Turbine Start Up

DOCUMENT SUBMISSION STATUS: FOR INFORMATION
4 19.07.2018 FOR INFORMATION M.S.KIM H.SHIN D.S.HEO

3 29.03.2018 FOR INFORMATION M.S.KIM H.SHIN D.S.HEO
2 12.09.2017 FOR INFORMATION Y.C.KIM H.SHIN W.G.CHOI

REV DATE DESCRIPTION PREPARED CHECKED APPROVED
PROJECT TITLE
SONG HAU 1 THERMAL POWER PLANT (2x600MW)
OWNER OWNER’S CONSULTANT
VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING
EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT
VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR
DATE NAME SIGN DOCUMENT TITLE
PREPARED 19.07.2018 M.S.KIM
Turbine Startup and

CHECKED 19.07.2018 H.SHIN
Shutdown Instruction
APPROVED 19.07.2018 D.S.HEO
DOCUMENT NO. REV.

SH1-DHI-P1MAA-M-M01-MAN-3005 4
SONG HAU 1 THERMAL POWER PLANT PROJECT
CONTENTS
1. GENERAL INFORMATION.............................................................................................. 3
1.1 INTRODUCTION................................................................................................................ 3
1.2 ABBREVIATIONS .............................................................................................................. 3
2. MAIN SPECIFICATION AND BACKGROUND ............................................................ 4
2.1 NOMINAL PARAMETER AT DESIGN (TMCR)............................................................ 4
2.2 MACHINE LIFETIME ....................................................................................................... 5
2.3 THERMAL STRESS AND DISTORTION........................................................................ 6
2.4 OPERATION ON CHANGED NETWORK CONDITIONS .......................................... 6
2.5 CRITICAL SPEED .............................................................................................................. 6
2.6 VIBRATION ......................................................................................................................... 6
3. PREPARATION FOR ROLLING...................................................................................... 7
3.1 DESIGN RESULT FOR ST START-UP ............................................................................ 8
3.2 ROTOR PREWARMING ................................................................................................... 8
3.3 CHEST WARMING REQUIRMENT .............................................................................. 10
3.4 DRAIN VALVE OPERATION.......................................................................................... 10
3.5 HP ROTOR COOLING DURING TURBINE SPEED-UP ............................................ 11
3.6 STEAM SEAL OPERATION ........................................................................................... 12
4. TURBINE START-UP PROCEDUE AND LIMITATION ............................................. 13
4.1 ROTOR WARMING AND PREPARATION .................................................................. 13
4.2 TURBINE ROLL-OFF ...................................................................................................... 16
4.3 SYNCHRONIZATION TO FULL LOAD ....................................................................... 17
4.4 TURBINE SHUTDOWN................................................................................................... 20
5. GENERAL PRECAUTION .............................................................................................. 22
5.1 ALLOWABLE VARIATION IN STEAM PRESSURE AND TEMPERATURE ......... 22
5.1.1 INLET STEAM PRESSURE ............................................................................................ 22
5.1.2 INLET STEAM TEMPERATURE .................................................................................. 22
5.2 OPERATION LIMITATION ON LP VACUUM INCREASE ....................................... 22
5.3 TURBINE SHUTDOWN................................................................................................... 23
5.4 VIBRATION LIMITS ....................................................................................................... 23
5.5 OVERSPEED TEST .......................................................................................................... 24
5.6 TURNING GEAR OPERATION AND ROTOR ECCENTRICITY ............................ 24
SH1-DHI-P1MAA-M-M01-MAN-3005 1 of 41
5.7 VACUUM BREAKING ..................................................................................................... 25

5.8 NORMAL AND EMERGENCY SHUTDOWN .............................................................. 25
Appendix A Steam Seal Temperature
Appendix B Bearing Lube Oil Temperature
Appendix C Allowable Inlet Steam Temperature for HP/IP Rotors
Appendix D Valve Position Diagram
Appendix E Condenser Backpressure Limitation
Appendix F Startup and Shutdown Flow Chart
Appendix G Operation Parameters Limitation
Appendix H Turning Gear Operation
Appendix I LP Exhaust Hood Spray
TURBINE STARTUP AND SHUTDOWN INSTRUCTION
1. GENERAL INFORMATION
1.1 Introduction
These operation directions have been prepared for the needs of the turbine operator as a basis
for the preparation of operation directions of the entire unit. Basically, the contents mentioned
in this document indicate the concept and necessary action in normal operation. It should be
recognized that the required actions are decided by the operating engineers considering the
situation of plant. The manufacturer, if required, will change or supplement these operation
directions to the experience gained during the trial operation. The testing engineer of the
company has the right to implement such change right in the operator’s plant. The directions
may only be assigned to a third party with the consent of the manufacturer.
This article is not a standalone article for starting and operating the turbine. Familiarity with the
turbine controls will enable the operator to memorize the correct sequence of operations, or
refer to an overall plant checklist if desired. This document should be integrated into the station
operating procedures. Special boiler or other station equipment characteristics which cannot be
foreseen may make changes in the procedures desirable, and experience or future technological
changes may show that revisions are needed. Therefore, this should be considered as a flexible
instruction rather than an inflexible rule.
Reference
- P&I Diagram Lube Oil Piping for Turbine (SH1-DHI-P1MAA-M-M01-PID-3124)
- P&I Diagram Steam Piping for Turbine (SH1-DHI-P1MAA-M-M01-PID-3129)
- P&I Diagram Lube Oil Tank for Turbine (SH1-DHI-P1MAA-M-M01-PID-3132)
- P&I Diagram Lube Tank for Turbine (SH1-DHI-P1MAA-M-M01-PID-3124)
- System Description for Generator Hydrogen Seal Oil System (SH1-DHI-P1MKW-M-

M01-PHL-3171)
- System Description for Generator Stator Winding Liquid Cooling System (SH1-DHI-
P1MKF-M-M01-PHL-3172)
- System Description for Generator Gas (H2&CO2) Control System (SH1-DHI-P1MKG-

M-M01-PHL-3173)
- System Description for Gland Seal Steam System (SH1-DHI-P1MAA-M-M01-PHL-

3175)
- General System Description for Steam Turbine and Auxiliaries (SH1-DHI-P1MAA-M-
M01-PHL-3137)
- Vacuum Pump System Description (SH1-DHI-P1MAJ-M-M01-PHL-3748)
1.2 Abbreviations
APS : AUTOMATIC PLANT STARTUP AND SHUTDOWN SYSTEM
AVR : AUTOMATIC VOLTAGE REGULATOR
BOP : BEARING OIL PUMP (P1MAV20AP002, P1MAV20AP 001)
BVV : BYPASS VENTILATOR VALVE (P1MAA10AA059)
BDV : BLOW DOWN VALE (P1MAL10AA502)
CO2 : CARBON DIOXIDE
CRV : COMBINED REHEAT VALVE
CV : CONTROL VALVE (P1MAA10AA051, P1MAA11AA051)
DCS : DISTRIBUTED CONTROL SYSTEM
EBOP : EMERGENCY BEARING OIL PUMP (P1MAV20AP003)
FSNL : FULL SPEED NO LOAD
H2 : HYDROGEN
HSBV : HEATING STEAM BLOCKING VALVE (P1MAW40AA090)
HSPV : HEATING STEAM PRESSURIZING VALVE (P1LBC11AA01)
IV : INTERCEPT VALVE (P1MAB10AA053, P1MAB11AA053)
F/F : FORWARD FLOW
MSOP : MAIN SEAL OIL PUMP
MSV : MAIN STOP VALVE (P1MAA10AA052, P1MAA11AA052)
MSVBV : MAIN STOP VALVE BYPASS VALVE
OCV : OVERLOAD CONTROL VALVE (P1MAA10AA055)
OSV : OVERLOAD STOP VALVE (P1MAA10AA056)
RFV : REVERSE FLOW VALVE (P1LBC10AA081)
R/F : REVERSE FLOW
RSV : REHEAT STOP VALVE (P1MAB10AA054, P1MAB10AA054)
TBN : TURBINE
TCS : TURBINE CONTROL SYSTEM
UMC : UNIT MASTER CONTROL
2. MAIN SPECIFICATION AND BACKGROUND

