03 04 T6497 Operation A4 DPLPG Color

s
T6497 KERINCI
Training on Industrial Steam Turbines

Start-up, Operation and Shut-down
Type of Machine: SST800 – EEHNK90/3,2
PG I14314 Training
Caution
This Document fits for training puposes

only. May not be used for operation.
Any use for operation may cause harm to
persons and materials.
Note
This manual is part of the plant documentation.
Please refer to the document "Editorial
Recommendations" for information about the
handling of the various types of publications.
Work on machines and plant components may
be performed only by properly trained
personnel!
The reproduction, transmission or use of this document or its We have checked the contents of this manual for agreement
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Suggestions for improvement are welcome.
© Siemens Power Generation 2007. Technical data subject to change.

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Operation Table of content
Instructions for operation of the condenser
1
Table of contents
1 User notes 5
1.1 Instructions for operation of the condenser 5
2 Startup and shutdown operation 7
2.1 Checks during plant standstill 7
2.2 Preparations for startup 10
2.3 Start up the Turbine 16
2.4 Testing during plant operation 22
2.5 Uploading the Turbine 24
2.6 Shutdown the Turbine 25
3 Emergency shutdown 27
4 Monitoring of operation 28
4.1 Overview of operational monitoring 28
4.2 Limit value monitoring 30
4.3 Monitoring of live steam pressure 37
4.4 Temperature monitoring 38
4.5 Monitoring of casing expansion 40
4.6 Monitoring of the internal efficiency 43
4.7 Salt and Silica deposits 46
4.8 Blade Breakages 54
4.9 Monitoring of power output 68
4.10 Speed monitoring 72
4.11 Monitoring of vibrations 76
4.12 Monitoring of turbine radial bearings 83
4.13 Monitoring the turbine's axial bearing 89
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Table of content Operation
1 Instructions for operation of the condenser
4.14 Oil pressure and oil temperature monitoring 91
4.15 Checking of drains 94
4.16 Turbine fouling 95
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Operation User notes
Instructions for operation of the condenser
1
1 User notes
1.1 Instructions for operation of the condenser
Operating principle
A protective coating must build up in cooling-water-end condenser tubes

made of Cu alloys to provide adequate corrosion resistance.
The formation and retention of this protective coating depends primarily on

the general conditions prevalent during commissioning and during
subsequent operation.
The cooling water velocity and the properties of the cooling water are two
major factors that can have an effect on this.
The more aggressive the cooling water, the more closely new condenser
tubes have to be treated and checked in the first few months of operation,
during which the protective coating is formed. This so-called "protective
oxidation film forming process" should be run continuously for around two (2)
months where possible using the cooling water that will also be used for later
operation. The protective oxidation film forming process should, if at all
possible, be scheduled so as to avoid any interruptions during
commissioning of the overall unit.
Cooling water velocity
The condenser is designed such that the maximum permissible cooling

water velocity for the tube material in use is not exceeded during operation
with the cooling water mass flow rate defined in the design specifications.
Destroying of the protective film or erosion corrosion

Exceeding the maximum permissible cooling water velocity prevents
formation of the protective film, or can destroy an existing film, resulting
in erosion corrosion.
ATTENTION
A minimum cooling water velocity of 1.5 m/s should be maintained to prevent

the formation of deposits to the greatest extent.
Where an automatic tube cleaning system is provided, the limiting conditions

for trouble-free functioning of this system must be taken into account when
operating the unit with reduced cooling water flow.
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User notes Operation
1 Instructions for operation of the condenser
Preventing steam-side corrosion due to ammonia
When the water/steam circuit is conditioned with ammonia it must be

ensured that the maximum pH value is < 9.3. If this value is exceeded,
ammonia build-up and, hence, ammonia-induced corrosion can occur due to
the structural characteristics in the region of the air cooling zone
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Operation Startup and shutdown operation
Checks during plant standstill
2
2 Startup and shutdown operation
The following instructions represent a standard description for startup and

shutdown of the turbine plant.
Project-specific adaptations are implemented after commissioning of the

plant.
refer also to
Checks during plant standstill [J 7]
Preparations for startup [J 10]
Start up the Turbine [J 16]
Testing during plant operation [J 22]
Uploading the Turbine [J 24]
Shutdown the Turbine [J 25]
2.1 Checks during plant standstill
Introductory remarks to the general startup instructions:
The sections added in the section "Operation" for turbine startup and
shutdown with the driven machine provide only general information about
operation of the machine train. Only after initial commissioning on site has
been completed are these operating instructions to be adapted to specific
conditions on site and handed over to the owner/operator of the plant with an
accompanying commissioning data record.
Contents
Lubricating oil and control oil system
Lifting oil system
Hydrailic shaft turning gear
Leak-off and seal-steam control system
Evacuation and condensing system
Beginning of operational readiness

Operational readiness of the plant should be established two (2) hours
prior to the planned startup time of the machine train.
NOTE
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Startup and shutdown operation Operation
2 Checks during plant standstill
Lube oil and control oil system (see instructions for driven machine)
Prerequisites
Familiar with P+I flow charts
Lubricating oil: 0-0640-TNo.-00
Control system diagram: 0-0641-TNo.-00
Oil supply system for driven machine
Lifting Oil System
Prerequisites
Familiar with P+I flow charts.
Measures
Jacking oil pump 4712 is set to Manual and is not in operation.

The duplex jacking oil filter 4570 is switched such that only one filter is in
operation.
Isolating devices to the differential pressure switch PDIS 366 are open.
Hydrauic shaft turning gear

The autocontrol for the hydraulic shaft turning gear 7121 is switched off.
Seal and Leak-off Steam Control System (Arca Controller), Item 7200
Seal-steam supply
Prerequisites
Turbine steam + drain system: 0-0642-TNo.-00

Condensing Plant: 0-0642-TNo.-01
Measures
1. Open the isolation valves upstream and downstream of the pneumatic

seal-steam supply valve 7200 and close the associated bypass valve for
emergency operation.
Instrument air supply available for the pneumatic seal-steam controller for
the turbine.
2.5 bar for control valve 7200.
Seal-steam controller set to "Manual".
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Checks during plant standstill
2
Observe the setting for the seal-steam controller

Seal-steam supply valve 7200 would open fully when the seal-steam
controller is set to Automatic and with a normal setpoint of 8 mbar steam
pressure in the seal-steam header. However, control valve 7200 will
NOTE remain closed as long as the seal steam is not heated and superheated
to 30K.
The automatic drains trap drain for the seal-steam supply line from the
main steam system remains open.
Option: Extraction control system

Valve 7200 closes if more leak-off steam is fed into the leak-off steam
header via the front turbine shaft gland (excess), with the turbine under
load, than is required by the rear turbine shaft gland.
NOTE
Evacuation and Condensing System
Prerequisites
Turbine steam and drains system 0-0642-TNo-00 and

Condensing plant 0-0642-TNo-01.
Evacuation using steam-jet air ejectors
6400
6311 / 6321
6310 / 6320
The induction steam valves to the steam-jet air ejectors are closed.
The air extraction valves to the duty jet pumps, or to steam-jet air ejector
6400 are closed.
The motive steam line has been drained and the motive steam
superheated.
Circulating water
Water is in continuous circulation through condenser 6000.

The highest points in the circulating water system are vented.
Follow all operating instructions provided by the manufacturer for air-
cooled condensing plants.
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2 Preparations for startup
Pumping of condensate
Condensate pumps 6110 and 6120 are shut down.

The pressure-side and suction-side isolation valves in the condensate
path are open.
The same applies to the isolation valves for the condensate minimum
flow control station 6522 and the condensate level control valve 6512.
Condensate level indicator LIT 510 or LT510 shows the level to be
>NOMINAL
If the level in the condenser hotwell is too low it is raised temporarily via a
filling line.
Vacuum breaker, condensate injection, seal water
Solenoid valve 6010 to the vacuum breaker is closed.

Solenoid valve 6020 for condensate injection into turbine exhaust steam
is closed.
Sealing water (condensate) to the condenser safety valve 2410 is pre-
set.
2.2 Preparations for startup
Contents
Startup of turning gear
Steam supply to the shaft glands and startup of leak-off steam extraction
system
Startup of the evacuation system
Startup of the condensing system
Heating of the turbine main steam line and the steam chest
Startup of turning gear

1. The turning gear may only be started up when the lube and control
system is in operation.
Danger - rotating shaft!

All service work in the area of the rotating shaft should be concluded.
Ensure that no persons are standing in the vicinity of the rotating shafts.
DANGER
1. Clear the turbine and driven machines for turning gear operation.
2. Switch the hydrailic turning gear 7121 from "Manual" to "AUTO".
3. Set the jacking oil pump to "AUTO".
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Preparations for startup
2
Should the jacking oil pressure exceed a value of p > 70 bar, the hydrailic
turning gear starts up and accelerates the machine train to the specified
speed.
Function test for hydrailic rotor turning gear "OK".
1. Measurement of overcurrent must be confirmed when excess current,
resulting from rubbing, for the turning gear motor lasts longer than 1 to 3
seconds.
2. The oil temperature to the bearings should be automatically regulated to
around 45 ±3 °C.
Steam supply to the shaft glands and, where required, startup of leak-off
steam extraction system
Prerequisites
The turbine is in turning gear operation.
All actions must be performed locally.
NOTE
1. If 50 K superheated main steam is present up to the main steam valve

upstream of the turbine, open the drains in the seal-steam line and,
where required, open the bypass around the continuous drain E 167.
2. Switch the pneumatic seal-steam and leak-off steam controller 7200 from
Manual to "AUTO".
Operation with seal steam limited by time

The maximum permissible time for operation of the turbine with the seal-
steam supply system activated and without any flow of duty steam
through the turbine is four (4) hours. The turbine must, however, be in
NOTE turning gear operation for this.
At the end of the four (4) hours a cooling phase of eight (8) hours
without seal steam is required before repeated operation of the turbine
with seal steam and without any flow of duty steam through the turbine is
permitted, or before the turbine can be started up and load applied.
Operation with seal steam and without any flow of duty steam through
the turbine is only permitted directly prior to the startup procedure (and
with repeated turning of the rotor by hand) for turbines equipped only
with manual turning gear.
The turbine manufacturer is not liable for any damage that occurs as a
result of not following these instructions.
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Option
Should excess pressure (backpressure) build up in the exhaust end
section after startup of the turbine, the seal-steam inlet is closed via
valve 7200. Any excess steam (leak-off steam) that then accumulates is
NOTE drawn off into a gland steam condenser.
Startup of the Evacuation System

1. In the process control system select the process display "Condensate".
2. Set the evacuating units to "AUTO".
Function test for vacuum pumps "OK".
When the design vacuum is reached only one vacuum pump is required
for continuous operation.
NOTE
Startup of the Condensing System

In the process control system select the process display "Condensate".
1. Select condensate pump 1, 6110, as the duty pump.
2. Switch condensate pumping from Manual to "AUTO".
Pump 1 remains in operation if the level in the condenser hotwell
stabilizes above the MIN level LS 511.
If switch LS 510 signals that the MAX level has been exceeded,
condensate pump 2, 6120, cuts in automatically.
If the water level falls below the MIN level LS 511 both condensate
pumps cut out.
If the water level exceeds the NOMINAL level LT 510 the standby
condensate pump switches off.
When steam is condensed in condenser 6000 the level in the condenser
will rise above the NOMINAL level LS 510.
The condensate level run-off control LT 510 opens the drain control valve
6512.
Condensate is pumped into the condensate collecting tank by the duty
pump.
The minimum flow valve 6522 is closed for normal condensate mass
flow.
Option
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Evacuation of the vacuum system via steam-jet air ejectors
Cooling condensate flows continuously through the steam-jet air ejector

condensers 6350/6351; all operator control activities must be performed
locally.
NOTE
Measures
For evacuation of the vacuum system using steam-jet air ejectors:
the motive steam to the five (5) steam-jet air ejectors has been drained of
moisture and is superheated.
Hogging ejector
1. Open the air extraction valve to hogging ejector 6400.

2. Open the motive steam valve to hogging ejector 6400.
The motive steam/air mixture for the hogging ejector is routed to the
atmosphere via a muffler.
1. When initial evacuation up to around 70% of the design vacuum is
reached with the hogging ejector, switch-over is made to one of the two
pairs of duty steam-jet air ejectors.
A duty steam-jet air ejector pair (first and second stage) consists of items
6310/6320, steam-jet air ejector A, and items 6311/6321, steam-jet air
ejector B.
Avoid air in-leakage!

The correct sequence for actuating the valves/gate valves must be
maintained when switching from the hogging ejector to one of the two
duty steam-jet air ejector groups to avoid any air in-leakage.
NOTE
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Switching over to duty steam-jet air ejectors
Risk of burns by escaping steam!
DANGER
1. First open the motive steam valve for the second stage of the duty steam-
jet air ejector 6320 and then the motive steam valve for the first stage
6310.
Keep the bypass valves which circumnavigate the automatic drains

traps closed!
The bypass valves for E181 and E180 around the automatic drains traps
must remain closed, as otherwise the vacuum system would be linked
NOTE with the second stage of the steam-jet air ejector condenser. This stage,
in turn, is linked directly to the atmosphere via the open deaerating line.
Changing the air extraction valve
1. Open the air extraction valve to the first stage of the duty steam-jet air
ejector group A 6310.
2. After that close the air extraction valve for the hogging ejector 6400 and
then the motive steam valve to the hogging ejector.
3. By analogy, steam-jet air ejector group B can also be started up instead
of steam-jet air ejector A.
When switch-over is made to one of the two duty steam-jet air ejector
groups, the temperature of the cooling condensate in the steam-jet air
ejector condenser definitively determines the vacuum level that can be
reached in the vacuum system.
Operation of the plant using all of the duty steam-jet air ejectors is not
NOTE economical, as the temperature of the cooling condensate increases.
The hogging ejector has not been designed for the design vacuum, i.e.
the vacuum that can be achieved is not optimal when the hogging
ejector is activated.
Heating of the Turbine Main Steam Lines and the Steam Chest
1. In the process control system select the process displays for Steam, Oil
system and Control system.
The main steam from the steam generator is initially heated via drain E...
up to the main steam valve upstream of the turbine and superheated to
at least 50 K (see also Seal-steam supply).
NOTE
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2
1. The following drain valves are opened manually at the location of the
valves:
Main steam system up to the turbine stop valves
Main steam line

Warming line
Strainers upstream of turbine stop valves
Internal turbine and pipe drains
Wheel chamber (downstream of first control stage)

HP outer casing
HP nonautomatic extraction point A4
HP nonautomatic extraction point A3
HP automatic extraction point E1
IP outer casing, front
Pressure equalization line from HP to IP
IP automatic extraction point E2
LP nonautomatic extraction point A2, A1
LP outer casing, front
Pressure equalization line from HP to LP
LP outer casing, center
Seal-steam line
Shaft gland steam header
All of the drains listed above are in regions with a vacuum during startup;
these drains are routed into the E header E198 and linked to the
vacuum system via the condenser drain collector; the drains with the
highest pressure should be located the farthest distance away from the
header inlet; continuously falling pressure ensures that all of the
NOTE pressurized regions are drained properly.
The two manual isolation valves to the automatic drains traps remain
open for the HP drains.
Initial heating of the main steam line, first step
On a cold start, the main steam line is initially drained and heated to a
temperature of approximately 120°C (read at TE 001) in a first step by
slowly opening the bypass valve which circumnavigates the main steam
valve.
Build-up of pressure in the line, and in the steam chest, is effected in the
second state when the turbine stop valves are open.
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2 Start up the Turbine
NOTE
Opening of turbine stop valves 2300/2301
The turbine stop valves are opened if no trip criterion is present in the
process display for Control system.
Ö Build up the startup oil pressure for latching the turbine stop valves
locally on turbine trip block 2003 via valve 1839; after this latch the
turbine trip gear by actuating valve 2049 and allow trip oil to flow
below the disks of the turbine stop valves. Reset valve 1839; the trip
oil that is present will cause the turbine stop valves to open. (Refer to
the operating manual for information about the function/operation of
the items of the turbine trip block SSBE).
Ö Both turbine stop valves open when the corresponding signal is

issued and the current trip oil pressure is indicated on the SSB only
via PT 301 (left display).
Initial heating of main steam line, second step, and initial heating of steam
chest
The requisite period for preheating the inlet chest (see information based
on startup curves, document 0-2040-TNo.-32) is determined by the
heating status of the turbine.
1. The information valid for pressure build-up in accordance with the startup
curve applies for a cold start (outage >1 day).
2. This is accomplished by further, gradual opening of the bypass valves
until the main steam pressure has built up fully in the required time.
3. Open the main steam valve and close the bypass valve.
4. Throttle the external line drain.
The turbine can now be started up with steam.
2.3 Start up the Turbine
General
Start-up sequences can make a major contribution to shortening service life,

as high stress conditions exist during these. This is particularly true of cold
starts. For this reason, it is best to match main steam temperatures as far as
possible to the casing metal temperatures existing on start-up. On start-up of
the cold turbine or where the turbine has cooled down below 200 °C, we
therefore advise that main steam temperature be matched to casing metal
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Start up the Turbine
2
temperature in so far as permitted by boiler and plant requirements. Main

steam temperature should nevertheless be at least 30 °C above the
associated saturation temperature for the main steam pressure. The
permitted rates of change for main steam temperature as a function of steam
flow are given in the commissioning data record. Step changes in
temperature are only allowed when these lie within the permitted rates of
change (see 3-0210).
Caution: On solo operation of compressor drive turbines for test and

