_WE_D300N-000106ASM(Turbine Start-up and Operation Manual)

REV: A

DONG FANG STEAM TURBINE WORKS

PROJECT: PROJEC T: CLIENT: LOCATION: LOCATION: CONTRACTOR:

REFERENCE REFERE NCE ONLY ONLY

JOB. NO:

E03033

PT. SUMBER SECARA PRIMADAYA PRIMADAYA KARANG TALUN VILLAGE, VILLAG E, CILACAP, ENTRAL JAV JAVA, INDONESIA INDONES IA CHENGDA ENGINEERING CORPORATION CORPORATION OF CHINA

Start-up and Operational Manual for Steam Turbine

STD NO. (WE) D300N-000106ASM


DES CHECK VER MFG

STD ENGR APP


DES CHECK VER MFG

STD ENGR APP

:


(WE)D300N-000106ASM

Content

No .

Chapter -Section

1

Na me

Pa ge

Preface

2

Essential Conditions for Start-up

1

Inspection before Start-up

2

Start-up with IP casing (IP)

1

2

1

3

1-1

4

2

5

2-1

Start-up under Cold State (IP)

7

6

2-2

Start-up under Warm State (IP)

5

7

2-3

Start-up under Hot State and Extremely Hot State (IP)

6

8

3

Combined Start-up of HIP Casing (HIP)

1

9

3-1

Start-up under Cold State (HIP)

14

10

3-2

Start-up under Warm State (HIP)

5

11

3-3

Start-up under Hot State and Extremely Hot State (HIP)

6

12

4

Operation

1

13

4-1

Normal Operation

2

14

4-2

Varying Duty Operation

2

15

4-3

Abnormal Operation

2

16

5

Shutdown

1

17

5-1

Slide Parameter Shutdown

2

18

5-2

Rated Parameter Shutdown

1

19

5-3

Emergency Shutdown

2

20

6

Restrictions for Start-up and Operation

1

21

6-1

Restrictions Operation

22

6-2

Limits for Start-up and Operation

5

23

6-3

General Precautions

2

24

6-4

Regular Check and Test

2

25

7

Auxiliary Operation of Start-up and Shutdown

1

for

Prohibiting

Start-up

and

Re ma rk

1

1


(WE)D300N-000106ASM

26

7-1

Pre-warming of HP casing

2

27

7-2

Heating System of HP casing Interlayer

2

28

7-3

Water Spray System of LP casing of Steam Turbine

1

29

7-4

Emergency Discharge System

1

2


(WE) D300N-000106ASM

Preface

The start-up mode described in this manual is proposed according to the structural features of main body of 300MW steam turbine made by our factory and by referring to the technical characteristics of imported digital electro-hydraulic control system (DEH) for HP hydraulic oil, which applies to our new generation of full electronic control type of 300MW steam turbine. There are three kinds of start-up operation modes for the steam turbine, namely "Self-Starting Mode", "Operator Automatic Mode" and "Manual Mode". The operating personnel may choose one o f them according to the actual conditions. Under " Self-Starting Mode ", the ATS of DEH control system is under " Control State ". The ATS controls the steam turbine based on the state of assembling unit to automatically complete the start-up process including turbine rolling, raising speed, synchronous incorporating in power network, picking up initial load. The detailed operational and monitoring requirements about the " Self-Starting Mode " can be found in the " Operation Instruction for Digital Electro-Hydraulic Control System (DEH) for HP Hydraulic Oil " (provided by the supplier of DEH). Under " Operator Automatic Mode", the ATS of DEH control system is under “Monitoring Mode” instead of participating in controlling. The operator manually sets the target values and rates of change for the speed or load on the operation board according to the condition of main body of steam turbine and the start-up operation pro ce du re pr ov id ed in th e ma nu al . Th e ba sic co nt ro l sy st em of DE H au to mati ca ll y completes the operations of turbine rolling, raising speed, synchronization and pic kin g up th e lo ad ac co rd in g to the target values and rates of change set by the operator. The DEH system automatically monitors the start-up parameters through the CRT display, sends out the signal "Alarm" or " Shutoff" when exceeding the limits, guides the operator and pri nt s th e cu rren t dat a an d hi st or ic al da ta fo r th e op er at or to st ud y an d an al yze .

1


(WE) D300N-000106ASM

Under “Manual Mode”, the valve position multi-functional processing of DEH control system controls the set according to the button of “VALVE LOWER” or “VALVE RAISE” on the operation board controlled by the operator. Under this operation condition, the set shall be controlled by skilled operating personnel according to relevant limits and operating procedures in the manual as well as relevant rules of power plant. The operator shall closely monitor various changes of par am et er s displ ay ed on th e CRT an d al ar m si gna ls to en su re th e sa fe op er at io n of set. The procedures for start-up and shutdown specified in this manual only apply to “Operator Automatic Mode” (i.e. ATS monitoring state). The user shall compile the site operation regulations according to the manual and correct them during the actual operation based on the accumulated operating experience. However, each control par ame te r in th e st ar t- up ope ra ti on sh all fo ll ow th e re qu ir em ent in th e ma nua l. Fo r a new machine, the initial start-up shall properly reduce the rates of raising speed and increasing load. Stable operating time shall be extended properly for each load point. When a new machine is put into operation, the evenness between the contact surfaces and the glidability between the glide surfaces of various parts need certain operating time to improve. Therefore, when a new machine is put into operation, it must experience at least 6 months operation under the complete cycle mode until the set reaches the stable state. Refer to the technical documentation, drawings and manuals supplied with the machine by us for relevant technical data, structural features, etc. about the steam turbine (refer to “Delivery List”). The start-up state of steam turbine is determined by the metal temperature of inner wall (stage adjusting place) of upper half of HP inner casing. Specifically as follows: Start-up under cold state: ≤ 15 0 ℃ Start-up under warm state: 150 ℃ ～ 30 0 ℃ Start-up under hot state: 300 ℃ ～ 40 0 ℃ 2


(WE) D300N-000106ASM

Start-up under extremely hot state: ≥ 40 0 ℃ The set has two operating modes: IP casing start-up as well as HP and IP casing combined start-up. It is recommended that the IP casing start-up be considered first. If the boiler and by-pass system are not adaptable, it is possible to only use the HP and IP casing combined start-up; if the IP casing start-up is adopted, the user needs to buy th e VV val ve an d by -p as s sy st em re qui re d by th e IP ca si ng st ar t- up . When the new machine is going to perform the load rejection test, the manufacturer shall be notified. The test requirements shall be discussed by the manufacturer and u ser jointly. The steam pressure in the manual is absolute pressure and the oil pressure is gauge pressure. The vacuum is converted according to the standard atmosphere, i.e.: Vacuum Mercury Column (mmHg)=760(mmHg)-Exhaust Absolute Pressure (MPa)×7500(mmHg/MPa) The user shall make corrections to the following formula according to local sea level height and the climate condition at that time: Vacuum

Mercury

Column

(mmHg)=Local

Atmosphere

(mmHg)-Exhaust

Absolute Pressure (MPa)×7500(mmHg/MPa) The curve attached in the manual is only for ModelN300-16.7/537/537-8 instead of other types.


(WE) D300N-000106ASM

1 Essential Conditions for Start-up

a. Each part shall be complete. Each part and system shall be installed, rinsed and adjusted according to the drawings, documentation and installation requirements from the manufacturer. Each part and system shall be firmly connected without looseness and leakage. Each kinetic part shall act flexibly without get stuck. The cleanness of each pa rt an d sy stem mu st re ac h re le va nt re qu ir em ent s in JB /T 40 58 -1 99 9 “ Stea m Turb in e Cleanness Standard”. b. Wh en a ne w se t is in st al le d or th e op era ti on al se t co mp le te s in sp ec ti on and repairing, before it is put into operation, the oil system must be rinsed by oil. The rinse acceptance must meet relevant regulations in “ Operation Instruction for Rinsing Oil System”. The acceptance for the hydraulic oil system must meet relevant regulations in “ Operation Instruction for Adjustment and Security System”. c. Parts and systems need to be separately tested must pass the tests and meet the installation test requirements of manufacturer. d. All the instruments, meters and measuring points for the set shall be complete. Installation and connection shall be correct and firm. All the instruments, meters and cables shall be inspected and qualified. e. The set must have good heat preservation. The turbine proper shall have heat pr es er vat io n

ac co rd in g

to

th e

“D es ig n

Sp ec if ic ati on

fo r

Stea m

Turb in e

He at

Preservation” provided by the manufacturer. The heat preservation for the pipeline and auxiliary devices shall be done according to relevant regulations for the power industry. The insulating layer shall not have the phenomena such as crack, come off, water and oil immersion. There shall be sufficient expansion gap reserved between the insulating layer and the foundation or other fixed parts. f. There shall not have any temporary facilities that hinder the operation (according to the safety rules for the power industry) g. The operating and maintenance personnel must go through special training and get familiar with the position, structure, principle, performance, operating method and emergency action of each responsible device.

Prepared by

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1-1


(WE) D300N-000106ASM

1-1 Inspection before Start-up

The inspection applies to HIP casing combined start-up (HIP) and IP casing start-up (IP). The time between the completion of inspection and formal start-up shall not be too long (normally not exceeding 10 days). a. Supply power to the DEH system and check whether the functions of each functional module are normal. Check whether the I/O interface communication with the CCS system and TBS system (by-pass control system) is normal. b. Ch eck th e fu nc tions of TS I sy st em . c. Check whether the central control room and local instruments work properly. d. Check the oil level in the lubricant box and hydraulic oil box. The oil indicators shall indicate the highest oil levels and the test of oil level alarm shall be performed. e. Check the working performance of each auxiliary oil pump. The electric control system must ensure various kinds of auxiliary oil pump can be switched properly. f. Check the working performance of each oil pump in the hydraulic oil system. The electric control system must ensure various oil pumps can be switched properly. g. Check whether the lubricant oil temperature, pressure and level are normal. h. Check whether the temperature, pressure and level o f hydraulic oil are normal. i. Check the working performance of jacking oil pump. The jacking test shall be per fo rm ed at th e in it ia l st ar t- up : ad ju st th e open in g of th ro ttle va lv e ac co rd in g to th e ja ck in g oi l pr es su re and pu sh ed up hei gh t in th e

“S pe ci fi ca ti on fo r Oi l Pi pel in e of

Jacking Device” and record the pushing up oil pressure and pushed up height of each bea ri ng pad . j. Star t th e sm ok e di sc harge fa n an d ch eck it s wo rk in g pe rf or ma nc e. Wh en th e fan is working ， the negative pressure in the oil box shall keep within 196 ～ 245Pa and the

Prepared by

Checked by

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1-1-1


(WE) D300N-000106ASM

negative pressure in the bearing box shall keep within 98 ～ 196Pa. The negative pre ssure in th e oil bo x sh all no t be to o hi gh . Ot her wi se , wa te r ca n eas il y ge t in to th e oil and dust can be sucked into. k. Check whether the working performances of various parts in the adjusting and security system meet the requirements. l. Check whether the working performances of various parts in the oil supply system of hydraulic oil meet the requirements. m. Start the jacking oil pump and confirm the rotor is jacking before performing turning gear engagement and disengagement. Adopt the reverse mode of turning gear motor for disengagement. No te : Wh en th e lu brica nt pr es su re is le ss th an 0.0 8M pa an d th e pre ssure of ja ck in g pip in g-mai n is le ss th an 9. 8M pa, th e au to an d ma nua l au to en ga ge me nt at zer o sp ee d of the turning gear will not work. This is realized by the pressure switch through electric interlock so as to prevent the friction of bearing Babbitt caused by inadequate oil supply. The details can be found in the “Operation Instruction of Turning Gear”. n. When the turning gear is engaged, check and record the eccentricity of rotor, compare with the original value of rotor (the variance shall not exceed 0.03mm), confirm that the rotor does not bend as well as monitor whether there is friction sound in the through flow part. No te : Th e origin al va lu e of ro to r is th e ec ce ntric ity of ro to r me as ure d at a sp ec if ic po si ti on by a me cha nic al ty pe ro to r ben d me te r wh en ro ta ti ng th e ro to r in it ia ll y aft er th e connection of axis series on the site, i.e.excircle runout. The value shall not exceed 0.02mm.

1-1-2


(WE) D300N-000106ASM

o. Close the vacuum breaking valve, add water to the hot well of steam condenser, engage the main vapor extractor to run the steam condenser and check whether the devices in the steam condensing system work properly. p. Ch ec k wh et he r th e st ea m su pp ly re gu la ti ng st at io n, te mp er at ur e co ntrol station and overflow station of each steam source in the self-seal gland seal system work properly. q. Check whether each electric stop valve in the drainage system works properly and perform the regular switch test for the system. r. Check whether the HP exhaust non return valve f and all the check valves of steam extraction work properly. Perform the linkage test. s. Check whether the RFV, ventilator valve(VV), emergency blowdown valve(BDV) and electric stop valve for interlayer heating work properly and perform the regular switch test. Check whether the working characteristics of electromagnetic valve of ventilator valve works properly. t. When the condense pump is engaged, the parameters for the sprayer of LP casing shall be reset. The reset values shall be: automatic engagement when the exhaust temperature

≥ 80 ℃ ;

automatic removal when the exhaust temperature

≤ 65 ℃ .

The regular switch test for the cooling system of LP casing sprayer shall also be per fo rmed . v. The HP main stop valve, IP reheat stop valve and HP control valve and IP control valve shall go through static test and be reset. w. Before turbine rolling, the protection test for axial displacement and other electric test shall be p erformed. All the inspections and tests above shall be performed according to relevant instructions.

