Turbine Mannual

JHARSUGUDA 9×135MW CAPTIVE POWER PLANT PROJECT Client: SEPCOⅢ ELECTRIC POWER CONSTRUCTION CORPORATION CORPORATION No.

26-W9-YX-01

TURBINE OPERATION RULES (A)

Operation Instruction

Total 151 Pages

JSG CPP TURBINE OPERATION RULES

CONTENTS PART 1 Overview Chapter 1 Specification of Main Equipment ……………………………… ……………………………………………… ………………5 5 Chapter 2 Specification of Auxiliary Equipment ………………………………… ………………………………………… ……… 14

PART 2 Unit Start-up Chapter 1 Cold Start of the Unit ……………………………………………….…………26 Chapter 2 Warm & Hot Start of the Unit ………………………………………….…..…38

PART 3 Unit Operation Chapter 1 Operating Parameters of Steam Turbine …………………………………… 42 Chapter 2 Operating Modes of the Unit ……………………………… …………………………………………..… …………..……..47 …..47 Chapter 3 Regular Works and Requirements …………………………………..………49


Chapter 15 Generator parallels off, while turbine does not trip ……………..….……77 Chapter 16 Generator parallels off, and turbine trips tr ips …………………………………7 …………………………………77 7 Chapter 17 Turbine trips, while the generator does not parallel off …………………78 …………………78 Chapter 18 Failure of Thermodynamic Power Supply ……………………………… …………………………………78 …78 Chapter 19 High Bearing Temperature of Turbine-generator Unit ……………………79 Chapter 20 Burning out of Turbine-generator Turbine-generator Bearing Bush ……………………….…79 ……………………….…79 Chapter 21 Steam Turbine Shaft Bending ………………………………………………80 Chapter 22 Steam turbine Overspeed ………………………………………………..…82 Chap Chapte terr 23 Feed Feed wate waterr pump pump set set outl outlet et chec check k valv valve e is unti untigh ghtt and and rota rotate tes s reversely.83 Chapter 24 Turbine-generator unit operates at abnormal frequency ………………… 83 Chapter 25 Boiler Fire Extinction …………………………………………………………84 Chapter 26 Treatment of Accidents & Abnormity of the Motor ………………………..85 ………………………..85

PART 6 Auxiliary Equipment & Common Service System


Appendix

2:

Cold

Start

Curve

at

Sliding

Parameters

………………………………….148 Appendix

3:

Warm

&

Hot

Start

Curve

……………………………………………..........149 Appendix 4: Normal Shutdown Curve ……………………………………………..…..150 Appendix 5: Shutdown Curve at Sliding Parameters…………………………………151


Chapter 1 Specification of Main Equipment 1.1 Specification of steam turbine equipment Model: N135-13.73/537/537 Type: super-high pressure, primary reheating, double cylinder, double-flow, single shaft, extraction and condensing steam. Rated power: 135MW Initial steam pressure: 13.73Mpa (a)


Rated speed:

3,000 rpm

Feed water temperature under rated condition: 244.4℃ Max back pressure at which the unit is permitted to operate: 18.6kpa (a) Regeneration stages: 2 HP heaters, 4 LP heaters & 1 deaerator Length of the last blade of LP cylinder: 690mm Critical speed of shafting: 1,950r/min for HP & MP rotor 2,450r/min for LP rotor 1,260r/min for generator rotor Stages of flow path: total 39 stages: HP cylinder: 1 governing stage + 13 pressure stages MP cylinder: 13 pressure stages LP cylinder: 2×6 pressure stages

1.3 Description of turbine characteristics 1.3.1 This unit can carry the base load of power network, as well as can be used as two-shift or peak regulation unit. 1.3.2 This unit’s operating time at no load when rejecting load must not exceed 15 mins. 1.3.3 This unit’s operating time without steam must not exceed 1 min.


pressure is 20.3kPa (a). 1.3.9 The unit is permitted to run for long when the exhaust temperature of steam turbine is less than 79℃. The max temperature at which exhaust is permitted to operate is 120℃ . 1.3.10 Permitted load variation rate of unit is: 1.3.10.1 From 100% to 50% MCR

5%/min

1.3.10.2 From 50% to 20% MCR and from 20% to 50% MCR 3%/min 1.3.10.3 Below 20%MCR

2%/min

1.3.11 The pressure after the governing stage must not exceed 10.34Mpa (a) at different working conditions.

1.4 General description of steam turbine 1.4.1 Brief introduction of steam turbine proper 1.4.1.1 Steam turbine type is: super-high pressure, primary reheating, double-flow and single shaft arrangement, reaction extraction and condensing type, which characteristics include: combination of HP and IP cylinder, reverse arrangement of through-flow parts, inlets of initial steam and reheat steam centered on the middle part of HP & MP cylinder and radial diffusion double-flow type of LP cylinder. This unit’s shafting is supported by three points: HP & MP rotor connected with LP rotor by rigid


The turbine unit is 13.5 meters long in total and arranged on the 9m operation floor, with a combination of HP initial steam stop valve and HP governing valve mounted on both sides in the front which is supported on the holder of main stop valve, 4 flexible HP steam inlet pipes connected with the 4 governing valves and the HP cylinder’s upper and lower steam inlets respectively, and governing valve controlled by oil servo-motor. The high pressure nozzle section consists of four groups of nozzle segments, with each group containing 29 nozzle steam paths and steam inlet flow of each group controlled by the corresponding governing valve. The unit can reach rated power by 3 valves opening fully and the fourth group provides guarantee for the availability of rated power in summer and at low parameters. HP & MP cylinder is single-floor cylinder with 1 governing stage and 13 pressure stages in the HP part. There is a section of steam extraction led to HP heater #1 after stage 10, and steam exhausted by HP flows through lower cylinder’s exhaust port and HP exhaust check valve to the reheater, a portion of which is led to HP heater #2 as regenerative extraction.


protect all bearings from damage. LP cylinder is equipped with atomizing nozzle type low-load spray regulator inside that may operate to spray automatically in the case where the LP cylinder exhaust temperature is higher than 80℃ so as to ensure normal operation of the unit. 1.4.1.2 Dummy piston & thermal shroud Dummy piston: Because this unit’s HP & MP rotor blade adopts reaction blade which reaction degree is higher and rotor thrust is also great correspondingly, the rotor is processed into several dummy clubs for the use of balancing the thrust on the blade. HP & MP cylinder has three du mmy pistons in all, including the dummy piston on HP exhaust side, on HP steam admission side and on MP steam admission side. There are two Ф133×4 pipes connecting between the dummy piston outside chamber on HP exhaust side and MP exhaust chamber, which allows the pressure on the exhaust side dummy piston outside and that on the MP exhaust side to be equal. At the same time, there are two Ф76×4 pipes connecting between the HP exhaust chamber and chamber between HP steam admission side dummy piston & MP steam admission side dumpy piston, through which HP steam is led to the chamber between HP & MP outer cylinder and MP thermal shroud to cool HP & MP outer cylinder. Thermal shroud: because high temperature steam flows into HP & MP cylinder directly, there is a thermal shroud mounted on the inner wall of MP part of HP & MP outer cylinder in order to


The sliding key system is the supporting and locating system of stator part, the steam turbine proper supporting and locating mode is: front frame, middle frame and rear frame and exhaust hood frame are fastened on the foundation by means of foundation bolts and back grouting and are equipped with front bearing pedestal, middle bearing pedestal, rear bearing pedestal and LP outer cylinder thereon respectively. Longitudinal keys are arranged on the front frame along the center axis, the front bearing pedestal can move on its frame along the axis. HP & MP outer cylinder upper claws are supported on the front and middle bearing pedestal, the lower claw’s transverse keys connect with the front and middle bearing pedestal, besides longitudinal keys, there are also transverse keys on some position of the middle frame, and the cross point of longitudinal and transverse key is the dead point of HP & MP stator part, the front bearing pedestal HP and MP cylinder and middle bearing pedestal take this as the dead point to perform axial expansion and contraction. There is a vertical key mounted on both upside and downside of both ends of HP & MP outer cylinder with key way plate fixed on the neighboring bearing pedestal for the purpose of smooth expansion and contraction and keeping cylinder center aligning. 1.4.1.5 Thrust bearing The unit adopts the Michell thrust bearing. The thrust collar integrates with steam turbine, and both its front and back sides are mounted with positive and negative thrust bearing pads with 12 pieces laid on the whole circle of each. And each pad is equipped with a RTD temperature


The steam turbine proper shafting consists of HP & MP rotor and LP rotor. Connection between HP & MP rotor and LP rotor relies on the rigid coupling integrated with main shaft forging, and the shims in between two halves of coupling are connected with screws. As configured for the purpose of meeting the requirement of rotor center aligning in assembly, in such a case, the center on both ends of coupling must keep correct and concordant in assembly so as to allow the rotor center line to become smooth and continuous curve in operation. The rigid coupling is very sensitive to the bearing load distribution because of high rigidity, thus its requirements for the assembly technology and shafting aligning are much higher, but it has such advantages as high strength, short rotor length, easy processing and reliable operation. Semiflexible coupling is used in between LP rotor and generator rotor, such coupling has a corrugated pipe joint on the end coupling connecting with generator rotor, which has certain flexibility, and connects with an minor axis on the other end coupling, and the minor axis covers the generator rotor to transmit the torque by means of interference and key, such semiflexible coupling may allow the unit safety operation not to be affected by slight change in the steam turbine and generator center in installation and operation. 1.4.2 Technical specifications of governing system 1.4.2.1 The governing system is able to keep idle running of steam turbine at rated steam inlet condition, rated vacuum and full open main stop valve, with speed oscillation value ≯ 6r/min.


d. LP cylinder differential expansion reaches +7.5mm; e. Lubricating oil pressure is lower than 0.06Mpa; f. Back pressure of the condenser is lower than 20.3kPa; g. Peak to peak vibration amplitude of the rotor is ≥ 0.254mm; h. Metal temperature of # bearing 1-3 reaches 112℃, the metal temperature of bearing #4 and #5 reaches 80℃ or the temperature of thrust bearing reaches 107℃; i. EH oil pressure decreases to 9.31 Mpa; j. Power failure to DEH system; k. Exhaust temperature of LP cylinder reaches 121℃ ; l. The oil level of the main oil tank is lower than 1245mm; m. MFT of the boiler; n. Main protection of the generator operates. 1.4.3.2.2 Oil injection test function 1.4.3.2.3 Emergency governor test function 1.4.3.2.4 Steam turbine reset function

1.5 Heat calculation data of the steam turbine

G

Name

Unit

Rated conditions THA

TMCR

VWO

Cutting off all HP Heaters

t

kW

135 029

135 101

145 005

135 043

d


Name

Unit

Rated conditions THA

TMCR

VWO

Cutting off all HP Heaters

No.3 extraction flow

t/h

8.066

8.47

9.124

9.863

No.4 extraction steam condition

MPa/℃

0.451/315.8

0.45/315.4

0.484/315.3

0.475/315


t/h

13.064

13.57

14.335

14.003


MPa/℃

0.251/248.4

0.25/247.8

0.269/247.8

0.264/247.5


t/h

22.097

22.912

24.148

23.568


MPa

0.067

0.0665

0.0718

0.0705


t/h

15.801

16.335

17.153

16.775


MPa

0.0143

0.0142

0.0152

0.015


t/h

2.905

2.95

3.977

3.621

Note: Turbine Heat Acceptance condition (THA): means the condition in which the unit can operate safely and continuously with generator’s net output power of 135MW when the turbine is under rated initial steam and reheat steam conditions, back pressure is 8.83kP, make-up water percentage is 0%, and regenerative system is put into operation all normally and generator’s efficiency is 98.35％, which heat rate is not more than the acceptance value of 8,402.9kJ/kWh. Turbine maximum continue rate (TMCR): means the condition in which the unit can operate safely and output maximum power when the turbine is under rated initial steam and reheat steam conditions, back pressure is 8.83kP, make-up water percentage is 3%, and regenerative system


Chapter 2 Specification of Auxiliary Equipment

2.1 Specification of heater 2.1.1 Specification of HP heater Item

Unit

Model Design pressure of shell side

Mpa

HP heater #2

HP heater #1

JG-530-2-00CK

JG-530-1-00CK

30

45


Design temperature of tube

℃

100

100

260

350

Working pressure of tube side

Mpa

1.724

1.724

1.724

1.724

Working pressure of shell side

Mpa

0.0152

0.07257

0.2693

0.454

℃

55

69.45

109.05

138.25

℃

55

90.63

129.9

150.6

side

Working temperature of tube side Working temperature of shell side Manufacturer

Shanghai Power Equipment Co., Ltd.

2.1.3 Specification of deaerator and deaerated water tank 2.1.3.1 Specification of deaerator Class

Class I

Test pressure

1.374MPa

Model

GC-514

Pressure drop of nozzle

0.0588MPa

Design pressure

0.88Mpa (g)

Opening pressure of safety valve

0.85MPa

Design temperature

380℃

Operating mode

Ma

ki

0.78Mpa (a)

Corrosion allowance (tank

Sliding pressure operation 1.6/2.5mm


Inlet water pressure

MPa

1.48

0.6837

Outlet water pressure

MPa

19.18

1.48

Shaft power

kW

2733.9

128.7

Rotating speed

r/min

4686

2982

Working temperature

℃

166.7

166.7

Medium density

kg/m3

900.59

900.59

Intermediate bleed-off pressure (stage 2)

MPa

8

Intermediate bleed-off flow

m3/h

35.5

Guarantee efficiency

%

81.32

Shanghai Power Equipment

Manufacturer

Maintenance Works Co., Ltd.

