Steam Turbine Starting the Turbine

Description

Introduction
Startup is a phase where almost all operating The startup Schematics of the turbine manual
values are subject to change, monitoring of this are compiled so that with their help the turbine
transient operating state demands close attention generator unit can be started up from the control
room by operating the control devices by watching
It is very important that all control operations the analog displays.
are always performed in the recommended
sequence. The operating staff must have command of
manual start-up to ensure that the startup
To fulfill these requirements, startup procedure can be continued even If faults occur in
schematics are prepared to show all control an automatic functional group control
operations and monitoring criteria for the turbine The schematics also include instructions that
and its auxiliary systems. must be followed during startup or operation of the
system. Instrumentation and control functions are
given in the functional schematics

BHEL, Haridwar 3-1110-00

 Steam Turbine Startup and Shut-down diagrams
Description Symbols

Insofar as symbols with indices are used Instead

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

BHEL, Haridwar 3-1120-00

 Steam Turbine Start of Turbine/Generator
Operation Startup Diagram (General)
(01) + TURBINE/GENERATOR START UP PREPARE REF. TO 3-1140
+ PREPARATION FOR START UP COMPLETED
(02) + EXTERNAL SYSTEMS READY FOR OPERATION CHECK
CIRCULATING WATER FOR CONDENSER AVAILABLE
COOLING WATER FOR COOLERS AVAILABLE
AUXILIARY STEAM AVAILABLE
DEMINERALIZED WATER SUPPLY AVAILABLE
CONDENSATE SYSTEM READY FOR OPRN.
VACUUM PUMP READY FOR OPRN.
THE EXTERNAL SYSTEMS DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAMS OF SYSTEMS.
INSTRUCTIONS OF EXTERNAL SYSTEMS MUST
COMPLY WITH TURBINE OPERATION.
+ EXTERNAL SYSTEMS READY FOR OPRN.
(03) + OIL SYSTEM AND TURNING GEAR START REF. TO 3-1210
START OF OIL SYSTEM APPROX.6 HOURS
PRIOR TO TURBINE START.EXTEND
TIME IN ADVANCE OF TURBINE START IF
OIL TEMPERATURES ARE EXTREMELY LOW.
WITH FGA (OIL SUPPLY)
OR
MANUAL OPERATION AT OPER. CONSOLE
FGA=FUNCTIONAL GROUP AUTOMATIC
+ SHAFT TURNS

(04) + CONDENSING PLANT START

TIMING OF CONDESING-PLANT START MUST
COINCIDE WITH TIMING OF FIRST TIME STEAM ENTRY
IN THE CONDENSING PLANT.
THE CONDENSING PLANT DOES NOT BELONG TO
THE SCOPE OF SUPPLY TURBINE/GENERATOR.
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAM OF SYSTEMS.
INSTRUCTIONS OF THE MANUFACTURER OF THE
CONDENSING PLANT MUST BE IN LINE WITH TURBINE
OPERATION.
+ CONDENSATE PUMPS ON
WITH FGA (CONDENSING PLANT)
OR
MANUAL OPER.AT OPER.CONSOLE

+ VACUUM PUMPS ON
WITH FGA (CONDENSING PLANT) :
OR
WITH SLC(AIR REMOVAL)
OR
MANUAL OPER, AT OPER, CONSOLE

+ SEAL SYSTEM SUPPLY ON

WITH SLC (SEAL STEAM)
OR
MANUAL OPER, AT OPER,CONSOLE
+ VACUUM <P
+ SEAL STEAM PRESSURE >P

3-1130-05/1
(05) + STATE OF OPERATION OF STEAM GENERATOR CHECK
+ STEAM GENERATOR IN OPERATION
+ CRITERIA FOR BYPASS OPERATION FULFILLED

(06) + START OF BYPASS OPERATION OBSERVE REF. TO 3-1410

(07) + MAIN STEAM (MS) LINE WARM UP REF. TO 3-1510

WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ MAIN STEAM (MS) LINE WARMED UP

(08) + CRITERIA FOR WARMING UP TURBINE CHECK

(09) + TURBINE WARM UP REF. TO 3-1510

WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ TURBINE WARMED UP

+ CRITERIA FOR SPEEDING UP TURBINE/ FULFILLED

GENERATOR

(10) + TURBINE/GENERATOR TO RATED SPEED SPEED UP REF. TO 3-1510

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

(11) + GENERATOR BREAKER ON

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

+ LOADING CRITERIA FULFILLED

(12) + TURBINE/GENERATOR LOAD

3-1130-05/2
 Steam Turbine Preparation for Startup
Operation Startup Diagram

(01) - PRESERVATION DEVICES REMOVE

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

(02) - INSPECTION OPENINGS CLOSE

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

(03) + VOLTAGE SUPPLY SWITCH ON

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

(04) + LIGHT BULBS FOR PANEL AND ALARMS CHECK

+ DEFECTIVE LIGHT BULBS REPLACED

(05) + MEASURING EQUIPMENT READY FOR OPERATION CHECK

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

(06) + LIQUID LEVELS CHECK

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

(07) - FILTERS CLEAN

(08) + TEST PROGRAM (STANDSTILL) CARRY OUT REFER TO 4-1170

TESTING INTERVALS OBSERVE REFER TO 3-0010

(09) + TEST PROGRAM (STARTUP) CARRY OUT REFER TO 4-1110

TESTING INTERVALS OBSERVE REFER TO 3-0010

(10) + GENERATOR READY FOR OPERATION CHECK

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

BHEL Haridwar 3-1140-03

 Steam Turbine Operating Position of
Operation Manually Operated Valves

Introduction = manually on the local control

console”
Most of the manually operated valves in + manually in the control room”
a turbine generator unit have to be in a
defined position prior to startup, and this * for remote controlled valves only
position must be checked before the unit
goes into operation. • Operating positions

Lead Sealing of Valves Open

Closed
It is recommended that all valves, the Mode-Dep. = Mode-dependent
position of which remains unchanged during (position varies with
operation be secured In position with lead mode of operation,
seals. All that need then be checked is that cannot be classed as
the seals are undamaged. Open or Closed) .
Permset = permanently set
The valves which are secured with lead Operational = ready to opetate (e,g,
seals must be identified in the check list. control valves)
/FG = Position cannot be
Symbols and definitions controlled manually
(controlled by
• Measures for the setting of valves automatic functional
- manually on location group controls or by
medium carried)