1-1-3


(WE) D300N-000106ASM

2 Start-up with IP Casing (IP)

Start-up with the IP casing is to utilize the reheat steam that has higher temperature and bigger flow to raise the temperature of IP casing more rapidly. This makes the IP exhaust temperature exceed the fragility transforming temperature of rotor so as to avoid the fracture of rotating shaft due to fragility, reduce the heat impact of HP casing, prevent the exhaust temperature of HP casing from exceeding the limit, realize the matching between the temperature of main steam and reheat steam as well as the metal temperature at the HP control stage and IP Stage 1, and achieve the purpose of shortening the start-up time and reducing the life loss of set. Start-up with the IP casing has better flexibility and is in favor of peaking operation in two shifts. For start-up with the IP casing, it is required that the by-pass capacity shall meet the requirement of ≥ 35%MCR and the by-pass system shall be engaged normally. It is bes t to se t it un de r th e au to ma tic st at e.

Prepared by

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2-1


2-1

(WE) D300N-000106ASM

Start-up under Cold State (IP)

1 Preparation before Turbine Rolling a.

Supply power to the DEH. The panel and system shall all be in normal

condition; b.

Start th e lu br ic an t pu mp an d ja ck in g oil pu mp and con fi rm wh et he r th e

lubricant system and jacking system are in normal working conditions; c.

Start the hydraulic oil pump;

d.

Engage the turning gear and ensure that before turbine rolling the turning

gearing time is no less than 4h; e.

Recheck the lubricant system, hydraulic oil system, DEH, TSI system and

turning gear according to Section 1-1; f.

After confirming there is no water in the gland seal steam pipeline, engage

the auxiliary steam source of gland seal system. The pressure of gland sea l pip in g- ma in sh al l be 0. 123 Mp a an d te mp er at ur e sh al l be un der 150℃ ～ 26 0 ℃ ； g

Create the vacuum for the steam condenser. The pressure in the condenser

shall be below 16.7kPa. h.

Press the “LATCH” button and the set will be turned on;

i.

Press the “PREWARM” button to pre-warm the HP casing, main steam pipe

and valve shell. See Section 7-1; j.

Op en th e dra in va lv es in th e HP, IP an d LP se ct io ns (r efer to Se ct io n 3- 1 fo r

the drainage in various sections); k.

Confirm whether the HP exhaust non return valve is closed completely;

l.

The TSI measured data display is in the permissible range;

m.

Prepared by

Confirm Steam Parameters for Turbine Rolling（ refer to Section 3-1 for the

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2-1-1


(WE) D300N-000106ASM

definition principle ） ; (1) Main steam pressure: 3.45MPa; (2) Reheat steam pressure: 0.686MPa; (3) Main steam temperature: 300 ℃ ; (4) Reheat steam temperature: 237℃ n.

Define Change Rate of Steam Temperature During Start-up See Item n in Article 1 of Section 3-1;

p.

Ope ra ti ng Re qu irem en ts fo r LP By -p as s be fo re Turb in e Ro ll in g

Along with the start-up of boiler, the valve opening of LP by-pass increases gradually. When the reheat steam pressure increases to 0.686MPa, the LP by-pass shall get the auto control of pressure feedback eng aged. 2 Turbine Rolling a.

Confirm whether the slide valve of emergency governor is engaged;

b.

Con fi rm wh eth er th e “H P＆ IP START/IP START” button is under the “HP ＆

IP START” sta te; c.

Press the “RUN” button and start the HP and IP reheat stop valves;

d.

Confirm whether the ventilator valve (VV valve) is at the closed state;

e

Select the speed of 500r/min for “TARGET”; the accelerating rate of

100r/min/min for “ACCELERATE”; f.

After pressing the “GO” button, the HP control valve opens gradually until

the speed increases to 500r/min. The set increases the speed according to the given accelerating rate; when the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall disengaged be

2-1-2


(WE) D300N-000106ASM

and the machine shall be stopped. 3

Inspection at 500r/min

At this speed, perform overall inspection for the set. Mainly inspect whether there is friction between the static and dynamic parts, whether the ventilator valve is at the close position, whether the HP exhaust non return valve is at the open position. The stop time shall not exceed 5 min. No te : Wh en in sp ec ti ng var io us st ar t- up st at es at 50 0r/ mi n in th e si tu at io n of start-up with the HP casing, the HP and IP control valves shall be closed. The inspection shall be done at the idling speed. Re-charge before the speed is more than 50r/min. a.

Select the speed of 1200r/min for “TARGET”;

b

Pr ess th e “G O” bu tt on , sl ig ht ly ope n th e HP co nt ro l va lv e un til th e sp ee d

increases to 500r/min; c

When the speed increases to 500r/min, the opening of HP control valve is

locked and the equilibrated valve of IP control valve opens gradually to increase the speed of steam turbine to 1200 r/min at the original acce lerating rate; 4

Warming up at Medium Speed of 1200r/min a.

Confirm whether the jacking oil pump is stopped;

b.

Che ck al l th e mo ni to ri ng in stru me nt s;

c.

At this speed, warm up for 30min. During the warming up, the speed of

steam turbine is controlled by the equilibrated valve of IP regulation. During the per io d, th e me ta l te mp er at ur e of th e HI P ca si ng ex hau st sh al l be mo ni to re d. Wh en th e metal temperature of HP exhaust lower half inner wall of reaches 200℃ , the VV valve shall be opened and adjusted for its manual door opening to control the metal temperature around 200 ℃ . d.

Completion of Warming up 2-1-3


(1)

(WE) D300N-000106ASM

If the metal temperature of HP exhaust lower half inner wall reaches 200

℃ and the metal temperature of IP exhaust lower half inner wall reaches 130℃ ,

“TARGET” can d irectly select 3000r/min. (2)

After the completion of warming up, check and confirm whether the HP

control valve is closed completely and the v entilator valve is fully opened. (3)

If the metal temperatur e of HP and IP exhaust lower half inner wall fail to

reach the above requirements, the "TARGET" selects the speed of 2000r/min for high speed warming up. During the process of raising speed afterwards, the set shall rapidly and steadily pas s ea ch step cr it ic al sp ee d of axi s se ri es . Th e vi br at io n of be ar in g co ver at th e critical speed shall be no more than 0.10mm (peak-peak value). Otherwise, the brake shall be disengaged and the machine shall be stopped. Warming up at the high speed can be done through adjusting the opening of manual valve after the ventilator valve to control the metal temperature of lower half inner wall to reach 200 ℃

around. If the temperature still can not reach the

requirement at this time, the manual valve before the reverse warming valve can be opened properly. When the metal temperature of HP exhaust lower half inner wall reaches 200℃ and the metal temperature of IP exhaust lower half inner wall reaches 200℃ , the warming up shall continue for 30min. Then the warming up at the high speed finishes. “TARGET” selects the speed of 300 0r/min. e.

Press the “GO” button to increase the speed.

5 Rated Speed 3000r/min At this speed, perform warming up under zero load for 30min; a.

The pressure of steam condenser shall be less than 13kPa and the vacuum

2-1-4


(WE) D300N-000106ASM

pro te ct io n sh all be en gag ed ; b.

Wh en th e ex ha ust te mp era tu re is

≥ 80 ℃ ,

the sprayer of LP casing shall

engage automatically. Otherwise, it shall be started manually. c. The TSI monitoring items shall be within the permissible range; d.

Check Lubricant System

(1) The switch between the main oil pump and AC lubricant pump shall be completed; (2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2; (4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2. e.

Check Hydraulic Oil System

The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2. f.

Requirements for Parameters

(1) The main steam pressure shall reach 5.88MPa; (2) The change rates of main steam temperature and reheat steam temperature shall not exceed the selected value before turbine rolling; g.

Operating Requirements for HP and LP By-pass

When the pressure of main steam reaches 5.88MPa, the HP by-pass shall have the auto control of pressure feedback engaged;

2-1-5


6

(WE) D300N-000106ASM

Perform following system tests before incorporating in power network (for new

machine start-up or after heavy repair of set): a. Oil spray test of emergency governor; b. On -lin e te st of HP em ergen cy go vernor IC (H PT) el ect ro ma gn et ic val ve ; c. On-line test of overspeed limit IC (OSP) electromagnetic valve; d. Manual shutdown button test; e. Speed acceleration test of emergency governor (before performing the acceleration test, the set shall run no less than 3h for warming up with20% load ); f. Electric overspeed protection test The specific requirements for various tests above can be found in the “Specification for Adjusting and Security System”, “Specification for Safety Monitoring Device of Steam Turbine” and “Specification for Electrical Appliance Monitoring and Protection System o f Steam Turbine” 7

Incorporating in Power Network After the completion of test and inspection of steam turbine generator set,

inform the operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase. Maintain the pressure in front of HP main stop valve during the process of accelerating, incorporating in power network and picking up the load. 8

Load Increase

2-1-6


a.

(WE) D300N-000106ASM

Select the final stable operating target load for "TARGET"; select the load

increase rate of 1.2MW/min for "LOAD RATE"; b.

Pr ess th e "G O" bu tt on to in cr ea se th e lo ad ;

Afterwards, the by-pass valve closes gradually. 9

Switching HP and IP casings a.

Before switching the HP and IP casings, pay attention to the matching of

steam temperature and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method; Under normal condition, the followings shall be controlled:

b.

Main Steam:

5.88MPa

400～ 43 0 ℃

Reheat Steam:

0.686MPa

350～ 380 ℃

Wh en it is ch an ge d fr om th e so le stea m ad missio n th roug h th e HP ca sing to

the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically. c.

When the by-pass valve is fully closed, (at this time, the load is about

40MW) the TBS system sends signals to the DEH to maintain the load; d.

When the by-pass is fully closed, perform warming up at low load. Monitor

the metal temperature of HP exhaust lower half inner wall. It shall reach 170 ℃ . Adjust the opening of manual valve in the back of ventilator valve to control the metal temperature of HP exhaust lower h alf inner wall within 220--250℃ for 30min; When all the above items are completed, the operator presses the "VALVE CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then ; e.

After the change is over, （ at the rate of

3MW/min） increase the load to 2-1-7


(WE) D300N-000106ASM

42MW and warm up for 30min; f.

Check the following items during the change over period:

(1) The ventilator valve (VV valve) is closed; (2) The HP exhaust non-return valve opens a utomatically. g.

When the change is over, engage the interlayer heating device based on the

concrete situation of HP casing temperature and expansion difference. h.

When warming up is completed, the DEH system sends signals to the TBS

and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback. 10

Increase Load to Target Value a.

When the load reaches the downslide point, the DEH system sends signals

to the CCS system. The set starts to slide the parameters and increase the load along with the boiler. b.

Th e set ge ts to th e do wn slid e poin t wh en th e load is ab ou t 10 5M W. At th is

time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not par ticip at e in th e ad ju st me nt (i .e . no t par ti ci pat e in th e lo ad co ntrol) un ti l th e lo ad approachs to 90% ECR. c

Stop using the heating system of cylinder interlayer at any time according to

Section 7-2. d.

Check the closing sequences of drainage system under the following

operating states: (1)

At 15% rated load, close the drainage of HP section;

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(WE) D300N-000106ASM

(2)

At 20% rated load, close the drainage of IP section;

(3)

At 30% rated load, close the drainage of LP section.

e.

When the target load is reached and the temperature of each measuring

poi nt of pr op er ge ts st abl e, pre ss th e “S EQ VALVE” but to n to ch an ge to th e co nt ro l state of sequence valve for better economical efficiency. f.

When the steam turbine runs stably upwards of 225MW and the air

extractor works properly, it is possible to perform the tightness test of vacuum system. (1) Close the inlet electric door of air extractor, the vacuum of steam condenser shall drop slowly. If the drop rate

≤ 0.13kPa/min

(1mmHg/min),

excellent

If the drop rate

≤ 0.27kPa/min

(2mmHg/min),

good

If the drop rate

≤ 0.4kPa/min

(3mmHg/min),

qualified

When the drop rate of vacuum is more than 0.67kPa/min (5mmHg/min), the machine shall be stopped for iden tifying the root cause. Restart the machine when the trouble is eliminated. (2) During the test, if the IP exhaust pressure increases to 17.86kPa (or vacuum decreases to 626mmHg) and the temperature is higher than 58℃ , the test shall be stopped. When the test is finished, open the electric valve immediately to recover the rated vacuum value.

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(WE) D300N-000106ASM

2-2 Start-up Under Warm State (IP)

1

Preparation Before Turbine Rolling

a.


condition; b.

Start th e lu br ic an t pu mp an d ja ck in g oi l pu mp and co nf ir m whe th er th e


Start the hydraulic oil pump;

d.

Engage the turning gear and ensure that the turning time is no less than 4h

bef ore tu rb in e ro ll in g; e.

Before turbine rolling, the auxiliary steam source of gland seal system shall

be en gag ed . It is re qu ir ed th at th e pr es su re of gl an d se al pi pi ng -m ai n sh al l be 0.123Mpa and the temperator shall be under 150℃ ～ 26 0 ℃ . f.

When the gland seal system runs properly, the vacuum of steam condenser

shall be created. It is required the pressure of steam condenser shall be below 16.7Kpa; g.


h.

Open the drain valves for the HP, IP and LP sections;

i. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met. j.

Co nfi rm wh eth er th e HP ex ha us t non -r et ur n va lv e has clo se d co mp le te ly ;

k.

Define Steam Parameters for Turbine Rolling:

（ 1）

main steam pressure: 5.88MPa;

（ 2）

reheat steam pressure: 0.686MPa;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

2-2-1


(WE) D300N-000106ASM

（ 3）

recommended temperature for main steam: 370℃ ;

（ 4）

Selection of Reheat Steam Temperature: refer to (2) in Item m of Section

3-1. l.

Define change rate of steam temperature during start-up: refer to Item n in

Article 1 of Section 3-1. m.

Operating Requirements for HP and LP By-pass before Turbine Rolling

With the start-up of boiler, the openings of HP and LP by-pass valves increase gradually. When the main steam pressure increases to 5.88MPa, the auto control of pre ssur e fe edb ac k sh al l be en ga ged in th e HP by -p as s; wh en th e re hea t st ea m pr es su re increases to 0.686MPa, the auto control of pressure feedback shall be engaged in the LP by-pass. 2

Turbine Rolling a.


b.




d.

Confirm whether the ventilator valve（ VV valve ） is closed;

e.

Select the speed of 500r/min for "TARGET"; select the accelerating rate of

200r/min/min for "ACCELERATE"; f.