2.2.2 Specification of feed-water pump motor 2.2.2.1 Specification of feed-water pump motor Item

80.84

Unit

Model

Specification YKOS3700-2

Rated power

kW

3,700

Rated voltage

V

6,600

Rated current

A

370


2.2.3.1 Parameters of hydraulic coupling Item

Unit

Specification

Model

R17K.2-E

Motor speed

r/min

2,986

Output speed

r/min

4,783

Max output power

kW

3,000

Slip

%

≤3

Scope of speed governing

%

25-100

Efficiency

%

94.7

Capacity of oil tank

m3

0.85

Manufacturer

Germany VOITH

2.2.3.2 Auxiliary equipment of coupling Item

Unit

Model

Working oil

Lubricating oil

cooler

cooler

CB-B125

LY54

LY16

30

17

Auxiliary oil pump

Oil flow

m3/h

7.5

Pressure

MPa

0 25


Inlet & outlet diameter

mm

Manufactured by

φ300

Shanghai Power Equipment Research Institute

2.3.3 Circulating water booster pump Specification of circulating water booster pump

Specification

of

circulating

water

booster pump motor

Model

10Sh-9A

Model

Y250M-4

Shaft power

40 kW

Voltage

415 V

Lift

30 m

Current A

Rotating speed

1,480r/min

Power

Flow

420 t/h

Efficiency

80%

Manufactured by

Shijiazhuang Kingda Pump Co, Ltd.

55 kW

Power factor Rotating speed

1,480 r/min

Manufactured by

Xi’an Motor Works

2.3.4 Indoor circulating sump pit blowdown pump Specification of indoor circulating sump pit

Specification of indoor circulating

blowdown pump

sump pit blowdown pump motor

Model

40PV-SP

Model

Y112M-2

Shaft power

3.1kW

Voltage

415V

Lift

15m

Current A


diaphragm with fillet; the seal ring of LP diaphragm seal is mounted in the septalium and fixed with spring leaf. 2.4.2 Shaft seal heater Item

Unit

Specification

Model

JQ-50-1 m2

50

m3/h

Total flow, 300 minimum

Design pressure

MPa

Tube side 3.1, shell side 0.1

Working pressure

MPa

Tube side 2.00

Test pressure

MPa

Tube side 3.9, shell side 0.125

Design temperature

℃

Tube side 100, shell side 100

Working temperature

℃

Tube side 60, shell side 100

Net weight

t

2.23

Heating surface area Design flow of main condensate flow

2.4.3 Shaft seal fan: Specification of shaft seal fan

Specification of the motor

Model

AZY-09.32-020.0-01

Model

132S

Full pressure

9.32kPa

Power

7.5kW


Co., Ltd. 2.5.2 Specification of condensate pump Specification of condensate pump


Model

7LDTNB-6PJS

Model

YLKK400-4

Flow

350m3/h

Power

280kW

Lift

190m

Voltage

6,600V

Npsh

2.2m

Current

31A

Shaft power

223kW

Rotating speed

1,487r/min

Rotating speed

1,487r/min

Insulation class

F

Shenyang Pump Co., Manufactured by

Shenyang Electric Manufactured by

Ltd.

Machine Works

2.5.3 Vacuum pump Specification of vacuum pump Model: 2BW4 253-0EK4 Min. suction pressure (min. vacuum degree):

Specification of the

Specification of

motor

vacuum pump cooler

Model: Y315M-8

Model: M16

Voltage: 415V

Heat exchange surface


Efficiency: 61％

Insulation class: F

Manufactured by: Shanghai Hualian Pump Co.,

Manufactured by: Jiamusi Electric Machine

Ltd.

Works

2.6 Specification of steam turbine lubricating oil system 2.6.1 Main oil tank Dimension (length×diameter)

5,810×3,020 mm

Maximum volume

40 m3

Working volume

24 m3

Operating oil level

1,808mm

Maximum oil level

2,616mm

Minimum oil level

1,245mm

Suction level of oil injector

1,045mm

2.6.2 Oil cooler Model

GX-64P

Cooling surface area

240m2

Working temperature

Above 0℃

Flow

80l/min


Manufactured by: Shanghai HP Oil Pump Works

Manufactured by: Shanghai WUYI Electric Company

2.6.5 AC lubricating oil pump Specification of AC lubricating oil pump


Model: YS150-50BⅡ

Model: YB180M-2

Water head: 36m

Power: 22kW

Flow: 133m3/h

Voltage: 415V

Rotating speed: 2950r/min

Current: 42.2A

NPSH: 4.5m

Insulation class: F

Manufactured by: Shanghai Pump Works

Manufactured by Shanghai Wuyi Electric Machine Works

2.6.6 Starting-up oil pump Specification of starting oil pump


Model: 150Y-150AⅡ

Model: Y315S-2

Outlet oil temperature: 1.1 MPa

Power: 110 kW

Flow: 186m3/min

Rotating speed: 2 982r/min


Matched power: 3kW

Current: 6.4A

Rotating speed: 2,960 r/min

Insulation class: B

Manufactured by: Mudanjiang Aidi Electric Power

Manufactured by: Hebei Chengde

Technology Co., Ltd.

Electric Machine Works

2.6.9 Specification of the oil purifying equipment Model:

HCP100 380 50 AS-SD

Power:

3.0kW

Voltage:

415V

Max current:

8.2A

Flow:

100l/min

System working pressure:

<1.0MPa -10~60℃

Operating temperature:

Max viscosity of treating medium: ≤46cSt Water discharge:

About 5 L/time

Manufacturer:

PaLL Filter Ltd.

2.6.10 Turning gear Model Motor capacity

horizontal 37 kW


Specification of EH oil pump


Specification of oil cooler

Code: 029-09941-5

Model: Y200L-4 B35

Model: GL02

Model: PV29 2R50 COO

Power: 30kW

Working pressure: 1.6MPa

Outlet pressure: 13.7MPa

Voltage: 415V

Working temperature: ≤100℃

Current: 56.8A

Cooling surface area: 2.1m2

Rotating speed: 1,470r/min

Manufactured by: Shanghai

Setting value of overflow valve:16.2MPa

Lubricating Equipment Plant Manufactured by Shanghai Wuyi Electric Machine Works 2.9 Specification of rapid cooling device Item

Unit

Specification YQL-Ⅱ150

Model Rated air flow

m3/min

40

Voltage

V

415

Power

kW

150


The two-stage series connection bypass system is adopted, in which, the flow capacity of HP pass is considered as 70% of steam flow under VWO condition and the flow capacity of LP bypass is considered as the sum of HP bypass flow plus HP bypass attemperating water flow. 2.11 2.11 Specification of air cylinder: Design pressure:

1.0 MPa

Design temperature:

100℃

Maximum Maximum working working pressure pressure:: 0.98 MPa MPa Working te temperature:

normal te temperature

Working medium

air

Test pressure: Volume:

:

1.25 MPa 1.0 m3


Chapter 1 Cold Start of the t he Unit 1.1 General rules of start-up 1.1.1 Division of the start-up state According to the inner wall temperature in lower half where HP inner cylinder governing stage is located, the start-up state of steam turbine is divided into:


pressu pressure, re, bearing bearing metal metal temper temperatu ature, re, bearin bearing g return return oil temper temperatur ature, e, thrust thrust bearing bearing pad temperature, pressure and temperature of initial steam and reheat steam, vacuum of condenser, pressure switch of control system, metal temperature of main cylinders and etc.). 9) Any safety protection or system fails or unit protection operating values are not in accordance with stipulation. 10) Any one of the following equipment has fault or the corresponding interlock protection test is unqualified: starting oil pump, AC (DC) lubricating oil pump, jacking oil pump, turning gear, EH oil pump. 11) The oil level of main oil tank and EH oil tank is lower than the limit value or the oil quality and clean cleanli line ness ss are are unqua unquali lifi fied ed.. Lubr Lubric icat atin ing g oil oil inle inlett temp temper eratu ature re is abnor abnorma mall and and retu return rn oil oil temperature is overhigh. 12) Water seeps through the turbine. 13) Quality of water and steam are not in accordance with requirements. 14) Heat preservation of the unit is imperfect. 15) Other auxiliary equipment or system fails in o peration.


through test; 14) Instrument and tools used in operation are to be prepared and checked; 1.2.2 Tests prior to turbine start-up (after overhaul and minor repair of unit) 1) Static test of turbine governing system; 2) ETS test of turbine; 3) Major interlock test of the unit; 4) Interlock test of starting oil pump, AC lubricating oil pump and DC lubricating oil pump of turbine, and interlock test of jacking oil pump and exhaust fan of main oil tank; 5) Interlock test of feed water pump; 6) Interlock test of circulating water pump; 7) Interlock test of vacuum pump; 8) Interlock test of condensate water pump; 9) Interlock test of EH oil pump; 10) Protection test of HP& LP heater and deaerator; 11) ON/OFF tests of all motor-operated valves, and pneumatical valves and hydraulic valves; 12) Interlock test of HP & LP bypass d evices;


test. Maintain the oil temperature inside the system within the range of 43~54℃ . 1.3.9 Put the jacking oil system into operation and put continuous turning of unit into operation after the jacking oil pressure of all bearings is normal through checking. The unit shall be put into continuous turning operation for at least more than 4 hours prior to the turbine start-up. 1.3.10 Put the inner cooling water system into operation and adjust the water inlet pressure of rotor and stator to be < 0.3Mpa. 1.3.11 Put the generator’s air cooling system into operation. 1.3.12 Start the vacuum pump to build up vacuum of condenser to 30kPa. 1.3.13 After warming up of shaft seal pipe by water drain is normal, start the shaft seal fan to put the shaft seal system of turbine into operation. The LP cylinder shaft seal steam temperature shall be within the range of 121~177℃ . Inform the boiler staff to ignite the boiler when the vacuum of condenser reaches 70kPa. 1.3.14 Ignite the boiler to increase temperature and pressure. 1.3.15 Put the bypass system (first the LP bypass and then HP bypass) into operation after warming up the piping. Put the bypass automatic control into operation. 1.3.16 Start the feed water pump according to the water level of steam drum. The water goes via


1.4.2 Check if the display of DEH panel is normal. 1.4.3 Condition and preparation for unit impulsing 1.4.3.1 Steam conditions of turbine cold impulsing: Initial steam pressure: 1.5~1.6Mpa; Initial steam temperature: 360℃; Reheat steam temperature: 300℃ (the temperature of the initial steam and reheat steam shall have the superheat degree of 50℃ at corresponding pressure); Temperature difference between initial steam side and reheat steam side <17℃ ; Vacuum: above 70 kPa; Oil temperature: about 35 ~ 42℃ . 1.4.3.2 Check the initial steam pressure and temperature on DCS and DEH that shall meet the requirement of turbine impulsing; 1.4.3.3 The turbine is in turning state, turning gear current is normal and continuous turning time is not less than 4 hours; 1.4.3.4 Water side of both HP and LP heater are into operation, HP and LP heater start along with the turbine prior to turbine impulsing.


1.4.4.1 Put the “Operator Auto” on “IN” in “Control Mode”. Click the button MODE on the upper left side of the “DEN OVERVIEW” picture, then the sub-picture “CONTROL MODE” will appear. Click the button “OA” and click button “IN” within 3 seconds to put in the Operator Auto Mode. 1.4.4.2 Reset the low pressure safety oil emergency governor on the head of turbine and check if the low pressure safety oil is normal; 1.4.4.3 Click “LATCH” button of hand-controlled panel on control panel “DEH MAN PANNEL” to reset the unit. After turbine reset, check the indicator of governor “TRIPPED” that shall change into “LATCHED” reset indicator. 1.4.4.4 Open the “Limit Value” picture to input valve limit value 120% and click button “GO”, check if the valve limit value is set normally and locally check if safety oil pressure is normal. Click the main stop valve opening button “TVOPN” on the control panel “DEH MAN PANNEL”, and locally check if HP & MP main stop valves are wide open and check if the HP & MP governing valves are closed after the picture displays that HP & MP main stop valve are wide open. 1.4.4.5 Set the target speed at 500rpm and speed up rate at 50rpm/min on the set value subpicture “CTRL SP”, press button “GO”, here the turbine starts to impulse and speed up, check the turbine speed that shall rise step by step.


Superheat degree of initial steam is ≥ 50℃. 1.4.4.9 Continue to set the target speed at 2,500 r/min and speed up rate at 40rpm/min. Jacking oil pump A and B shall stop automatically when the speed reaches 1,500r/min, otherwise stop them manually; 1.4.4.10 Time of turbine speed up and warming is distributed as follows: Time (min)

Rotating speed

Temperature of HP

Overall expansion

Vacuum of

stator lower carrier

of cylinder

condenser

(℃)

mm

Mpa (a)

r/min

Speed up

Stay

Hold 300~500

10

4

60

1

0.0347

From 500 to 2,500

50

4

130

3.5

0.0213

2

Above 150

5~6

/

Above 150

5~6

From 2,500 to 2,960 Up to 3,000 to incorporate into

10 10

network

Full vacuum Full vacuum

It requires about 90 min from impulsing to full speed. 1.4.4.11 Make speed up to 2,500 r/min by the operating procedure above-mentioned and warm up the turbine for 4 min:


1.4.4.16 Check the main oil pump locally if its outlet oil pressure of is 1.18Mpa, inlet oil pressure is 0.098~0.3Mpa and operation is normal. 1.4.4.17 Check if AC and DC lubricating oil pump interlock are on Auto position, after main oil pump operates normally through check, stop the starting oil pump and confirm the starting oil pump interlock is on Auto position. 1.4.4.18 Check if lubricating oil pressure, EH oil pressure and temperature are normal.

