspected damage, e.g. Caution: stop turbine
following operating broken blades or metal to immediately even when
parameters exceed their metal rubbing accuracy of reading is
limits: doubtful.
Casing wall temperature, Clearances eliminated by Check whether increased
because of rapid temperature casing distortion. vibration is maintained after
changes. load is reducing and when
coasting down.
Casing top-bottom differential Clearance eliminated by Measure the time taken to
temperatures. casing distortion. coast down; listen for noises
during this period.
Bearing metal temperatures Bearing damage

ƒ Low-frequency vibration. Unstable running due to self Reduce turbine load

Vibration frequency less excited vibration immediately until vibration
than rotational frequency. decreases; examine vibration;
Irregular point trace from load turbine slowly to stability
recording Instrument. limit.

Vibration increases above

normal value for specific
power outputs and operating
conditions
ƒ Vibration values less than Many possible causes Carryout the following tests to
permissible limits find out the causes:

BHEL, Hardwar 6.2-0420-00/1

 Fault Cause Remedy
ƒ Other symptoms
Determine main frequency of
vibration.
Measure vibration at all
bearings in three plans:
h - Horizontal
v - Vertical
a - Axial
Measure shaft vibration in two
directions at right angles, if
possible.
Measure the phase relation
ship of the bearings and shaft
vibration.
Measure the foundation
vibration.
Measure the vibration in
relation to all principle
operating parameters and their
variations.
Increased vibration at rated
speed
ƒ Increased vibration over
Changes in shaft system
entire load range under Examine magnitude and
balance due to:
steady-state operation. direction of vibrations.
Vibration increased above Rotor condition induced by
previous values, including eccentric coupling. Check the coupling for:
when passing through - Firm and proper fit of
critical speed ranges. coupling bolts
- Fit of centering spigot and
recess; redial runout of
coupling faces
- Alignment
Initial corrective action:
- Dynamically re-balance the
rotors (except if coupling
bolts are not tight and
alignment unsatisfactory)
- Correct any discrepancies
found during the checks

Permanent shaft distortion due Measure redials runout of

to metal to metal rubbing shaft.
Initial corrective action:
Dynamic re-balancing of rotor,
if runout is less.

BHEL, Hardwar 6.2-0420-00/2

 Fault Cause
ƒ Other symptoms
Blade damage
Modifications or repair on the
blades during on overhaul
ƒ Temporary increase in Temporary shaft distortion due
vibration during non steady to temporary non-uniform
state operating conditions temperature distribution during
(startup, loading and temperature changes.
unloading, main steam
temperature changes etc.)
Temporary distortion of shaft
resulting from metal to metal
rubbing at the seal rings
caused by misalignment due to
temperature changes.
Alignment changes due to
restricted expansion at turbine
casing and bearing housings.
ƒ Constant relationship Many possible causes
between vibration and
specific changes in
operating parameters.
BHEL, Hardwar
Remedy
Final corrective action: Stress
relieving, thermal stabilisation
and balancing at
manufacture’s works, if runout
is more.
Inspect blading.
If blades in the final LP stages
are damaged, a temporary
corrective measure is to
shorten the blade in the 180°
opposite position to damaged
blade or to attach a balancing
weight in the plane of damage
to compensate for the missing
piece (consult manufacturer).
If the blade damage is
suspected elsewhere the
appropriate turbine casing
must be opened.
Dynamic balancing of rotor.
Reduce speed, load and/or
rate of change of temperature.
Wait until vibration improves
when steady state conditions
are reached.
Reduce speed, load and/or
rate of change of temperature.
Remove restriction to
expansion by improving sliding
of bearing housings and
casing guides.
Determine relationships by
measuring magnitude and
direction of vibration under
varied operating conditions.
If possible, vary only one
operating parameter at a time.
6.2-0420-00/3
 Fault
ƒ Other symptoms
Note: Changes in vibration
characteristics due to changes
in temperature usually occur
slowly and at a constant rate.
ƒ Increased vibration during
warm-up.
ƒ Increased vibration during
turbine acceleration.
Vibration is normal at rated
speed.
ƒ Increased vibration during
turbine acceleration. No
improvement in vibration at
rated speed.
BHEL, Hardwar
Cause
Warm-up speed near a critical.
Increased vibration while
passing critical speeds.
Distortion remaining from an
interruption of turning gear
operation before start-up.
Remedy
After, each variation there
must be a delay for steady
state conditions.
Check the following operating
parameters and conditions:
- Speed
- Active load
- Reactive load
- Valve lift
- Steam temperatures
- Casing temperatures
- Steam pressure
- Oil temperatures
- Bearing metal temperatures
- Casing expansion
- Thrust bearing position
- Shaft eccentricity
Check turbine casing and
bearing housing for:
- Freedom of spacing
washers
- Seating and freedom of
expansion of casing palms
- Freedom of movement for
bearing housings
- Freedom of movement for
piping
Change the warm-up speed
within permissible ranges.
Pass through critical speed
ranges rapidly.
Reduce turbine speed to less
than 400 rpm. And eliminate
shaft distortion before
increasing speed.
6.2-0420-00/4
 Fault Cause Remedy
ƒ Other symptoms

ƒ Increased vibration in LP Balancing pressure of Adjust seal ring balancing

turbine and generator generator axial seal ring not pressure.
area. correctly set.

Sudden sharp increase in

vibration with accentuated
low-frequency components.
Vibration frequency less
than rotational frequency.
ƒ Irregular point trace from
recording instrument
Many possible causes
After finding out the stability
limits, identify the operating
parameters affecting vibration:
- Oil temperature
- Load
- Control valve lift
- Expansion
- Shaft displacement
- Bearing metal temperatures

ƒ Vibration is related to load Bearing loading too low. Increase bearing loading by
and valve lift. changing the alignment.
ƒ Vibration related to Bearing clearance excessive Change oil temperature
lubricating oil temperature
Changes in damping
changes.
properties due changes in
viscosity.

BHEL, Hardwar 6.2-0420-00/5

 Steam Turbine Bearing Temperature
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Bearing Temperatures High
ƒ Rapid rise of one or more If a fault in the temperature Shut down turbine
bearing metal temperatures measuring equipment can immediately to prevent
to the preset alarm level; be ruled out, the bearing is consequential damage.
similar temperature rise not damaged
Check bearing, analyse
observed before under
cause of bearing damage
comparable conditions
and take corrective action.
ƒ Inadequate oil supply Check oil pressure upstream
of damaged bearing.
Check throttle valve setting.
Check filters for chocking.
ƒ Dirt in oil Check bearings for sign of
wear; take oil samples.
ƒ Tilting of bearing Check bearing assembly.
ƒ Excessive thrust (in Analyse cause of excessive
thrust bearings) thrust.
ƒ Rapid rise of bearing metal Fault in oil temperature Check oil temperature
temperatures control system downstream of cooler.
Switch off controller.
Establish normal oil
temperature.
ƒ Fault in oil controller Establish oil temperature
manually
ƒ Fault in cooling water Check water flow through
supply cooler.
Shut-down turbine generator
unit, in case oil temperature
reaches the maximum
permissible limit in the event
of cooling water supply
failure.
ƒ Cooling water Startup stand-by cooler.
temperature high
ƒ Oil cooler chocked Change over to stand by oil
cooler
ƒ Slow rise of one or more Misalignment Check alignment
bearing metal temperatures

BHEL, Hardwar 6.2-0421-01

 Steam Turbine Casing Temperatures
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Annunciation: Casing
temperature differentials
top/bottom high
+ (positive) = higher
temperature in top half casing
- (negative) = lower
temperature in top half casing

ƒ During start-up, Δθ + / - Uneven heat dissipation due to If possible, increase steam

not enough steam flow through flow through turbine to obtain
casing uniform warm-up.

ƒ After load reductions, As above As above

during low power
operation, Δθ + / -

ƒ After load reductions, Δθ +
Steam backflow or entry of
water into turbine through
extraction lines
Open drain valves in extraction
lines; test functioning and leak-
tightness of extraction valves.
Take measures at the feed
water heaters to prevent back
flow.

ƒ During power operation,
Δθ + / -
Casing temperatures affected
by leaks in sealing elements
inside the turbine
Check condition and measure
clearances at sealing elements
during overhaul and refit or
replace leaky elements as
necessary.
notify manufacturer and ask to
calculate if turbine can be
operated at higher temperature
differentials for the time being

ƒ During start-up, Δθ - Casing or steam lines not Check position of drain valves,
properly drained open any close drain valves.

ƒ During start-up, Δθ + Drain valves still open too Close drain valves further or
wide, causing uneven steam completely.
flow through turbine

BHEL, Hardwar 6.2-0423-02/1

 Fault
ƒ Other symptoms
ƒ During standstill or turning
gear operation, Δθ +
ƒ During standstill or power
operation
Casing temperature
differentials excessive
ƒ In any operating mode
(additional turbine
protection not operative)
ƒ Turbine generator comes
to standstill after coast
down ( in turning gear
operation)
BHEL, Hardwar
Cause Remedy
Uneven cooling due to air Start turbine very carefully;
currents within the foundation wait until the steam admitted
or inside the turbine begins to reduce temperature
differentials before running up
to rated speed.
Uneven heat dissipation due to Repair lagging
imperfect lagging
Coast down turbine
immediately by tripping;
observe coast down; record
coast down time.
Carefully try to turn shaft
system using manual shaft
turning device.
Warning: Do not rotate the
shaft system forcibly.
Wait until temperature
differential has fallen to
permissible level; set turning
device in operation.
6.2-0423-02/2
 Steam Turbine
Operation
Fault
ƒ Other symptoms
Upper margin of turbine
stress controller restricted
during non-steady-state
operation (Upper margin
becoming O)
ƒ Limitation by TSC
admission monitoring
channel by TSC detector in
stop valve and/or TSC
detector in control valve
during warm-up of the
main steam line and the
stop and control valves.
Stop valves open.
ƒ Limitation by TSC
admission monitoring
channel by TSC detector in
control valve during warm-
up of the main steam line
and the main steam valves
immediately after opening
of the stop valves.
ƒ Limitation by TSC turbine
monitoring channel during
warm-up of the main
steam line.
BHEL, Hardwar
Turbine Stress Controller
Measures to Avoid Impermissible
Operation
Cause
Admission into main steam line
and main steam stop and
control valves too high, i.e. too
rapid warm-up reduces the
margin.
Stop valves opened at too high
a pressure.
Steam already entering the
turbine, causing reduction of
the margin.
Remedy
Open warm-up valves (drains)
between stop and control
valves more slowly.
or
Hold warm-up valve position
until a sufficient margin has
developed.
or
Continue to close warm-up
valve(s) until a sufficient
margin has developed.
Check whether warm-up
valves (drains) between stop
and control valves are closed;
if not, close-warm up valves;
wait for sufficient margin
before re-opening warm-up
valves. If margin is negative,
repeatedly open and close the
main steam stop valves.
General rule: If main stem
temperature can be reduced
when margins narrow, this
should be done in order to
avoid prolonging warm-up.
Both the admission channel
and the turbine channel must
be observed and step must be
taken to avoid reduction of
margin; retard temperature
increase up-stream of turbine
by throttling the warm-up
valves (drains) between stop
and control valves.
6.2-0430-01/1
 Fault Cause
ƒ Other symptoms
ƒ Limitation by TSC turbine Turbine is being warmed up
monitoring channel during too quickly.
warm-up in wait step below
critical speed range.
ƒ Limitation by TSC turbine Increase in steam flow during
monitoring channel during acceleration of turbine
turbine run-up to rated diminishes margin.
speed.
Turbine run-up causes an
increase in the supply steam
temperature so that the margin
is reduced.
BHEL, Hardwar
Remedy
Reduce main steam
temperature, if possible.
Reduce supply steam flow by
closing the control valves by
means of the speed set point
controller or the starting and
load limit device.
The influence of the TSC on
the set-point controller reduces
the speed gradient or, at a
certain margin, caused the
speed gradient to tend
towards 0.
A certain TSC margin
(determined empirically) must
be available before the turbine
generator until is run up to
rated speed.
Operation of the turbine
generator unit at constant
speed within the critical speed
range is inadmissible.
The control valves must
therefore be closed and the
turbine generator must be
warmed up at a speed below
the lower boundary of the
critical speed range specified
in the Technical Data 6.1-
011... Until an appropriate TSC
margin is available.
The turbine generator unit is
automatically run down to the
set warm up speed by means
of the gradient monitor as soon
as a certain permanently set
minimum speed gradient is not
attained.
Automatic and/or manual
measures as above.
6.2-0430-01/2
 Fault Cause Remedy
ƒ Other symptoms

The TSC display and the

recorder make it possible to
recognize which turbine
section has the smallest
margin.
It is therefore possible to widen
the margin reducing the
temperature of the supply
steam to that specific section
within the limits permitted by
the steam generator.
If the supply steam
temperature cannot be
reduced, further run-up will
have to be delayed until the
trailing turbine has warmed up
sufficiently.

ƒ Margin for IP turbine Warm up operation does not Automatic and/or manual
reduced; temperature of IP warm up the IP turbine measures as above.
turbine low; reheat sufficiently to prevent reduction
temperature high. of the margin. Proper adjustment of the
reheat temperature within the
limits permitted by the steam
generator is recommended.
If the turbine generator unit
can be run up to rated speed,
wait for IP turbine to warm up
sufficiently at rated speed
before synchronizing the
generator, since further margin
reductions are to be expected
when the unit goes on load if
the IP turbine has not been
warmed up sufficiently.

Limitation by TSC turbine Steam flow too high in relation The influence of the TSC on
monitoring channel during to turbine temperature the setpoint controller reduces
power operation. conditions. the speed gradient and/or the
turbine load is reduced and the
generator is possibly
disconnected from the grid by
the reverse power protection
relay.

BHEL, Hardwar 6.2-0430-01/3

 Fault
ƒ Other symptoms
Lower margin of turbine
stress controller restricted
during non-steady-state
operation (Lower margin
becoming 0)
ƒ Limitation by TSC
admission monitoring
channel during warm-up of
the main steam line and
the main steam stop and
control valves.
ƒ Limitation by TSC turbine
monitoring channel during
warm-up and/or start-up of
the turbine.
ƒ Limitation by TSC turbine
monitoring channel during
unloading of the turbine.
ƒ Limitation by TSC
admission and turbine
monitoring channels
during disturbances in
steam generator
operation.
ƒ Limitation by TSC after
load rejection with or
without residual load, or
TSC margin becomes
negative.
BHEL, Hardwar
Cause
Main steam temperature too
low in relation to main steam
line and valve temperature.
Main steam temperature too
low in relation to turbine
temperature
Load change leads to a
reduction of throttle
temperature down stream of
main steam control valves.
Rapid, pronounced
temperature reduction due to
fault in steam generator.
Normal occurrence as a
consequence of the reduction
in throttle temperature; will
reduce turbine life only if
repeated frequently.
Remedy
Does not open main steam
stop valves until temperature
has been adjusted
accordingly?
Check steam conditions
upstream of the turbine; raise
steam temperature before
warming and/or starting up the
turbine.
Reduce load gradient and/or
hold load constant until non-
steady-state condition has
passed.
Note: Turbine shut-down by
trip actuation is permitted from
any load condition.
Immediately adjust turbine
output to changed steam
generator conditions by means
of load setpoint limiter so as to
significantly reduce the steam
flow; if the additional influence
due to throttling prevails and/or
if there is no end to the steam
generator malfunction in sight,
the turbine must be tripped.
No particular measures
required in the event of
isolated load rejections.
6.2-0430-01/4
 Fault Cause Remedy
ƒ Other symptoms

Fault in turbine stress

controller
ƒ Alarm Electrical fault in turbine stress In the event of a fault in the
controller. turbine stress controller during
speed and load operation, the
TSC influence on the turbine
controller is immediately
cutout.
Cut out TSC influence.
Continue monitoring of the
turbine generator unit for
thermal stress by comparing
recorded temperatures with the
permissible temperatures
curves shown in Technical
Data 6.1-011.
Locate and eliminate fault in
turbine stress evaluator as
described in the TSC manual.

BHEL, Hardwar 6.2-0430-01/5

 Steam Turbine Stop and Control Valves
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Stop valve fails to open
ƒ Stop valve system ready Test valve closed Verify opening of stop valves
for operation. Start-up locally. Open test valve.
pressure < valve opening
ƒ Stop valve system is made Pressure above piston has not Wait until starting and load
ready for operation by built up sufficiently when test limit device is in 0% position
driving the starting and valve is changed over and pressure above piston of
load limit device towards stop valve has built up.
0%
ƒ Stop valve closes when Pressure difference preventing Close drain downstream of
internal pilot valve has main valve from opening stop valve.
reached the end of its
travel. Drains downstream
of stop valve open
ƒ Pressure above piston Internal pilot valve jammed Overhaul stop valve and free
drops immediately when inside the main valve internal pilot valve.
pressure builds up below
piston (steam pressure
present)

Control valve fails to open

ƒ Secondary oil pressure Cut off valve in secondary line Open cut off valve in
present closed secondary line.
Gear of test valves not in Bring gear of test valves into
operating position operating position.

Control valve opens and

closes erratically
ƒ Slight changes in Defect in feedback system of Check feedback system for
secondary pressure actuator blockages.

Control valve fails to

respond to control signals
ƒ Starting and load limit Starting and load limit device Bring starting and load limit
device not in 100% limiting hydraulic governor device into 100% position.
position
ƒ Reference speed setter not Reference speed setter limiting Bring reference speed setter
in 100% position during hydraulic governor into 100% position.
operation with electro-
hydraulic turbine controller

BHEL, Hardwar 6.2-0440-01/1

 Fault Cause Remedy
ƒ Other symptoms
Change in relationship
between secondary pressure
and control valves
ƒ Steady-state operation Many causes possible Check hydraulic governor,
converter and actuators.
Record control characteristics:
ƒ Travel of start-up and load
limit device
ƒ Travel of converter
ƒ Secondary auxiliary
pressure
ƒ Secondary pressure
ƒ Travel of control valve
and have control setting
corrected by manufacturer

Change in mutual
relationship of control valve
travels
ƒ Steady-state operation Many causes possible As above
ƒ Restriction in movement of Less clearance between valve Maintain required clearance
valve stem cone & bush between valve cone & bush by
machining ID of bush
Slightly reduce the tightening of
Excessive tightening of glands
the glands of the valves
of the valve

BHEL, Hardwar 6.2-0440-01/2

 Steam Turbine
Operation
Fault
ƒ Other symptoms
Turbine trip
ƒ Manual trip-out
ƒ Automatic trip-out
Automatic turbine trip
ƒ Main trip valves operated
ƒ Overspeed trips operated
BHEL, Hardwar
Protective Devices
Fault Tracing
Cause
Main trip valve actuated locally
or from control room
Protective device operated.
Many causes possible.
The main trip valves operate
whenever trip is started.
The overspeed trips operate
when the preset speed limit is
reached.
Remedy
Check condition that was the
reason for tripping turbine
locally or from the control desk
and find out if turbine
generator unit can be
restarted.
Find out cause of turbine trip
from recorder plots or
annunciation.
If trip started due to protection
criteria within turbine, check for
damage or irregularities that
would prevent further
operation of the unit.
If trip started due to faults
outside the turbine, check
whether turbine trip operation
was called for in accordance
with the protection concept.
The cause of trip must be
identified and must be rectified
before the unit is started up
again.
Check annunciation to find out
if both main trip valves
operated.
If only one main trip valve has
operated, test signaling circuit
(limit switches, wiring, and
lamps) and repair any
mechanical fault affecting the
defective valve.
Operation of the overspeed trip
is normally prevented by the
turbine governor if load
rejection occurs, i.e., when the
generator breaker is opened.
Check if trip was caused by
these:
6.2-0450-01/1
 Fault Cause Remedy
ƒ Other symptoms

Overspeed trips operate too Perform oil pressure test on

early. overspeed trips.
Find out oil pressures when
trips operate and compare
with pressures previously
set.
Perform overspeed test
with turbine is at operating
temperature.
Adjust overspeed trips.
Check if spring fatigued.

Turbine control malfunctions. Check free movement of

hydraulic control elements:
− Control valves
− Converter
Remove blockage or other
malfunctions.
Check electrical turbine
controller.

Load rejection relay failed to Check solenoid valves.

respond
Leak in turbine control valves.
Actuate contactor and note
effect on secondary pressure
of solenoid valves opening.
If secondary pressure does not
collapse, test coils of solenoid
valves for operation.
If actuation of load rejection
relay is not annunciated, check
measuring circuit.
Check for leaks in turbine
control valves:
Note operation of reverse
power protection if turbine
control valves are closed
during synchronized generator
operation.

Failure of reheat control Exercise reheats control

valves. Extraction check valves. Check position of
valves fail to close or leaking. extraction check valves.

BHEL, Hardwar 6.2-0450-01/2

 Fault Cause Remedy
ƒ Other symptoms

Check temperature in
extraction lines.
Rapid temperature drops after
load rejection is probably due
to extraction check valves
leaking.

ƒ Thrust bearing trip Excessive play in thrust Check bearing metal

responded bearing temperature.
Check thrust bearing.
Find out cause of high thrust
bearing wear (axial thrust,
damage, lack of oil).

ƒ Electrical low vacuum trip Loss of condenser vacuum Identify the cause of
responded condenser vacuum loss.
Fault in circulating water Check circulating water
supply pumps. Check flow of
circulating water through
condenser.

Fault in gland seal steam Check position of control

supply valves.
Check controller.
If fault in controller or if control
valves malfunction, switch of
controller and maintain gland
seal steam pressure manually
or by local operation of valves.

Fault in vacuum pumps Check operation of vacuum

pump.
Air entry into condenser Test for leaks.
Shutdown vacuum pumps and
measure pressure rise.
Locate and repair leaks.
Examine rupture disks for
cracks.

BHEL, Hardwar 6.2-0450-01/3

 Fault Cause Remedy
ƒ Other symptoms

ƒ Hydraulic low vacuum trip Loss of condenser vacuum As stated earlier

responded
ƒ Turbine trip started via Temperature differentials high Check recording instruments;
electrical signal from identify causes as described in
additional turbine instruction 6.2-0423.
protection system because
casing temperature
differential (s) high.
ƒ Turbine trip started via Cooling steam flow too low Check valve setting
electrical signal because
temperature of exhaust Pressure of exhaust steam Reduce pressure by suitable
steam from HP turbine from HP turbine too high measures
high. Main steam temperature in HP Reduce main steam
turbine too high temperature

ƒ Turbine trip started via Trip by fire protection system See 6.2-0410
electrical signal from the
fire protection system

Faults in protective devices

ƒ Main trip valves fail to Jammed Turbine generator unit must
operate not be operated if main trip
valves are not functioning
perfectly.
Locate and repair fault
immediately.

ƒ Trip solenoids Fault in solenoids Do not operate turbine

generator unit if trip solenoids
are not functioning perfectly.
Locate and repair fault.

ƒ Both overspeed trips fail to Overspeed trip jammed or Repeat testing by test oil
operate during over speed fouled pressure several times until
testing turbine trip starts at normal test
oil pressure values.
Attention : Normal trip speed
must not be exceeded by more If the defective overspeed trip
than 2% still does not operate
satisfactorily, operation of
turbine generator unit must not
been continued.
Trip devices jammed. Locate and repair fault
Incorrect speed reading immediately.

BHEL, Hardwar 6.2-0450-01/4

 Fault
ƒ Other symptoms
ƒ One over speed trip fails to
operate during over speed
testing
ƒ Over speed trip operates
at too high a test oil
pressure when tested by
test oil pressure
ƒ Over speed trip fails to
operate when tested by
test oil pressure
ƒ Overspeed trip operates at
too low a test oil pressure
BHEL, Hardwar
Cause
Jammed or fouled
Staggering of overspeed trip
settings
Turbine generator unit speed
too low when generator not
synchronized
Movement of over speed trip
mechanism impaired
Leak in test-oil line inside the
bearing pedestal
Cause of maloperation may be
too high a test oil pressure
Movement of overspeed trip
mechanism impaired
Turbine generator unit speed
too high when generator not
synchronized
Remedy
Check speed indicator
(compare frequency of excited
generator with system
frequency by means of
synchronizing device).
Adjust speed indicator.
Perform testing by test oil
pressure.
If testing by test oil pressure
reveals that the two overspeed
trips respond at slightly
staggered settings, no further
action is necessary.
Check speed indicator.
(Compare frequency of excited
generator system frequency by
means of synchronizing
device).
Correct speed
Adjust speed indicator.
Repeat testing by test oil
pressure several times until
turbine trip operates at the test
oil pressure values previously
measured.
Check test oil line at next
opportunity.
Adjust test oil pressure.
Increase speed with generator
unsynchronized and perform
test. If the defective over
speed trip still does not
operate satisfactorily,
operation of the turbine
generator device must not be
continued until fault has been
corrected.
Check speed indicator (for too
high a trip speed)
6.2-0450-01/5
 Fault
ƒ Other symptoms
ƒ One overspeed trip fails to
operate when tested by
test oil pressure. Test oil
pressure maximum,
second trip responds
normally.
ƒ Thrust bearing trip fails to
operate during testing
using the automatic turbine
tester
ƒ Hydraulic low vacuum trip
operates too late (at too
low a condenser vacuum)
ƒ Hydraulic low vacuum trip
operates too early at too
high a condenser vacuum.
BHEL, Hardwar
Cause
Drift of trip speed
(e.g. spring fatigue)
Movement of one overspeed
mechanism impaired
Malfunction of test device
Malfunction due to jamming or
drift in setting
Speed – dependent release for
operation faulted by jamming
of piston
Drift in setting
Diaphragm damaged
Remedy
Test overspeed trip by actual
over speeding at the next
opportunity.
Adjust overspeed trip setting if
necessary.
Turbine generator unit my
continue to be in operation but
may be liable to premature
tripping.
Test intact overspeed trip daily
by test oil pressure until fault
can be corrected at next
opportunity.
Check test device and control
medium pressure
There is a danger of the
condenser and last-stage
blades in the LP turbine being
damaged. Therefore correct
malfunction as quickly as
possible or adjust trip setting.
Until this can be done, test
intact low vacuum trip at
frequent intervals.
See above for consequences.
Overhaul piston for speed
dependent release for
operation.
See above for interim
measures pending correction
of fault.
Danger of outage of turbine
generator unit due to
premature trip.
Correct setting
Check diaphragm and replace.
6.2-0450-01/6
 Fault Cause Remedy
ƒ Other symptoms

Protection systems operating Fault in signal transmitter Check signal transmitter

largely with electrical signal
or
formation fail to operate or
operate at too high or too low Fault in signal path Check signal path
limit levels.
or
Fault in protective devices Check protective devices

In the fire protection system Fault in signal path Check signal path and
test, one or more fire control devices.
or
protective devices do not Correct fault or inform and
operate automatically. Device malfunction
instruct shift personnel that fire
protective device must be
manually operated if a fire
occurs.