After pressing the “go” button, the HP and IP control valves open gradually.

The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the mac hine shall be stopped. 3 Inspection at 500r/min At this speed, perform overall inspection for the set. Mainly check whether there 2-2-2


(WE) D300N-000106ASM

is friction between the static and dynamic parts. The stop time shall not exceed 5 min. a.


b.

Pr es s th e “G O” bu tt on to in cre as e th e sp eed ;

Based on the metal temperature of HP exhaust lower half inner wall, control the temperature to reach 200℃ or so through adjusting the opening of manual valve in the back of ventilator valve. 4

Rated Speed 3000r/min a.




≥ 80 ℃ ,


engage automatically. Otherwise, it shall be started manually. c.

The TSI monitoring items shall be within the permissible range;

d.


(1) The change over between the main oil pump and AC lubricant pump shall be completed; (2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2; (4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2. (5) Stop the jacking oil pump when the speed reaches 1200r/min. e.


2-2-3


(WE) D300N-000106ASM

The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2; g.

Requirements for Steam Parameters

The change rates of main steam temperature and reheat steam temperature shall not exceed the selected values before turbine rolling; 5

Incorporating in Power Network After the completion of inspection of steam turbine generator set, inform the

operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase. 6

Load Increase Select the load of 30MW for “TARGET” and the load increase rate of 3MW/min

for “LOAD RATE”; Afterwards, the LP by-pass valve closes gradually. 7 Change over between HP and IP Casings a.

Before changing over between HP and IP casings, pay attention to the

matching of steam temperature and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method; b.

Wh en it is ch an ge d fr om th e so le stea m ad missio n th roug h th e HP ca sing to

the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically. c.

When it is changed from the sole steam admission through the HP casing to 2-2-4


(WE) D300N-000106ASM

the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically. d.

When the by-pass is fully closed, perform warming up at low load. Monitor

the metal temperature of IP exhaust lower half inner wall. It shall reach 170℃ . Adjust the opening of manual valve in the back of ventilator valve to control the metal temperature of HP exhaust lower half inner wall within 220--250℃ for 15 min; e.

When all the above items are completed, the operator presses the "VALVE

CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then ; f.


(1) The ventilator valve (VV valve) is closed; (2) g.

The HP exhaust non-return valve opens automatically. When the change is over, engage the interlayer heating device based on the

concrete situation of HP casing temperature and expansion difference. h.

When the change over is completed, the DEH system sends signals to the

TBS and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback. 8

Increase Load to Target Value a. When the load reaches the downslide point, the DEH system sends signals to

the CCS system. The set starts to slide the parameters and increase the load along with the boiler. b. Th e se t get s to th e do wn sl id e po in t wh en th e lo ad is ab out 135 MW. At th is time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with

2-2-5


(WE) D300N-000106ASM

the pressure increase of boiler. At this time, the DEH control system does not par ticip at e in th e ad ju st me nt (i .e . no t par ti ci pat e in th e lo ad co ntrol) un ti l th e lo ad approachs to 90% ECR. c.

Stop using the heating system of cylinder interlayer at any time according to

Section 7-2. d.




(2)


(3)


e. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.

2-2-6


2-3

(WE) D300N-000106ASM

Start-up Under Hot State and Extremely Hot State (IP)

1

Preparation before Turbine Rolling

a.


condition; b.

Start th e lu br ic an t pu mp an d ja ck in g oil pu mp and con fi rm wh et he r th e


Start the hydraulic oil pump

d.

During the period from shutdown to restart, the set shall be at continuous

turning gearing state; e.

Before turbine rolling , steam shall be sent to the gland seal. Then the

vacuum of steam condenser shall be extracted. It is required that the pressure of gland seal piping-main shall be 0.123MPa and the temperator shall be under 250℃ ～ 350 ℃ ； f.

Create the vacuum for the steam condenser after the gland seal system runs

normally. The pressure for the con denser shall be below 16 .7kPa; g.


h.

Open the drain valves in the HP, IP and LP sections;

i.

The TSI measured data display shall be in the permissible range. The

eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning shall be co nt in ued bef or e start -u p un ti l th e re qu ir em en ts ar e me t; j.

Co nf ir m wh eth er th e exh aust non -r et ur n va lv e is clo se d co mp le te ly ;

k.

Define the steam parameters for turbine rolling: pay attention to the

matching of reheat steam temperature after the work done by IP Stage 1 and metal temperature. (1) Pressure of Main Steam: hot state 7.85MPa, extremely hot state 9.81MPa; Prepared by

Checked by

Reviewed by

Standardized by

Entered by

2-3-1


(WE) D300N-000106ASM

(2) Reheat Steam Pressure: 0.883MPa; (3) Temperature of Main Steam: hot state 450℃ , extremely hot state 460 ℃ ; (4) Selection of Reheat Steam Temperature: refer to (2) in Item m in Article 1 ofSection 3-1; m.

Define the change rate of steam temperature during start-up: refer to Item n

in Article 1 of Section 3-1. n. Operating Requirements for HP and LP By-pass before Turbine Rolling Along with the start-up of boiler, the valve openings of HP and LP by-pass increase gradually. When the main steam pressure increases to 7.85MPa for hot state and 9.81MPa for extremely hot state, the HP by-pass shall get the auto control of pre ssur e feed bac k en ga ge d. When the pressure of reheat steam increases to 0.883MPa, LP by-pass shall also get the auto control of pressure feedback enga ged. 2

Turbine Rolling a.


b.




d.


Selection for “ACCELERATE”: hot state: 200r/min/min and extremely hot state: 300r/min/min e.

After pressing the “go” button, the IP control valves open gradually. The set

increases the speed according to the given accelerating rate. The ventilator valve is opened. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the machine shall be stopped. 2-3-2


3

(WE) D300N-000106ASM

Inspection at 500r/min At this speed, perform overall inspection for the set. Mainly check whether there

is friction between the static and dynamic parts. The stop time shall not exceed 5 min. a.


b.

Pr es s th e “G O” bu tt on to in cre as e th e sp eed ;

4 Rated Speed 3000r/min a.




≥ 80 ℃ ,


engage automatically. Otherwise, it shall be started manually. c.

The TSI monitoring items shall be within the permissible range;

d.


(1) The switch between the main oil pump and AC lubricant pump shall be completed; The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (2) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2; (4) The lubricant pressure shall be at the normal value. See Article c in 1.2 of Section 6-2; (5) Stop the jacking oil pump when the speed reaches 1200r/min. e.


The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2; 2-3-3


f.

(WE) D300N-000106ASM

Requirements for Steam Parameters

The change rates of main and reheat steam temperature shall not exceed the selected values before turbine rolling; 5


operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the con trol of load increase. 6

Load Increase Select the final stable operating target load for “TARGET”; selection for

“LOAD RATE”:

hot state: 4.8MW/min

extremely hot state: 7MW/min

Afterwards, the LP by-pass valve closes gradually. 7

Change over between HP and IP casings a.

Before changing over between HP and IP casings, pay attention to the

matching of steam temperature and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method; b.

Af te r th e LP by -p as s val ve is fu ll y cl os ed , th e TB S sy stem send s sign al s to

the DEH to maintain the load; c.

When all the above items are completed, the operator presses the "VALVE

CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then;

2-3-4


d.

(WE) D300N-000106ASM


（ 1 ） The ventilator valve (VV valve) is closed; （ 2 ） The HP exhaust non-return valve opens automatically.

When the change over is completed, the DEH system sends signals to the TBS and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback. 8

Increase Load to Target Value a.

When the load reaches the downslide point, the DEH system sends signals to

the CCS system. The set starts to slide the parameters and increase the load along with the boiler. b.

Th e se t ge ts to th e do wn slid e po in t when th e lo ad is ab ou t 16 5M W. At th is

time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not par ticip at e in th e ad ju st me nt (i .e . no t par ti ci pat e in th e lo ad co ntrol) un ti l th e lo ad approachs to 90% ECR. c.



At 10% rated load, close the drainage of HP section

(2)


(3)


e.

When the target load is reached and the temperature of each measuring

poi nt of pr op er ge ts st abl e, pre ss th e “S EQ VALVE” but to n to ch an ge to th e co nt ro l state of sequence valve for better economical efficiency.

2-3-5


(WE) D300N-000106ASM

3 Combined Start-up of HIP Casing (HIP)

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

3-1


(WE) D300N-000106ASM

3-1 Start-up under Cold State (HIP)

1

Preparation before Turbine Rolling a. Supply power to the DEH. The panel and system shall all be in normal

condition; b. Star t th e lu br ic an t pu mp an d ja ck in g oi l pu mp

et c an d co nf irm wh ethe r th e

lubricant system and jacking system are in normal working conditions; c. Start the hydraulic oil pump; d. Engage the turning gear and ensure that before turbine rolling the continuous turning gearing time is no less than 4h; e. Recheck the lubricant system, hydraulic oil system, DEH, TSI system and turning gear according to Section 1-1; f. Create the vacuum for the steam condenser. The pressure for the condenser shall be below 16.7kPa; g. After confirming there is no water in the gland seal steam pipeline, engage the auxiliary steam source of gland seal system. The pressure of gland seal piping-main shall be 0.123MPa and the temperature shall be u nder 150℃ ～ 26 0 ℃ ; h. Press the “LATCH” button and the set will be turned on; i. Press the “PREWARM” button to pre-heat the HP casing, main steam pipe and valve shell. See Section 7-1; j. Op en th e dr ai n val ve s in th e ca si ng pr op er and st eam pi pe in g: a) HP Section 1 ） upper valve body drainage of HP main stop valve; 2 ） lower valve body drainage of HP main stop valve;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

3-1-1


(WE) D300N-000106ASM

3 ） drainage of HP main steam pipe; 4 ） drainage of HP inner casing; 5) drainage of casing interlayer heating connection with steam combination box an d it s in le t tu be ; 6 ） drainage of interlayer between HIP inner and outer casings 7 ） drainage of exhaust check valves at Stage 1 and 2 and valve front; b) IP Se ct io n 1 ） Drainage of IP steam admission chamber; 2 ） Drainage of valve front and back of H P exhaust check valve; 3 ） drainage of exhaust check valves at Stage 3 and 4 and valve front; 4 ） drainage of IP combined steam valve; 5 ） drainage of steam drain of IP casing; c) LP Section 1 ） drainage of exhaust check valves at Stage 5 and 6 and valve front; 2 ） drainage of self-seal system and shaft seal steam supply pipe; All the drainage valves in the HP, IP and LP sections mentioned above must be opened when the set is under cold, warm, hot and extremely hot states to prevent water hammer during turbine rolling. The specific close sequences can be found in Paragraph 11 of this section. k. The TSI measured data display is within the permissible range. Following major records shall be noted before turbine rolling: 1 ） absolute expansion of cylinder; 3-1-2


(WE) D300N-000106ASM

2 ） expansion difference; 3 ） axial displacement; 4 ） shaft eccentricity and turning cu rrent; 5 ） upper and lower half inner wall temperature at HP inner casing adjusting stage; 6 ） each bearing pad temperature and return oil temperature; 7 ） temperature of inner and outer wall of valve shell of HP main stop valve; 8 ） temperature of inner and outer wall of valve shell of HP control valve; m. Define Parameters of Turbine Rolling Steam 1) main steam pressure: 3.45MPa; 2) Selection of turbine rolling steam temperature The selection criteria is to make the temperature of main steam and reheat steam after the HP control stage or doing work at HP Stage 1 match the metal temperature. Selection of main steam temperature: determine the steam temperature after the HP control stage according to the metal temperature after the HP control stage before turbine rolling and the temperature difference between the metal and steam in Article 2.4 of Section 6-2. Then based on Fig.3-1-1, determine the temperature of main steam according to the pressure of main steam and steam temperature after the control stage

3-1-3


(WE) D300N-000106ASM

For example: Calculation Procedure

Calculation Basis

Metal temperature after the control stage and pre-warming of HP casing be fo re tu rb in e ro llin g According to Article 2.4 of Section

Calculati on Result

Measured

15 0 ℃

t （ selected ）

90 ℃

6- 2 Steam temperature after the control stage

t+ metal temperature after the control stage

Temperature of main steam

Find in Fig.3-1-1

24 0 ℃

32 0 ℃

Selection of reheat steam temperature: determine the steam temperature after IP Stage 1 according to the metal temperature after IP Stage 1 before turbine rolling and Article 2.4 of Section 6-2 (temperature difference between the metal and steam). Then determine the reheat steam temperature according to the temperature drop (about 37 ℃ ) of IP Stage 1. For example: Calculation Procedure

Calculation Basis

Calcul ation Result

Metal temperature after MP Stage 1 before turbine rolling

Measured

50 ℃

According to 2.4 of Section 6-2

t （ selected ）

15 0 ℃

t+ metal temperature after IP Stage

20 0 ℃

Steam temperature after IP Stage 1 + temperature drop（ 37 ℃ ）after IP Stage 1

23 7 ℃

Article

Steam temperature after IP Stage 1 1 Reheat temperature

steam

3-1-4


(WE) D300N-000106ASM

n. Define Change Rate of Steam Temperature During Start-up When the ATC does not get the control engaged, it is necessary to select a rational change rate of metal temperature (equivalent to the change rate of steam temperature) by adopting the rotor life loss curve so as to ensure the safe operation of set. (1) Selection of Change Rate of Main Steam Temperature: Before start-up, the operator sets a target stable operating load for the set, calculates the temperature after the HP control stage according to Fig. 3-1-2, Fig.3-1-3 or Fig.3-1-4, determines the change of metal temperature of HP casing (change of metal temperature in short), and then selects the change rate of metal temperature after the HP control stage according to the HP rotor life loss curve. For example: Calculation Procedure

Calculation Basis

Calcul ation Result

Steam temperature after Set the target load as 50%ECR and the HP control stage at a main steam pressure as 10.79MPa, and target stable operating load adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537 ℃ -temperature drop at control stage Metal temperature after the HP control stage before turbine rolling Change temperature

of

Change rate steam temperature

metal

of

main

Measured

Steam temperature after the control stage-metal temperature after the control stage Find the normal loss in Fig.3-1-5.