BHEL Haridwar 3-1150-00

 Steam Turbine Oil System & Turning Gear
Operation Start-up Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES (GENERAL) CHECKED
AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
VALVES BEFORE/AFTER PUMPS OPEN
PERMANENT VENTS OPEN
VENTS OF COOLERS OPEN
VALVES IN FILLING LINES (PERMANENT) OPEN
VALVES BEFORE/AFTER FANS IN SERVICE OPEN
VALVES BEFORE/AF’TER STAND BY FANS CLOSED
DRAIN VALVES OF COOLERS CLOSED
DRAIN VALVES OF TANKS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN TEMPORARVVENTS CLOSED
VENTS OF COOLERS (WATER SIDE) CLOSED
VENTS OF FILTERS CLOSED
VALVES IN TEMPORARY FILLING LINES CLOSED
VALVES OF PRESSURE TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE PIPES FOR TESTING CLOSED
MULTI WAY VALVES OF COOLERS IN SERVICE
MULTI WAY VALVES OF FILTERS IN SERVICE
THROTTLE VALVES IN VAPOUR LINES ADJUSTED
THROTTLE VALVES IN JACKING OIL LINES ADJUSTED
RELIEF VALVE OF JACKING OIL SYSTEM ADJUSTED
+ OIL PUMPS READY FOR OPRN MAV22AP001
MAV23AP001
MAV24AP001
.MAV25AP001
MAV31AP001
MAV32AP001
OIL PUMPS ON MANUAL CONTROL SWITCH ON
OR
OIL PUMPS ON SUBLOOP CONTROL SWITCH ON
OIL PRESSURES NORMAL

+ OIL VAPOUR FAN (TURBINE) ON MAV82AN001

OR READY FOR OPRN OR MAV82AN002
+ OIL VAPOUR FAN (GENERATOR) ON MKQ31AN001
OR READY FOR OPRN OR MKQ32AN001
- ONE OIL COOLER OIL SIDE IN SERVICE MAV41 BC001
OR MAV41BC002
CHECK OIL COOLER (S) IN SERVICE AT THE
INDICATOR AT THE” CHANGE OVER VALVE (S).
DO NOT ADJUST ANY INTERMEDIATE POSITION
OF CHANGE OVER VALVE.

COOLING WATER FOR OIL COOLER (S) AVAILABLE

OPERATION OF THE COOLING WATER SYSTEM
ACCORDING TO SEPARATE INSTRUCTIONS NOT
INCLUDED IN THE TURBINE MANUAL

- SERVICE OIL COOLER (WATER SIDE) FILLED MAV41 BC001

AND VENTED OR MAV41BC002
- COOLING WATER PIPE VENTED
- STAND BY OIL COOLER WATER SIDE DRAINED MAV41 BC001

BHEL, Haridwar 3-1210-05/1

 + SLC OIL TEMPERATURE CONTROL ON
THE OIL TEMPERATURE CONTROLLER CAN BE
SWITCHED ON/OFF MANUALLY. IT ALSO GETS
ON/OFF COMMANDS FROM FGA ON FULFILLMENT
OF CERTAIN CRITERIA
SLC = SUBLOOP CONTROL
FGA = FUNCTIONAL GROUP AUTOMATION

+ OIL TEMPERATURE REFERENCE VALUE 450C MAV42CT011

FIX SET POINT
- OIL LEVEL IN TANK NORMAL MAV1OCL521
COMPARE ACTUAL VALUES DURING STAND
STILL CONDITION OF OIL PUMPS
- OIL FILTERS INCLUDING STAND BY FILTERS READY FOR OPRN
FILTER ELEMENTS CLEANED OR REPLACED
- OIL PROPERTIES NORMAL
NO COLLECTION OF WATER AT THE BOTTOM
OF THE OIL TANK

(02) + GENERATOR READY FOR OPERATION CHECK

+ MANUAL OPERATED VALVES GENERATOR ADJUSTED
REFER TO GENERATOR MANUAL
+ GENERATOR HYDROGEN FILLED
+ HYDROGEN PURITY CHECK
+ AC SEAL OIL PUMP ON
THE DC SEAL OIL PUMP WILL BE OPERATED
ONLY IF THE AC POWER SUPPLY IS FAULTY
+ SEAL OIL SYSTEM NO ALARM
+ LIQUID IN GENERATOR NO ALARM

(03) + CRITERIA FOR BEGIN OF STARTUP CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE STARTED UP FROM
STANDSTILL
+ AUXILIARY OIL PUMP OFF MAV22AP001
AND MAV23AP001
+ EMERGENCY OIL PUMPS OFF MAV24AP001
THE DC EMERGENCY OIL PUMP WILL OPERAT AND MAV25AP001
IF AC POWER SUPPLY FAILS
+ SLC AUX OIL PUMPS OFF
AND
+ SLC EMERGENCY OIL PUMPS OFF
+ JACKING OIL PUMPS OFF MAV31 AP001
AND MAV32AP001
+ SLC JACKING OIL PUMP OFF
+ SHAFT STAND STILL

(04) + FGA OIL SYSTEM START

FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THEFGA
OR
+ OIL SYSTEM MANUAL OPERATED START

(05) + AUXILIARY OIL PUMP SWITCH ON MAV22AP001

OR MAV23AP001
+ AUXILIARY OIL PUMP ON MAV22AP001
OR WITH FGAOIL SUPPLY OR MAV23AP001

3-1210-05/2
(05/S) - + AUXILIARY OIL PUMP 1 ON MAV22AP001
OR AUXILIARY OIL PUMP 1 FAULTED MAV22AP001
+ AUXILIARY OIL PUMP 2 MANUAL OPERATION ON MAV23AP001
+ OIL PRESSURE > 5 KG/CM2 MAV21CP001
+ LUB OIL PRESSURE > 1.1 KG/CM2 MAV42CP901
+ OIL LEVEL IN TANK NO ALARM MAV10CL001
+ FILTER LUB OIL SYSTEM NO ALARM
DIFFERETIAL PRESSURE ACROSS FILTER NOT HIGH MAV42CP901
PRESSURE BEHIND FILTER NOT LOW MAV42CP901
LOCAL INDICATOR NOT INITIATED MAV43BT001
CHECK STAND BY FILTER BY LOCAL CHANGE OVER
+ EMERGENCY OIL VALVE OPEN MAX41 AA02 1

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

AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH ON
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
AND
+ SUBLOOP CONTROL OF E~ERGENCY OIL PUMPS ON
OR WITH .FGA OIL SUPPLY
(06/S) - + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
THE SUBLOOP CONTROLS START THE AUXII-IARY
OIL PUMPS AND THE DC EMERGENCY OIL PUMPS
DEPENDING ON PRESSURE
AUXILIARY OIL PUMP 1 4.8KG/CM2 MAV21CP901
AUXILIARY OIL PUMP 2 4.5KG/CM2 MAV21CP901
AC EMERGENCY OIL PUMP 1.2KG/CM2 MAV42CP901
DC EMERGENCY OIL PUMP 1.1KG/CM2 MAV42CP901
AND FAULT IN AC EOP
SIMULTANEOUSLY ALARMS WILL BE ACTUATED
THE SUBLOOP CONTROLS OF EMERGENCY OIL PUMPS
AND JACKING OIL PUMP MUST NOT BE SWITCHED
OFF UNTIL THE SHAFT IS STOPPED COMPLETELY

(07) + SEAL OIL PRESSURE GENERATOR END CHECK

+ SEAL OIL PRESSURE TURBINE END >P
+ SEAL OIL PRESSURE EXCITER END >P
+ GENERATOR S~L OIUHYDROGEN DIFF. PRESSURE CHECK

(08) + TURNING GEAR SOLENOID VALVE OPEN MAV51AA012

(09) + JACKING OIL PUMP SWITCH ON MAV31 AP001

OR MAV32AP001
+ JACKING OIL PUMP ON MAV31 AP001
OR MAV32AP001
OR WITH SUBLOOP CONTROL
SUBLOOP CONTROL OF JACKING OIL PUMP SWITCH ON
+ SUBLOOP CONTROL OF JACKING OIL PUMP ON
OR WITH FGA OIL SUPPLY
(09/S) - + SUBLOOP CONTROL OF JACKING OIL PUMP ON
+ JACKING OIL PUMP ON MAV31AP001
OR JACKING OIL PUMP FAULTED MAV31 AP001