BHEL, Hardwar 6.2-0450-01/7

 Steam Turbine Automatic Turbine Tester
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms

Fault after selecting and

starting program
ƒ Group and individual Electrical or mechanical faults. Find out and record program
alarms on automatic status preliminary test (PT),
turbine tester control test program (TP), reset
panel. program (RP) – and program
step where fault occurs.
Record and decode group and
individual alarms.
Locate fault and check if safety
or functioning of the turbine
generator unit is impaired (e.g.
if the device being tested fails
during testing).
Correct fault as stated in the
description section of the
turbine manual and the
Automatic Turbine Tester
(ATT) manual.
If reset program (RP) runs
without fault (program status
after (RP) = status as before
starting ATT), repeat the test
to get further information on
the nature of the fault.
Continue to perform non-
faulted test programs as
normal.
Program cannot be started
ƒ Alarm: No starting Operating condition of the Check starting conditions from
condition turbine generator unit does not the functional diagrams and
correspond to the interlock compare with actual operating
release criteria for the conditions of turbine and
Automatic Turbine Tester. restart test program.
Note: During turbine
shutdown, the starting
conditions for various
programs will not be fulfilled if
testing is to be performed
while the turbine is shut down,
the missing starting conditions
must be simulated.

BHEL, Hardwar 6.2-0455-00/1

 Fault
ƒ Other symptoms
Fail signal during Protective
Devices Test Program
ƒ Alarm: Fail signal and
possibly also Time overrun
Fail signal during valve test
program
ƒ Alarm Fail signal and
possibly also Time overrun
Turbine trip due to operating
criteria while test program is
running
ƒ Alarm Fail signal and
annunciation from general
alarm system
BHEL, Hardwar
Cause Remedy
Electrical or mechanical fault in Reset program started
a protective or test device or automatically.
monitoring element.
Check running of program in
the control room and, if
necessary, locally on the basis
of the program status and the
positions of the protective and
test devices.
If possible, return protective
and test devices to normal
operating position
mechanically.
If reset program runs without
fault, repeat individual test to
obtain further information
about cause of fault or to stop
jamming of protective and test
devices.
Electrical or mechanical fault in Reset program started
a protective device, valve or automatically.
monitoring element (pressure
Check running of program in
switch, position transmitter
the control room and, if
etc.)
necessary, locally also, on the
basis of the program status
and the positions of the valves
and test devices.
Restore to normal operating
condition if possible.
Main stop valve fails to open Close all downstream valves
by remote control (also drain
valves).
Open faulty stop valve using
test valve.
Open downstream valve by
remote control.
Normal occurrence, since the Reset program started
turbine generator unit will be automatically.
shut down by the protective
Observe running of reset
devices even during testing if
program.
6.2-0455-00/2
 Fault Cause Remedy
ƒ Other symptoms
The criteria for turbine trip are Check criteria that caused trip
fulfilled. to make trip conforms to
protection concept.
Locate and remove fault in
Automatic Turbine Tester if trip
was caused by wrong test
procedures.
Running of protective
devices test program
interrupted, program
stopped in faulted program
step
ƒ Several annunciation show Fault in electronic circuitry of Test circuit remains in force.
fault in electronic circuitry Automatic Turbine Tester.
Protection of the turbine is
of Automatic Turbine
ensured for the duration of this
Tester
fault by the protective
equipment operative during
testing.
Call in maintenance personnel
for the electronic equipment of
the Automatic Turbine Tester
to repair faults as described in
the ATT manual.

Running of valve test

program interrupted,
program stopped in faulted
program step
ƒ Several annunciation show
fault in electronic circuitry
of Automatic Turbine
Tester
Fault in power supply to
Automatic Turbine Tester for
protective devices
ƒ Several annunciation show
fault in power supply
Fault in electronic circuitry of
Automatic Turbine Tester
Fault in power supply
Return valves tested to normal
operating position.
− Check control valve and
other downstream valves,
and close valves by
remote control, if
necessary.
− Open stop valve using test
valve.
− Open control valve and
downstream valves.
Redundant design of the
power supply ensures best
security against outage of the
turbine generator unit.

BHEL, Hardwar 6.2-0455-00/3

 Fault Cause
ƒ Other symptoms
Circuit breaker of test motor,
solenoid valve, or other
electrical equipment tripped.
Fault during reset program
after testing of protective
devices
ƒ Program stopped, Position of protective and test
changeover valve in test devices incorrect due to
position electrical or mechanical faults.
− Test signal transmitter for
overspeed trip not in
operating position, e.g.
because miniature circuit
breaker tripped.
− Main trip valve or trip
device not in operating
position.
False electrical signals due to
faults in monitoring elements
(pressure switches, position
transmitters, etc.). This type of
fault is present if devices are in
operating position but no
checkback signal is generated.
Incorrect operation of
protective device during
testing
ƒ Trip solenoid valves for Fault in electrical operation or
protecting the turbine mechanical fault in solenoid
testing are not actuated. valves.
BHEL, Hardwar
Remedy
If a circuit breaker has tripped,
actuate test equipment or
valves locally to restore normal
operating condition.
Identify and remove cause of
fault in power supply as
described in the Automatic
Turbine Tester manual.
Check position of test or
protective devices locally and
return to operating position by
hand, if necessary.
Move test signal transmitter for
overspeed trip into normal
operating position by hand.
Actuate contactor for
approximately 10s to return
main trip valve or trip device
to normal operating position.
If normal operating position
cannot be restored, there is a
mechanical or hydraulic fault
(e.g. jamming of solenoid
valves, worn latching edges,
oil pressure too low for
latch-in) that must be
corrected.
Check monitoring equipment
and signal paths.
Check valves of pressure
switches (desired status:
open).
Check circuitry of position
transmitter; correct setting if
necessary.
Testing of protective devices is
not permissible if this fault
occurs, the test will be
6.2-0455-00/4
 Fault Cause Remedy
ƒ Other symptoms
Incorrect operation of Prevented by the electronic
monitoring equipment circuitry.
− Operating fault Check trip signal.
− Fault in solenoid valves Check operation.
Check power supply.
Check solenoid.
Check freedom of valve
movement.
− Fault in monitoring Check valves of pressure
equipment switches (desired status:
open).
Vent pressure switch.
Check signal path of
checkback signal.
Check functioning of faulted
pressure switch.
Replace pressure switch.

ƒ Failure of remote trip Fault in electrical operation or The protection of the turbine
solenoids mechanical fault in solenoid generator unit is not fully
valves. guaranteed.
Incorrect operation of The turbine must be shut down
monitoring equipment unless the fault can be cleared
during operation (e.g. by
switching on the power
supply).
- Fault in operation Check signal path for
formation of trip signal.
Check operation.
- Fault in solenoid valves
Check power supply.
Check freedom of movement
of valve.
- Fault in monitoring Check valves of pressure
equipment switches (desired status:
open).
Vent pressure switch.
Check signal path of
checkback signal.
Check functioning of faulted
pressure switch. If necessary
replace pressure switch.

BHEL, Hardwar 6.2-0455-00/5

 Fault Cause Remedy
ƒ Other symptoms
ƒ Main trip valves fails to Fault in protective device See trouble shooting
operate instructions for protective
devices.
Main trip valve jammed Turbine generator unit must
not remain in operation.
Fault may be corrected
immediately.
Fault in monitoring equipment Check valves of pressure
switches (desired status:
open).
Check position transmitter,
reset if necessary.
ƒ Overspeed trips fail to Actuation fault in test device or Take action if incorrect
operate (running time incorrect operation of operation of the overspeed
exceeded) overspeed trip. trips occurs.
See instruction: Protective
Devices. Troubleshooting:
6.2-0450.
Actuation fault in test signal Check if the test signal
transmitter transmitter operates during
test.
Fault in power supply If the test signal transmitter
does not operate, check power
supply and motor.
Check actuation.

ƒ Overspeed trips operate at Mechanical blockage of Repeat last several times.

too high a test oil pressure
overspeed trips
Determine test oil pressures
where trips respond.
If this does not clear fault, take
action described in 6.2-0450
e.g. set overspeed trips during
overspeed tests.

ƒ Overspeed trips operate at Limit switch of test signal Correct setting of limit switch.
normal test oil pressure, transmitter incorrectly set.
but after test signal
transmitter has reached its
limit position.

ƒ Overspeed trips operate at Functioning of overspeed trip Danger of premature turbine

too low a test oil pressure impaired trip.
(annunciation only, no
interruption).

BHEL, Hardwar 6.2-0455-00/6

 Fault Cause Remedy
ƒ Other symptoms
Check overspeed trip setting
by precise oil pressure testing
or actual overspeed test.
Check setting.

ƒ Overspeed trips operate at Fault in functioning, circuitry or Check functioning of pressure

test oil pressures setting of pressure switches for switches.
previously observed monitoring response.
Check circuitry and setting.
Locate fault and repair.
Correct setting if necessary.

ƒ Trip mechanism of Latch-in pressure too low Check auxiliary start-up

overspeed trips fails to pressure.
latch-in.
Latch-in edges or trip Repair trip mechanism.
mechanism worn out.

ƒ Low vacuum trip fails to Fault in operation of test Check operation.

operate solenoid
Incorrect operation of solenoid Check solenoid.
valve
Air inlet duct obstructed Clear air inlet duct using
probe.
Primary circuit piston not in Repair low vacuum trip device.
normal operating position

ƒ Low vacuum trip operates
too late (at too low a
vacuum)
Incorrect operation of
vacuum trip device
low For consequences and steps
to be taken, see instruction
6.2-0450.
Check condenser vacuum
where trip device operates.
Repair mechanical fault or
correct setting.

ƒ Low vacuum trip operates
too early (at too high a
vacuum) annunciation
only, no interruption
Incorrect operation of
vacuum trip device
low Availability of turbine generator
unit may be reduced due to
premature tripping.
Check condenser vacuum
where trip device operates.
Repair mechanical fault or
correct setting.

BHEL, Hardwar 6.2-0455-00/7

 Fault Cause Remedy
ƒ Other symptoms
Incorrect operation of
valves during testing
ƒ Stop valve fails to close Control valve not closed
- Fault in valve test Check power supply and motor
positioner or its actuation of valve test positioner.
Check actuation circuitry.

- Check back Control valve Check functioning of limit

closed missing switch, signal path and setting
of limit switch.
Repair fault in signal path.
Correct setting of limit switch
Replace limit switch.

- Fault in actuation of stop Check operation of trip

valve solenoid.
Test solenoid;
Check freedom of movement
of valve.

ƒ Stop valve closed too Incorrect mechanical Repeat test.

slowly operation of stop valve
Measure time taken for valve
to close.
Repair valve if no other cause.

Malfunction of monitoring Check monitoring equipment.

equipment (pressure
Check functioning and setting
switches, position transmitters
of pressure switches.
etc.)
Check functioning and setting
of limit switches.

ƒ Stop valve fails to open Fault in operation of solenoid Check operation solenoid
valves.
Open stop valve with test
valve.
Locate fault in operation.
Check power supply and
solenoid as soon as
downstream valves are closed.

BHEL, Hardwar 6.2-0455-00/8

 Fault Cause
ƒ Other symptoms
ƒ Stop valve opens abruptly Jamming of valve positioner
Control valve or other valve
downstream of stop valve
open
BHEL, Hardwar
Remedy
Locate fault immediately and
repair valve.
Close valve downstream of
stop valve.
Identify why control valve was
open (step sequence, step
criteria).
Locate fault and repair.
6.2-0455-00/9
 Steam Turbine Oil System
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms

Oil properties inadequate

ƒ Air release property > limit Oil contamination Examine oil samples, remove
value according to impurities through centrifuge,
Specification and remove water.
Water content high Remove water
Improper sealants Check sealants used, do not
use any sealant containing
silicon.
Oil mixed with too much Consult oil supplier
antifoam additive.

ƒ Foaming on oil surface of
oil tank
Foaming during startup due to Introduce waiting period
simultaneous release of air between closure of turning
trapped in the oil and air gear oil valve and run-up of the
entrained in the system as a turbine.
result of temperature increase
Check oil level and correct by
in the oil tank.
topping up or draining.

ƒ Water content Entry of steam vapour into oil Remove water from oil system
system by separation or draining.
Check vapours pressure in
bearing pedestals.
Locate cause of excessive
leak-off steam from shaft seals
and repair.
Oil level in oil tank low
ƒ During rated speed Normal oil loss (oil level drops Top up with oil of the same
operation slowly) make and type.
High oil loss Examine system for leaks. If a
large leak occurs, unload
turbine generator immediately
and/or initiate fire protection
measures. Examine oil coolers
for punctured tubes.
Plug leaky tubes.

BHEL, Hardwar 6.2-0460-00/1

 Fault Cause Remedy
ƒ Other symptoms

ƒ During turning gear Measures as for oil level

operation changes during rated speed
operation.
On topping up make allowance
for oil level recorded during
turning gear operation.
Attention: 2-out-of-3 fire
protection ineffective during
turning gear operation.

ƒ During rated speed or
turning gear operation
Oil pressure low
ƒ In pressure oil system
during shut-down of
turbine generator unit
Oil builds up in return
compartment due to choked
strainer.
Normal procedure
Open oil tank cover
Check strainer and if heavily
choked, change strainer and
clean.
Examine residues in strainer.
Observes start up of auxiliary
oil pump.
If subloop control fails, start
auxiliary oil pump manually
from control desk.

ƒ In pressure oil system
immediately after rated
speed has been reached
Main oil pump is not taking
over oil delivery.
Check for leakage through
valve downstream of auxiliary
oil pump.
See incorrect operation of
main oil pump.
Check pressure downstream
of auxiliary oil pumps and
pumps for reverse rotation.
Start up and shut down
auxiliary oil pumps with
defective valve once more.
Shut down turbine generator
and ensure freedom of check
valve movement by alternating
auxiliary oil pumps.
Overhaul check valve.

Turning gear oil valve still open Close turning gear oil valve
from control desk or locally by
hand.

BHEL, Hardwar 6.2-0460-00/2

 Fault Cause Remedy
ƒ Other symptoms

ƒ In pressure oil system Oil level too low Check oil level in oil tank.
during rated speed
Top up if necessary.
operation
Main oil pump faulty Check main oil pump.
Air content of oil too high Examine air release capability
(ARC) (joint investigation by
operator, oil supplier and
turbine manufacturer).

ƒ In lubricating oil system Examine as for oil pressure

drops in pressure oil system.
With heavy pressure loss
observes whether turbine trip
is initiated.

ƒ In lubricating oil system on Filter not filled and vented Check bearing metal
filter changeover before changeover temperatures.
Check bearings after
temperature increase.

ƒ In lubricating oil system on
oil cooler changeover
Standby oil cooler not filled
and vented before changeover
Measures as for pressure loss
on filter changeover.
Warning: Danger of bearing
damage is considerably
greater than with improper
filter changeover.

ƒ Differential pressure Filter choked Changeover filters properly.

across filter high
Clean filter inserts.

Main oil pump does not take
over oil supply on startup
Oil temperature high
ƒ During rated speed
operation after startup
Oil level in tank low See faults: Oil level low
Air content of oil too high See faults: Oil properties
inadequate
Main oil pump faulty Check main oil pump.
Turbine sped may be
temporarily raised to force
main oil pump to take over.
No flow of cooling water Check positions of cooling
through oil cooler in service water isolating valves for oil
(malfunction can also occur on cooler in service. Open if
oil cooler changeovers) closed or throttled.

BHEL, Hardwar 6.2-0460-00/3

 Fault Cause Remedy
ƒ Other symptoms

Oil temperature not yet set Set selector valve.

ƒ During startup and power Oil cooler not vented on oil Check vents.
operation side or cooling water side.
Cooling water inlet Look for cause of cooling
temperature too high. water temperature increase
and correct.
Oil cooler choked on cooling Changeover oil cooler.
water side.
Note: Follow changeover
instructions
Clean choked oil cooler.
Oil temperature low
ƒ During shut-down of Oil temperature control valve Close oil temperature control
turbine generator unit not closed. valve.
ƒ During rated speed Oil temperature controller Close oil temperature control
operation after startup faulty. valve manually.

Turning gear does not

startup automatically
ƒ Turning gear oil valve Compare actual jacking oil
open, Jacking oil pump on pressures with set pressures.
Correct pressure if necessary.
Check oil temperature, if too
high (> 45 ºC), reduce.
Check using manual turning
gear, whether shaft turns
easily.
Warning: Do not rotate the
shaft system forcibly.

ƒ Turning gear oil valve
open, jacking oil pump on.
Differential temperature on
one casing > limit
temperature.
or
Turbine generator unit shut
down due to high bearing
metal temperature.
Radial clearance bridged by
casing or rotor distortion.
Rubbing of rotor due to
damage of bearing or shaft
journal in bearing not jacked.
Let turbine cool down.
Jacking oil pump must be
operating.
Warning: Do not rotate the
shaft system forcibly.
Check bearing and replace.

BHEL, Hardwar 6.2-0460-00/4

 Fault Cause Remedy
ƒ Other symptoms

Turning gear oil valve does

not close
ƒ During startup Turning gear oil valve faulty Close turning gear oil valve
(acceleration to warm-up manually.
ƒ Drive
or rated speed)
ƒ Control or
ƒ AC-power supply
ƒ After initiation of fire Turning gear oil valve Acknowledge fire-protection
protection system interlocked. measures.
ƒ When shutting down Closure of turning gear oil Allow turbine generator unit to
turning gear valve interlocked via casing cool down further or make
temperature. interlock ineffective.
Note: Record release and
cancel if turbine is to be
restarted.
Turning gear oil valve does
not open
ƒ On start up Turning gear oil valve faulty Open turning gear oil valve
manually in place.
or ƒ Drive
ƒ On shut down of the ƒ Control
turbine generator

Main oil pump bearing

failure
ƒ Test oil pressure built up Failure due to electro-erosion. Replace damaged MOP
during normal operation components.
and turning gear operation
Rotor earthing arrangement Attend rotor earthing
not healthy arrangement.
Poor insulation at generator Improve insulation.
rear pedestal

Oil vapour coming from

bearing pedestal
ƒ Vapour fan running
Vapour fan faulty
Wire cloth in the oil stripper is
choked
Vapour suction Flap valve at
the bearing pedestal closed
Start standby vapour fan.
Clean or replace the wire cloth.
Readjust the flap valve.

BHEL, Hardwar 6.2-0460-00/5

 Fault Cause Remedy
ƒ Other symptoms

Seal steam leaking from

glands
ƒ Seal steam pressure Seal steam exhauster fan not Startup one seal steam
normal operating exhauster fan. Check position
of valves upstream of
exhauster fan and correct
(valves of standby exhauster
fan must be closed).
Mechanical or electrical fault in Discharge seal steam to
seal steam exhauster fan atmosphere.

ƒ Seal steam pressure high, Seal steam pressure set point Lower set point
no fault in valve or too high
controller functions

Seal steam pressure low

ƒ Both control valve Mechanical or electrical fault Open bypass valve and
operating in a sequence maintain constant pressure
faulted manually.

Mechanical fault in seal

steam control valve
ƒ Valve fails to follow control Pressurizer valve faulty or set Check pressure, reset
signals too low pressurizer valve.
Filter choked (annunciation) Clean / replace filter and
change oil of the actuator as
specified.
Electrical fault
ƒ Valves Many causes possible Determine problem on the
basis of valve and description,
and correct.

ƒ Control system Many causes possible Determine problem on the

basis of instrumentation and
control manual and correct.

BHEL, Hardwar 6.2-0460-00/6

 Steam Turbine Control Fluid System
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Control fluid properties Impure control fluid Examine control fluid samples.
inadequate
Start up bypass regeneration
ƒ Rise in neutralization unit immediately.
number (Observed on the
or
basis of constant values
measured continuously Check its operational status.
under the same
conditions). Examine control fluid for water
content, (take sample from
surface).
Change over to other control
fluid cooler.

Fuller’s earth filter exhausted Replace Fuller’s earth filter,

even if replacement not yet
scheduled.
Clean fine mesh filter.

ƒ High water content Water entering via cooler Change over to other control
fluid cooler; determine cause
of water entry.
ƒ Air release property Take measures as for rise in
diminished neutralization number.

Level in control fluid tank

low
ƒ Slowly sinking level in fluid Normal fluid loss not replaced Top up with control fluid of
tank. same make; take sample of
topping-up fluid

ƒ Level sinking rapidly (2 out Excessive loss Caution: Stop turbine

of 3 level very low monitor generator immediately. Stop
responds) control fluid pumps and initiate
fire protection measures.

Control fluid pressure low Pump faulty Check control fluid pumps.
Change over to standby pump
or observe start up of standby
pump.

BHEL, Hardwar 6.2-0470-00/1

 Fault Cause Remedy
ƒ Other symptoms

Control fluid differential Filter chocked Change over to other filter,

pressure across clean filter element or insert
interchangeable filter high new filter element.

Control fluid temperature Excessive cooling of system Check temperature controller;

low piping or fault in closed-loop if control valve is open, switch
control off temperature regulator and
close control valve. Switch on
heater when control valve is
closed.

Control fluid temperature Inadequate cooling Check temperature controller;

high check cooling water
temperature, check cooling
water adequately vented,
change over to other control
fluid cooler.
Heater switched on Switch off heater
(fault in open loop control)

Temperature at heater Control fluid heater overheated Switch off control fluid heater
protective tube high

Leak in hydraulic devices

ƒ Control fluid/ oil leakage
monitor responds Check carefully which medium
à Leakage of control fluid at is escaping: oil, control fluid or
the hydraulic governor both?
Operation of the turbine
generator may be continued
provided that the escape of
fluid is continuously monitored.

à Leakage of oil or control Diaphragm damaged: Repair leak

fluid and oil at the
hydraulic governor Difficulties in regulating during
operation using hydraulic
governor in the event of both
media escaping.

à Leakage of oil at the trip Operation of the turbine

mechanisms of the over generator may be continued
speed governor or the provided that the escape of
shaft position monitor. fluid is continuously monitored.

BHEL, Hardwar 6.2-0470-00/2

 Fault
ƒ Other symptoms
à Leakage of oil or oil and
control fluid at the trip
mechanisms of the over
speed governor or the
shaft position monitor.
ƒ Alarm : Control fluid/water
leakage monitor responds
à Leakage of control fluid
at hydraulic pressure
alarm
à Leakage of water at
hydraulic pressure alarm
BHEL, Hardwar
Cause Remedy
Diaphragm damaged on the Repair leak
control fluid side, danger of
turbine trip. If both oils are
leaking, danger of control fluid
mixing with oil.
Operation of turbine generator
may be continued.
Danger of water mixing with Repair leak
control fluid
6.2-0470-00/3
 Steam Turbine Gland Steam System
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Seal steam escaping from
glands
ƒ Seal steam pressure normal Seal steam exhauster fan not Start one seal steam
operating exhauster fan.
Check position of valves
upstream of exhauster fan
and correct (valves of
standby exhauster fan must
be closed).
Mechanical or electrical fault in Discharge seal steam to
seal steam exhauster fan atmosphere.
ƒ Seal steam pressure high; Seal steam pressure set point Lower set point.
no fault in valve or controller too high
functions

Seal steam pressure low

ƒ Both control valves Mechanical or electrical fault Open bypass valve and
operating in sequence are maintain constant pressure
faulty manually.

Mechanical fault in seal steam

control valve
ƒ Valve fails to follow control Valve faulty or set too low Check pressure; reset valve.
signals Clean / replace filter and
Filter chocked (annunciation)
change oil of the actuator as
specified.

Electrical fault
ƒ Valves Many causes possible Determine problem on the
basis of valve description
and correct.
ƒ Control system Many causes possible Determine cause on the
basis of instrumentation and
control manual and correct.

BHEL, Hardwar 6.2-0480-01

 Steam Turbine Bypass System
Operation Fault Tracing

Fault Cause Remedy

ƒ Other symptoms
Bypass stop and control
valves fail to open
ƒ Reheat pressure > Check condensate pressure,
constant or variable condenser vacuum and
pressure setpoint. bypass steam temperature.

Injection water pressure

downstream of injection water
control valves < interlock
pressure
ƒ Condensate pump(s) Check operating conditions of
failed. condensate pump or
condensate system.
ƒ Pressure downstream of Establish normal conditions.
Condensate pump(s) too
low.
ƒ Fault in injection water Check actuators of injection
control valves or their water control valves, e.g. slide
actuators. valves for valve operation.
Condenser vacuum low. See fault tracing instructions
for condenser plant.
Bypass steam temperature See fault tracing instructions
high. for condenser plant.

ƒ Reheat pressure < Constant pressure setpoint too Lower constant pressure
constant pressure setpoint high. setpoint.
but > variable pressure
setpoint.
ƒ Reheat pressure > Fault in control
Check fault annunciation in
constant or variable
control cabinet.
pressure setpoint.
Interlocks ineffective Attend fault as described in
bypass control manual.
Shut down control until fault is
attended, and control the
reheat pressure manually.
Bypass stop and control
valves close during bypass
operation
ƒ Reheat pressure > Injection water interlocks
constant pressure setpoint effective.