50 0 ℃

15 0 ℃

35 0 ℃

57 ℃ /h

(2) Selection of Change Rate of Reheat Steam Temperature

3-1-5


(WE) D300N-000106ASM

The steam temperature after IP Stage 1 under various working conditions is the difference between the IP steam admission temperature and the temperature drop a t IP Stage 1 under the rated working condition. Compare it with the metal temperature at IP Stage 1 before turbine rolling to get the change of metal temperature of MP casing. Then select the change rate of metal temperature at IP Stage 1 according to the IP rotor life loss curve (Fig. 3-1-6) (equivalent to the change rate of reheat steam temperature). For example: Calculation Procedure

Calculation Basis

Calcul ation Result

Metal temperature after IP Stage 1 before turbine rolling

Measured

50 ℃

Steam temperature after IP Stage 1

（ 537-37 ） ℃

50 0 ℃

Change temperature

of

metal

Change rate of reheat steam temperature 2

Steam temperature after Stage 1-metal temperature after IP Stage 1 Find the normal loss in Fig.3-1-6.

45 0 ℃

84 ℃ /h

Turbine Rolling a. Confirm whether the slide valve of emergency governor is engaged; b. En ga ge th e he ating fo r th e cyl in der in te rl ay er an d re fe r to Se ct io n 7- 2 fo r

details; c. Confirm whether the “HP ＆ IP START/IP START” button is under the “HP＆ IP START” sta te; d. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGL E VALVE” state;

3-1-6


(WE) D300N-000106ASM

e. Press the “RUN” button and start the HP and IP reheat stop valves; Select the speed of 500r/min for “TARGET”; the accelerating rate of 100r/min/min for “ACCELERATE”; g. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the mac hine shall be stopped. 3

Inspection at 500r/min At this speed, perform overall inspection for the set. Mainly inspect whether

there is friction between the static and dynamic parts, whether the ventilator valve is at the close position, whether the HP exhaust non return valve is at the open position. The stop time shall not exceed 5 min. No te : un de r va rious st ar t- up st at es fo r th e HI P co mb in ed start-u p, wh en per fo rmin g in sp ec ti on at 50 0r/ mi n, th e HP an d IP co ntrol va lv es sh al l be clo se d an d it shall be done at idling speed. Before the speed is more than 50r/min, re-open the HP and IP control valves and raise the speed to 1200r/min according to the accelerating rate. a. Select the speed of 1200r/min for “TARGET”; b. Pre ss th e “G O” bu tton ; 4

Warming up at Medium Speed of 1200r/min Warming up at the speed for 30min. a. Stop the oil pump for jacking; b. In sp ect al l th e mo ni to ri ng in stru me nts ; c. Select the speed of 2000r/min for the "TARGET”;

3-1-7


(WE) D300N-000106ASM

d. Press the “GO” button to increase the speed; During the process of raising speed afterwards, the set shall rapidly (at the accelerating rate of 250～ 300r/min/min) and steadily pass the critical speed at each step in the axis series. The vibration of bearing cover at the critical speed shall be no more than 0.10mm (peak-peak). Otherwise, the brake shall be disengaged and the machine shall be stopped. 5

Warming up at High Speed of 2000r/min At this speed, monitor the metal temperature of IP exhaust lower half inner wall

no more than 130℃ and keep warming up for 60 min. After the completion of warming up, the following values shall be met: Metal temperature after the control stage of upper half inner wall of HP inner casing: more than 250 ℃ ; Expansion of HP and IP casings: more than 7mm; Expansion of HP and IP less than 3.5mm a nd getting stable; a. Select the speed of 3000r/min for “TARGET”; b. Pr es s th e “G O” but to n to in cr ea se th e sp ee d. 6

Rated Speed 3000r/min: At this speed, perform warming up under zero load for 30min; a. The pressure of steam condenser shall be less than 13kPa and the vacuum

pro te ct io n sh all be en gag ed ; b. Wh en th e exh au st te mp er at ure is

≥ 80 ℃ ,

the sprayer of LP casing shall engage

automatically. Otherwise, it shall be started manually. c. The TSI monitoring items shall be within the permissible range;

3-1-8


(WE) D300N-000106ASM

d. Check Lubricant System (1) The switch between the main oil pump and AC lubricant pump shall be completed; (2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2; (4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2. e. Check Hydraulic Oil System The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2. f. Requirements for Steam Parameters (1) The main steam pressure shall reach 5.88MPa and main steam temperature shall reach 370 ℃ ; (2) Before incorporating in power network, the difference between the main steam temperature and reheat steam temperature shall meet Article c in 2.3 of Section 6-2; (3) The change rates of main steam temperature and reheat steam temperature shall not exceed the selected value before turbine rolling; 7

Perform following system tests before incorporating in power network (for new

machine start-up or after heavy repair of set) a. Oil spray test of emergency governor; b. On -lin e te st of HP em ergen cy go ver no r IC (H PT) el ect ro ma gn et ic val ve ; 3-1-9


(WE) D300N-000106ASM

c. On-line test of overspeed limit IC (OSP) electromagnetic valve; d. Manual shutdown button test; e. Speed acceleration test of emergency governor (before performing the acceleration test, the set shall run no less than 3h for warming up with 20% load); f. Electric overspeed protection test The specific requirements for various tests above can be found in the “Specification for Adjusting and Security System”, “Specification for Safety Monitoring Device of Steam Turbine” and “Specification for Electrical Appliance Monitoring and Protection System o f Steam Turbine” 8

Incorporating in Power Network After the completion of test and inspection of steam turbine generator set,

inform the operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase. 9

Load Increase a. Select the load of 30MW for “TARGET”, the load increase rate of1MW/min

as the “LOAD RATE”; b. Pr es s th e “G O” but to n to in cr eas e th e lo ad . 10

Warming up Under Low load

3-1-10


(WE) D300N-000106ASM

Perform steadily under the low load of 30MW, ensure the metal temperature of IP exhaust lower half inner wall more than 176℃ and keep warming up for 30 min; a. Select the final stable target operating load for “TARGET”; the load increase rate of 1MW/min as the “LOAD RATE”; b. Pr es s th e “G O” but to n to in cr ea se th e lo ad . 11

Increase Load to Target Value a. The set gets to the downslide point when the load is about 105MW. At this

time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not par ticip at e in th e ad ju st me nt (i .e . no t par ti ci pat e in th e lo ad co ntrol) un ti l th e lo ad approachs to 90% ECR. b. Stop us in g th e he ati ng sy st em of cyl in der in te rl ay er at an y ti me ac cor di ng to Section 7-2. c. Check the closing sequences o f drainage system under the following operating states: (1) At 10% rated load, close the drainage of HP section; (2) At 20% rated load, close the drainage of IP section; (3) At 30% rated load, close the drainage of LP section. d. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency. e. When the steam turbine runs stably upwards of 225MW and the air extractor works properly, it is possible to perform the tightness test of vacuum system.

3-1-11


(WE) D300N-000106ASM

(1) Close the inlet electric door of air extractor, the vacuum of steam condenser shall drop slowly. If the drop rate

≤ 0.13kPa/min

(1mmHg/min),

excellent

If the drop rate

≤ 0.27kPa/min

(2mmHg/min),

good

If the drop rate

≤ 0.4kPa/min

(3mmHg/min),

qualified

When the drop rate of vacuum is more than 0.67kPa/min (5mmHg/min), the machine shall be stopped for iden tifying the root cause. Restart the machine when the trouble is eliminated. (2) During the test, if the exhaust pressure increases to 17.86kPa (or vacuum decreases to 626mmHg) and the exhaust temperature is higher than 58℃ , the test shall be stopped. (3) When the test is finished, open the electric valve immediately to recover the rated vacuum value.

3-1-12


(WE) D300N-000106ASM

e r u t a r e p m e m a e t

g n e i r l a l e o n r e n i e b r u t e v g o n i a r u s r d e d e e t i m b a r i h a o r p

Parameters on the left side and line are

rohibited

n a

Main Steam Pressure

Steam Temperature after Control Stage ℃ Fig.3-1-1 Relation Curve of Steam Temperature Under Steam Pressure during Initial Turbine Rolling and Steam Temperature after Control Stage

3-1-13


(WE) D300N-000106ASM

3-2 Start-up Under Warm State (HIP)

1

Preparation Before Turbine Rolling a Supply power to the DEH. The panel and system shall all be in normal

condition; b. Star t th e lu br ic an t pu mp an d ja ck in g oil pu mp and co nf ir m wh et he r th e lubricant system and jacking system are in normal working conditions; c. Start the hydraulic oil pump; d. Engage the turning gear and ensure that the turning time is no less than 4h bef ore tu rb in e ro ll in g; e. Before turbine rolling, the auxiliary steam source of gland seal system shall be en gag ed . It is re qu ir ed th at th e pr es su re of gl an d se al pi pi ng -m ai n sh al l be 0.123MPa and the temperature shall be und er 150℃ ～ 26 0 ℃ . f. When the gland seal system runs properly, the vacuum of steam condenser shall be created. It is required the pressure of steam condenser shall be below 16.7Kpa; g. Press the “LATCH” button and the set will be turned on; h. Open the drain valves for the HP, IP and LP sections; i. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met. j. Def in e Stea m Pa ra me te rs fo r Turb in e Ro llin g (1) Recommended pressure for main steam: 7.84MPa; (2) Refer to (2) in Item m of Article 1 of Section 3-1 for the selection of steam temperature for turbine rolling.

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3-2-1


(WE) D300N-000106ASM

Selection of Main Steam Temperature: For example: Calculation Procedure

Calculation Basis

Calculation Result

Metal temperature after the control stage of HP casing before turbine rolling

Measured

18 0 ℃

According to Article 2.4 in Section 6-2

t （ selected ）

13 0 ℃

Steam temperature after the control stage


31 0 ℃

Main steam temperature

Find in Fig.3-1-1

41 0 ℃

Selection of Reheat Steam Temperature: For example: Calculation Procedure

Calculation Basis

Calculation Result


Measured

14 0 ℃

According to Article 2.4 in Section 6-2

t （ selected ）

15 0 ℃


t+ metal temperature after IP Stage 1

29 0 ℃

Reheat steam temperature

Steam temperature after IP Stage 1+ temperature drop after IP Stage 1 （ 37 ℃ ）

32 7 ℃

k. Define the change rate of steam tempe rature during start-up: refer to Item n in Article 1 of Section 3-1 (1)

Selection of Change Rate of Main Steam Temperature

3-2-2


(WE) D300N-000106ASM

For example: Calculation Procedure

Calculation Basis

Calculation Result

Steam temperature after the HP control stage at a target stable operating load

Set the target load as 100% ECR and main steam pressure as 16.67MPa, and adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537 ℃ -temperature drop at control stage

50 4 ℃

Metal temperature after the HP control stage before turbine rolling

Measured

18 0 ℃

Change of metal temperature

Steam temperature after stage-metal temperature control stage

Change rate of main steam temperature

Find the normal loss in Fig.3-1-5.

the control after the

32 4 ℃

57 ℃ /h

(2) Selection of Change Rate of Reheat Steam Temperature For example: Calculation Procedure

Calculation Basis

Calculation Result


Measured

14 0 ℃

Steam temperature after IP （ 537-37 ） ℃ Stage 1

50 0 ℃

Change of metal temperature

Steam temperature after Stage 1-metal temperature after IP Stage 1

36 0 ℃

Change rate of reheat steam temperature

Find the normal loss in Fig.3-1-6

84 ℃ /h

3-2-3


2

(WE) D300N-000106ASM

Turbine Rolling a. Confirm whether the slide valve of emergency governor is engaged; b. En ga ge th e he at in g fo r th e cy li nd er in te rl ay er acc ord in g to th e ex pa nsion

difference of set; c. Confirm whether the “HP ＆ IP START/IP START” button is under the “HP＆ IP START” sta te; d. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGL E VALVE” state; e. Press the “RUN” button and start the HP and IP reheat stop valves; f. Select the speed of 500r/min for “TARGET”; the accelerating rate of 100r/min/min for “ACCELERATE”; g. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the mac hine shall be stopped. 3

Inspection at 500r/min Running at this speed, perform overall inspection for the set. Mainly check

whether there is friction between the static and dynamic parts, whether the ventilator valve and emergency blowdown valve are at the closed position, whether the HP exhaust non-return valve is at the opened position. The stop time shall not exceed 5 min. a. Select the speed of 3000r/min for “TARGET”; b. Pr es s th e “G O” but to n to in cr ea se th e sp ee d; 4

Rated Speed 3000r/min

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(WE) D300N-000106ASM

a. The pressure of steam condenser shall be less than 13kPa and the vacuum pro te ct io n sh all be en gag ed ; b. Wh en th e ex ha ust te mp er at ur e of LP ca si ng is

≥ 80 ℃ ,

the sprayer of LP casing

shall engage automatically. Otherwise, it shall be started manually. c. The TSI monitoring items shall be within the permissible range; d. Check Lubricant System (1) The switch between the main oil pump and AC lubricant pump shall be completed; (2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2; (4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2. (5) Stop the oil pump for jacking when the speed reaches 1200r/min. e. Check Hydraulic Oil System The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2; f. Confirm Steam Parameters (1) Main steam pressure: 7.84MPa; (2) Before incorporating in power network, the difference between the main steam temperature and reheat steam temperature shall meet Article c in 2.3 of Section 6-2;

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(WE) D300N-000106ASM

(3) The change rates of main steam temperature and reheat steam temperature shall meet the selected value before turbine rolling; 5


operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the con trol of load increase. 6

Load Increase a. Select the load of 30MW for “TARGET”, the load increase rate of 3MW/min

as the “LOAD RATE”; b. Pr es s th e “G O” but to n to in cr ea se th e lo ad . 7

Warming up under Low Load Operate steadily under the low load of 30MW, ensure the metal temperature of

IP exhaust lower half inner wall more than 176℃ and keep warming up for 20 min; a. Select the final stable target operating load for “TARGET”; b. Se le ct th e lo ad in cr ea se ra te of 3MW/m in as th e “L OA D RATE ”; c. Press the “GO” button to increase the load. 8


time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not par ti ci pa te in th e ad ju st me nt un ti l th el oa d ap pr oa ch s to 90 % EC R. 3-2-6


(WE) D300N-000106ASM

b. Stop us in g th e he ati ng sy st em of cyl in der in te rl ay er at an y ti me ac cor di ng to Section 7-2. c. Check the closing sequences o f drainage system under the following operating states: (1)


(2)


(3)


d. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.