1.5 Unit incorporation into power network & initial load on 1.5.1 Generator synchronous paralleling Hold the speed of unit at 3000rpm and perform an overall check, if everything is normal, advise the electric personnel to parallel in the generator. After the electric test ends and the automatic synchronization conditions are fulfilled (with speed at 2950~3050rpm) and upon receiving the signal “ASPERM” from electric personnel, press the button “MODE” on the upper left of DEH control picture, then MODE sub-picture will appear, press the button and click button “IN” within 3 seconds to put “AUTOSYNCHRONIZATION” control mode into operation, the main picture will display enter the mode “AS” at the same time. 1.5.2 Checking after generator paralleling in and precautions in load on


1.6.1 After warming up with initial load ends, check if the turbine cylinder expansion is normal without jamming; 1.6.2 Put the governing stage pressure circuit into operation as the case may require in the process of load up; 1.6.3 Make the load up to 13.5MW (10% of rated load) by means of valve position at a load up rate of 0.6MW/min. 1.6.4 Check if the auto operation of bypass system is normal, bypass valves close gradually with rise of unit parameters. 1.6.5 When the load is up to 13.5MW (10% of rated load), steam pressure to 2.0~3.5 Mpa, initial steam temperature to 450℃, reheat steam temperature to 400℃ and the temperature of HP stator lower carrier to 390 ℃, check if the drain valve at upstream of MP combined valve closed automatically, if not, close it manually. 1.6.6 When the load reaches 27MW (20% of rated load), check if the water spray device closed automatically according to LP cylinder exhaust temperature, if not, close it manually. It may put the unit power control circuit into operation at this time. 1.6.7 When the load reaches 27MW (20% rated load):


according to the water level of LP heater, close water drain of LP heater to drain valve of condenser, and put the auto control of drain into operation when the water level is adjusted to be normal. 1.6.13 When the load reaches 121.5MW (90% of rated load), steam conditions shall be up to nominal parameters in which initial steam pressure is 13.73Mpa, initial and reheat steam temperature are 537℃: 1.6.13.1 From warming up with initial load to 90% of rated load, the time of steam conditions reaching the ratings shall be controlled at 120 min; 1.6.13.2 Put the “Initial Steam Pressure Control” into operation on the DEH panel as the case may require after initial steam pressure reaches the rating; 1.6.14 Change the control mode of valves from “Single Valve Control” to “Sequence Valve Control” after the unit load reaches over 50MW, and pay attention to the change in load in changeover. 1.6.15 Continue to make load up until 135MW, perform an overall check and report the check results to the unit supervisor.


which value shall be <0.076mm, turbine impulsing is not permitted as the rotor eccentricity reaches this value. 1.7.9 Vibration: when the speed reaches over 600r/min, monitor the bearing vibration. It can be regarded as qualified if bearing vibration ≯0.076mm. When the speed is lower than 1300r/min, it shall be regarded as qualified if pad vibration ≯0.03mm, it is necessary to trip to shut down the turbine in excess of 0.03mm. It is necessary to trip to shut down the turbine as the pad vibration exceeds 0.1mm over critical speed (or vibration increases suddenly with abnormal noise if not up to 0.05mm). 1.7.10 Differential expansion: Positive differential expansion of HP & MP cylinder must not exceed +8mm, and it is necessary to shut down the unit immediately if so; negative differential expansion of HP & MP cylinder must not be less than -3mm and it is necessary to shut down the turbine immediately if up to -3mm; in the process of speed up, closely monitor the differential expansion, hold the speed if discovering differential expansion alarm, and shut down the turbine as up to the shutdown value. 1.7.11 Absolute expansion of cylinder: In start-up, pay attention to monitoring the absolute expansion of cylinder and compare with the


unit speed up so as not to affect the rotating speed. After the unit paralleling in, check if the automatic control of bypass is normal and pay attention to that the tracking of attemperating water shall be normal; the adjustment of the opening extent of HP & LP bypass shall be based on the need of boiler to prevent too acute oscillation of MP governing valve as a result of too high steam pressure of boil side and too large opening of bypass, at the same time pay attention to the pressure difference before and after HP exhaust steam check valve to prevent it from being closed and causing chocking. 1.7.17 Strictly monitor the water level of HP & LP heater, deaerator and condenser in the process of start-up. 1.7.18 Temperature rise & decrease rate Name

Temperature rise rate

Temperature decrease rate

Temperature of initial steam

<2~2.5℃/min

<1.5℃/min

Temperature of reheat steam

<3~3.5℃/min

<2.5℃/min

Outer wall of initial and reheat steam pipe

8℃/min

Outer wall of steam valve

4~6℃/min

Flange wall of cylinder

2~2.5℃/min


Chapter 2 Warm & Hot Start of the Unit


down, so it is inappropriate to maintain the vacuum of condenser and initial steam pressure too high. 4) In the case where there is excess pressure in boiler, the extraction system must be put into operation to set up the vacuum of condenser prior to boiler ignition so as to prevent the exhaust rupture disk of LP cylinder from operating.

2.2 Boiler ignition 2.2.1 The start-up procedure of boiler follows that of Cold start and temperature & pressure rise follows the Hot Start Curve of turbine. 2.2.2 For hot start, pay attention to maintaining the parameters stable as up to impulsing parameters.

2.3 Impulsing speed up of turbine 2.3.1 Preparations prior to turbine impulsing 2.3.1.1 Keep continuous turning time more than 4 hours prior to impulsing with the shaft eccentricity of less than 0.076mm. 2.3.1.2 Feed water pump shall be in good standby condition.


Max

speed

in

speed up (r/min)

450 100

Must not be more than 500

2.3.3 Impulsing speed up of turbine: 2.3.3.1 Checking and tripping operation of DEH panel are the same with that of Cold Start; 2.3.3.2 Fix the impulsing time and speed up rate according to cylinder temperature; 2.3.3.3 Other operations and checking in the process of turbine speed up are the same with that of Cold Start. 2.3.3.4 Because HP automatic main stop valve, speed governing valve, MP combined valve and steam lead pipe, etc. parts can cool quickly after shutdown, pay attention to the temperature rise rate of them in start-up to prevent excessive heating and pay attention to the vibration of unit.

2.4 Unit paralleling in & load on 2.4.1 “Operator Auto” mode: 2.4.1.1 Make load up to the rated value according to the load variation rate looked up in the Hot Start Curve;


2.5.6 Make the unit have initial load according to cylinder temperature as soon as possible after paralleling in; 2.5.7 Reinforce water drain of the initial steam pipe and turbine proper in hot start to prevent cold water or steam from flowing into the cylinder in impulsing. 2.5.8 In hot start, prevent overhigh HP cylinder exhaust temperature to parallel in quickly as up to the rated speed. If necessary, open wider the low pressure bypass to lower the reheat steam pressure and control the HP cylinder exhaust temperature to be lower than 360℃ .



between two sides of initial steam and reheat steam HP

cylinder

exhaust

pressure HP

cylinder

exhaust

temperature LP

cylinder

exhaust

pressure LP

cylinder

exhaust

temperature

MPa

2.531

3.0

℃

312.1

321.6

kPa

8.83

20.3

℃

<65

120

Alarm at 80℃

％

shut down at

121℃

1.2 Pressure of each monitored section: (MCR) Unit: Mpa (a)

Governing stage 10.34

Extraction

Extraction

Extraction

Extraction

Extraction

Extraction

Extraction

steam

steam

steam

steam

steam

steam

steam

No.1

No.2

No.3

No.4

No.5

No.6

No.7

3.5516

2.4566

0.7301

0.4509

0.2515

0.067

0.0143


Note: motor vibration of all auxiliary equipment It is qualified if bearing pad vibration is < 0.085mm for rotating speed at below 1,500r/min; It is qualified if bearing pad vibration is < 0.05mm for rotating speed at below 3,000r/min.

1.6 Operating parameters of deaerator Name

Unit

Item

Operating

Operating result

value

Normal value

2,550

High value I

2,750

High value II

2,850

Alarm Interlock open the motor-operated overflow valve of deaerator Interlock close the steam extraction No.3

Water level of deaerator

motor-operated

mm High value III

2,950

interlocking,

valve

interlock

and

check

valve

close

the

motor-

operated overflow valve of the deaerator when the water level decreases to below 2,750mm;

Pressure of deaerator

MPa

Low value I

2,350

Alarm

Low value II

680

Feed water pump trip

Normal

0.68

Operate at sliding pressure

Low pressure

0.3

Alarm for low pressure


Name

Unit

Normal

Max

Mini

Remarks

journal bearing #4-5 Metal temperature of thrust bearing Oil level of main oil tank Inlet oil pressure of jacking oil pump oil pressure of jacking oil header

℃

<85

mm

1808

Alarm at 99℃, shut down at 107℃ 2,616

1,245

MPa MPa

Shut down at 1,245 mm Refuse to start at below 0.039MPa Block start turning gear at below

10~12

4.2MPa Overflow valve operates at 16.2

EH oil pressure

MPa

Mpa;

13.7~14.5

Start standby pump at 11.03 Mpa; Shut down at 9.31 Mpa.

Oil level of EH oil tank

mm

438.15~558.8

EH oil temperature

℃

35~45

438.15

558.8

Low value II: 295.15mm Low value III: 193.54mm Start electric heater at below 23℃


Name

Unit

Journal

Normal

Max

Min

Remarks

bearing

temperature of feed water ℃

Alarm at 80℃, stop pump at 90℃

pump motor Journal temperature

bearing of

booster ℃

70

90


70

90


75

95


pump Journal

bearing

temperature of feed water ℃ pump Thrust bearing temperature of feed water pump High inlet flow of feed water pump Low inlet

flow of feed

water pump Temperature

of

℃ t/h

Recirculation is ON at > 280 t/h

t/h

Recirculation is OFF at < 132 t/h

rotor

winding of feed water pump

℃

130


95

Al

motor Temperature of all bearings

℃

90

t 90℃ trip pump at 95℃


1.10 Quality requirement for various types of water Hardness

Dissolved oxygen

Conductivity

(μmol/l)

(μg/l)

(μs/cm)

Name

SiO2 (μg/l)

PH value

Condensate

Approach 0

≤40

≤0.3

≤20

Feed water

Approach 0

≤7

≤0.3

≤20

8.8~9.3

≤50

≤450

9.0~10

Boiler water

1.11 Steam quality Conductivity Item

Iron ppb

Copper ppb

Sio2 μg/l

Sodium μg/l ms/cm

Permitted value

≤20

≤5

≤20

≤10

≤0.3


compared with the energy balance demand and calculated to be taken as the demand of main controller of boiler. When the load changes, the turbine makes control demand first to take advantage of the boiler’s thermal storage capacity to adapt to the need of load. Here the initial pressure decreases gradually; when the deviation between initial steam pressure and specified value is higher than the dead-band of module, the output and unit power demand are summed up and sent to the turbine side to limit the initial steam pressure to change further. At the same time, the combustion rate on boiler side changes quickly to make the initial steam pressure return to the range of specified value. This control mode is commonly used by general unit plant that takes advantage of thermal storage capacity of boiler and ensures the stability of steam pressure. Cooperative control system requires both boiler main controller and turbine main controller are on Auto position, otherwise it is unavailable.

2.3 Boiler following In this mode, the main controller of boiler is on Auto position, the initial steam pressure governing circuit is in operation, the main controller of turbine is on Manual position, the unit’s power control


The TF mode takes no advantage of the thermal storage of boiler, so the output power is only able to respond to the change in actual load demand by means of change in combustion of boiler making evaporating capacity, thermal storage capacity and steam pressure change, which has a much longer delay and poor adaptability of unit to change in load, so it is unfavorable to carrying variable load and participating in frequency modulation of power network and is generally used in the case where main auxiliary equipment of boiler fail.

2.5 Operating mode of unit protection & interlock All protections and interlocks must be put into operation as long as the equipment starts. They can only be stopped by order given by the shift engineer after strict procedures of examination and approval. After the auxiliary equipment become normal after start-up, the standby equipment’s interlocking switch shall be put into operation in time to ensure good standby function. After power equipment trips, it must first check if the electrical protection operated and then confirm thermodynamic protection. The tripped equipment must not be put into operation until trip cause is found out, clear written report by maintenance personnel and approval by shift engineer


Chapter 3 Regular Works and Requirements 3.1 In order to ensure normal operation of the unit, the operator on duty shall check and maintain all systems and equipment regularly. 3.2 When the unit is operating normally, record the operation log table every hour. The records shall be punctual, accurate and written legibly, compare and analyze the running state from time to time, and find out the cause and give treatment in time if discovering any abnormity. 3.3 The operator on duty is required to check the subordinate equipment regularly. 3.4 Test and regular switching of equipment shall obtain approval from the unit supervisor and be performed by the supervisor and operator duly who shall fulfill each work required by the test under unified leadership of the shift engineer. 3.5 Record the regular work; record detailedly the cause for the equipment that can not be tested and switched, and report to the shift engineer and shift leader; Contact for treatment if any problem in test, stop the test if necessary and continue test until the problem is solved. 3.6 The switched equipment must be restored to standby. 3.7 Release the interlocking of the equipment with automatic interlock in regular works that shall put into operation as standby state restores.