adjustment purposes, main steam temperature should be at least 30 °C
above saturated steam temperature but should nevertheless not exceed
400 °C. To achieve this, the turbine must be rolled with main steam line only
partly warmed and with drains open.
Oil Supply
The oil pump used for start-up was started previously during preparations for
start-up to allow check out of control systems and to warm the oil.
Where a jacking pump is provided, the isolation valve in the supply line to
this shall first be opened and this pump then started. It must be checked that
oil pressures at bearing journals stabilise at the values listed in the
commissioning data record.
Where hydraulic turning gear is provided, this is started by opening the

dedicated motive oil isolation valve; if necessary, engage gear. After the
turbine has reached the set turning speed, the jacking oil pump can be
stopped again as formation of an oil film can be expected at this speed.
Condenser Plant
Start up circulating water supply system for condenser as appropriate for

site-specific conditions. The circulating water pump can usually be started up
with isolation valve throttled. This does, however, depend on the type of
pump fitted.
Where start-up has to be performed with this isolation valve closed, the
closed isolation valve must be opened slowly and completely on reaching
pump-operating speed. The outlet lines are to be vented in the process of
this. Appropriate action is also to be taken to ensure that circulating water
can be supplied at the appropriate time to all other equipment to be cooled
by water.
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One condensate pump is to be started. It is to be ensured that the suction

side, water lubricated bearing is adequately lubricated and water supply to
the glands is to be set such that there is a continuous slight discharge of
seal water from the gland. There must also be an adequate level of
condensate in the hotwell of the condenser to allow condensate pump
operation and the isolation valve in the pressure equalising line to the
condenser which can always remain open must be opened.
Open suction valve fully. The minimum flow valve for the condenser is to be
opened far enough to allow continuous and adequate condensate circulation
but without causing any significant pressure drop in the condensate pressure
line.
The control system for water level in the condenser (implemented as a drain
controller or a level controller in most cases) is to be activated. Besides this,
it must be ensured that the condensate produced is passed to the feedwater
tank via the intermediate equipment such as feed heaters, deareators, etc.
The air extraction system is to be started (also see separate operating
instructions) to evacuate the condenser.
Opening of Main Steam Isolation Valve
After thoroughly draining the line ahead of the main steam isolation valve,
open this valve and progressively pressurise and warm the main steam line
up to the turbine.
If a bypass line round the main steam isolation valve is fitted, open this first
to reduce the load on the main steam isolation valve.
Where a non-return valve is fitted between turbine and exhaust line isolation
valve, this valve should likewise be opened before the isolation valve.
To achieve good evacuation of the condensing plant, steam must be

supplied to the shaft glands, that is, these must be pressurised with steam to
a pressure about 6 mbar above atmospheric pressure. This prevents ingress
of steam into the turbine casing along the turbine shaft.
Open air extraction valve 1 to 2 turns and open seal steam valve sufficiently
to give slight discharge at gland vapour stacks.
Latch turbine trip gear. Where further trip devices are fitted in the trip circuit,
these are likewise to be brought into their operating position.
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Opening of Turbine Stop Valve and of Control Valves
When the main steam line has been adequately drained, turn handwheel of
start-up positioner in opening direction. This causes pressure to build up
behind the piston plate of turbine stop valve. Observe pressure gages to see
when trip oil pressure exceeds starting oil pressure acting behind the piston,
at which point turbine stop valve opens. As soon as the turbine stop valve
moves in the opening direction, do not move start-up positioner further, but
wait until oil pressure behind the piston has dropped. Now move start-up
positioner further to increase secondary oil pressure. The valves start to
open at the secondary oil pressure level listed in the commissioning data
record. Where no turning gear is provided, secondary oil pressure must be
increased somewhat further to overcome the breakaway torque of the
bearings. As soon as the turbine rotor starts to turn, decrease secondary oil
pressure slightly. Next run up turbine to minimum speed as specified in the
start-up and loading diagram (see 3-0210).
Oil supply to the hydraulic turning gear must be shut off as soon as the
turbine accelerates and expansion of steam in the blading provides sufficient
energy to turn the rotor.
The main steam drains can be throttled gradually and can then be closed as
soon as continuous steam flow is in force and can be expected to continue,
and so long as about 50 °C superheat has been achieved ahead of the
turbine.
For compressor, pump or fan drives, speed increases are not possible
independent of load increases. This means that start-up and shutdown here
are only possible in line with the start-up and loading diagram (3-0210).
The start-up and loading times are limited by the thermal stresses occurring
in the turbine during the start-up and loading sequence.
Reference values for rates of change for speed and load are specified in the
commissioning data record along with the required start-up times as a
function of the duration of time the turbine has been stopped. The times
specified do, however assume that the rotor is not bowed on admission of
steam to the turbine. This can be ruled out by the use of turbine turning gear.
Where turbine restart is required before this has cooled down and no
hydraulic turning gear is fitted, after shutdown the turbine rotor must then be
turned at regular intervals using the manual turning gear, where fitted. Here,
the turbine rotor should be turned by 180° every 3 to 4 minutes for the
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duration of a set period and thereafter at longer intervals of approx. 10

minutes.
Should bowing of the rotor nevertheless occur, the slow roll time required
and thereby turbine start-up time must be lengthened significantly to rectify
this bowing.
A bowed rotor makes itself noticeable at an early stage due to increased

vibration. Should this take place, speed must be decreased, till vibration is
no longer present. Remain at this speed till it appears appropriate for turbine
run-up to be repeated. It is possible that this procedure will have to be
repeated several times, thereby requiring warm-up times, which are
significantly longer than the values specified in the commissioning data
record. During warming of the turbine, monitor absolute casing expansion,
free movement of the paw spacers, bearing oil temperatures and turbine
running noises.
Turbine Run-up
The turbine is run up by moving the handwheel of the start-up positioner

further in the open direction while observing the start-up curve and here
particulary observing the no-dwell zones and the running smoothness of the
turbomachinery as a whole. The maximum admissible values for expansion,
temperature etc. specified in the commissioning data record must not be
exceeded under any circumstances.
Control oil and particulary bearing oil pressure are subject to a number of
small pressure drops during run up. This normal process is caused both by
changes in oil temperature as well as the increasing suction effect of the
bearing journals.
Control take-over by Speed Controller
The speed controller takes over maintenance of constant speed from the
minimum speed set at commissioning with due allowance for control system
droop.
After this the start-up positioner is to be moved further in the opening

direction until it reaches its limit position. Further turbine run-up is performed
using the speed changer in line with plant requirements and observing the
maximum loading gradient.
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Transfer of Oil Supply to Main Oil Pump
Where an oil pump driven by the main turbine is fitted, it is to be checked

that this has taken over oil supply. This is usually marked by an increase in
oil pressure.
Where turbine start-up was performed using a steam-driven auxiliary oil

pump, the main steam valve for the steam-driven auxiliary oil pump is to be
throttled slowly. The main oil pump has taken over oil supply when oil
pressure in the control oil and lubricating oil circuits remain constant on
falling oil pressure for the steam-driven auxiliary oil pump. After this take
over, both main steam valves for the steam-driven auxiliary oil pump are to
be closed and the associated drain to be opened.
If turbine start-up was performed with an electrically driven auxiliary oil

pump, this is to be stopped when the turbomachinery reaches minimum
speed for loading this, so long as it is evident that the main oil pump has
taken over oil supply. There are several pointers to this changeover, these
usually include a sudden slight increase in control oil pressure and a drop in
current consumption by the electric motor driven auxiliary oil pump.
Autocontrol for oil pumps
After the auxiliary oil pump has been stopped, it should be ensured that the
autocontrol for the oil pump is not deactivated. This ensures that the
auxiliary oil pumps will be started immediately in response to the fall in oil
pressure in event of failure of the main oil pump, thereby assuring oil supply.
Oil cooling
If oil temperature behind the oil cooler exceeds 40 °C, open the circulating
water inlet valve wide enough to give a constant temperature of 45 °C
(bearing inlet temperature).
The oil outlet temperatures at the turbine bearings vary, lying between 50
and 65°C for an inlet temperature of 45 °C. The values which result will be
noted in the commissioning data record on initial start-up by the supplier. It
must be ensured that temperatures do not exceed these levels, particularly
on turbine loading.
Thermocouples or resistance temperature detectors are provided to

measure the temperature of the babbitt. These temperatures are subject to
large fluctuations. If these temperatures reach levels higher than those listed
in the commissioning data record during start-up or operation, the bearings
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2 Testing during plant operation
concerned are to be watched with extra care. Should these temperatures

reach a level of approx. 130 °C, the turbine is to be shut down immediately.
2.4 Testing during plant operation
Contents
Manual part-lift testing of turbine stop valves
Manual testing for proper functioning of the solenoid valves for remote
turbine trip
All tests are conducted locally on turbine trip block SSB. The design of
the turbine trip block (diagram 0-0635-TNo.-00) and the connections to
the turbine stop valves and to the turbine trip gear are known.
NOTE
Manual Part-lift Testing of Turbine Stop Valves
Part-lift testing possible only with turbine stop valves are open.
Part-lift testing may only be conducted when the turbine stop valves are
open. It is necessary to always conduct testing under the same general
conditions, such as operation of the main oil pump and at a normal main
NOTE steam pressure, in order to obtain comparable test oil pressures. These
conditions are met when the machine train is under load.
Risk of burns by escaping steam!

The turbine stop valve moves in its closing direction when the test
procedure is begun. Because there is no mechanical return seal in
place, superheated main steam escapes along the valve stem. It is
DANGER therefore prohibited to stand or remain in the direct vicinity of the valve
stem. Keep a minimum distance of one (1) meter from the valve stem!
Test sequence
1. Push the lever for the test valve 1845 from the neutral middle position to
the right until it stops.
2. Move the test valve 1845 lever back to the center position.
3. If two (2) turbine stop valves are provided, move the test valve 1845 lever
to the left until it stops to test the second stop valve 2301; read PI 339 for
the test oil pressure.
The turbine stop valves function properly when the test oil pressures read
off at the test pressure gauges PI 338 and PI 339 essentially concur with
the values documented in the commissioning data record.
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Testing during plant operation
2
Manual testing for proper functioning of the solenoid valves for remote
turbine trip (option)
All items are shown in their de-energized state, i.e. solenoid valves de-
energized, in the SSB-B system diagram 0-0635-TNo.-00.
NOTE
Testing of electrical trip initiation for Channel 1
Prerequisites:
The protective system has been activated, i.e. the solenoid valves are de-
energized and there is no trip criterion present.
Test phase 1 is initiated by switching of valve 2225 (de-energization of

solenoid valve) to position "a" (trip position).
Control chambers F of valves 2027 and 2036 are linked to the SSB T
circuit by valve 2225.
Valves 2027 and 2036 open.
Switching status of channels on testing of channel 1:
Circuit E → 2026 → 2027 → circuit T: blocked off by 2026
Message from limit switch ZS 480 "Valve 2027 open" and from ZS 489
"Valve 2036 open" is issued (generated); this indicates that trip
initiation functions properly.
Test phase 2 is initiated by switching of valve 2225 (energization of
solenoid valve) to position "b" (operating position).
Control chambers F of valves 2027 and 2036 are linked to the SSB P
circuit by valve 2225.
Valves 2027 and 2036 close.
Testing for closed position of valves 2027 and 2036 (operating
position of trip channel solenoid valve 2225) by ZS 483 and pressure
switch PS 306, i.e. the turbine trip block is in its operating position
The test cycle is then complete.
Testing of electrical trip initiation for Channel 2
Prerequisites:
The protective system has been activated.
Testing of electrical trip initiation in Channel 2 is started by switching

valve 2226 to position "a".
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2 Uploading the Turbine
Testing of channel 2 is performed in the same manner as "Testing of

Channel 1", with the associated valves of channel 2.
Option: Three-channel design
Testing of electrical turbine trip initiation - Channel 3
Prerequisites:
The protective system has been activated.
Testing of electrical trip initiation in Channel 3 is started by switching

valve 2227 to position "a".
Testing of channel 3 is performed in the same manner as "Testing of

Channel 1", with the associated valves of channel 3.
2.5 Uploading the Turbine
Regular unloading
Regular unloading of the turbine will be carried out in accordance with the
load chart given in the Test Report. However, there is no fundamental
objection against brusque unloading by taking the turbine directly back to
idling speed.
For unloading the turbine, decrease the reference value slowly. This should
result in a continuous decrease of secondary-oil pressure so that the control
valves are going to close. The possible effect of the unloading operation on
the boiler controls, on other auxiliary apparatus, and on the turbine-
dependent elements of the power plant in general, should be taken into
account as far as possible. Prior to unloading, all personnel involved has to
be contacted and mutual understanding be reached about the measures to
be taken.
Unloading after a disturbance
In the event of a disturbance calling for immediate unloading and for taking
the turbine out of operation, the machine may be shut down by releasing the
automatic trip gear, regardless of its actual load.
Closing the valves for uncontrolled extraction
Where uncontrolled extraction is provided, make sure that at decreasing

load the extraction valves will not be closed before secondary-oil pressure
has dropped below the assigned value. In a case of spontaneous unloading,
all extraction valves are going to close simultaneously, even if the
emergency stop valve of the turbine remains open. There is also the
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Shutdown the Turbine
2
possibility of closing the extraction valves independently from the secondary-

oil pressure prevailing at the moment. For this, the small handwheels
arranged on the changeover valves have to be turned clockwise.
Opening the drains
In installations equipped with extraction stop valves, the drains provided in

the lines between these valves and the turbine have to be opened
immediately after the extraction stop valves are closed, if it is intended to
operate the turbine plant in that condition for some time. This does not apply
to installations equipped with ”condensomatic” devices or permanent drains.
In cases of regular unloading, it will be sufficient to fully open the drains of
the extraction and other lines after the turbine has been shut down. All
supplementary shutting-off devices in the extraction lines have to be closed.
Extraction pressure regulator
Where an extraction-pressure regulator is installed and the turbine is to be

operated at low load for a protracted period, the regulator has to be set to
zero extraction. This will eliminate possible fluttering in the governing
system. Such instabilities may arise from the fact that the extraction pressure
regulator attempts to maintain the pressure at the extraction point constant.
2.6 Shutdown the Turbine

The turbine should not be shut down until it is certain that the auxiliary oil
pump is fully operational.
When the reference setter has been turned to minimum speed the turbine
can be shut down by means of the starting device. An alternative method is
to effect an emergency trip. The emergency stop valve and control valves
must close. All pressure gauges in the trip oil circuit and secondary oil circuit
must be reading zero.
Monitor the coast-down time of the turbine. The value can very, however,
depending on the load on the driven machine. If the machine is equipped
with hydraulic turning gear is should be started up at approximately 300 min-
1. With hydraulic turning gear simply open the appropriate motive oil valve.
As the speed of the turbine falls so also does the pressure produced by the
turbine-driven main oil pump. Ensure that the electric auxiliary oil pump
starts up at the preset value. If the auxiliary oil pump does not start
automatically it must be switched on immediately by hand.
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2 Shutdown the Turbine
If the machine is equipped with a steam driven auxiliary oil pump open the
necessary is good time and start the pump.
As soon as the emergency stop valve and the control valves have closed,
closed the valve in the main steam line. Open the appropriate drain so that
the pressure in the line is reduced to zero. After shutdown, open all turbine
drains fully.
Shut down the condensing system. The fall in condenser vacuum should not
be too rapid and can be controlled by appropriate shutting-down of the
vacuum pumps. Do not turn off the shaft seal steam until the vacuum has
been reduced completely- The condensate pump can be shut down.
When a hot turbine is shut there is still a considerable amount of heat

reaching the bearings.
Therefore, the auxiliary oil pumps must be in operation that the temperature
of the babbit of the bearings does not exceed the preset limit values. The oil
coolers must be adjusted so that oil inlet temperature at the bearings is
approximately 35 °C.
When it is certain that not distortion of the rotor can occur, turning-gear
operation can be discontinued. When the rotor has come to a standstill the
oil pumps can be shut down.
All other auxiliaries, valves, etc. should be restored to their initial positions.
refer also to
Start up the Turbine [J 16]
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Steam turbine Alfasel Emergency shutdown
Operation
3
3 Emergency shutdown
In the event of risk to the plant or operating personnel the machine train can
be shut down at any load by trip initiation either using manually-operated
valve 2274 on the turbine trip block, or via solenoid valve 2225 for remote
turbine trip.
Immediate shutdown may also be necessary due to:
sudden increase in vibration levels;

reaching or exceeding of limits for bearing metal temperatures at the
thrust bearing or at the journal bearings;
exceeding of alarm values for axial shifting;
exceeding of permissible expansion;
loss of auxiliary equipment vital for continued operation of the machine
train.
Load can also be removed from the plant by reducing the speed setpoint at
the turbine controller in cases of less risk to the machine train.
The degree of risk posed to the machine train determines whether the
turbine must be shut down directly after trip initiation, or after having the load
removed previously. If in doubt, you should always opt for immediate trip
initiation.
Requisite measures after emergency shutdown