3-2-7


(WE) D300N-000106ASM

3-3 Start-up Under Hot State and Extremely Hot State (HIP)

1

Preparation before Turbine Rolling a. Supply power to the DEH. The panel and system shall all be in normal

condition; b. Star t th e lu br ic an t pum p and ja ck in g oi l pu mp et c and con firm wh et he r th e lubricant system and jacking system are in normal working conditions; c. Start the hydraulic oil pump and enable it under no rmal working condition; d. During the period from shutdown to restart, the set shall be at continuous turning gearing state; e. Before turbine rolling, steam shall be sent to the gland seal. Then the vacuum of steam condenser shall be extracted. It is required that the pressure of gland seal pip in g- ma in sh al l be 0. 12 3MP a an d th e te mp er at ur e sh al l be und er 25 0℃ ～ 350 ℃ ; f. Create the vacuum for the steam condenser after the gland seal system runs normally. The pressure for the con denser shall be below 16 .7kPa; g. Press the “LATCH” button and the set will be turned on; h. Confirm the difference between the rolling steam temperature and the main stop valve metal temperature of inner wall. If it is more than 120℃ , the valve shall be pr e-h eat ed ; i. Open the drain valves in the HP, IP and LP sections; j. The TS I me as ur ed dat a di sp la y sh all be in th e per mi ssib le ra ng e. Th e eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met; k. Define Steam Parameters for Turbine Rolling (1) Main steam pressure: hot state: 9.81MPa

extremely hot state: 11.76MPa

(2) Refer to (2) in Item m of Article 1 of Section 3-1 for the selection of steam Prepared by

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3-3-1


(WE) D300N-000106ASM

temperature for turbine rolling Selection of Main Steam Temperature: For example: Calculation Result Calculation Procedure

Calculation Basis

Metal temperature after the control stage of HP casing before turbine rolling According to Section 6-2

Article

Steam temperature control stage

2.4

after

in

the

Main steam temperature

Hot State

Extremely Hot State

31 0 ℃

42 0 ℃

30 ℃

10 ℃


34 0 ℃

43 0 ℃

Find in Fig.2-1-1

45 0 ℃

51 0 ℃

Measured

t （ selected ）

No te : Th e pre ssur e of ma in st ea m sh al l no t ex ce ed 11.7 Mp a du ring st ar t- up under the extremely hot state. The temperature of main steam shall not exceed 510℃ as much as possible. In the meanwhile, attention shall be paid to the constraints of load compatibility in Article 2.4 of Section 6-2. （ 3）

Selection of Reheat Steam Temperature:

For example: Calculation Result Calculation Procedure

Calculation Basis

Hot State

Extremely Hot State


Measured

29 0 ℃

44 0 ℃

According to Section 6-2

t （ selected ）

90 ℃

10 ℃

Article

2.4

in

3-3-2


(WE) D300N-000106ASM

Steam temperature after t+ metal temperature after IP Stage 1 IP Stage 1

380 ℃

45 0 ℃

Reheat temperature

417 ℃

48 7 ℃

steam

Steam temperature after IP Stage 1+ temperature drop after IP Stage 1（ 37 ℃）

m. Define the change rate of steam temperature during start-up: refer to Item n in Article 1 of Section 3-1. (1)

Selection of Change Rate of Main Steam Temperature

For example: Calculation Result Calculation Procedure

Calculation Basis

Steam temperature after the HP control stage at a target stable operating load

Set the target load as 100% ECR and main steam pressure as 16.67MPa, and adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537 ℃ -temperature drop at control stage

Metal temperature after Measured the HP control stage bef ore tu rb in e ro ll in g Change of temperature

metal

Change rate of main steam temperature

Steam temperature after the control stage-metal temperature after the control stage Find the normal loss in Fig.3-1-5.

Ho t State

Extremely Hot State

50 4 ℃

50 4 ℃

31 0 ℃

42 0 ℃

19 4 ℃

84 ℃

62 ℃ /h

80 ℃ /h

(2) Selection of Change Rate of Reheat Steam Temperature For example:

3-3-3


(WE) D300N-000106ASM

Calculation Result Calculation Procedure

Calculation Basis Ho t State


Measured


（ 537-37 ） ℃

Change temperature Change reheat temperature 2

of

metal

Steam temperature after Stage 1-metal temperature after IP Stage 1

rate of Find steam Fig.3-1-6

the

normal

loss

Extremely Hot State

29 0 ℃

44 0 ℃

50 0 ℃

50 0 ℃

21 0

60 ℃

95

>300

℃

in ℃ /h

℃ /h

Turbine Rolling a. Confirm whether the slide valve of emergency governor is engaged; b. Co nfirm wh et he r th e “H P＆ IP START/IP START” button is under the “HP＆

IP START” sta te; c. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGL E VALVE” state; d. Press the “RUN” button and start the HP and IP reheat stop valves; select the speed of 50 0r/min for “TARGET”; e. Selection for “ACCELERATE”: hot state: 200r/min/min and extremely hot state: 300r/min/min f. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning g aer shall come away automatically.

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(WE) D300N-000106ASM

the brake shall be disengaged and the machine shall be stopped. 3

Inspection at 500r/min Running at this speed, perform overall inspection for the set. Mainly check

whether there is friction between the static and dynamic parts, whetherthe ventilator valve and emergency blowdown valve are at the closed position, whether the HP exhaust non-return valve is at the opened position. The stop time shall not exceed 5 min. a. Select the speed of 3000r/min for “TARGET”; b. Pr es s th e “G O” but to n to in cr ea se th e sp ee d; 4

Rated Speed 3000r/min a. The pressure of steam condenser shall be less than 13kPa and the vacuum

pro te ct io n sh all be en gag ed ; b. Wh en th e exh au st te mp er at ure is

≥ 80 ℃ ,

the sprayer of LP casing shall engage

automatically. Otherwise, it shall be started manually. c. The TSI monitoring items shall be within the permissible range; d. Check Lubricant System (1) The switch between the main oil pump and AC lubricant pump shall be completed; (2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2; (3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2;

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(WE) D300N-000106ASM

(4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2. (5) Stop the jacking oil pump when the speed reaches 1200r/min. e. Check Hydraulic Oil System The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2; 5


operator that it is permissible to incorporate the set in power network. Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase. 6

Load Increase a. Select the final stable operating target load for “TARGET”; selection

for“LOAD RATE”:

hot state: 4MW/min

extremely hot state: 6MW/min

b. Pr es s th e “G O” but to n to in cr ea se th e lo ad . 7


time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not par ti ci pat e in th e ad ju st me nt un ti l th e lo ad ap pr oa ch s to 90 % EC R.

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(WE) D300N-000106ASM

b. Ch ec k th e cl osing se qu en ces of dra in ag e sy st em unde r th e fo ll ow in g op er at in g states: (1)


(2)


(3)


c. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.

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(WE) D300N-000106ASM

4 Operations

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4-1


4-1

1

(WE) D300N-000106ASM

Normal Operation

When the steam turbine is in the normal operation period, the following items

shall be within the normal value ranges defined in Section 6-1 “ Limited Values for Set Start-up and Operation”: a.

controlling oil pressure (refer to the security and hydraulic oil pressures)

and bearing lubricant pressure; b.

sh af t and bea ring pa d vi bra ti on ;

c.

HIP and LP expansion differences;

d.

temperatures of bearing inlet oil, return oil and tungsten steel;

e.

axial displacement;

f.

metal temperature;

g.

pressure of steam condenser;

h.

exhaust temperature of LP casing;

i.

steam temperature of HP casing exhaust;

j.

oil le vel s of ma in an d hyd ra ul ic oi l ta nk s.

In order to ensure the set safe operation for long term, regular inspection and test shall be performed according to Section 6-4. 2 2.1

Precautions of Normal Operation Permissible Variable Ranges for Steam Parameters a.

Pressure of Main Steam （ refer to the pressure before the HP main stop valve）

Rated Pressure Po:

16.7MPa

Mean annual Pressure of Continuous Operation:

not exceeding Po

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4-1-1


(WE) D300N-000106ASM

Pressure Permissible for Continuous Operation While Ensuring the Mean annual Pressure:

not exceeding 1.05Po

Under abnormal conditions, the permissible pressure variance shall not exceed 1.20Po. However the total time of this value in any year’s operation shall not exceed 12h. b.

Ma in an d Re hea t Stea m Tem per at ur es（ refer to the temperatures before the

HP and IP reheat stop valves ） Rated Tempera ture To:

537℃

Mean annual Temperature of Continuous Operation:

not exceeding To

Temperature Permissible for Continuous Operation While Ensuring the Mean not exceeding To+8℃

annual Temperature:

The total operating time no more than To+14 ℃ shall not exceed 400h; it is allowed to vary between 551℃ and 565℃ . However, the continuous operating time shall not exceed 15min and the total operating time in any year shall not exce ed 80h. 2.2 Partial Periodicity operation Periodicity： f Unit ： Hz f<47.0Hz

Permissible Operating Time Each Time （ se c ）

Total （ min ）

Non-permissible Operation

47.0Hz ≤ f<47.5Hz

15

15

47.5Hz ≤ f<48.0Hz

65

65

48.0Hz ≤ f<48.5Hz

350

350

48.5Hz ≤ f<50.5Hz

Continuous Operation

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(WE) D300N-000106ASM

50.5Hz ≤ f<51.0Hz

200

200

51.0Hz ≤ f<51.5Hz

35

35

51.5Hz ≤ f<52.0Hz

5

5

52.0Hz ≤ f<52.5Hz

2

2

f>52.5Hz

Non-permissible Operation

No te : Above partial periodicity operation restrictions apply to the process from partial to full load. The partial Periodicities occurred during the period of no load operation, shutdown and overspeed shall not be counted into the restricted time. Refer to Section 6-2 and 6-3 for others.

4-1-3


4-2

1

(WE) D300N-000106ASM

Varying Duty Operation

Operating Mode The set can operate in two modes: constant pressure and constant-slide-constant

pre ssur e. During peaking operation, the operating mode of constant-slide-constant is recommended, i.e. adopt the operating mode of constant pressure when the sets runs at more than 90% rated load; adopt the operating mode of slide operation when the sets runs between 90%-40% rated load; adopt the operating mode of constant pressure when the sets runs under 40% rated load. This operating mode can improve the heat economical efficiency, reduce the temperature difference of steam admission part and temperature change when the load changes, thus reduce the fatigue damage of low per io di city. When the set adopts the operating mode of nozzle adjustment (i.e. sequential valves), if the load reaches 90% rated load, No.I and II control valves are fully opened and No.III control valve is slightly opened. When the set runs between 90 ％～ 40 ％ , the boiler enters into the operation of slide pressure. The main steam

pre ssur e re du ce s alo ng wi th th e lo ad wh il e th e op en in g of HP va lv e re ma in s al mo st the same within this range. When the load is smaller than 40% rated load, the set enters the operation of constant pressure. In this phase, the HP control valve is used to change the load. When the load is smaller than 30% rated load, the IP control valve par ti ci pat es in th e lo ad ad ju st me nt. Refer to Fig. 4-2-1 for the variable curve of slide pressure operation.

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4-2-1


2

(WE) D300N-000106ASM

When the mean annual operating time is no less than 7500h, the permissible stable

operating time for the peaking operating: Load ( ％ ECR)

Hour/Year

100

4500

75

2000

40

1000

（ No te : Th e op er ating ti me fo r 75 % an d 40 % lo ad is not al lo we d to ex ce ed th e

above time ） 3

Change Rate of Load: Under 20% nameplate power, no more than 2％ ECR/min; From 50% to 20% nameplate power, no more than 3％ ECR/min; From 100% to 50% nameplate power, no more than 5％ ECR/min and permissible

variable range: 20% 4

During the normal operation period under high load, if the load varies frequently

and the change rate is bigger, in order to have the minimum temperature change in the HP casing and minimum thermal stress, the throttle-governing mode (i.e. single valve adjustment) shall be used. However, if the set stably runs below the rated load for long term, the nozzle-governing mode (sequential valve governing) shall be used to obtain higher economical efficiency.

4-2-2


(WE) D300N-000106ASM

e r u s s e r m a e n a

Load

Fig. 4-2-1 Varying Curve of Slide Pressure Operati on

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(WE) D300N-000106ASM

4-3 Abnormal Operation

When the steam turbine operates, if one or several limited values in Section 6-2 are out of limit and enter into the alarming state but none of them reaches the shutdown value and the power plant does not want to shut down the machine immediately, the short operation under this state is called as abnormal operation. When the steam turbine operates abnormally, close attention shall be paid to the trends of various overrun, the root causes shall be found out as soon as possible and proper measures shall be taken to eliminate them. Once the overrun value becomes the shutdown value, the machine shall be shut down immediately. Followings are the contents to be checked when some of limited values enter into the alarming state. Overrun Project

1 Big Axial Displacement

Major Inspection Content

Remark

1) Check whether the parameters of main and reheat steam as well as the vacuum fluctuate greatly. 2) Check the temperature of bearing pad and discharged oil and confirm whether the tungsten steel is worn. 1) Big HIP Expansion Difference a Confirm the direction of expansion difference（Positive expansion difference or negative expansion difference decreases） b Maintain the load on the set and reduce the fluctuation of main steam temperature. Check the exhaust temperature of HP casing.