Att. List of Equipment Regular Works No. 1 2 3 4 5

Work contents Test

of

emergency

&

Check of the oil level gauge of oil tank Moving test of HP & MP main stop valve Moving test of extraction check valves Water drain of main oil tank and feed water pump oil tank Vacuum leak test

7

Switching of vacuum pump

9

sound

thermodynamic signal

6

8

Time requirement Per shift

Switching of industrial water pump

Supervisor

Vice operator

Operator

on duty

on duty

Daytime shift per

Vice operator

day

on duty

Daytime shift on

Operator on

Unit

Monday

duty

supervisor

Daytime shift on

Operator on

Unit

Monday

duty

supervisor

Daytime shift on

Routine

Thursday

inspector

Daytime shift on the

Operator on

Unit

5th per month

duty

supervisor


Vice operator

Operator

10th per month

on duty

on duty

Vice operator

Operator

10th of per month

on duty

on duty


Routine

Operator

10th per month

inspector

on duty

Switching of LP heater drain water Daytime shift on the pump

Operator



1.1 Preparations prior to unit shutdown 1.1.1 After receiving shutdown command from the unit supervisor, contact all posts to make preparations for shutdown; 1.1.2 Do starting test of AC and DC lubricating oil pump, jacking oil pump and starting oil pump of turbine and they are normal through test, and do starting test of the steam turbine turning gear motor and it is normal through test; 1.1.3 Switch the auxiliary steam supply to be supplied by neighboring turbine (or supplied by starting boiler); 1.1.4 Check the unit thoroughly and count detects of equipment.

1.2 Normal shutdown 1.2.1 Confirm DEH is in “Operator Auto” mode; confirm ”lower limit of initial steam pressure” is released. 1.2.2 Open the sub-picture of set value control on the main control picture of DEH to set the target load at 110MW, and set the load down rate at 1.25MW//min by turning down the governing valve in the condition of holding steam temperature and pressure, then press the button “GO” to make the unit load start to decrease. At the same time, the main operator shall decrease the


“GO” button, the unit load continues to decrease. 1.2.7 When the differential pressure between HP heater #2 steam side and deaerator is < 0.3MPa, stop the HP heater steam side from high to low; close the drain motor-operated valve of deaerator, change HP heater water drain to the condenser; close HP heater #1 and #2 to the deaerator air valve and close the air inlet value of HP; open the drain valves before and after extraction check valve of No. 1 and 2. 1.2.8 When No. 3 extraction pressure decreases to 0.25MPa, check if the auxiliary steam header’s steam supply valve is opened, close the No. 3 extraction to deaerator air inlet valve; make the deaerator run at constant pressure of 0.192Mpa. 1.2.9 Set the target load at 54MW, load down rate at 2.33MW/min and the unit load continues to decrease; when the load decreases to 54MW, the initial steam temperature decrease to 472℃ , reheat temperature to 450℃ and HP stator lower carrier metal temperature to 410℃ . 1.2.10 When the load decreases to 45~60MW, stop the LP heater drain pump and open LP heater #6 l to multistage water-seal inlet and outlet valve; change LP heater #6 drain water to condenser 1.2.11 Set the target load at 5.4MW, load down rate at 4.42MW/ min, and the unit load continues


to decrease to zero. 1.2.20 Start AC lubricating oil pump, advise electrical personnel that the generator can be paralleled off, at this time the steam turbine and boiler shall interlock trip (press the button “OFF” to trip them in special case). Check HP & MP main stop valve, governing valve, extraction check valve and exhaust check valves of HP cylinder A & B that shall close all; unit speed decreases. 1.2.20 Works to done during unit idle time 1.2.20.1 Check the condition of unit idling, listen to its internal sound and record the idle time; 1.2.20.2 When the rotating speed is 2,500r/min, close the air valve of condenser; when the rotating speed is 1,500r/min, check if the jacking oil pump opened automatically, if not, open it manually; 1.2.20.3 When the rotating speed is 300~400r/min, open the vacuum breaker valve to decrease vacuum degree, control the rotating speed to “0” and vacuum to “0”; stop the shaft seal motor, stop the shaft seal steam supply and close isolating valve; stop the vacuum pump. 1.2.20.4 When the unit comes to rest, put the continuous turning into operation and record the shaft bending and turning gear current. 1.2.21 Operation after shutdown


& MP cylinder, when the differential expansion reaches -1mm, stop load down, if such negative value continues to increase, take measures to reduce the load quickly to zero for shutdown. 1.2.22.3 When the vibration at unit idling increases, reduce the vacuum degree to make the unit speed lower quickly. 1.2.22.4 After the unit shuts down and before the boiler, deaerator and auxiliary steam header release pressure completely, closely monitor the metal temperature of steam turbine to prevent steam & water from escaping into the steam water. 1.2.22.5 If discover exhaust cylinder temperature increases after shutdown, find out the cause and cut off steam source, or else start the condensate pump and put the LP cylinder spray into operation to reduce the exhaust cylinder temperature. After shutdown, pay attention to monitoring the water level of condenser and deaerator to prevent overfeed of water.

1.3 Sliding pressure shutdown 1.3.1 After receiving “Sliding pressure Shutdown” command from shift engineer, make preparations for shutdown and get done with division of work and conduct referring to normal shutdown. 1.3.2 Decrease the load to 100MW according to normal shutdown requirement, and then take


1.3.5.1 The main controller operator on duty shall reduce the pressure and temperature at the rate of 0.04~0.049MPa/min and 1.5℃ /min for initial steam and 2.5℃/min for reheat steam; pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.2 Reduce the initial steam temperature to 500℃ and pressure to 10.79MPa slowly, open wide the speed governing valve gradually and reduce the load to 100MW and keep stable operation for 20 minutes. 1.3.5.3 Reduce the initial steam pressure and temperature at the rate of 0.03~0.04MPa/min and 1.5℃/min, unit load continues to decrease and pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.4 When the load decreases to 40MW, keep stable operation for 40 minutes. 1.3.5.5 When the initial steam flow is ≤ 30%, put HP & LP bypass and three-stage attemperating water into operation, continue to reduce the initial steam pressure and temperature at the rate of 0.03~0.04Mpa/min and 1.5℃/min, unit load continues to decrease and pay attention to controlling the load down rate at 0.4MW/min. 1.3.5.6 When the load decreases to 10MW, initial steam pressure to 1.6~2.0MPa and initial steam temperature to 370℃~380℃, the sliding pressure shutdown is over and prepare to shut


of running parts after unit trips. 1.3.6.4 Closely monitor the unit vibration and metal temperature in the process of sliding pressure shutdown, and it is strictly prohibited t o release the axial-displacement protection. 1.3.6.5 Pay attention to the water level of deaerator and condenser, vacuum of condenser and exhaust temperature that shall be normal. 1.3.6.6 After shutdown, cut off all steam and water sources inside the cylinder to prevent cold steam and water from entering. 1.3.6.7 Pay attention to that the initial steam pressure shall not rise in the process of load down so as to ensure the superheat degree of initial steam not lower than 50℃ minimally, and the initial steam temperature shall decrease steadily to prevent much fluctuation. 1.3.6.8 The governing stage temperature must not be 20℃ lower than the lower cylinder temperature; When the temperature difference between upper and lower cylinder is higher than 35℃, control the initial steam temperature more than 50℃ higher than the governing stage temperature. As negative differential expansion increases, contact the boiler operator to stabilize parameters, adjust the pressure of shaft seal and temperature to normal and pay attention to steam puffing up at the shaft seal. 1.3.6.9 Stop sliding parameter and reduce the load to zero quickly to trip to shut down the unit in


deaerator water level and HP & LP heater water level to prevent valves of steam, extraction and drain system from untightness and resulting in cold steam and water entering the turbine; 1.4.6 In turning, pay attention to monitoring lubricating oil inlet temperature of all bearings that shall be higher than 21℃, as well as indications of metal temperature of all bearings, turning gear current and turbine cylinder temperature that shall be normal and record them once every hour; 1.4.7 Keep the turning gear and oil circulating system running for not less than 48 hours after normal shutdown; 1.4.8 After turbine shutdown, it is prohibited to fill the condenser and heater to test leak when the cylinder temperature is higher than 200℃, If it must be conducted, work out reliable preventive measures against sharp cooling of cylinder resulting in shaft bending that shall be approved by the shift engineer; 1.4.9 After bypass system is stopped, check to make sure attemperating water valve is closed tightly; 1.4.10 If there is clear friction sound inside the cylinder during turning, stop turning, but change to 15 minutes interval and turn the rotor by180°, and forced turning is not permitted; 1.4.11 When the first stage metal temperature of HP cylinder is higher than 150℃ , the turning can only be stopped with approval of unit supervisor, get done with marking clearly, record the


within 21~35℃ during which; 1.4.15 If the rotor bending is not very serious, it can be rotated to become straight by 1~2 hours turning.


1. Treating Rules of Accidents 1.1 In case of accident, the unit supervisor shall lead all staff of the unit to treat the accident according to the rules quickly under direct leadership of shift engineer. If the company of unit supervisor is harmful to person and equipment directly, the operator on duty shall explain the reason and refuse to execute it. 1.2 If case of fault, the operator shall eliminate the danger to person and equipment and find out the cause for the fault and remove it, at the same time shall keep non-faulted equipment operating normally. 1.3 If case of fault, the operator shall ensure normal operation of the auxiliary power system. 1.4 Once concluding that the equipment has fault according to the instrument indication, CRT display, and alarming of alarm window, faulted copier and appearance of unit, the operator shall: Eliminate the danger to person and equipment and parallel off the faulted equipment immediately if necessary;


supervisor. 1.10 The operator shall not leave the post in the process of treatment of fault and accident, If the fault occurs during work shift, it postpone the time of shift, the staff to hand over shall go on working and eliminate the accident with assistance by the staff to take over until the unit recovers normal operation or receiving the order a bout shift from the unit supervisor. 1.11 People irrelevant to the accident shall not stay at the spot. 1.12 After treatment of fault and accident, the staff on duty shall report the time, phenomenon, reason, development and the treatment process to the shift engineer and keep detailed records, and the meeting it after work shift shall analyze the fault. 1.13 First make every effort to eliminate the danger to personal and equipment safety in case of accident. 1.14 Strive to keep normal running of non-faulted equipment. 1.15 Prevent wrong judgment or treatment caused by bad contact, uncertain condition and inaccurate report.

2. Condition of Steam Turbine Tripping


3.2 In the case where the initial and reheat steam temperature on turbine side increases to above 545℃ and cannot recover after running for 30 minutes; where the temperature continues to rise to 555℃ and cannot recover within more than 15 minutes; or where the temperature exceeds 565℃; 3.3 The initial steam pressure increases to above 14.71Mpa; 3.4 The back pressure of conderser reaches 20.3KPa or circulating water interrupts; 3.5 The steam turbine rejects load to 0 to run for more than 15 minutes; 3.6 The change in frequency is lower than 46HZ; 3.7 The initial and reheat steam and feed water pipe or valve breaks to endanger the equipment safety; 3.8 The MFT operates, but the major interlock of turbine-boiler refuses to operate; 3.9 The main stop valve, governing valve and MP combined valve are jammed and cannot recover; 3.10 LP cylinder exhaust temperature reaches 121℃ ; 3.11 The steam turbine motor operates for more than 1 minute; 3.12 When an important monitoring meter displays inaccurately or fails, it must stop running in


decreases to the limit value; 4.12 The oil pump pipe broke and cannot be isolated, which resulting serious leak of oil to endanger the safety of equipment; 4.13 The rotating speed of steam turbine increases to 3,300r/min, but the emergency governor refuses to operate; 4.14 The HP & MP differential expansion reaches +8 or -3mm and LP differential expansion reaches +7.5mm; 4.15 The axial displacement reaches ±1.2mm, and at the same time the temperature of thrust bearing increases sharply.

5. Procedure of Emergency Shutdown with Vacuum Broken 5.1 Press the “emergency shutdowm” button or push the emergency governor handle locally with hand to check if the HP & MP main stop valve, speed governing valve, extraction check valve and HP exhaust check valve are closed tightly immediately and the rotating speed shall decrease; 5.2 It is prohibited to open the HP & LP bypass; 5.3 Release the starting oil pump interlocking and start the lubricating oil pump;


hand to check if the if the HP & MP main stop valve, speed governing valve, extraction check valve and HP exhaust check valve are closed and if the rotating speed of unit decreases; 6.3 Release the starting oil pump interlocking and start the lubricating oil pump; 6.4 If boiler MFT operates, treat it according to MFT operation emergency shutdown; 6.5 Adjust the steam supply pressure of deaerator and shaft seal, and switch to the standby steam source in time; 6.6 Check thoroughly, listen to the sound of unit and record the idle time; 6.7 Other operations as per normal shutdown procedure.

7. Decreasing of Vacuum 7.1 Phenomenon 7.1.1 The condenser vacuum indication decreases, local vacuum gauge, DEH or DCS displays vacuum decreasing; 7.1.2 The exhaust temperature of steam turbine rises; 7.1.3 “Conderser Vacuum Low “sound & light alarms. 7.2 Cause


for fault to result in decreasing of condenser vacuum, it shall close the outlet valve of faulted pump quickly; b. Check the outlet valve of circulating water pump, and ope n it in time if it is closed by mistake; c. Check if the circulating water pressure is normal, if it is low, check if the circulating water system leaks or is blocked; d. Check the differential pressure between the circulating water outlet and inlet of condenser is normal, if it is high, then clean a half of condenser; e. Check if the disc valve of condenser inlet & outlet is closed by mistake; if so, open it immediately; 7.3.5 Check the shaft seal system: a. If the shaft seal header pressure is low, then check if the shaft seal steam source and overflow valve are normal to adjust the shaft seal header pressure to normal; b. If the steam pressure of LP shaft seal is low, then turn down the shaft seal attemperator spray isolating valve and adjust the LP shaft seal steam temperature at 149℃; c. If the shaft seal heater pressure is high, then start the standby shaft seal heater blower to check if the multi-stage water seal of shaft seal heater is broken and water level is normal.