2.1 Nominal Parameter at Design (TMCR)
Figure 2-1 Schematic of Full-train Rotor Bearing System
Turbine model : DS108/109

Direction of rotation (view from the generator to the turbine) : Clockwise
Rating unit output : 600MW
Turbine and generator rotating speed : 3,000rpm
Nominal steam conditions
- Steam condition for HP turbine : 566°C / 242.2bara
- Steam condition for IP turbine : 593°C / 44.0bara
Exhaust Pressure : 0.073bara
Stage number : 10(HP) / 8(IP) / 6(LP)
2.2 Machine Lifetime
The steam turbine is equipment which runs in high speed and its elements are loaded both
mechanically and thermally. For this reason, high emphasis is put on the selection of first-class
materials and on the designing solution of the elements loaded most.
The centrifugal loading and the stresses caused by the steam pressure and dynamic effects are
given by the machine design and physical parameters and are proportionate to the equipment
power at rated speed. The additional stresses in the material caused by the occurrence of non-
stationary temperature fields during turbine heating / loading and/or relieving / cooling play a
considerable role in crack occurrence and in machine lifetime influenced by the way of
operation. When the prescribed trends are observed, the expected number of cold, warm and hot
start-ups given in the following table;
Table 2-1 Turbine Startup Modes
Shutdown period Speed rate No. of startup

Startup mode
(hours) (rpm/min) (per year)
Hot Start <8 300 120
Warm Start 8 ~ 48 150 30
Cold Start > 48 100 4
2.3 Thermal Stress and Distortion
During steady-state operation, the combined thermal and pressure stresses in the valves and
shells, and the combined thermal and centrifugal stress in the rotors, are maintained at a
relatively low level. However, during transient operation, such as startups, shutdowns, load
changes, and emergencies, large thermal stresses can be superimposed on the pressure stresses
in the shells and valves, and on the centrifugal stresses in the rotors. A severe transient will
produce yielding, resulting in a certain percentage of the fatigue life of the main high-
temperature parts being consumed. The amount of life expenditure depends on the level of
combined stress developed during each operation. One aim of these instructions in this
document, therefore, is to limit these stresses to an acceptable level by suitably controlling the
rates of temperature change. Proper control of thermal stresses will not only inhibit the tendency
for premature fatigue damage, but together with proper prewarming will greatly reduce the
possibility of a catastrophic rotor burst.
2.4 Operation on Changed Network Conditions

The turbine can be operated without any limitation within the frequency range 48.5 ~ 51.5 Hz.
2.5 Critical Speed
Critical speed is calculated considering the rigidity of bearing supports and the oil film on the
bearings, and is far enough from the operating and warming-up speed. When the set is being
started up, the passing of the critical speed area manifests itself in vibrations. It is necessary not
to dwell on this speed and to pass it with a continuous, faster trend. It is forbidden to retain
(restart) the turbine within this speed range.
If, for any reason (when testing the safety equipment, for instance), the turbine is not retained
within the range of operating speed, the speed must be let drop to the level of warming-up speed
before restarting.
Model analysis was made for the whole shaft train, which includes the HP/IP turbine rotor, LP
turbine rotor and the generator. (For the detail information of steam turbine rotor system, refer
to SH1-DHI-P1MAA-M-M01-TEN-3001, ROTOR DYNAMICS REPORT.)
The actual value may vary in practice due to the damping qualities of the base, the rigidity of
the bearing pedestals and the oil film.
2.6 Vibration
The turbine should operate without any considerable noise and vibrations in all the designed
operating states. A well-balanced rotor will not made excessive vibration except rubbing of the
packing equipment for uneven heating or cooling on shaft or bowing of rotor caused by some
other reason.
Light rubbing may be experienced during turbine rolling despite proper operation. Rubbing may
develop during operation near a critical speed where rotor deflections are large. Also, due to a
temporary rotor bow caused by uneven temperature distribution in the rotor or shell, unexpected
vibration may result. These rubbing and vibration will affect shaft seal clearances. The
clearances for shaft packing are designed to reduce the possibility of rubbing and maintain sharp
packing teeth to minimize leakage.
Rotor vibrations are measured in two perpendicular planes and the quantities measured during
the initial operation period should be considered as a reference for assessing operation quality.
The limiting values of rotor vibrations are set in compliance with the international standard ISO
7919-2. (refer to see section 5.4 in this document)
3. PREPARATION FOR ROLLING

The start of steam turbine and its accessories is the process when individual technological
equipment is started up gradually. This process follows from certain initial state and is finished
after achieving the target state, i.e. the required electrical / thermal power.
The initial state for start-up is particularly influenced by the temperature state of the turbine
(HP/IP metal temperature), depending on the turbine cut-off period and the parameters prior to
the cut-off, i.e. turbine temperature.
The steam admission conditions are in the table below. These conditions might be changed
during commissioning. The steam temperatures in table are based on the startup shutdown
curves for power unit. In general operation, the inlet steam temperature will is selected in
consideration of an allowable steam temperature for synchronization.
Table 3-1 Recommended Steam Conditions for Turbine Startup
HP Steam IP Steam
Start Case
Pressure Temperature Pressure Temperature
(brag) (°C) (brag) (°C)
Cold Start
400 390
(rotor prewarming)
Warm Start
91 470 11 460
(48hr after TBN trip)
Hot Start
490 480
(8hr after TBN trip)
3.1 Design result for ST Start-up
This preliminary operation direction has been prepared as a basis for training or to be
commented by the customer and its contents correspond to the state of project development at
the time of preparation. Therefore, the DHI reserves the right to amend and/or supplement these
preliminary operation directions.
3.2 Rotor Prewarming
The HP rotor and shells should be warmed when HP rotor bore temperature is lower than 149℃,
for cold start-up. The turbine should be put on turning gear operation and lube oil system is in
service during rotor prewarming. The steam will be condensed into water in the HP section
during rotor prewarming. The condensed water is removed through turbine drain valves.
Figure 3-1 Rotor Prewarming using HSPV
Figure 3-2 Rotor Prewarming using RFV
The prewarming target temperature recommended herein is the minimum to be achieved.