BHEL, Hardwar 6.2-0490-00/1

 Fault
ƒ Other symptoms
Bypass control valves close
ƒ Reheat pressure > Steam flow
constant pressure setpoint
Bypass stop and control
valves fail to open
ƒ Reheat pressure > Fault in injection water control
constant pressure set point
Condensate pressure
upstream of injection water
control valves normal.
Condensate pressure
downstream of injection water
control valves < interlock
pressure.
Reheat pressure > constant
pressure setpoint.
Condensate pressure
upstream and downstream of
injection water control valve >
interlock pressure.
BHEL, Hardwar
Cause
ƒ Injection water pressure <
interlock pressure.
Condenser vacuum interlock
effective.
Bypass system temperature
interlock effective.
rate limitation
effective.
valves or their actuators.
ƒ Signal pressure not
present: Fault in regulator
or hydraulic control gear.
ƒ Signal pressure present,
Pressure beneath pistons
of one or more injection
water control valves not
present: Changeover valve
defective.
ƒ Signal pressure present,
Pressure beneath pistons
of injection water pilot
valve present: Injection
water control Valve
jammed.
Fault in interlock elements
ƒ Limit pressure control gear
fails to open: Fault in limit
pressure control.
Remedy
Check operating conditions of
condensate pumps or
condensate system.
Establish normal operating
conditions.
See fault tracing instructions
for condenser plant.
Injection water flow rate too
low, check 2nd stage water
injection if bypass steam flow
rate is high.
Reduce steam generator
output.
Check signal pressure and
pressure beneath pistons of
injection water control valves.
Locate fault in regulator or
hydraulic control gear and
attend.
Attend fault in changeover
valve for injection water
control valves.
Open bypass valve until fault
is removed.
Remove blockage in injection
water control valve
Check limits pressure control
gear.
Locate and attend fault in limit
pressure control gear.
6.2-0490-00/2
 Fault Cause Remedy
ƒ Other symptoms
ƒ Limit pressure control gear Locate and attend fault in
opens: fault in pressure pressure switch.
switch.
If only one of the hydraulic
condensate pressure
monitoring channels is faulty,
the faulty channel may be
blocked and bypass operation
continued.
Attention: No redundant
pressure monitoring effective:
use other criteria, e.g. bypass
steam temperature, to asses’
injection water flow rate.
Attend fault as soon as
possible.
ƒ Reheat pressure > Fault in interlock elements for
constant pressure setpoint. loss of condenser vacuum.
Condensate pressure
ƒ Diaphragm of limit Replace diaphragm;
normal.
pressure control gear
damaged.
ƒ Diaphragm of bypass Replace diaphragm.
condenser safety device
damaged. Close cutoff valve upstream of
measuring element.
Insert lever and lock.
Replace diaphragm.
In this case bypass operation
may be continued for the
duration of the repair.
ƒ Reheat pressure > Fault in interlock elements for Check temperature measuring
constant pressure setpoint. high bypass steam instrument circuit, actuators of
Bypass steam temperature temperature. solenoid valves and attend
normal. fault.

BHEL, Hardwar 6.2-0490-00/3

 Steam Turbine
Maintenance
The availability, reliability and economy of a turbine
generator depend on the proper condition of all
components. This goal can only be achieved through a
comprehensive maintenance program.
This maintenance program specifies activities to be
performed with the unit in service to establish the actual
condition at regular intervals (inspection = tests and
recording of operating data) and to maintain the desired
condition (maintenance).
Inspection Schedule
The inspection schedule [1] includes all essential testing
and operating data recording activities as well as
procedures to identify the condition of components.
BHEL, Hardwar
In-Service Maintenance
Introduction
The inspection schedule is supplemented by tables
specifying the testing intervals, instructions and test
records for comparison of the desired and actual
conditions.
Maintenance Schedule
The maintenance schedule [2] contains all maintenance
activities to be performed during turbine operation or
outages at specified intervals.
The maintenance work to be performed during prolonged
outages, e.g. overhauls, has been elaborated separately
[3].
Also refer to the following sections:
[1] 6.3-0010 : Inspection Schedule
[2] 6.3-002... : Maintenance Schedule
[3] 6.3-0200 : Instructions for Overhaul
6.3-0001-01
 Steam Turbine Inspection Schedule
Maintenance

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1.0 Testing of Tests according to:
1.1 Controllers Functioning Ref. 6.2-0021 6.3-0030
& setting 6.3-0035
1.2 Automatic Turbine Tester Functioning Ref. 6.2-0022 6.3-0060
& 6.2-0023 6.3-0061
1.3 Protective devices Functioning Ref.6.2-0024 during start up,
& setting power operation,
1.4 Safety devices Functioning Ref. 6.2-0025 shut down & stand
& setting still
1.5 Valves Functioning Ref. 6.2-0026
free movement
leak tightness
1.6 Monitoring devices Functioning Ref. 6.2-0027
setting and
accuracy

2.0 Recording and Comparison Ref. 6.2-0028 Also ref. 6.3-0037

documentation of of specified and for long term
operational parameters actual data monitoring
and conditions
2.1 Steady state operation h
2.2 Non-steady state operation every start-up
2.3 Faults every occurrence
2.4 Analysis of steam Purity d Ref. 6.3-0050
2.5 Measurement of internal Internal 3m
efficiency condition of
turbine

3.0 Inspection of LP turbine During Ref Tech. Circular

free standing blades intermediate No. X-68
3.1 Visual inspection Erosion, and major
looseness inspections,
every 50,000
3.2 Blade profile and root Crack
hrs. of
crack examination
operation
3.3 Cleanliness of blade root Cleanliness
and groove
3.4 Blade natural frequency Natural freq.
test

BHEL, Hardwar 6.3-0010-04/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
4.0 Inspection of accessible During minor, during shut down
expansion joints in cross intermediate
around and extraction lines and major
4.1 Visual inspection Damages inspections
4.2 Surface crack examination Crack
5.0 Inspection of casing
guides and supports
5.1 Seating of casing on w
support elements
5.2 Cleanliness w
5.3 Integrity of keys & packers Damage During During shut down
5.4 Thermal clearances as per Clearances intermediate
drawing and major
inspections
6.0 Visual inspection for Leakage d
steam-tightness noise
6.1 Casing joints
6.2 Flanges
6.3 Shaft seals
6.4 Valve stems
6.5 Instrument connections
7.0 Inspection of drains
7.1 Internal leak-tightness w
7.2 External leak-tightness w
8.0 Inspection of pumps,
motors and other drives in
continuous operation
8.1 Vibration behaviour d
8.2 Head d
8.3 Bearing temperatures d
8.4 Thrust d
8.5 Leak-tightness d
9.0 Visual inspection of piping
9.1 Leak-tightness d
9.2 Vibration d
9.3 Hangers w
9.4 Expansion w
9.5 Vibration dampers 3m

BHEL, Hardwar 6.3-0010-04/2

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
10.0 Inspection of hydraulic
accumulator
10.1 Check charge pressure 2w

11.0 Inspection of Main oil tank

11.1 Level check d
11.2 Foaming characteristics w
11.3 Water collection on bottom 2w
of oil tank
11.4 Level check in bucket filter w
to assess filter chocking
11.5 Water content of oil d
11.6 Solid particle content of oil d
11.7 Analysis of properties Ref. 6.1-0130 Ref. 6.3-0080
12.0 Inspection of FRF tank
12.1 Level check d
12.2 Level check in bucket filter w
to access filter chocking
12.3 Foaming characteristics of w
FRF
12.4 Analysis of fluid properties Ref. 6.1-0140 Ref. 6.3-0082
13.0 Oil / FRF filter
13.1 Check differential pressure d
reading
13.2 Check venting d
14.0 Inspection of TG-deck
springs
14.1 Reference spring heights Ref. Technical After first year
14.2 Alignment check circular No. X-85 of operation
14.3 Catenary check

BHEL, Hardwar 6.3-0010-04/3

 Steam Turbine Maintenance Schedule
Maintenance Turbine

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of sliding Visual 1m
surfaces inspection
ƒ casing supports
ƒ spacer bolts and discs
for bearing pedestals and
turbine casings
2. Cleaning of turbine blading measurement as indicated by The criteria
by flushing through with of ηi criteria indicating stage
saturated steam as pressure when
prescribed in 6.3-0070 saturated steam
flushing is
necessary are the
internal efficiency
ηi and the stage
pressures
3. Preservation of turbine relative continuous During shutdowns
using air drying equipment humidity in lasting longer than
as prescribed in 6.2-0360 turbine < 50% 1 week
4. Lubrication of components as prescribed in
of the turbine control and 6.1-0690
turbine protection systems
5. Tightening of turbine 1m
control valve packings
6. Tightening of valve stem 3m or in the
seals event of
leakages
7. Lubrication of valve stems as prescribed
6.1-0690

BHEL, Hardwar 6.3-0021-02

 Steam Turbine Maintenance Schedule
Maintenance Oil system, Seal Steam system, Drains

Oil System
Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of filters and
strainers
ƒ Switch over duplex filters Δ p across as indicated by
and clean fouled filter filter criteria, max 6m
cartridges as prescribed
in 6.1-1130
ƒ Turn plate-type filters d
through two three
revolutions as
prescribed in 6.1-1 120
ƒ Clean plate-type filters 6m -1y during
appropriate
shut-downs and
overhauls
ƒ Replace filter papers in Δ p across as indicated by
fine mesh filter filter criteria, max 6 m
ƒ Change oil tank oil level in As indicated by during
strainers, clean chocked bucket criteria, appropriate
strainers as prescribed strainers max. 6m - 1y shut-downs and
in 6. 1-1 010 overhauls
ƒ Clean wire mesh of oil 6m
stripper
2. Cleaning of oil using solid or liquid continuous, as
centrifuge foreign matter indicated by
in oil criteria
3. Cleaning of centrifuge as deposits in 1m as
specified by the centrifuge indicated by
manufacturer criteria
4. Cleaning of oil tank after deposits in oil 3 -4 y during overhauls
draining oil tank
5. Maintain oil tank level at level in oil tank 1 d (check),
service level; top up with topping up as
oil of same make and indicated by
properties criteria
6. Draining of water from the water collecting as indicated by establish cause
oil tank on oil tank criteria of water
bottom accumulation

BHEL, Hardwar 6.3-0022-01/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
7. Oil or grease change in as specified by
valve actuators actuator
ƒ Motive oil valve manufacturer
ƒ Oil temperature control
valve
8. Lubrication of pump and as specified by
fan motors motor
ƒ Auxiliary oil pumps manufacturer
ƒ Emergency oil pump
ƒ Jacking oil pumps
ƒ Oil vapour exhauster
fans
9. Lubrication of oil vapour as prescribed by
exhauster fan bearings fan manufacturer
10. lubrication of valve stem at as prescribed in
the lubrication points 6.3-0081
provided
11. Tightening of valve, steam 3m or in the
seals event of leakages
12. Elimination of oil leakages oil leakages continuous
by tightening of flanges
and bolted joints
13. Check vibration dampers 1y
as prescribed in 6.3-0100
14. Charging of hydraulic charge 1m
accumulators pressure

BHEL, Hardwar 6.3-0022-01/2

 Seal steam system
Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
1. Change of control fluid for 1y
seal steam control valve
actuators as prescribed in
6.1-0690
2. Filter change for seat 1y
steam control valve
actuators as prescribed in
its manual
3. Lubrication of vapour as specified by
exhaust fan motors motor
manufacturer
4. Lubrication of vapour as prescribed by
exhaust fan bearings fan manufacturer
5. Lubrication of valve stems 3m
at the lubrication points as
prescribed in 6.3-0081
6. Tightening of valve stem 3m or in the
seals event of leakages

Drains
Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
1. Oil or grease change in as specified by
drain valve actuators actuator
manufacturer
2. Lubrication of drain valve 3m
stems at the lubrication
points provided as
prescribed in 6.3-0081
3. Tightening of drain valve 3m or in the
stem seals event of leakages
4. Check on drain line sludge 1 -2y
traps

BHEL, Hardwar 6.3-0022-01/3

 Steam Turbine Maintenance Schedule
Maintenance FRFsystem

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of filters Δ p across filter
and strainers
ƒ Switch over duplex
filters; and clean fouled
filter cartridges as
prescribed in 6.1-1130
ƒ Turn plate-type filters d
through two three
revolutions
ƒ Clean plate-type filters 6m -1y during appropriate
shut-downs and
overhauls

ƒ Replace filter papers in Δ p across filter as indicated by

fine mesh filter as criteria, max 6 m
prescribed in 6.1-1140
ƒ Replace fuller’s earth Neutralization 6m or as
filling in regenerating number indicated by
filter as prescribed in criterion
6.3-0082
ƒ Change FRF tank FRF level in as indicated by during appropriate
strainers; clean chocked strainers criteria shut-downs and
strainers overhauls
ƒ Regenerate air filters or Discoloration of 3m, or as
exchange filter filling filter filling indicated by
criterion

2. Cleaning of FRF tank after deposits in FRF 3-4y during overhauls

draining FRF tank
3. Keeping the FRF in FRF
tank at operating level.
ƒ Top up using FRF of the Level in FRF 1 d check; Top
same brand and with the tank up as indicated
same properties by criterion
4. Lubrication of motors of as specified by
pumps and fans the motor
ƒ FRF pumps manufacturer
ƒ FRF circulating pump
ƒ FRF vapour extraction
fan

BHEL, Hardwar 6.3-0023-01/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
5. Lubrication of the bearings as specified by
of the FRF vapour fan manufacturer
extraction fan
6. Lubrication of the valve 3m
stems at the lubricating
points provided
7. Retightening of the valve 3m of if leakage
stem packing detected
8. Elimination of leaks by leakage regularly, as
retightening flanges and indicated by
unions criterion
9. Checking of damping fluid 1 -2 Y
in vibration dampers
as prescribed in 6.3-0100
10. Charging of hydraulic Filling 1m
accumulators pressure

BHEL, Hardwar 6.3-0023-01/2

 Steam Turbine Testing during Start-up
Maintenance
Introduction
Tests demonstrate the readiness for operation and the
proper functioning of important components. They must
be performed before and during start-up of the turbine
generator unit, irrespective of the time of the preceding
shutdown.
If all prerequisites for performance of the complete test
program are not fulfilled, reduced testing to ensure the
readiness of the auxiliary, emergency and jacking oil
pumps for operation must be performed.
The scope of the test program for start-up of the turbine is
to make sure that all tests required to be performed
before start-up after a shutdown period of approx. 4
weeks [1, 2] have completed.
Test procedures
Tests, prerequisites, test activities and criteria in table
form is intended to simplify testing. The symbols at the
head of the columns in the tables are an aid to
understanding the concise test instructions.
The tables are also suited to use as checklists. Whenever
no specific test instructions are prescribed for any test,
the sequences shown in the table must be followed.
A number of tests require that certain components be in a
definite position (e.g. main trip valves in operating
position, stop valve closed etc.)
BHEL, Hardwar
The operation sequence establishing certain operating
conditions is given in the form of general instructions to
avoid constant repetition in the table of test sequences.
Test Performance
Take care to avoid any risks to people or machines while
performing tests.
Any simulated conditions necessary for the tests must be
cancelled after completion of tests.
Steam inlet valve may only be operated for test purposes
if the piping systems upstream of the valves are not
under pressure and the systems concerned have been
expressly cleared for testing.
Test performance must be recorded.
If incorrect operation of the equipment being tested
occurs, take action establishing full operational reliability
of the turbine generator unit immediately. Pay attention to
fault tracing instructions.
Also refer to the following sections:
[1] 6.3-0061: Testing During Standstill
[2] 6.2-002..: Testing of turbine Component
6.3-0030-02/1
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Main trip valves in
operating Position
o Stop valves closed o Starting and load limit device not in 0% position
o Test valves of stop valves in left-hand end
position (=stop valves open)
(1) Move test valve pilot into right-hand end position
using hand wheel (= stop valves closed)
(2) Bring starting and load limit device into 0%
position
• Main trip valve in operating position
(3) Bring starting and load limit device into 40%
position
• Main trip valve in operating position and ready to
trip
• Stop valves closed

Main trip valves in
operating Position
o Stop valves open
(1)
(2)
o Starting and load limit devices not in 0% position
o Test valve of stop valve in left-hand end position
Bring starting and load limit device into 0%
position
• Main trip valve in operation position
Bring starting and load limit device into 40%
position
• Main trip valve in operating position and ready to
trip
• Stop valves open

Auxiliary oil pumps

o Pressure-dependent o Shaft at standstill
on command from
o Oil system depressurized
subloop control before
starting turning gear o Auxiliaries and emergency oil pumps off
operation
o Subloop controls on Manual
(1) Switch auxiliary oil pump 1 subloop control to
Auto
• Auxiliary oil pump 1 on
• System oil pressure present
(2) Switch auxiliary oil pump 2 subloop control to
Auto

BHEL, Hardwar 6.3-0030-02/2

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
(3) Switch auxiliary oil pump 1 subloop 1control to
Manual
(4) Switch auxiliary oil pump 1 off
• Auxiliary oil pump 2 on
• System oil pressure present

D.C. Emergency oil

pump
o Pressure-dependent (1) Switch D.C. emergency oil pump subloop control
on command from on
subloop control before (2) Switch auxiliary oil pump 2 subloop control to
starting turning gear Manual
operation
(3) Switch auxiliary oil pump 2 off
• DC emergency oil pump on
• Lubricating oil pressure present
(4) Switch DC emergency oil pump subloop control
to Manual
(5) Switch DC emergency oil pump off
• Oil system depressurized
• Auxiliary and emergency oil pumps off
Auxiliary and
Emergency oil pumps
o Operational readiness o Shaft at stand still
before starting turning
o Oil system depressurized
gear operation
(testing not required if o Auxiliary and emergency oil pumps off
sob loop controls
have already been o Subloop controls on Manual
successfully tested) (1) Switch auxiliary and emergency oil pumps in turn
to Manual on
• System oil pressure present
Auxiliary and o Turning gear in operation
Emergency oil pumps
o One auxiliary oil pump operating
o Operational readiness
after starting turning (1) Switch stand-by auxiliary oil pump to Manual on
gear operational • Pressure buildup in system
(2) Switch stand-by auxiliary oil pump to Manual off
(3) Switch emergency oil pump to Manual on
• Pressure buildup in system
(4) Switch emergency oil pump to Manual off

BHEL, Hardwar 6.3-0030-02/3

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Auxiliary Oil pumps
o Speed-dependent o Turbine generator unit speed = rated speed
cutout when rated
(1) Verify cut out of auxiliary oil pump
speed is reached
Jacking oil pumps
o Speed-dependent on o Shaft at standstill
command of AC
o Jacking oil pumps off
jacking oil pump from
sub loop control o Subloop controls on Manual
before starting
turning gear operation (1) Switch AC jacking oil pump sub loop control to
Auto
• AC jacking oil pump on
• Jacking oil pressure present
(2) Switch AC jacking oil pump sub loop control to
Manual
(3) Switch AC jacking oil pump off
• AC jacking oil pump off
• Jacking oil system depressurized

Jacking oil pumps

o Manual on of AC o Shaft at stand still
jacking oil pump
(1) Switch AC jacking oil pump to Manual on
before starting turning
gear operation • AC jacking oil pump on
• System oil pressure present
(2) Switch AC jacking oil pump to Manual off
• AC jacking oil pump off
• System depressurized
Jacking oil pumps
o Speed-dependent on o Shaft at stand still
command of DC
o Jacking oil pumps off
Jacking oil pump from
sub loop control o Sub loop control on Manual
before turning gear
operation (1) Switch DC jacking oil pump sub loop control to
Auto
• DC jacking oil pump on
• Jacking oil pressure present

BHEL, Hardwar 6.3-0030-02/4

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
(2) Switch DC jacking oil pump sub loop control to
Manual
(3) Switch DC jacking oil pump off
• DC jacking oil pump off
• Jacking oil system depressurized
Jacking oil pumps
o Operational readiness o Shaft at stand still
of Jacking oil
o Jacking oil pumps off
pumps
o Sub loop controls on Manual
(1) Switch jacking oil pumps in turn to Manual on
• Jacking oil pressure present
Control fluid pumps
o Pressure-dependent o Control fluid system depressurized
on command from sub
o Control fluid pumps off
loop control
o Sub loop control on Manual
(1) Select one control fluid pump (e.g. pump 1)
(2) Switch sub loop control to Auto
• Control fluid pump 1 on
• Control fluid system pressure present
(3) Select control fluid pump 2
(4) Switch control fluid pump 1 off
• Control fluid pump 2 on
• Control fluid system pressure present
(5) Switch sub loop control to Manual
(6) Switch control fluid pump 2 off
• Control fluid system depressurized
• Control fluid pumps off
Control fluid pumps
o Operational readiness o Control fluid system depressurized
(Testing not required
o Control fluid pumps off
if sub loop controls
have already been o Sub loop control on Manual
successfully tested)
(1) Switch control fluid pumps in turn to Manual on
• Control fluid system pressure present

BHEL, Hardwar 6.3-0030-02/5

 Equipment tested Preconditions
o Date
() Test Step Result
o Type of test
• Result Tested by

Remote trip initiation

o Push button operation o Main trip valve in operating position
o Stop valves closed
(1) Press trip push button
• Trip annunciated

Stop valves
o Leak test o Main steam pressure present upstream of stop
valves
o Stop valves closed using test valves
(1) Open control valves
• No speed increase
(2) Bring back test valves to operating position
Control valves
o Leak test o Control valves closed using motorized actuator
o Main steam pressure present upstream of turbine
(1) Open stop valves
• No abnormal speed increase
(2) Bring back motorized actuator to open position

Overspeed trip
o Oil injection test o Turbine speed < 2970rpm or
o Unit in low-load operation
(1) Release testing device for operation
(2) Press and hold down test valve for inhibiting trip
(left-hand valve)
(3) Turn hand wheel of hydraulic test signal
transmitter to right until test oil circuit is
pressurized
(4) Observe oil pressures where overspeed trip
device operates
• Auxiliary trip circuit depressurized

BHEL, Hardwar 6.3-0030-02/6

 Equipment tested o Preconditions Date
() Test Step Result
o Type of test
• Result Tested by

(5) Turn hand wheel of hydraulic test signal

transmitter to left until test oil circuit is
depressurized
(6) Bring trip device of overspeed trip into operating
position using right-hand valve
• Auxiliary trip pressure built up
(7) Repeat test until overspeed trip operates at the
same test oil pressure in successive tests

BHEL, Hardwar 6.3-0030-02/7

 Steam Turbine Testing during Power Operation
Maintenance

Test that demonstrate the readiness for operation and the
proper functioning of important components, must be
performed during power operation of the turbine
generator unit. The time intervals between tests are given
in a separate instruction [1].
Test performance must be recorded. If incorrect operation
of the equipment tested occurs, take action establishing
full operational reliability of the turbine generator unit
immediately.
Pay attention to fault tracing instructions. [2]

Test Procedures
The table containing tests, prerequisites, test activities
and criteria is intended to simplify testing. The tables can
be used as checklists. When no specific instructions are Also refer to the following sections:
prescribed for any test, the test sequences shown in the [1] 6.2-002. : Testing of turbine components
table must be followed.
[2] 6.2-0400 : Fault tracing
Test performance

Equipment tested o Preconditions Date

o Type of test () Test Step Result
• Result Tested by
Turbine controllers
o Functional test o Control valve opening < 100%
(1) Change setpoint of effective controller
• Change in control valve-opening corresponding
to setpoint change

Bypass control
o Functional test o Load approx. 50%
(1) Open HP bypass station slowly by operating
pushbutton on control panel
• Reheat pressure increases
• Injection water pressure present
• Bypass stop valves open
• Bypass control valves begin to open
(2) Close HP bypass station
• Reheat pressure drops
• Bypass control valves close
• Bypass stop valves close
• Injection water pressure reduced

BHEL, Hardwar 6.3-0035-02/1

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Seal steam controller
o Functional test o Seal steam controller on
(1) Seal steam controller off
(2) Induce control deviation by operating control
valves (Pushbutton on control panel)
(3) Seal steam controller on
(4) Verify correction of seal steam pressure
Oil temperature
controller
o Functional test o Oil temperature controller on
(1) Oil temperature controller off
(2) Induce control deviation by operating temperature
control valve (Pushbutton on control panel)
(3) Oil temperature controller on
(4) Verify correction of oil temperature

Auxiliary and
emergency oil pumps
o Operational readiness o Auxiliary and emergency oil pumps off
test
(1) Auxiliary pumps subloop control off
(2) Auxiliary oil pump 1 Manual on
• Pressure buildup downstream of pump
(3) Auxiliary oil pump 1 Manual off
(4) Auxiliary oil pump 2 Manual on
• Pressure buildup downstream of pump
(5) Auxiliary oil pumps 2 Manual off
(6) Auxiliary oil pumps subloop control on
(7) Emergency oil pump Manual on
• Pressure buildup downstream of pump
(8) Emergency oil pump Manual off
Control fluid pumps
o Operational readiness o Service control fluid pump on
test
(1) Stand-by control fluid pump Manual on
• Pressure buildup downstream of tested pump
(2) One control fluid Manual off

BHEL, Hardwar 6.3-0035-02/2

 Equipment tested
o Type of test
Main trip valves
o Ease of movement
test
Remote trip solenoids
o Functional test
Overspeed trips
o Functional test and
testing of setting
Overspeed trips
o Manual functional test
and testing of setting
BHEL, Hardwar
o Preconditions Date
() Test Step Result
• Result Tested by
o Automatic turbine tester available
(1) Select and start test program for one protective
device
• Main trip valves respond
• No fault annunciations on automatic turbine tester
o Automatic turbine tester available
(1) Select and start Remote trip solenoids test
program
• Main trip solenoid respond
• No fault annunciations on automatic turbine tester
o Automatic turbine tester available
(1) Select and start Remote trip test program
• Overspeed trips respond
(2) If ATT annunciates fault repeat overspeed trip
test
(1) Release hydraulic test signal transmitter
(2) Depress left-hand piston of hydraulic test signal
transmitter to limit and hold down
(3) Increase test pressure using hand wheel of
hydraulic test signal transmitter
o Overspeed trip(s) respond(s)
(4) Ascertain pressure at which trip(s) respond(s)
and record
(5) Reduce test pressure using hand wheel of
hydraulic test signal transmitter
(6) Depress right-hand piston of hydraulic test signal
transmitter to limit
• Auxiliary trip pressure builds up
(7) Release right-hand piston of hydraulic test signal
transmitter
(8) Release left-hand piston of hydraulic test signal
transmitter
6.3-0035-02/3
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