8.1.4 The initial steam and reheat steam pipe or the extraction pipe vibrate, shaft seal has water hammer sound, and there is white steam belching from the main stop valve and speed governing valve lever, as well as the flange of extraction pipe; 8.1.5 Temperature of initial and reheat steam decreases sharply; 8.1.6 Temperature of LP shaft seal header decreases sharply. 8.2 Cause 8.2.1 The boiler drum is overfed with water; 8.2.2 The steam drum pressure drops sharply, which result in the carry-over; 8.2.3 Adjustment of the boiler steam temperature is inappropriate; 8.2.4 When the unit is started, the drainage of turbine proper, shaft seal system and all relevant steam pipes are not smooth; 8.2.5 The heater leaks or drainage is not smooth and deaerator is overfed water; 8.2.6 The unit load changes abruptly; 8.2.7 Boiler water is unqualified or carry-over (priming); 8.2.8 The attemperating water valve of bypass system is not closed tightly; 8.2.9 When the superheat degree of initial steam and reheat steam is low, the speed governing


bearing temperature reach the tripping value, idle time shortens obviously, or there is any abnormal sound inside the turbine, it shall shut down to check.

9. Increasing of Axial Displacement 9.1 Phenomenon 9.1.1 It gives an alarm when the axial displacement is larger than ±1mm; 9.1.2 Thrust pad temperature increases sharply, and the return oil temperature increases; 9.1.3 Vibration of the unit increases; 9.1.4 The differential expansion indication changes correspondingly. 9.2 Cause 9.2.1 The initial steam conditions decrease, and the through-flow part is overloaded; 9.2.2 The unit rejects load abruptly; 9.2.3 Water hammer occurs to the steam turbine; 9.2.4 Vacuum decreases greatly 9.2.5 The thrust pad is worn and oil interrupts; 9.2.6 The steam quality is unqualified and the stator blade scaled seriously.


10.1 Phenomenon 10.1.1 The fire monitor control raises the alarm; 10.1.2 Flare or smoke is discovered locally; 10.1.3 When the turbine oil pipe leaks, the oil level of main oil tank decreases; 10.1.4 When the lubricating oil system leaks, lubricating oil pressure decreases, signal “Lubricating Oil Pressure Low” may be raised and AC & DC lubricating oil pump may interlock start. 10.2 Cause 10.2.1 Oil system leaks; 10.2.2 Oil leaks to high temperature hot body or faulted electrical equipment; 10.2.3 Oil pipe is broken due to external causes and oil leaks to the hot body. 10.3 Treatment: 10.3.1 If any abnormal change in the oil level of main oil tank and all oil pressure, it shall find out the cause, if due to oil leak of oil system, it shall ascertain the leaking point and try to isolate it from surrounding hot body pat and operating equipment to prevent the oil system from catching fire, meanwhile, contact the maintenance personnel to treat the leaking point temporarily;


become abnormal. 11.1.1 Phenomenon a. Initial steam and reheat steam pressure gauge change; b. DEH and DCS display the initial steam and reheat steam pressure alarm; c. When the unit operating in coordinated control mode, its load changes correspondingly. 11.1.2 Cause a. Fault in control system; b. Unit’s load changes abruptly. 11.1.3 Treatment a. If it is the fault in control system that caused abnormality of initial and reheat steam pressure, it shall adjust the charge of fuel to restore the initial and reheat steam pressure; b. If it is the too quick change of unit’s load that caused abnormality of initial and reheat steam pressure, it shall try to stabilize the load and change it after the initial and reheat steam pressure recovering; c. If the initial and reheat steam pressure are high, it may increase the unit’s load to make the pressure recover;


f. In soot blowing of boiler; g. Coal quality changes. 11.2.3 Treatment a. If Auto mode of the initial steam and reheat steam attemperator fails, it shall adjust manually to keep initial steam temperature not exceed 545℃; b. Check the water level of steam drum and adjust the water level to normal; c. If the boiler combustion rate is high, which caused initial and reheat steam temperature becoming high, it shall reduce the load at the same time of reducing coal; d. In the case where initial and reheat steam temperature exceed 545 ℃ and cannot recover after running for more than 30 minutes; where the temperature continues to rise to 555℃ and cannot recover within more than 15 minutes; or where the temperature exceeds 565℃ , treat according to fault shutdown; e. Temperature difference between the left and right of initial steam and reheat steam temperature shall be less than 17℃; f. When the initial steam and reheat steam temperature change in operation, it shall pay attention to the unit’s vibration, sound, differential expansion and axial displacement, as well


valve, shaft seal and junction plane of cylinder, if any water hammer, it shall shut down the turbine for emergency. Closely monitor the change in metal temperature and differential expansion; 11.3.4 Pay attention to the change in shaft seal pressure and water level of condenser and all heaters, switch over the steam source of deaerator in time; 11.3.5 When the initial steam temperature and pressure decrease at same time, although not to the shutdown temperature, the initial steam temperature is over 50℃ lower than the first stage metal temperature, it shall report to the unit supervisor and request for fault shutdown.

12. DEH Failure 12.1 Phenomenon 12.1.1 “DEH Power Failure” light and sound alarm is raised; 12.1.2 DEH displays “Main Power Supply Failure” and “Standby Power Supply Failure”; 12.1.3 DEH displays “DEH failure” and the indicator lamp lights; 12.1.4 The indicator lamp of “Operator Auto” on DEH operating pan el goes out; 12.1.5 The indicator lamp of “Manual” on DEH operating panel lights; 12.1.6 DEH displays “Speed Failure”. 12.2 Cause


13.1.5 Auxiliary oil pump operates abnormally; 13.1.6 Too low oil level of the oil tank; 13.1.7 Oil system catches fire. 13.2 Fault in the main oil pump 13.2.1 Phenomenon a. Outlet oil pressure decreases; b. Sound in the unit’s head is abnormal; c. When the case becomes serious, the starting oil pump starts to operate automatically and the alarm window raises an alarm. 13.2.2 Treatment a. The starting oil pump shall start to operate automatically when the oil pressure decreases to 0.883MPa, otherwise start it immediately and check if the inlet oil pressure of main oil pump and stage I oil injector are normal; b. Listen to the sound of main oil pump carefully, closely observe the change in system oil pressure and report to the unit supervisor; c. Ascertain the fault in main oil pump and treat according to emergency shutdown with vacuum broken.


f. Switch the lubricating oil strainer, and operate and check if the stage Ⅱ oil injector is blocked. g. If the overpressure valve operates by mistake, contact the maintenance personnel to treat; h. If the lubricating oil pressure still decreases to 0.06MPa, the DC lubricating oil pump should start to operate automatically, otherwise start it manually; i. The lubricating oil pressure still decreases to 0.06MPa even if various measures, it shall break the vacuum for emergency shutdown. 13.4 The oil pressure does not change, while oil level decreases: 13.4.1 Cause: a. Oil leak in the return oil pipe of the oil cooler, oil system or oil catch of bearing; b. Emergency oil drain valve, oil drain valve of oil tank, sampling valve or water discharging valve etc. leak or opened by mistake; c. Oil gauge malfunctioned; d. If the oil pump packing set leaks oil seriously. 13.4.2 Treatment: a. Check if the indication of the oil level gauge of oil tank is right; b. Check if the emergency oil drain valve and sampling valve etc. leak or opened by mistake;


e. Ascertain the cause of water flowing into oil system th en eliminate it. 13.6 Oil pressure and level decrease at the same time. 13.6.1 If the oil supply system leaks seriously, it shall report to the unit supervisor to try to stop the leak and take measures against fire, change the direction of oil leakage to keep it off the hot body if necessary, meanwhile advise the maintenance personnel to make up oil of oil tank and eliminate the defect; 13.6.2 Check if the oil and water discharge valves are on closed position; 13.6.3 Check leak of the oil cooler, if any, it shall switch to the standby oil cooler in time; 13.6.4 If the bearing oil inlet pressure decreases to below 0.06Mpa or oil level decreases to 1,245mm due to a great deal of oil leak, it shall start the lubricating oil pump immediately to break the vacuum for emergency shutdown. 13.7 The return oil temperature of bearing rises 13.7.1 Cause a. The outlet oil temperature of the oil cooler rises; b. The lubricating oil pressure decreases or the oil inlet pipe of bearing is blocked; c. The bearing pas is damaged and inlet hole is blocked;


13.8.1 In the process of unit start, it shall treat the fault in the starting oil pump as follows: a. When the rotating speed of steam turbine reaches below 2500rpm, start the lubricating oil pump immediately, trip to shut down the turbine, and it can only restart the turbine after removing the fault in the starting oil pump; b. When the rotating speed of steam turbine reaches above 2500rpm, it shall start the AC lubricating oil pump at once, if the main oil pump is able to maintain normal oil pressure, increase the speed up to 3,000rpm quickly, stop and service the starting oil pump, it can only restart after removing the fault in the starting oil pump. 13.8.2 Treatment of fault in the auxiliary oil pump in the process of unit shutdown: a. If it is the AC lubricating oil pump that gets fault, start the starting oil pump or DC lubricating oil pump immediately to make shutdown contin ue; b. If all three oil pumps get fault: it shall start the jacking oil pump immediately to break the vacuum for emergency shutdown.

14. Abnormal Vibration of the Unit 14.1 Phenomenon 14.1.1 The vibration indication on DEH panel increases;


14.2.12 The generator rotor is not heated equally. 14.2.13 The running components in the front bearing case fall off. 14.2.14 Center of the turbine-generator is abnormal, or the rotor bending is relatively large and exceeds the specified value as starting. 14.2.15 Condenser vacuum is low; 14.2.16 The generator exciter caused the vibration; 14.2.17 Anchor bolts of all bearing bushes of the turbine-generator unit become loose; 14.2.18 Oil contains foreign matters that wear the bearing bush tungsten-base alloy or water mix in oil and oil is emulsified. 14.3 Treatment 14.3.1 The unit vibrates sharply suddenly, or metal sound inside the unit can be heard clearly, it shall break the vacuum for emergency shutd own quickly. quickly. 14.3.2 Abnormal vibration occurs during operation: a. When discovering the bearing vibration increases gradually, if the rotor vibration exceeds 0.08mm or bearing vibration exceeds 0.03mm, it shall report to the unit supervisor to try to elim elimin inat ate e the vibr vibrat atio ion, n, if the the roto rotorr vibr vibrat atio ion n excee exceeds ds 0.25 0.254m 4mm, m, it shal shalll shut shut down down


b. It shall cease the start-up when there is friction at end shaft seal or through-flow parts, report to the unit supervisor and relative leaders, it can only restart the unit after finding out the cause; c. In the process of shutdown, if friction sound inside the end shaft seal or cylinder can be heard clearly, it shall break the vacuum for emergency shutdown; d. In the case of shutdown due to abnormal vibration, it shall pay attention to the idle time and listen to the inner sound of the unit carefully and increase the time of continuous turning.

15. Generator parallels off, while turbine does not trip 15.1 Phenomenon 15.1.1 15.1.1 Load Load reache reaches s 0, genera generator tor parall parallels els off, off, all extrac extractio tion n check check valves valves close close and make make signals; 15.1.2 The electric overspeed OPC protection operates, after closing, HP & MP speed governing valves open to no load position, and the speed decreases to about 3,000r/min; 15.1.3 Running sound of the turbine changes suddenly and the speed rises.


start the lubricating oil pump; 16.2.2 Pay attention to adjusting the water level of condenser and HP & LP heater, put the LP cylinder spray into operation; 16.2.3 Maintain the water level of deaerator and switch into standby steam source of deaerator; 16.2.4 Check the unit completely and switch the steam supply of shaft seal to the standby; 16.2.5 Record the idle time when the speed decreases to zero, and stop the steam supply of shaft seal when the vacuum decreases to zero and put the turning gear into operation in time; 16.2.6 After shutdown, check the unit thoroughly, find out the causes of speed governing system operating abnormally and generator paralleling off, it can only restart the unit after eliminate the causes and unit being normal through test.

17. Turbine trips, while the generator does not parallel off 17.1 Phenomenon 17.1.1 17.1.1 Some Some protect protection ion operate operates s and makes makes signal signals, s, power power reache reaches s zero zero or displa displayed yed in negative; 17.1.2 HP & MP Main stop valve, speed governing valve, extraction check valve and HP exhaust check valves closed;


automatic governing; 18.1.4 Partial protections and interlocks of the unit can not operate. 18.2 Treatment 18.2.1 Immediately contact heat en gineer to recover the power supply, check and monitor primary meters locally, and switch the automatic into manual governing; 18.2.2 Report to the unit supervisor and keep the unit load stably as much as possible; 18.2.3 Avoid adjusting as much as possible, monitor the operation of equipment according to the indication of local meters and ammeter of each auxiliary equipment, etc., and make necessary adjustment locally; 18.2.4 When the system or equipment becomes abnormal, and the unit loses operating and monitoring means, which affect the safety of main equipment, report to the unit lead and conduct fault shutdown; 18.2.5 If the heat control power supply can not recover within 30 minutes, make fault shutdown. 18.2.6 If the heat control power supply of turbine and boiler fail at the same time, it shall conduct fault shutdown.


temperature alarm; 19.3.4 If the shaft seal pressure is high and the steam leak of shaft seal is serious, it shall check the steam source governing valve of shaft seal and adjust the shaft seal pressure to normal; 19.3.5 When the temperature of journal bearing #1-3 of turbine reaches 112℃ , the temperature of journal bearing #4-5 of generator reaches 80℃ and the temperature of thrust bearing reaches 107℃, the steam turbine should trip automatically; if bearing return oil reaches 80℃, it shall treat according to emergency shutdown for fault; 19.3.6 Pay attention to adjusting the unit load and vacuum of condenser.