BHEL, Hardwar 3-1210-05/3

 + JACKING OIL PUMP MANUAL OPERATION ON MAV32AP001
SUBLOOP CONTROL STARTS AND STOPS THE
JACKING OIL PUMP 1 DEPENDING ON
TURBINE/GENERATOR SPEED CRITERIA
JACKING OIL PUMP 1 ON < 510 RPM
JACKING Oil PUMP 1 OFF > 540 RPM
AND
SUBLOOP CONTROL STARTS THE JACKING OIL
PUMP 2 DEPENDING ON JACKING OIL PRESSURE
JACKING 011. PUMP 2 ON < 150 KG/CM2 MAV 35CP00l
DO NOT SWITCH OFF SUBLOOP CONTROL OF
JACKING OIL PUMP TO MAKE SURE JACKING
OIL PUMP STARTS DURING COASTING DOWN
AFTER SHUT DOWN OF THE TURBINE

+ WAIT
(10) + SHAFT TURNS
NO FURTHER ACTIVITIES REQUIRED TO START
TURNING GEAR OPERATIQN WHEN SHAFT IS TURNING
OR
+ SHAFT DOES NOT TURN

REFER TO FAULT TRACING INSTRUCTION 3-4220 FOR

MEASURES TO BE TAKEN

DO HOT EMPLOY FORCE IF THE SHAFT DOES NOT TURN

ON MANUAL TURNING GEAR

3-1210-05/4
 Steam Turbine Air Ejection and Sealing System
Operation Start-up Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES IN REQUIRED POSITION CHECKED
+ SET POINT SEAL STEAM CONTROLLER >P CHECK FIX SETTING

(02) + CRITERIA FOR BEGIN OF START UP CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE STARTED UP FROM
STANDSTILL
+ TURNING GEAR IN OPERATION
+ DRAINS OF SEAL STEAM HEADER CLOSED MAL81AA001
+ SEAL STEAM EXHAUST FAN OFF MAW80AN001/002
+ VACUUM PUMP & EJECTORS OFF
+ AIR SUCTION VALVE OF VACUUM PUMPS CLOSSED
+ SEAL STEAM CONTROL OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSED MAW10AA001

(03) + DRAINS OF SEAL STEAM HEADER OPEN MAL81AA011

+ DRAINS OF SEAL STEAM HEADER OPEN MAL81AA011
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL DRAINS SWITCH ON
+ DRAINS OF SEAL STEAM HEADER OPEN MAL81AA011
POSITION OF DRAIN VALVE (S) DEPENDING
ON TEMPERATURE CRITERIA IN HEADER
VALVE (S) OPEN AT STEAM TEMPERATURE < 1200C
VALVE (S) CLOSE AT STEAM TEMPERATURE > 1500C

(04) + ONE CONDENSATE PUMP ON

CONDENSING SYSTEM IS NOT IN TURBINE SCOPE

(05) + SEAL STEAM EXHAUST FAN SWITCH ON MAW80AN001/002

+ SEAL STEAM EXHAUST FAN ON MAW80AN001/002
AND
+ WARM UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM UP VALVE SEAL STEAM OPEN MAW10~011
BY STEAM FLOW THROUGH THE WARM UP VALVE
THE STEAM TEMPERATURE UPST~EAM OF THE
SEAL STEAM SUPPLY VALVE WILL INCREASE
UNTIL THE REQUIRED TEMPERATURE IS REACHED

THE SEAL STEAM SUPPLY VALVE MUST NOT BE.

OPENED UNTIL THE REQUIRED TEMPERATURE
AND A MINIMUM VACUUM IS REACHED IN THE
CONDENSER

CRITERIA FOR OPENING THE SEAL STEAM

SUPPLY VALVE
STEAM TEMPERATURE > 1950C
VACUUM > 0.85 KG/CM2

(06) + VACUUM PUMP SWITCH ON

+ VACUUM PUMP ON

BHEL, Hardwar 3-1310-04/1

(07) + AIR SUCTION VALVE OF VACUUM PUMP OPEN
+ AIR SUCTION VALVE OF VACUUM PUMP OPEN

+ VACUUM < 0.85KG/CM2 MAG10CP001

+ TEMPERATURE AHEAD OF SEAL STEAM SUPPLY VALVE > 195 0C MAW10CT001
(08) + SEAL STEAM CONTROLLER SWITCH ON
AND
+ OPENING OF SEAL STEAM SUPPLY VALVE OBSERVE MAW11M001
+ SEAL STEAM PRESSURE >P MAW20CP001

3-1310-04/2
 Steam Turbine Bypass System
Operation Start of Operation

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES ACCORDING TO VALVE POSITION CHECKED

+ BYPASS CONTROLLER ON

+ BYPASS CONTROLLER NOT FAULTED

+ FIXED PRESSURE REFERENCE VALUE ..KG/CM2

THE SETTING OF FIXED PRESSURE

REFERENCE VALUE DEPENDS ON THE
REQUIREMENTS OF THE STEAM
GENERATOR e.g. THE STEAM FLOW
THROUGH THE REHEATER. THE SET
POINT HAS TO BE RAISED DURING
START UP TO MEET THE DESIGN
VALUE FOR MINIMUM LOAD OF THE
STEAM GENERATOR. FIXED
PRESSURE REFERENCE VALUE AS
DESIGNED- ..KG/CM2

+ HYDRAULIC PRESSURE SWITCH UNLOCKED MAN01AA011

THE HYDRAULIC PRESSURE
SWITCH MUST ONLY BE LOCKED FOR
THE PURPOSE OF TESTING

(02) + EXTERNAL SYSTEM READY FOR OPERATION CHECK

EXTERNAL SYSTEMS ARE BEYOND THE
SCOPE OF SUPPLY OF TURBINE /
GENERATOR.

+ CIRCULATING WATER OF CONDENSER AVAILABLE

+ CONDENSATE PUMPS IN OPERATION

+ VACUUM PUMPS IN OPERATION

+ VACUUM > 0.12 KG/CM2

(03) + INTERNAL SYSTEMS READY FOR OPERATION INTERNAL CHECK

SYSTEMS ARE WITHIN SCOPE OF SUPPLY OF TURBINE / GENERATOR.