(9) Repeat test as often necessary until trip operates

at the same test pressure as set during
commissioning
Hydraulic low-vacuum
trip
o Functional test and o Automatic turbine tester available
testing of setting
(1) Select and start Low-vacuum trip test program
• low vacuum trip operates
• No fault annunciations on automatic turbine tester
Differential pressure
switch in extraction
lines
o Functional test o Extraction system in operation
o Extraction swing check valve open
o Hydraulic release present
(1) Reduce differential pressure across differential
pressure switch
• Extraction swing check valve closes slightly
Stop and control valves
o Exercising o Automatic turbine tester available
(1) Apply test load
(2) Select and start test program for stop and control
valve unit to be tested
• Control valve closes
• Stop valve closes
• Stop valve opens
• Control valve opens
• No fault annunciation on automatic turbine tester
Extraction swing check
valves
o Exercising o Extraction system in operation
(1) Change load or extraction flow
• Extraction swing check units perform movements

BHEL, Hardwar 6.3-0035-02/4

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Alarms
o Functional test o Alarms generated
(1) Record alarms generated
Speed indicator (1) Compare with grid frequency

Important operating
values
o Recording (1) Record important operating values in accordance
with 6.3-0036 & 6.3-0037
Drains
o Leak test (1) Test temperature condition of drain values

BHEL, Hardwar 6.3-0035-02/5

 Steam Turbine
Maintenance
Introduction
It is in the interest of both the plant operator and the
supplier that the causes of faults, severe damage and
unfavourable inspection findings be determined, and
actions taken to prevent a recurrence of such incidents.
In order to determine the cause of such faults, it is
essential that information be available, in the form of
operating documentation, on the operating history of the
turbine generator unit both in the past and immediately
before and during the fault or damage.
This instruction contains recommendations on the
acquisition and archiving of operating data.
Scope of measurement and instrumentation
The scope of measurements and also, therefore, the
instrumentation of the turbine generator unit are dictated
by the agreements between plant operators and
suppliers.
The data are of importance for operations management.
The scope of data recommended in Table-1 should
therefore be available to permit post-event analysis.
Scope of operating documentation
Operating documentation comprises the following
documents:
▪ Printouts from continuous-line printer
▪ Operating data logs or curves based on the data
archived in the electronic data acquisition system
▪ Alarm and switching logs; such logs document the
histories of faults or damage and should be archived
▪ Logs with handwritten entries are required in cases
where certain data are not recorded or archived
▪ Logs used to document the long-term behavior of the
turbine generator unit
▪ Documents showing the availability statistics
BHEL, Hardwar
Acquisition and Archiving
of operating data
Procedural Instruction
Documents from the electronic data acquisition
system
▪ processing of analog measured values
All the data specified in Table-1 should be archived in
MAXSTORIAN of electronic data acquisition system. It
should be possible to retrieve data in the form of logs or
time curves at any time over the course of the intended
archiving period. Long-term data archiving is to be done
on magnetic tape / disc.
Only those values for an operating parameter should be
electronically archived which, after the scanning interval
has elapsed, lie outside the scatter band given in Table-1,
when compared to the last recorded value.
▪ processing of binary signals
Normally, binary signals resulting from annunciations and
switching operations are continuously printed out with
high time resolution by the electronic data acquisition
system, alarm and switching logs are thus generated
which form an important source of information for
operations management.
For troubleshooting purposes, the alarm and switching
logs printed immediately before, during and after the fault
should be retained and archived.
Documents for long-term monitoring of the turbine-
generator unit
Certain operating data should be recorded at long
intervals in order to document the long-term behaviour of
the turbine generator unit, as well as any data relevant in
terms of life expectancy considerations.
The associated logs may be of use in analysing faults or
damages if the cause can be traced back to or is
indicative of a gradually developing adverse change.
Documents on availability statistics
For the purpose of providing information on the operating
behaviour and the status of the plant, it is recommended
that availability statistics is compiled which show, among
other things, the causes and duration of periods of non-
availability.
6.3-0037-03/1
If the statistics show a frequent recurrence of an event
which leads to plant non-availability, in-depth
investigations should be performed.
Processing of operating documents
▪ Fault report
The control room personnel should prepare reports on
fault or damage, showing all relevant data on the
evolution of the event leading to the fault or damage, as
well as the countermeasures implemented. Copies of the
printouts from the continuous-line recorder or dotted-line
recorder, operating data tables and curves generated by
the electronic data acquisition system, and the fault and
damage logs should be appended to the fault or damage
reports.
▪ Evaluation of the fault report and the operating
documentation
Faults and damage usually occur when several adverse
influences are present simultaneously. Because of the
multiplicity of conceivable faults and their possible
influencing factors, it is not possible in this procedural
instruction to present a reliable and complete picture of all
the correlations involved.
It is the duty of the operator’s or supplier’s own experts to
define the correlation between the event and the adverse
influencing factors and to evaluate them and decide on
countermeasures to be implemented.
BHEL, Hardwar
Retention period for documentation
The documents described above must be archived in a
magnetic tape for consultation for a long time after the
operating data have been logged in order, among other
things, to analyse any correlations between component
status and operating conditions.
▪ Documents containing operating data which are
relevant in terms of life expectancy considerations must
be archived until the turbine generator unit is taken out of
service.
▪ It is recommended that all other documents be archived
until the next inspection and overhaul has been
completed.
Importance of documents for settling guarantee
claims
Without the data contained in the documents described
above, the supplier of the turbine generator unit is not
always able to check the legal validity of guarantee
claims in the event of damage or a complaint regarding
component defects and may therefore reserve the right to
reject any claims for which the requisite documents are
not available.
Table-1 lists the required operating data for acquisition
and archiving in accordance with the operating
instruction, in order to permit evaluation of turbine
performance. The requirements will have to be adapted
on the basis of the actual measuring point list.
Also refer to the following:
[1] BHEL-EDN document on MAX control system
6.3-0037-03/2
 Table – 1

Data acquisition recommended for post event analysis

ID Code Measuring point Measuring Scatter band Retention

cycle Period
Power/Speed
MKA CE Active Power 30 s 0.002 Pnom service life
MKA CE Reactive Power 30 s 0.002 Pnom service life
MYA FS Turbine generator speed 5s 0.05 to 0.1 s-1 inspection cycle
Steam pressure
LBA CP Upstream MS stop valves 30 s 0.01 Pnom service life
MAA CP Upstream HP blading 30 s 0.01 Pnom service life
LBC/MAA CP Downstream HP blading 30 s 1 bar inspection cycle
LBB CP Upstream reheat stop valves 30 s 0.01 Pnom service life
MAB CP Upstream IP blading 30 s 0.01 Pnom service life
LBQ CP HP extractions 30 s 0.005 to 0.01 Pnom inspection cycle
LBS CP LP extractions 30 s 0.02 Pnom inspection cycle
MAG CP Condenser 30 s 0.01 bar inspection cycle
Steam temperatures
LBA CT Upstream MS-stop valves 30 s 2K service life
LBC/MAA CT Downstream HP turbine 30 s 2K inspection cycle
LBB CT Upstream reheat stop valves 30 s 2K service life
MAB CT Downstream IP turbine 30 s 2K inspection cycle
LBO CT HP extractions 30 s 2K inspection cycle
LBS CT LP extractions 30 s 1K inspection cycle
MAW CT Seal steam header 30 s 1K inspection cycle
Casing temperatures
MAA CT MS-SV/CV 100/50% 30 s 2K service life
MAA/MAB CT Turbine casing 100/90/50% 30 s 2K service life
MAA/MAB CT Turbine casing top/bottom 30 s 2K inspection cycle
MAC CT Turbine casing front/rear 30 s 1K inspection cycle
Bearing temperatures
MAD CT Turbine radial/axial bearings 5s 1K inspection cycle
MKD CT Generator/exciter bearings 5s 1K inspection cycle
Vibrations
MAD/MKD CY Turbine / generator bearing 5s 1 μm inspection cycle
casing
MAD CY Turbine shaft abs. or relative 5s 5 μm inspection cycle
MKD CY Generator / exciter shaft 5s 5 μm inspection cycle
absolute or relative

BHEL, Hardwar 6.3-0037-03/3

 Steam Turbine Remedial Actions for
Maintenance off-normal operating conditions

Turbine

Off-Normal Condition Action Classification of action

Main steam pressure > Pmax Increase turbine load or reduce In-service correction
(Long-term) steam generator output
Main/reheat steam Reduce main / reheat steam In-service correction
temperature > θmax (long- temperature
term)
Main / reheat steam Raise main / reheat steam In-service correction
temperature < θdesign temperature
Steam pressure ahead of Reduce turbine load until pressure In-service correction
turbine blading > Pmax (long- ahead of turbine blading < Pmax
term) (long-term)

HP turbine exhaust steam Take ηi measurements In-service check

temperature or extraction
If internal efficiency ηi degraded Maintenance (saturated
temperatures > normal under
flush through with saturated steam steam washing) during
otherwise comparable
short shut-down
operating conditions Clean blading
Maintenance (cleaning)
during overhaul
Seal steam pressure Check control system; if In-service check and
deviates from setpoint or necessary correct setpoint correction
fluctuates adjuster
Repair during service or
If necessary repair control valves overhaul
Replace filters at seal steam Maintenance during short
control valves shut-down
Seal steam pressure > pnormal Measure temperature in leak-off In-service check
Seal steam leak-off valve steam lines of casings, valves etc.
100%
Check functioning of Gland Steam In-service check
condenser
Check shaft seal and repair Inspection and repair
if necessary during overhaul
Temperature differential , top Check temperature sensors In-service check
and bottom casing > normal
Establish cause of temperature Actions during service or
differential as per 6.2-0423 overhaul depending on
findings
Discrepancies at TSC
- TSC test function not Check TSC and/or temperature In-service check and
correct sensors; check and repair repair
TSC or temperature sensors
- High wall temperature
differentials during steady-
state operation

BHEL, Hardwar 6.3-0040-01/1

 Off-Normal Condition Action Classification of action

Spacer plates at casing Check for casing lift In-service check

supports not free to move
Clean spacer plates and other In-service check and
fixture elements; establish maintenance (cleaning)
freedom of movement only if casing does
not lift when fixture
elements are removed;
inspection and
maintenance (cleaning) or
repair during overhaul
Check forces exerted by piping, In-service check;
check adjustment of piping correction during shut-
hangers down
Bearing or shaft vibration Perform checks as prescribed in In-service check
> normal under otherwise 6.2-0420 provided vibrations
comparable operating < trip limits
conditions
Actions as appropriate to
finding e.g.
- Rebalance rotor system In-service check
- Check alignment, bearings, In service correction
shaft seals Check during overhaul
or after turbine shut-down

Bearing metal temperatures Perform examinations and checks In-service check

> normal under otherwise as prescribed in 6.2-0421
comparable operating
If temperature changes wide with Immediate inspection and
conditions
rapid rates of change, shut down repair during forced shut-
turbine and inspect bearing down
If temperature changes small and Inspection and repair
slow, inspect and repair at earliest during overhaul
opportunity
Drain valves leaking Open drain, blow through and In-service correction
close again
Loss of integrity of stem Tighten stem seals In-service maintenance
packing of drain valves
LP turbine outlet temperature Leak in internal expansion joint In-service check
> normal under otherwise suspected if high temperature
comparable operating localised
conditions (especially
Perform inspection and if Visual inspection and
condenser vacuum)
necessary repair repairs during overhaul
or after shut-down

BHEL, Hardwar 6.3-0040-01/2

 Oil system

Off-Normal Condition Action Classification of action

Oil system pressures < pnormal Perform examinations and checks Check and remedial
as prescribed in 6.2-0460 and take actions may in many
appropriate action cases be performed
during operation;
otherwise shut down
plant and perform repairs
Lubricating oil pressure Change over filter and clean In-service maintenance
downstream of filter < Pnormal
Control fluid pressure Change over filter and clean or In-service maintenance
< Pnormal replace, or clean filter by rotating
filter plates
Oil temperature downstream Perform examinations and checks In-service checks and
of oil cooler > θnormal as prescribed in 6.2-0460 check maintenance
control system, if necessary
correct setpoint or repair
Check oil cooler vents;
check that no water is
being admitted to standby oil
cooler; check oil cooler for
chocking, where necessary
change over and clean
Oil level in oil tank < normal
- Slow change Top up with oil of same make and In-service check and
type maintenance
Locate leak and take appropriate In-service check and
- Rapid change
actions, e.g. initiate fire protection remedial action
measures
Oil level in tank strainer high Change and clean strainer Maintenance during
service or shut-down
Water collecting on oil tank Drain off water; separate water In-service maintenance
bottom from oil
Establish causes and eliminate Check and repair during
overhaul
Oil escaping at oil guard Check if oil vapour exhauster In-service check and
rings of bearing pedestals fan is in operation correction
Adjust throttle valves on bearing
pedestals
Check leak-tightness of oil tank
covers and if necessary reseal
Oil properties, e.g. air Perform additional oil In-service maintenance
separation capability and examinations; consult on
antifoaming, changed appropriate actions with oil
supplier and turbine manufacturer

BHEL, Hardwar 6.3-0040-01/3

 Control Fluid System

Off-Normal Condition Action Classification of action

Control fluid level in control

fluid tank < normal
- Slow change Top up with control fluid of same In-service check and
make and type maintenance
- Rapid change Locate leak and take appropriate In-service check and
actions; e.g. initiate fire protect- remedial actions
ion measures
Control fluid level in tank Change and clean strainer Maintenance during
strainer high service or shut-down
Control fluid properties, e.g. Operate regeneration plant In-service maintenance
air separation capability or continuously; shorten sampling
neutralization value, changed intervals; replace Fuller’s
earth in filter
Control fluid temperature Check control system, where In-service checks and
downstream of control fluid necessary adjust setpoint or maintenance
cooler > normal repair
Check control fluid vents
Check that no water is being
admitted to the standby cooler;
check control fluid coolers for
chocking, if necessary change
over and clean
Charge pressures of Recharge accumulators In-service maintenance
accumulators < Pnormal

BHEL, Hardwar 6.3-0040-01/4

 Control System, Protective Devices

Off-Normal Condition Action Classification of action

Change in control system Check control system, if Correction during short

setting necessary reset or correct, shut-downs or overhauls
establish cause of discrepancy
- Control valve lift sequence
and eliminate
- Control valve
synchronisation
- Control valve travel
changed
as function of secondary
pressures
Primary oil pressure Examine antifoaming performance In-service check
fluctuates or < Pnormal of turbine oil
Check oil supply to hydraulic Check during short shut-
speed transducer downs or overhauls
Open main oil pump and check Check and repair during
hydraulic speed transducer overhauls
Control valve streams not
leak-tight
- Control valve opening Replace back seat Repair during overhaul or
100% short shut-downs
- Control valve opening < Replace steam packing rings
100%

Control valve leaking Replace valve stem; rework seat Repair during overhaul
(internal steam leak)
Load shedding relay Repair load shedding relay In-service repair
defective
Faults in valves detected by
automatic turbine tester
- Running time exceeded Adjust limit switch In-service repair
during testing of stop and
control valves
Extraction swing check valve Repair position indicators In-service repair
position indicators defective

BHEL, Hardwar 6.3-0040-01/5

 Pumps and Piping

Off-Normal Condition Action Classification of action

Pump and motor bearing Inspect bearing, renew or In-service maintenance

temperatures > normal replenish grease or oil charge
Pump shaft seals not leak- Tighten and if necessary In-service maintenance
tight repack shaft seals
Performance degraded Switch in standby unit In-service correction
If necessary perform overhaul Repair during overhaul
Discharge head < normal Switch in standby unit In-service correction
under otherwise comparable
Perform system check, if In-service correction
operating conditions
necessary correct system
operation
Pipes vibrating Inspect dampers In-service maintenance
Check and repair piping hangers In-service repair
and supports
Piping and/or piping
connections leaky
- Large-scale escape of Immediately shut down turbine Repair during stoppage
flammable media (initiate fire protection
measures); eliminate leak
- Small-scale escape of Establish cause of leak and Repair during stoppages
flammable media eliminate or overhauls
Valve stem seals not leak- Tighten or replace stem seals In-service maintenance,
tight repair during stoppages
and overhauls

BHEL, Hardwar 6.3-0040-01/6

 Steam Turbine Measurement of
Maintenance Internal Efficiency
Test Instructions

Introduction The intervals between measurements should be either in

accordance with the recommendations given in Table-1
This test instruction describes the procedure used for or as specified by the operator on the basis of practical
measuring the internal efficiency of turbines whose experience with the particular plant, which also includes
expansion line lies within the superheated steam region. the trend of any changes in efficiency.

Recommendation for measurement
The economic performance of any power plant unit
depends, among other factors, on the overall efficiency of
the steam turbine and thus, on the internal efficiency of
each cylinder.
Changes in the internal condition of a turbine (e.g. due to
buildup of deposits on blades, increased seal clearances,
or mechanical damage) cause a marked deterioration in
internal efficiency.
Consequently, the internal efficiency of a turbine cylinder
is an important parameter with which the effect of the
changes in internal condition on its performance can be
assessed.
Measurement of the internal efficiency of each turbine at
regular intervals and comparison with values recorded
previously or when the unit was new, are recommended.
This will provide useful additional information for planning
the type, scope and timing of maintenance work (e.g.
restoring original gaps and clearances, blade repairs
etc.).
Principle of measurement
▪ Prerequisites and limitations
The steam conditions in the reference plane at the inlet
and exhaust of the turbine, whose internal efficiency is to
be measured, must lie within the superheated steam
region.
The internal efficiency of turbines whose expansion line
lies totally or partially within the wet steam region cannot
be measured, since there is no simple way of measuring
the actual steam content of a flow of wet steam with
sufficient accuracy. This means that the method
described here cannot be used for measuring the internal
efficiency of LP turbines, operating under wet steam
condition.
▪ measuring the steam conditions at the turbine inlet and
exhaust
The steam pressures and temperatures in the reference
plane at the inlet and exhaust of a turbine as indicated in
Figure-1 are measured, recorded and calculated during
normal steady-state operation under comparable rated
design conditions. Carrying out test at identical load and
steam parameters makes the comparison / trend more
realistic.

Table-1: Test intervals

Type of test Boundary conditions Test interval

Measuring Steady state operation under ▪ 6-months

the internal rated design conditions
efficiency comparable with those of ▪ before and after inspections and overhauls
previous measurements.
▪ before and after wet steam washing

BHEL, Hardwar 6.3-0050-02/1

 P1
h1 T1

Δh
S1

Δhs
P2
h2
T2

hs

Figure-1: Steam conditions and enthalpies for calculating the internal efficiency of a turbine cylinder

Notations: Δh h1 - h 2

Internal Efficiency in % = -------- x 100 = ----------- x 100

Δhs h1 - hs

Where,

P1: Pressure of inlet steam before group stage section

T1: Temperature of inlet steam before group stage section

P2: Pressure of exit steam after group stage section

T2: Temperature of exit steam after group stage section

h1: Enthalpy of inlet steam corresponding to P1 & T1

S1: Entropy of inlet steam corresponding to P1 & T 1

h2: Enthalpy of exit steam corresponding to P2 & T2

hs: Adiabatic steam Enthalpy corresponding to P2 & S1

Note: Values of h1, S1, h2 and hs are to be worked out from steam table.

BHEL, Hardwar 6.3-0050-02/2

▪ determining the enthalpy
The enthalpies for the steam conditions measured in the
reference plane at the turbine inlet and outlet are taken
from steam table.
▪ calculating the internal efficiency
The internal efficiency of a turbine cylinder is calculated
with the ratio of the actual decrease in enthalpy to the
isentropic decrease in enthalpy.
▪ Trend of change in internal efficiency
Trend of changes in internal efficiency can be seen when
the measurements are plotted versus time in a graph.
Measuring points and instruments
When taking measurements for calculating the internal
efficiency of a turbine, the measuring points should be in
the same reference plane at the turbine inlet and outlet as
for the acceptance tests.
The turbine is also provided with test measuring points for
installing precision instruments to measure pressures and
temperatures.
Appropriate instruments can be installed in addition to the
operational instrumentation and used for taking
necessary measurements.
If the measurements are to be taken by means of
operational instrumentation installed in the reference
planes, the instruments must be tested and calibrated
regularly in order to eliminate any inaccuracies due to
problems such as drift.
Measuring procedure
The procedure for measuring the steam pressures and
temperatures and calculating the internal efficiency of a
turbine is as follows:
▪ Install precision pressure gauges or recalibrate the
operational instrument
▪ Vent the pressure-sensing lines
BHEL, Hardwar
▪ Install precision thermocouples or use the operational
instruments for temperature measurement
▪ Adjust the inlet steam conditions and the control valve
lift to the same values used for previous measurements
▪ Wait until turbine temperatures have stabilized under
steady-state operating conditions
▪ Measure and record the steam pressures and
temperatures
▪ Use steam tables to determine the enthalpies of the
steam condition at the turbine inlet and outlet
▪ Calculate the efficiency
▪ Compare the measured internal efficiencies with the
values recorded previously or when the unit was new,
and evaluate
Duration of testing
For reliable measurement, arithmetic averages of
pressure & temperature measurements should be taken
for at least half hour duration at stable load condition and
rated steam parameters.
Reasons for actual conditions deviating from
reference condition
Changes in internal efficiency can be due to one or more
of the following reasons:
▪ Increased roughness of the blade surfaces due to a
build-up of deposits, corrosion, or solid particle erosion
▪ Increase in clearances in the blading flow path
▪ Increased tip clearance losses due to seal strip wear
▪ Bypass flow due to internal leaks
▪ Increase of losses in valve seats
▪ Deposits on heat transfer surfaces
6.3-0050-02/3
 Steam Turbine Testing during Shut-down
Maintenance

Introduction Test performance

Tests that demonstrate the proper functioning of
important components must be performed during shut
down of the turbine generator unit.
The scope of the tests performed is listed in the Test
interval instruction [1].
Test Procedures
Test prerequisites, test activities and criteria in tabular
form are intended to simplify testing.
Take care to avoid any risks to people or machines while
performing tests.
Any simulated condition necessary for the tests must be
cancelled after completion of tests.
Steam inlet valves may only be opened for test purposes
if the piping system upstream of those valves is not under
pressure and the system concerned have been cleared
for testing.
Test performance must be recorded.

The tables can also be used as checklists. When no If incorrect operation of the equipment being tested
specific instructions are given for any test, the test occurs, take action establishing full operational reliability
sequences shown in the table must be followed. of the turbine generator unit immediately.

A number of tests require certain components be in a Pay attention to fault tracing instructions.
definite position (e.g. main trip valves in operating
position, stop valves closed, etc.).

The operating sequence establishing certain operating

conditions is given in the form of general instructions to
avoid constant repetition in the tables of test sequences. Also refer to the following sections:

[1] 6.2-002. : Testing of turbine components

[2] 6.3-0061 : Testing during standstill

Equipment tested o Preconditions Date

() Test Step Result
o Type of test
• Result Tested by
Main trip valves in operating
position
{ Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand
end position ( = stop valves open)
(1) Move test valve pilot into right-hand
end position ( = stop valves closed)
using hand wheel
(2) Bring starting and load limit device
into 0 % position
• Main trip valves in operating position
(3) Bring starting and load limit device
into 40 % position

BHEL, Hardwar 6.3-0060-01/1

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Main trip valves in operating position

and ready to trip
• Stop valves closed

o Stop valves open o Starting and load limit device not in 0%

position
o Test valves of stop valves in left-hand
end position
(1) Bring starting and load limit device
into 0 % position
• Main trip valves in operating position
(2) Bring starting and load limit device
into 40 % position
• Main trip valves in operating position
and ready to trip
• Stop valves open
Overspeed trip
o Overspeed test after test interval o Generator not synchronized
or after inspections and repairs o Turbine generator unit at rated speed
(See also instruction 6.3-0030)
o Turbine at operating temperature
(1) Raise speed reference to maximum
• Speed approx. 107%
(2) Switch off Electro-hydraulic controller
(3) Run up to trip speed by pressing
mechanical push button on hydraulic
speed governor
(4) Verify operation of overspeed trip
• Trip speed
• Stop and control valves closed
Control valves and reverse power
protection relay
o Leak test valves o Generator synchronized
and o Load > 0 %
o Functional test (reverse power o Speed governor effective
relay)
(1) Lower speed set point

BHEL, Hardwar 6.3-0060-01/2

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Secondary pressures < opening

pressure for control valves
• Control valves 0%
(2) Verify operation of reverse power
protection relay
• Reverse power protection relay
operated
• Generator breaker tripped
or
• Reverse power protection relay not
operating (see serious faults 6.2-0410)

Auxiliary oil pump

o Pressure dependent on o Stop and control valves closed
command
o Turbine speed dropping
(1) Verify startup of auxiliary oil pump on
pressure-dependent command
• Auxiliary oil pump on

Jacking oil pump

o Speed dependent on command o Stop and control valves closed
o Turbine speed dropping
(1) Verify startup of jacking oil pump on
speed-dependent command
• Jacking oil pump on

Turning gear oil valve

o Speed-dependent open o Stop and control valves closed
command
o Turbine speed dropping
(1) Verify opening of turning gear oil
valve on speed-dependent command
• Turning gear oil valve open

Condenser Safety devices

o Response of electrical o Turbine generator unit not operating
condenser safety device
o Condenser plant operating

BHEL, Hardwar 6.3-0060-01/3

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Criteria for shut down of condenser

plant fulfilled
o Main trip valves in operating position
o Stop valves closed
(1) Reduce condenser vacuum
(2) Verify operation of electrical condenser
safety device
• Trip initiated
(3) Restore main trip valves to normal
operating position

o Response of hydraulic low o Condenser safety device test

vacuum trip (electrical) performed
o Condenser vacuum > trip vacuum
(hydraulic)
o Main trip valves in operating position
o Stop valves closed
(1) Simulated turbine speed by screwing
in locking bolt on low-vacuum trip
(2) Reduce condenser vacuum
(3) Verify operation of electrical condenser
safety device
• Trip initiated
(4) Restore main trip valves to normal
Operating position
(5) Cancel hydraulic speed simulation
(Unscrew locking bolt on low-vacuum
trip)
(6) Move test valve into operating position

Condenser Safety devices for

bypass operation
o Response of hydraulic low o Condensate extraction pumps
vacuum trip operating
o Condenser pressure Pabs < 0.5 bar
o Criteria for shut down of condenser
plant fulfilled

BHEL, Hardwar 6.3-0060-01/4

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Bypass operation ended

(1) Press push-button of LP bypass
governor
• Signal pressure for bypass control
valves > 1.7 bar < 2.06 bar
• Bypass stop valves
(2) Operate push-button of LP Bypass limit
controller to inhibit response due to
reduction of condenser vacuum
(3) Reduce condenser vacuum
(4) Verify operation of low vacuum trip
• Signal pressure upstream of bypass
control valves reduced

BHEL, Hardwar 6.3-0060-01/5

 Steam Turbine Testing during Standstill
Maintenance

Introduction Test performance

Tests that demonstrate the proper functioning of
important components, must be performed during stand
still of the turbine generator unit.
The time intervals between tests are given in a separate
instruction [1].
Test Procedures
Test prerequisites, test activities and criteria in tabular
form are intended to simplify testing.
Take care to avoid any risks to people or machines while
performing tests.
Any simulated conditions necessary for the tests must be
cancelled after completion of tests.
Steam inlet valves may only be opened for test purposes
if the piping systems upstream of those valves are not
under pressure and the system concerned have been
cleared for testing.
Test performance must be recorded.