20. Burning out of Turbine-generator Bearing Bush 20.1 Phenomenon: 20.1.1 The bearing metal temperature rises abruptly; 20.1.2 The bearing return oil temperature rises abruptly; 20.1.3 The unit vibration increases; 20.1.4 Bearing smokes. 20.2 Cause


20.3.4 If any bearing oil interrupts, smokes or metal temperature and return oil temperature of bearing reach the limit, it shall break the vacuum to trip and shut down the unit immediately.

21. Steam Turbine Shaft Bending 21.1 Phenomenon: 21.1.1 Steam turbine has abnormal vibration and bearing box swags; 21.1.2 The steam seal of shaft end sparkles or form a fire ring; 21.1.3 Idle time of the bearing shortens obviously after shutdown; 21.1.4 The turning gear can not be put into operation or the turning gear current is larger than normal value and oscillates periodically after shutdown; 21.1.5 The shaft eccentricity is large after shutdown; 21.2 Cause 21.2.1 The eccentricity of rotor exceeds the specified range before start; 21.2.2 High temperature difference between upper and lower cylinder; 21.2.3 Inlet steam temperature is low; 21.3.4 Cold water and steam enter the cylinder;


21.3.5 If it is the fault in turning gear that caused shutdown, after shutdown, it shall monitor the change in rotor bending, when the bending is high, it shall operate the turning gear by 180º and put the continuous turning into operation after the turning becomes normal in time; 21.3.6 After shutdown, continuous turning time must not be less than 4 hours, only after the temperature difference between upper and lower cylinder, turning gear current, and rotor eccentricity meeting the starting conditions, can restart the unit after reporting to the unit supervisor, closely monitor the rotor vibration and eccentricity etc. parameters in start, if any abnormality, trip and shut down the unit immediately.

22. Steam turbine Overspeed 22.1 Phenomenon: 22.1.1 The unit rejects the load to zero suddenly and sends out abnormal sound; 22.1.2 Rotating speed and frequency indication of the unit exceed the stipulated value and keep on rising;


22.3.2 When the unit speed rises up to 3,300r/min, check that the mechanical and electromagnetic overspeed protection shall operate. Otherwise it shall trip and shut down the unit manually, verify that the HP & MP main stop valve and all extraction check valve shall be closed, cut off all possible steam access to turbine and immediately open the vacuum breaker valve for emergency shutdown; 22.3.3 If the overspeed is caused by HP & MP main stop valve being jammed, it shall immediately start the overheater or reheater atmospheric exhaust valve, and etc. to reduce the pressure; 22.3.4 Eliminate the cause of overspeed after the turbine is shut down for overspeed, and it can be restarted after it is qualified through calibration, it shall intensify overall check of the unit in restart, if any abnormality, it shall find out and eliminate the cause immediately.

23. Feed water pump set outlet check valve is untight and rotates reversely 23.1 Phenomenon: 23.1.1 Feed water pump reverses; 23.1.2 The pressure of the outlet header pipe decreases and the current of the parallel running


24. Turbine-generator unit operates at abnormal frequency 24.1 Phenomenon: 24.1.1 Indication of frequency meter decreases or rises. 24.1.2 Sudden change of the unit’s sound. 24.1.3 DEH shows that the indication of steam turbine speed decreases or rises. 24.1.4 Indication of power meter decreases or rises. 24.2 Cause: Fault in the electric power network system. 24.3 Treatment 24.3.1 If frequency decreases and unit load increases, it shall stabilize the unit load at the rating as soon as possible that is not permitted to exceed max limit to load. Pay attention to that the pressure of all monitored sections and initial steam flow shall not exceed the maximum value, otherwise reduce the load manually; 24.3.2 Check if the initial steam conditions, vacuum, axial displacement, thrust bearing temperature & vibration and lubricating oil pressure are normal. 24.3.3 Pay attention to the operation of each auxiliary equipment and check if any operating equipment is overloaded to heat.


upper, middle and lower layer raised an alarm; 25.1.4 Steam’s pressure and temperature decrease sharply, the water level of steam drum first decreases and then rises; 25.1.5 Boiler fire extinguishing, MFT operates, steam turbine trips, generator-transformer unit parallels off the system; 25.2 Cause 25.2.1 Conditions of the MFT operation are met; 25.2.2 Auxiliary power interrupts; 25.2.3 Boiler load is too low, operation and adjustment are improper, disproportion between air and pulverized coal, primary air speed is too high or proportioning of primary and secondary air is improper; 25.2.4 Jet burner operates with seriously unfilled corner, coal feeder gets fault, pulverized coal chute is blocked, level of pulverized coal is too low, which make combustion unstable that is not adjusted and treated in time; 25.2.5 Water-cold wall pipe, economizer, superheater and reheater burst seriously; 25.2.6 Boiler has serious fouling and coke residue fall off by a large area;


pressure and temperature down rate not exceed the permitted value and fulfill the operations or checks as specified in section 25.3.2~25.3.4. 25.3.6 In the process of treatment, closely monitor we various differential expansion, axial displacement, temperature, vibration and sound, etc. of thrust bearing pad.

26. Treatment of Accidents & Abnormity of the Motor 26.1 Conditions of motor emergency shutdown (shut down first and then start the standby) a)

When there is a fatal accident requiring emergency shutdown of motor (including

electric shock and the mechanical injury). b) The machine driven by the motor is damaged or motor fan dropped out. c) The motor and its subsidiary electrical equipment smoke or catch fire. d) The rotating speed of motor slows down sharply and the current rises or reaches 0 (including the abnormal voltage and mechanical failure). e) The temperature of motor or bearing rises sharply to exceed the permitted value and keeps on rising. f) Much vibration above the rated value occurs or shock occurs inside and friction exists in between the stator and rotor. g) In th

of fl

d

Wat

cident

fi

cident et

that

da

fe


unit ), when there is no standby one or the standby one cannot be started quickly, in order to keep the unit keep on operating, once forced closing of the tripped motor is permitted. But the following cases are not included: a. In case of fatal accident that requires immediate shutdown. b. The equipment driven by the motor is broken. c. The motor with protection operating to trip (for feed water pump & water circulating pump) 26.3.3 Treatment of motor tripping a. Start the standby power. b. If there is no standby power, it shall assign person to check, if no problem, restart it, if it trips again, then prohibit starting and advise the maintaining personnel to treat. 26.3.4 Treatment of motor starting with sound but without rotating or abnormal rotating speed a. Cut off the power supply of motor immediately and check it according to the cases above; if the fuse has blown, replace with a new one, if the voltage is too low, there is the means to adjust the voltage. b. Advise the maintenance personnel to treat. 26.3.5 Treatment of motor rotor with current oscillating periodically in operation a. Start the standby motor unit and stop the equipment with fault b. It shall intensify monitoring of the equipment with fault if there is no standby one, and it


d. If the equipment drive is jammed and caused overload. 26.3.9 Check and treatment of motor with bearing temperature rising in operation a. Check if the oil ring can rotate, if oil carriage is normal, if oil pipeline is blocked or oil interrupted. b. If oil quantity is sufficient, pressure and temperature are normal. c. If the rolling bearing is overfed with or lacks oil. d. If the cooling water of bearing is normal. e. If there is abnormal sound or worn parts of the bearing. 26.3.10 Precautions for treatment of abnormal operation & accident of motor a. When auxiliary power disappears, do not switch off the motor within 1 minute (except that with low voltage trip). b. In the case of tripping for low voltage protection operating, it is strictly prohibited to start the motor forcedly. forcedly.


PART 6 Auxiliary Equipment & Common Service System


Chapter 1 General Operation Rules of Auxiliary Equipment 1.1 Precautions for auxiliary equipment start-up 1.1.1 The auxiliary equipment after servicing must go through various interlocking and protection tests and be qualified through test prior to trial run, and must be qualified through trial run prior to operation. 1.1.2 Auxiliary equipment can only be powered on after the conditions are met through check locally. 1.1.3 Before starting the 6,600V and principal 6,600V equipment, it shall assign special person to check locally and starting conditions shall be met. The staff on duty shall stand by the emergency button and stop it in time once discovering any problem. 1.1.4 After the outlet valve of the centrifugal pump is closed, can it be started (except the standby pump) after the scoop tube opening is placed on “0”, forbidden to start with load; 1.1.5 After the motor is closed, it shall monitor tightly the returning time of current, forbidden to start other equipment until the current returns; 1.1.6 Immediately reset the switch if trips after closing, and do not start any more until finding out


there is no regulation from the manufactory. Permitted Temperature Rise of Different Insulation Grades Insulation A

E

B

F

Max

Max p

Max

Max

Grade

Permitted

Permitted

Permitted

Permitted

Permitted

Permitted

Permitte

Permitted

temp.

temp. rise

temp.

temp. rise

temp.

temp. rise

d temp.

temp. rise

95℃

55℃

105℃

65℃

110℃

70℃

125℃

85℃

100℃

60℃

115℃

75℃

140℃

80℃

140℃

100℃

100℃

60℃

110℃

70℃

140℃

80℃

130℃

90℃

80℃

40℃

80℃

40℃

80℃

40℃

80℃

40℃

100℃

60℃

100℃

60℃

100℃

60℃

100℃

60℃

Stator and rotor winding Stator core Sliding ring Sliding bearing Rolling


it is subordinate.

1.4 Ceasing of rotating equipment 1.4.1 If there is reversal after the equipment stops, separate it immediately, find out and eliminate the cause. 1.4.2 It shall be in standby state after the equipment stops, it shall keep the cooling water smooth, if considering saving water, it can turn down the cooling water valve, but keep a record. 1.4.3 The rotating equipment is divided into “Run”, “Standby” and “Service”, three states. Any person must not break the standby into service without approval.

1.5 Conditions of emergency shutdown of rotating equipment: 1.5.1 In the case where the motor or driven equipment has such accident that emergency shutdown can avoid personal injury. 1.5.2 The driven equipment by motor is damaged seriously and can not keep on running; 1.5.3 In case of fire accident that endangers the equipment and personal safety; 1.5.4 IN case of serious leak of water and oil; 1.5.5 Bearing oil interrupts, smokes or temperature exceeds the specified value;


Chapter 2 Industrial Water System 2.1 General Industrial water pump house holds 3 industrial water pumps, 1 is vacuum pump and 2 water filtering pumps. In normal condition, 1 or 2 industrial water pumps operate and others for standby; for number of operating sets may be determined according to variation of season and water consumption in the precondition of guaranteeing header pressure. There are interlocking devices in between #1~3 industrial water pumps, if operating pump trips, the standby pump will start automatically. One industrial pump house contains 2 blowdown pumps, which can realize automatic start-up and shutdown in case foul water level is high.

2.2 Equipment specification Equipment specification

Industrial water pump

Model Water specification

pump

SX400-650

Flow

m3/h

2,066

Head

m

50

Speed

r/min

980


2.4 Start-up and operation 2.4.1 As receiving command or it is necessary to start pump, release the interlocking switch of this pump, close operating switch and open outlet valve after water pump being normal in operation. 2.4.2 Switch the interlocking switch of standby water pump on “Interlock” position; 2.4.3 Attention shall be paid to checking water level variation in clarified water pond to prevent water shortage and overflow. 2.4.4 Shutdown the water chamber vacuum pump after industrial water pump is normal in operation through checking.

2.3 Shutdown of water pump 2.3.1 As receiving pump shutdown command or it is necessary to shutdown water pump, open the console switch, then water pump stops, check pump that shall not inverse, otherwise close the outlet valve for treatment; 2.3.2 Put the water pump into “standby” state; 2.3.3 Check water level in clarified water pond;


Chapter 3 Oil Purification System of Steam Turbine 3.1 Introduction of equipment The GJZ-6 coalescing & isolating oil purification system can remove free water and solid pollutant in steam turbine oil with high efficiency, and also can give bypass or on-line purification to oil independently according to requirement. It comprises circulating filtering system, coalescing system, isolating system, water discharge system, oil discharge system and safety protection system, etc., and the main operating principle is: the steam turbine oil is pumped into circulating filter that has a 6 micron filter element, which can meet the requirement of oil cleanliness in common condition. When it is necessary to separate water content, steam turbine oil will flows into the coalescing filter element in coalescing and isolating vessel via protective filter, because the unique effect of polar molecule in coalescing filter element material, free water and emulsified water in oil will form larger water drop after flowing through filter element, and will settle to the vessel bottom with gravity action, and globule of small size will enter the isolating filter element together with steam turbine oil under effect of inertia, since this element is made of special


3.3.3 Close inlet valve and outlet valve of oil purification device; 3.3.4 Turn the power switch to OFF position.

3.4 Safety protection 3.4.1 Motor overload protection: in case of motor short circuit or overload, auto air switch will break to stop the device, meanwhile the entire six alarm indicator lamps will flash from left to right, and top alarm lamp will flash. 3.4.2 Power source open-phase and fault-phase protection: in case of incorrect phase sequence or open-phase in three-phase power, the six red alarm indicator lamps and yellow alarm lamp will flash synchronously. 3.4.3 Monitoring and negative protection of inlet vacuum degree: in equipment operation, if pressure of inlet piping is lower than set value (-0.8 Bar), inlet vacuum switch will operate to stop equipment, and then outlet pressure alarm lamp (LP01) and top alarm lamp (LP10) will flash synchronously. 3.4.4 Differential pressure alarm of protection filter: in operation, if differential of protection filter is up to 2.4Bar, protection filter differential pressure switch (PS02) will operate, and differential


3.4.8 Low water level control and alarm: After opening water discharge valve, water level will decrease promptly, as decreasing to the set water level, water discharge valve will close, water level will no longer decrease thereupon. In case water level keeps on decreasing to the set ultra low level, equipment will shut down, meanwhile low level alarm lamp (LP07) will flash. 3.4.9 Alarm of water discharge time being over long: if water level is lower than the high water level as a result of water discharge valve opening, and if the discharge time is over long that exceeds 5min, the water discharge valve can not close, equipment will shut down, and meanwhile alarm lamps of low water level and high water level will flash synchronously.