All requisite measures shall also be initiated or carried out after an
emergency shutdown in accordance with the instructions for
"Shutdown".
NOTE
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Monitoring of operation Operation
4 Overview of operational monitoring
4 Monitoring of operation
refer also to
Salt and Silica deposits [J 46]
4.1 Overview of operational monitoring
Introduction
The economic efficiency of a turbine plant is to a large degree dependent on

its operational reliability. The availability of the turbine is a criterion for the
operational reliability.
The availability is most strongly influenced by damage, which can occur at

the main parts of the turbine, the rotor and the casing. Slight primary
damage or operational irregularities at these components can cause
consequential damage necessitating larger repairs with considerable
expenditure of time and money.
Types of damage
Apart from damage due to foreign bodies, a distinction can be made

between the following main types of damage:
Damage as a result of the influence of overspeed,

bridging of axial and radial clearances in the blading or the shaft seals,
bearing damage, which as primary damage can lead to the other types of
damage listed above,
damage or wear phenomena at the casings, the blading and other parts
due to incompotent operation of the machine.
Wear of parts, which as a result of the high stress to which they are
subjected, have a naturally lower service life than that of the main
components of the turbine.
By means of operational monitoring, damage and faults are to be avoided or

at least limited in their extent. Operational conditions, which can lead to
immediate damage or on frequent repetition, must be stopped on detectíon
by taking suitable steps to alter the operational conditions. Limiting and
protection devices are employed to monitor those operational values, which
are subject to high rates of change on occurrence of faults. Automatic
counteraction is initiated as soon as limit values are exceeded.
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Operation Monitoring of operation
Overview of operational monitoring
4
Monitoring functions to be carried out by the operating staff
The monitoring functions of the operating staff encompass detection and

clearance of faults and irregularities associated with low rates of change of
the operational values.
Making use of limit values not specifiically mentioned in the "Commissioning

report" within the safety margin of the report and the damage limit value is
not permitted. This rule is also applicable when values near these limit
values are approached during testing of the turbine with assessible risks and
under abnormal operational conditions by representatives of the
manufacturer and under his responsibility.
Supplementary means for operational monitoring
The following supplementary means are available to the operating personnel

for monitoring purposes:
indicating instruments,
recording instruments,
audible and/or optical signals,
position and operational status indicators.
The values displayed by the instruments should be compared with the

nominal values in the "Commissioning report". The response values for the
alarm annunciation plant are also to be found in the "Commissioning report".
The recording of measurements facilitates reconstruction of operational

phenomena. For this reason, the measuring instruments must operate
simultaneously.
The measuring equipment must be checked and maintained at regular

intervals.
Inspection rounds
It is not possible to monitor all those conditions, which effect operational

reliability, solely by means of the operational measurements. Regular
inspection rounds – approx- once or twice per shift – should form an integral
part of the monitoring measures.
In particular the oil, steam and water tightness of the plant should be
checked locally during such rounds in addition to the operational behaviour
of the auxiliary drives (pumps, motors, etc.)
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4 Limit value monitoring
4.2 Limit value monitoring
Introduction
The turbine plant is equipped with monitoring, limiting and protection

devices. These are designed to detect or avoid operational conditions, which
are impermissible or uneconomic for the turbine .
Monitoring devices are designed to make it possible to recognise the

operational status of the plant and/or to signal deviations from the
nominal condition.
Limiting devices are designed to detect and correct impermissible
operational conditions of the turbine plant. These are designed and their
parameters are set in such a manner that they become active before the
protection devices and thus prevent tripping, thus avoiding, where
possible, an interruption of service.
Protection devices are designed to shut down either the turbine or plant
sections, on occurrence of operational conditions, which endanger the
turbine.
The operating personnel is thus in a position to continuously monitor the

behaviour of the turbine plant. Their task is to correctly evaluate both the
time characteristic and the amplitude of the displayed operational values.
However, the specified permissible values must be taken into account, on
exceeding which the turbine plant must be shut down. Some of the following
operational and limit values are to be found in the "Technical data"; in cases
where these values differ, the latter are binding.
Monitoring must also cover those operational values, on exceeding whose

limit values visual or acoustic signals are generated and emergency
shutdown tripping is initiated. Consequential damage can be avoided in
many cases, if the turbine plant is shutdown, either automatically or
manually, before the operational limit values are actually reached. For this
reason, the turbine must be shutdown immediately, when it is reasonably
certain that a limit value will be reached or it can be deduced from the time
characteristic (trend) of the operational values that a fault must exist, which
necessitates immediate shutdown.
The following remarks about normal and abnormal behaviour of bearing

temperatures, vibrations, casing and steam temperatures are intended to
make it easy for the operating personnel to correctly monitor the measured
values of the monitoring devices and to take the right decisions. Experience
has shown that the following operational values are normally subject to large
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Limit value monitoring
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changes, on occurrence of an operational condition which endangers the

turbine plant. This does not exclude the possibility that endangerment of the
plant can also be deduced from other operational values.
The most important criteria, from which it is possible to detect endangement

of the tirbine plant during normal operation are:
the oil and bearing metal temperatures,

the bearing housing and shaft vibrations,
the relative shaft expansion and the absolute casing expansion,
the steam and component temperatures,
the steam pressures,
the speed.
Bearing-metal and oil temperatures
The temperatures at the radial bearings and the axial bearing are measured
immediately below the babbitt lining of the bearing shell and of the axial
bearing segment respectively. The temperature of the exhausted oil
downstream of the bearings is measured in exceptional cases only.
The babbitt temperatures can be subject to widely differnet temperatures

even where the oil temperature remains constant. In the axial bearing this is
dependent on the magnitude of the residual thrust. In the case of the radial
bearings, changes can occur as a result of changes in direction and
magnitude of the bearing loads exerted by the rotor journal end due to the
steam flow conditions.
The normal values and maximum values associated with large changes,
which occurred during initial commissioning, form the basis for evaluation of
the bearing temperatures, which must be evaluated analogously when the oil
temperature deviates from the normal oil inlet temperature 45 °C ±3 K (in
special cases max. 60 °C). A sensible measure is to document these values
in tabular or graphic form from the very start of initial commissioning,
especially where these values are subject to load-dependent changes, in
order to be always in a position to compare them with the actual values.
Such documentation facilitates deduction of wear or damage.
Bearing damage with consequent temperarture increase can occur rapidly

and in a very short time. In this connection it should be noted that
temperature increases often occur for a short time only and that the
temperature at the bearing can return to normal after the damage has been
done. Immediately after a sharp temperature rise, which exceeds the limit
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value, as a very minimum, the oil sieve in the oil tank should be examined in
order to determine whether white-metal tailings are present, which could
originate from bearing damage. However, it is explicitly recommended that
the affected bearing be checked, even when no white-metal tailings are
discovered, since this is only one indication for severe damage. Lubrication
damage cannot be ascertained in this manner.
In practice, a distinction is made between two types of temperature

measurement:
the babbitt temperature measurement and

the lubricant temperature measurement.
In practice, temperature measurement in the bearing metal of the sleeve

bearing is the most accurate type of measurement.
Ín addition to measurement and recording of the bearing metal temperature,

provision should also be made for generation of a signal on reaching the
limit value and of a tripping pulse on exceeding the alarm limit value. This is
of particular importance, where continuous monitoring is not provided, since,
as mentioned above, bearing metal temperature rises happen quickly and
are of short duration.
Spontaneous changes of bearing temperatures above previously measured

maximum values is always a sign of an irregularity. For this reason, bearing
inspection should always be carried out subsequently. On occurence of a
spontaneous rise in bearing temperature and after also taking other
operational values into account, the turbine should be shutdown without
hesitation by emergency tripping before the maximum temperature is
reached.
Vibrations
The task of the bearing housing and shaft vibration measurements is

monitoring of the running condition of the turbine and its time characteristic.
The objectives of vibration measurement are:to protect the turbine plant

and its environment against harmful vibrations,
to detect the cause of changed vibration behaviour or excessive vibration,
to create a basis for countermeasures on occurrence of undesireable
vibrations.
The vibration measurements provide information about:
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4
changes in the running condition caused by: blade rupture, deposits,

erosion, changes in orientation, shaft distortion, temperature-dependent
imbalances:
dynamic overstressing, in particular of the bearings. These lead to
premature depletion of the bearing stress capability.
bridging of radial clearances, which are of significance during transitory
operational conditions, in particular on start-up.
As already discussed for evaluation of bearing temperatures, the prime

consideration for evaluation of the vibration parameters is deviation from the
normal values and, in the last analysis, the amplitude of the measured value.
Comparison with previous measurements and, in particular, with those
obtained during initial commissioning takes precedence. If, for example, the
vibration measured continuously at a bearing is 25 µm, an irregularity is not
necessarily present, if the vibration amplitude increases to 30 µm. However,
if the normal vibration amplitude is only 5 µm and the amplitude suddenly
increases to 30 µm, it can be safely concluded that damage or some
irregularity has occurred.
On running up to speed and loading of the turbine, in particular from a cold

condition, it is to be expected that the measured values of transitory vibration
(e.g. due to thermal imbalance) will by far exceed those measured when the
turbine is at its operating temperature and is running normally. If these
vibrations occur regularly under specific conditions, it cannot be necessarily
concluded that damage exists.
If, on the other hand, vibrations of unknown origin occur suddenly on loading
or during a starting-up phase, in which on the basis of operational
experience unusual permanent or transitory vibration is not to be expected, it
can be safely concluded that damage or an irregularity has occurred, even if
the limit values have not been exceeded. In this case the specified limit
values are no longer relevant and the turbine plant must be shut down. An
exception is permissible, when the cause of the vibration is known and it can
thus be concluded that continued operation is justified. In all such cases, we
recommend that the service department of the turbine supplier be consulted.
Relative and casing expansion
Relative expansion gives an overview of the axial position of the rotor with
respect to the turbine casing. Where necessary, a measuring device is
installed by the turbine manufacturer at the rear turbine bearing housing for
monitoring of the relative rotor position. In this case, the maximum
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permissible relative expansion in the plus and minus directions are given in
the "Commissioning report". Under no circumstances may these values be
exceeded, since otherwise axial rubbing of the rotating parts against the
stationary parts could occur. The turboset must always be shutdown, when a
limit value is reached or it is anticipated that it will be exceeded.
The absolute relative expansion of the casing is measured in order to

monitor the warming-up condition of the turbine. On the basis of measured
results it can further be determined, whether the anti-friction property of the
bearing housing and of the casing supports is intact and whether all parts of
the casing glide simultaneously and without jerking.
The sliding casing should not assume a new position with a sudden jerk
either during start-up and shutdown or during load changes.
Steam and component temperatures
Normally different temperatures do not occur at the turbine casing wall

above and below within the same vertical plane. If such temperature
differences are still experienced, this can generally be attributed to cold
steam entering the hot turbine through bleed and extraction lines. Possible
causes are leaky or incorrectly operating valves in the bleed and/or
extraction lines.
Temperature differences result in deflection of the casing and endanger the

turbine plant through bridging of clearances or jamming of the inner casing
or of the guide blade carriers.
The permissible values for the temperature difference are dependent on the
type of construction of the turbine. These are determined separately for each
turbine and are documented in the "Commissioning report".
Overtemperatures reduce the strength values of the component materials

and reduce the safety margin and service life of the affected components. In
addition, temperature changes cause thermal stresses in the components,
which are superimposed on the base load; too rapid temperature changes
result in overstressing in the components and in consequence shorten the
service life. Moreover, rapid temperature changes lead as a result of
different expansion behaviour of the rotor and casing to relative expansion,
which, under certain circumstances, could endanger the turbine plant.
When the temperature of the live steam is too low, the exhaust wetness of
the steam increases, which leads to cavitation (erosion) at the last stage and
may also result in uneconomic operation of the turbine.
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The permissible steam temperature is generally exceeded for short periods

only. Since even short-term exceeding of the temperature is permissible only
within the specified limits (refer to "Design data"), a temperature recorder
should be provided in addition to the temperature indication.
Temperature differences between the inner wall and the outer wall at a
specific point of the housing can be taken as a measure for thermal stress in
the casing and may also be applied indirectly to the rotor. Such stresses can
also be caused by an excessively high rate of change of the live steam
temperature or by excessively large load changes.
Where agreed on, measurement of the temperature difference in the casing

partial surface flanges – in some cases additionally in the wall of the
admission section – gives an indication of the thermal load during start-up,
especially during the condensation phase and during running up to speed. In
the case of fully loaded turbines, it is also a measure for the permissible
temperature gradient and, in the case of partially loaded turbines, for the
permissible load gradients.
In cases where the measurement in the area of the admission section is

employed as a substitute for shaft measurement, this measurement in
conjunction with the automatic trip device protects the rotor against
impermissible sudden temperature drops.
Since this measurement is provided to special order only, normally on

occurrence of impermissible sudden temperature drops, e.g. on failure of
burners, the turbine must be shutdown immediately.
Steam pressures
The live steam pressure is reduced in the turbine in stages to the exhaust
steam pressure. The turbine can be endangered by exceeding of the upper
or lower limit values for live steam pressure, wheel chamber pressure, bleed
pressure, back pressure, condenser or shaft sealing steam pressure. The
key operational pressures of the turbine must therefore be continuously
monitored by means of the pressure measurements provided. If limit values
are reached, the operating personnel must take immediate action and clear
the fault.
If the pressure characteristic inside the turbine alters, this generally causes a
change in the horizontal thrust and thus of the load on the axial bearing.
The pressure characteristic can be disturbed by:
fouling of the blading, e.g. by salt deposits or silification,
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damage to the blading, which can result in changes of the cross-sectional

areas,
alterations in steam flow in the individual stages, e.g. change of the bleed
and extraction flows, deviations from the design values.
The nominal stage pressure characteristic, where capable of being

measured, should be available in the form of diagrams for various rates of
steam flow. Deviations from the nominal characteristic indicate that one of
the faults described above has occurred.
The safety valves of the steam generator or of the steam network provide
protection against excessively high live steam pressure and blow-off the
excess steam as soon as the permissible pressure is exceeded.
In the case of severe salt deposits or when the flow-passing ability of the
turbine is much larger than the steam flow which passes through the turbine
at rated output, the wheel chamber pressure can increase to such an extent
that the casing and blading are endangered. At the same time an
impermissibly high axial thrust can occur. On exceeding the limit values,
specified in the "Design data", the steam flow through the turbine should be
limited to such an extent that normal values are once more obtained.
Speed
The speed of the turbine plant must be monitored during start-up, on

synchronisation of the generator, during normal operation, on shutting down
and during operation with turning gear. The limit values given in the "Design
data" and the values of the "Start-up and loading curves" are to be observed.
The turbine is protected by the speed controller against impermissible speed

rise during normal operation and on isolation from the power system without
reaching the tripping speed of the overspeed trip device, which would
otherwise shutdown the turbine.
The turbine blading can be endangered even on operation at reduced

speed, when the natural frequencies of the blades are in resonance with
harmonics of the turbine speed.
The following limit values for deviations from the rated speed apply to steam
turbines for driving generators without endangering the steam turbine plant:
continuously permissible from +3 % to -3 % ;

up to -4 % for 20 min; in total 2 hours/year are permitted;
up to -5 % for 10 min; in total 1 hour/year is permitted;
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Monitoring of live steam pressure
4
4.3 Monitoring of live steam pressure
Introduction
The live steam pressure must be monitored during start-up and operation.
The purpose of monitoring is to maintain the live steam pressure:
within the permissible deviation limits, in oder to ensure that the yearly
average value (refer to the Section "Design data") is not exceeded;
constant, in so far as this is possible, during steady-state operation;
so that it is matched to the requirements for power output;
so that matching and changes are effected as a function of the casing
temperature during start-up, so far as this is possible.
Nominal values and permissible deviations of the live steam pressure
The design value and the permissible deviations of the live steam pressure
are given in the "Technical data".
The average pressure during a 12-month period of operation may not

exceed the design value; the time during which the design value may be
exceeded is limited.
The turbine may be operated at any steam pressure which lies below the
design value, provided this can be tolerated by the plant as a whole.
Regulation of the live steam pressure
If the turbine controller is not involved in regulation of the live steam

pressure, the live steam pressure is maintained constant by the boiler
controller during steady-state operation.
During transient operating conditions, e.g. on loading and unloading the

turboset, the type of control performed and the limits, within which the live
steam pressure is involved in power output regulation of the steam
generator, is dependent on the design and interlocking logic of the steam
generator controller.
This description does not deal with any such interlocking logic.
During operation of the turbine with fully open control valves, the turbine
output is dependent exclusively on the live steam pressure. Changes in
power output can be effected only by changing the live steam pressure, so
that in this case the task of controlling the power output is assumed by the
steam generator.
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4 Temperature monitoring
Limiting the live steam pressure
The live steam pressure is limited by an upper limit value imposed by the
limiting devices of the steam generator. These open and blow-off steam, as
soon as the pressure exceeds a defined preset limit value.
Measures on sharp fall of the live steam pressure
On sharp fall of the live steam pressure, it can be assumed that a fault has
occurred in operation of the steam generator. Among other possible causes,
leakage can have occurred within the steam generator, in which case
operation must be ceased immediately.
Faults in the controller of the steam generator can likewise result in strong
pressure changes. In this case it is adviseable to unload the turbine to such
an extent that the pressure is maintained until the cause of the fault has
been ascertained and the fault has been rectified. Since a severe drop in
pressure also causes a severe drop in temperature, endangerment of the
turbine can thus be held within limits.
Matching the live steam pressure during start-up
By virtue of the relationship between the live steam pressure and the
corresponding saturated steam temperature, the increase in pressure in the
main steam line must be controlled so that impermissible stress of the
components does not occur, especially during a cold start.
4.4 Temperature monitoring
Introduction
The functional integrity and the service life of the turbine components are
dependent to a high degree on the absolute temperature of the live steam
and on its rate of change.
The objective of continuous monitoring of the live steam temperature during

operation is:
to keep the live steam temperature at the values given in the "Design
data" and to make use of the permissible deviations in such a way that
the specified yearly average is not exceeded;
to keep the live steam temperature constant;
to match the live steam temperature during start-up to the casing
temperatures in the best possible manner;
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Temperature monitoring
4
to hold the necessary live steam temperature changes within the limits
specified in the Section "Start-up and loading curves".
Consequences of exceeding the maximum permissible deviations
Excessive live steam temperature lead to:
shortening of the service life of the affected components;