Prewarming to higher than the target temperature will help to decrease turbine start-up time,
because the rotor prewarming is accomplished with more gradual transients, the life expenditure
of rotor and shell is minimized.
The preferred methods to warm the HP section are 1) using HSPV (Heating Steam
Pressurization Valve) 2) using RFV (Reverse Flow Valve). Figure 3-1 shows a diagram for
rotor prewarming using HSPV. If sufficient steam conditions are available in the auxiliary
steam header, that steam can be admitted to the HP turbine inlet via HP turbine exhaust by
opening HSPV. This prewarming procedure may be conducted prior to startup of the main
boiler if the auxiliary steam is available from elsewhere (auxiliary boiler or another Unit etc).
Figure 3-2 shows a diagram for rotor prewarming using RFV. In general, Prewarming is
performed using HSPV. And if HSPV is not available, is used with RFV that steam is provided
from the cold reheat pipes which are pressurized by the HP bypass system. No inlet pressure
limiter is provided. The HSPV (or RFV) admits the warming steam into the exhaust bowl of the
HP section. Both valves have pressurization limitation to control the warming rate of the turbine
and avoid turning gear disengaging.
If disengaging turbine during rotor prewarming, close valve and stop prewarming. The valve
position would be reset by 80~90% of the latest position to decrease pressure in HP section and
rotor prewarming is restarted. Optimized valve position for prewarming should be tuned during
commissioning period.
The reheat section, simultaneously, should be prewarmed to 54°C by maintaining allowable

condenser back pressure with the steam seals in operation. The time required for the reheat
section to reach 54°C may not exceed the time to prewarm the high pressure to 149°C. In
experience, the reheat bowl will in almost have been above 54°C for 1 hour. The reheat section
is considered to be prewarmed when all the metal temperature thermocouples read 54°C or
higher.
NOTE
The pressure normally specified is 3.8 ~ 4.9 barg to raise the high-pressure shell and rotor
temperature to 149°C. If the turning gear is disengaged and the turbine speed is increased
during rotor warming, the warming should be stopped and placed back on turning gear.
3.3 Chest Warming Requirment
Figure 3-3 CV Chest Warming using MSVBV
The stop valves on this unit is provided with an integral bypass valve for prewarming the CV
chest. This prewarming should be done before opening the stop valves preparatory to make a
startup. The chest warming shout be required if the difference between main steam temperature
and CV chest outer temperature is greater than the allowable difference temperature or the
difference between CV chest outer/inner temperatures is greater than the allowable difference
temperature. The allowable difference temperature is calculated by TCS based on CV Chest
temperature before TBN rolling off.
During chest warming, the CV chest and MSV temperature should be observed. If the difference
between CV chest outer/inner temperatures is greater than the allowable difference temperature
during load operation, the load should be held and chest warming should be performed again.
3.4 Drain Valve Operation
Drain valves are located at low-point of steam line, a control valve chest and turbine shell. Each
steam line may be piped to a common drain manifold which is routed to the condenser through a
power operated manifold drain valve (electric or pneumatic), this valve being arranged for
external remote operation. All drain valves should be opened during startup, shutdown, and
during periods of no load operation, even if the turbine has been brought to this condition from
high load. While the drain valves are open, an operator should give attention to prevent backing
up into the turbine.
Drain valves will be considered three groups as follow.
Table 3-2 Drain Valve Open/Close Condition
Turbine RFM to Load Load Turbine

Group
speed-up FFM 15% 30% Trip
A open close close close open
B open open close close open
C open open open close open

RFM: reverse flow mode
FFM: forward flow mode
Group A: a) main stop valve before seat drain valve

(P1MAL10AA001, P1MAL10AA 003)
b) control valve before seat drain valve
(P1MAL10AA002, P1MAL10AA 004)
Group B: a) main steam lead drain valve (P1MAL20AA005)
b) main steam lead pipe drain valves (based on P1MAL20AA005)
c) OLV drain valve (P1MAL20AA010)
d) HP outer cashing drain valve (P1MAL30AA007)
e) HP inner cashing drain valve (P1MAL30AA006)
f) CRV after seat drain valves
(P1MAL40AA008, P1MAL40AA009)
g) extraction line drains (HP & IP extraction)
Group C: a) extraction line drain (LP extraction)
The drain valves in extraction line may be changed based on the operating condition of an
auxiliary system and plant condition.
3.5 HP Rotor Cooling During Turbine Speed-up
When boiler supplied the proper steam to turbine, CRV or IV is opened for turbine rolling. The
some of the steam being passed from the HP Bypass Valve and Reheater is admitted to IP
turbine, and then the steam is entered to LP turbine throughout Crossover pipe. The surplus
steam is delivered into STG condenser throughout LP Bypass Valve. (This is the bypass
operation)
Figure 3.4 HP section cooling using RFV and BVV
As the turbine rotational speed is increased, HP turbine exhaust can be overheated due to wind-
age heating. So in order to cool the HP turbine exhaust, RFV (Reverse Flow Valve) is opened at
75 % of the rated speed, and the steam in the Cold Reheat Line is provided through this valve
and flowed to the condenser by BVV (Bypass Ventilator Valve). This operation should be
maintained until the operation mode is changed from RF (Reverse Flow) mode to FF (Forward
Flow) mode. The opening rate of RFV was evaluated and fixed (25%~75%) for proper HP
cooling. This rate may be re-evaluated based on HP cooling condition during commissioning.
3.6 Steam Seal Operation
The steam seal system is required to establish condenser vacuum and to seal the turbine end
packings so that air does not leak into the sub-atmospheric section of the turbine and excess
steam in the high-pressure section of the machine does not blow out into the turbine room or
into bearing housings to contaminate lubricating oil.
Figure 3.5 Sealing Steam Flow at Strtup
Figure 3.6 Sealing Steam Flow at Rated Load
Period of startup and low load operation, the source of sealing steam is from auxiliary steam.
This sealing steam is introduced between intermediate packing rings, vented between outer
packing rings to a gland exhauster and condensed by cold feed water flow through the primary
side of a heat exchanger (see figure 3.5).
As steam turbine load increases, the steam flow out of the end packings of high pressure rotor
and the reheat rotor reaches a point where it is sufficient to provide 100% of the sealing steam
for the LP section end packings. The turbine is said to be “Self-Sealed” above this load level.
The excess steam from the high-pressure packings, over that required for sealing the low-
pressure end, is diverted to the condenser. Control of these steam flows is maintained by a
steam seal regulator which maintains the steam seal manifold pressure at a constant 0.28barg by
admitting or dumping steam through the steam seal feed or steam seal dump valves.
The gland exhauster system prevents steam from escaping into the turbine room by establishing
a subatmospheric pressure between the two outer rings of packing. Air is thus drawn in through
the last ring of packing, and steam enters this cell from the opposite direction. This steam and
air mixture is piped to a condenser where the steam is condensed, and the air is evacuated by
means of a centrifugal blower.
4. TURBINE START-UP PROCEDUE AND LIMITATION

This section describes the detailed process and guidelines for initial cold start-up. This will
suffice warm/hot start-up expect for HP/IP rotor warming and/or CV chest warming.
4.1 Rotor Warming and Preparation
1. TCS Power-on
2. Start lube oil system
a. Lube oil pressure : 1.5 ~ 2.5barg (P1MAV30CP504)
b. Lube oil temperature (refer to appendix B) (P1MAV20CT060)
- Minimum lube oil Temperature : 10°C
- Recommend lube oil Temperature : 27°C