3.5 Daily operation and maintenance of oil purification device 3.5.1 Daily operation and maintenance of oil purification device: a. Perform alarm indicator lamp test in the day shift of every Monday, press the alarm lamp test button, then all the alarm buttons will light, thus it can c heck if the alarm lamp works normally; b. After fault is removed every time, alarm reset button shall be pressed down for tripping alarm state, and then equipment can be re-started; c. Pay attention to the checking of main oil tank oil level to prevent oil leak as a result of water


recirculating filter can be used to discharge oil in filter element. 3.6 Abnormal operation of oil purification device and its treatment 3.6.1 Frequent fault of oil purification device mainly includes the following: a. Auto water discharge valve operates disorderly resulting in oil spills from discharge outlet or no water discharging. b. Oil water interface instrument is out of order; c. Blocking occurs in inlet filter element, circulating filter, and coalescing and isolating filter element; d. Oil pump operates abnormally, and has abnormal sound or vibration. 3.6.2 The above fault shall be treated after stopping oil purification device.


Chapter 4 Lubricating Oil System of Steam Turbine 4.1 Inspection prior to lubricating system start-up. 4.1.1 Check if the position of lubricating system valves is correct; 4.1.2 Affirm the emergency oil release valve of main oil tank is closed. 4.1.3 Affirm the oil release valve of main oil tank is closed. 4.1.4 Oil level of main oil tank is normal and oil quality is qu alified; 4.1.5 Oil temperature of main oil tank shall be kept higher than 25ºC prior to unit start-up and 38~42ºC in steam turbine normal operation. Electric heater can be put into operation when oil temperature is low and stopped when oil temperature is up to 40ºC. 4.1.6 Make sure inlet and outlet valves of oil cooler are closed; 4.1.7 Make sure inlet baffle of smoke exhaust fan is closed; 4.1.8 All the motors are in good insulation; 4.1.9 No leak phenomenon in oil piping; 4.1.10 All oil pumps are on “Manual” position; 4.1.11 Pressure of gas tank is normal.


metallic friction sound inside steam turbine. And stop one jacking oil pump. 4.2.10 Measure the eccentricity of shaft that shall be < 0.076mm and less than the original value by 0.03mm.

4.3 Stop of lubricating system 4.3.1 Stop the steam turbine turning gear, and rotor will stop rotating thereupon; 4.3.2 Trip auto, and stop operation of jacking oil pump; 4.3.3 Trip the “auto” mode of DC lubricating oil pump; 4.3.4 Stop the AC lubricating oil pump; 4.3.5 Trip the “auto” position of standby smoke exhaust fan of main oil tank, and stop the smoke exhaust fan. 4.3.6 Put electric heater of main oil tank on “stop” position.

4.4 Put-in and shutdown of oil cooler 4.4.1 Precautions for oil cooler put-in and shutdown: 4.4.1.1 Prior to operation, it shall check if oil system operates normally, and oil temperature and


prevent fullness of oil cooler water side from being little, and deposit corrosion from accelerating.

4.4.3 Oil cooler shutdown 4.4.3.1 Check if the oil outlet valve of oil cooler has been closed; 4.4.3.2 Close cooling water outlet valve of oil cooler; 4.4.3.3 If servicing is necessary, the oil inlet valve and water inlet valve of oil cooler shall be closed, and maintenance personnel shall be contacted to discharge the accumulated oil & water in this oil cooler thoroughly; 4.4.3.4 Standby mode of standby oil cooler For standby oil cooler, oil inlet valve & water inlet valve shall be opened and oil outlet valve and outlet valve shall be closed to guarantee oil cooler in oil-filled and water-filled state for standby and prevent water side from scaling, and oil side from water or air ent ering.

4.5 Inspection and maintenance in lubricating oil system operation 4.5.1 Check if operation of all the oil pumps and smoke exhaust fans are normal, and vibration and motor current within specified range.


4.5.11 Remarks 4.5.11.1 When unit starts and stop, the main oil pump operating at above 2,700r/min ( 90% rated Rev) can meet all the oil demand of speed governing and lubrication; 4.5.11.2 The capacity of single oil cooler is 100%, and only one set is enough in normal operation; 4.5.11.3 The brand of lubricating oil is 32# steam turbine oil with cleanness up to grade NAS7.


Chapter 5 Circulating Water System 5.1 Check & put-in before circulating water system start-up 5.1.1 Make sure the interlock protection of circulating water system is qualified through test and has been put into operation; 5.1.2 Make sure the circulating water pump is qualified in insulation and has been powered on, the circulating water inlet & outlet motor-operated disc valves on side A and B of condenser and outlet disc valve of circulating water pump have been powered on, and the outlet disc valve of circulating water pump is on “Auto” position; 5.1.3 Check if the position of the circulating water system valves is right: a. Put the bearing cooling water of circulating water pump into operation; b. Close all the water-discharging valves of circulating water system; c. Make sure that the water level of the cooling water tower and suction bay at inlet of circulating water pump is normal; e. Fill the pump with water; f. Open the circulating water outlet and inlet valves on side A of condenser and the inlet valves on


5.1.8 Open slowly the strainer inlet valve of circulating water to the generator air cooler manually, fill the cooling water pipeline of turbine oil cooler slowly with water, and thereafter put it into operation.

5.2 Normal shutdown of circulating water system 5.2.1 When the exhaust temperature of LP cylinder is lower than 50℃ and circulating water has no user, it can contact the relative staff to stop the running of the circulating water pump; 5.2.2 Check if the circulating pump and outlet disc valve are on the “auto” position, assign special staff to monitor locally before pump shutdown; 5.2.3 Contact the local staff to close the outlet disc valve of circulating water pump, when closing to the extent of 75%, it shall interlock stop the circulating pump and check that the pump should not reverse.

5.3 Normal switching of circulating water pump 5.3.1 Circulating water system is normal, standby pump is good and has the starting conditions as checked in an all round way; 5.3.2 Make sure the outlet disc valve of standby pump closed;


5.4.1.4 Close slowly the air valve of condenser on stopped side and circulating water inlet motoroperated disc valve, pay attention to that the back pressure of condenser shall not be lower than 16.9Kpa, start another vacuum pump if necessary to intensify monitoring of the vibration, differential expansion and axial displacement; 5.4.1.5 Close the circulating water inlet and outlet motor-operateddisc valve of condenser on the stopped side, open the circulating water discharge valve on the stopped side, pay attention to the change in vacuum. If there is serious leakage in the condenser’s pipe, here pay attention to vacuum decreasing, it shall close the circulating water discharge valve immediately, report to the unit supervisor to restore the original running mode immediately and make decisions after reporting; 5.4.1.6 After circulating water on the stopped side drain away, the vacuum shall keep within the permitted range, power off the motor-operated inlet disc valve of condenser on the stopped side, motor-operated outlet disc valve and rubber ball pump motor, then it may permit the maintenance personnel to open the manhole to work; 5.4.1.7 In the whole process of cleaning and leak stoppage, it shall monitor strictly the change in the condenser vacuum and exhaust temperature, if any abnormality and vacuum decreases


5.5 Washing of condenser rubber ball 5.5.1 Hand-operated put-in: 5.5.1.1 Before putting the rubber-ball system into operation, the operator shall contact with the personnel of Centralized Control Room to make good preparation for operation; 5.5.1.2 Check that there is no need of maintenance and the equipment is in good condition, the meters are all presented and the spot is clean; 5.5.1.3 Turn the rubber ball pump shaft to run flexibly and without jamming. Confirm the motor insulation is good and power on; 5.5.1.4 Check that the inlet valve of rubber-ball pump on the washing side has closed and the water discharge valve of Loaded Ball Room has opened, and the outlet valve has closed too, and the switch valve of Loaded Ball Room has been turned to the position of collecting the balls; 5.5.1.5 Open the top cover of Loaded Ball Room, and close it and water discharge valve after putting into adequate rubber-ball (500 pieces); 5.5.1.6 Open the inlet valve of rubber-ball pump slightly and fill Loaded Ball Room with water. When there is water overflowing, close the air valve and open the inlet valve of rubber-ball pump


the hand- operated process; 5.5.3.2 Check that the rubber ball washing equipment is in the state of “program control”, press the button “Program/ON” to check if all motor-operated valves and rubber-ball pumps operating normally; 5.5.3.3 The washing is to end 30 minutes later and the system automatically starts to fetch the balls ball fetching is to end after another 20 minutes with all motor-operated valves closed and rubber ball pump shut down.

5.6 Inspection & maintenance in operation 5.6.1 Reinforce the inspection and maintenance of circulating water system in operation, pay attention to the variation of steam condenser vacuum. 5.6.2 Control the circulating water inlet temperature not to exceed the specified value; 5.6.3 Check if the valves of circulating water system are sound without leak, and water outlet temperature difference between steam condenser two sides are not more than 2ºC; 5.6.4 Monitor the water outlet differential pressure between two sides of condenser is normal; 5.6.5 Monitor and check if the open & close positions of steam condenser inlet & outlet motor-


5.7.2.1 Once circulating water interruption is ascertained, unit load shall be decreased to zero immediately, inlet & outlet disc valves of steam condenser or outlet valve of circulating water pump shall be checked for mis-close, if any, it shall be opened at once. The auxiliary water pump shall be started for recovering water supply as soon as possible, if fails, shutdown shall be performed promptly; 5.7.2.2 After shutdown for fault, if water supply for steam condenser can not be recovered temporarily, condensate pump recirculation valve shall be opened in time. 5.7.2.3 In case of circulating water interruption, the interconnection valve between industrial water and circulating water shall be opened in time, and attention shall be paid to the metal temperature of all the auxiliary equipment, outlet temperature of oil cooler and air cooler that must not exceed the specified value; 5.7.2.4 In case of circulating water interruption, pay attention to if the steam condenser rupture disk operates, if any, perform shutdown immediately.


Chapter 6 Shaft Seal & Vacuum System of Steam Turbine 6.1 Specification of shaft seal system 6.1.1 Steam seal of the steam turbine is divided into HP steam seal, MP seal and LP seal. The high & MP external steam seals and LP rear steam seal are equipped with steam seal casing and steam seal ring, the latter is mounted in the former and pressed hard with spring leaf, the steam seal casing is made up of two-half, the horizontal split is fixed with bolt and located with taper pin, the bottom of lower half is located with flat key, and the shaft direction position is adjusted with adjustable gasket. Steam seal rings of both HP and medium are stepped labyrinth structure, and LP steam seal ring is plain structure. Steam seals of high and MP cylinder diaphragms are the flush type, and are riveted into diaphragm with fillet. The steam seal ring of LP diaphragm steam seal is mounted in septalium, and is pressed tightly with spring leaf. 6.1.2 The steam seal system is self-sealing system, in steam turbine start-up and with low load, seal steam is supplied by auxiliary steam header; in high load condition, steam exhausted by high and MP cylinders will escape into the steam seal casing, and will be discharged from steam supply chamber to supply to LP steam seal, and excess seal steam will escape into steam


6.2.2.1 Open the motor-operated valve of overflow valve and auxiliary steam inlet governing valve; 6.2.2.2 Regulate the pressure of seal steam supply header to that of governing valve setting point; 6.2.2.3 Start a shaft seal heater blower, and the other for standby, regulate the water level of shaft seal heater; 6.2.2.4 Close drain valves of steam seal return steam pipes of HP & MP cylinder, and close the drain pipe of steam seal return steam header. 6.2.2.5 Regulate pressure of steam seal header to 0.02~0.03MPa, LP steam seal temperature to 121ºC~176ºC, and difference between rotor metal temperature of high & MP steam turbine shaft seal and steam pressure of shaft seal to ≯111ºC; 6.2.2.6 Check if the continuous drain operation of steam seal header between steam attemperating section and LP steam seal is normal. 6.2.2.7 Close drain valve on steam seal piping after steam supply of steam seal being normal; 6.2.2.8 Precaution:

① In cold start-up, it shall pump vacuum first, and then supply steam to steam seal;


6.4 Shutdown of shaft seal and vacuum system 6.4.1 As steam turbine rotor idle runs to 2,500r/min, trip interlocking switch of standby vacuum pump to stop vacuum pump operation; 6.4.2 As vacuum degree of steam condenser decreases to 0, stop shaft seal steam supplying and shaft seal heater blower; 6.4.3 Close steam inlet governing valve of steam seal and the motor-operated valve on both sides of overflow control valve.