scaling at the control and sealing organs;
permanent casing deformations;
transitory or permanent change of the radial clearances.
Changing the live steam temperature during operation
Transient operation, such as start-up or load changes, result in temperature

changes and in consequence thereof to temperature differences at different
levels of the components. The thereby resulting material stresses are
discussed in a separate Section. Stress also occurs on change of the live
steam temperature with otherwise constant operational parameters.
For this reason, the live steam temperature should be maintained as

constant as possible during operation of the turbine in order to reduce the
number of stress changes to an unavoidable minimum.
Simultaneous increase or decrease of both the power output and the live
steam temperature should be avoided, since such action results in increased
stress, of which no account has been taken in the limit values specified in
the "Start-up and loading curves".
Matching of the live steam temperature to the casing temperatures during

start-up
The times given in the Section "Start-up and loading curves" are limit values,
which should be extended as far as possible in order to reduce stressing of
the material. On the other hand, a turbine plant can be started up with the
desired economic efficiency, when the warm-up period is kept as short as
possible. Short warm-up times are possible, where the live steam
temperature is optimally adapted to the casing temperatures.
As a matter of principle, steam admission of steam of any temperature to the

components is possible, provided that the limit values for material stress are
not exceeded.
It is therefore recommended that the boiler outlet steam temperature be

matched to the casing temperature before warm-up of the live steam lines
and valves and before acceleration of the turbine to rated speed. As a result,
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transient cooling down and excessively high stresses and extended starting-
up times are avoided.
However, it should be hereby ensured that during warm-up neither wet

steam nor saturated steam conditions exist within the turbine, since the drain
lines would otherwise not be capable of discharging the volume of water.
Under particularly unfavourable circumstances, the casing can warm up on

one side only. Care should therefore be taken to ensure that the steam
temperature selected lies at least 50 K above the saturated steam
temperature (at least 100 K in the case of high-pressure turbines).
During start-up and in steady-state operation, neither the limit values for the
casing temperature differences at different wall depths nor those for casing
expansion should be exceeded as a result of changes in the steam
temperature. If such limit values are reached, the steam temperature should
be changed in the opposite sense in order to suppress a dangerous
condition for the turbine.
Likewise, the consequences of large changes in the power output at a high

rate of change can be reduced by temperature changes in the opposite
sense. This also applies to the effects of large temperature changes, which
can be counteracted by corresponding changes in the power output.
As a matter of principle, such corrections are always dependent on the

limitations of other components.
4.5 Monitoring of casing expansion
General
During erection, the fixed and moving parts are aligned with respect to one
another, when in a cold condition and after having previously carried out
zero-point calibration of all the measuring devices. Starting on the basis of
this zero position all parts of the turbine, which are subjected to the
operating temperature, such as the casing, the bearing housings and rotor,
expand axially and radially. The expansion of the various parts may differ
due to different temperatures and material characteristics.
Radial expansion
As a result of design measures, changes in the radial clearances, which are

caused as a result of different radial expansion between the stationary parts
and the moving parts, are held within limits, which do not cause
endangement of the turbine. Special operating conditions, which result in
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generation of temperature differences at the upper part and lower part of the
outer casing, form an exception. The rotor, the inner casing and the guide
blade carrier are exposed to approximately the same temperatures at a
certain level, so that only the different coefficients of expansion of the
materials come into play. Different expansions between the outer casing and
the internal components, which are installed so as to be capable of sliding,
do not result in changes of the clearance.
Axial expansion
Changes in length in the axial direction have a more marked effect than
expansion in the radial direction. The turbine casing is supported at a casing
anchor point in the axial direction and expands with the front bearing
housing on the pedestal under the influence of the temperature. The bolted
connections of the front casing brackets have been tightened, however, they
are designed so that free movement of the brackets is ensured at all times.
Especially during start-up and shutdown, particular attention should be paid
to ascertaining that the rings at the bolted connections of the casing brackets
are always capable of being moved by hand.
The same requirement respecting freedom of movement exists naturally also

for expansion of the turbine casing in the vertical plane. The casing centre
guides are likewise of similar design. Care must, however, be taken to
ensure that no stops or obstacles prevent free movement, which, for
example, could occur as a result of improper attachment and support of
pipes.
Freedom of movement of the turbine casing can be easily monitored by

means of a simple measuring device at the bearing housing. Expansion of
the casing should occur smoothly and not in sudden jerks.
Relative expansion
As already mentioned, the turbine casing expands axially under the

influence of the steam temperature and consequently causes shifting of the
front bearing housing. The axial bearing, which represents the fixed point of
the turbine rotor, is situated in this bearing housing. This fixed point is shifted
as a result of casing expansion. The steam flowing through the turbine also
heats the turbine rotor, which likewise expands.
The differential expansion between the turbine rotor and the casing is known
as "relative expansion". The relative expansion ± 0 designates the condition
as erected. It becomes positive (+), when the turbine rotor is longer than the
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turbine casing and negative (-), when the expansion of the turbine rotor is
less than that of the turbine casing.
Causes for relative expansion in steady-state operation are:
Different coefficients of expansion of the rotor and casing materials.

Different average temperatures of the rotor and the casing.
In the case of transitory operational processes (start-up, power output

change or temperature change), relative expansion occurs as a result of the
fact that different parts of the turbine require different lengths of time for
transition from one steady-state temperature to another. The times are
determined by differing heat transfer rates, temperatures, wall thicknesses
and weights of the rotor and of the casing.
Differing average temperatures have their origin in specific design

circumstances. The turbine casing is designed as a double shell casing.
High heat transfer capability of the inner casing and of the guide blade
carrier is achieved as a result. Design of the outer casing is thus simplified
(wall thickness, section joints, sealing elements), since it is exposed to an
internal pressure which lies very much below the live steam pressure. Since
the outer casing is responsible for the expansion between the rotor and the
casing and not the inner casing, whose expansion is better matched to the
expansion of the rotor and of the guide blade carrier, considerable
differences can exist between the average temperature of the rotor and of
the casing even during steady-state operation, as a result of which positive
relative expansion results in the majority of cases.
In transitory operation, during start-up, on changes of power output and on

temperature changes, expansion of turbine components, which on account
of their weight and exposure to steam reach a new steady-state temperature
more rapidly, is matched much quicker to the temperature conditions. For
this reason higher transitory differential expansion occurs between the
stationary and the rotating parts of the turbine.
Axial rubbing of the rotating and stationary parts is prevented by provision of

larger axial clearances of the turbine at the rotor seals and at the blade gap
seals than would be necessary for steady-state operation.
After taking additional factors of safety into consideration, constructional limit

values for the permissible relative expansion were defined. These limit
values may not be exceeded during operation. For this reason, all the start-
up and loading times as well as the load and temperature change rates must
be strictly observed.
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In some cases (dependent on the live steam temperature and the casing
length), a measuring device for monitoring of the relative expansion is
attached to the rear bearing housing.
In such cases, the limit values for relative expansion are documented in the
"Commissioning report" and in the "Technical data".
These limit values may likewise not be exceeded. If impermissible values

occur, the turbine must be shut down immediately or other suitable
operational measures must be initiated, which result in return of the relative
expansion to normal.
4.6 Monitoring of the internal efficiency

Contents Introduction
Pressure monitoring
Pressure characteristic code
Internal efficiency
Inspection intervals
Introduction Blade deposits have considerable influence on the power output of the
turbine. These also affect operational safety and must therefore be either
removed or avoided.
The following leaflets, which describe how blade deposits are formed, the
consequence of blade deposits (blade damage) and measures to prevent
and remove blade deposits, are to be found as an appendix to the operating
instructions:
Blade damage
Steam quality
Removal of blade deposits
Flushing of industrial-type turbines
Deposits form in particular on the guide and rotating blades. As a result, the
steam paths are narrowed and the blade surfaces are roughened. Possible
consequences are:
Reduction of the steam flow-passing ability;

Reduction of the power output;
Disturbance of the pressure characteristic inside the steam turbine;
Increase of axial thrust and possible overloading of the axial bearing;
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Additional bending forces on the blading; i.e. overstressing under certain

circumstances:
Impairment of the efficiency;
Roughening of the blade surfaces; as a result local notch effect on
corrosion.
In addition, deposits may form on valve spindles and thus cause jamming of
the control valves, especially where the load is kept constant over a long
period of operation.
The internal condition of the steam turbine with regard to contamination

should therefore be checked regularly during operation. Such monitoring is
possible only indirectly by means of the steam data.
Pressure monitoring The simplest form of pressure monitoring is measurement of the steam
pressures inside the turbine commencing at the wheel chamber. Additional
measurements are made at specific points of the blading, e.g. at bleed and
extraction points, that is at the beginning and end of blading sections. These
pressures are dependent on the steam mass flow rate. They can be
depicted for various measuring points, as shown in the Figure below.
These recorded values should be compared with the setpoints, or better still,
with the values recorded during initial commissioning. If pressure rises are
detected, nozzle and blade channels have been narrowed and measures
must be taken to remove the deposits.
In case of doubt or insufficent experience in this field, our expert service

personnel should be consulted.
Pressure characteristic as a function of the live steam flow
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Pressure characteristic code Exact monitoring of the pressures in the turbine is possible by determination
number and comparison of the pressure characteristic code number, since in this
case the influence of the current backpressure on the pressure characteristic
inside the turbine is taken into consideration.
The pressure in a turbine stage changes with the steam flow rate in
accordance with the "Stodola steam cone".
The slope of the cone side of the steam cone or the asymptote on a cone
section is a constant (C). When these relationships are applied to the
conditions in the drum section of the turbine, the equation for these
constants is as follows:
where:
p1abs: Pressure upstream of the blade area under consideration

p2abs: Pressure downstream of the blade area under consideration
D: Steam mass flow rate
In the case of a condensing turbine, p22 is negligibly small. For these

turbines, only the blading sections are considered.
The constant C can either be obtained on request from the manufacturer or

can be determined on the basis of an initial measurement.
If in the course of subsequent measurements carried out during operation,

results which deviate from the original C value are obtained or changes are
detected in the course of time with a constant steam mass flow rate, these
should be evaluated and, where necessary, measures should be taken to
remove the deposits. Continuing contamination as a function of time can be
seen by entering the different values obtained for C in a diagram.
In case of doubt or insufficent experience in this field, our expert service

personnel should be consulted.
The operational measurements should be carried out at the same steam

mass flow rate in order to increase the reproduciability. Differences in
the steam mass flow rate of 5 % are permissible.
NOTE
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Internal efficiency A further possibility is monitoring of the internal efficiency and determination
of the steam consumption. However, this is too inaccurate when using the
operational instrumentation and, moreover, is not possible in the condensing
section of the turbine and is therefore not to be recommended.
Inspection intervals The inspection time intervals should be adapted to the operational
conditions. At the beginning, when no operational experience is available,
we recommend:
Pressure monitoring and determination of the C value on a weekly basis,

Efficiency on a monthly basis.
When field values are available, the inspection intervals can be extended.
4.7 Salt and Silica deposits

Very high steam pressures considerably in excess of 50 bar were first
achieved in the 1930s and the shortcommings in the methods of water
treatment being employed became quite apparent, resulting in the
occurence of salt deposits in the turbines in some cases. Although there
have been great improvements in feedwater treatment by means of
evaporators and demineralizing plants since then, complaints about salt
deposits, and even silica deposits, in steam turbines having a very serious
effect on plant availability are still a common phenomenon.
Deposits of salt and silica are justly feared because they can have a very
serious effect indeed on the running of the turbine. The deposits constrict the
passages in the fixed and moving blades, thereby causing a noticeable drop
in efficiency and power output. In addition to reducing the power output,
however, the deposits can also cause mechanical disturbances such as an
increase in the axial thrust, which can overload the turbine thrust bearing,
and seizing in control devices and the emergency stop valves. There are
also chemical effects which can result in corrosion of the blade materials [1].
Types of Deposit In order to achieve a better understanding of the mechanisms by which salt
and silica deposits occur in steam turbines it is necessary to trace the path
of the steam from the superheater outlet to the condenser inlet. In all steam
boilers, regardless of type, a small quantity of water in the form of a very
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small droplets is carried over from the drum or evaporating section into the
superheater. There it heated to a temperature considerably above that of the
boiling water. This causes most of the water to be evaporeted, leaving a
highly concentrated salt solution.
There is still much controversy over the manner in which salt deposits occur
in the turbines. There are four main theories:
The Straub agglomeration theory;

The Michel fused salt theory;
The Werner ice formation theory;
The Wickert adhesive forces theory.
A discussion of these theories is beyond the scope of this description but it

should be noted that the four theories are not applicable to all salt and silica
deposits, only in specific cases.
There has been a re-appraisal of the theory of deposit formation based on

practical experience gained during recent years and the analysis of results
obtained from the inspection of turbines which have suffered from salt and
silica deposits.
When the steam leaves the boiler superheater and is admitted to the turbine
it contains salts in crystalline form as atomized salt, fused salt in droplet form
and also a small quantity of salts dissolved in the steam. This mixture of
salts and steam enters the turbine and, depending on the pressure and type
of turbine, is accelerated in the nozzles to a velocity of several hundred
metres per second, at which it passes through the various turbine stages.
The very fine droplets of liquid fused salt suspended in the flow of steam are
very sticky and adhere to the turbine blades (see Flow of salts through the
turbine in the following figure). Then, they either remain liquid, if they have a
predominantly NaOH content, or solidify, if they are a composite salt mixture
in the undercooled state. Separation of the latter is promoted if the
temperature of the fused salt droplets in the steam flow is always higher than
the relevant turbine stage. In this process, salt particles are caught by the
sticky layer in the manner of flypaper and are incorporated into the growing
mass of the deposit.
A mineralogical study of a number of turbine deposits carried out by Kirsch

[2] has succeeded in giving an insight into the mechanism of turbine fouling;
it is a process known as the hydrothermal formation of minerals, which is
wellknown in the field of geology.
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As shown in the following Figure “Temperature and pressure relationships of

some typical turbine blade deposits”, certain substances are deposited in
characteristic ranges of pressure and temperature. In the very high pressure
section of the turbine, for example, cooper oxides and aluminium silicates
are the typical deposits.
Salts and silicates occur in the high-pressure to medium-pressure section of

the turbine, whereas at the end of the medium-pressure section into the low-
pressure section the characteristic deposit is silica, usually combined with
Fe2O3.
In the depositing of silica in many different forms it is possible to detect the

effect of the companion substances in solution, e.g. aluminium in the case of
the aluminium silicate deposits, beginning in the very high-pressure section
of the turbine.
Flow of salts through the turbine
1 Slight deposits of fused salt A Turbine admission

and salt dust
2 Atomized salt deposit B Nozzle inlet
3 Fused salt deposit C HP turbine inlet
4 Atomized salt deposit (mostly D LP turbine inlet
insoluble in water)
5 Slight separation of salts E Condenser inlet
dissolved in steam
6 Heavy separation of salts
dissolved in steam
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The presence of alkalis and alkaline earths encourages the deposition of

many different types of silicate in the high-pressure section. If there is only
silica in the steam (once-through boiler) it is deposited in amorphous form at
the end of steam turbine. If there are traces of alkali present, the silica can
be deposited in its crystalline forms such as quartz, cristobalite and tridymite.
The studies have revealed the predominance of silicates in 80 % of all

samples. NaCl deposits were found in approximately 22 % of all samples.
The remaining compounds occur very seldom and then only in very small
quantities.
The following turbine deposits are dealt with individually in this description:
SiO2 Silica or quartz

NaCl Sodium chloride (salt)
Na2SO4 Sodium sulphate
Na2OH Sodium hydroxide (caustic soda)
Na3PO4 Sodium phosphate
Temperature and pressure relationships of some typical turbine blade deposits