2 Big Expansion Difference

c If the positive expansion difference increases, the temperature of main steam shall be reduced or the load on the set shall be decreased gradually. d If the negative expansion difference increases, the temperature of main steam shall be increased or the load on the set shall be increased gradually. Or other measures shall be taken to raise the cylinder temperature.

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(WE) D300N-000106ASM

2) Big expansion Difference of LP Casing （Limited value for positive expansion difference only） a Maintain the load on the set and reduce the fluctuation of reheat steam temperature. Check the exhaust temperature of LP casing. b Reduce the temperature of reheat steam and gradually reduce the load on the set. 1) Pay attention to the vibration trend of each bearing and ascertain the vibration type. 2) Check whether the following indications are normal a Temperature of Bearing Tungsten Steel and Inlet Oil; b Pressure of Oil Film on Each Pad; c Whether the unmatched value between the temperature of main and reheat steam vs. temperature of cylinder metal is too big; d Pressure of steam condenser and LP exhaust temperature; 3 Big Vibration

e Temperature Difference of HIP Cylinder Metal; f Cylinder Expansion and Expansion Difference; g Check shaft bend value when shutdown; h Measure vibration frequency spectrum and axes track, etc. 3） If the vibration is too severe during the start-up period of steam turbine, the set shall not operate in the range of critical speed. If excessive vibration occurs during the load increase period, the load increase shall be stopped and the steam shall operate under the original load. Increase the load again after the cause is found out and eliminated. If the vibration in the accelerating period exceeds the limit, the machine shall be shutdown for inspection. It is not allowed to operate at a reduced speed. 1) Check the oil level of main steam oil box;

4 Low Lubricant 2) Check whether the lubricant system has leakage; Pressure 3) Check whether the main oil pump and oil injector are normal.

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(WE) D300N-000106ASM

1) Check the pressure of oil film of bearing; 5 High 2) Check the lubricant quality and confirm whether there is any Temperature of impurity in the oil; Supporting Bearing Pad and 3) Check whether the inlet oil temperature is normal; Return Oil 4) Check whether the gland seal leakage is severe. 6 High Temperature of Thrust Bearing Pad and Return Oil

1) Check whether the axial displacement is too big; 2) Check lubricant quality and confirm whether there is impurity in the oil; 3) Check whether the inlet oil temperature is normal. 1) When the oil level of main oil tank is low, check whether there is leakage in the lubricant system.

7 High or Low Oil Level of 2) When the oil level of main oil box is high, check whether there is Main Oil Tank water leakage in the oil cooler or whether the pending in the main oil tank is too much. 1)

Check whether the LP exhaust temperature is normal;

2) check whether the vacuum breaking valve and emergency blowdown valve are closed; 8 Low Vacuum 3) Check whether the feeding pressure for the gland seal before and of Steam after the LP casing; Condenser 4) Check whether the cycling water temperature and level of steam condenser are normal; 5) If it is under the LP spray state, check whether the water spray is normal.

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(WE) D300N-000106ASM

5 Shutdowns

The set shutdown includes slide parameter shutdown, rated parameter shutdown and emergency shutdown. Slide parameter shutdown: mainly to reduce the cylinder metal temperature after shutdown to a lower temperature level. Normally it applies to light repair, heavy repair and other planned shutdown. Rated parameter shutdown: mainly to enable timely start-up after short time trouble-shooting. Therefore, it is desired to maintain a higher temperature level for the cylinder metal to shorten the star-up time. Emergency Shutdown: mainly applies to the accidents, dangers and sudden nature disasters. Preparations before the slide and rated parameter shutdown: a.

Test AC and DC lubricant pumps, jacking oil pump and turning gear motor.

All shall work properly; b.

Co nfirm wh eth er th e ma in st ea m va lv e, co ntrol va lv e an d ex tr ac ti on no n

return valve are agile without stuck; c.

Heat the pipelines for the shaft seal auxiliary steam source and backup steam

source for the deaerator.

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5-1


(WE) D300N-000106ASM

5-1 Slide Parameter Shutdown

The steam turbine follows the boiler to slide the pressure to reduce the load according to the slide pressure curve. In the meanwhile, the speed governing port opens gradually and fully. During the load decrease period, the operator shall monitor the metal temperature after the control stage of HP inner casing and metal temperature change gradient of steam admission area of IP casing. Under the “Manual” and “Operator Auto” states, the limited value for the load decrease rate is given by the operation board. Refer to the operating procedures of set start-up for the operating modes. a.

Limitations for the reduction of temperature, pressure and load according to

the slide parameter shutdown curve of boiler descending speed of main and rehe at steam temperature: less than 1℃ /min; descending speed of main and reheat steam pressure: less than 0.098MPa/min; degree of superheating of main and reheat steam: more than 50℃ ; b. des ce nd in g sp ee d of cy li nd er me ta l te mp er at ure : no t ex ce ed in g 1℃ /min; c. When the main steam temperature descends 30 ℃ or so, the state shall be kept for 5 ～ 10min before further temperature reduction. The purpose is to control the temperature difference between the main and reheat steam as well as the heat expansion and expansion difference of steam turbine; d.

When the steam temperature after the control stage is 30℃ lower than the

metal temperature of flange inner wall at the control stage of HP inner casing, the reduction of temperature shall be paused; e.

Attention shall be paid to the change of expansion difference of HIP casing

during the load reduction process. When the negative expansion difference reaches -1mm, stop reducing the load. If the negative expansion difference continues to increase and no effect is shown by taking measures, which affects the safety of set, the load shall be rapidly reduced to zero;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

5-1-1


f.

(WE) D300N-000106ASM

During the load reduction process, engage the by-pass system and the spray

cooling system of LP casing according to the o peration situation; g.

During the load reduction process, pay attention to the change over of shaft

seal and steam source of deaerator; h.

Control of drainage system during the load reduction process

（ 1 ） At 30 ％ rated load, open the drainage in the LP section; （ 2 ） At 20 ％ rated load, open the drainage in the IP section; （ 3 ） At 10 ％ rated load, open the drainage in the HP section;

i.

When the load is reduced to 50MW, open the condensed water recirculating

door to ensure the normal working of condensing pump and water level of steam condenser; j.

Wh en th e new st ea m pre ss ur e re du ce s to 4. 9 ～ 5.88MPa and steam

temperature reduces to 330 ℃ ～ 36 0 ℃ , if reducing the load to 5% rated load under the constant pressure, after the completion of inspection without finding abnormal, the machine shall be shutdown and the HIP reheat stop valve, control valve and exhaust non return valve shall all be closed; k.

When

the steam turbine trips, the

AC

lubricant pump shall start

automatically. Otherwise, it shall be started manually and start to record/plot the idling curve of steam turbine; l. m.

When the speed reduces to 1200r/min, start the jacking oil pump; When the set idles at 300r/min, open the vacuum breaking valve to break

the vacuum (if the boiler is not stopped, it is not necessary to open the vacuum bre ak in g va lv e) . Wh en th e se t sp ee d re du ce s to zer o, en gag e co nt in uo us tu rn in g ge ar , stop the water-jet ejector and record the shaft bend value and turning gear current at the same time; n.

When the vacuum becomes zero, stop the steam supply and blower for the

gland seal; 5-1-2


o.

(WE) D300N-000106ASM

When the HP inner casing upper half inner wall temperature of reduces 200

℃ , interval turning gear can be used. Turn over 180 ℃ every half hour. When the

temperature reduces below 150℃ , stop the turning gear and jacking.oil pump. After the turning gear is stopped for 8h, stop the lubricant pump; p.

Af te r sh ut do wn , co nf ir m th ere is no oi l smok e in th e ma in oi l ta nk be fore

stopping the smoke discharge fan; r.

Following points shall be monitored during the load reduction and shut down

per io d: （ 1 ） When sliding the parameters to reduce the load, closely monitor the set

vibration. Should there by any abnormal vibration, stop the reduction of temperature and pressure. And stop the machine immediately; （ 2 ） During turning gear, if there is any friction sound or other abnormal

situations, continuous turning gear shall be changed to regular turning gear. If there is hot bending, use the mode of regular turning gear to eliminate it, and then continuously perform turning gear for over 4 hours; （ 3 ） After shutting down, closely monitor and take measures to prevent cold

steam and water from pouring into the cylinder, which will cause shaft bend and cylinder deformation.

5-1-3


5-2

(WE) D300N-000106ASM

Rated Parameter Shutdown

The rated parameter shutdown normally applies to temporary shutdown. If it is pla nn ed to re pa ir th e se t aft er sh utd own , it is be nef ic ia l to ad op t th e no zzl e go ver ni ng mode. Because the metal temperature is lower if the set is shut down with this mode, the cooling time can be shortened. For the peaking set whose shutdown time only has a few hours or other short temporary shutdown, in order to have higher metal temperature after shutdown to facilitate quick re-start, normally the throttle governing mode is adopted. Based on different shutdown purposes, it is possible to select the valve management mode on the operation board—single valve control or sequential valve control (i.e. throttle governing or nozzle governing). a.

Select 1MW/min as the rate of load reduction on the operation board;

b.

Ba se d on th e bo il er op er at in g si tu ation, en ga ge th e by -p as s sy st em at an y

time; c.

When reducing the load, watch the changes of expansion differences of HIP

casing and LP casing. If the expansion difference is too big, the load reduction speed shall be slowed down. Check to see whether the steam source for the gland seal needs to be changed over. When the expansion difference reaches –1mm, stop reducing the load and keep stable operation. If the negative expansion difference continues to increase and the measures taken are non-effective, which affect the set safety, the load shall be rapidly reduced to zero; or the set shall be disengaged and shut down; d.

During the load reduction process, pay attention to the change over of steam

source for the deaerator; e.

During the load reduction process, refer to Article h in Section 5-1 for the

control of drainage system; f.

When the load is reduced to 50MW, open the recycling door of condensed

water to ensure the normal working of condensed water pump and water level of steam condenser;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

5-2-1


g.

(WE) D300N-000106ASM

When the load reduces to 5% rated load, check whether the set has

abnormal. Press the tripping button of steam turbine to disconnect the motor. The HIP reheat stop valve, control valve and exhaust non-return valve shall all be closed; h.

Other operations are the same as the slide parameter shutdown. Refer to

Article k to r in Section 5-1.

5-2-2


(WE) D300N-000106ASM

5-3 Emergency Shutdown

1

Principle of Management for Emergency Shutdown a.

Accident management shall follow the principle of ensuring personal safety,

not damaging equipment or damaging eq uipment as less as possible; b.

Wh en an ac ci de nt oc cu rs, th e faul ty eq ui pm en t sh al l be st op pe d im me di at ely

and relevant measures shall be taken to prevent the expansion of accident. If necessary, the non-faulty equipment shall continue working; c.

Accident management shall be done quickly, precisely and promptly;

d.

The spot shall be maintained, in particular the data recorded in the

instruments and meters before the accident and at the time of accident for the references when investigating the root cause and working out corrective measures; e.

When an accident is eliminated, the on-duty personnel shall completely and

pre ci se ly re co rd th e ph en om en a ob se rv ed , op er at in g par am et er s at th at ti me , co ur se of accident management and occurring time to facilitate the inquiries made by relevant people when analyzing the root cause. 2

Under the following circumstances, after the set is disengaged, the vacuum shall

be br ok en fo r em er ge ncy sh ut do wn a.

The set vibrates intensively with the amplitude of pad vibration reaching

over 0.10mm; b.

Cl ear me ta l fr ic ti on an d im pa ct so un d in th e st ea m tu rb in e or gen era to r;

c.

Water hammer occurs in the steam turbine or the temperature of main or

reheat steam drastically drops over 50 ℃ in 10min; d.

Return oil temperature of any bearing rises to 75℃ or any bearing runs out

of oil and smokes; e

Babbitt alloy temperature of any support bearing rises to 115℃ or Babbitt

alloy temperature of thrust bearing rises to 110℃ ; Prepared by

Checked by

Reviewed by

Standardized by

Entered by

5-3-1


(WE) D300N-000106ASM

f.

Shaft seal or oil ring rubs seriously and sparks occur;

g.

When the lubricant pressure drops to 0.039MPa and no effect occurs even

starting auxiliary oil pump; h.

When the oil level of main oil tank drops below the shutdown value of low

oil level and no effect occurs even refilling the oil; i.

The oil system catches file;

j.

Th e ax ia l di sp la ce me nt ex ce ed s th e tr ip pi ng va lue, bu t th e pr ot ec tion de vi ce

for axial displacement does not act; k.

The speed of steam turbine exceeds 3360r/min, but the emergency governor

does not act;

3

l.

The pressure of steam condenser rises to more than 19.7kPa;

m

The cycling water discontinued and can not be recovered immediately;

n

HP casing exhaust temperature ≥ 42 0 ℃ .

Under the following circumstances, after the set is disengaged, it is possible not to

bre ak th e va cuu m fo r sh utd own . a.

The pipelines of main and reheat steam break and the set can not operate;

b.

Th e co nd en si ng wa te r pu mp is in tr ou bl e an d th e wa te r le ve l of st ea m

condenser is too high ， but th e ba ck -u p pump ca n no t be en ga ged ; c.

The set idles after the load is rejected or runs with the plant power for more

than 15min; d.

Due to the trouble of DEH system and governing security system, the set can

not maintain normal operation; e.

Expansion differences of HIP and LP casings increase and exceed the limited

values after non-effective adjustment;

5-3-2


f. 4

(WE) D300N-000106ASM

The set’s operating time under the motor state exceeds 1min.

Precautions for Emergency Shutdown a.

The HP and IP reheat stop valves as well as control valves shall be closed

immediately; b.

Al l

th e

ex tr ac ti on

an d

ex ha us t

non -r et ur n

val ve s

sh all

be

cl os ed

immediately; c.

The AC or DC lubricant pump shall be engaged immediately;

d.

All the drainage valves for the steam turbine shall be opened;

e.

When the speed drops to 1200r/min, the jacking oil pump shall be started.