The tables are also suited to use as checklists. Wherever If incorrect operation of the equipment being tested
no specific instructions are prescribed for a test, the test occurs, take action establishing full operational reliability
sequences shown in the table are to be followed. of the turbine generator unit immediately. Pay attention to
fault tracing instructions.
A number of tests require certain components be in a
definite position (e.g. main trip valves in operating
position, stop valves closed, etc.)

The operating sequence establishing certain operating Also refer to the following sections:
conditions is given in the form of general instructions to
avoid constant repetition in the tables of test sequences. [1] 3-001x : Testing of turbine components

Equipment tested o Preconditions Date

o Type of test () Test Step Result
• Result Tested by
Main trip valves in operating
position
o Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand end
position ( = stop valves open)
(1) Move test valve pilot into right-hand end
position ( = stop valves closed) using hand
wheel
(2) Bring starting and load limit device into 0%
position
• Main trip valves in operating position
(3) Bring starting and load limit device into 40%
position

BHEL, Hardwar 6.3-0061-02/1

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Main trip valves in operating position and

ready to trip
• Stop valves closed

o Stop valves open o Starting and load limit device not in 0%

position
o Test valves of stop valves in left-hand
end position
(1) Bring starting and load limit device into 0%
position
• Main trip valves in operating position
(2) Bring starting and load limit device into 40%
position
• Main trip valves in operating position and
ready to trip
• Stop valves open

Turbine control
o Testing of setting o Main trip valves in operating position
Hydraulic amplifier
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of travel of starting
and load limit device (use starting and load
limit device to change auxiliary secondary
oil pressure by 0.1 – 0.2 bar per reading).
• Travel of starting and load limit device
• Travel of governor bellows
• Auxiliary secondary pressure
• Travel of converter (mm or %)
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer

BHEL, Hardwar 6.3-0061-02/2

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Testing of setting o Main trip valves in operating position

Electro hydraulic converter
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of input voltage of
turbine valve controller
• Input voltage of turbine valve controller
• Travel of converter
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer
Load rejection relay
o Functional test o Main trip valves in operating position
o Control valves open
(1) Use contactor to energize solenoid valves
operated by load rejection relay
• Control valves close for as long as solenoid
valve is energized
Bypass control
o Testing of setting o As per vendor’s recommendation

Main trip valves

o Ease of movement and trip o Main trip valves in operating position
pressure
o Stop valves closed
(1) Reduce control medium pressure of
governor linkage by closing cutoff valve
• Main trip valves close
(2) Measure pressure where main trip valves
close

BHEL, Hardwar 6.3-0061-02/3

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Remote trip solenoids
o Functional test o Main trip valves in operating position
o Test valves of stop valves in closed
position
(1) Press pushbutton to start remote turbine
trip
• Trip initiated
Low vacuum trip
o Functional test and testing of o Condenser vacuum > response level
setting
or
o Test pump operating and simulated
condenser vacuum > response level
(1) Reduce condenser vacuum or increase
pump pressure
• Low vacuum trip responds
(2) Determine vacuum where trip started
Fire protection system
o Functional test o Shaft at standstill
o Normal operating conditions of oil system
established (exception : jacking oil pump
subloop control off)
o Main trip valves in operating position
(1) Operate fire protection switches 1 and 2 in
succession in the control room and at the
local control stations in the power plant
• Start of fire protection measures in
accordance with functional diagram
• No annunciation “Fire protection measures
not performed”
(2) Acknowledge fire protection measures and
re-establish normal operating conditions for
further testing

BHEL, Hardwar 6.3-0061-02/4

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Low lub oil pressure trip
o Functional test o Oil system operating
o Main trip valves in operating position
o Stop valves closed
(1) Simulate pressure Transmitters (2 out of 3)
for lubricating oil trip
• Trip started
Stop valve
o Exercising o Oil system operating
o Main trip valves in operating position
o Stop valves open
(1) Actuate main trip valves (manual trip-out
from control system rack or remote trip
• Stop valves closed

o Cut-off pressure o Oil system operating

o Main trip valves in operating position
o Stop valves to be tested open
(1) Reduce trip oil pressure by means of cut-off
valve upstream of control system cabinet
• Stop valve closes
(2) Measure and record trip oil pressure where
valve starts to close

Turbine control valves

o Exercising o Main trip valves in operating position
o Stop valves closed
o No limitation by parallel acting controllers
(1) Open and close control valves by starting
and load limit device

Bypass Stop & Control valves

o Exercising o Bypass interlock criteria not present
or
o Release criteria simulated
(1) Open and close bypass stop and control
valves

BHEL, Hardwar 6.3-0061-02/5

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

Vacuum breakers
o Functional test (1) Operate vacuum breakers

Alarms
o Functional test 4-1190

Binary signal transmitters

o Functional testing of o Remove pressure switches
pressure switches
(1) Test pressure switches with test pump

General measuring
instrumentation
o Functional and annunciation (1) Test and calibrate in accordance with
test manufacturer’s instructions

BHEL, Hardwar 6.3-0061-02/6

 Steam Turbine Testing of Safety Valves
Maintenance

Introduction The set values must be entered in the commissioning

protocol.
The set pressure of the safety valves of turbine integral
system (e.g. oil or other control media) are checked Bypass valves, which open in the event of excessive
during commissioning. pressure upstream of turbine components may form part
of the over pressure steam removal system and must be
The scope of instruction in the turbine manual is, apart likewise set and tested.
from certain exceptions, strictly limited to the scope of
supply of the turbine factory. Safety valves of the steam
and water systems are not normally a part of the turbine
Testing of Safety Valves
factory’s scope of supply. Thus the following instructions
may only be regarded as recommendations. Regular testing of the safety valves is the responsibility of
the turbine generator unit operator. The testing intervals
If the pressure in a system increases impermissibly from
must comply with the technical requirements and the
the operating pressure, it is the function of the safety
recommendations of the valve and turbine generator unit
valve to reduce this pressure to the normal value thus
manufacturer [2] and must be observed.
protecting the system concerned from damage.
Therefore, the turbine manufacturer must approve the
valve settings to be used [1].
Performance of Testing

Shut-down can be avoided if the testing is carried out

Setting of the Safety Valves during operation of the turbine. From the point of view of
the turbine manufacturer, however, they can only be
The set values recommended by the turbine
performed if the turbine generator unit is not endangered.
manufacturer are contained in the Technical Data [1] of
the turbine manual and must be observed. Operation of the turbine with elevated reheater pressure
may lead to impermissible temperatures or the control
Setting and testing must be carried out in accordance
and thrust characteristics of the turbine being disturbed.
with the technical requirements and the instructions of the
valve manufacturer. Furthermore, faults in the safety valves may cause
impermissible load changes or instability of the steam
When the initial setting is performed during
generator. In this case, it is best to carry out testing when
commissioning of the turbine generator unit, a
the turbine is not operating.
representative of the turbine manufacturer is to witness
the test or be informed of the set values

Also refer to the following sections:

[1] 6.1-0100 : Technical data
[2] 6.2-002... : Testing of turbine components

BHEL, Hardwar 6.3-0062-01

 Steam Turbine
Maintenance
Introduction
Signaling devices in their various forms are important
aids to operational supervision. However, they are of
value only if they are completely reliable in operation.
Therefore, the signaling devices must be tested at regular
intervals.
These instructions deal with the fundamentals of testing
and maintenance of signaling devices.
Types of signaling devices
Alarm signaling devices give a visual and audible
indication of operating values reaching predetermined
limits. This results in automatic intervention in the plant
process. E.g. triggering of the turbine trip, then this is also
signaled.
Condition signaling indicates the state of control devices,
e.g. whether a stop valve is open or closed.
Finally, signaling can provide a reminder that certain
action needs to be taken.
Basis of signaling device testing
Whenever possible, testing of the signaling devices
should be carried out under a close approximation to
operating conditions. The test should also enclose all
components of the device.
In addition to functional testing, the device settings should
also be checked at longer intervals, especially after
inspections.
Test procedures
There are various ways to test the functioning of signaling
devices.
▪ Testing during operation by varying the operating
values. This type of testing is most appropriate when
operating values can be varied by intervention in the plant
process.
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Testing of Signaling Devices
Example: A water level can be raised to its signaling limit
by closing the appropriate drain valve.
Care must be exercised with this method to ensure that
the maximum point reached is not sufficient to cause an
unintentional shut-down.
▪ Testing during operation by varying the operating
condition. When shutting down and starting up the turbine
and its auxiliaries. And when testing control and
protection equipment, all alarms and condition signals
must be carefully observed and a record made of their
response. It is also important to check that the signaling
actually reflects the operating condition accurately.
Examples: When shutting down the turbine the “low oil
pressure” alarm must come before the auxiliary oil pump
starts automatically. When testing the overspeed trips,
the “Overspeed trip operated” alarm must come.
▪ Triggering of the sensor. In this method the sensor is
operated without there being any change in operating
value or condition.
Examples: The travel-controlled limit switch which
signals response of the thrust bearing trip is operated by
hand. The pressure switch for the “condenser vacuum
low” alarm is isolated and then vented to atmosphere.
▪ The response limit value is adjusted so that signaling
response occurs. (With this method it is possible for
mistakes to be made when returning the settings to their
original values. Therefore the method should only be
used in exceptional cases.)
▪ Signaling response is produced by an electrical pulse.
If, for some reason, none of the previous methods can be
used, a partial test of the signaling device must be
performed by means of an electrical pulse.
6.3-0063-00/1
Examples: If the level in the oil tank does not normally
fall to its minimum value during operation, the level
monitor is disconnected and the alarm initiated by the
application of an electrical pulse. This method of testing
presupposes that the level sensor itself is not suffering
any malfunction.
Other tests
The lamps of visual signaling devices have only a limited
life. Therefore, they must be tested regularly by means of
the lamp test facility to ensure that they are operative and
be replaced if they are blown. When
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Replacing colored lamps in operating condition displays,
ensure that the correct color lamp is used.
Malfunctions
Any malfunctioning of signaling devices must be rectified
immediately upon discovery.
If necessary, the monitored operating values or sensor
settings must be subjected to critical examination. This is
particularly true when there is a continuous alarm
although there is no dangerous operating condition in the
plant.
6.3-0063-00/2
 Steam Turbine Testing of
Maintenance Turbine Stress Controller (TSC)

Introduction All steam and component temperatures as well as the

This test instruction describes the plausibility checks to
be carried out on the measured values acquired by the
temperature sensors for turbine stress monitoring, as well
as the recording of measured and calculated values for
long-term evaluation of temperature acquisition and of
calculation circuitry.
Using the stress monitoring function of the turbine stress
controller (TSC), the non-steady-state thermal stresses to
which the steam turbine is exposed during startup and
shut-down and as a result of changes in heat input to
components during power operation are acquired and
compared with the permitted limits.
The margins obtained from this comparison define the
stress and set the limits for permitted temperature load.
Evaluation of measured temperatures recording and
action of the calculated margins on the setpoint control
for the turbine controller allow an optimum operating
mode as regards both degree of component fatigue and
economical operation.
Test recommendations
A pre-requisite for the proper functioning of turbine stress
monitoring as described in the introduction is fault-free
operation of the measured value acquisition and
evaluation functions.
calculated margins are either recorded on dotted-line
printers or stored by the computer.
The plausibility of the measured data can be checked at a
later date using the printed or stored measured and
calculated values. It is however possible that, by that
time, faulty turbine stress monitoring will result in
selection of either too fast an operating mode, which will
have an adverse effect in terms of the degree of
component fatigue, or of too slow an operating mode,
which will have an adverse effect in terms of economical
operation.
For this reason, plausibility checks should be carried out
on the measured values at the intervals specified in
Table-1, in order to detect and correct any functional
defects or faulty circuits within the temperature
acquisition equipment.
As part of the long-term monitoring of operating
parameters, all measured and calculated TS values
should be registered during steady-state operation under
the same boundary conditions. These values should then
be recorded and archived to allow comparison at a later
date.
Measurement should be performed at the intervals
specified in Table-1.

Table-1: Test Intervals

Type of check or measurement
Plausibility checks on
measured values
Recording of measured and
calculated values for long-term
monitoring purposes
Boundary conditions Test interval
Non-steady-state and After inspections and overhauls or
steady-state operation after work on the TS sensor
Steady-state operation 3 months or after work on the TS
sensor or TS monitoring
equipment

BHEL, Hardwar 6.3-0064-01/1

Plausibility checks on measured values ame
When performing plausibility checks on the measured TS
values, the steam and component temperatures must be
compared with each other, taking certain criteria into
consideration. During non-steady-state operation, it is
also important to evaluate the trend of the measured
values over time.
If the actual values do not conform to expected values,
this may be due to incorrect assignment of measuring
points or to a polarity fault, e.g. at the transducers.
As regards the criteria to be considered, a distinction
must be made between plausibility checks performed
during non-steady-state and steady-state steam turbine
operation.
Criteria for plausibility checks during non-steady-
state operation
The temperature at the heated surface of a component
must respond faster than that at the mid-wall of the
component.
▪ The temperature at the heated surface of a component
is higher during warm-up and lower during cooling-down,
as compared to the temperature at the mid-wall of the
component.
▪ During linear changes, the temperature difference Δθ (in
K) arising in the component is directly proportional to the
rate of change dθ/dt (in K/min)
▪ During a cold start or startup after an extended shut-
down, the HP turbine warms up rapidly, even while still
operating below rated speed. In the case of the IP turbine
however, warm-up of the shaft takes place to a certain
extent as a sudden step change and occurs only just
before rated speed is reached, and then to a greater
extent during subsequent loading.
Criteria for plausibility checks during steady-state
operation
▪ The absolute temperatures and temperature margins
must exist for the same steady-state operating conditions.
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▪ The steam temperatures upstream of the turbine must
be higher than the component temperatures.
▪ The differences that exist between the main steam
temperature and the temperature at the heated surface in
the main steam valve bodies or the steam admission area
are only very slight
(< 5 K).
▪ During steady-state operation, temperature differences
of approximately 15 K maximum develop between the
measuring points on the heated surfaces and at the mid-
wall of valve bodies or the steam admission area.
▪ The closer the turbine operating mode comes to the
conditions for purely constant-pressure operation, the
stronger will be the Influence of turbine output on the
differences between main steam temperatures and the
temperatures at the heated surfaces of the turbine casing
and the shaft.
▪ The temperatures at the heated surfaces of the casing
and the shaft cannot be higher than those at the heated
surface of the valve body or the steam admission area.
▪ For the shafts, the differences between the
temperatures at the heated surfaces and the mean
integral shaft temperatures are always approximately 0.
▪ For the barrel-type casing of the HP turbine, differences
of upto approximately 10 K between temperatures at the
heated surfaces and those at the mid-wall are normal
during steady state operation.
▪ For the IP turbine, the surface temperature of the IP
turbine shaft is not measured directly but only at the
heated surface of the inner casing. Depending on the
design-related location of the measuring point,
differences of 10 to 40 K between the reheat steam
temperature and the surface temperatures of the shaft
can occur during steady-state operation.
6.3-0064-01/2
Long-term monitoring through recording of all
measured and calculated values
By registering and recording all measured and calculated
values at the intervals specified in Table-1 during steady-
state turbine operation, the thermal behavior of the
turbine and the function of the turbine stress monitoring
equipment can be monitored on a long-term basis.
Long-term monitoring can be used to detect and rectify
any gradually developing changes.
If the check on the measured values reveals that the
margins have changed due to the measured absolute
temperatures and the differences arising between them,
this can probably be traced to a fault in the calculation
circuitry. The cause of the fault must be determined, e.g.
by checking the specified limit curves in accordance with
the procedure described in the manual for the TS
monitoring equipment.
Table-2 contains all measured and calculated values
which may be required for
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The turbine stress monitoring equipment. These must be
adapted to plant-specific requirements.
Actions to be taken when actual conditions deviate
from reference conditions
If actual conditions deviate from reference conditions, the
measured value acquisition function must be carefully
checked and any faults corrected.
If the deviations in measured and calculated values are
particularly large, it must be assumed that the behavior of
the turbine plant will be adversely affected. In this case,
action of the TS monitoring equipment on the setpoint
control for the turbine controller must be temporarily
deactivated.
As long as action of the TS monitoring equipment on the
set point control for the turbine controller is deactivated,
the TS limit curves must be used for evaluation of the
thermal stresses imposed on the turbine components.
6.3-0064-01/3
 Table-2: Measured and calculated values for long-term monitoring

Measured and calculated values Terms Unit

Effective power and reactive power
ƒ effective power peff MW
ƒ reactive power preact MVA
Main steam upstream of HP turbine
ƒ mass flow mms kg/s
ƒ pressure pms bar
ƒ temperature θms ºC
Exhaust steam downstream of HP turbine
ƒ pressure pHPexh bar
ƒ temperature θHPexh ºC
HP expansion section
ƒ differential temperature θms - θexh Δθ K
Reheat steam upstream of IP turbine
ƒ pressure pRS bar
ƒ temperature θRS °C
Exhaust steam downstream of IP turbine
ƒ pressure pIPexh bar
ƒ temperature θIPexh °C

Wall temperatures, MS admission area

ƒ surface θi-adm °C
ƒ mid metal θm-adm °C
Wall temperatures, HP casing
ƒ surface θi-HPC °C
ƒ mid metal θm-HPC °C
Temperatures, HP shaft
ƒ surface θi-HPS °C
ƒ simulated, shaft center θm-HPS °C
Temperatures, IP shaft
ƒ surface θi-IPS °C
ƒ simulated, shaft center θm-IPS °C
Upper TS margins
ƒ steam admission area Δ Δ θ adm-u K
ƒ HP casing Δ Δ θHPC-u K
ƒ HP shaft Δ Δ θHPS-u K
ƒ IP shaft Δ Δ θIPS-u K
Lower TS margins
ƒ Steam admission area Δ Δ θadm-l K
ƒ HP casing Δ Δ θHPC-l K
ƒ HP shaft Δ Δ θHPS-l K
ƒ IP shaft Δ Δ θIPS-l K

BHEL, Hardwar 6.3-0064-01/4

 Steam Turbine
Maintenance
Introduction
During operation, deposits occur on the turbine blading to
a greater or lesser degree depending on the steam purity
[1] and the pressures and temperatures of the operating
steam. These deposits cause a reduction of the turbine
generator unit’s efficiency due to:
▪ Changes in the flow profiles
▪ Thicker boundary layers in the steam flow as a result of
rough surfaces.
In extreme cases the flow area of turbine may get
reduced with consequent reduction in the maximum
possible steam flow through the turbine, and
corresponding output.
Choking of blade flow path can be detected on the basis
of internal efficiency (ηi) measurements [2].
If deposit leads to an increase in stage pressures, the
maximum stage pressures shown in the Technical Data
should not be exceeded. If necessary, the output must be
reduced.
Complex, i.e. water-insoluble, silicate deposits occur in a
temperature range between 500°C and 350°C. Alkali
silicates and silicic acid are deposited between 350°C
and 60°C. Salt deposits occur at temperatures ranging
from 480°C to the blading stages where condensation
begins. Salt deposits are water-soluble and can be
removed by steam washing with saturated steam.
Depending on their composition, silicate deposits are
either water-soluble (e.g. alkali silicates) or occur as a
hard Water-insoluble coating. In latter case the deposits
can only be removed mechanically during overhauls.
General Instructions
The effort required for saturated steam washing is
considerably lesser than that required for opening the
turbine. If efficiency reduction occurs, saturated steam
washing should be performed first. In that case, the major
part of the turbine generator unit downtime is accounted
for by
BHEL, Hardwar
Steam Washing of Turbine
The cooling own time of the turbine. Special measures
should be taken to accelerate cooling [3].
For maximum success, steam washing should not be
started until the casing temperatures have dropped to <
100°C.
When Steam Washing the turbine stages, the initial
saturated steam temperatures must be as low as
possible. Steam washing with a constant steam condition
is not very effective. After a certain time the turbine
blading reaches the temperature of the washing steam
and the condensation that brings about the effect is lost.
To get maximum success in the shortest possible time, it
is necessary to increase the steam temperature in stages
by increasing the pressure. As the temperature is raised
the turbine speed will generally increase (take care to
avoid critical speed ranges). Increased speed will also
promote cleaning. The steam entering the condenser
must be condensed during the entire process i.e. one
circulating water pump must be in operation.
If possible, the turbine generator unit should be started up
and loaded after steam washing. Any dissolved salt
residue remaining on the blading will be blown out due to
the high velocity of the steam under load conditions.
Steam washing with saturated steam will only have the
desired success if the steam has adequate moisture
content upstream of the blading.
The saturated steam is introduced into the HP turbine via
the connection flanges provided between the stop and
control valves.
The steam is introduced into the IP turbine between the
control valves and the turbine. Appropriate blind flanges
are provided.
The steam line must be blown-out before saturated steam
washing commences.
It may be ensured that no external condensate can enter
the condenser during steam washing.
6.3-0070-02/1
 Fig. 1: Flow diagram for saturated steam washing
Steam Washing of IP Turbine
All stop and control valves and all valves in the extraction
lines remain closed during steam washing of the IP
turbine. Any isolating valves present upstream of the
feedwater heaters must also be closed.
The drains from the IP turbine between the reheat control
valves and the IP outlet, the extraction valves or the
swing check valves in the extraction lines must be vented
during steam washing only to the extent required to allow
the condensate arising to drain off whilst preventing
excessive loss of steam. All other drains from the turbine
generator must be full open.
BHEL, Hardwar
After the saturated steam line (Fig.1, item 2) has been
joined up at the connection points (3), the washing steam
can be routed into the IP turbine, from there via the cross-
around lines to the IP turbine and then to the condenser.
There are two possible ways of discharging the
condensate condensing in the condenser to the
atmosphere. These are:
▪ By opening the blind flanges (4) on the condenser. The
condenser must be under atmospheric pressure. With
this method of steam washing samples for finding out the
saIt content may also be taken at this point.
6.3-0070-02/2
▪ With the vacuum pump \ ejector switched on and the
blind flange (4) closed, i.e. with the condenser at sub
atmospheric pressure, via the condensate discharge line
of an operation condensate pump. In this case, make
sure that the condensate is discharged to the atmosphere
downstream of the pump. Samples for finding out the salt
content are also taken at this point.
The first method of steam washing with the condenser
under atmospheric pressure guarantees a slight
overpressure at the drains so that it is possible to perform
additional sampling at these points. For this purpose, the
appropriate drains may be cut off at the sludge traps, or
the steam inserts of the drain valves may be removed.
It is suggested to record the salt content at the sampling
point continuously throughout the washing Process. Also,
water samples should be taken every half an hour for
deposit analysis.
Steam washing may be stopped when the purity of steam
entering the turbine (as determined by sampling) is
approximately the same as that of the condensate or
steam extracted at the discharge sampling point.
The steam washing may be stopped when the salt
content in condensate remains constant at a very low
level.
Steam Washing of HP Turbine
The main control valves must be open during steam
washing of the HP turbine.
BHEL, Hardwar
All drains (7, 8) from the HP turbine situated between the
main stop valves and the HP outlet may be vented during
steam washing only to the extent required to allow the
condensate arising to drain off while preventing excessive
loss of steam.
All other drains particularly those in the cold reheat line,
must be fully open. Local drainage may also be provided
so that no steam can enter the Reheater of the Boiler, if
at all possible.
After the steam line (6) has been joined up at the
connection points (3), the stream can be routed into the
HP turbine. The steam leaving the HP turbine is
exhausted to the condenser via the drains (9).
The condensate is discharged and samples are taken to
determine the salt content as described in steam washing
of IP turbine, the completion criteria remaining same.
Restoring the Turbine to Operating Condition
On completion of steam washing, all temporary fittings
must be dismantled and the flanges closed off. Any drain
lines cut off must be rewelded. Controllers and control
valves must be returned to normal position. The
temporary lines are to be preserved for future use.
Also refer to the following sections:
[1] 6.1-0120 : Steam purity
[2] 6.3-0050 : Measurement of internal efficiency
[3] 6.2-0350 : Fast cooling down of the turbine
6.3-0070-02/3
 Steam Turbine Turbine Oil Care
Maintenance Maintenance Instructions

The following oil properties are particularly important for

Introduction: Function of the turbine oil is to
turbine oil care:
lubricate and cool the bearings of the turbine generator
and to actuate governing system components. Turbine oil ▪ Total-acid number
is subjected to high physical loads, should have a long
service life and must not have any adverse effect on the ▪ Water contents and water separability efficiency
proper functioning of the bearings and other turbine oil
consumers ▪ Solid contaminant quantities, purity

The physical and chemical properties of new turbine oil ▪ Air release properties
must comply with the requirements of the Turbine Oil
Specification [1]. The aim of turbine oil care is to maintain ▪ Foaming characteristics
the properties and the useful service life of the turbine oil
for as long as possible. Turbine oil properties and the values which can change
those properties are discussed briefly below.
This general maintenance instruction discusses the
necessity for, and the procedures involved in turbine oil Further information can be found in the standards cited in
care. the Turbine Oil Specification [1] as well as technical
literature, including those issued by turbine oil
The program for the care of turbine oil includes regular manufacturers.
inspection and analysis of turbine oil samples. In this way
changes in turbine oil properties can be determined and Actions to be taken to rectify typical changes in turbine oil
the necessary actions can be taken to remedy the properties are listed in Table-1.
situation.
Total-acid number of the turbine oil
The filters and strainers in the operating oil systems
retain solid contaminants which can cause damage The total-acid number is an easily determined reference
and/or impair functioning if they ingress into turbine oil value for turbine oil aging.
consumers.
Catalysts and thermal loading of the turbine oil can trigger
By centrifuge (i.e. oil conditioning station) which is an oxidation process in which oleic acids are formed,
independent of the oil operating systems, contaminants raising the total-acid number of the turbine oil. The oil
and aging and corrosion products which are not soluble in ages.
oil are removed from the turbine oil.
The oleic acids attack oil system component materials
Thorough cleaning of the oil system during initial startup and corrosion products are formed which can, in turn,
and after inspections and overhauls is one of the catalytically accelerate the oxidation process.
prerequisites for successful turbine oil care. In addition,
Under certain circumstances, contaminants which ingress
the ingress of contaminants into the oil system must be
into the oil system from outside can promote the oxidation
prevented.
process.
Turbine oil properties
New turbine oil contains additives which, provided that oil
As a rule, turbine oils are paraffin-based mineral oils is properly cared for, give sufficient protection against agi
which contain additives to improve their resistance to
corrosion and their oxidation stability. The Turbine Oil
Specification [1] contains standards and selection criteria
for turbine oil as well as the requirements in terms of
physical and chemical properties.