- Lube oil temperature should be controlled by each RPM
3. Start seal oil system (SH1-DHI-P1MKW-M-M01-PHL-3171)
a. Seal oil difference pressure : 0.55barg (P1MKW05AA081)
- Alarm : < 0.42barg
b. Seal oil common discharge pressure : 9.8barg (P1MKW05CP082&083)
- Alarm : < 7.0barg
4. Fill H2 gas in the generator (SH1-DHI-P1MKG-M-M01-PHL-3173)
a. Replace air by CO2 before filling H2
b. H2 gas pressure : 5.17barg (P1MKG20CP001)
- Alarm (L) : < 5.03barg, Alarm (H) : > 5.45barg
c. H2 gas purity : above 98% (for NR) (P1MKG20CQ001&002)
- Alarm (L) : < 95%, Alarm (LL) : <90%
5. Start generator stator cooling water system (SH1-DHI-P1MKF-M-M01-PHL-3172)
a. Winding cooling water flow rate : 65m3/hr (P1MKF10CP501)
- Alarm (L) : < 59m3/hr, Alarm (LL) : < 56m3/hr
b. Check conductivity : 0.12~0.20 micro siemens/cm (P1MKF09CE001, P1MKF01CE001)
- Alarm (H) : > 0.5micro siemens/cm, Alarm (HH) : > 9.9micro siemens/cm
6. Start turning gear system
a. Turning gear speed : approximate 4rpm
b. Observe the eccentricity is in usual limits.
- Initial Start-up : Set eccentricity value 0.075mm
- After Initial Start-up : Reset normal eccentricity value which was saturated
eccentricity after initial start-up.
- If turbine was tripped with abnormal status, discuss with customer for start-up.
c. Start-up Permissive Condition
- Eccentricity < Normal eccentricity + 0.038mm
- The normal eccentricity value is to be determined at the initial turning gear

operation after 8 hours or more continuous run.
NOTE
Following long periods off turning gear, four hour minimum turning gear period is essential
to prevent temporary rotor bows due to internal distortion and to provide subsequent smooth
trouble–free starting. Every effort should be made to avoid stopping the rotor longer than 10
minutes, particularly when hot. Following each stopped period, the rotor should be rolled on
turning gear 10 minutes for each stopped minute, up to four hours maximum.
7. Start hydraulic power system
a. Hydraulic fluid temperature : 29.4°C ≤ temp. ≤ 49°C (P1MAX40CT004)
b. Hydraulic fluid pressure : 160barg ≤ press. ≤ 170barg (P1MAX40CP006~008)
- Alarm : < 131barg, Trip : < 110barg
8. Check all drain valve open
9. Start steam seal system (SH1-DH1-P1MAA-M-M01-PID-3129)
a. Steam seal header pressure : 0.28barg (P1MAW50CP002&003)
b. Steam Seal header temperature : based on HP/IP bowl temp. (refer to appendix A)
(P1MAW50CT002)
- Cold reheat steam : max. 49.3barg / max.329°C
- Auxiliary steam : 15.0barg / 255°C
10. Start condenser vacuum pulling (P1MAC10CP001~006)
a. Check vacuum breaker valve “close”
b. Condenser vacuum : lower than 0.133bara (design value is 0.074bara)
11. Start HP rotor warming using RFV or HSPV
a. Rotor warming target temperatures : 149°C (HP) / 54°C (IP)
b. Prewarming steam condition : Enthalpy : 2773 ~ 2993 Kj/kg, Pressure : 3.8~4.8barg
c. Check turning gear disengage during HP rotor warming
d. Turning gear may be disengaged because of too high pressure of warming steam
from HSPV or RFV (refer section 3.2 in this document)
e. Close HSPV or RFV after HP rotor temperature reached the target temperature.
12. Start CV chest warming using MSVBV
a. Open the MSVBV and slowly pressurize the CV chest.
b. CV chest heat soaking until to meet the requirement of CV chest warming.
NOTE
It should be verified that the CVs are fully closed before opening MSVBV.
4.2 Turbine Roll-off
1. Check permissive conditions for turbine rolling
a. Turbine status : Reset
b. Turning gear operation : Engaged
c. All drain valve open : group-A, group-B, group-C
f. Inlet steam conditions are satisfied : Pressure, Temperature, and superheat
g. Steam pressure is identical with Start-up Shutdown Curves for Power Unit
h. Check condenser vacuum (< 0.169bara (127mmHga) (P1MAC10CP001~006)
- Recommend value on start-up : 0.133bar.a or lower
i. Check HP rotor eccentricity : ECC. < Normal Eccentricity + 0.038mm
j. Check steam seal header temperature and pressure are in normal
k. Check lube oil temperature (P1MAV20CT060)
- Recommend lube oil temp before rolling off : 27°C
l. HP rotor bowl temperature : 149°C or higher (P1MAA10CT010~012&015)
m. System : Ready signal on
n. No problems and hold signals should be indicated on the turbine control system.
2. Rub check (for initial start-up)
a. Select turbine speed rate : 100rpm/min
b. Check turning gear disengage
c. Close valve or master trip after turbine speed reaches in 200rpm
- Confirm there is not any abnormal noise at each gland seal
3. Start turbine rolling to 1000rpm
a. Check turning gear engage
b. Check [Startup Permissive]
- Confirm all startup permissive conditions are satisfied
c. Check speed rate : Cold - 100rpm/min, Warm - 150rpm/min, Hot - 300rpm/min
d. Select [1000rpm]
e. Check IV open, turning gear disengage and turbine speed-up
f. Hold speed for 10minutes when reaching 1000rpm
g. Check operation data
- If the temperature of IP rotor is higher than 110°C, this speed holding is not
essential.
a. Select [2500rpm]
b. Hold speed for 20minutes when reaching 2500rpm
- Check RFV and BVV open at 2250rpm (refer to section 3.4 in this document)
- Check “WOBBULATOR” is on (± 100rpm)
- Check operation data
a. Select [3000rpm]
b. Check turbine speed : 3000rpm
- Check operation data
NOTE
After the turbine speed reaches FSNL, the unit should be synchronized without any
unnecessary extension operation as soon as possible. Long operation at FSNL can lead to
asymmetric heating and distortion of HIP shell and N2 packing equipment which may result
in radial rub induced vibration. In case of Hot Start-up, operation at FSNL for extended
periods can result in elevated L-1 steam temperatures and elevated LP exhaust temperatures.
The first and/or second speed holding can be changed by site conditions or protection of
rotating machinery.
4.3 Synchronization to Full Load
1. Check synchronization permissive condition
- Generator / line voltage difference
- Generator / line frequencies difference
- Generator / line phase difference
Figure 4.1 Typical Synchronization Window of TBN Control System
2. Check lube oil temperature : 43°C ~ 49°C (P1MAV20CT060)
3. Start turbine synchronizing
a. Manual Operation Mode
- The operator selects either [Remote] synchronization or [Local]

synchronization on synchronization panel. Selected synchronization mode
signal shall be transmitted to TCS.
- After the Start Permissive from the Exciter is in the TCS and the exciter is in
the AVR state. TCS will automatically send a [Exciter start] command signal
to the excitation system at 95% of TBN rated speed.
- The operator selects either [GCB] or [Line Breaker] to perform the synchroni-
zation on TCS screen after TBN speed is reached at rated speed(3000 rpm).
- Selected breaker signal shall be transmitted to synchronization panel.
- The operator selects either [Auto] synchronization or [Manual]

synchronization on TCS screen. Selected synchronization mode signal shall be
transmitted to synchronization panel.
- The synchronization panel will check the synchronization permissive

conditions and perform the synchronization.
b. Auto Operation Mode
- The operator selects either [Remote] synchronization or [Local]

synchronization on synchronization panel. Selected synchronization mode
signal shall be transmitted to TCS.
- After the Start Permissive from the Exciter is in the TCS and the exciter is in
the AVR state. TCS will automatically send an ‘Exciter start’ command signal
to the Excitation System at 95% of TBN rated speed.
- GCB shall be automatically selected as default breaker. And GCB selection

signal shall be transmitted to synchronization panel.(APS in progress)
- [Auto] synchronization mode shall be automatically selected as default. And