(according to Kirsch)
From a study of a large number of actual blade deposits a diagram (see

following diagram of salt deposits in the turbine) has been produced for the
most common deposits which shows their
distribution and composition. The two principal substances are NaCl and
SiO2; as NaCl decreases, SiO2 increases in the same proportion.
If the NaOH is imagined to be in the form of a narrow channel at the junction

between the two salts, it illustrates the reaction zone between NaOH and
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SiO2 leading to the formation of Na2Si2O5 which is soluble in water. During

the flow through the turbine, only a small quantity of SiO2 is deposited
initially so that there is an excess of NaOH, and this has been detected in
the first few stages of actual turbines. As the deposition of silica increases,
more and more NaOH is taken up until, finally, the process is reversed and
the deposited NaOH is only sufficient to neutralize a small quantity of SiO2.
The water-soluble silica component falls to practically zero and the zone of
total silica deposition commences being the more concentrated the quicker
the NaCl content in the deposits decreases.
Specific Salt Concentration in An investigation of numerous turbines has shown that deposits are found
Turbine Steam more often in turbines fed from drum-type boilers than those fed from once-
through boilers. The reason is thought to be that the total salt content in the
feed water of once-through boilers is very low. The study of the deposits has
also shown that the turbines remain almost completely free from any
deposits provided a certain value of salt concentration is not exceeded – the
value is known as the specific salt concentration.
Operators of steam turbine plants will normally always follow the instructions
given by the boiler manufacturer concerning the required purity of feed water
and steam. However, in order to provide some terms of reference for actual
operation, some average values have been assembled in tabular form (see
the following figure: Specific salt concentration in turbine steam).
Conforming with normal practice in turbine operation, the specific salt

concentration has been subdivided into permanent and temporary
components. The permanent specific salt concentration a means the value
at which the turbine suffers no notable deposition of salt during 8,000 h of
continuous operation. Temporary specific salt concentration b means the
salt content resulting from operational conditions (frequent starting and
stopping).
Finally, for the sake of completeness, there is a salt limit value c from which
salt deposits in the turbine occur most quickly. Of course, the values given
should not be regarded as absolute values but as varying within certain
limits, with additional fluctuations caused by the steam pressure, steam
temperature and type of turbine involved. However, this effect is not as great
as between the individual groups a, b and c. In fact, the table in the following
figure: Specific salt concentration in turbine steam provides very useful
information for steam turbine operation.
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NaCl As can be seen from the table, the permanent specific salt concentration is
0.4 mg/l. Up to this value the turbine can run safely for 8,000 h. The
temperature range and quantity of NaCl deposit depend chiefly on the life
steam conditions. With very high-pressure turbines (120 bar and above) the
deposits occur at a higher rate, beginning at a high temperature (approx.
450°C) and falling sharply as the temperature decreases. In medium-
pressure turbines (40 to 60 bar) the deposits begin at a lower temperature
and the rate is also lower. The difference is due to the maximum salt content
of saturated steam in relation to the pressure, i.e. steam at a higher pressure
can support a higher concentration of salt.
SiO2 Silica has an exceptionally strong tendency towards the formation of

deposits, a point mentioned earlier. There is no value of maximum salt
content for it, only a maximum solubility in steam depending on the pressure
and temperature. During its passage through the boiler the silica dissolves in
the saturated steam, which increases the solubility in superheated steam by
a multiple of that saturated steam. This steam entering the turbine deposits
an increasing quantity of silica from the gaseous phase as the pressure and
temperature fall. This means that at each value of silica content, deposition
of silica takes place in a zone which moves further towards the end of the
turbine and the lower temperatures the SiO2 content in the steam if the
turbine is run continuously for a sufficient length of time. If there were no
other kinds of salt present, the end of the turbine would become completely
blocked with silica deposit. However, when there are other salts such as
NaOH or NaCl they lend the silica deposits a greater or lesser degree of
solubility. In the greater or lesser degree of solubility. In the presence of
NaOH the silica changes to the Na2Si2O5 form which is soluble and can be
washed out when the turbine is shut down. If there is only NaCl present it
causes a mixture of SiO2 and NaCl crystals which also give the SiO2 deposit
a certain solubility because, on stopping and restarting the turbine, the NaCl
dissolves out of the compound and the remaining SiO2 crystalline structure
disintegrates. When there are only small quantities of NaCl and NaOH
present, however, the deposits of insoluble silica are severe.
Na2SO4 In cases where the boiling temperature of the steam generator is appreciably
above 250 °C (50 bar), nearly all of the Na2SO4 dissolved in the water
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carryover is deposited already in the superheater. During the subsequent

evaporation in the superheater the water very quickly attain the temperature
at which Na2SO4 is precipitated.
Diagram of salt deposits in the turbine
Due to the evaporation of the water, however, the salt concentration in the
water increases at the same time. As this does not occur at as high a rate as
that at which the water evaporates, only small amounts of salt can reach the
turbine. This applies particularly to a high value of NaCl. Only at boiler
pressures below 40 bar when he superheated steam temperatures are
usually low does the increased salt concentration become effective earlier
than the increased temperature of the salt solution. Less Na2SO4 is
deposited the superheater, with the result that most of the salt reaches the
turbine.
Specific salt concentration in turbine steam
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NaOH As there is nearly always NaOH in the boiler water it is logical that this too
must be present in the water droplets. Due to the continuous heat absorption
in the superheater, not only does the concentration of the salt solution rise,
but also its boiling point, until the steam has left the superheater and entered
the turbine. Where the boiler water to contain on NaOH, any salt whose
solubility limit was exceeded would come out of solution and either deposit in
the superheater or be carried into the turbine as salt dust in the steam flow.
In the presence of NaOH, however, the conditions change fundamentally.

The NaOH does not form a deposit but a fused mass which, at the
temperatures prevailing in the superheater, has a boiling point which rises
with increasing concentration and steam pressure. In very-high pressure
turbines the proportion of NaOH deposits will be very low due to the low
alkalinity of the feed water. In medium-pressure plants, however, the
anticipated NaOH deposit is much higher.
Na3PO4 The chemical, physical nature of this salt lies between that of NaCl and
NaOH in its tendency towards the formation of deposits. It is added to the
feed water of all drum-type boilers to provide protection against temporary
increases in hardness.
Summary The composition of the blade deposit in LP turbine stages varies widely but
is mainly a combination of water-soluble salts, scale-forming agents (Ca and
Mg compounds) and erosion and corrosion products. At very high pressures
the principal soluble salt in the blade deposits is NaCl with smaller quantities
of NaOH and silicates. Na2SO4 is deposited in the superheater of the boiler.
The insoluble compounds consist mainly of SiO2.
The deposits of the various salts on the turbine blades depend on the
temperature of each stage of the turbine. Numerous studies have shown the
series to be: sodium silicate, sodium cloride and silica with its subgroups:
quartz, cristobalite and amorphous silica. However, the specific
temperatures of the various compounds overlap considerably.
The salts found in the blade deposits have only a slight relationship to
pressure. In general, however, the water-soluble silicates only occur in large
quantities at low pressures whereas quartz and amorphous silica only
predominate at high and very high pressures. The reason for this is the
NaOH content in the boiler water which is substantial at low pressures but
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only slight or non-existent at high and very high pressures because it is

usually replaced by other alkalizing agents such as ammonia or hydrazine.
Serious deposits in the turbine can be prevented by keeping in the specific

salt concentration below the values specified for the turbine. It varies
according to the composition of the boiler water salts.
Even concentrations substantially below the given value of specific salt

concentration can lead to blade damage due to a reduction in the alternating
bending strength of the material. The salt content of the steam from natural-
circulation boilers depends on the kinetic energy introduced into the boiler
drum and the effectiveness of the drum internals as well as the
concentration of the boiler water. Maintaining the correct water level and
avoiding sudden rises in hardness are absolutely essential to satisfactory
operation.
In once-through boilers the salt content of the steam depends on the care of
operation of the evaporators and demineralizing equipment. Leak-tightness
of the condensers is also an important factor. With this type of boiler the salt
content of the feed water is usually lower than the specific salt concentration
for the turbine, which means that turbine deposits other than silica occur only
rarely.
When there are traces of salts in the steam, fouling of the turbine will nearly
always occur if it is run for long enough. However, provided sufficient care is
taken with boiler operation and water treatment it can be kept to a minimum,
with minimal outage time for operation. However, as mentioned before, it will
always be necessary to remove deposits of silica and salt from the turbine
regularly.
References [1] Dr. Ing. Th. Geissler, Stuttgart: Salzablagerungen in Dampfturbinen und
Kesselanlagen, Parts 1 to 3, ”Energie”, Vols. 7 and 8
[2] VGB-Mitteilungen, Vol. 104 (1966)
4.8 Blade Breakages

Blade breakages in steam turbines continue to occur in isolated cases. Only
in a very few cases is a breakage the result of a material, design or
manufacturing fault. The breakages seldom occur in the high temperature
part of the turbine, nearly always at the beginning of the condensation zone
[1]. Depending on the steam throughput, the initial steam conditions and the
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condenser vacuum, the position of this endangered zone varies over several
blade rows. Most broken blades exhibit fatigue fractures (refer to figure
“Fatigue fracture in a LP rotor blade”). Sometimes the fatigue fracture is
initiated by a non-deformed fissured crack (refer to figure “Non-defined
fissured crack”). Deposits from the steam are almost always found on the
blades and when examined are found to contain small quantities of
chlorides.
Blade material All turbine manufacturers use blade steels with 11 to 14% Cr. Siemens
select their steels from the table “Chemical composition and mechanical
properties of 11 - 14 % Cr steels for turbine blades” (below) depending on
the stresses and temperatures involved.
At the beginning of the condensation zone mainly X20Cr13 and steels

XCrMo13 are used.
Steam quality and blade It has been shown that the steam quality and the related blade deposits
deposits have a considerable influence on the life of the turbine blades [2 to 5]. The
view was often expressed in the past that such deposits were quite normal
and could not be prevented. Since then, however, developments in the
steam boiler field have led to the necessity for feed treatment which has
made a great contribution towards the elimination of blade deposits. With
once-through boilers the same purity is demanded of the boiler feedwater as
of the initial steam, since practically all salts pass straight through the boiler
and will otherwise be deposited in the turbine. With natural circulation boilers
on the other hand, the salts are separated in the boiler drum and
concentrate there. Of course there is the danger that the salts will be carried
into the turbine with the steam if the boiler should prime and, if the density of
the boiler water becomes excessive, there is the possibility of some salts,
mainly silica, becoming fully dissolved and being carried over with the
steam.
The VGB have issued recommendations for feedwater, boiler water and
turbine steam [6].
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Fatigue fracture in a LP rotor blade
Non-deformed fissured crack, the starting point of a fatigue fracture
Chemical Composition (minimum values) in %
Material C SI Mn Cr Mo Ni V
X20Cr13 0.20 <0.30 0.45 13.5 – – –
X20CrMo13 0.20 <0.30 0.45 12.5 0.8 – –
X22CrMoV121 0.21 <0.30 0.50 12.5 0.8 0.40 0.30
Mechanical Properties at 20 °C (minimum values)
Material 0.2% Tensile Elongatio Notch impact strength

Yield strength n DVM test or
strength % ISO test
N/mm2 N/mm2 N/mm2
X20Cr13 590 785 15 40
X20CrMo13 590 785 15 40
X22CrMoV121 590 785 15 50
Chemical composition and mechanical properties of 11 - 14 % Cr steels for

turbine blades
Experience has shown that blade breakages will seldom occur if these
values are adhered to closely. There are also target values for steam quality
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[3], which will result in practically a complete absence of deposits if they are
attained (refer to table “Recommended values for turbine steam”).
The VGB recommendations are usually maintained only by the large power
stations. Smaller stations, particularly the industrial power stations which
require a large amount of make-up water, often ignore these values for
economic reasons. However, it must be remembered that the factors which
lead to blade damage are only dependent on the steam quality and not on
the size of the station.
The substances deposited on the blades from the steam (refer to figure
“Deposits on turbine blades”) restrict the blade channels and roughen the
blade surfaces which causes a reduction in efficiency, an increase in stress
and interference with the thrust. The blades are particularly susceptible to
corrosion when the deposits contain chlorides. At the beginning of the
condensation zone, and at places of moderate steam wetness, silicic acid is
most commonly found, usually in amorphous form but also as crystals and
as silicates. It is assumed that the amorphous silicic acid absorbs, amongst
other substances, chloride ions [3].
The first droplets of condensate formed, although very small, are sufficient to
dampen the salt deposits on the blades. Sufficient quantities of condensate
to wash away the deposits only occur in the later rows of blades, so that the
chloride salt solutions of a concentration perfectly suited to corrosion attack
are formed on the blades in that zone of the turbine in which condensation
begins to occur.
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Target values
Unit VGB * Normal

operation
Conductivity at 25°C measured µS/cm ≤ 0.2 0.1
locally in the flow a continuous
sampling point after a strongly acid
cation exchange
(only applicable toCO 2-free water)
Silicic acid (SiO2) mg/kg <0.02 0.005
Total iron (Fe) mg/kg <0.02 0.005
Total copper (Cu) mg/kg <0.003 0.001
Sodium (Na) mg/kg <0.01 0.002
* VGB recommended values (extract) 1988
Recommended values for turbine steam (abridged)
There are also other reasons why this zone is particularly liable to corrosion
attack [3 to 10]. It is common practice in modern boiler plant to absorb any
residual oxygen in the boiler water with hydrazine. The excess hydrazine
also acts as an alkalinization agent, but only up to approx. 350°C. Above this
temperature the hydrazine in the boiler breaks down into ammonia and
nitrogen and only traces of hydrazine are found in the turbine condensate.
Ammonia is an effective alkalinization agent avobe 350 C. Because of its
very high partition coefficient, ammonia remains largely in the gas phase so
that the first small droplets of condensation are not alkalized. Also, if calcium
chloride and magnesium chloride are present in the circuit, they break down
and form hydrogen chloride. The partition coefficient of hydrogen chloride is
less than unity which means that it tends towards the liquid phase as
condensation begins and hence forms hydrochloric acid which, to begin with,
cannot be neutralized by the ammonia. This results in the first droplets of
condensation having a low pH value and hence they are corrosive.
The pH value in the affected zone can be raised by injecting hydrazine or

another volatile alkali into the turbine when the temperature is under 350 C,
but before reaching the saturated steam limit.
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Deposits on turbine blades
Blades covered with deposits and pitting occuring underneath
Blade corrosion Corrosion in turbine blades takes various forms. Depending on the corrosive
agent, the resistance of the material to corrosion and the stress conditions,
the attack can take the form of:
pitting
corrosion fatigue
stress corrosion
Pitting The resistance to corrosion of the Cr steels results from their passive surface
film of chromium oxide. This film can be destroyed by halide ions, in
particular the chloride ions. The attack which occurs under the deposit on
the blades concentrates at a large number of small areas so that very small
anodic areas are opposed by very large cathodic areas. The small areas
quickly reach a considerable depth. Because of the mechanism of the
attack, this form of pitting corrosion is also called chloride ion corrosion.
Pitting is most frequently found under blade deposits in the wet steam range
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(refer to figure “Blades covered with deposits and pitting occuring

underneath”). Blades free of deposits are not attacked at all or perhaps only
slightly. Pitting can also occur when the machine is not running if steam is
leaking into the cold turbine.
Quite considerable damage can be caused (refer to figure “Blades pitted

through shut-down corrosion”) which is then known as shut-down corrosion.
Corrosion of this type can occur on all blades of the turbine, there appears to
be no particular preference for the blades in the wet steam zone.
In the wet steam region, cracks are often found which clearly originate from
the pitting (refer to figure “Cracks originating from pitting corrosion”). The
notch effect of the small pits assists the formation of these cracks. The
possible higher concentration of the chloride ions in the pitting also plays a
role but, in fact, the pitting and cracks must be considered separately. Pitting
is clearly related to corrosion alone whereas the cracks arise as a result of
corrosion fatigue.
Corrosion fatigue When a component is subjected to stress reversals without the presence of
corrosion, a definite value of stress will be withstood indefinitely without a
fracture occurring, this is called the endurance limit (the horizontal leg of
curve a in figure “S-N diagram in air and subject to corrosion”). If the stress
reversals are accompanied by corrosion attack, however, not only will the
fatigue strength be reduced but the curve will also continue at a slight angle
to the horizontal axis.
The result is simply a fatigue strength of finite life depending on the number
of stress reversals (curves b and c, figure “S-N diagram in air and subject to
corrosion”). All metals are subject to corrosion fatigue, even the stainless
blade steels. The occurrence fo corrosion fatigue is not necessarily
combined with the appearance of corrosion on the outside surface of the
metal.
It is found on blades which have no deposit or visible signs of corrosion.

However, in this case only one crack is found, in contrast to figure “Cracks
originating from pitting corrosion”. The damage caused by corrosion fatigue
in the internal structure of the metal is sub-microscopic, which makes
evaluation difficult. In appearance, the fracture always resembles a fatigue
fracture (refer to figure “Fatigue fracture in a LP rotor blade”). The corrosion
is caused by the wet steam condensate whose impurities play a very
important role in the process.
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Blades pitted through shut-down corrosion
Cracks originating from pitting corrosion (after magnetic crack detection)
S-N diagramm in air and subject to corrosion
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Stress reversal fatigue strength of flat bar pieces of X 20 Cr 13 steel
1 unnotched test piece, 5 unnotched test piece,

ground longitudinally ground transversely,
in NaCl solution
2 unnotched test piece, 6 notched test piece,
ground transversely (form factor αK = 2.4)
in NaCl solution
3 notched test piece, A Deterioration caused by
(form factor αK = 2.4) condensate free of Cl
4 unnotched test piece, B Deterioration caused by NaCl
ground transversely, content > 1 %
in condensate free of Cl
Stress reversal fatigue strength of VN26/35 blades of (X15Cr13)
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1 unnotched blade, 4 notched blade, as 2,

ground transversely in NaCl solution
2 notched blade, Iso V notch (2 B Deterioration caused by NaCl
mm deep) at the trailing edge content > 1 %
3 unnotched blade,
ground transversely,
in NaCl solution
The stress reversal fatigue strength is not at all so sharply reduced (curve b,
figure “S-N diagram in air and subject to corrosion”) by condensate droplets
free of chlorides (pH value: 6.5 to 8, conductivity: 2 to 5 µS/cm) as with
droplets containing chlorides (curve c). The effect of the chloride ion
concentration on a carbon steel has been examined by Glinkman [11]. The
results show that even a NaCl content of 0.0025% has a considerable effect.
The corrosion fatigue strength becomes greater as the NaCl content
becomes less. This means if the very slight slope of the curve in the S-N
diagram is taken into account, that by reducing the NaCl content of the
steam the possibility of a blade breakage can be delayed by a considerable
time. All sources quoted on this problem are generally of the opinion that all
NaCl concentrations over 1% have a strong damaging effect.
For many years we have been studying the various factors involved in these
processes by means of tests of both flat bar test pieces and actual blades.
Some results had already been published and these were subsequently
confirmed [12 to 21]. Only the most important results have been selected
from the extensive research programme and for the sake of simplicity they
are presented in diagrammatic form.
The results obtained with flat bar pieces of X20Cr13 steel are shown in
Figure 10. The determination of the corrosion fatigue strength is based on 5
x 107 stress cycles. The following conclusions can be drawn from the test
results:
The stress reversal fatigue strength of X20Cr13 with the surface ground
in the same direction as the stress application is, in air, ±390 N/mm2, i.e.
approx. 0.5 x tensile strength.
If the surface is ground at right angels to the direction of stress
application, the stress reversal fatigue strength falls only slightly to ±330
to ±350 N/mm2.
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The fatigue strength of the unnotched test piece in clean condensate is

between ±275 and ±315 N/mm2.
In chloride solutions (NaCl content greater than 1%) the corrosion fatigue
strength of the unnotched test piece is reduced very sharply to ±115 to
±135 N/mm2. This means a reduction of the stress reversal fatigue
strength by approx. 65% over the value obtained in clean condensate.
When the test piece is notched, the stress reversal fatigue strength
without the presence of corrosion is reducted to ±155 N/mm2.
When the notched test piece is subjected to a salt solution with a NaCl
content greater than 1%, the corrosion fatigue strength is reduced even
further to ±50 to ±70 N/mm2.
Stress corrosion Three conditions must be fulfilled before stress corrosion can occur:
The component must be subjected to static tensile stress (including

internal stress).This is the case with turbine blades which are subjected
to a tensile load by centrifugal force. Internal stress plays little part.
The material must be susceptible to stress corrosion. Generally speaking,
the 11 to 14 % chrome steels are known to be resistant to stress
corrosion. It can be seen from the references [22 to 28] that these steels
will only be affected by stress corrosion if they are tempered below
600°C. The turbine blade steels however, are tempered at 650 to 740 °C.
A corrosive medium must be present. With the 11 to 14% chrome steels,
both anodic and cathodic stress corrosion occurs. The latter is better
called hydrogen embrittlement because the hydrogen liberated by the
corrosive action diffuses into the metal and causes embrittlement which
may subsequently lead to a brittle fracture. Cathodic stress corrosion is
mainly observed under attack by weak acids, particularly hydrogen
sulphide. An excess of hydrochloric acid in the first droplets of
condensate within the turbine has the same effect. Anodic stress
corrosion occurs mainly in chloride solutions but also in other salt
solutions[25]. Tests on a standard blade steel in a boiling 3% NaCl
solution resulted in no cracks. if the metal had been tempered at under
600°C, however, intercrystalline cracking occured.
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Stress corrosion cracks in a blade
In spite of this, however, blade damage has occurred in isolated cases which
was most probably the result of stress corrosion. Figure 12 shows cracks
found in a blade at the beginning of the condensation zone.
Characteristically, a high proportion of iron (III)chloride was contained in the
deposit found on the blades. It can be concluded that there was a reaction
between the hydrochloric acid and the blade material (see ”Steam quality
and blade deposits”).
Our own tests on X22CrMoV121 have shown that at tempering temperatures

of 700 to 740°C, stress corrosion (refer to figures “Stress corrosion crack,
boiling 40 % MgCl2 solution” and “Stress corrosion crack, boiling 40 % CaCl2
solution”) only occurs in boiling solutions of:
40% CaCl2 + 0.1% HgCl2