5-3-3


(WE) D300N-000106ASM

6 Restrictions for Start-up and Operation

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

6-1


(WE) D300N-000106ASM

6-1 Restrictions for Prohibiting Start-up and Operation

Before start-up or during turbine rolling to pick up the load, confirm whether the following circumstances occur. If yes, start-up shall be prohibited or shut down for inspection. a.

Failure of any safety protection device;

b.

Th e pr ot ec tion ac ti on val ue doe s no t me et th e re qu ir eme nt;

c.

The speed governing system of steam turbine can not maintain no load

operation. After the load rejection, the set can not control the speed below that causes the emergency governor acting; d.

Any main steam valve, control valve, exhaust non-return valve is stuck or

not closed tightly; e.

The rotor bend value of steam turbine is 0.03mm more than the original

value; f.

When turning gear, there is clear metal friction sound or the current for

turning gear increases obviously or swings greatly; g.

Main display instruments (such as the sensors and display instruments for

measuring speed, vibration, axial displacement, relevant exp ansion, speed modulation, lubricant pressure, hydraulic oil pressure, outlet oil temperature of oil cooler, temperature of bearing return oil, pressure and temperature of main and reheat steam, vacuum of steam condenser, the pressure switch of governing and security system, the double-branch thermocouple and display instrument for measuring the cylinder metal temperature, etc.) are not complete or out of order; h.

The AC and DC auxiliary oil pump, lubricant system and hydraulic oil

supply system are in trouble. The jacking device and turning gaer are out of order; i.

The lubricant and hydraulic oil are not qualified. The inlet temperature of

lubricant is abnormal and return oil temperature is too high;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

6-1-1


j.

(WE) D300N-000106ASM

In th e hea t re co up sy st em , th e ma in go ve rnin g an d co nt rol syst ems (suc h as

the water level of deaerator, pressure auto governing, by-pass system protection and auto governing, control system for the steam (electric) feed pump, etc.) are out of order; k.

Water flooding into the steam turbine;

l.

Incomplete heat conservation for the set;

m.

During start-up and operation, the set exceeds the limited values; (see the

limited values for start-up operation in Section 6-2) n.

The water vapor quality does not meet the requirement; for details, refer to

“ Water Vapor Quality Standard for Thermal Power Generator Sets and Steam Dynamic Devices” (GB12145-89); p

Tr ou ble of DE H con tr ol sy st em .

6-1-2


(WE) D300N-000106ASM

6-2 Limits for Start-up and Operation

1 1.1

Alarming and Shutdown Value TSI a.

Axial displacement: (The rotor positions itself at the working pad at the

generator side. The displacement of rotor towards to the direction of generator is pos it iv e, vise ver sa , it is ne ga ti ve )

b.

Alarming value:

-1.05mm

+0.6mm

Shutdown value:

-1.65mm

+1.2mm

Un de r th e st at e of tu rning ge ar , it ala rms wh en th e ecc en tr ic it y ex ce ed s

0.03mm of the original value. If it is more than 0.03mm, continue to turn the gear until it becomes less than 0.03mm before start-up; c.

Expansion difference

Alarming value: HIP expansion difference

-3mm

LP expansion difference

/

Shutdown value: HIP expansion difference

d.

/

+7mm +15mm

Shaft vibration: (peak, peak value)

No rm al val ue :

0. 07 6m m

Alarming value:

0.127mm

Shutdown value:

0.25mm

e.

+14mm

-4mm

LP expansion difference

+6mm

Vibration of bearing cover: (peak, peak value)

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

6-2-1


1.2

No rm al val ue :

0. 02 5m m

Alarming value:

0.05mm

Shutdown value:

0.08mm(manual)

(WE) D300N-000106ASM

Oil System a.

Lubricant pressure （ value at bearing midsplit surface ）

No rm al valu e:

0.0 78 5～ 0.0981MPa

Alarming value:

0.049MPa

Shutdown value:

0.039MPa

Stop turning gear:

0.029Mpa

b.

Pr essur e of hy dr au li c oi l

No rm al val ue :

14 MP a

Alarming value:

11.2MPa

c.

Lubricant temperature

No rm al wo rk in g ra ng e of in le t oil te mp er atu re

40℃ ～ 45 ℃

Oil return temperature: No rm al va lu e: le ss th an

65℃

Alarming value:

65℃

Sh utdown v alue:

75℃ (manual)

d.

Babbitt temperature of support bearing

Alarming value: Shutdown value:

105℃ 115℃ 6-2-2


e.

Thrust pad temperature of thrust bearing

Alarming value:

100℃

Shutdown value:

110℃

f.

(WE) D300N-000106ASM

Oil level of lubricant tank

Highest oil level: Lowest oil level: see《 Specification for Lubricating System 》

Alarming value: Alarming value for low oil level: Shutdown value for low oil level: g.

Oil level of hydraulic oil tank

Highest oil level: Lowest oil level: Alarming value:

see the operation instruction for hydraulic oil system from the supplier

Alarming value for low oil level: 1.3.

1.4.

Pressure of Steam Condenser No rm al val ue :

5.8 kPa

Alarming value:

14.7kPa

Shutdown value:

19.7kPa

Steam Temperature at Steam Drain of HP Outer Casing No rm al valu e:

le ss th an 34 0℃

6-2-3


1.5.

1.6.

Alarming value:

380℃

Shutdown value:

420℃

(WE) D300N-000106ASM

Exhaust Temperature of LP Casing: No rm al va lu e: le ss th an

3 6℃

Alarming value:

80℃ （ engaging the water spray ）

S h ut ut d o w n v al al u e :

1 1 0℃ (manual)

When operating at the rated load, if the temperatures temperatures of main and reheat steam

are lower than 520 ℃ , the set shall reduce the load. During the load reduction, if the steam temperature recovers, the load reduction shall be stopped. Otherwise, the load reduction shall continue. When the steam temperature reduces to 450℃ , the load shall be reduced to zero. If the steam temperature continuously drops to 430℃ an d cannot be recovered, the set shall be manually stopped. 1.7.

During start-up, start-up, load variation variation and shutdown, the the dropped values for the

temperatures of main and reheat steam shall be less than 50 ℃ in the period of continuous 15 min. If it reaches over 80 ℃ , the set shall be manually stopped. 2 Operation Surveillance 2.1 Oil System a.

Outlet Oil Pressure of Main Oil Pump

No rm al Wo rk in g Ra ng e: b. b .

1. 9～ 2.05MPa

Temperature of Hydraulic Oil

No rm al Wo rk in g Ra ng e:

35 ℃ ～ 5 4 ℃

When the oil temperature is lower than 18 ℃ , start-up is prohibited.

6-2-4


(WE) D300N-000106ASM

2.2 Metal State When a failure is found during the ATS’s rotor stress surveillance, the following restrictions on start-up operation shall be monitored for the set proper: a.

Temperature rising rising rate of HIP cylinder wall metal less than 1.5℃ /min

(inner wall metal at Stage 1 of HP and IP casings); b. b .

Te mp er at ur e di ff er en ce s be tw ee n th e HP an d IP ou te r ca sing si ng s as we ll as th e

inner and outer walls of HP inner casing less than 50 ℃ respectively; c.

Temperature difference difference between the inner and outer walls of HP main stop

valve casing; d.

Temperature difference between the inner wall wall of HIP casing casing and outer wall wall

of HP inner casing less than 50 ℃ ; e.

Temperature difference difference between the upper and lower half of outer wall of

HIP outer casing less than 50 ℃ ; f.

Temperature difference difference between between the upper and lower half half of outer wall wall of HP

inner casing less than 35 ℃ ; g.

Temperature difference between the inner and outer wall wall of flange of HIP

outer casing less than 80 ℃ ; h.

Temperature difference difference between the left and right right flanges of upper half of

HIP outer casing less than 10 ℃ ; Temperature difference between the upper and lower half flanges of HIP outer casing less than 10 ℃ .

6-2-5


(WE) D300N-000106ASM

2.3 Steam a.

Temperature rising rate of main steam steam not exceeding 1.5℃ /min;

b. b .

Te mp er at ur e ri sing si ng ra te of re he at st ea m 2℃ /min;

c.

The limited value for the the temperature temperature difference difference between the the main steam (in

front of main steam valve) and reheat steam (in front of IP combined steam valve) is in Fig.6-2-1; e.

The difference of steam temperature temperature of each main steam pipeline pipeline and and that of

each reheat steam pipeline shall not exceed 17 ℃ ; f.

When the temperature difference between the flooding flooding proof proof thermocouples thermocouples

on each section of extraction pipeline is more than 40℃ , it can be regarded as the flooding of cylinder. Measures shall be taken immediately to remove the ponding; g.

When the set operates at 5%-10% rated load, the maximum permissible permissible

exhaust pressure of LP casing of steam turbine shall be 13kPa and the exhaust temperature of LP casing is not more than 52 ℃ . In this load section, long term operation is prohibited; h.

When the set is is allowed to run at 30%-100% 30%-100% rated rated load for for long term, at this

time the maximum exhaust pressure shall be 14.7kPa. When exceeding the value, the condensing system shall be checked; if exceeding the value but not exceeding the shutdown value, the operating time shall be less than 60min. Otherwise, the set shall be b e st op p ed ; i.

The highest permissible exhaust pressure during idling idling after the load

rejection shall be 13.8kPa, the exhaust temperature shall be less than 80℃ an d operating time shall be less than 15 min. Otherwise, the set shall be stopped; j.

Li mite mi te va lu e fo r ea ch se ct io n of ex tr a ct io n pr es su re an d co nt ro l stag st ag e

pre p re ss ur e du ri ng th e st ar t- up an d op e ra ti on p er io d

6-2-6


2.4

(WE) D300N-000106ASM

After the control stage:

13.78MPa

1# steam extraction

6.56MPa

2# steam extraction

3.98MPa

3# steam extraction

1.86MPa

4# steam extraction

0.89MPa

5# steam extraction

0.525MPa

6# steam extraction

0.29MPa

7# steam extraction

0.154MPa

8# steam extraction

0.071MPa

Temperature Difference Between Metal and Steam: (main and reheat steam)

Before start-up, the steam temperature after the HP control stage or IP Stage 1 shall match the metal temperature. The temperature difference between the metal and steam temperatures of cylinder inner wall after the HP control stage or IP Stage 1 shall meet the following requirement: Δ t=steam temperature-metal temperature Δ t ideal value

10 ℃

Δ t permissible value

Δ t limit

90 ℃

15 0 ℃

-2 0 ℃

-5 0 ℃

6-2-7


t a e h e e R r u t e r a u r t e a p r m e e T p m ) e T = e r u t m a a r ℃ e e t p e S m c e n T e r n m e i a f a e f M t i S D

(WE) D300N-000106ASM

Prohibited O eratin Area

Permissible O eratin Area

Lo a Pro te O eratin Area

Fig. 6-2-1 Permissible Temperature Difference Between Main Steam and Reheat Steam

6-2-8


(WE) D300N-000106ASM

6-3 General Precautions

a.

The set is not permitted to operate for long term when the main steam value

opens at one side and closes at the other side; b.

Lo ng te rm op er at io n at le ss th an 30 % ra te d lo ad sh all be av oi de d;

c.

Before the set is disconnected, the operating time of motor shall not exceed

1 min and the vacuum of steam condenser shall be normal; d.

Before engaging the turning gear, steam shall not be supplied to the gland

e.

When the exhaust temperature is high, watch the changes of expansion

seal;

difference, vibration, bearing oil temperature and bearing metal temperature. When the exhaust temperature reaches the alarming value, besides engaging the spray system, other methods such as increasing the degree of vacuum or load shall be taken as well; f.

Except that emergency shutdown requires to break the vacuum immediately,

normally, the vacuum shall be maintained if the set trips until it drops to 10% rated speed under the idling state; g.

The drainage systems of steam proper, main steam pipe, hot section of reheat

steam pipe, cold section of reheat steam pipe and steam extraction pipe shall keep unblocked during start-up and shutdown; h.

The overspeed test can not be performed right after the oil spray test in order

to avoid the inaccuracy of ov erspeed test due to accumulated oil; i.

When the set runs at 50%-60% rated load, the steam condenser is allowed to

be cl ea ned an d re pa ir ed at th e ha lf side. Ho we ve r, th e ch an ges of vi br ati on , oi l temperature and metal temperature of 3# and 4 # bearings shall be watched out;

Prepared by

Checked by

Reviewed by

Standardized by

Entered by

6-3-1


j.

(WE) D300N-000106ASM

Wh en th e se t is ou t of pow er gri d an d us es th e pl an t po we r, an y con tinu ou s

operating time shall not exceed 15 min. During the life time of 30 years, the total times shall not exceed 10 times;k.

When all the HP heaters are removed, the rated

output (300MW) can be ensured, but no exceeding is allowed; The removal of HP heater shall be performed from HP to LP. If the LP heater needs to be removed as well, the steam turbine g enerator set must reduce the load; When the heaters are removed, the pressure after the control stage and the extraction pre ssur e of ea ch st ag e sh al l no t ex ce ed th e li mi te d val ue . Se e A rtic le J in Se ction 6-2 ; l.

When engaging the heaters, they shall be engaged with the start-up from LP

to HP in turns; m.

During the accelerating process, the set shall rapidly pass through the

following critical speeds of various steps. During this phase, the vibration of bearing pad sh al l no t ex cee d 0.1 0mm; Shafting Critical Speed (calculated value) Step 1(Step 1 of Generator Rotor)

1370r/min

Step 2(Step 1 of LP Rotor)

1688r/min

Step 3 (Step 1 of HIP Rotor)

1750r/min

Step 4 (Step 2 of Generator Rotor)

3517r/min

For the initial start-up of newly installed set, the shafting critical speeds shall be recorded. After confirmation, the actual measured values shall be used for the actual shafting critical speed. n.

The speeds of Step 1 vibration type of long blade at the last two stages of LP

casing and harmonic resonance of k ≤ 6 are lower than the working speed. In order to ensure the safety of blades, warming up a nd stop in the resonance speed range are not allowed. The shade line part in Fig. 6-3-1 represents the resonance speed range to be avoided; p.