6.5 Shaft seal system operation of steam turbine in abnormal cases 6.5.1 In case of load reduction, transfer the steam seal to auxiliary steam header for steam supplying, in transferring, drain away the drainage in pipe, and pay attention to regulating steam supplying temperature of steam seal to match with the metal surface temperature of HP & LP rotor with the temperature difference ≯111ºC. 6.5.2 In case of steam turbine shutdown, seal steam shall be supplied by neighboring unit and the temperature shall be guaranteed for matching so as to avoid mismatching between HP steam temperature and cylinder end wall metal temperature as a result of prompt transfer of steam seal


Chapter 7 Condensate System 7.1 Inspection prior to start-up 7.1.1 Check if the maintenance of condensate system is completed, the site is clean, and equipment is sound; 7.1.2 Check if the positions of all the valves in condensate system are correct; 7.1.3 Contact thermodynamic personnel to power on all the meters, motor-operated valve and protections, check if pointers are all complete and indicating correctly; 7.1.4 Condenser has circulating water supplied to the water side; 7.1.5 Check if the water level of steam condenser is normal. Check if the water make-up system of condenser is normal; 7.1.6 Check if the oil level of condenser pump bearing is normal, and oil quality is qualified; the bearing cooling water and packing sealing water are smooth; the rotor is flexible and unjammed in turning;


interlocking switch of auxiliary condensate pump first. Start the standby pump first in switching condensate pumps. 7.3.2 Adjust the condensate recirculation valve to maintain the pressure of condensate water within the normal range. 7.3.3 Close the outlet motor-operated valve of condensate pump, pay attention to the variation of condensate header pressure and the water level of steam condenser and deaerator. 7.3.4 Shut down the condensate pump. 7.3.5 When the condensate pump acts as standby after shutdown, put it on the “auto” position and open the outlet motor-operated valve. Check the motor-operated outlet valve and pay attention to the pressure change of the condensed water main pump and water level of the Condenser and deaerator;

7.4 Put-in and stop of LP heater 7.4.1 Startup of LP Heater along with the turbine 7.4.1.1 Before the turbine impulsing, LP Heater has been supplied with condensate, close the water discharge valves of all LP Heaters that use emergency drain mode. Open the extraction valve of LP heater #4, 5, 6 & 7, creation of vacuum of LP heater is in good condition, position of


temperature at a rate of 2℃/min that shall not exceed 3℃ /min maximally; 7.4.2.7 Close the drain valves before and after corresponding extraction check valve; 7.4.2.8 Gradually open the steam inlet valve of LP Heater in operation according to the temperature rise of LP heater in operation; 7.4.2.9 The drain water of LP Heater # 4 & 5 shall be dumped into the LP Heater #6, and it shall start the drain pump according to the water level of #6m and check the automatic control equipment in normal operation and adjusting water level normally.

7.4.3 Paralleling off of LP Heater 7.4.3.1 Close the steam inlet and the corresponding check valve of the LP heater paralleled off; 7.4.3.2 In paralleling off the LP Heater, it shall dump the drain water from last stage LP heat er into condenser, close the drain governing valve and hand-operated valve of this stage LP heater to the next stage LP heater; in paralleling off the LP heater #6, it shall dump the drain water of LP heater into the condenser and stop the LP heater drain pump; 7.4.3.3 Close the extraction valve of paralleled-off LP Heater and open the water discharge valve on the steam side; 7.4.3.4 Open the condensate bypass valve of paralleled-off LP Heater and close the water outlet


7.5.2.4 When the pump shuts down for servicing, close all cooling system valves, sealing water valves, air extraction valves and the pump outlet & inlet valves.

7.6 Check & maintenance in normal operation 7.6.1 Condenser: 7.6.1.1 Monitor the temperature rise of circulating water; 7.6.1.2 Monitor the differential pressure between inlet and outlet of circulating water; 7.6.1.3 Exhaust temperature of the condenser is not more than 80℃ ; 7.6.1.4 The temperature difference between both sides of condenser is not more than 2℃ ; 7.6.1.5 Vacuum is normal; 7.6.1.6 The water level of condensate sump is normal.

7.6.2 Condensate pump 7.6.2.1 Sound is normal and there are no friction and vibration; 7.6.2.2 Check the outlet pressure of the condensate pump that shall be normal; 7.6.2.3 Check the leakage of condensate packing set that shall be normal;


7.7.1.4 Bearing has smoke belching; 7.7.1.5 Leak occurs in condensate pump that endangers personal and equipment safety. 7.7.2 Vaporization or air leak occurs to condensate pump 7.7.2.1 Phenomenon: a. Outlet pressure of condensate pump fluctuates, the flow is unsteady or decreases to zero; b. Motor current decreases or fluctuates; c. Abnormal sound in pump body, vibration in outlet header and the check valve makes impact sound; d. Dissolved oxygen in condensate rises. 7.7.2.2 Causes: a. Steam condenser water level is low; b. Air leak in condensate pump inlet pipe; c. Air leak in condensate pump packing, the sealing water valve is not opened or opened too little; d. Inlet strainer of condensate pump is blocked; e. Condensate flow is too low, and the recirculation valve is not opened. 7.7.2.3 Treatment a. Check if the water level of steam condenser hot well is normal, if lower, make up water to


f. Auto control device of steam condenser water level operates disorderly; g. Recirculating valve of steam condenser is not closed tightly; h. Overflow valve or water discharge valve of deaerator is untight or mis-opened. 7.7.3.3 Treatment of low steam condenser water level a. Check if make-up water control valve of steam condenser operates normally, otherwise open its make-up water bypass to make up to normal; b. Check if water level control valve of deaerator is mis-opened large or jammed, if any, adjust to normal in time. c. Check if water discharge valve of LP heater #4 outlet is mis-opened, if any, close it in time; d. Check if any leak in condensate system. 7.7.3.4 Treatment of high steam condenser water level a. In case condensate pump gets fault in operation, it shall start the standby pump, stop faulted pump, and contact maintenance personnel for treatment. b. Check if make-up water control valve of steam condenser operates normally, if inlet water flow is too large, if such, turn it down. c. In case of leak in steam condenser brass pipe, check if the steam condenser half side leaks, if serious, shut it down for treatment.


shall be opened; d. When the water level of LP Heater is III, the protection operates, it shall close the extraction check valve and steam inlet valve of LP Heater, parallel off and isolate the LP Heater; e. When discovering the copper pipeline leaks, it shall be isolate and service it in time.

Chapter 8 Feed Water & Deaerating System 8.1 Starting conditions of the Feed Water & Deaerating System 8.1.1 If any case as follows, it is prohibited to start the feed water pump: 8.1.1.1 The main instruments meters (ammeter, speed counter, oil pressure gauge, Inlet & outlet pressure gauge) lack or are damaged; 8.1.1.2 The outlet check valve of feed water pump is not closed tightly; 8.1.1.3 The protection test is unqualified; 8.1.1.4 The scoop tube is jammed or regulation failed; 8.1.1.5 The oil level of oil tank decrease to the limit value or oil quality is unqualified and oil temperature is lower than 15℃; 8.1.1.6 The sealing water can not be put into operation normally; 8.1.1.7 The insulation of motor is unqualified;


gauges and protections are powered on and indicates correctly; 8.2.1.4 To confirm the water level and the higher-and-lower pressure signal can alarm well. The motor-operated valves and governing valves switch can open and close flexibly and Open-Close operating direction is correct; 8.2.1.5 8.2.1.5 Contact Contact the chemist chemist to prepar prepare e enough enough demater dematerial ialize ized d water water pump pump and start start the demineralized water pump, make up the makeup-water tank of condensate to the high level and test the water quality that is qualified; 8.2.1.6 Supply steam to the auxiliary steam header, prior to which, it shall warm up and drain water of the auxiliary steam header; 8.2.1.7 Ask the chemist to test the water level quality when the water level of the Deaerator reaches 600mm. If the water is n ot qualified, discharge water until it becomes qualified. The water overflow value shall be placed on the “AUTO” position; 8.2.1.8 When the water is qualified and the water level rises to 1,600mm, open the deaerating valve of Deaerator properly; 8.2.1.9 Open the hand-operated valve of heating & steam inlet valve at the bottom of deaerator slowly and put the bottom heating of deaerator into operation. Pay attention to controlling the


8.2.2.4 The oil level of the oil tank is on the upper-limit the oil quality is qualified, when the auxiliary oil pump operating, the oil tank temperature of hydraulic coupling is ≥ 15°C, oil pressure within 0.17~025Mpa or so and 018Mpa minimally; 8.2.2.5 Drain out the gas in the oil and water pipeline of cooler and feed oil to circulate. When the filter’s differential pressure is > 0.06Mpa, switch it to the cleaning side. The lubricating oil shall keep on circulating until the strainer of filter is clean; 8.2.2.6 Check if the water level of the deaerator is normal, the temperature is > 50°C, the feed water pump has a temperature difference between its upper and bottom pump body is lower than 20°C; 8.2.2.7 The sealing water system works normally and loop is smooth; Check if the pressure after the sealing water governing valve is the ring is 0.05~0.1Mpa higher than the unloading water pressure; 8.2.2.8 Check if all transmission contacts of hydraulic coupling speed governing mechanism are firm transmitting reliably, and the handle is flexible, after it is normal through hand operation, set the scoop tube at 0 position; 8.2.2.9 Power on the feed water pump motor after it is qualified through insulation test and it is


8.3 Start-up of feed water pump set 8.3.1 All equipment of t feed water pump set and valves of pipe are checked and verified as normal; 8.3.2 Confirm the inlet valve of booster booster pump is fully opened and the water discharge valve has been closed; 8.3.3 Verify the feed water pump motor-operated outlet valve and the center tap valve is closed, the recirculation valve of feed water pump is opened; 8.3.4 Verify the scoop tube of the hydraulic coupling is in the maximum position; 8.3.5 Verify when the auxiliary oil pump is working, the lubricating oil pressure is more than 017Mpa; 8.3.6 Click the “Start” button of feed water pump and record the constant speed’s time; if no-load current is normal, then start the feed water outlet electric value; 8.3.7 After feed water pump starting, check the sound and vibration, etc. of the feed water pump and booster pump that are normal; 8.3.8 When the lubricating oil header pressure is > 0.22MPa, the auxiliary oil pump shall stop automatically;


8.3.14.2 When the auxiliary oil pump is operating, the lubricating oil pressure is >0.17Mpa; 8.3.14.3 Open the booster pump inlet valve, feed water pump outlet valve and the recirculation valve; 8.3.14.4 The temperature difference between the pump body and feed water pump inlet is < 20°C; 8.3.14.5 The differential pressure of the sealing water of feed water pump is > 0.1Mpa; 8.3.14.6 The interlocking switch of feed water pump in on AUTO position, and the scoop tube’s opening is on 60% position.

8.4 Start-up of HP heater along with the turbine 8.4.1 Prior to the unit start, the check of HP heater shall be done according to the preparation done prior to operation, all steam inlet and water inlet valves are closed, steam & water discharge valves are closed and protective water source of HP heater is put into operation; 8.4.2 After the feed water pump start, and the feed water pressure is more than 6MPa, check and verify the emergency drain motor-operated valve of HP heater is on AUTO position, open the water filler valve

％1

and

％2

on the water side of HP heater, open the air release valve on the


8.5.1 Put the HP protective water source into operation; 8.5.2 Verify the inlet and outlet four-way value of HP heater are closed, feed water runs along the bypass, the water filler valve is closed tightly and open the steam discharge valve on the water side of HP heater; 8.5.3 Open the primary and secondary oil filler valve of HP heater to fill HP heater with water, after there is water overflowing the air valve, close the air release valve on the water side of HP heater, after the internal pressure of HP heater becomes equal to the feed water pressure, check the HP heater four-way valve that shall open automatically, close the water filler valve, check that there is no water level on the steam side of HP heater and verify no leak in HP heater; 8.5.5 Open the drain valves before and after the steam extraction section 1 and 2 check valve to warm up the pipe; 8.5.6 Open the water discharge valve at the bottom of HP heater ％1 & 2 HP heater, as well as the air release valve on the top; 8.5.7 Open the check valves of steam extraction section 1 and 2; 8.5.8 Open the air inlet motor-operated valves of HP heater

％1

& 2, maintain the HP heater

pressure within 0.05~0.1Mpa for warming, after there is steam coming from the air valve of HP


that the feed water temperature decreasing rate must not be more than 1.83℃ /min; 8.6.3 When the differential pressure between the steam side of HP heater and deaerator is less than 0.3MPa, switch the drain to the condenser, close the

％2

HP heater drain and lead it to the

hand-operated valve of deaerator; close the continuous exhaust valve of HP heater; 8.6.4 Close the air inlet motor-operated valve of HP heater ％1, close the extraction 1 check valve fully, close the air inlet motor-operated valve of HP heater #2 and the extraction 2 check valve. When closing the all, verify the inlet valve is closed tightly, then stop the water side of HP heater, close the inlet & outlet four-way valve of HP heater with the feed water running along the bypass. Check if the feed water pressure is normal; 8.6.5 Open the pipe of steam extraction 1 and 2 to drain water appropriately; 8.6.6 When there is a short time maintenance work on HP heater steam side, it is permitted to operate with only the steam side stopped, but it shall verify there is no leak in the HP heater, and open the water discharge valve on the steam side to discharge water until the steam side pressure decreases to 0 prior to operation. It is forbidden strictly for HP heater to operate with only steam side.

Turbine Mannual

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