40% MgCl2
1% FlCl3 +0.1n HCl
As a result of more recent investigations [29], it is assumed that 11 to 14%

chrome steels are subject only to cathodic stress corrosion.
Stress corrosion crack, boiling 40 % MgCl2 solution
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Stress corrosion crack, boiling 40 % CaCl2 solution
Summary and conclusions Pitting is easily recognizable. More difficulty is experienced in distinguishing
between corrosion fatigue and stress corrosion. However, it is not so
important to determine whether the fracture has been caused by corrosion
fatigue or by stress corrosion as to recognize the cause of the corrosion and
to take appropriate corrective action.
Without doubt, the best solution to the problem would be to operate with
steam completely free of salts so that no deposits form on the blades.
Referring to corrosion fatigue, this would correspond to curve b in figure “S-
N diagram in air and subject to corrosion”. In actual fact, a low salts content
and occasional heavy carryovers must be reckoned with so that the result
will be a corrosion fatigue strength lying between curves b and c. Thus it can
be seen that every successful attempt made to improve the purity of the
steam/water in the system results in an increase in the corrosion fatigue
strength. The test durations are plotted on a logarithmic base which means
that even a very small increase results in a substantial gain in time, and
hence a considerable increase in the life of the turbine blades. The operator
is, therefore, in a position to exert a considerable influence on the life of the
blades by the manner in which he operates the turbine. The costs of
feedwater treatment must be weighed against those incurred in the event of
blade damage, including damage, to other components and the reduced
availability.
Continuous monitoring of the water/steam system is essential to avoid, or

possibly, evaluate corrosion damage to the turbine blades. Turbine
operators and builders are unanimous in strongly recommending the
recording of the electrical conductivity of the live steam and turbine
condensate after a strongly-acid cation exchange water treatment plant. This
permits even the slightest leaks of cooling water into the circuit to be
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detected. If salts should gain access to the turbine, flushing with saturated
steam according to our special instructions should be carried out
immediately in order to remove any chlorides which may have deposited
themselves on the blades. if such measures are not taken, there is a danger
that the fatigue strength of the blades will be reduced by more than half and
the possibility of a fracture is correspondingly greater.
References [1] Bericht der 15. Sitzung des Arbeitskreises "Turbine" der Vereinigung
deutscher Elektrizitätswerke am 11. November 1960 in Leverkusen.
[2] Holdt, H.: BBC-Nachrichten, Dezember 1958, S. 382-390.
[3] Heitmann, H.G.: Mitteilungen der VGB, H. 90 (1964), S. 171-190.
[4] Pohl, E. J.: Der Maschinenschaden 37 (1964) H. 9/10, S. 185-196.
[5] Schmitt-Thomas, K. J.: Der Maschinenschaden 37 (1964), H. 5/6, S. 79-

89.
[6] VGB-Richtwerte für das Speise- und Kesselwasser von

Wasserrohrkesseln: 2. Ausgabe 1974.
[7] Stange, E. und Kiekenberg, H.: Mitteilungen der VGB, H. 69 (1960),

S.384-394.
[8] Held, H.-D. und Bujak, W.: Mitteilungen der VGB, H. 89 (1964), S. 89-
99.
[9] Hömig, H. E.: Technische Mitteilungen 55 (1962), H. 5, S. 197-201.
[10] Hömig, H. E.: Physikochemische Grundlagen der

Speisewasserchemie, 2. Auflage (1963), Vulkan-Verlag, Essen.
[11] Glikman, L. A.: Corrosion-Mechanical Strength of Metals, Butterworth,

London (1962).
[12] Spähn, H.: Metalloberfläche 16 (1962), S. 197-202, S. 233-239, S.

267-272, S. 299-307, S. 335 bis 340, S. 369-373; 17 (1963), S. 1-9.
[13] Houdremont, E.: Handbuch der Sonderstahlkun-de, Bd. I, III. Auflage

(1956), S. 780-804.
[14] Thum, A. und Ochs, H.: Korrosion und Dauerfestigkeit, Mitt.

Materialprüfungsanstalt Darmstadt, H. 9 (1937).
[15] McAdam, D. J.: Zahlreiche Arbeiten aus den Jahren 1926-1932;

besonders:
a) Influence of Cyclic Stress on Corrosion, Amer. Inst. Min. Met. Engrs.;

Techn. Publ. 329E (1930).
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b) Corrosion of Metals as affected by Time and by Cyclic Stress, Amer.

Inst. Min. Met. Engrs. (1928), S. 571-607.
[16] Gough, H. J. und Mitarbeiter: Zahlreiche Arbeiten aus den Jahren

1928-1936; besonders: Corrosion Fatigue of Metals, Journal Inst. Metals 49
(1932), S. 17-92.
[17] Rjabchenkow, A. V.: Korrosion und Verschleiß von Stählen und ihre
Bekämpfung in Dampferzeugungsanlagen sowie im Maschinen- und
Fahrzeugbau, VEB-Verlag Technik, Berlin (1956).
[18] Ludwik, P.: Metallwirtschaft 10 (1931), S. 705.
[19] Mailänder, R.: Kruppsche Monatshefte 13 (1932), S. 56-81.
[20] Fuller, T. S.: Trans. Amer. Soc. Steel Treat 19 (1931), S. 17.
[21] Castro, R., Guessier, A. und Tricot, R.: V. Journées de l'Hydraulique,

Question I, Rapport A 2, Société Hydrotechnique de France (1958).
[22] Lahiri. A. K., Banerjee, T. und Nijhawan, B. R.: NML Technical Journal,
May 1965, S. 20-24.
[23] Truman, J. E., Perry, R. and Chapman, G. N.: Journal of The Iron and
Steel Institute, Sept. 1964, S. 745-756.
[24] Bhatt, H. J. and Phelps, E. H.: Corrosion (Houston) 17 (1961), S. 430 t-

434 t.
[25] Phelps, E. H. a. Loginow, A. W.: Corrosion (Houston) 16 (1960), S.

325 t-335 t.
[26] Lillys, P. and Nehrenburg A. E.: Transactions of the ASM 48 (1956), S.

327-355.
[27] Bloom, F. K.: Corrosion (Houston) 11 (1955), S. 351 t - 361 t.
[28] Badger, W. L.: SAE Transactions 62 (1954), S. 307-313.
[29] Wilde, B. E.: Corrosion-Nace Vol. 27 (1971), S. 326/333.GB, H. 69

(1960), S.384-394.
4.9 Monitoring of power output
Introduction
The turbine drives the generator and thus generates electric power. The
measure for the power generated is the active power in MW measured at the
generator terminals. A limiting definition of the term "output power" is given
below as a supplement to the power values given in the "Design data". The
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dependency of the output power on key operational values will be shown. An

explanation will also be given, how output power can be limited and which
criteria are to be taken into consideration on altering the output power.
The output power must be continuously monitored during operation.
Definitions
The "rated power" is the guaranteed maximum continuous output power

under normal conditions, whose values are defined in the guarantee.
The "maximum economic rating" is the power output at the lowest specific
heat or steam consumption.
The "maximum output" is the maximum continuous output under defined

operational conditions (e.g. with feed-water heaters out of service, increased
live steam pressure, etc.). Since the maximum output was given for specific
fault and abnormal conditions, the following points must be taken into
account:
During operation at maximum output, the permissible limit values for

pressure and temperature given in the Section "Design data" may not be
exceeded even under fault and special conditions.
The mode of operation must be altered immediately on occurence of a
fault, in order to satisfy this requirement. The simplest way to alter the
mode of operation is to change the power output.
Dependency of power output on key operational values
The thermal energy of the steam is converted into mechanical energy in

each blading stage of the turbine. The converted energy is dependent on the
specific thermal gradient, which corresponds to the steam conditions before
and after each blading stage and the steam flow, which passes through the
blading stage. On alteration of the steam flow rate, the thermal gradient also
changes.
The mathematical interrelationship for a blading stage also applied to the

entire turbine provided that any bleed flow rates correspond to the design
flow rates and that no other irregularities exist, which could alter the turbine
efficiency.
The steam generator supplies steam of variable pressure. The temperature

is maintained constant. The control valves are fully or nearly fully open.
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Variable operational values Invariable operational values Graphic
Live steam valve stroke hν Live steam pressure A)

Live steam temperature
Exhaust steam pressure
Live steam pressure PFD Live steam valve stroke B)

Live steam temperature tFD Live steam valve stroke C)

Live steam pressure
Exhaust steam pressure PAbd Live steam valve stroke D)

Live steam pressure
Power output curves
Power measurement and monitoring
The generated output power is measured at the terminals of the generator.

The output power is monitored by means of indicating and recording
measuring devices.
The following must be observed with particular vigilance:
exceeding of limit values of power output in conjunction with monitoring of

other operational values as reference criteria (pressure, temperature),
the constancy and
agreement with the output of the steam generator.
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The monitoring devices themselves must be monitored by comparison with

other power indications or power-dependent criteria.
Power output limiting
Special operational conditions of the overall plant may necessitate limiting of

the maximum power output of the turbo-set. This requirement is satisfied by
the power output limiting devices of the turbine controller.
Reverse power
If the steam supply to the turbine is interrupted without isolation of the

generator from the power system, the generator acts as a motor. It
consumes electric power taken from the power system and drives the
turbine. The turbine blading becomes heated up, since there is no steam to
act as a cooling medium.
For this reason reverse power protection is provided, which opens the
generator circuit-breaker as soon as the generator operates as a motor. The
reverse power protection can also be used for checking tightness of the
emergency stop and control valves. For this reason the reverse power
protection should be allowed to open the generator circuit-breaker to isolate
the generator from the power system on shutting down the turbo-set.
Operation of the generator on reverse power over a longer period of time is

not permitted and such operation must be stopped immediately.
Load change
The steam temperatures in the turbine change as a function of the steam

flow and of the expansion characteristic on loading and unloading the turbo-
set. In particular, the casing wall temperatures are influenced by such
changes and transitory temperature differences occur at different depths of
the casing wall, as a result of which the material is subjected to additional
stresses.
On account of the material stresses, the permissible casing wall difference

temperatures may not be exceeded on changing the power output. This
applies in particular to loading subsequent to start-up of the turbine. The
permissible temperature differences also determine the permissible value for
suddenly occurring proportional load step changes and their rate of change
(power gradient).
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The limit values are depicted in the form of curves in the Section "Start-up
and loading curves", by means of which the turbine can be effectively
protected against material overstressing.
Load shedding
Basically a distinction is made between two types of suddenly occurring load

reduction.
On isolation of the generator from the power system, the turbine controller
prevents the speed reaching the tripping speed of the overspeed trip device.
The controller of the turbo-set is designed in such a manner that a turbo-set
can be operated at the station service load after tripping of the generator
circuit-breaker, provided that the tripping procedure had no effect on
additional disturbance parameters.
On isolation of the generator from the power system by tripping the

generator circuit-breaker, the following must be monitored to ensure that:
no limit values are exceeded

the station service load is maintained constant without hunting.
If the steam supply to the turbine is interrupted first, the generator will act as
a motor and will be isolated from the power system by the reverse power
protection. This case arises, when protection devices of the turbine act on
the turbine trip or this is operated manually.
4.10 Speed monitoring
Introduction
The following description applies to turbines for driving generators fitted with
an electronic speed controller.
The speed of the turbine must be monitored
during turbine start-up,

during synchronisation,
during normal operation,
during shotdown and
during turning-gear operation.
The permissible speed deviations are to be observed and operation in the

critical speed ranges should be avoided. Steps should be taken to ensure
that the speed-dependent switching devices function correctly.
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On occurrence of operational faults, the turbine is protected against the

consequences of impermissible overspeeding by means of limiting and
protection devices. Correct functioning of the limiting and protection devices
must be checked regularly (refer in this connection to the Section
"Maintenance and inspection overview").
The same applies to the monitoring devices provided. In most cases these
include a calibrated hand speed measuring device, stroboscope or
comparison with the power system frequency.
It is a basic rule that a steam turbine, which is not operated in parallel with a
power system, can only remain in operation for a short time in the absence
of speed measurement, even where there is no concern about the
operational safety of the speed controller.
Speed monitoring devices
The speed of the turbine plant is monitored from activation up to the rated
speed by means of electrical speed measurement. The arrangement and
function of the transmitters of the electrical speed measurement are
described in the Section "Description of the turbine plant".
Permissible frequency deviations
In the case of turbine driven generators, underfrequency and overfrequency

generally occur on occurrence of power system faults. Transitory frequency
deviations can be caused by a mismatch between the power consumed and
the power generated in a sector of the power system.
If, at the moment of isolation of a power system section from the overall
network, the power consumed exceeds the power generated, the frequency
falls until the power generated once more corresponds to the power
consumed as a result of the proportional characteristic of the controller. If the
power consumed is less than the power generated, the frequency rises and
the power output is reduced.
Possible damage to the blading

Operation for a longer period at underfrequency or overfrequency can,
under certain circumstances, result in endangerment of the turbine
blading, where the blade natural frequencies or their harmonics lie in the
ATTENTION region of the changed operating frequency. Apart from the absolute
values, time limitiation of operation at frequencies different from the
nominal frequency should be observed.
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If the turbine is isolated from the power system and operated at the station
service load, care should be taken to ensure that the speed corresponds to
the nominal speed. After interruptions, power system faults and similar
incidents, the speed setpoint should be set to the nominal speed.
Maximum speed
The permissible maximum speed of the turbine is to be found in the Section

entitled "Design data".
Speed after load shedding
Incidents, which result in a speed change, generally occur with a high rate of
change. Human response is inadequate in such cases.
The task of the speed controller, which acts as a limiting device on

occurrence of a fault, is to ensure that the unavoidable transitory speed rise
does nor lead to tripping of the turbine.
The magnitude of the speed rise subsequent to load shedding is determined,

on the one hand, by the dynamic behaviour of the control loop (turbine
reaction time and the enclosed steam volume) and, on the other hand, by
unavoidable delay times in the control devices (in particular, the actuation
times of the control valves).
Perfect setting and functioning of the speed controlling devices and the
freedom of movement and tightness of the valves are important
prerequisites for correct operation on occurrence of faults. For this reason,
tests in accordance with the instructions for testing must be carried out at
regular intervals.
Freedom of movement of the control valves can be impeded as a result of

scaling or steam deposits. Therefore the permissible live steam
temperatures, which are given in the "Technical data", may not be exceeded
and the Requirements for "Steam quality" must be fulfilled.
Tripping by the overspeed trip device
The overspeed trip device together with the tripping devices and the
automatic trip gear form part of those protection devices, which protect the
turboset by closure of all the emergency stop valves, the control valves and
the extraction and bleed valves, as soon as a defined speed value is
exceeded.
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The setpoint is defined in the "Technical data". The actual setting of the
overspeed trip device and the valve unseating pressures of the automatic
trip gear and of the emergency stop valve are to be found in the
"Commissioning report".
The mode of operation of the protection devices is described in the Section