BHEL, Hardwar 6.3-0080-03/1

The additives become depleted over time. Under
unfavorable conditions, e.g. where there is improper or
negligent oil care, this depletion process can result in
premature aging of the turbine oil.
In this case, the turbine manufacturer and the turbine oil
supplier should be consulted in order that measures for
restoring the turbine oil can be implemented.
The turbine oil cannot be used if the function of sensitive
turbine generator components is impaired through
corrosion and/or aging products and if the aging process,
i.e., the change in the total-acid number, cannot be
reversed by treating the turbine oil.
From this highly simplified description of the turbine oil
aging process, it can be seen that aging is affected not
only by physical loading of the turbine oil but also by
catalysts and aging products, e.g., oleic acids. Treatment
of the turbine oil in the oil conditioning station removes
products of aging and corrosion which are not soluble in
oil, thereby slowing down the aging process.
Water content and water separability of the turbine oil
With healthy gland sealing & oil vapor extraction system
during normal operation the moisture content in turbine oil
is not expected to be more then 100 ppm as in the turbine
oil specification (1). In case the moisture content found
more then 300 ppm during sample testing, the reason is
to be investigated. With moisture content value more then
1000 ppm machine should be tripped and source of water
entry is to be eliminated.
Water which ingresses into the oil system from an oil
cooler, in the form of shaft seal steam or leakage water
results in the corrosion in ferrous materials and can
adversely affect the aging process and foaming
characteristics of the turbine oil.
Corrosion causes changes in the surfaces and shape of
the sensitive turbine generator components. The
corrosion products behave in the same as solid
contaminants, and lead to impaired component
functioning.
The cause of any increase in turbine-oil water contents
must be determined and remedied. High water contents
of the turbine oil can also be the result of low water
separability of the turbine oil. In this case, it is particularly
Important that the ingress of water in to the oil system be
prevented.
BHEL, Hardwar
Solid-contaminant quantities and purity of turbine oil
Whereas the material property value for solid-
contaminant quantity defines the overall content by
weight of solid-contaminant quantities in turbine oil
sample, when defining turbine oil purity only the
proportion of solid-contaminants of a specified size is
determined. Turbine oil purity is the more reliable
criterion.
Solid-contaminants can ingress into the turbine oil from
outside, or as a result of the aging process or corrosion.
They contribute, along with other factors, to the turbine-oil
aging process and impair the condition and function of
the turbine components.
Among the principal areas which can be affected are
turbine and generator bearings. Their load capacity can
be reduced due to scoring caused by solid-contaminants
in the turbine oil. In addition, changes of state and
impaired functioning in control and protection equipment
can be expected.
The oil system is thoroughly cleaned during initial startup
of the turbine generator set. Flushing of the entire system
is included in the cleaning process.
The filters and strainers of the operating oil systems are
used to retain contaminants with a particle size larger
than the filter mesh size, before the turbine oil reaches
the oil consumers. The dwell time of the oil in the filters
and strainers will depend on the purity of the turbine oil.
Purity in accordance with the Turbine Oil Specification [1]
is achieved through continuous filtration or separation of
turbine oil in the oil centrifuge.
During inspections and overhauls the turbine must be
drained and the main oil tank, the oil coolers and the
bearing pedestals must be thoroughly cleaned. It is
recommended that the turbine oil be either filtered or
treated in a separator during drainage an refilling.
The ingress of solid contaminants into the turbine oil must
be prevented.
6.3-0080-03/2
Air release properties of the turbine oil
The air release property represents the time taken for a
specific volume of air to be released from the turbine oil
sample under the boundary conditions stipulated in the
testing standard of the Turbine Oil Specification [1].
The turbine oil circulates inside the oil system and
becomes aerated. This air is released during the dwell
time tv = 60n-1 (in min) of the turbine oil in the main oil
tank, n corresponds to the number of passes per hour
made by the turbine oil.
If the time required for air release by the turbine oil is
longer than the dwell time in the main oil tank, an oil-and-
air mixture will develop, which will not have as favorable a
density and compressibility as non aerated turbine oil.
This can lead to faults in the operating oil pumps,
fluctuations in oil pressure and impaired functioning of
any control and protection equipment which is supplied
with turbine oil.
Only in rare cases it is possible to improve the Air release
properties of turbine oil with economically viable
treatment methods. For this reason, any factors which
might lead to deterioration of the air release properties of
the turbine oil must be avoided.
It has been proven that the air release properties of
turbine oil are adversely affected by materials containing
silicone, e.g., seal materials or foam inhibiting additives.
Foaming characteristics of the turbine oil
The material property values for foaming tendency and
foam stability of turbine oil should comply with Turbine Oil
Specification [1].
A certain amount of foaming on the surface of the oil in
the main oil tank can be expected as a result of air
release. If the turbine oil shows an increased foaming
tendency and high foam stability, the space above the oil
level in the main oil tank becomes partially or completely
filled with foam which can, under certain circumstances,
result in foam being released
BHEL, Hardwar
From the oil system. Turbine oil is entrained with the
foam, resulting in a drop in the oil level in the main oil
tank. This change in the level can cause activation of the
level monitoring equipment for the main oil tank.
Increased turbine oil foaming tendency occasionally
occurs due to high water content or increased dust
contamination of the turbine oil.
Silicone-based foam inhibiting additives have an adverse
effect on air release properties. There is no generally
binding evidence regarding any further correlation
between foaming tendency and air release properties,
although such a correlation may exist in individual cases
and should be investigated.
Turbine oil care program
Owing to correlation between the turbine oil properties
and the factors influencing turbine oil during operation,
the following care program for turbine oil must be
implemented during and after initial startup of the turbine
generator set:
▪ Regular inspection of turbine oil samples
▪ Continuous treatment of the turbine oil
▪ Protection of the turbine oil system from the effects of
contaminants
▪ Drainage of the turbine oil and cleaning of the oil system
and the turbine oil during inspections and overhauls.
Inspection of turbine oil samples
By regularly sampling and inspecting turbine oil and by
evaluating the results, it is possible to adapt oil care
measures optimally to the particular properties of the
turbine oil being used.
Turbine oil samples are taken simultaneously upstream
and downstream of the oil centrifuge and the inspection
results thus permit an evaluation of the efficiency of the
relevant oil care measures.
The scope and the intervals for turbine oil inspections are
listed in the turbine oil maintenance instruction.
6.3-0080-03/3
If the turbine oil inspections reveal that alarm levels for
certain properties have been reached or exceeded, it is
advisable to request inspection and evaluation of the
turbine oil by the turbine oil supplier. All data relevant to
turbine oil inspection should be sent in together with the
turbine oil sample
When taking turbine oil samples, care must be taken to
ensure that sampling bottles are clean.
In case of deviation in properties, actions to be taken as
per table 1.
Treatment of the turbine oil in the oil filters or
strainers of the operating oil systems
▪ Switchable oil filters
The switchable oil filters of the operating oil systems are
used to protect downstream consumers. Contaminants
which, because of their size or consistency, can cause
damage and/or impair functioning are retained in the oil
filters. Because of their relatively large mesh size, the
operating oil filters are not suitable for complete removal
of contaminants from the turbine oil. The differential
pressure across the oil filters is monitored.
If the differential pressure across an oil filter increases,
this filter should be isolated from the system and cleaned.
▪ Oil Strainers of the main oil tank
The oil strainers of the main oil tank have a relatively
large mesh size and are used to retain contaminants in
the returning turbine oil and to protect the oil pumps from
contaminant damage.
If the strainer mesh becomes clogged during the course
of operation, this can lead to a drop in the level in the
suction space of the main oil tank as a result of an
increase in the level in the riser space.
For this reason, the oil strainers of the main oil tank must
be regularly cleaned, if possible while the oil pumps are
shut down. Metal particles in the oil strainers can be an
indication of bearing damage
▪ Static separator
A static separator is used to remove water from the
turbine oil. Since the efficiency of the filter elements
deteriorates due to deposits of solid contaminants, and in
view of the expense of filter elements, it is recommended
that the static separator be used in conjunction with an
upstream fine mesh filter.
BHEL, Hardwar
Is particularly important that the ingress of water in to the
oil system be prevented.
Treatment of the turbine oil in the oil centrifuge
The oil centrifuge can be continuously operated
independent of the operating oil systems. A small volume
of turbine oil is fed through oil centrifuge with a high
separation efficiency. This achieves a high degree of
purity for the treated turbine oil.
As regards the treatment of turbine oil in the centrifuge,
oil filter, dynamic or static separators, and multipurpose
oil purification units can be used either independently or
in combination. In addition, many power plants have
centralized oil purification equipment, either permanently
installed or mobile.
The function of the most commonly used oil purification
equipment is described below:
▪ Fine-mesh filter
The turbine oil can be conditioned in an oil filter with filter
elements made of fine-pored cloth or filter paper. Since
the fine-mesh filter has high separation efficiency, a high
degree of turbine oil purity can be achieved.
Contaminants insoluble in oil which ingress into the oil
system from outside, as well as products of system-
internal aging and corrosion mechanisms are almost
completely removed from turbine oil.
Fine-mesh filters with cloth or paper elements can also
retain small amounts of water. If the turbine oil has a high
water content, a dynamic or static separator must be
used to reduce the water content in the turbine oil to the
value stipulated in the Turbine Oil Specification [1].
▪ Dynamic separator
The dynamic separator uses centrifugal force to remove
either solid or liquid contaminants as required from the
turbine oil. The dynamic separator must be set to operate
in either solid contaminant or water separation mode in
accordance with the manufacturer’s instructions.
▪ Multipurpose oil purification unit
The multipurpose oil purification unit is used to remove
solid and liquid contaminants from the turbine oil.
Operation and maintenance instructions of the oil
purification unit manufacturer must be complied with.
6.3-0080-03/4
The maintenance interval for oil filters depends on the
differential pressure across the oil filters. For this reason,
the differential pressure instrumentation must be regularly
checked and corresponding annunciations noted.
Cleaning of the oil system during inspections and
overhauls
Over the course of time, solid contaminants settle in
areas of the oil system not subjected to high flow
velocities, e.g. the main oil tank. For this reason, the
turbine oil must be drained via filters during inspections
and overhauls, and the main oil tank, the oil coolers and
the bearing pedestals must be thoroughly cleaned. The
drained turbine oil must either be refilled into the main oil
tank via fine-mesh filters or treated in a centralized oil
purification unit before refilling.
Measures to protect the oil system from contaminant
ingress
Just as important as turbine oil care are measures
designed to protect the oil system from contaminant
ingress:
▪ Turbine oil
Problems can arise as a result of the incompatibility of
turbine oils from different manufacturers and containing
different additive packages. For this reason, when
topping up, turbine oil which has the same product
designation and which is supplied by the same
manufacturer as was originally filled, should be used.
▪ Hydraulic oil
Hydraulic oil or control fluid containing phosphoric esters,
if in use, must not be allowed to ingress into the oil
system.
▪ Main oil tank
Openings in the main oil tank must always be closed and
sealed in such a way that there can be no ingress of
contaminants into the main oil tank. The cover plates of
the main oil tank must be tightly bolted. There must be no
bolts missing from the plates.
▪ Oil coolers
If the water content of the turbine oil increases, the leak
tightness of the operating oil cooler must be checked.
▪ Oil return lines
BHEL, Hardwar
Inspection holes in oil return lines must be sealed to
prevent the ingress of contaminants into the oil system.
▪ Oil vapor extraction system
The throttle check valves in the oil vapor extraction
system must be set so that the pressure in the bearing
pedestals and the main oil tank is slightly sub
atmospheric. This ensures that no leakage steam, or
airborne water and/or dust is drawn into the oil system in
the event of turbine oil or oil vapor being released to the
atmosphere.
▪ Dirty fluid
Fluid from the dirty-fluid tank must not be refilled into the
main oil tank without thorough inspection and treatment.
Small amounts of turbine oil which accumulate in the
dirty-fluid tank are to be disposed properly.
▪ Material
The compatibility of materials with the turbine oil has
been taken into account by the turbine manufacturer
during materials selection. During inspections and
overhauls, care must be taken to ensure that no
incompatible materials are used. This applies particularly
to gaskets and silicone-based seal materials.
▪ Leakage steam system
The butterfly valves of the leakage steam system must be
set to prevent leakage steam from escaping via the
turbine shaft seals since this could result in water ingress
into the oil system.
▪ Disposal of Turbine Oil
For disposal Turbine oil may be send back to oil
company (OEM) for its recycle.
Also refer to the following sections:
[1] 2-0400: Oil Specification
6.3-0080-03/5
 Table1: Actions to be taken when actual conditions deviate from reference conditions
Fault
ƒ Boundary conditions
The Turbine oil properties
do not comply with the
Turbine Oil Specification
ƒ Total-acid number
> mg KOH/g
BHEL, Hardwar
Cause Actions
Turbine oil aging Inspect turbine oil samples for:
- Solid contaminant content
- Purity
- Water content
- Air release properties
- Foaming
- Other physical and chemical
properties
Send further oil samples to
turbine oil supplier for inspection
and evaluation. Check operating
performance and condition of
components supplied with
turbine oil, in order to determine
the effect of the change in total-
acid number. Check oil
purification system and intensify
turbine oil maintenance in
accordance with the
recommendations of the turbine
oil supplier and the turbine
manufacturer:
- Keep oil centrifuge in
continuous operation
- Adjust operation of oil
centrifuge to contaminant
content of turbine oil (solid
contaminants or water)
- If necessary install additional
oil purification equipment
- Take turbine oil samples
upstream and downstream
of oil centrifuge and check
separation efficiency (solid
contaminants and/or water)
6.3-0080-03/6
 Fault Cause Actions
ƒ Boundary conditions
- Reduce intervals for turbine
oil inspections and monitor
evaluation of total-acid
number
Investigate the origin of
contaminants and prevent
contaminant ingress into oil
system.

ƒ The solid contaminant
content or the purity of the
turbine oil does not comply
with the Specification
The oil centrifuge is not in
operation
The contaminant separation
efficiency of the oil centrifuge
does not comply with the
requirements
Put oil centrifuge into operation.
Take turbine oil samples
upstream and downstream of
the oil centrifuge and determine
the separation efficiency.
Implement measures in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements; replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.

Solid contaminants ingress Check whether and at what

into the oil system
point it is possible for air borne
contaminants to ingress into the
oil system.
Check atmospheric pressure in
the main oil tank, the bearing
pedestals and the oil return lines
and, if necessary, correct using
the check valves in the oil vapor
extraction lines.
If necessary, close or reseal the
maintenance covers of the main
oil tank.

High air borne dust content in Reduce airborne dust content in

area around turbine generator area around turbine generator
set set

BHEL, Hardwar 6.3-0080-03/7

 Fault
ƒ Boundary conditions
ƒ The water content of the
turbine oil does not comply
with the specification
BHEL, Hardwar
Cause
There is no permanently
installed dynamic or static
separator for removing water
from the turbine oil
The permanently installed
dynamic separator of the oil
conditioning system is not in
operation
Water is ingressing into the oil
system
Actions
Install a dynamic or static
separator for removing water
form the turbine oil. Take turbine
oil samples upstream and
downstream of the separator
and check water separation
efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
Put dynamic separator of the
centrifuge into the operation.
Note that the required
separation temperature must be
complied with in accordance
with the operating instructions of
the separator manufacturer, and
that the separator must be
protected from the effects of
solid contaminants.
Take turbine oil samples
upstream and downstream of
the separator and check water
separation efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
Check whether leakage steam is
ingressing into the oil system.
If necessary, prevent the escape
of leakage steam from the
steam seals by the correcting
the seal steam pressure or by
adjusting the butterfly valves in
the seal steam lines.
Check the leak tightness of the
operating oil cooler.
6.3-0080-03/8
 Fault Cause Actions
ƒ Boundary conditions
ƒ The air release properties In many cases, there is no Check whether the deterioration
of the oil do not comply specific cause for a in air release properties has an
with the Specification deterioration in air release adverse affect on the operating
properties performance of the systems of
components supplied with
turbine oil.
Involve oil supplier and turbine
manufacturer in inspection
program. If effects are
particularly unfavorable,
consider replacing the turbine
oil.
As a precautionary measure,
care should always be taken to
prevent the ingress into the
turbine oil of materials which
could adversely affect the air
release properties (e.g. silicone-
based materials)
ƒ Turbine oil foaming The foam inhibiting additives in Consult oil supplier and top up
characteristics do not the turbine oil have been turbine oil with foam inhibiting
comply with the depleted over time additives.
Specification
As a rule, foam inhibiting
additives have an adverse effect
on the air release properties and
for this reason, the air release
properties must be closely
monitored when topping up with
such additives.

The turbine oil contains Determine the water content of

materials which adversely the turbine oil and, if necessary,
affect the foaming take appropriate measures to
characteristics reduce this. In certain
circumstances it may be
advisable to skim off the foam
from the surface of the turbine
oil.

BHEL, Hardwar 6.3-0080-03/9

 Fault Cause Actions
ƒ Boundary conditions
The oil centrifuge is
defective or the operating
conditions for the oil do not
comply with the
requirements
ƒ Oil filters
The differential pressure Isolate duplex oil filter and clean
across one oil filter is high filter cartridge
Take oil centrifuge filters out of
operation and replace filter
elements

One oil filter is not sufficiently Open valve in oil filter venting
vented line and adjust

ƒ Unit-specific or additional
dynamic separator
The mode of operation of the
dynamic separator does not
correspond to the content of
solid or liquid contaminants in
the turbine oil
Adapt the mode of operation of
the separator (solid-contaminant
separation or water separation)
according to the content of solid
contaminants or water in the
turbine oil

ƒ Unit-specific or additional The efficiency of the static Replace filter elements.

static separator
separator is reduced due to
Implement measures to prevent
clogged filter elements
filter element clogging. E.g.
install an upstream fine-mesh
filter.

Turbine oil temperature If necessary, put heating system

ƒ Oil circulating pump (if
installed)
upstream of static separator
too low
The oil circulating pump of the
oil centrifuge is not in
operation
of oil centrifuge into operation
If necessary, put oil circulating
pump into operation

BHEL, Hardwar 6.3-0080-03/10

 Steam Turbine Grease and Oil Lubrication
Maintenance

Introduction Of lubricant deviating from the manufacturer’s

To ensure satisfactory functioning and to limit wear, a
small number of components on the turbine must be
lubricated at regular intervals.
Scope
The following are the individual components, which
require regular lubrication.
▪ Control device in accordance with the lubrication Chart
[1]
▪ Actuators for remote-controlled governing, control and
similar devices
specification in the maintenance instructions, it must be
clarified beforehand whether this will be universally
suitable.
Application of Lubricants
Before re-lubricating components which are exposed to
the collection of dirt {e.g. shut-off valve stems) they must
first be carefully cleaned.
Over-greasing or overfilling must be avoided.
Grease guns, which cause no damage to greasing
nipples, etc., should only be used.

▪ Spindles of hand-operated shut-off devices Lubrication Intervals

▪ Pumps and similar machines
▪ Drive motors
Lubricants
Only the lubricants stated by the respective
manufacturers in the maintenance instructions may be
used.
If for reasons of stocking or for simplifying regular
maintenance, it is desired to use only one particular type
The lubrication intervals are stated by the manufacturers
in the maintenance instructions. It is essential for them to
be maintained, especially in the case of motors, pumps
and similar equipment.
It is advisable to prepare lists of items requiring
lubrication, noting when the various items are to be re-
lubricated. This will ensure that lubrication is carried out
at the regular, prescribed intervals.

Also refer to the following sections:

[1] 6.1- 0690: Lubrication Chart

BHEL, Hardwar 6.3-0081-00

 Steam Turbine
Maintenance
Introduction
The use of fire resistant control fluid for turbine control
and protection systems reduces the risk of fire. This is
due to the higher ignition temperature (compared to
mineral oil) in case of leaks.
Phosphoric esters with a low water and chlorine content
(HS-D series) are used and must be carefully maintained
to preserve their properties.
This instruction contains the following:
▪ Guidelines for handling control fluid and for treatment of
control fluid systems.
▪ Data on the compatibility of the control fluid with other
materials.
▪ Procedures to preserve the control fluid properties.
▪ Data on sampling points in the cycle.
▪ Sampling and analysis programs.
▪ Maintenance procedures to be followed if the property
characteristics of the fluid reach the permissible limits.
Guidelines for Handling Control fluid and for the
Treatment of Control Fluid System
Initial filling of system
The control fluid system must be cleaned after assembly.
The same control fluid may be used as service filling as
well as for flushing the system. However, when the
control fluid has been regenerated by the manufacturer,
especially after filtering through 5 μm fine mesh filters,
the property characteristics of the control fluid must
comply with the requirements of the specification [1].
All moisture must be carefully eliminated from the system
(e.g. by drying and/or evacuation) otherwise the control
fluid forms acid components when in contact with water.
The control fluid tank must be thoroughly cleaned before
it is filled with control fluid for flushing or service. Check
for dust and dirt by first wiping with white filter paper. All
traces of detergent must be removed.
BHEL, Hardwar
Care of Control Fluid
Although the control fluid manufacturer must ensure that
there are no solid or liquid impurities in the control fluid
supplied for the initial filling, the tank must be filled
through the Fuller’s earth and fine-mesh filter equipment.
Baseline reference samples for later comparison must be
taken before filling with control fluid for flushing the
system and after regeneration of the fluid used for
flushing.
Refilling with Control Fluid
The system must be refilled from lead-sealed barrels;
precautions must be taken to prevent filling with a control
fluid that is not identical to the one specified for use or
with mineral oil from similar casks.
Changing Control Fluid
The entire system must be drained when changing the
fluid. New filter elements must be installed or those
present thoroughly cleaned.
If unavoidable, old control fluid residue (up to 3%) may be
tolerated.
The system must be refilled and samples taken for
comparison with the initial filling. The amount of
residue of control fluid within the system and the
neutralisation number must be checked by analysing
and comparing the samples taken before filling and
after the system has been put into operation. If this
shows an increase in the neutralisation number, it
must be reduced by passing the control fluid through
the bypass regenerating system.
Treatment of waste control fluid
Biological decomposition of control fluid is difficult; control
fluid is heavier than water and affects it adversely and
therefore must
6.3-0082-02/1
Not be passed into the sewage system. The competent
Regional Water Authority is responsible for determining
the maximum concentration limit in ppm for sewage
water.
All containers for storing new or used control fluid must
be clearly and permanently marked. A record of the
quantity of used control fluid and of fluid lost due to
maintenance, leakage and damage must be kept.
For disposal, control fluid may be send back to oil
company (OEM) for its recycle.
When control fluid is burned, carbon dioxide (CO2) and
phosphorus pentaoxide (P4O10) are produced, the latter in
such small quantities, making it harmless.
Disposal must be done by companies authorised and
licensed by legislation for the collection, storage and
disposal of waste materials.
Control fluid leaks must be absorbed by using sawdust or
oil binding granules and removed immediately.
Control fluid has the same effect on concrete as mineral
oil. Floors or foundations made of asphalt are not
compatible with control fluid.
Preservative Agents in Control Fluid System
Spare parts are maintained in serviceable condition by
using anti-corrosion agents and/or suitable packing
(enclosing in plastic foil and use of desiccants); storage in
dry area is recommended.
When removing anti-corrosion agents, or cleaning spare
parts, take care to ensure the parts are dry and, above
all, that all traces of solvents containing chlorine have
been removed. Then apply an intermediate protective
coating immediately to protect the freshly cleaned surface
against corrosive attacks by the control fluid used.
Note: Chlorine presence in the control fluid causes
erosion-corrosion at the control edges of the control
components.
BHEL, Hardwar
Only the following may be used for cleaning: No felting
textile and paper clothes, benzene, white spirit and
hydrochloric acid based cleaning agents approved for
general use.
Caution: Observe all safety regulations when using
cleaning agents to clean the tank’s interior.
Precautions to Ensure Compatibility of the Control
Fluid with other Materials
All components of the control fluid system are selected by
the turbine manufacturer in regards to their material to
ensure they are compatible with control fluid and that no
interactions are to be anticipated between the control fluid
and materials used.
To avoid confusion, all spare parts and materials used in
the control fluid system must be stored separate from
other materials and clearly marked.
Caution: Not all components that are compatible with
control fluid are also compatible with oil.
Where possible, components and materials for use in the
control fluid system should be obtained from the turbine
manufacturer. This will make sure compatibility with
control fluid by prescribing specifications to be used by
subcontractors and by using suitable materials. If parts
must be obtained from other sources, the chapter
referring to the compatibility of the control fluid must be
observed.
Whenever an order is placed with the-turbine
manufacturer or with third parties for parts or materials, it
must be expressly stated that these will be used for the
control fluid system.
Health care measures
No special safeguards are required to protect against
toxic properties of the control fluid. Follow manufacturer’s
instructions and/or other legal provisions. Here are some
recommendations:
▪ All containers for control fluid must be kept tightly
sealed and permanently marked with the Health Hazard
danger sign.
6.3-0082-02/2
▪ Do not eat, smoke or drink when working with control
fluid or parts in contact with control fluid.
▪ Keep control fluid away from foodstuffs.
▪ Keep control fluid away from skin, eyes and clothes.
▪ If control fluid gets into eyes, sponge carefully and rinse
with water. Obtain medical attention if irritation persists.
Materials for pumps and electric motors
Bearing and shaft seals and the nonmetallic parts of
couplings on pumps and their drive motors most are
compatible with control fluid.
Since aerosols of the fluid may reach the motors windings
through the motor ventilation system, the windings must
be designed to be compatible with control fluid.