+ OIL SYSTEM IN OPERATION

+ TURNING GEAR IN OPERATION

+ VACUUM PUMPS IN OPERATION

+ VACUUM > 0.12 KG / CM2

(04) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION

+ REHEAT PR : FIXED PR REF VALUE <1

BHEL Haridwar 3-1410-02/1

(05) + CRITERIA FOR BEGIN OF START UP CHECK

+ BYPASS CONTROL VALVE CLOSED MAN42AA001

+ BYPASS CONTROL VALVE CLOSED MAN52AA001

+ REHEAT PR FIXED PR REF VALUE =1

(06) + START OF BYPASS OPERATION OBSERVE

BYPASS OPERATION STARTS IF THE STEAM PR UPSTREAM
OF THE BYPASS VALVE EXCEEDS THE PR REF VALUE

* + BYPASS STOP VALVE OPENS MAN41AA001 & MAN51AA001

* + SPRAY WATER INJECTION VALVE OPEN MAN43AA001

DESGINATION OF SPRAY WATER VALVES ACCORDING TO
SINGLE LINE DIAGRAM

* + BYPASS CONTROL VALVE OPEN MAN42AA001 & MAN52AA001

* + SPRAY WATER INJECTION VALVE OPEN MAN43AA001

CRITERION PR AFTER LPBP CV AS PER CHARACTERISTIC CURVE

+ INTERLOCKS OF BYPASS CONTROLS NOT INITIATED

THE BP CONTROL & STOP VALVES CLOSE IF THE FOLLOWING
CRITERIA FLFILLED:

VACUUM < 0.6 KG /CM2

SPRAY WATER PR MIN (AS PER CHARACTERISTIC CURVE)
CONDENSER WALL TEMP > 90 C

+ LIMIT VALUE OF STEAM FLOW NOT INITIATED

IF THE REHEAT PR FALLS BELOW THE REF VALUE THE BP CVs
CLOSE

+ LIFT OF BYPASS CONTROL VALVES 100%

(07) + FIXED PR REF VALUE SET HIGHER

+ FIXED PR REF VALUE HIGHER

3-1410-02/2
 Steam Turbine Warm up and Startup of Turbine
Operation Startup Diagram

(01) + TURBINE READY FOR STARTUP CHECK

AND
+ MAIN STEAM LINES READY FOR WARMUP CHECK
+ MANUAL OPERATED VALVES OPEN.
(POSITION ACCORDING TO LINE DIAGRAM)
TEST VALVES OF STOP VALVES OPEN
HYDRAULIC VALVES OF EXTRACTION NRV OPEN
+ ELECTROHYDRAULIC TURBINE CONTROL ON
+ ELECTROHYDRAULIC TURBINE CONTROL NOT FAULTED
+ SPEED REFERENCE VALUE < N TURN GEAR
NORMALLY THE TURBINE WILL BE CONTROLLED
BY THE ELECTROHYDRAULIC CONTROLLER.
REFER TO 3-1710 FOR CHANGE OVER TO AND
OPERATION OF HYDRAULIC GOVERNOR
+ STARTING AND LOAD LIMIT DEVICE 0% MAX47 BY001
+ SPEED SETTER HYDRAULIC GOVERNOR 100 % MAX46 BY001
+ TURBINE STRESS EVALUATOR/CONTROLLER (TSE/TSC) ON
+ TSE/TSC NOT FAULTED
TSE/TSC TEST POSITIVE
NO ALARM
.NO FAULT INDICATOR ILLUMINATED
NO UNREASONABLE POSITION OF DISCS
+ TSE/TSC INFLUENCE ALWAYS ON
EXEMPTION: TSE/TSC FAULTY
CHANGE OVER WHEN DISTURBED. REFER TO 3-4170
IF THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURE AT THE MEASURING POINTS
WHICH REPRESENT THE THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED. REFER TO 2-020..
REF 3-4170 IF TSE/TSC ALLOWANCE IS REDUCED.
APPLIES TO ALL MODES OF OPERATION
+ TRIPPING DEVICE TURBINE PROTECTION NO ALARM
OVERSPEED TRIP MAY10 AA001
AND MAY10 AA002
IF STARTING AND LOAD LIMIT DEVICE > 20 %
+ ELECTRICAL TRIP NO ALARM
+ CASING DIFFERENTIAL TEMPERATURES NO ALARM
HP TURBINE CASING TOP/BOTTOM < 55°C MAA50 CT051
AND MAA50 CT052
OR IP TURBINE FRONT TOP/BOTTOM < 30°C MAB50 CT043
AND MAB50 CT044
OR IP TURBINE REAR TOP/BOTTOM < 30°C MAB50 CT061
AND MAB50 CT062
CASING DIFFERENTIAL TEMPERATURES DETERMINE
THE DISTORTION OF THE TURBINE CASINGS

(02) + GENERATOR READY FOR OPERATION CHECK

ALL REQUIREMENTS AS PER GENERATOR MANUAL
FULFILLED BEFORE STARTUP
+ GENERATOR BREAKER OFF
+ GEN FIELD BREAKER OFF

(03) + OPERATING CONDITIONS OF EXTERNAL SYSTEMS CHECK

EXTERNAL SYSTEMS = SYSTEMS NOT BELONGING

BHEL Haridwar 3-1510-05/1

 TO TURBINE/GENERATOR SCOPE OF SUPPLY
+ CONDENSING PLANT IN OPERATION
+ CIRCULATING WATER OF CONDENSER AVAILABLE
+ CONDENSATE PUMPS IN OPERATION
+ VACUUM PUMP IN OPERATION
+ VACUUM < 0.5KG/CM2
+ TURBINE EXTERNAL DRAINS ADJUSTED

WATER OR COLD STEAM MUST NOT FIND ACCESS

TO TURBINE. DRAIN ALL PIPES BEFORE
PRESSURING TO AVOID WATER HAMMER

(04) + DRAIN UPSTREAM OF MCV OPEN MAL11AA011

AND MAL12AA011
+ DRAIN HP OUTER CASING OPEN MAL22AA011
CRITERION: TEMPERATURE HP TURBINE < 300 °C
OR
+ DRAIN HP OUTER CASING CLOSED MAL22 AA011
CRITERION: TEMPERATURE HP TURBINE > 320 °C
+ DRAIN AHEAD OF SWING CHECK CRH NRV OPEN MAL66 AA011
CRITERION: CRH NRV CLOSED
+ DRAIN BEFORE IP CONTROL VALVE OPEN MAL26 AA011
AND MAL27 AA011
+ DRAIN DOWN STREAM IP CONTROL VALVE OPEN MAL31 AA011
AND MAL32 AA011
CRITERION: VALVE CASING TEMPERATURE
MINUS SATURATION TEMPERATURE OF STEAM < 20 °C
OR
+ DRAIN BEFORE IP CONTROL VALVE CLOSED MAL26 AA011
AND MAL27AA011
+ DRAIN DOWN STREAM IP CONTROL VALVE CLOSED MAL31 AA011
AND MAL32 AA011
MINUS SATURATION TEMPERATURE OF STEAM > 50 °C ‘
CRITERION: EXTRACTION VALVE CLOSED

(05) + CRITERIA FOR BEGIN OF START UP CHECK

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

+ EXTRACTION VALVE CLOSED

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

(07.) + PREWARMING OF TURBINE START

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

3-1510-05/2
 OPERATION OF PUSH BUTTONS
REFER TO MANUAL FOR THE FGA

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

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

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

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

(10) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 3-1610
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 3-1610

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

(11) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION

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

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

(13) + STEAM TEMPERATURE CRITERIA CHECK

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

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

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

(15) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX4BY001

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

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

3-1510-05/3
 OPERATION OPERATE DRAIN VALVES OF THE HP
CONTROL VALVES MANUALLY. CLOSE ON DECREASING
TSE/TSC ALLOWANCE. OPEN ON INCREASING TSE/TSC
ALLOWANCE. IF THE TSE/TSC IS FAULTY OPERATE
DRAIN V ALVES ACCORDING TO WALL TEMP
AT THE TSE/TSC RECORDER. REFER TO TECHNICAL
DATA FOR LIMITS OF DIFFERENTIAL
TEMPERATURES OF THE TSE/TSC.