[Auto] synchronization mode signal shall be transmitted to synchronization
panel. (APS in progress)
- Synchronization panel will check the synchronization permissive conditions

and perform the synchronization.
4. Initial Load
a. TCS will automatically increase the turbine load reference by 4~6% immediately
after synchronization. That is performed by the Initial Load function and the target
load is selected by site tuning in accordance of the plant requirement.
b. The Initial Load function is operated automatically even in the manual operation
mode
c. The load rate for initial load is 1%/sec (60%/min).
5. Operation Mode Transfer (R/F mode → F/F mode)
- The operator needs to increase load reference until satisfying 'Ready to F/F
Mode Transfer' condition by entering load target on TCS screen.
- The operator selects a [F/F Mode Transfer] button on TCS screen after
satisfying 'Ready to F/F Mode Transfer' condition.
- After F/F Mode Transfer, the operator should increase load reference as fast as
possible in order to prevent ‘HP Exhaust Temp. Hi-Hi Trip’ through opening
IVs.
NOTE
'Ready to F/F Mode Transfer' condition is not a fixed value. It depends on the pressure
ratio of 'Main Steam' and 'Hot Reheat Steam
- TCS will increase load reference automatically with load rate calculated by
TBN stress until satisfying 'Ready to F/F Mode Transfer' condition. The target
load will be determined by site tuning in accordance of the plant requirement.
- TBN operation mode will be automatically transferred from ‘R/F Mode’ to

‘F/F Mode’ after satisfying 'Ready to F/F Mode Transfer' condition.
- After F/F Mode Transfer, TCS will continue to automatically increase the load
reference with calculated loading rate in order to prevent ‘HP Exhaust Temp.
Hi-Hi Trip’ through opening IVs. (APS in progress)
6. UMC Mode
- The operator needs to select [UMC Mode] button on TCS screen after
checking Boiler and BOP status.
- From now on, TBN shall be operated by UMC load demand transmitted from
DCS.
- TCS will continue to increase load reference automatically with calculated

loading rate until proper load target. Typically, the target is tuned to the point
at which the HP bypass valve is closed. (APS in progress)
- DCS sends ‘In UMC Mode’ signal to TCS. And TBN shall be operated in
UMC mode by UMC load demand transmitted from DCS.
4.4 Turbine Shutdown
The load of Steam turbine will be decreased gradually, except in case of emergency shutdown.
The steam turbine system can be tripped at any load. It is recommended that the unit is tripped
either manually or remotely when the load is decreased below 10% of rated load. Experience
indicates that the speed of turbine will be not increased by tripping turbine-generator system
under the load. After tripping, all steam inlet valves are closed quickly and generator is
disconnected from the grid to avoid unnecessary motoring of the turbine-generator system.
1. Decrease turbine load (5% ~ 15%NR)
a. Manual shutdown
- Decrease the turbine load gradually by UMC Load command as much as

possible within the range that the Boiler can be operated.
b. Auto shutdown
- Decrease the turbine load by UMC Load Command to shutdown smoothly
NOTE
It is recommended that the boiler load is hold after the boiler load reaches 30~50%
(site tuning required) to prevent the unacceptable thermal stress at turbine rotor which
is caused by steam temperature decreased.
Drain valves are opened automatically in accordance with plant load(refer to

section 3.4).
2. Verify that the Emergency Bearing Oil Pump (EBOP) is in [AUTO].
3. Check turbine trip.
a. Manual turbine trip
- After the turbine load reaches target load or below, the turbine shall be tripped
immediately according that the operator pushes an emergency push button.
b. Auto turbine trip
- The operator selects ‘Auto Stop’ button on TCS screen. The load reference
will be decreased with 20%/min unloading rate.
- The turbine system shall be tripped by ‘Auto Stop’ function when load
reference is reached at 0%
4. See that all turbine valves have closed.
- Observe that the generator KW output has gone to zero or negative.
- Observe maximum journal bearing vibrations while shutdown
- Observe lube oil temperature
NOTE
The generator breaker should be opened automatically by other plant equipment

when the turbine valves are closed and the generator load is negative. RFV &
BVV are automatically opened when the turbine is tripped.
5. Check turning gear engage after the turbine speed reaches ‘0’rpm.
NOTE
Do not shut off Turning Gear Motor and BOP until maximum shell surface metal
temperature is less than 260° C For a shutdown with turbine maintenance, a cool
down period of 1 to 3 days on turning gear is recommended
5. GENERAL PRECAUTION
5.1 Allowable Variation in Steam Pressure and Temperature

5.1.1 Inlet Steam Pressure
The average pressure at turbine inlet during any period of 12 months of operation may not
exceed the nominal pressure. When keeping this average value, pressure must not exceed 105 %
of the nominal pressure. Accidental variations in pressure not exceeding 120 % of the nominal
pressure are admissible, provided that the overall period of duration of such variations will not
exceed 12 hours in any period of 12 months of operation.
5.1.2 Inlet Steam Temperature
The average temperature at any turbine inlet during any period of 12 months of operation may
not exceed the nominal temperature. When keeping this average value, temperature may
normally not exceed the nominal value by more than 8C. Exceptionally only, if temperature
exceeds the nominal value by more than 8C, the instantaneous value may vary between this
value and 14C above the nominal value, provided that the overall period of operation within
these two limits will not exceed 400 hours during any period of 12 months of operation.
Operation from 14C to 28C above the nominal temperature can only be allowed on short
variations up to 15 minutes or less, provided that the overall period of operation within these
limits will not exceed 80 hours during any period of 12 months of operation.
On no account, temperature may exceed the nominal value by more than 28C.
If steam is supplied to any turbine connection point through two or more parallel pipelines,
steam temperature in any of these pipelines should not vary from that in another pipeline by
more than 17C, except that a temperature difference not exceeding 28°C is allowed during
variations not longer than 15 minutes in any period of four hours. Steam temperature in the
hottest of the pipelines must not exceed the limits set in the previous paragraph.
5.2 Operation Limitation on LP Vacuum Increase
The designed range of the condenser vacuum is 0.02 ~ 0.10bar.a (15~75mmHga). If the vacuum
increases during operation above 0.169bar.a (127mmHga) with no leaks of the vacuum system
and proper function of the evacuation and gland steam systems, it means that the condenser is
not capable of cooling the steam quantity produced by the turbine and that the power of the
whole equipment must be reduced, because if only power of the steam turbine is reduced, the
by-passes would open, adding naturally to the load of the condenser. The temperature of the
turbine outlet part is the supporting information on the vacuum system condition.
5.3 Turbine Shutdown
Any shutdown must be shut down in accordance with the generator operating instructions.
 After arriving minimum load, shut down by tripping the turbine (closing the stop valve
subsequently) either manually using the TURBINE SHUTDOWN” push-button or try
any of the machine protections.
 At standstill turbine check the automatic start of the turning gear.
Shut down options Maximum rate