▪ After handing control fluid, wash hands immediately. Materials for tools

▪ Wear protective clothes, gloves and goggles.
▪ Change any article of clothing that comes into contact
with control fluid. If skin contact occurs, flush areas with
water. Obtain medical attention if irritation persists.
▪ If control fluid is swallowed, give large amounts of warm
salty water to cause vomiting; if unsuccessful tickle inside
the patients throat with a finger. Obtain medical attention
if stomach discomfort persists.
▪ Avoid inhaling spray clouds (aerosols) or decomposition
products (e.g. use clothes to protect respiratory tract).
Nonmetallic parts of tools (handles) must be made of
material compatible with control fluid or covered with
suitable surface protection (See plastics). Remember this
when ordering new tools.
Plastics
Plastic materials are susceptible to swelling, shrinking
and surface deterioration.
Plastic incompatible with control fluid may impair the
control fluid properties. Following plastics are compatible
with control fluid:

▪ Wear gas mask if thick clouds of control fluid are Fluorocarbon elastomers FKM Viton
present.
Butyl rubber IIR Butyl IIR-40
Compatibility with other materials
Polytetrafluorethylene PTFE Teflon
Control fluid’s foaming, air release capability and its
resistance to aging are impaired by contact with materials Polyethylene PE Hostalene
incompatible with control fluid. Also materials, which are
Polyamide PA Nylon
incompatible with control fluid, can be attacked.
Following Plastics are incompatible with control fluid:
Metallic materials PVC plastic, Polycarbonate-Makrolon, normal plexiglass.
Phosphoric esters have a negligible effect on steel,
Only glass or Plexidur T may be used for sight glasses.
copper alloys, zinc, tin and aluminum alloys provided the
Protective caps on switches, plungers and valves must
neutralization number is within the admissible limits. The be of metal or plastic material compatible with control
solid outer oxide layer of aluminum alloys must not be fluid.
destroyed due to friction.
Sealing material, hose, cable insulation
Pure copper cannot be used due to its catalytic effect on and accumulator bladders
the decomposition of the phosphoric ester. Sealing
material made of Following sealing materials are compatible with
phosphoric esters:
Copper does not apply since the surface area exposed to
control fluid is small. ▪ For o-rings, packing rings, collars and diaphragms:
viton, Teflon, butyl rubber and composite material such
Only austenitic steel may be used for filter meshes; brass as cotton-viton, Teflon-white asbestos, viton asbestos.
is unsuitable.

BHEL, Hardwar 6.3-0082-02/3

▪ For flat gaskets: viton, Teflon, butyl rubber and
compressed asbestos.
▪ For hoses and cable insulation: viton, Teflon and nylon
coatings.
▪ For accumulator bladders: butyl IIR-40 (up to 80 ºC),
viton
▪ Liquid sealing materials: Hylomar SQ32L, Loctite 270,
Ciba-Geigy CY246.
Caution: Butyl rubber IIR is not compatible with oil.
Silicon rubber must not be used since it severely impairs
the properties of the control fluid (reduces its air release
capability).
Paints
Only two-component, desmodur / desmophene (DD)
base and epoxy resin base lacquers may be used. When
painting the inner surface of containers, make sure the
coating is applied properly. If the paint flakes off, it may
cause considerable damage.
Caution: Paints compatible with control fluid (epoxy resin
and desmodur /desmophene base) give off toxic vapor
when exposed to heat. (e.g. during welding or grinding).
Repair procedures must specify the presence of such
paints. Signs on parts, containers with these paints must
not be removed.
Control Fluid properties
Requirements
Requirements for control fluid are listed in
specifications for control fluid (1).
Special care must be taken during commissioning and
operation to preserve control fluid properties.
Keeping a daily service log is recommended; all values
from analysis and details of important events (filter
changes and exchange of filter mass, refilling) must be
entered. All changes and their cause should be readily
detectable on the basis of these records.
BHEL, Hardwar
Preservation of Properties
- Stability
Acid and aging products may cause a loss of stability; the
speed of aging increase in the manner of a chain
reaction, drastically reducing the service life of the control
fluid (resulting from chemical reactions of the control fluid
with water, air and other impurities).
+ Removal of acids and aging products
The presence of acids and aging products raises the
neutralization number; the permissible limit is 0.5 mg
KOH/g.
Acid and aging product must be eliminated from the
control fluid by continuous bypass filtration through a
Fuller’s earth filter.
Regeneration through a Fuller’s earth filter is based on an
ion exchange reaction.
The Fuller’s earth used must be dry (1 % by weight
expellable water at 105 ºC). We recommended drying the
Fuller’s earth before filling. The design of the Fuller’s
earth and filter regenerating equipment conforms to the
control fluid manufacturer’s requirements.
Design and functioning of the filters are explained in the
Description Section. The flow diagram of the regenerating
plant is also given in the relevant chapter.
The grain size of the fuller’s earth should be US screen
number 16/30 to 30/60 meshes. The dust portion must
not be used.
the
When filling the filter, ram down and/or shake the earth
into the filter elements to prevent formation of gaps or
channels that would reduce the efficiency of the Fuller’s
earth.
Unnoticed exhaustion of the Fuller’s earth is prevented by
changing the earth filling at six- month periods, unless
this interval does not have to be reduced for other
reasons.
Since the control edges of electro hydraulic servo valves
are subjected to erosion-corrosion if the control fluid is
not suitably treated, regular regeneration of the Fuller’s
earth is always necessary, even if there is no increase in
neutralization number.
6.3-0082-02/4
Regeneration should be started about 48 hours before
commissioning of the servo valves.
The control element of control circuits actuated by servo
valves must be filled with new control fluid through the
regeneration equipment even when the fluid supplied by
the manufacturer has the specified neutralisation number.
This applied both for initial and refills.
A fine-mesh mechanical filter (polishing filter)
downstream of the Fuller’s earth filter traps Fuller’s earth
particles and other foreign matter that would act as a
catalyst in the control fluid. The fine-mesh filter has the
added function of establishing the required purity of the
control fluid in the overall system.
The fine-mesh filter must be cleaned in the same way as
other fitters in the system. When changing the filter
elements, do not remove the protective covers from the
new elements until just before they are installed.
Strainers must be cleaned using the cleaning agents
recommended by the filter and control fluid manufacturer;
make sure that dirt does not get onto the clean side.
Immerse filters in the cleansing fluid only up to their upper
edge. Filters must always be blown-out from the clean
side towards the dirty side. Use only dry air for blowing-
out (relative humidity 60% at 20 ºC).
Confirm absence of oil and dust by using filter paper test.
Use a magnifying glass to check the completeness of the
cleansing process.
+ Prevention of thermal influences
The control system requires a service medium viscosity
that complies with the specification at a control fluid
service temperature of 55±5 ºC.
No adverse effects on the stability of the control fluid due
to thermal influences are to be expected at this service
temperature.
A maximum temperature of 90°C is admissible locally, for
example, at heating element / protective pipes with heat
conducting oil fillings. Compliance with this limit
temperature is monitored the heating
Number if and after the accumulation of the water is
detected.
BHEL, Hardwar
Element being cut out as soon as the limit is reached.
Temperatures above 75°C are admissible for a short
period only during flushing procedures.
Note: If the temperature rises from 60°C to 70°C, the
speed of oxidation doubles.
+ Prevention of influence due to foreign matter
Measures must be taken to stop the entry of solid or
liquid foreign matter or other impurities with a view to
maintaining the stability of the system. All possible
measures must be taken to protect the system from rust.
The system is vented and deaerated via a defined
opening to stop degeneration of the control fluid due to
moisture and contamination. The opening is sealed by
absorbers or filters to prevent the entry of moisture and
contamination when venting and to ensure adequate
deaeration.
Silica gel absorbers are used to indicate the buildup of
absorbed moisture by changing colour. Evaporating
moisture is necessary in the absorbers during deaeration.
Refill Silica gel if a permanent change in colour is noticed.
A large absorber or filter is used when the system is
vented or deaerated via exhaust fans to ensure that the
control fluid is separated from the air downstream of the
fan.
When deaerating using fans, the system must not be
under a substantial vacuum.
If deaerating valves are used that open when a slight
internal over pressure has built up, make sure the moist
air is unable to enter into the system.
Accumulated water is annunciated by using electrodes.
The cause of water accumulation must be located
immediately and corrected. Water accumulating on the
surface of the control fluid tank due to its low density,
must be removed by siphoning or pumped off.
Condensate occurring in small amounts evaporates at
service temperature. Increase monitoring the
neutralisation
6.3-0082-02/5
 About 3-4 % mineral oil will dissolve in, control fluid
- Fire resistance between room temperature and 50°C. If oil enters the
control fluid circuit, the control fluid manufacturer must
Following are the causes of impairing the fire resistance examine the effect this has on the fluid’s fire resistance
properties of the control fluid: properties. It is impossible to separate oil from the control
fluid since the mixture is a genuine solution. Only when
▪ Mixing of mineral oil by mistake; this can be prevented if the oil content exceeds 3-4% does a two-phase liquid
filling guidelines are followed. result.
▪ Penetration of mineral oil from the lubricating oil circuit. - Air release capability
Design measures have been taken to prevent oil and The air release capability of the fluid depends on the
control fluid from intermixing. presence of foreign matter. The chapters on the subject
of stability and prevention of the influences of foreign
Contact points between the lubrication oil control systems matter must be observed to ensure the air release
are separated by interface made of metal bellows
capability complies with the requirements.
between which there is a drain line to the leakage tanks;
the tank has a device to annunciate the accumulation of - Purity
control fluid due to leaks.
SAE guidelines (Table-1) govern the purity requirements
The bellows are arranged if one ruptures, the second for media used in hydraulic systems.
takes over its shielding function. Penetration of one
media into the other is only possible if both dividing
elements have leak.

Magnitude Particles / 100 ml

0 1 2 3 4 5 6
5 – 10 μm 2700 4600 9700 24000 32000 87000 128000
10 – 25 μm 670 1340 2680 5360 10700 21400 42000
25 – 50 μm 93 210 380 780 2510 3130 6500
50 – 100 μm 16 28 56 110 225 430 1000
> 100 μm 1 3 5 11 21 41 92
Table-1: SAE permissible degrees of contamination for hydraulic systems

SAE Class classification applicable for maintaining the They must then be sent to a laboratory (turbine
service reliability for protection and control systems are manufacturer, control fluid supplier or operator) for
as follows: examination.

Class-6: Protection and Control systems without servo It is possible to filter the samples at the site by using the
valves field monitoring method so only the diaphragm filter has
to be sent for analysis to a laboratory outside the power
Class-3: Protection and Control systems with servo plant.
valves
Performing routine analysis of the same fluid filling
Sampling and analysis involves relating the degree of colour change of the test
filter (relative measuring method) to the quantitative
Samples must be taken and examined to be able to degree of contamination as determined by counting the
ensure the control fluid meets the purity requirements. contamination particles.

Samples must be taken at sampling points from the
flowing liquid into clean laboratory bottles. Take care to
avoid any secondary contamination. The sampling bottles
must be permanently marked with these data: facility,
sampling point, fluid manufacturer and type, date,
sampler.
The precondition for application of the field monitoring
method using diaphragm filters or of the relative
measuring method is the availability of reliable sampling
and analysis equipment at the plant site.

BHEL, Hardwar 6.3-0082-02/6

Sampling and analysis program me
The sampling and analysis program according to Table-2
makes it possible to perform the essential assessment of
the control fluid properties and purity at all stages of
commissioning and during continuous service.
Besides, it allows assessing the flushing procedures and
the condition, efficiency and regeneration of the filter
equipment.
When required, it is possible to compare the results of the
routine analysis with the analysis of the baseline
reference samples taken before filling and completion of
commissioning.
The samples taken before filling the control fluid system
must be representative of each consignment delivered;
the samples must be taken from a collecting container
where a certain amount of control fluid mixture from each
individual container has been retained. The first control
fluid container opened is to be used as the collecting
container to prevent contamination due to use of a vessel
that was not a part of the control fluid consignment.
Table-2 gives the sampling program for SAE purity grade
class-6, which is applicable for this turbine.
Sampling points are marked as follows:
Sampling point - Supply (PNV)
The PNV is provided within the supply unit. Analysis of
the samples from this point makes it possible to ensure
the degree of purity of the fluid downstream of the fine
mesh filter, before it enters control system sections
susceptible to contamination, and at the same time to
check the function of the fine-mesh filters.
BHEL, Hardwar
Sampling point - Return (PNR)
The PNR is provided in the return line. Analysis of the
samples from this point makes it possible to determine
the degree of purity of the fluid in the overall system
without the direct influence of the service filters.
Sampling point - Fluid Tank (PNB)
The PNB is provided at the tank.
Sampling points downstream of the circulation pump
(PNU), downstream of Fuller’s earth filter (PNFB) and
downstream of the fine-mesh mechanical filter (PNMF)
are provided.
Samples from the sampling points (PNU, PNBF and
PNMF are used to determine the efficiency of the
regeneration and filtration processes.
The sampling program applies both to the initial filling and
to all fillings thereafter.
Maintenance measures to be carried out to ensure
Fluid property characteristics
Table-3 contains maintenance measures to be taken if
analysis values obtained for the samples approach the
limits prescribed in the specification [1].
Examination of system components
During inspections and major overhauls, carefully
examine the system components for formation of
deposits or scale and for erosion-corrosion at the control
edges of sensitivity control equipment. If any deposits are
found, they must be analysed in consultation with the
control fluid manufacturer. Then checks must be carried
out to find out if rust or other forms of corrosion have
developed within the system.
6.3-0082-02/7
 Time of Sampling Degree of purity NZ ASC Water Density Kinem. Anti-
3
Discol Particle KOH min content g/cm Visco corro.
mg/g % by
2 Props.
oration count V mm /s
test vol. (2)
Before filling FRF
Lab sample x x x
x x x
Control sample
Two weeks after filling
FRF, if flushing not yet x x x
started
Before commencing PNB
flushing for record of
as-delivered condition
Continuous sampling PNR
during flushing
Towards end of refilling x x x x
via superfine filter
Continuous monitoring PNB(3)
during superfine PNU
filtering
PNBF
PNMF
Before commencing
hot operation (Last x x x
sample taken more
than 2 weeks earlier)
24h after
commencing hot x x x x x
operation
One month after
commencing of x x x
operation: weekly
One month after
x x x x x
commencing hot
operation : monthly(1)
Before handing over PNR x x x x x
with final log
Table-2: Sampling program for SAE purity grade class 6

Entire program applies for refills also.

(1) Continuous monitoring programme after handing over

(2) Anti-corrosion properties to DIN 51585, ASTM D 665-60

(3) Test intervals according to filter capacity

PNB = Tank PNU = downstream of recalculating pump

PNV = supply line PNBF = downstream of fuller’s earth filter

PNR = return line PNMF = downstream of mechanical filter

BHEL, Hardwar 6.3-0082-02/8

 Parameter and Inspection Permissible Inspection Measures to be taken if
dimensions method limit interval limits exceeded
Water content No free water weekly Evaporate, suction-extract,
% by vol. visible to ladle-off, centrifuge using
naked eye special device
Neutralisation DIN 51 558-1 0.5 Monthly, Check regeneration plant,
number ASTM D974 weekly if Replace fuller’s earth, Check
NZ (mg KOH/g) negative effects by frequent
trend measurement of NZ
Kinematic DIN 51562-1 26-50 monthly Replace filling
viscosity at ASTM D445
2
40°C (mm /s)
Solid impurities Particle count SAE purity monthly Check filters for proper
and grade class 6 functioning. If necessary,
discolouration replace filter elements.
test Examine deposits on filter
elements
Air separation DIN 51381 Proper every 4th Check fluid for contamination
capability functioning of month (chemical and mechanical,
(min. at 50°C) system must entrained oil)
be assured
Density at 15°C DIN 51757 every 4th Check points in system
3
(g/cm ) ASTM D1298 month where oil can enter FRF
system. Examine fluid for
entrained oil, air or water
Fire resistance DIN/ISO 14935 ≤ 5 sec after Replace FRF filling
test determining
oil content
Anti-corrosion DIN 51585 no corrosion every 4th Have anti-corrosion additive
properties ASTM D665-60 permissible month analysed by fluid
manufacturer. Replace FRF
filling if necessary.
Oil content nuclear 3% max. see note Replace FRF filling. Perform
% by vol. resonance test, fire resistance test.
density
Table-3: Maintenance Measures

Note: If examinations of the points in the system where the oil and FRF loops are structurally separated reveal that oil has
entered the FRF system as a result of structural failure, the oil content in the FRF must be determined.

Also refer to the following sections:

[1] 6.1-0140 Fire Resistant Fluid
[2] 6.1-1110 Control Fluid Pump
[3] 6.1-1120 Plate Type Filter
[4] 6.1-1130 Duplex Filter
[5] 6.1-1140 Regenerating Plant
[6] 6.3-0083 Analysis of Fire Resistant Fluid

BHEL, Hardwar 6.3-0082-02/9

 Steam Turbine
Maintenance
Introduction
A fire-resistant control fluid (FRF) is used in control and
governing systems. The purity of the fire-resistant fluid is
of vital importance to the reliable operation of the plant
and must be monitored continuously.
Brief Description of the Procedure
To determine its purity, a defined quantity of the fire-
resistant fluid is dissolved in n-heptane and filtered
through a diaphragm of pore size 0.45 µm. Size and
quantity of the separable foreign matter particles are then
determined. A comparison shows whether the fire-
resistant fluid lies within the purity requirements
established in the specification [1].
Equipment and Chemicals Required
ƒ Membrane filters, 50 mm dia., 0.1µm and 0.45 µm
pore size
ƒ Filtering device and aspirator
ƒ n-heptanes, p.a., purified by filtration
ƒ Filter the quantity of n-heptane p.a. that is required for
dissolving and washing of the fire-resistant-fluid
specimen through a membrane filter of pore size 0.1
µm four times to exclude even the most minute
impurities.
ƒ 100 ml ground glass flasks
ƒ 100 ml Erlenmeyer flasks with ground glass stoppers
ƒ Vacuum pump, e.g. water jet pump
ƒ Microscope slides
ƒ Adhesive tape
Preparation of Sampling Vessels
Note: Flasks cleaned by a normal cleaning procedure still
contain far too many minute impurities which can give a
false impression of purity.
ƒ Then flush the Erlenmeyer flask five times with about
50 ml each purified n-heptane. p.a. and also pass
the n-heptane used for flushing through the filter.
ƒ After drying the filter, place it between two cleaned
microscope slides and seal the edges with adhesive
tape.
BHEL Hardwar
Fire Resistant Fluid
Determination of Fluid Purity
For this reason, the ground glass flasks and Erlenmeyer
flasks must be flushed three times with extra-purified n-
heptanes.
Sampling
ƒ Always perform sampling at the same
location directly from the system.
ƒ Recirculate the fire-resistant fluid long enough prior to
sampling to avoid settling and give a homogeneous
sample.
ƒ Always perform sampling while the FRF system is in
operation.
ƒ Flush the sampling point prior to sampling by draining
about 10 litres of fire-resistant fluid into a clean
receptacle; return this into the system after sampling.
ƒ Allow about 10 litres of fire-resistant fluid to pass
through the sampling point before performing
sampling by filling the fire-resistant fluid directly into
the cleaned ground-glass flask.
ƒ Do not use aids such as syringes or beakers.
ƒ Always identification-mark the specimens uniquely
and durably.
ƒ Complete the sampling records and send to the
analysing laboratory together with the FRF sample.
Determination Procedure
ƒ Measure 20 ml (about 23 g) of fire-resistant fluid into
an Erlenmeyer flask previously cleaned with purified
n-heptane, p.a., and dissolve in 80 ml of purified n-
heptane, p.a.
ƒ Use a clean hair brush to remove any dust from the
membrane filter and clamp the filter into the filtering
device.
ƒ Connect up the water jet pump to the aspirator and
filter the fire-resistant fluid / n-heptane mixture through
the membrane filter.
ƒ Determine the sizes and quantities of the separable
foreign matter particles.
Also refer to the following sections:
[1] 6.1-0140: Fire Resistant Fluid
[2] 6.3-0082: Care of Control Fluid
6.3-0083-01/1
 Steam Turbine Vibration Dampers
Maintenance

Introduction:- With foreign matter. Another point to watch are the

If the piping of the lubricating and control fluid system is
excited to vibration, the deflections involved could cause
inadmissible stressing of the piping material.
Dampers are used to attenuate piping vibration. These
consist essentially of a cylindrical casing enclosing a
plunger embedded in a viscous bitumen mass that
performs the actual damping function. The upper part of
the damper is sealed by a fabric-base plastic guard
sleeve.
This damper design is not subject to wear, but the
damping medium properties may be impaired by
temperature influences or, if the guard sleeve is
damaged, by contamination
attachments of the dampers to the piping and to any
thermal installation plates installed between them, as
these connections may work loose. For these reasons,
regular inspections are necessary to ensure that the
vibration dampers are in good condition and functioning
properly.
Inspection Intervals, scope of Inspection:
Table-1 gives all important criteria to be reviewed during
vibration damper inspections. The intervals between
inspections are given in “y” (years).
The inspections may also be performed during plant
operation.

Table-1: Inspection Intervals, Scope of inspections and Criteria

Inspection Scope of Inspection
Intervals - Criteria
1y Damper Attachment
- firm seating of damper components on pipe and support sides (and at
thermal insulation plates, if applicable)
Motion reserve
- cold condition: position of plunger as in support drawing
Guard sleeve
- correct and firm seating
- tension of the clamps
- damage (cracking or perforations)*
External influences
- effects of water, oil or similar *
5y As for 1 y
Condition of the damper medium
- surface appearance
- elasticity

* If found, perform 5-year inspection immediately

BHEL, Hardwar 6.3-0100-00/1

Points to Note
If welding work is to be performed close to the piping
dampers, take care to protect the dampers (and
particularly the guard sleeves) from weld spatter and
other potential damage.
To preclude any deterioration due to ingress of foreign
matter such as water, oil, etc., replace guard sleeves as
soon as any damage is discovered. In that event, also
check the condition of the damper medium immediately.
BHEL, Hardwar
If cracking, crumbling or loss of elasticity is discovered on
the surface of the damper medium, or if the plunger has
worked itself out of the medium, this indicates that
ambient temperatures in excess of design have caused
deterioration in the damper medium properties.
Consult the damper manufacturer if the damper medium
is unserviceable and has to be replaced. Damper medium
can be removed from the casings without leaving residue
if heated to about 80°C.
6.3-0100-00/2
 Steam Turbine Instructions for Overhaul
Maintenance

In this chapter scope and schedule of overhaul has been Detailed knowledge of the next major overhaul can be
described. gained from the medium overhaul.

The following criteria form the basis for deciding whether

Types of Overhaul or not to open a casing: conclusions drawn from long-
term observation, operating experience and
▪ Minor Overhaul (inspection, servicing) manufacturer’s recommendations.
A minor overhaul should be carried out as required
simultaneously with shutdowns of other plant components ▪ Major Overhaul (inspection, servicing, repair)
or during standstill of the turbine-generator unit due to
faults. A “major overhaul” is a planned shutdown. It permits
detailed inspection and the determination of the condition
The purpose of the minor inspection is to avoid reduction of all components. All casings are opened.
in availability due to forced outages by inspection and
servicing and, if necessary, by preventive maintenance, Schedule inspection interval: After 50,000 equivalents
operating hours.
The casings are not opened.
The term equivalent operation hours is defined by the
Detailed knowledge of importance for intermediate following equation:
overhaul or major overhaul is gained during minor
overhaul. Te = To + ns x 25

Scheduled interval: after about 17,000 equivalent hours Where,

of operation.
Te = equivalent operating hours

▪ Medium Overhaul (Inspection, servicing, repair) To = actual operating hours

A Medium Overhaul is a planned shutdown, if possible,
simultaneously with other plant components during which Ns = the number of starts, without differentiation
a casing may be opened. It covers all work which has a between cold, warm and hot starts.
bearing on the availability of the turbine-generator unit.