(17) + DRAINS MAIN STEAM LINE CLOSE

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

(18) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REF. 3-1610 FIG.1.4
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REF 3-1610 FIG.1..5
THE RELEASE OF STEP (12) OF FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PRO(1RAMME
HAVE BEEN FULFILLED

(19) + LOAD REFERENCE VALUE CHECK MYA01 DU001

+ LOAD REFERENCE VALUE > 10 % MYA01 DU001

(20) + SPEED REFERENCE VALUE SET HIGHER

+ SPEED REFERENCE VALUE > 650 RPM
THE WARMUP SPEED’MUST NOT EXCEED THE
MINIMUM SPEED OF THE BARRED SPEED RANGE
IN ORDER TO AVOID OPERATION IN RANGES
WHERE NATURAL FREQUENCY OF FREE STANDING
LP BLADES IS TO BE EXPECTED,
OR WITH FGA (TURBINE)
(20/S)*+ SPEED REFERENCE VALUE SET HIGHER
THE PREWARMING PROCEDURE IS GUIDED BY THE
TSE/TSC INFLUENCE TO THE ELECTRO HYDRAULIC
CONTROL, THE SPEED WILL BE REDUCED IF THE
TSE/TSC ALLOWANCE IS REDUCED TO ZERO, IF
THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE THERMAL STRESSES OF CASING
AND ROTOR MUST BE EVALUATED. REFER 5,2-0430
IF TSE/TSC ALLOWANCE IS REDUCED

+ SPEED OF TURBINE/GENERATOR > 240 APM

(21) + TURNING GEAR OIL VALVE CLOSE MAV51 AA012
OR WITH SUBLOOP CONTROL
(21/S)*+ TURNING GEAR OIL VALVE CLOSED MAV51 AA012

+ SPEED OF TURBINE/GENERATOR > 540 RPM

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

3-1510-05/4
OR WITH SUBLOOP CONTROL

(22/S)*+ JACKING OIL PUMP OFF MAV31 APO01

AND MAV32 APOO1

(23) + STEAM TEMPERATURE CRITERIA CHECK

AND
+ OPERATIONAL VALUES OF TURBINE CHECK
+ STEAM TEMPERATURE CRITERIA FULFILLED REF. 3-1610 FIG,6
+ TURBINE STRESS MARGIN > 30 °K
+ BEARING VIBRATION NORMAL
+ SHAFT VIBRATION NORMAL
DEFINITION OF NORMAL VALUES OF VIBRATION:
VIBRATION PREVIOUSLY OBSERVED WHEN OPERATING
WITH SAME SPEED AND OTHER PARAMETERS

(24) + WARM-UP CONTROL SWITCH OFF

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

(25) + SPEED REFERENCE VALUE SET HIGHER MYA01 DU001

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

(26) + WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITICAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCUR. THE TSE/TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC .
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSE/TSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED REFER TO 2-02...
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.

+ SPEED REFERENCE VALUE 3000 RPM

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

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

3-1510-05/5
 AND MAL 12 AA011

+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL 11 AA011

AND MAL 12 AA011
OR WITH FGA (TURBINE CONTROL)
(28/S)* + DRAIN AHEAD OF HP CONTROLVALVES CLOSED MAL 11 AA011
AND MAL 12 AAO1 1

(29) + AUXILIARY OIL PUMP SWITCH OFF MAV22 AP001

AND MAV23 AP001

OR WITH FGA (TURBINE CONTROL)

+ STEAM TEMPERATURE CRITERIA CHECK

+ GENERATOR SYNCHRONIZE

3-1510-05/6
 Steam Turbine Warming-up and Starting the Turbine
Description Temperature Criteria

The admission steam temperatures should meet the

metal temperatures as shown n the diagrams below in
order to start and load the turbine in shortest possible time.

Note: The following criteria c represent approximate

values, which can be optimized y operational experience.

Turbines with Automatic Turbine Run up system (A

TRS) must under go optimizing.

Criteria for the opening of stop valves

When opening the main stop valves the main steam
parameters should meet the following recommended
values.

n Minimum main steam temperature

ϑ> ϑS + 500C Fig.1

ϑMS = Main steam temperature at steam generator

outlet

ϑS = Temperature of Saturated Steam (depending

on main steam reassure)

and

ϑS> f ϑCV 50% Fig. 2

υMS = Main steam temperature at steam generator

outlet

υMCV 50% = Middle wall temperature of main control valve

casing

BHEL, Hardwar 3-1610-02/1

n Maximum main steam saturation temperature
ahead of the turbine

ϑS < f (ϑMCV 5%) Fig. 3

ϑS = Maximum main steam saturation temperature

ahead of the turbine

ϑMCV 50% = Middle wall temperature of main control valve

Starting criteria

When the main control valves are opened the main

steam and reheat steam temperatures should fulfill the
following criteria:

n Minimum main steam temperature

ϑMS > ϑS + 500C Fig. 1

ϑMS = Main steam temperature ahead of the turbine

ϑS = Temperature of saturated steam (depending on

main steam pressure)

and

ϑMS < f (ϑHT 50%) Fig. 4

ϑMS = Main steam temperature ahead of the turbine

ϑHT 50% = Middle wall temperature of HP-casing or

simulated middle phase shaft temperature

3-1610-02/2
n Minimum reheat temperature

ϑReh > f (ϑIT 50%) Fig. 5

ϑReh = Steam temperature in the hot reheat line

ϑIT 50% = Simulated mid wall temperature of the IP-shaft

Speeding up criteria

Before the turbine Is brought to rated speed the main

steam temperature ϑMS ahead of the turbine should fulfill
the following criteria:

ϑMS < f (ϑHT50%) Fig. 6(a) & (b)

ϑMS = Main steam temperature ahead of the turbine

ϑHT 50% = Middle wall temperature of the HP-turbine casing

or simulated mid wall temperature of HP shaft

3-1610-02/3
Loading criteria

Before the turbine is loaded the reheat temperature

ahead of the turbine should fulfill the following criteria

ϑReh < f (ϑ IT 50%) Fig. 7

ϑReh = Steam temperature in the hot reheat Iine

ϑIT 50% = Simulated mid wall temperature of the IP-

turbine shaft

3-1610-02/4
 Steam Turbine Warming Up and Starting Up
Operation the Turbine
Controllers

1 Operating modes of the control systems and of

the starting and load limit device
n Electrical speed control “
– Warm-up operation

– Running up the turbine/generator unit The turbine generator unit is accelerated and
– Rated speed operation maintained at constant warm-up speed
n Hydraulic governor accelerate unit to rated speed
– Warm-up operation maintain unit at rated speed