”M an ua l Mo de” co ntr ol ca n no t be us ed as th e co nt rol mo de fo r lo ng te rm

operation;

6-3-2


q.

(WE) D300N-000106ASM

During the entire operation period, monitoring and inspection shall be

enhanced. Any found p roblem shall be handled timely to avoid accidents.

t t s spee , listen to the soundsand check the monitoring instruments

a rm n g u p Speed at Medium Speed

a rm n g u p Speed at High Speed

Rated Speed

Fig.6-3-1

6-3-3


6-4

(WE) D300N-000106ASM

Regular Check and Test

Besides the tests performed during the start-up period, regular performance tests are necessary to ensure the reliability of set operation. The tests shall be performed strictly in accordance with relevant test regulations and specifications. Any defective par t fo un d sh al l be re pa ir ed or re pl ac ed imme di at el y. a.

Valve Movement Test

once per week

Before doing the valve movement test, the set load shall be reduced to 50%-70% rated load. Otherwise, the main steam parameters or reheat steam parameters and boi le r le ve l wi ll ch ang e gr ea tl y du ri ng th e te st per io d, wh ic h af fe ct s st ab le ope ra tion. When performing the test, follow the valve test buttons on the operation board. After a group of valves are tested in sequences, test another group of valves. The sequence of valve test follows the arrangement on the operation board. Test process of IP valve group: close Control valve→ close Main Steam Valve → open Main Steam Valve→ open Control valve, return to normal. The HP valve test is not restricted in this way. During the valve movement test period, the pressure feedback of control stage shall be engaged. b.

St ar t- up te st of AC an d DC lu br ic an t pu mp

on ce ev er y 15 day s

c.

Change over test of hydraulic oil pump

once every week

d.

Movement test of extraction check valve (except for the HP exhaust non

return valve) e.

once every month

Vacuum tightness test, see Item e of Article 11 in Section 3-1 once every month

f.

Tightness test of HP and IP reheat stop valves as well as HP and IP control

valves

Prepared by

once every six month

Checked by

Reviewed by

Standardized by

Entered by

6-4-1


(WE) D300N-000106ASM

(1) The test shall be performed at the rated steam pressure, normal vacuum and zero load; (2) When the HP and IP reheat stop valves as well as HP and IP regulating values are fully closed respectively, the steam turbine speed shall be reduced below 1000r/min;When the main steam pressure is low but not lower than 50% rated, the dropped value “n” of steam turbine steam can be corrected by the following formula: n=(p/p. )x1000r/min n the formula:

p

---main steam pressure during test

p. -- -r at ed ma in st eam pr es su re No te : Th e va lv e ti gh tn es s te st sh al l be pe rform ed af te r ea ch disin te gra te d repairing of HP and IP reheat stop valves as well as HP and IP control valves, set heavy repair and load rejection test. g.

Oil spray test of emergency governor

h.

Raising speed test of emergency governor

i.

On-line test of HP emergency governor IC (HPT) electromagnetic valve;

j.

according to “ Specifications for Governing and Security System”

On -l in e te st of ov er sp ee d li mi t IC (O SP ) electromagnetic valve;

k.

Check whether the TSI, steam temperature and pressure as well as other

meters are normal and precise once every month l.

Protection device test of low lubricant pressure

verify during light repair

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(WE) D300N-000106ASM

Other tests for the DEH system can be found in the DEH manual Check whether the sprayer of spray device of LP casing is blocked

check

during heavy repair

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(WE) D300N-000106ASM

7 Auxiliary Operation of Start-up and Shutdown

The auxiliary operation of start-up and shutdown mainly refers to the operations of pre-warming system of HP casing, interlayer heating system of HP casing, emergency discharge system and ventilator valve system. Because the operating sequence of ventilator valve has been explained in the section of start-up with the IP casing, there is no more explanation in this section.

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Pre-warming of HP Casing

Inspection before Warming up

1.1 Confirm whether the HP control valve is closed and the steam parameters: Steam pressure:

0.4 ～ 0.8MPa; steam temperature:

200～ 25 0 ℃ ， maintain

over 50 ℃ degree of superheating. 1.2 Confirm whether the operation of turning gear after engagement is over two hours. 1.3 Confirm whether the gland seal at the shaft end of HIP casing is engaged. 1.4 Confirm whether the pressure of steam condenser does not exceed 19.6kPa. 1.5 Confirm whether the metal temperature at the control stage of HP inner casing is under 150℃ . 2

Operation Process of Warming up The operator runs the warming up system on the operation board according to

the set state displayed on the CRT. 2.1 Operation Preparation a.

Fully open the drain valve on the HP main steam pipe, forcibly close the

exhaust non-return flap of HP casing and confirm that each extraction non-return flap of HP casing is closed; b.

Fu lly op en th e dra in va lv e in fr on t of th e exh au st no n-re tu rn flap of HP

casing; c.

Fully open the drain valve of HP inner casing;

d.

Fully open the ventilator valve (VV valve).

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Warming up Operation Gradually open the RFV to let the warming steam flow into the HP casing. Part

of steam enters into the drainage system through each drain hole. Another part of steam leaks into the IP casing through the gland seal between the HP and IP casings. Then it is discharged into the steam condenser through the connecting pipe and LP casing. Maintain the pressure in the casing within 0.4～ 0.5MPa by adjusting the RFV and drain valve. During the warming up period, the operator shall not let the temperature rising rate exceed 50℃ /h. The temperature difference and expansion difference of each cylinder wall shall be maintained within the permissible range (by adjusting the RFV and drain valve of each section in the HP casing). When the metal temperature of upper half inner wall at the control stage of HP inner casing reaches 150 ℃ over, the throttle valve in front of the RFV opens 10%. Refer to Fig.7-1-1 for the warming up maintaining time. 2.3

3

Finishing Warming up Operation a.

When warming up is finished, the RFV shall be closed (RFV);

b.

Fu ll y cl ose all th e dr ai n va lv es of HP ca si ng ;

Pre-warming of HP Control valve When the inner or outer wall temperature of HP main steam control valve is

lower than 150 ℃ , during the pre-warming of HP casing, the HP main steam control valve casing shall be pre-warmed. During the pre-warming of HP main steam control valve casing, the HP main stop valve is at the closed state. The main steam for pre -w ar ming en te rs in to th e co ntr ol va lv e ca si ng th ro ug h No .2 Ma in St ea m Va lv e. The pre-warming operational method is as follows:

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a.

Confirm that the HP main stop valve and control valve are fully closed;

b.

Op en th e dra in val ve on th e HP ma in stop va lv e ca si ng;

c.

Open the electric main steam valve, turn No.2 Main Steam Valve of HP

casing to the pre-warming position. At this time, actions shall be taken to prevent the rotor from turbine rolling and turning gear from being released due to the untightness of governing port. d.

Monitor the temperature difference between the inner and outer walls of

control valve, when it exceeds 80 ℃ , close No.2 HP Main Stop Valve when it is less than 70 ℃ , return No.2 HP Main Stop Valve to the pre-warming position. Repeat the pro ces s un ti l th e meta l te mp er at ur es of in ne r an d ou te r wa lls of va lv e ca si ng ri se to 150 ℃ over and reach the requirement of valve p re-warming. e.

When the pre-warming is finished, close the HP main stop valve;

f.

Close the drain valve of HP main stop valve casing.

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(WE) D300N-000106ASM

e m i T n o i t a v r e s n o C t a e H

Metal Temperature of Upper Half of Inner Wall at Control Stage of HP Inner Casing before Pre-warming

Fig.7-1-1 Curve of Heat Conservation Time

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(WE) D300N-000106ASM

Heating System of HP Casing Interlayer

System Composition and Function The system composition is shown in Fig.7-2-1. The function is to introduce the

main steam into the interlayer between the HP inner and outer casings to heat them so as to reduce the positive expansion difference of HIP casing and the temperature difference of inner and outer walls of HP inner casing as well as make the temperature of HP outer casing even along the axial direction. The control means is to change the flow to control the heating speed by adjusting the interlayer steam admission pressure. The steam admission box pressure of cylinder interlayer: Nor ma l Va lu e:

0.9 8--4.9 Mp a

Maximum Value: 2

3

6.5Mpa

Test Before System Engaged a.

The safety valve is reset according to 6.5MPa;

b.

Th e el ec tr ic val ve an d ma nu al val ve ar e agi le ;

c.

The thermocouple and pressure gauge are installed and work properly.

Preparation before System Engaged a.

Confirm the drain valve of heating steam admission box of cylinder

interlayer is opened; b.

Co nf ir m th e me ta l te mp er atur e of up pe r ha lf in ne r wa ll of HP ou te r ca sing is

less than 300 ℃ ;

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(WE) D300N-000106ASM

The operator manually opens the manual stop valve in the back of heating

steam admission box of cylinder interlayer (the manual stop valve in front of the steam admission box is closed). 4 System Operation a.

Open the electric stop valve in front of heating steam admission of cylinder

interlayer; b.

Be fo re th e new ma ch in e is pu t in to op er at ion, th e op erat or ma nu al ly ad just s

the manual stop valve in front of the heating steam admission box of cylinder interlayer to let its pressure lower than that of main steam when engaging the system so as to reach the normal working pressure; c.

During the process of acceleration or picking up the load, the operator

adjusts the manual stop valve in the back of heating steam admission box of cylinder interlayer to control the interlayer steam volume according to the HIP expansion difference, upper and lower temperature difference of outer walls of HP inner casing as well as the upper and lower temperature difference of inner walls of HP outer casing; d.

Closely monitor the temperature rising rate of cylinder not to exceed 50℃ /h ,

the upper and lower temperature difference of outer walls of HP inner casing and the upper and lower temperature difference of inner walls of HP outer casing not exceed 50 ℃ . e.

When the outer wall metal temperature of HP outer casing lower half at the

steam inlet exceeds 350 ℃ and the HIP expansion d ifference is within the permissible range, the heating system of cylinder interlayer can be stopped.

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Finishing Operation Close the electric stop valve in front of the steam admission box; Close the manual stop valve in front of the steam admission box; Close the electric stop valve in the back of the steam admission box; Close the drain valve. Pressure Thermocouple

Gauge

Relief Valve

Manual Electric Valve

ew Steam

Valve

Steam Admission Box of Cylinder Interlayer

Connect to left half of interlayer chamber

Interlayer Chamber of HP Inner and Outer Casings

To HP Exhaust

onnect to right half of interlayer chamber

Drainage to Steam Condenser

Fig.7-2-1 Diagram of Heating Interlayer System of HP Casing

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Water Spray of LP Casing of Steam Turbine

Composition, Function and Control The spray system consists of atomization sprayer, electric valve, manual throttle

valve, manual stop valve, sieve, pressure gauge and steel tube. Refer to “ Spray Device System Diagram” for the detailed composition. During the initial start-up, in order to prevent the steam condenser system from not timely taking the exhaust steam of LP casing and heat of LP by-pass steam, which causes the temperature rise of exhaust temperature of LP casing, as well as the exhaust temperature rise of LP casing due to the blast of LP stage when the set has low load and high back pressure, which impacts the movable blades of last several stages of LP casing and LP through flow, the water spray system of LP casing is built. The control can be manual and auto: 1.1 Auto Control: When the exhaust temperature at any point before or after the LP casing equals or is more than 80 ℃ , the water spray is engaged. When the temperature of each point bef ore or af te r eq ual s or is le ss th an 65℃ , stop the water spray. 1.2 Manual Control When the spray control is under the manual control state, the temperature does not control the spray. The operator can start or stop the spray system based on the concrete situation. No te : Fo r th e au to or ma nua l co nt ro l, th e st ar t or st op of wa te r sp ra y shall be done at the front and rear sides at the same time.

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2 Test before Spray System Engaged a ） In the system , all the electric and manual valves shall be agile; b ） before connecting to water (water source is the condensed water from the desalting device), fully open the electric and manual valves, remove the sprayer, and then connect to water to rinse the system until there is no impurity left on the sieve. Install the sprayer and firmly fix it by spot welding; c ） Start the electric valve after the manual throttle valve and adjust its opening so as to control the spray pressure after the throttle valve within 0.49 ～ 0.784MPa; d ） Check the atomization of sprayer and spraying angle. They are adjustable through changing the spraying pressure. After the adjustment is done, record the opening of throttle valve and spraying pressure. No te : a ） The electric valve on the spray pipe shall be opened before start-up and closed after shutdown. b ） The normal engagement and shutdown are controlled by the electric valve after the throttle valve. When it fails to act, the manual by-pass valve can be used for that purpose.

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Emergency Discharge System

Composition, Function and Control The system consists of emergency blowdown valve, electromagnetic control

ventilator valve and steel tube. Refer to “Diagram of Auxiliary System of Steam Turbine Proper” for details. When the set rejects the load, in order to prevent the residual steam in the HP casing and HP steam guiding pipe from fleeing into the IP and LP casings from the HIP gland seal gap and impacts the set, the BDV is installed. When the gland seal teeth wear and the gap becomes bigger, the overspeed possibility will increase. When the set trips, the BDV opens rapidly and directly guide the residual steam at the HIP gland seal to the steam condenser to prevent the overspeed of set. The BDV open and close are controlled by the oil servo motor stroke of IP control valve: When the oil servo motor stroke of IP control valve is

≥ 30mm,

the BDV is

closed. When the oil servo motor stroke of IP control valve is <30mm, the BDV is opened. 2

Test Before Start-up a ）Check and confirm that the compressed air enters into the upp er part of piston

of BDV when the electromagnetic control ventilator valve excitates. The piston overcomes the downward shift of spring force to close the valve. When the electromagnetic control ventilator valve dis-excitates, the upper part of piston of BDV connects with the exhausted air to release the air pressure. Under the action of spring force, the piston moves upward to open the valve. b ） The controlling compressed air pressure shall be within 0.4 ～ 0.7MPa to ensure the close of BDV.

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No te : it is be tt er to ta ke th e hi ger va lu e of co mp re ssed ai r. c ） Check and confirm the correctness of electric control interlock.

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_WE_D300N-000106ASM(Turbine Start-up and Operation Manual)

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