"Description of the turbine plant".
Operational safety of the mechanical overspeed trip is mainly dependent on

prevention of jamming. Causes thereof, among others, can be:
fretting corrosion (fretting rust),

leakage currents,
water or other corrosive substances in the oil,
unsuitably blended lubricating oils,
foreign bodies in the oil.
For this reason, the function of the overspeed trip device must be checked at
regular intervals in accordance with the "Maintenance and inspection list".
The turboset may not be operated with an overspeed trip device, which has
either been set to a higher value or which is not functioning, or with other
tripping devices.
Speed monitoring on start-up of the turboset
The speed must be particularly carefully monitored on starting up, this

applies in particular to the warm-up process. The dwell times before speed
increase may under no circumstance be less than those specified in the
"Start-up and loading curves": where possible, these should be extended so
as to reduce stress on the material.
A check must be carried out to ensure that the main oil pump correctly takes
over oil supply within the previously set speed range.
As soon as the speed controller takes over control during start-up, a check
should be carried out to ensure that the speed controller increases the
speed or maintains it constant without hunting.
Coast-down time
The coast-down time of a turboset, in particulat that of condensing turbine, is

an operational parameter, which allows conclusions to be drawn about the
condition of the turboset, for which reason it must be monitored. The coast-
down time determined during initial commissioning is documented in the
"Commissioning report". When the coast-down time is shorter under
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comparable operating conditions, the conclusion can be drawn that

irregularities have occurred inside the turbine.
The coast-down time is dependent to a marked degree on the condenser

pressure and the gland sealing steam system. A dependency on the live
steam conditions can exist as a result of leaking valves with low steam
supply to the turbine.
It is of particular importance that the coast-down time be determined and

documented subsequent to faults, where there is a danger of bridging radial
or axial clearances.
Turning-gear operation
Shaft deflection of turbine rotors during standstill is avoided by operation of

turning gear. Such deflection can also occur when the rotor comes to a
standstill for a short time only.
Possible damage to bearings

If the speed falls below a defined speed in turning-gear operation,
severe bearing damage may also occur (refer to the Section "Monitoring
turbine radial bearings").
ATTENTION
Monitoring of the speed during turning-gear operation is therefore an
essential prerequisite for unrestricted operational readiness of the
turboset after interruptions of service.
4.11 Monitoring of vibrations

By satisfying the requirements for high manufacturing accuracy,
homogeneity of materials, precise support and balance of the rotating parts
and accurate alignment during installation, the manufacturer has established
a good basis for satisfactory running qualities of the turbine. Nevertheless, it
is still possible for a turbine to suffer vibration of various kinds and for
various reasons.
It is beyond the scope of these operating instructions to deal exhaustively

with all the possible modes and causes of vibration because it is a
specialized field of considerable extent and complexity.
Therefore, the instructions are limited to giving the necessary information to

ensure safe monitoring of turbine vibration. These essentially embrace:
type, arrangement and readings of the vibration measuring system,

normal values and limit values of vibration,
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assessment of vibration and

consequent action on increased vibration.
Vibration measuring system The turbine is equipped with bearing and/or shaft vibration measuring
systems which can measure the absolute velocity of vibration transverse to
the shafting system at the bearing housings and/or at the shafts adjacent to
the bearings. The displayed value is deflection and its variation with respect
to time is recorded.
The construction and mode of operation of vibration measuring systems are

described under "Description" in these operating instructions. They should
be consulted in the event of any malfunction of the measuring systems.
In addition to the continuous monitoring by means of the measuring systems

permanently installed on the machine, the running qualities of the turbine
should be checked at regular intervals by means of portable equipment. The
results should be compared with those obtained from previous
measurements. Portable equipment is also advisable when investigations
are being conducted involving the measurement of vibration in more than
one plane.
Shaft and bearing vibration The relationship between shaft vibration and vibration of the associated
bearing housing depends on:
the ratio of the stiffness of the oil film to the foundation spring constants
the mass ratio of the foundation to the shaft
the ratio of the damping effect of the oil film to the spring force of the
shaft
the relationship between the operating speed and the critical speed and
the arrangement of the measuring systems.
These factors are primarily dependent on the design of the turbine and the
foundation. The ratio of shaft vibration to bearing vibration can vary from 3:1
to 1:1 as a result.
Shaft vibration measurement is normally more sensitive than bearing

vibration measurements and this is an advantage in monitoring the running
qualities and changes therein.
However, shaft vibration should not be the sole basis for an assessment of
the running qualities but, wherever possible, should be used in conjunction
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with assessment criteria for bearing vibration which have proved to be

reliable in the past.
Normal and limit values of As a basis for the assessment of running qualities, we recommend the two
vibration DIN ISO standards
DIN ISO 10816-3:

Assessment of vibration of machines using measurements at non-rotating
parts, Part 3: Industrial machines with rated loads greater than 15 kW
and rated speeds between 120 and 1500 rpm with measurements at the
installation location (ISO 10816-3:1998)
DIN ISO 7919-3:
Measurement and assessment of shaft vibration, Part 3: Coupled
industrial machines (ISO 7919-3: 1996)
These guidelines contain definitions of terms, measured variables and

proposals for assessment which can be used as a measure of the specified
running qualities of the turbine.
Both of these standards classify the measured vibration levels into four
evaluation zones. These evaluation zones are defined on the basis of
international experience, permit a qualitative assessment of the vibration of a
machine and provide information about possible measures that may be
required.
Zone A:
Vibration levels of newly commissioned machines are within this zone.
Zone B:
Machines with vibration levels in this zone are generally considered to be
suitable for continuous operation without any restrictions.
Zone C:
Machines with vibration levels in this zone are generally considered not
suitable for continuous operation. The machine can, however, generally be
operated for a limited time in the continuous operating mode until a
convenient opportunity arises for implementing remedial measures.
Zone D:
Vibration level values within this zone are generally considered to be so
severe as to pose a risk of damage to the machine.
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Bearing housing vibration Two criteria are given for evaluation of bearing housing vibration in DIN ISO
10816-3 for assessing the vibration intensity of various groups of machines.
The one criterion is concerned with the magnitude of wideband vibration in
the radial direction, measured using orthogonally arranged sensors; the
other with the change in the vibration quantity, regardless of whether the
change represents a rise or fall in the vibration level.
Criterion I. vibration quantity
This criterion deals with defining the limits for the quantity of vibration with
regard to permissible dynamic loading on the bearing and the permissible
transfer of vibration to the surroundings via the lower sub-structures and the
foundation. The maximum value for the vibration quantity measured at each
bearing or bearing support is classified in the evaluation zone for each
subassembly. Industrial turbines and industrial turbine-generators are
assigned to Group 1. The installation configuration for this equipment is
usually flexible.
Subassembly Zone limit Effective value for Effective value for

vibration displacement Vibration velocity
amplitude [mm/s]
[μm]
Rigid A/B 29 2.3
B/C 57 4.5
C/D 90 7.1
Flexible A/B 45 3.5
B/C 90 7.1
C/D 140 11.0
Breakdown of vibration intensity zones for machines within group 1:

Large machines with rated outputs greater than 300 kW but no more than 50
MW; electric machines with shaft center heights H > 315 mm
Criterion II: change in vibration quantity
This criterion serves to assess the change in the vibration quantity with
regard to a previously defined reference value. A considerable increase or
drop in wideband measured vibration may occur which calls for appropriate
measures, even if Zone C as per Criterion I has not been reached. Such
changes can occur suddenly, or over time, and can be an indication of the
onset of damage or other irregularities. Criterion II is based on changes in
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the wideband vibration quantity under steady-state operating conditions. A

prerequisite is that the vibration measurements that are being compared are
conducted at the same measuring point and under approximately the same,
steady-state operating conditions. Any considerable deviation from the
normal vibration values, regardless of the magnitude, should be investigated
to preclude any hazardous conditions. When the increase or drop in the
vibration quantity exceeds 25% of the B/C zone limit, as given in the above
table, this change must be taken as being "considerable" especially if it
occurs suddenly.
Shaft vibration Vibration measurement directly on the turbine rotor is the best monitoring
method that has proven itself under actual conditions. Here, relative shaft
vibration is measured by a pickup attached securely to the bearing, the
bearing housing or the turbine casing. DIN ISO 10816-3 describes two
criteria for assessing relative shaft vibration for coupled industrial machines.
The one criterion is concerned with the magnitude of wideband shaft
vibration that is measured; the other with the change in vibration quantity,
regardless of whether the change represents a rise or fall in the vibration
level.
Criterion I: vibration quantity at rated speed and under steady-state

operating conditions
This criterion deals with defining the limits for the quantity of shaft vibration
with regard to permissible dynamic loading on the bearing, acceptable
values for the clearance to the machine casing and the transfer of vibration
to the installation structures and the foundation.
The maximum value for the shaft vibration measured at each bearing is
classified into one of the four evaluation zones A-D, as explained previously.
In line with the experience gained to date with shaft vibration measurement
in this sector, the recommended values for the zone boundaries are
proportional to the reciprocal value of the square root of the shaft speed n (in
rpm). The recommended values shown in Figure 1 result from the following
equations:
Zone boundary:
Zone boundary:
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Zone boundary:
Monitoring of vibrations, recommended values for the maximum relative vibration

level of the shaft as a function of the maximum operating speed for coupled industrial
machines.
Criterion II: change in vibration quantity
This criterion serves to assess the change in the vibration quantity with
regard to a previously defined reference value. A considerable increase or
drop in shaft vibration quantity may occur, which calls for appropriate
measures to be taken, even if Zone C as per Criterion I has not been
reached. Such changes can occur suddenly, or over time, and may be an
indication of the onset of damage or other irregularities. These changes
warn of an impending failure or other irregularities. Criterion II is based on
changes in the shaft vibration quantity measured under steady-state
operating conditions. The reference value for this criterion is derived from
typical, reproducible, standard vibration levels, based on previous
measurements made under specified operating conditions. If a significant
change occurs with respect to this reference value, in particular if this
change exceeds the high limit for Zone B by more than 25%, regardless of
whether this represents an increase or a drop in the vibration quantity,
appropriate measures must then be taken to establish the cause of the
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change. The decision as to what measures to take should be based on the

magnitude of the change and whether the new condition has stabilized.
Assessment of vibration, consequent action
Shaft vibration causes dynamic bearing loads. Measurement of vibration

gives an indication of the condition of the shafting system and illustrates the
relationship between the shaft amplitude and the dynamic bearing loading.
Vibration measurement detects rotor movement and distortion which can
cause dynamic overstressing, in particular of the bearings. Excessive
vibration leads to a premature reduction in the bearing carrying capacity;
continuous monitoring limits this risk.
Gradual or suddenly occurring increases in vibration usually transpire as a

result of damage or changes which pose a risk to the operational safety of
the turbine.
In deciding on the appropriate action to be taken in the event of elevated

vibration levels, in ensuring the protection of the turbomachinery, it is
essential to first ask as to what extent a hazard is posed to the
turbomachinery.
We recommend that the turbine be shut down immediately if:
Limit values are exceeded, especially if similar occurrences and the

comparable conditions have not been observed before and if there is a
substantial increase in the vibration value above the normal level.
Load noises occur and limit values of other parameters, such as
differential wall temperatures as a result of rapid temperature reduction,
expansion and bearing metal temperatures are exceeded.
If it is certain that the increasing vibration is of the low-frequency variety

(vibration frequency of lower rotational frequency), it is normally sufficient to
reduce the load on the turbine until the vibration decreases.
If vibration increases above the normal level but does not exceed the limit
value, it is nevertheless possible that some other change has occurred.
Such increases in vibration usually permit the cause of the changed
oscillatory characteristics to be examined. The character of the vibration and
its severity should be ascertained first, if possible using different instruments
from those permanently mounted on the machine.
In such cases, we recommend measurement of the following:
the frequencies
the vibration severity horizontal, vertical and axial to the turbine rotor and
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the phase angle of the vibrations and variations thereof.
The investigations should also include measurement of the foundation

vibration and the relationship between the vibration and other operating
parameters such as speed, power output, temperature, pressure and
expansion and changes thereof.
4.12 Monitoring of turbine radial bearings
Introduction
The radial bearings keep the turbine rotor at a central position with respect
to the fixed guide blade carrier and the outer casing. Bearing damage can
trigger substantial consequential damage as a result of bridging of
clearances and thus give rise to repair and outage costs.
An important precondition for trouble-free operation is ensurance that an

adequate supply of lubricating oil is available for each sleeve bearing.
During standstill, the rotor, as a result of its weight, rests on the bearing
shell. Immediately on commencement of rotary movement the lubricating oil
is pressed under pressure into the wedge-shaped gap and lifts the rotor. As
a result of balance between the lubricant viscosity, the rotor circumferential
speed and the wedge-shaped gap, the carrying capacity and the friction
vary. Where the pressure development in the oil wedge is no longer capable
of bearing the load and only partial bearing is possible, unavoidable contact
between the solid bodies occurs with friction (wear). Continuous operation
under such conditions must be avoided at all costs.
During start-up and shutdown, in the absence of shaft-turning operation, the

same conditions exist, however, in view of the short time involved, these
have no appreciable influence on the service life of the turbine bearings.
Critical speed
The speed, at which the transition from partial carrying capacity to full
carrying capacity occurs during start-up and in the reverse case during
shutdown from full carrying capacity to partial carrying capacity is important
(in particular in plants with turning gear but without a lifting-oil system).
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This critical or transition speed must always lie below the operating speed, if
wear is to be avoided under all operational conditions, even with turning
gear.
The critical speed is dependent on the bearing load, the bearing dimensions
and the viscosity of the oil type employed as a lubricant. It is determined
separately for both bearings of the turbine rotor.
The thus determined speed is the lowest speed. at which a rotor should be
operated, in order to avoid bearing damage. Turbines with a jacking oil pump
are an exception. With their aid, the rotor can be lifted from the lower bearing
shell even at standstill, so that metallic contact can be effectively avoided
during start-up and shutdown.
Turning-gear operation
The turbine plant should be operated only in conjunction with the
lifting.oil system.
ATTENTION The turbine radial bearings can be damaged on operation with hydraulic
turning gear but without a lifting-oil system.
Hydrodynamic lubrication
The effect of hydrodynamic lubrication is based on non-interrupted repetition

of the basic function. Reliable functioning of lubrication is therefore
dependent on a number of essential factors:
continuous flow of lubricant and complete filling of all sleeve bearing

cavities;
in conjunction therewith, an assured oil level in the tank;
incompressibility of the lubricating oil;
adhesion of the lubricating oil to the sleeve surfaces, i.e. the adhesion
must be considerably larger than the cohesive force.
continuous and adequate dissipation of the friction heat losses, in order
to limit the lubrication gap temperature and the lubricating oil viscosity.
precise maintenance of the very narrow gap widths in the microscopic
range (0.01 to 0.03 mm) by means of dimensional precision, form
stability, surface quality, lubricating gap constancy and material density:
oil, which is free of impurities, since foreign matter causes damage even
where complete separation exists between the rotor journal end and the
bearing shell.
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Important requirements for the plant components and the mode of operation
can be adduced from the above.
Oil supply to the bearings
The bearing ability of the lubricating oil film is dependent mainly on the
viscosity of the oil employed. This again is strongly dependent on the
temperature of the oil film. For this reason it is possible that, although the
lubricating oil quantity is adequate, the carrying capacity at the sleeve can
fall to such a degree, that the load can no longer be supported. This is then
the case, when the temperature, which results from balance of the heat
generated, the heat input and the heat dissipated, is too high.
Friction heat + transfer heat =

heat dissipated by the cooling oil
In this case, the lubrication film becomes so thin that it breaks down. Partial
carrying occurs and, in consequence, increased wear at the bearing. In the
worst case, this can lead to destruction of the sleeve components.
This process is influenced to a high degree by the oil temperature and the oil
throughput. For this reason, in addition to the lubricating oil quantity required
for formation of a oil bearing wedge, a corresponding additional quantity
must be pumped through the bearing parts for dissipation of the friction
losses and the heat input through the rotor journal end, in order to prevent
the temperature in the oil bearing wedge rising above the desired average
value. However, for a given geometric design and oil type, this is possible
only when the oil inlet temperature does not exceed a defined value.
Lubricating oil temperature
Design of the bearings is based on a constant inlet oil temperature of 45 °C

to 50 °C upstream of the bearings to take the oil viscosity into account and
ensure good air separation in the oil tank. To this end, the oil pumped from
the oil tank is cooled in the oil cooler. The oil temperature is maintained
constant by means of a control valve on the water inlet side of the oil cooler.
If the oil inlet temperature is constant and the temperature difference
between the oil inlet and outlet at the oil cooler falls, it can be deduced that
the quantity of cooling water is inadequate or that the cooler is fouled.
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Lubricating oil pressure
A further precondition for proper lubrication and cooling of the bearings is

that the lubricating oil pressure should not fall below the minimum oil
pressure of 0.8 bar.
The lubricating oil pressure is set to approx.2.5 bar by means of variable oil
throttles during initial commissioning.
This does not apply to turbines with gearing not manufactured by Siemens.
In such cases, the required oil pressure can be considerably higher. If the oil
pressure falls to approx. 75 %, the auxiliary oil pump should be switched on
automatically for support or takeover of the oil supply. Emergency tripping is
initiated at approx. 50 % of the normal oil pressure.
Under all circumstances, it must be ensured that the sleeve bearings are
supplied with lubricating oil on emergency tripping until the turbine rotor
comes to a standstill.
The settings of the oil throttles should not be altered in the absence of
compelling reasons. If the pressure deviates from the commissioning value,
the cause should be ascertained immediately.
Possible causes could be:
oil throttles clogged or the setting was changed;

oil filters fouled;
oil pump fault;
excessive oil outflow due to increase of the clearance at the bearings.
Oil filter in the lubricating oil circuit
As already mentioned, safe operation of the bearings is assured only when

the lubricating oil is clean. An oil filter, through which the oil flows
continuously, is provided in the lubricating oil circuit for this reason. As a
general rule, sieve fabric with a nominal filter mesh size of 25 µm is
employed in the lubricating oil filter.
For this reason an oil filter, through which the oil flows continuously, is
provided in the lubricating oil circuit. The indicating instrument provided at
the oil filter should therefore be monitored at regular intervals.
Monitoring of the oil system
In summary, the following inspections and periodical inspections of the oil

system should be carried out, in order to maintain its functional integrity:
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1. Remove contamination from the oil tank and check for any condensate.
2. Clean the oil filter before the max. permissible pressure difference limit
value is reached.
3. Analyse the oil at the specified intervals, however, at least once a year, in
a laboratory (in-house or in that of the oil supplier). Precise records
should be kept about consumption, initial filling and subsequent topping-
up quantities including additives and regenerating agents.
4. Daily inspection should be carried out to check for possible leakage or
movements in the oil system; the oil pressures, oil temperatures and the
oil levels should be compared.
5. Analysis should be carried out on foreign matter trapped in the filter and
oil tank deposits to detect any bearing metal wear.
6. Functional checks should be carried out at the specified intervals by
switching on the main and the emergency oil pumps.
7. Listen for bearing noise at the pumps.
Conclusions from oil analysis
The following conclusions can be drawn form the results of oil analysis:
Babbitt metal or bronze abrasion in the oil