The turbine generator unit is accelerated and

– Running up the turbine generator unit .. maintained at constant warm-up speed by manual
actuation of the starting and load limit device
When the reference speed setter is, in the 0 %
position, the hydraulic governor takes over speed
control at approx. 80 % rated speed
So, run-up of the turbine generator unit from
– Rated speed operation approx. 80 to 100 % rated speed is controlled by
– Overspeed trip test the hydraulic speed governor,
maintain unit~ at rated speed
Acceleration to 107 % of rated speed by the governor;
speed is increased to trip speed using acceleration
lever on casing of hydraulic governor;
During overspeed trip test, the electrical speed
n Starting and load limit device controller must be disengaged and switched off.
– Setting operating configuration of main
trip valves

– Opening the stop valves The main trip valves are brought into operating
position when the starting and ‘load limit device is
in the 0 % position.
When the starting and load limit device is in
approx 40 % open position, the stop valves should.
be open;
– Warm-up operation the test valves of the stop valves must be in the
operating position for the opening procedure.
2 Electrical speed control see Hydraulic speed governor
n Control range in % rated speed
n Setpoint control
– Target setpoint/actual setpoint 0 -107 % (Limitation by hydraulic speed governor)

– Limitation of setpoint by turbine The actual set point follows the target set Point
stress evaluator (TSE) / Controller (TSC) along preset gradients.

– Application of the ,TSE / TSC signal The preset gradient is reduced according to a
predetermined characteristic to conform to the
margin generated by TSE / TSC.

– Operation with TSE / TSC faulted The TSE / TSC signal must always be present if the TSE /
TSC is not faulted. The actual set lows the target setpoint if
the TSE / TSC is faulted must be matched up before the
TSE / TSC signal can be switched ‘off. .When the signal
from the TSE / TSC is not present, the thermal stresses in
the turbine components must be figured out by comparing
the actual temperstures and their differences with the
curves for permissible temperature margins a given in 2-
0200 to 2-0203.

BHEL, Haridwar 3-1710-00/1

 n Limitation by higher-level or alternative
controllers or other devices
– Minimum value selection Effective controller = controller with the lowest
setpoint setting at any time (also applies to other
devices influencing the opening characteristic)
– Hydraulic speed governor limits setpoint by hydraulic minimum
(speed setting device approx. 80 %) value selection;
– Starting and load limit device limits setpoint by hydraulic minimum
value selection;
excessive control valve opening can be prevented
by using the starting and load limit device to
limit valve travel.

n Operation
– Operating elements and monitoring see arrangement of control desk as described in
instruments controller manual. Pay attention to notes on operation
of release pushbuttons-
– Operating logic sequences for changing, See Appendix (for changing the operating mode during
the operating mode no-load operation

3 Hydraulic Speed Governor

n Setpoint control
– Target setpoint/actual setpoint The actual setpoint immediately follows the target
setpoint (no influence from turbine stress evaluator).
During operation with the hydraulic speed governor,
the thermal stresses in the turbine components must
be figured out on the basis of the TSE / TSC display or,
if the TSE / TSC is faulted, by comparing the actual
temperatures and their differences with the curves
for permissible temperature margins
n Limitation by higher-level or
alternative controller or other devices
– Minimum value selection Effective controller = controller with lowest
setpoint setting at any time (Also applies to other
devices influencing the control characteristic)

– Electro-hydraulic controller Limits set point by hydraulic minimum

< 100 % value selection
– Starting and load limit device Limits setpoint by hydraulic minimum
value selection

n Operation
– Operating elements and monitoring
instruments See arrangement of control desk as described in
– Operating logic sequences for controller manual
changing operating mode See Appendix

3-1710-00/2
 APPENDIX

Operating logic sequence 1: Starting up the turbine with the

startling and load limit device and the hydraulic
speed governor
A see Warming; up the Main Steam Line
B see Warming up and Starting up the Turbine

+ Turbine generator unit speed = Turning gear speed

+ Stop valve position =0%
+ Control valve position =0%
+ Main trip valves depressurized
+ Starting and load limit device ~ 40 % open
+ Reference speed setter =O %
+ Electrical speed reference =0%

(1) + Electrical speed reference raise

+ Electrical speed reference = 100%

(2) + Plunger coil deenergize

+ Plunger coil deenergized

(3) + Starting and load limit device lower

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

(4) + Starting and load limit device raise.

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

(A) + Main steam lines warm-up

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

(5) + Starting and load limit device raise

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

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

(B) + Turbine warm-up

+ Run-up criteria fulfilled
+ Steam generator output adequate

(7) + Starting and load limit device raise

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

(8) + Starting and load limit device raise

+ Starting and load limit device = 100 % open

(9) + Reference speed setter raise

+ Turbine generator unit speed = rated speed

3-1710-00/3
Operating logic sequence 2: Transition from operating with electrical speed controller to
operation with starting and load limit device
(Speed approx. 80 % rated speed)

+ Turbine speed > turning gear speed and

< 75 % rated speed
+ Electrical speed reference = turbine generator unit speed
+ Reference speed setter = 1 00 %
+ Starting and load limit device = 56 to 100 %

(1) + Starting end load Ilmit davice lower

+ Starting and load limit device effective

(2) + Electrical speed reference raise

+ Electrical speed reference = 100 %

(3) + Plunger coil deenergize

+ Plunger coil deenergized

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

(6) + Reference speed setter lower

+ Refernece, speed setter =0%

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

+ Turbine generator unit speed > Turning gear speed and

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

(1) + Plunger coil energize

+ Plunger coil energized

(2) + Electrical speed reference. lower

+ Turbine generator unit speed = electrical speed reference

(3) + Starting and load limit device raise

+ Starting and load limit device 56 to 100 %

(4) + Reference speed setter raise

+ Reference speed setter = 100 %

3-1710-00/4
 Steam Turbine Load Operation
Operation Introduction

Power operation begins by synchronisation of the The operating staff must detect all operating conditions
generator: The turbine generator load may than be raised that is hazardous to the turbine generator and must
or lowered according to the commands from the monitoring immediately correct them.
equipment, in particular the margins from the turbine stress
evaluator, to meet the grid power requirement. Regular checking of protection equipment, long-term
monitoring of operating variables and operational
During power operation, monitoring is essential for the maintenance are very important for early detection and
economic operation of the turbine generator. Neglecting elimination of system faults’.
this principle runs the risk of reduction in availability and
reliability.