Remark
of load down
100% => 40%  2% / min
40% => min load  1% / min
5.4 Vibration Limits
It is important for operators to be aware of vibration levels which are acceptable, and those
which need attention. The following levels are, therefore, provided for operator guidance and
are recommended for vibration monitoring system alarm and trip in accordance with on ISO
7919-2. The limits of rotor vibration will be set for relative displacement in VMS and TCS.
Trip Immediately If
Vibration Monitored Alarm If Vibration Exceeds*
Vibration Exceeds*
Absolute Shaft
200m 300m
Displacement
Relative Shaft
165m 240m
Displacement
*All Reading Peak to Peak
These limits are established to allow additional latitude while passing through the critical speeds.
Also, it may be necessary to change these allowable limits for the purpose of turbine protection
during start-up. If difficulties in maintaining acceptable vibration levels are experienced, the
Doosan Representative should be contacted in order to review the desirability of taking
corrective action.
5.5 Overspeed Test
When the lowest rotor bore temperature exceed 200C or after the unit is running 25% load over
for at least 3 hours (for cold start-up) to make sure of the adequate rotor warm, the turbine is
recommended for overspeed testing.
If this load is not attainable, Doosan is prepared to review the prevailing steam generator and
turbine metal temperatures, and in most cases, offer an alternative combination of lower load
and longer hold time to achieve satisfactory warming.
5.6 Turning Gear Operation and Rotor Eccentricity
To prevent the temporary rotor bow caused by a thermal distortion or rotor gravity when the
rotating system is shut down, use of the turning gear system prior to starting the steam turbine
system is essential. The temporary rotor bow affect seal clearance between rotor surface and
seal tooth and dynamic mass unbalance.
The other purpose of the turning gear is to obtain a circumferentially uniform state of
temperature in the turbine rotor. Because of the reason, the turning gear system should be in
operation before steam seal is entered into the turbine and the pressurized rotor warming is in
service. In due course of procedure, the lube oil system must be in operation when the turning
gear is in operation to insure proper bearing lubrication.
In case of initial turbine start-up, it might be required to put turbine on turning gear for 8 hours
or more until the normal eccentricity of rotor is determined. The time of turning gear operation
is dependent on an outage of steam turbine and the rotor metal temperature. The time of turning
gear operation is 10 times than the outage time. The maximum time is two hours before
restarting. However, for relatively short outage where restart is expected, the continuous turning
gear operation is recommended as long as possible.
When the turning gear operation is discontinued while the lowest rotor metal temperature, HP
and IP rotors, exceed 260C, it is recommended that the stopping time is no longer than 10
minutes as possible. It is to avoid a locked rotor condition (no-turned the rotating system with
turning gear). If it is impossible, the bearing lube oil system must be in service to prevent the
bearing metal temperature exceed 150C or higher. In experience, this overheating does not
occur while the turning gear is out of service when the rotor metal temperature is lower than
260C.
When the steam turbine system should be stop during extended periods (e.g., weeks or months)
due to lack of need for unit operation, regulatory restrictions, etc., it is not needed that the
turning gear is operated continuously. To minimize the possibility of unnecessary wear or
damage on the rotating components and to maintain a protective surfaces of rotor journal and
bearing pads, it is recommended that the lube oil system is operated for at least half an hour per
week and the turbine-generator system is on turning gear for about five minutes during
operating of the lube oil system.
While the rotating system is operating on turning gear, the shaft eccentricity indicator shows the
degree of rotor bowing. The eccentricity value should be in a normal range before turbine roll-
off. The normal eccentricity value is to be determined at the initial turning gear operation after 8
hours or more continuous run.
NOTE
Although the shaft must be stopped by any reason while the machine is hot, oil flow
to the bearings should be maintained to prevent damage to the bearing metal by
overheating.
The turbine should be left on turning gear until the eccentricity indication has
reached and maintained its normal for at least one hour before the unit is restart.
There is a high probability that rolling a turbine with abnormal eccentricity will lead
to excessive vibration and radial rub damage, with the possibility of permanently
bowing the rotor.
Because an eccentricity value below the normal value is just as undesirable as a

value above normal, the shaft should be under turning gear operation until the
eccentricity value reaches into a normal range.
5.7 Vacuum Breaking
Opening the vacuum breaking valves at rated speed, after separated from the grid system, result
in LSB damage due to the braking action suddenly. It is recommended therefore, that vacuum
not is broken until turbine speed reaches lower than 2000rpm, unless an emergency condition,
such as high vibration, when the unit is required to shutdown as fast as possible.
5.8 Normal and Emergency Shutdown
The unit can be tripped from any load that is compatible with plant and system requirements.
Except in emergency it is desirable, however, to reduce load gradually to a lower load before
tripping.
Forced-cooling of the turbine with steep downramps should always be avoided by:
 Unloading at a gradual rate, which allows a planned thermal downramp chosen from the
cyclic life curves.
 Rapid unloading in one to three minutes by closing the control valves quickly.
 Tripping load when necessary - generally it is better to avoid tripping when carrying a
large load.
For planned shutdowns, it would be good practice to establish a shutdown load based on plant
and system requirements, and on the desired degree of turbine cooling. The need for turbine
cooling should be based on steam temperature matching conditions planned for any restart,
planned maintenance during the outage, etc.
The shutdown load should then be approached gradually, utilizing thermal ramps that are
chosen appropriately from the cyclic life curves. Once the shutdown load has been reached, the
remaining load down to 5% should be removed quickly (one to three minutes). The unit can
then be tripped from loads of 5% or less with reduced risk of overspeeding.
As the load is reduced, the drains should be opened starting with Group B at about 15%. Group
A should be opened after trip. EHC (Electro Hydraulic Control) units can be tripped with the
master trip solenoid button or with the lever at the front standard.
In all cases, it is desirable to trip the generator circuit breaker a few seconds after the turbine
valves have been tripped and are known to be closed.
In emergencies, the unit can be tripped from any load, as stated above.
Appendix A Steam Seal Temperature
Zone Operation limits

(1) Allowable continuous Operation
(2) Transient operation only(<1hr)
(3) Acceptable during short time (<400hr/yr)
(4) Have to be avoided
Appendix B Bearing Lube Oil Temperature
Appendix C Allowable Inlet Steam Temperature for HP/IP Rotors
Appendix D Valve Position Diagram
The below figure shows the flow diagram of drain valves and main steam valves.
Appendix E Condenser Backpressure Limitation
Steam turbine exhaust pressure limitations are necessary to minimize the possibility of latter stage
bucket fatigue damage, high vibration caused by bearing misalignment, and bucket or exhaust hood
damage due to overheating. Overheating at last stage buckets especially at bucket tip zones can occur
due to low load and high exhaust pressure induced windage. Unexpected high vibration can be
appeared while the exhaust pressure is increased or decreased rapidly, because of bearing elevation
changing.
For turbine start, the steam seal system should be in operation before establishing condenser vacuum
by the proceed as follows:
 Check vacuum breaker valve close