BHEL, Hardwar 6.3-0200-05/1

 TURBINE OVERHAUL

Variant-1 Variant-2

Equivalent Operating hours

Minor
Major Overhaul Medium Overhaul
Overhaul

Turbine bearings

Turbine bearings

Turbine bearings
Operating years

Coupling check

Coupling check

Coupling check
Turbine valves

Turbine valves

Turbine valves
HP turbine

HP turbine
LP turbine

LP turbine
IP turbine

IP turbine
8600 01

02
* *
25800 03

04

43000 05

06

60200 07

08

77400 09

10

94600 11

12

111800 13

14

129000 15

16

146200 17

18

-Mandatory, -Optional, *Mandatory for turbines with spring mounted TG deck

BHEL, Hardwar 6.3-0200-05/2

 Medium Overhaul

Major Overhaul
Minor Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul

For units with spring mounted TG deck, check reference readings of deck * *
spring units, carryout alignment and catenary check and readjust spring
units after first year of operation.
Check guides of inner casing for freedom of movement and wear. Overhaul.
Measure permanent elongation of bolts in high temperature zone and check
them for embrittlement, check all bolts for cracks.
Check shaft seals and labyrinth glands for abrasion and scaling. Check
springs of spring-mounted ring segments. Replace springs of high
temperature zone.
Check shaft for cracks. Perform run out check, eliminate score-marks in
shaft journals. Inspect coupling.
Visually examine last stage blades of LP turbine (check for cracks if
necessary).
Clean rotors and casings and examine for damage. Pay particular attention
to blades and seal strips.
After every 50,000 equivalent hours of operation, remove LP free standing
blades from fir-tree grooves, clean root & groove, check complete blade
with specific attention to blade root for crack by MPI and carry out NFT.
Check earthling brush contact surface of shaft.
Open main oil pump, check bearings, seal rings, shaft, impeller etc.
Open auxiliary, emergency and jacking oil pumps.
Check control and protective devices. Pay particular attention to parts
subject to wear or deposits, replace these if necessary.
Perform mechanical, electrical and/or hydraulic functional tests on
monitoring instrumentation; if necessary, overhaul and re-calibrate.
Disconnect couplings, measure elongation of coupling bolts, check axial *
and radial alignment, perform run out check, clearance check.
Disassemble bearings, check Babbitt surface, measure clearances, check
seating of bearing in bearing pedestal.
Check, overhaul and, if necessary, replace seal rings of bearing pedestals.
Check casing guides for deposit, if guides are jammed, remove, clean and
overhaul keys. Ensure design key clearances.
Check stop valves, control valves, bypass valves; if necessary, replace
worn parts on the hydraulic and steam sides.

- If necessary, if applicable, - Mandatory, * for turbines with spring mounted TG deck

BHEL, Hardwar 6.3-0200-05/3

 Medium Overhaul

Major Overhaul
Minor Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul

Remove and check steam strainers for deposits and damage, clean/replace
if necessary.
Check drains for foreign material, open and clean sludge traps.
Measure casing distortion, check casing joints for erosion, check for cracks.
Replace springs of sealing segments in high temperature zone
Drain main oil / control fluid tank, separate impurities, change oil / control
fluid if necessary. Inspect tank. Clean strainers.
Check oil / control fluid filters for leaks, remove and clean the inserts, pay
attention to damage.
Examine oil / control fluid lines for damage, eliminate leaks. Retighten
flange joints. Change gaskets, if applicable.
Examine steam turbine integral piping for cracks, deformation and
ballooning. Special attention is to be given to balance piston leak-off line of
HPT.
Check pipe supports and hangers and readjust if necessary. Check casing
horn drop and eliminate pipe pull by adjusting hangers & supports
Replace TSE/TSC thermocouples fitted in IP inner casing whenever IP
turbine is overhauled.

= If necessary, if applicable, = Mandatory, * for turbines with spring mounted TG deck

BHEL, Hardwar 6.3-0200-05/4

 MINOR OVERHAUL
Casings are not opened. Bearing check, coupling check if
necessary, and mandatory for spring mounted TG deck
after first year of operation, checks of controls, safety and
protective equipment on steam and oil sides.
Components to be inspected
If couplings are to be opened, carry out swing check &
coupled runout measurement before loosening the
coupling bolts, measure the pretension of the coupling
bolts while loosing and tightening. Check the alignment
radially and axially. If deviations ceed the permissible
tolerance, realignment is required.

 TG deck springs (if applicable) after 1st year of
operation, alignment & catenaries
 Casing roll check (if rotors realigned)
 Bearings
 Oil guard rings of bearing pedestals
 Sliding pieces in casing guides and supports
 Control valves, bypass valves
 Emergency stop valves and extraction
 Non-return valves
 Control and safety equipment
 Piping supports and hangers
 Steam strainers
 Drains
 Oil lines
 Pumps (main oil pump, jacking-oil pump, auxiliary oil
pumps and emergency oil pumps, if necessary)
If couplings are disengaged it is advisable to perform a
roll check, especially if the couplings need to be
realigned. At the same time measure the axial
displacement of the rotors relative to the casing. If
disengagement of the couplings is not performed,
coupled run out checks are to be performed in the vicinity
of the bearing as a minimum requirement. For accurate
runout measurement, rotor system temperature should be
close to ambient.
▪ Bearings
Dismantle bearings. It is necessary to check the babbitt
metal lining for damage and looseness by UT. Check
seating of bearing in bearing pedestal. Measure
clearances of bearings.
▪ Oil guard rings of bearing pedestals
Remove contaminants and abraded particles on the seal
edges to prevent oil leakage. Replace oil guard ring in
case of excessive clearance.
▪ Sliding pieces in casing guides and supports
Inspect keys and sliding pieces for any abnormality. If
there are indications of jamming, dismantle and overhaul.
Check and ensure thermal clearances as per design.

 Oil / control fluid tanks ▪ Control valves, bypass valves

 Oil / control fluid filters
 Last stage of LP Turbine
 Monitoring equipment
Scope of activities
▪ TG deck springs (where applicable)
For units with spring mounted TG deck, the deck springs
are to be inspected and reference dimensions compared
and adjusted after first year of operation. This will also
call for alignment, catenaries and roll check.
▪ Couplings
Activities should generally be concerned with checking of
parts subject to wear. Decisions on further activities and
valves to be covered are to be taken according to the
circumstances on the basis of performance in the
preceding period of operation. Spindle seals consisting of
packing material are to be replaced in all cases.
Clearances between moving and stationary parts should
be checked and corrected.
▪ Emergency stop valves
Emergency stop valves should always be inspected
completely (steam and oil side). This includes spindle,
cone, seat, bush, and actuator. With mechanical drives
(lever linkage) in particular, attention is to be give to
compliance with plays and travel reserves.

▪ Piping supports and hangers

BHEL, Hardwar 6.3-0200-05/5

Check and measure alignment dimensions in the cold
conditions and adjust, if necessary. Verify adjustment by
casing horn drop test. Check pipes for visible changes.
▪ Steam strainers
Dismantle and check for foreign bodies and damage.
Replace gasket.
▪ Drains
The scope of activities depends on performance during
the preceding period of operation and susceptibility to
malfunctions. The sludge traps should be opened in all
cases.
▪ Oil lines
Remove leaked oil, inspect pipes and mounting for
fretting point and strengthen accordingly.
▪ Pumps
The main oil pump is to be opened in order to inspect
bearings, sealing rings, shaft, impeller and coupling.
Check other pumps in redundancy configuration only as
necessary.
▪ Oil / Control fluid tanks
Clean strainers
▪ Oil / Control fluid filters
Remove elements and clean. Check for damage.
▪ Last stages of LP turbine
Visual inspection of condition. Crack examination where
necessary.
▪ Monitoring equipment
Check that mechanical, electrical and hydraulic
monitoring equipment function properly and repair or
recalibrate as necessary.
MEDIUM OVERHAUL
At least one casing is to be opened and the rotor lifted
out. Otherwise as for minor overhaul.
Components to be inspected
As for minor overhaul but augmented by the following:
 Inlet and outlet connections
 Casings
BHEL, Hardwar
 Inner casing guides
 Blading
 Glands
 Rotors
 Fasteners
Scope of activities
▪ Inlet and outlet connections
Inspect for scale and freedom of movement at I-and L-
seal rings. Inspect U-seal rings and measure
recompression.
▪ Casing
Measure for deformation, crack examination. Rework
according to findings. Inspect casing joint plane for
erosion
▪ Inner casing guides
Check for freedom of movement and wear.
▪ Blading
Clean entire blading with casing open and inspect for
damage and incipient cracks, Check shrouds for scale
according to temperature. Check for blade looseness and
lock blade lift.
The fir-tree root free standing blades of LP rotor need
special attention. After every 50,000 hours of operation,
take out the blades from groove, clean root and groove,
carry out crack detection of the entire blade including
root, check natural frequency in position with
technological pieces.
▪ Glands and labyrinths
Check for abrasion and scale (dependent on
temperature). Check condition of springs.
▪ Rotor
Check for cracks in fillets. Perform run out check.
Eliminate scoring on the journals. Check coupling.
▪ TSC thermocouples
Replace TSC thermocouples fitted in IP inner casing,
whenever IP Turbine in opened for overhaul. Take
advance action for procurement of the TSC
thermocouples and associated fittings.
6.3-0200-05/7
6.3-0200-05/6
▪ Fasteners in high temperature zone
Replace all fasteners of size upto M64 in high
temperature zone after 100,000 equivalent hours of
operation. Carry out destructive test on sample fastener
of higher sizes to determine usability of the lot.
MAJOR OVERHAUL
All casings are to be opened and the rotors lifted out.
Otherwise as for medium overhaul, but instruction if
necessary is inapplicable.
Depending on the results of the inspection the examined
components are to be:
▪ Left in the as-inspected condition, because no faults
have been found.
▪ Left in the as-inspected conditions although damage
(e.g. crack formation) has been found. Continued
operation, either in an unaltered or altered mode, is to be
justified. The propagation of the damage is to be kept
under observation; spare parts, often requiring lengthy
delivery periods, are to be ordered.

Components to be inspected ▪ Replaced with spare parts (in general small parts
subject to wear are normally kept in stock e.g. spindles,
As for medium overhaul but instruction “if necessary” is fasteners)
inapplicable, and augmented by the following:
▪ Repaired by reworking at site or in the works of the
 Oil / Control fluid tanks supplier
 Steam lines It is necessary to increase the scope of the inspection as
soon as the units have clocked more than 100,000
 Casing center guides equivalent hours of operation. Component integrity
assessment and/or residual life assessment studies are
Scope of Activities
to be initiated at this stage. Inspection planning must
▪ Oil / Control fluid tanks allow for the additional time and costs consumed by the
inspections. Apart from this, the intervals between major
Drain and clean tank. Purify oil / Control fluid, change if overhauls necessitate the coverage of considerably more
necessary. components by the inspection as has been customary
hitherto.
▪ Steam lines
When stipulating the scope of the inspection, the
Check steam lines exposed to main or reheat steam for experience gained from comparable units should be
expansion, deformation and crack. taken into account in the plans and/or the manufacturer is
to state at which highly stressed points the various
▪ Casing centre guide components are to be inspected. It is advisable to get the
special checks and tests conducted by the specialists
Disassemble and overhaul. Ensure design clearances from turbine plant.
SUGGESTED INSPECTION & TESTING INTEGRITY ASSESSMENT
PROCEDURES
During integrity assessment, following examination /
During inspection of steam turbine generator units, inspection / testing of steam turbine parts may be done.
certain components are required to be inspected in-depth
to achieve more accurate evaluation of their condition.

BHEL, Hardwar 6.3-0200-05/7

▪ Visual Inspection ▪ Surface crack examination
 With the naked eye and good illumination e.g. 500 Watt  Dye penetration test (DPT)
photographic lamp, mirror
 Magnetic particle inspection (cannot be used on
 Magnifying glass austenitic materials)
 Bore scope

 Eddy-current examination ▪ Hardness test

 Crack depth determination as far as possible with

capacitance probe or ultrasound ▪ Material verification test

▪ Ultrasonic examination  Manual spectroscope

▪ X-Ray examination
▪ Material testing
▪ Detection of permanent deformations
 Tensile test to determine yield strength, tensile
 Out-of-roundness (ovality), angle of bend (in pipe strength, and elongation after fracture and necking down.
elbows), warp
 Notched bar impact test
 Wall thickness measurement
 Chemical composition
 Expansion measurements (measurement of diameter,
length, circumference).  Metallographic microstructure evaluation

▪ Surface micro-structure examination

▪ Testing of electrical insulation against shaft
 Microscopic examination at site currents
 Contact print (Replica) procedure after etching material
surface

BHEL, Hardwar 6.3-0200-05/8

 Steam Turbine
Maintenance
Introduction:
Following extensive boiler repairs, measures must be
taken to protect the turbine against erosion by solid
particles.
Bypass Operation:
When extensive repairs have been carried out on the
boiler, it is not possible to prevent solid particles
remaining in the system in spite of chemical cleaning. For
this reason, provision must be made for a lengthy period
of bypass operation with the highest possible bypass
steam mass flow rate at the time of unit restart. During
this bypass
BHEL, Hardwar
Turbine Restart
after Boiler Repairs
Operation, all solid particles remaining in the system are
blown down into the condenser, which prevents them
from causing particle erosion on the turbine blades
Particles blown down into the condenser must be
removed from the hot well before commencement of
process operation. The bypass steam mass flow rate
must comply with the limits (mass flow rate and duration
of operation) defined in the specifications.
The bypass stop and control valves may suffer slight
damage to their seats and discs as a result of steam
dumping and must, where necessary, be checked by
sampling.
6.3-0210-00
 Steam Turbine
Maintenance
Introduction
The operational reliability and availability of a steam
turbine unit are determined by, among other factors, the
care with which the unit was initially started up. The same
rule also applies to restarts after large scale maintenance
and repair work, e.g. in the course of major inspections.
Information Required for Restart
In restarting a turbine it is useful to possess the following
data:
▪ The performance of the turbine unit and its components
prior to inspection
▪ The scope of the inspection
▪ Findings and checks made during the inspection
▪ Repairs carried out on the basis of the findings
▪ Retrofitting and upgrading measures taken
▪ Checks planned for the restart period
The information required may be found in the following
documents:
▪ Reports on turbine performance prior to inspection
▪ Operating parameters and setting records for the unit
when new or at the last restart
▪ Reports on inspections, findings and repairs
▪ Documents on retrofitting and modifications
The following are also required:
▪ Diagrams showing current control system setting (in the
case of special settings the most recent records are
binding)
▪ Documents from the turbine manual, such as controller
circuit diagrams and descriptions.
BHEL, Hardwar
Turbine Restart after Major
Inspections or Repairs
Pre-service Inspections
The functioning and the setting of all of the major
equipment of the turbine must be checked. This applies
both to mechanical / hydraulic components and to
instrumentation and control devices. The scope of
inspection and testing of defined in instruction 6.2-002x,
and covers:
▪ All closed-loop controls
▪ All protective devices
▪ All sub loop controls and automatic changeover controls
The characteristics of all electro-hydraulic controllers
must be recorded. The test programs appear in
maintenance instructions 6.3-0030 and 6.3-0061.
Alarm system and monitoring equipment must like wise
be overhauled and tested.
If the result of operating parameters and setting checks
reveal changes from earlier results, new records must be
prepared.
In-Service Inspections
The tests, which could not be carried out in the pre-
service phase because the boundary conditions had not
been fulfilled, must be performed during the service
phase subsequent to the pre-service inspections. The
essential step-by-step test schedules appear in
maintenance instruction 6.3-0060.
▪ Protective devices
Service phase testing applies mainly to those devices
which protect the turbine against over speed. The test
programs of the automatic turbine tester may also be
executed if required.
▪ Controllers
The performance of the controllers must be observed
throughout the restart phase.
6.3-0220-00/1
The control range of the hydraulic controller must be
checked and, if necessary, corrected during no-load
operation.
▪ Automatic functional group controls
The turbine systems and the turbine generator unit
should be started up with the aid of the automatic
functional group controls, and checks carried out to
establish whether all criteria for the execution of the step
programs are fulfilled.
▪ Operating parameters
 Condensate temperatures
 Condenser leak tightness (leak test)
During non-steady-state operation, e.g. during a cold
start, all operating parameters which are subjected to
large-scale changes in this phase must be recorded.
The operating parameters of the turbine stress controller
must be subjected to critical analysis, because the start-
up time, and hence the cost-efficient operation of the
turbine unit, is largely determined by the limits set by the
TSC.

The values of all operating parameters must be recorded

during steady-state operation when they have remained Evaluation of Tests and Operating Parameter
constant for an adequate length of time, and then Records
compared either with the set point or with previous
recorded values. The test results and the operating parameter records
provide vital information on the compliance of the turbine
 Output and its components with the performance specifications.

 Control system characteristics Malfunctions and other major discrepancies must be

eliminated as far as possible, especially when they
 Steam mass flow rates constitute a hazard to the operational reliability of the
turbine unit.
 Feed water / condensate mass flow rates
Where necessary, spare parts must be ordered and/or
 Steam pressure and temperatures measures to facilitate future elimination of the off-norn1al
conditions detected must be defined.
+ Main steam
These measures may include further measurement of off-
+ Extraction steam
normal conditions, rebalancing and other similar actions.
+ Exhaust steam

 Casing temperatures Re-Commissioning of the set

 Expansions Most of the activities which have to be performed in the
course of turbine restarts go beyond the scope of normal
 Vibrations maintenance work. They call for special knowledge which
is too detailed to be described in full in the turbine
 Oil pressure and temperatures manual, especially where fault elimination is involved.
 Bearing metal temperatures It is therefore expedient to assign commissioning
personnel to assist in restarting the turbine.
 Control fluid pressures and temperatures
The following is one conceivable allocation
 Circulating water temperatures of functions:
+ Condenser ▪ Pre-service inspection and in-service testing of the unit
by one specialist engineer each for turbine and generator
+ Coolers from the supplier company.

BHEL, Hardwar 6.3-0220-00/2

▪ Pre-service inspection and testing of major C&I
hardware
 Controllers and protective devices
 Turbine stress controller
 Automatic testers
 Automatic functional group controls
▪ Pre-service inspection and testing of controls, interlocks
and alarms by owner / operators personnel.
Summary of results from major inspections and
repairs
Full documentation of the history of a turbine unit
includes, among other elements, reporting on turbine
restart following major inspections or repairs.
The report on restart should make reference to certain
preceding reports, namely:
▪ Report on the performance of the turbine unit prior to
the major inspection
BHEL, Hardwar
▪ Report on the scope of the inspection
▪ Report on the findings and checks made
▪ Report on repairs and other actions
▪ Report on the replacement and spare parts used or
required
If these special reports are not available, brief details
must be given on these subjects under the above
headings.
The main section of the reports must cover:
▪ The scope and nature of pre-service inspections
▪ Findings from the pre-service inspections
▪ The scope and nature of in-service testing
▪ Evaluation of turbine performance
▪ Findings from in-service testing
▪ Matters remaining open (actions, replacement parts,
implementation deadline, etc.)
6.3-0220-00/3
 Steam Turbine
Maintenance
It is the social and moral obligation of all concerned to
ensure adequate protection of the environment in every
wake of operation.
During maintenance inspection and capital overhauls, it is
of paramount importance to ensure safety of work force
by adhering to the applicable safety codes. In addition,
while handling and disposing hazardous materials,
necessary precautions, as published from time to time,
are to be adhered.
Some material, through harmless in normal regime, may
become quite hazardous under different circumstances.
Gaskets made of Fluorelastomers (viz. Viton), when
exposed to temperatures in the region of 400 0C or higher
due to fire or any other reason, get decomposed. One of
the products of such decomposition is Hydrofluoric acid,
which is highly corrosive and any skin contact with it must
be prevented.
To protect the natural environment and to control
pollution from disposed hazardous or non-bio-degradable
material, a proper system of disposal is to be evolved and
compliance ensured.
BHEL, Hardwar
Environmental protection
Oil leakage does not only pollute the environment but is
also a potential fire hazard. Oil leakage from any source
is to be quickly attended. In the viscinity of high
temperature equipment & pipes, any oil leakage has to be
immediately attended, even if it calls for unit shutdown.
Steam leakage from any source is associated with
thermal & noise pollution of the environment. Depending
on the source & parameters of the leakage steam, it can
be injurious to the associated equipment and also to any
individual coming in contact. Any such leakage is to be
quickly attended.
Proper upkeep & periodic lubrication of all rotating
equipment as per the manufacturer’s instructions goes a
long way in ensuring their smooth and noise-free
operation.
To promote environment friendly aesthetic appearance,
the external surface of all the equipment should be
painted once in two years. General upkeep and
cleanliness standard should be maintained all around,
especially around the turbine floor to promote a pleasing
look.
Also refer to the following sections:
[1] 6.3-0251: Fluorelastomer products Safety notice
[2] 6.3-0252: Safe disposal of Turbine Oil
6.3-0250-00
 Steam Turbine Fluorelastomer Products
Maintenance Safety Notice

Precautions to be taken during handling of Viton The affected areas must be decontaminated before either
synthetic rubber and other Fluorelastomer products inspection or maintenance is resumed. Do not touch
after they have been exposed to very high anything in the vicinity of the decomposed material until it
temperatures has been decontaminated.

Fluorelastomers are synthetic rubber like materials
commonly used for making gaskets and seals of various
kinds.
‘Viton’ is used extensively in control fluid (FRF) system
due to its compatibility with phosphate ester fluids. It is
also compatible with mineral oil and can appear in ‘O’ ring
form in the lubricating oil, jacking oil and power oil
systems. In normal use, fluid temperature excursions
beyond 100 °C are rare and therefore the use of ‘Viton’
seals does not constitute a hazard to safety. However,
extreme care should be taken when dismantling
equipment which may have been subject to fire damage.
When exposed to temperatures in the region of 400 °C or
higher, fluorelastomers do not burn but decompose into a
number of materials, one of which is hydrofluoric acid.
This is corrosive and almost impossible to remove once it
contaminates the skin.
Personnel who could come into contact with degraded
‘Viton’ (or any other fluorelastomer) should be made
aware of its hazardous nature. Equipment which has
been exposed to a very high temperature (e.g. equipment
which has been involved in a fire), and which may contain
fluorelastomer components, should not, under any
circumstances, be touched until it has been visually
inspected for gaskets or seals which have suffered
decomposition. If decomposition has occurred, the
component will appear as a charred or black sticky mass.
Supervisory staff should be informed immediately and
inquires made to confirm whether fluorelastomer
components are involved. Meanwhile, access to the
equipment should be denied to unauthorised or
unprotected personnel and warning notices posted.
Decontamination procedures for decomposed
Fluorelastomer products
Decontamination of equipment exposed to
decomposed Fluorelastomer products
If decomposed fluorelastomer products are suspected,
great care must be taken when removing the residues
from equipment. Protective equipment and clothing must
be used and worn, including heavy duty rubber gloves
and full face protection, to prevent accidental skin contact
with the Hydrofluoric acid (H-F).
The residues should be disposed of with great care, such
as very high temperature incineration. All containers or
bags used to transport the residues must be clearly
marked to ensure careful handling to the point of
disposal.
H-F residues may be washed away using sufficient
quantities of water to dilute them to harmless
concentrations.
Decontamination of personnel exposed to
decomposed Fluorelastomer products
H-F residues should not be handled without adequate
protection. If accidental exposure occurs, wash well with
water and apply an H-F Antidote Gel as directed. Medical
attention should be obtained immediately. A Calcium
Gluconate injection is the normal treatment for
Hydrofluoric Acid Burn.

BHEL, Hardwar 6.3-0251-00

 Steam Turbine Safe disposal of
Maintenance Turbine Oil

Oil of viscosity class ISO VG 46, commonly known as ▪ To send the discarded oil to registered refiners who
turbine oil, is used for lubrication of turbine bearings as have facilities to reclaim the oil by physico-chemical
well as for hydraulic turning gear. treatment for further use in non-critical applications.

The oil should comply with the requirements given in ▪ To send the used oil to the parties who are licensed to
Operation and Maintenance Manual [1]. It is handle and dispose used lubricating oil.
recommended that the condition of oil in use, be
periodically monitored to ascertain the quality and
properties of turbine oil [2]. All major oil manufacturers
have facility for complete checking of oil properties. ▪ To burn-off the discarded oil in boiler furnace by mixing
with fuel oil.
Turbine oil has to be changed if its properties have
crossed discard limits. The procedure for safe disposal of
used turbine oil is as follows:

Also refer to the following sections:

[1] 6.1-0130: Oil specification
[2] 6.3-0080: Turbine Oil care

BHEL, Hardwar 6.3-0252-00

 Steam Turbine Ordering of Spares
Maintenance

While ordering for spares, complete
identification details of the required
component should be furnished. The details
of components described in various
chapters of this manual are given only to
understand the functioning. For ordering
spares, only the project specific drawings
supplied separately should be referred and
following details may be furnished:

Enquiry for Steam Turbine O&M Spares

Name of the project:

Capacity:

Unit No. :

Previous enquiry / offer / order reference:

A] BHEL Supplied Spares

Sl.No. Assembly Item No. Qty. Description Part Drg.No. / Application
Drawing Code No. /
No. KKS tag No.
1.
2.
3.
4.
5.

B] Purchase resold items

1. Name of the supplier :

2. Model :

3. Year of manufacturing / supply :

4. Equipment Serial / Fabrication No. :

5. KKS Tag No. :

6. Other details noted from name plate :

7. Supplier’s catalogue reference No.

8. Supplier’s Sketch / Drg. No.

9. Application / location where installed :

10. Details of spares

Sl.No. Description as above Installed Quantity Required Quantity
1.
2.
3.

BHEL, Hardwar 6.3-0300-00