BHEL, Haridwar 3-1800-00

 Steam Turbine Power Operation
Operation Controllers

1 Control System Operating Modes

n Electrical speed control Setting and maintenance of constant synchronization
– During synchronization of generator speed.
Run-up to approx. 2 x unit auxiliary power requirement
– After synchronization of generator before changeover to load control.
(normal operating mode) Power operation up to PMax or until control
– After synchronization of generator valves fully open.
(operating mode if load controller defective) interception of turbine generator before it reaches
– Load shedding trip speed;
(disconnection of generator from power grid) Maintenance of constant speed at residual load
(auxiliary power requirement);

n Hydraulic control
(operation if electrical control system defective) Setting and maintenance of constant synchronization
– During synchronization of generator speed.
Power operation up to Pmax or until control
– After synchronization of generator valves fully open.
Interception of turbine generator before it reaches
– Load shedding trip speed;
(disconnection of generator from power grid) Back up by overspeed anticipatory relay.
Maintenance of constant speed at residual load
(auxiliary power requirement).

n Electrical load control of turbine generator Maintenance of constant load up to Pmax by

– Constant pressure operation without positioning control valves.
frequency influence As above. turbine generator assists in grid frequency
– Constant pressure operation with stabilization when frequency changes.
frequency influence as given bypass
proportional setting of the frequency Maintenance of constant load (steam generator control
control and by the thermal storage system takes over control when max. control
capacity of the steam generator valve lift reached).
– Variable pressure operation without Maintenance of constant load;
frequency influence Turbine generator assists in grid frequency stabilization
when frequency changes.
– Variable pressure operation with frequency
influence as given by the proportional
setting of the frequency control unit
and the thermal storage capacity of the
steam generator by controlled throttling of
the control valves
n Initial pressure control by the electrical Maintenance of constant pressuring steam generator
load controller (alternative to limit initial as given by proportional settings characteristic of
pressure control) pressure reference value.
– Constant pressure operation
(with or without frequency influence)

n Limit initial pressure control by the electrical Maintenance of constant pressure in steam generator
load controller as given by proportional setting characteristic of
(alternative to initial pressure control) pressure reference value incorporating response
– Operation of load controller with or reference value.
without frequency influence for stabilization
of steam generator operation
in the event of pressure drops

BHEL, Haridwar 3-1810-01/1

2 Electrical Speed Control
n Control range
– Speed (as % of rated speed) 0 -107 %
(limited by hydraulic governor).
– Valve lift 1 00%
– Load at design pressure. 100%
n Reference limiter The actual reference value tracks the target
– Target reference value/actual reference along a preset gradient.
reference value The preset gradient is reduced In accordance with
– Limitation of reference limiter by TSC a predetermined characteristic to conform to the
(turbine stress controller) component load margin generated by the TSC.
The TSC signal must always be present unless the
– Application of TSC signal TSC is faulted.
The actual reference value no longer tracks the
– Operation with TSC faulted target reference value if the TSC is faulted;
Actual and target reference value must be matched
up before the TSC signal can be switched off.
The thermal stresses in the turbine components
must be assessed by comparison of the actual
temperatures and their differences with the curves for
permissible temperature margins given in
Technical Data
n Limitation by priority or alternative
controllers or other equipment Controller in effect = controller with lowest
– Minimum value selection setpoint;
(also applicable to other equipment that affects
the controller output signal),
Limits reference value by means of hydraulic minimum
value selection.
Limits reference value by means of hydraulic minimum
– Hydraulic governor < 100 % value selection.
Control valve lift overshot ~n be prevented by
– Starting and load limit device < 100% means of starting and load limit device

See desk allocation diagram in controller manual.

n Operation Note instructions on use of release push buttons !
– Control and monitoring devices See appendix
– Control logics for changing operating
mode
n Instructions for control and operational After changeover to load control the speed
monitoring reference value is to be set such that speed will
– Speed reference value after changeover revert to approx. 0.5.% above rated speed in the
to load control event of load shedding.

3 Hydraulic Governor
n Control range 80-107%
– Speed 100%
– Valve travel at rated speed 100%
– Load at design pressure

3-1810-01/2
 n Reference limiter Actual reference value tracks target reference
– Target reference value / actual value directly (no TSE component).
reference value During operation with the hydraulic governor in
control, the thermal stresses in the turbine components
must be assessed by referring to the TSC display or, if the
TSC is faulted, by comparing
the actual temperatures and their differences with
the curves for permissible temperature margins as
given in Technical Data

n Limitation by priority or alternative

controllers or other equipment Controller in effect = controller with lowest
– Minimum value selection reference value
(also applicable to other equipment that affects
the controller output signal).
Limits reference value by means of hydraulic
– Electrohydraulic controller < 100 % minimum value selection.
Limits reference value by means of hydraulic
– Starting and load limit device < 100'% minimum value selection.

n Operation See desk allocation diagram in controller manual.

– Control and monitoring devices See appendix
– Control logics for changing operating
mode
n Instructions for control and operational
monitoring As dictated by setting of speed reference value
– Actual speed after load shedding before load shedding with allowance for droop;
After shedding, the actual speed must revert to
rated speed.
During operation with the hydraulic governor in
– Starting and load limit device control, the turbine generator assists in grid
frequency stabilization as governed by the droop
of the controller;
The influence of the frequency component on the
load reference~ value tending to raise power can
be eliminated by switching in starting and load
limit device

4 Load Control by the Electrical Controller

n Control range 100%
– Valve travel 100%
– Load at design pressure
n Reference limiter The actual reference value tracks the target
– Target reference value/actual reference value along a preset gradient.
reference value The preset gradient is reduced in accordance with
– Limitation of reference limiter by TSC a predetermined characteristic to conform to-the
load margin generated by the TSC.
– Application of TSC signal The TSC signal must always be present unless the
TSC is faulted.
– Operation with TSC faulted The actual reference value no longer tracks the
target reference value if the TSC if faulted;
Actual and target reference value must be matched
before the TSC signal can be switched off.
The thermal stresses in the turbine components
must then be assessed by comparison of the actual
temperatures and their differences with the curves
for permissible temperature margins given in
Technical Data

3-1810-01/3
 n Limitation by priority or alternative
controllers or other equipment Controller in effect = controller with lowest
reference value;
(also applicable to other equipment that affects
the controller output signal).
– Minimum value selection Limit reference values by means of electric minimum
selection;
Active in the event of unit malfunctions.
– Absolute limit load reference value limits reference value by means of hydraulic
minimum value selection
– Hydraulic speed governor < 100 % See above

– Starting and load limit device < 100 %

n Operation
– Control and monitoring devices See desk allocation diagram in controller manual.
Note instructions on use of release pushbuttons !
– Control logics for changing operating See appendix
mode
n Instructions for control and operational
monitoring
– Changeover from speed to load and from Valve lift reference value must be matched up prior
load to speed control to changeover.
– Switching off load controller in the Changeover from load to speed control is effected
event of load shedding when the load falls below a preset value;
Changeover back to load control is effected if the
actual load rises above the lower limit within
approx. 2 s.
– Cut-in of initial pressure controller The pressure control deviation must be 0 before
the initial pressure can cut in.