 Open all turbine casing drain valve
 Drain an warm the line supplying steam to the steam seal system
 Open the manual valve to admit steam directly to the steam seal regulator
 Check regulator pressure is normal.
NOTE
If inlet steam pressure to the regulator is low, open the manual by-pass valve. Excessive flow
through the regulator by–pass can roll the turbine off turning gear or cause the regulator to
dump steam to the low–pressure turbine stages which can result in excessive heating.
 Start the air removal equipment and establish the maximum vacuum obtainable
If the manual by–pass valve is being used, close it as soon as the steam–seal regulator is able to
maintain the correct sealing pressure.
The turbine should not be operated continuously with exhaust pressure above the alarm setting.
Operation at low load should be performed at the best attainable exhaust pressure. If the exhaust
pressure exceeds the alarm setting, load should be reduced until the proper pressure is restored. If load
reduction to 30% of rated output does not reduce the exhaust pressure below the alarm setting, the unit
should be tripped for making sure all turbine valves close and negative generator power is obtained
before the main circuit breaker is opened, to avoid a serious overspeed incident. For a steam turbine
trip, during the unit shutdown period from full to 2/3 rated speed, the exhaust pressure should be as
low as possible. The exhaust pressure level should not exceed the trip setting, during this time period.
Figure E-1 shows the limitations of the condenser vacuum pressure. The vacuum level should be lower
than alarm line to roll turbine off. The curve in figure E-2 is for information. That may be changed
based on site conditions.
0.35
0.30
Backpressure Limit (bara)
Trip line
0.25
0.20
Alram line
0.15
0.10
0.05
0.00
0 20 40 60 80 100
Turbine Load (%)
Figure E-1 Condenser Vacuum Limitation
Figure E-2 Vacuum Curve Trend
※ Quentity of Vacuum Pumps : Unit#1(3x50%), Unit#2(3x50%)
Appendix F Startup and Shutdown Flow Chart
1. Start-up Diagram
2. Shutdown Diagram
Appendix G Operation Parameters Limitation
TRIP SETPOINT
DESCRIPTION
LL HH
normal
LUBE OIL LEVEL
-406mm
LUBE OIL HEADER PRESSURE 0.41barg
HYDRAULIC FLUID PRESSURE 110barg
HYDRAULIC FLUID LEVEL 263mm
479.4℃
HP EXHAUST TEMPERATURE
*451.7℃
LP HOOD A EXHAUST TEMPERATURE 107.2℃
LP HOOD B EXHAUST TEMPERATURE 107.2℃
LP A L-1 STAGE TEMPERATURE 260℃
LP B L-1 STAGE TEMPERATURE 260℃
EXHAUST VACUUM A PRESSURE **0.237bara
EXHAUST VACUUM B PRESSURE **0.237bara
MAIN STEAM TEMPERATURE DOWNWARD ***83.3℃
REHEAT STEAM TEMPERATURE DOWNWARD ***83.3℃
ACTIVE/INACTIVE THRUST BRG METAL

105℃
TEMPERATURE
JOURNAL BRG#1~3 METAL TEMPERATURE 127℃
JOURNAL BRG#4~8 METAL TEMPERATURE 121℃
*: exceeded during 15 min.

**: above 300rpm.
***: dropped during 15 min.
TRIP SETPOINT
DESCRIPTION
LL HH
SCW TEMPERATURE 82.9℃
SCW PRESSURE 1.7barg
SCW FLOW 55.21 ㎥/h
JOURNAL BRG#1X/Y~8X/Y VIBRATION 0.240mm
THRUST BRG AXIAL POSITION -0.89mm 0.89mm
DIFFERENTIAL EXPANSION -12.44mm 11.78mm
ROTOR EXPANSION -12.49mm 38.10mm
PRIMARY OVERSPEED 110%
EMERGENCY OVERSPEED 110.5%
Appendix H Turning Gear Operation
The primary purpose of the turning gear is to provide a means to obtain a circumferentially uniform
state of temperature in the turbine rotors to prevent temporary bowing of the rotors when the turbine–
generator unit is shut down. Use of the turning gear prior to any startup of the unit is essential to
ensure there is no temporary rotor bow that would be detrimental to the restart. A temporary rotor bow
will affect shaft seal clearances and the dynamic mass unbalance of the rotor, possibly causing rubbing
and vibration problems during startup. (NOTE: Turning gear operation is not beneficial for the case of
a permanently bowed rotor.)
A secondary use of the turning gear is to position the rotors during off–line activities (e.g., installation
of balance weights in rotors). This article contains recommendations for the use of the turning gear for
various situations. The recommendations depend upon the purpose and duration of the unit outage.
There are some situations where use of the turning gear is essential and others where use of the turning
gear is not recommended. The following are descriptions of four basic outage categories:
 Category A: The outage is due to a temporary problem and restart of the unit is expected
imminently or within a few days during which no work is performed on the turbine–generator
that would normally require stopping turning gear operation.
 Category B: Same as Category A except some minor work is done on the turbine–generator
unit that requires stopping turning gear operation, either for short or extended time periods.
 Category C: The outage is due to significant maintenance and/or repair work on the turbine–
generator such that it is desirable to stop turning gear operation as soon as possible to permit
timely disassembly of the turbine components (e.g., shells, diaphragms, bearings, rotors, etc.).
 Category D: An extended outage (weeks, months) due to lack of need for unit operation,
regulatory restrictions, etc.
Under any set of conditions, the turbine–generator bearing lube oil system must be in operation when
the turning gear is in operation to provide proper lubrication to the bearings. This prevents damage to
the bearings and rotor journal surfaces. For recommended bearing oil temperature, during turbine gear
operation, refer to publications on Main Journal Bearings and Lubricating Systems.
Also, regardless of whether the turning gear is in operation or not, the bearing lube oil system must be
operated in a manner that will ensure that the bearing metal temperatures will not exceed
300℉(150℃) to prevent damage to the bearing Babbitt metal. For those units that do not have bearing
metal thermocouples as part of the supervisory instrumentation, experience shows that if all shell
metal temperatures are less than 500℉(260℃), there is no risk of overheating the bearing Babbitt
metal. The general rule should be to maintain the bearing lube oil operation if in doubt of the bearing
temperature.
On 1500 and 1800 RPM units high pressure lift pumps are furnished to reduce the torque requirements
of the turning gear motor and keep the gear teeth stresses at safe levels. A separate pump is provided
for each bearing requiring the lift feature, however, the pumping units are arranged as either a single
pump and motor combination or two pumps with one double ended motor. To prevent the turbine
generator from rolling off turning gear it may be necessary to have one or more lift pump motors shut
down following turning gear engagement.
The following guidelines are given for turning gear operation for the four outage categories previously
described.
1. Applicable to Categories A and B:

For relatively short outages where restart is expected, continuous turning gear operation is
recommended as long as any shell metal temperature is above 500℉(260℃), as indicated by the
turbine supervisory thermocouples. Occasionally it is necessary to discontinue turning gear
operation while the rotors are still hot [as indicated by one or more shell metal temperature(s)
being above 500℉] to do rotor balancing, inspect turbine buckets, or correct some equipment
malfunction. Such intervals of discontinued turning gear operation should be kept as brief as
possible, not longer than 10 minutes immediately following a shutdown. This is to avoid a
“locked rotor” condition (inability to turn the rotor system with the turning gear). Permanent rotor
bowing will not result from a locked rotor but a temporary bow of this magnitude will delay
restart of the unit until the high–temperature rotor(s) are cooled and straightened sufficiently to
start the turning gear. No attempts should be made to free a locked rotor by defeating the turning
gear overload circuit. (Note: Alternate methods of periodically turning a free rotor may be
employed in the event of a turning gear malfunction.) Steam seal operation may be continued,
depending on the circumstance, without causing excessive bearing temperatures.
The degree of bowing, if any, of the high–pressure rotor is shown through the use of the shaft
eccentricity indicator, while the system is operating on turning gear. This device should be used
to determine, from actual experience, the normal runout as measured at the control rotor. The
device should then be used when preparing to accelerate the turbine off turning gear for any
startup to ensure that eccentricity is in the normal range before attempting to start the unit.
Eccentricity can usually be restored to normal following brief stationary intervals by turning gear
operation of ten times the stationary interval.
2. 2. Applicable to all Categories:

Following any shutdown, turning gear operation may be discontinued indefinitely after all shell
metal temperatures are less than 500℉(260℃).
Following any extended period during which the turning gear was not in operation, the unit
should be placed on turning gear for at least four hours immediately prior to attempting restarting.
The unit should be left on turning gear until the eccentricity indication has reached and
maintained its normal minimum value for at least one hour. Rolling the unit with a higher– than–
normal eccentricity can lead to excessive rotor vibration and radial rubbing damage, with the
possibility of permanently bowing the rotor.
3. Applicable to Categories B and C:

Following any shutdown for an extended outage, the turning gear operation may be safely
discontinued at any time following the shutdown. However, as previously stated, the bearing lube
oil system must be operated such that bearing metal temperatures do not exceed 300℉(150℃).
4. Applicable to Category D:
If the turbine–generator unit is going to be out of service for an extended period (weeks, months),
continuous or extended turning gear operation should not be practiced because this can cause
unnecessary wear of turbine–generator rotating components and possibly lead to forced outages.
For such periods, it is recommended the bearing lube oil system be operated for at least 1/2 hour
per week to maintain a protective surface oil film throughout the lubrication system. It is also
recommended the unit be put on turning gear for about 5 minutes during each of the 1/2 hour
periods that the lube oil system is in operation.
Appendix I LP Exhaust Hood Spray
1. Purpose
During turbine startup or operation at no-load following loss of load, it is probable that steam
temperature will be high enough to cause excessively high exhaust hood temperature. To cool
the last-stage buckets, and to minimize temporary distortion of the low-pressure hood and shell
structures, this unit is equipped with exhaust hood water sprays in the low-pressure section of
the turbine.
2. Operation
These sprays have a significant potential for quenching the LP turbine structure, and thus should
only be operated in AUTO mode. The turbine control system monitors exhaust hood
temperature via redundant exhaust steam thermocouples. These temperature measurements
provide the feedback for the turbine control system’s modulation of the control signal to the
water spray valve positioner. The flow of water to the nozzles is controlled by a pneumatically
operated water spray valve driven by the steam turbine control system. The control signal is
proportional to exhaust hood temperature. The valve travels from fully closed to fully open as
exhaust hood temperature changes from 57.2C to 79.4C.
Figure I-1. Exhaust Hood Spray Position
The condensate supply pressure is adjusted by means of the water spray calibrating valve. This
pressure is set at 2.8 barg, which corresponds to the required flow. This is achieved by adjusting
the manual calibration valve to obtain the pressure on the supplied pressure gauge downstream
of the water spray calibrating valve with the air operated water spray valve fully open.
3. Protection
If the temperature of the exhaust hood is higher than 93.3°C, the turbine control system will
alarm an operator. In the abnormal condition, the operator should investigate the cause. The
typical cause is:
 High condenser pressure

 Failure of the exhaust hood sprays
 Excessive motoring operation
If the temperature of the exhaust hood is higher than 107.2°C, the steam turbine system will be
tripped automatically by the turbine control system to protect the overheating of the low
pressure turbine from exceeded temperature.

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DOCUMENT SUBMISSION STATUS: FOR INFORMATION

4 19.07.2018 FOR INFORMATION M.S.KIM H.SHIN D.S.HEO

2 12.09.2017 FOR INFORMATION Y.C.KIM H.SHIN W.G.CHOI

1 13.09.2016 FOR INFORMATION Y.C.KIM H.SHIN W.G.CHOI

0 04.02.2016 FOR INFORMATION Y.C.KIM H.SHIN W.G.CHOI

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

DATE NAME SIGN DOCUMENT TITLE

PREPARED 19.07.2018 M.S.KIM

Turbine Startup and

DOCUMENT NO. REV.

5.7 VACUUM BREAKING ..................................................................................................... 25

Appendix A Steam Seal Temperature

Appendix B Bearing Lube Oil Temperature

Appendix C Allowable Inlet Steam Temperature for HP/IP Rotors

Appendix D Valve Position Diagram

Appendix E Condenser Backpressure Limitation

Appendix F Startup and Shutdown Flow Chart

Appendix G Operation Parameters Limitation

Appendix H Turning Gear Operation

Appendix I LP Exhaust Hood Spray

TURBINE STARTUP AND SHUTDOWN INSTRUCTION

- P&I Diagram Lube Oil Piping for Turbine (SH1-DHI-P1MAA-M-M01-PID-3124)

- P&I Diagram Steam Piping for Turbine (SH1-DHI-P1MAA-M-M01-PID-3129)

- P&I Diagram Lube Oil Tank for Turbine (SH1-DHI-P1MAA-M-M01-PID-3132)

- P&I Diagram Lube Tank for Turbine (SH1-DHI-P1MAA-M-M01-PID-3124)

- System Description for Generator Hydrogen Seal Oil System (SH1-DHI-P1MKW-M-

- System Description for Generator Gas (H2&CO2) Control System (SH1-DHI-P1MKG-

- System Description for Gland Seal Steam System (SH1-DHI-P1MAA-M-M01-PHL-

- General System Description for Steam Turbine and Auxiliaries (SH1-DHI-P1MAA-M-

- Vacuum Pump System Description (SH1-DHI-P1MAJ-M-M01-PHL-3748)

2. MAIN SPECIFICATION AND BACKGROUND

Figure 2-1 Schematic of Full-train Rotor Bearing System

Turbine model : DS108/109

2.2 Machine Lifetime

Table 2-1 Turbine Startup Modes

Shutdown period Speed rate No. of startup

Hot Start <8 300 120

Warm Start 8 ~ 48 150 30

Cold Start > 48 100 4

2.3 Thermal Stress and Distortion

2.4 Operation on Changed Network Conditions

2.5 Critical Speed

3. PREPARATION FOR ROLLING

Table 3-1 Recommended Steam Conditions for Turbine Startup

3.1 Design result for ST Start-up

3.2 Rotor Prewarming

Figure 3-1 Rotor Prewarming using HSPV

Figure 3-2 Rotor Prewarming using RFV

The prewarming target temperature recommended herein is the minimum to be achieved.

The reheat section, simultaneously, should be prewarmed to 54°C by maintaining allowable

3.3 Chest Warming Requirment

Figure 3-3 CV Chest Warming using MSVBV

3.4 Drain Valve Operation

Drain valves will be considered three groups as follow.

Table 3-2 Drain Valve Open/Close Condition