3-1810-01/4
 + Turbine generator speed = rated speed
+ Turbine generator load = 0 MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller” not in operation
+ Electrical speed reference valves = rated speed
+ Speed changer = 100 %
+ Starting and load limit device = 1 00 %

(1) + Speed changer lower

+ Speed changer reference value < electrical speed reference value

(2) + Electrical speed reference value raise

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

(3 ) + Plunger coil switch off

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

(4) + Speed changer raise or lower

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

+ Turbine generator speed = rated speed

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

(1 ) + Plunger coil switch on

+ Plunger coil on

(2) + Electrical speed reference value lower

+ Electrical speed reference value < speed setter reference value

(3) + Speed changer raise

+ Speed changer = 100 %

+ Required speed higher or lower

(4) + Electrical speed reference value raise or lower

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

3-1810-01/5
 + Turbine generator load >0 MW
+ Individual valve controllers in operation
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical road controller not in operation
+ Electrical speed reference value = rated speed + load component
+ Speed changer = 100 %
+ Starting and load limit device = 100 %

(1) + Speed changer lower

+ Speed changer reference value < electrical speed reference value

(2) + Electrical speed reference value raise

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

(3 ) + Plunger coil switch off

+ Plunger coil off
+ Load reference value higher or lower

(4) + Speed changer raise or lower

+ Hydraulic frequency control not required

(5) + Starting and load limit device lower

+ Starting and load limit device in effect

(6) + Speed changer raise

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

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

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

3-1810-01/6
 + Turbine generator load >0 MW
+ Plunger coil off
+ Electrical speed controller not in operation
+ Electrical load controller not in operation
+ Electrical speed reference valve = max. speed
+ Speed changer = 100 %
+ Starting and load limit device in effect

(1) + Speed changer lower

+ Speed changer “ in effect

(2) + Starting and load limit device raise

+ Starting and load limit device = 100 %

(3) + Plunger coil switch on

+ Plunger coil on

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

(5) + Speed changer raise

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

(6) + Electrical speed reference value raise or lower

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

3-1810-01/7
 + Turbine generator load > 0 MW
+ Plunger coil on
+ Electrical load controller in operation
+ Pressure component on
+ Pressure controller in operation
+ Electrical load reference value = actual load ± pressure component
+ Electrical speed reference value = approx 1.005 × rated speed
+ Speed changer = 100%
+ Starting an9 load limit device = 100%

(1) + Electrical initial pressure controller switch off

+ Initial pressure controller off
+ Limit initial pressure controller on

(2) + Initial pressure component switch off

+ Initial pressure component off

(3) + Speed changer lower

+ Speed changer reference. value < electrical load reference value

(4) + Electrical speed and load reference values raise

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

(5) + Plunger coil switch off

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

(6) + Speed changer raise or lower

+ Hydraulic frequency control off

(7) + Starting and load limit device lower

+ Starting and load limit device in effect

(8) + Speed changer raise

+ Speed changer = 100 %
+ Turbine generator load reference value higher or lower
(9) + Starting and load limit device raise or lower

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

3-1810-01/8
 + Turbine generator load > 0 MW
+ Plunger coil off
+ Electrical load controller not in operation
+ Electrical load reference value = max. load
+ Electrical speed reference value = max. speed
+ Speed changer = 100%
+ Starting and load limit device in effect

(1) + Speed changer lower

+ Speed changer in effect

(2) + Starting and load limit device raise

+ Starting and load limit device = 100 %

(3) + Plunger coil switch on

+ Plunger coil on

(4) + Electrical load controller switch on

+ Electrical load controller on

(5) + Electrical speed reference value lower

+ Electrical speed reference value = approx. 1.005 x rated speed

(6) + Electrical load reference value lower

+ Electrical load reference value < speed setter reference value

(7) + Speed Changer raise

+ Speed changer = 100 %
+ Load higher or Lower

(8) + Electrical load reference value raise or lower

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

(9) + Initial pressure component switch on

(10) + Initial pressure controller control balance

deviation
+ Initial pressure controller control balanced
deviation

(11) + Initial pressure controller switch on

+ Initial pressure controller on
+ Load higher or lower

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

Control logics 6: Changeover from hydraulic to electrical load control in power operation
Procedures (1) + (2) Switching off hydraulic frequency cornball
Procedures (91 + (10) Switching on pressure controller

3-1810-01/9
 Steam Turbine Coastdown Time
Operation Test Instructions

Introduction
is sufficient resolution of the recorded values. If this is
This test instruction describes the procedure for not ensured, the speed must be read with time and
determining the coastdown time for the line of shafting of plotted manually.
the turbine generator unit: n Measurement of coastdown time from rated speed to
start of turning gear operation
n coastdown of the line of shafting from rated speed to The coastdown tome should be measured under the
turning gear speed most identical boundary conditions possible and
n coastdown of the line of shafting from turning gear operating parameters
speed to shaft standstill – position of the main stop valves (normally closed)
– condenser pressure values with time
Test recommendation – starting criteria for turning gear (speed criteria for
jacking oil supply to the bearings and speed-related
The coastdown time of the line of shafting for a turbine criteria for start of turning gear).
generator unit essentially depends on the energy of the Measurement begins at rated speed and ends with the
rotating masses, on the mechanical losses in the bearing start of turning gear operation.
and, in the upper speed range, on the losses due to blade n Measurement of coastdown time from turning gear
wind age. speed to shaft standstill
A prerequisite for accurate measurement of coastdown
Additional friction of rotating parts against stationary time is that shutdown of the line of shafting be
parts of the turbine leads to shortened coastdown times. performed in accordance with the operating
For this reason, coastdown time should be measured each instructions, i.e., the bearings must be supplied with
time turbine generator unit is run down and likewise on jacking oil during coastdown.
each shaft standstill after completion of turning gear
operation. The results should be compared with the Criteria for successful testing
coastdown times measured when the turbine generator unit
was in new condition. Measurement of coastdown time must be recorded
together with the results and the date of the measurement.
Determination of the coastdown times during or after The coastdown curve forms an integral part of the record.
faulted rundowns of the turbine generator unit is of
particular Importance. Actions to be taken when actual conditions deviate
from reference conditions
Measurement procedure
Actions to be taken to determine the causes for
n Plotting the sp(led versus time curve The speed versus deviations between coastdown times under previous
time curve Is normally plotted using the operational conditions from the coastdown time in new conditions are
monitoring devices (computers or recorders). A listed in Table 1.
prerequisite for accurate evaluation of the resulting log

BHEL, Hardwar 3-2140-00/1

 Table 1 Actions to be taken when actual condition deviate from reference conditions Coastdown time

Cause Actions
Fault
n Boundary conditions

Coastdown time of the line of

shafting Is shorter than normal
n from rated speed to turning gear Condenser pressure or condenser pressure Check condenser pressure level and
speed rate of change higher than normal on rate of change; match condenser
coastdown pressure to reference conditions’ on
next coastdown

Temperature difference between top and Determine cause of temperature

bottom casing halves excessive difference
= casing distortion

Bearing temperature very high before Determine cause of high temperature;

rundown = shaft displacement
Determine cause of increased
Bearing or shaft vibration high before vibration
rundown = shaft bowing or blade damage
n from turning gear speed to shaft etc.
standstill
Boundary conditions on coastdown not Check boundary conditions
comparable, e.g., loss of jacking oil pump
Determine cause of temperature
Temperature difference between top and difference
bottom casing halves excessive = casing
distortion

Check condenser pressure level and

Coastdown time of the line of Condenser pressure or condenser pressure rate of change; match condenser
shafting Is considerably longer rate of change lower than normal ‘pressure to reference conditions on
then next coastdown
normal Check leak tightness of main stop
n from rated speed to turning gear Main stop and control valves leak and control valves in accordance with
speed 3 .2340

3-2140-00/2