Bearing damage in the overall system
Steel abrasion in the oil
Gear tooth damage or metallic contact between rotating components;
Raw water in the oil
Leakage in the oil cooler
Condensate in the oil
Blow-off of leaking steam from the shaft seals is directed at the bearings
Drawn in as a result of excessive suction of the oil vapour blower
In all the cases listed above, immediate measures must be taken to rectify
the faults and prevent consequential damage.
Temperature measurement
The temperatures can be employed for generation of event messages, alarm

messages and tripping signals for shutdown of the turboset, in order to
detect danger and to obviate damage to the bearings. From experience, it is
known that the same temperatures always occur under the same conditions.
For this reason, the temperatures should be recorded in tables or graphs
starting with initial commissioning, in particular when load-dependent
changes occur, in order to be able to subsequently compare these reference
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values with the actual values occurring during operation. Such

documentation facilitates deduction of wear or damage.
Temperature rise at the bearing as a result of damage to the bearing occurs

rapidly and for a short time only. Particular attention should therefore be paid
to the fact that temperature rises are of short duration. If damage has
occurred, the temperature at the bearing may revert to its normal value.
Immediately following a marked temperature deviation, which exceeds the

limit value, as a minimum measure, the oil sieve in the oil tank should be
examined for white-metal tailings resulting from damage to a bearing.
However, it is explicitly recommended that the affected bearing be checked,

even when no white-metal tailings are discovered, since this is only one
indication for severe damage. Lubrication damage cannot be ascertained in
this manner.
In practice, a distinction is made between two types of temperature

measurement:
the babbitt temperature measurement and

the lubricating medium temperature measurement, which, however, is not
used here.
In practice, temperature measurement in the bearing metal of the sleeve

bearing is the most accurate type of measurement.
We recommend that, based on the previously mentioned oil inlet

temperature of 45 °C, the limit values listed in the Function list 0-2020-TNo.-
16 should not be exceeded.
These limit values apply for arrangement of the temperature sensor

(thermocouple, RTD) directly beneath the Babbitt sleeve within the region of
the narrowest lubricating gap. In the case of multipad bearings with 5 pads,
this is in the lowest pad.
In addition to a recording instrument, provision should be made for

generation of an alarm event messages, on reaching limit values. Under all
circumstances, steps must be taken to ensure that the turbine is shutdown
on reaching the tripping limit value. This is particularly important, where the
turbine in not continuously monitored.
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4.13 Monitoring the turbine's axial bearing
Introduction
The turbine's axial bearing absorbs the residual thrust of the turbine rotor. At
the same time, the axial bearing fixes the turbine's rotor in place with respect
to the turbine case in the axial direction.
With regard to the axial bearing, when it comes to ensuring long-term fault-
free operation the same notes and monitoring criteria fundamentally apply as
in the case of the turbine's radial bearing (see also the section entitled
"Monitoring the turbine's radial bearing").
Temperature measurement
On each side of the axial bearing, the temperatures of the bearing's white
metal surfaces is measured in two tilt segment blocks. With little delay, the
temperatures of the bearing's white metal surfaces follow all bearing load
and bearing condition changes.
A constant oil inlet temperature is the prerequisite for correct assessment of

the temperatures of the bearing's white metal surfaces . If all temperatures of
the bearing's white metal surfaces change at the same time, this is generally
an indication that the oil inlet temperature has changed.
The following notes are important when it comes to assessing the

temperatures of the bearing's white metal surfaces :
In most cases, the temperatures on the axial bearing change in relation to

output, doing so all the more so the higher the turbine's output-dependent
axial thrust change is from the zero to the rated load.
As the result of linings on the blades, other irregularities such as internal
leaks and operational conditions (e.g. tapping not in operation in the case
of turbines with tapping), the thrust may change considerably. Then, the
temperatures are also subject to changes in comparison with the
reference status.
The thrust direction can be assessed on the basis of the temperatures
measured. On the axial bearing end, which is subject to the load of the
axial thrust, higher temperatures set in than on the unloaded side.
The temperatures of the bearing's white metal surfaces that are
measured during commissioning (normal values) are detailed in the
section entitled "Commissioning report". The actual values must be
compared against the normal values.
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Limits
On the basis of an oil inlet temperature of 45 °C, you are advised not to
exceed the limits stated in the function list 0-2020-TNR-16.
These limits apply if the temperature sensor (thermocouple, resistance

thermometer) is located directly under the white metal sliding surface in the
zone of the narrowest lubrication gap.
Measures to avoid follow-up damage
In view of possible severe follow-up damage, you are kindly requested to

imperatively observe the following notes:
The turbine must be shut down and the bearings must be checked if the
temperatures of the bearing's white metal surfaces increase to the
switch-off value and thus the "damage limit" (see function list 0-2020-
TNR-00). In the event of axial bearing damage with extreme wear of the
bearing's white metal surface, clear changes occur in the axial position of
the turbine's rotor. Continued operation of the turbine may lead to severe
damage of the blading resulting from radial scraping of the rotor on the
fixed casing.
The bearings should be checked if one or several bearing white metal
temperature(s) should increase to the response value of the "Bearing
white metal temperature too high" signal or by more than 15 to 20 °C
above the highest bearing white metal temperatures previously measured
on a bearing. In most cases, this phenomenon is an indication of partial
damage of the bearing that does not fully influence the temperature
measuring point.
A drop in the bearing white metal temperatures to normal values after a
temporarily extreme rise is frequently typical of bearing damage and must
not deceive users into believing that operation of the turbo-generator can
be continued.
If there are any doubts as to the reliability of measurement, it is often
difficult and time-consuming to obtain evidence of an incorrect
measurement. Valuable time is lost and, during this time, follow-up
damage sets in. You are therefore advised to shut down the turbine if the
correctness of the measured temperature is questionable. Incorrect
measurement can certainly be ruled out if the temperatures at several
points on the axial bearing increase considerably.
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4.14 Oil pressure and oil temperature monitoring
General
Turbine oil is an important operating material for the turbine plant. This oil is
called upon to perform lubricating and control functions. The oil pressures
and temperatures required for performance of these functions must be
monitored during normal operation, during starting up and shutting down and
possibly also during turning-gear operation.
The nominal pressures and temperatures of the oil system are documented
in the "Commissioning report".
The oil pressures are dependent on:
the characteristics of the pumps,

the throttling characteristic of the system,
the oil temperature and
the air content of the oil.
During normal operation the oil is drawn from the oil tank and brought to a
pressure of 6 to 9 bar. In compressor or pump operation, the operational
speed of the turbine lies within a defined speed range. If, in this case, the oil
pump is driven directly by the turbine rotor, the oil pressure, can lie between
6 and 13 bar, depending on the speed range.
Influences on the oil pressures
As already mentioned above, the oil pressures are dependent on a number

of influencing factors. The percentage content of air in the oil, which is
absorbed during circulation within the system, is of special importance. This
air must be separated during the dwelling time in the oil tank (refer in this
connection to the Section "Requirements for turbine oils"). As a result of
strong turbulence in the bearing housings and control devices, the oil
absorbs air, especially where there is leakage in the suction line of the main
oil pump or at the pump itself.
The capacity of the oil tank and the circulating oil flow are therefore matched
to one another so that the time, during which the oil remains in the oil tank, is
normally long enough for achievement of good separation of the air from the
oil.
If the circulation factor is increased as a result of increased oil consumption

or too low an oil level in the oil tank, there is a danger that the oil will become
slowly enriched with air. Air separation is also influenced by a number of
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other factors, e.g. by the oil temperature. Air separation is improved when
the temperature in the oil tank increases. The oil temperature should not sink
to such an extent that air separation is impeded.
The air separation characteristics of the oil can be influenced not only by the
oil temperature, but also as a result of alteration of the oil characteristics due
to foreign matter, such as dust, tailings of sealing agents, and also by oil
additives. Presence of substances containing silicon in the oil is particularly
disadvantageous. Fir this reason it is strongly recommended that silicone
fluid should not be added to the oil as a "foam remover" where there is a
tendency to foam formation without having previously carried out special
investigations.
Moderately strong foaming of the oil is moreover generally a sign of good

venting and not for deterioration of the oil characteristics.
If foreign matter is responsible for deterioration of the air separating ability,

this can be improved only by removal of the harmful materials by filtering.
On the basis of present day knowledge, there is no known method of

improving poor air separating ability, which has been caused by addition of
silicon oils, oither by means of oil treatment or using additives.
If no improvement of the air separating ability is obtained as a result of

filtering, there is no alternative to replacement of the oil filling. In this case,
the system must be carefully emptied and cleaned in order to ensure that no
remnants of the old oil remain.
An excessively high air content leads to
suction problems as a result of air bubble expansion at the inlet to the

pump,
reduction of the specific oil density, as a result of which the delivery head
is reduced and
compressibility of the oil-air mixture.
The oil pressure can fall considerably through the influence of the air
content, especially during turning-gear operation by means of an oil turbine
shaft rotation equipment, and to a greater extent than would be expected
from the pump and system characteristic.
Moreover, excessively high air content of the oil can also lead to controller
faults, since control processes are based on the assumption that the oil is
incompressible.
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The oil mass flow rate, which is nearly constant during operation of the main
oil pump, has an additional influence on the oil pressures.
Wher an oil turbine is employed for shaft turning, the oil pressures during
operation with the auxiliary oil pump can be strongly influenced by opening
the hydraulic turning gear oil valve. The oil pressure change is not only
transitory during shifting of the operating point in accordance with the pump
and system characteristics, but is also dependent on the now increased
circulation factor of the oil. As a result the lingering period in the oil tank is
shorter, so that the air separation deteriorates. It is therefore possible that
the oil pressure continues to sink slowly for some minutes after opening the
hydraulic turning gear valve.
Oil temperatures
The most important oil temperature is the temperature downstream of the oil
cooler; it is normally 45 °C.
If the oil mass flow rate and the oil pressures were set correctly during initial
commissioning, the correct temperatures are necessarily obtained in the oil
tank and in the oil return lines.
The lubricating oil temperature downstream of the oil cooler must be

monitored continuously.
The oil temperatures, normally obtained during operation of the turbine, are
documented in the "Commissioning report".
Heating-up of the oil in the bearings
The lubricating oil supplied to the bearings is heated up by the friction heat
losses and by heat emission from the rotor, which is heated by the steam,
and flows back through the return oil lines to the oil tank. The calculated
temperature rise of the oil in a bearing during operation at rated speed is
approx. 20 °K and is dependent on the heat dissipated by the bearing and by
the oil mass flow rate through the bearing. In the case of the radial bearings,
the heat to be dissipated is independent of the load and is constant. In the
case of the axial bearing, it varies to a slight extent only with the axial thrust.
The oil mass flow rate through the bearings is set by means of throttles
during initial commissioning and should normally not be altered.
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Oil temperature of the oil tank
The temperature in the oil tank settles at approx. 60 to 65 °C during

operation. The temperature increases slowly during starting up until the
abovementioned steady-state value is reached.
The oil for regulating, limiting and protection devices is taken from the
pressure oil system immediately downstream of the pumps. The temperature
of the oil for regulating, limiting and protection devices thus corresponds
approximately to the oil tank temperature.
refer also to
Fehler! Verweisquelle konnte nicht gefunden werden. [J Fehler!
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4.15 Checking of drains
General
During startup, the hot steam entering the system condenses on the cold
surfaces of the piping and casing. If large amounts of this condensate
accumulate, or if water is routed into the turbine, it is not possible for the
turbine to heat up uniformly. The result is temperature differences in the
casing walls, leading to unwanted thermal stress and casing deformation
with considerable consequential damage.
Draining during startup
Main steam lines, the turbine casing and all interconnecting piping must be
drained prior to and during turbine startup until it can be assumed that no
further condensation will form on the surfaces concerned. The drains for
piping in which steam is stationary must remain open until an adequate
steam flow rate is present. This applies in particular to automatic extraction
lines between the turbine and the automatic extraction stop valves, until
these valves are open. All lines leading from the automatic extraction stop
valves must also be drained adequately in advance to prevent water
hammer.
The drains must be closed in accordance with the "Startup and Shutdown
Instructions" specified by the commissioning engineer.
Draining during shutdown
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The drains must be opened in accordance with the "Startup and Shutdown
Instructions" specified by the commissioning engineer.
4.16 Turbine fouling

Fouling of the turbine has a considerable effect on output and, in particular,
on the operating reliability of the turbine and must therefore be prevented.
To accomplish this, specific requirements are placed on steam purity.
The following factors influence steam purity:
Feedwater quality (demineralization, softening);

Steam generator design (once-through, natural circulation);
Boiler design (internals in drum, cyclone);
Boiler operation (loading, boiler water concentration);
Monitoring of condensate produced during operation and cleaning.
Deposits form especially on moving and stationary blades. The flow

channels are then narrowed and their surfaces roughened. This occurs as a
result of:
Reduction of the maximum steam swallowing capacity, leading to a drop

in output;
Disruption of pressure distribution in the steam turbine;
Increase of axial thrust and overloading of thrust bearing;
Additional bending forces exerted on blading, i.e. overloading of blading
under some circumstances;
Degradation of efficiency;
Mineral deposits on the stems which can lead to jamming of the valves if
the unit is run at continuous load over an extended period;
Roughening of blade surfaces, resulting in local concentration of stress
when corrosion present.
With regard to soiling, the internal condition of the steam turbine must be
monitored constantly during operation. Such close and constant monitoring
is only indirectly possible using steam data.
Pressure Monitoring The simplest method of monitoring the pressure is measuring the steam
pressures through the turbine, both in the wheel chamber and at defined
points in the remaining blading, e.g. at the beginning or end of the blade
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sections. These pressures are a function of the steam mass flow and can be
displayed for different measuring points (see pressure profile diagram).
During turbine operation, the operator measures the indicated steam

pressures and compares them to the values given in the diagram. In this
way it can be determined whether the pressures are above or below the
specified curves and whether they are below the limit curves.
If elevated pressure is established, this indicates that the nozzle and blade
channels have been constricted as a result of fouling.
Pressure profile as a function of main steam flow
Pressure Profile More precise monitoring of pressures in the turbine is possible by

Characteristic determining and comparison of pressure profile characteristics, as the
associated backpressure and its effect on the overall pressure profile within
the turbine can be taken into account.
The pressure within a stage in the turbine changes in accordance with

Stodola's ellipse law.
The inclination of the cone side of the mach cone, or the asymptotic curve
for the cone section is a constant. When applied to the relationships within
turbine drum sections of the turbine concerned, the equation for these
constants is as follows:
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with
p1 abs = pressure upstream of observed region
p2 abs = pressure downstream of the observed region
D = steam flow rate
If elevated values are obtained, or if pressure fluctuations are ascertained

over time with a constant flow rate, the turbine manufacturer must be
consulted to assess the condition.
In a condensing turbine p22 is negligible. With these types of turbines the

following applies for blade sections:
The constant (C) is specified by the manufacturer.
The operator measures the pressure values at the steam flow rate for that
turbine for monitoring pressure during turbine operation. The constant (C) is
then calculated from this and compared to the specified values for C. Setting
of the control equipment should be made in a similar manner. Steam flow
rate variances of ±5% are permissible. Progression of soiling over a defined
period can be shown by entering the C values measured at different times in
a diagram over time.
Other options include monitoring of internal efficiency and establishing the

steam rate. This method is not recommended, as the accuracy is insufficient
using normal instruments.
The intervals for checking these conditions must be adapted to the operating
conditions present at each plant. The following is recommended:
Pressure monitoring using recorded operating data;

C values, weekly.
Mineral deposits in the turbine can be prevented when the alkalinity number
and density are adapted to the current operating conditions.
Based on the VGB guidelines, the mineral content of the steam is

determined by the conductivity, which is measured after a highly acidic
cation exchanger and after removal of CO2.
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Essential prerequisites must be fulfilled at the plant to obtain these values.

The cause must be determined in the event of mineral deposits.
Separation of water and steam must be complete. In the event that droplets,
or even large amounts of water ar entrained in the saturated steam, the
mineral content of the steam will increase considerably. These processes
can be controlled by monitoring the saturated steam samples continuously
using the conductivity instrumentation.
If an injection cooler is provided it must be ensured that it is only supplied

with completely demineralized water.
The feedwater and boiler conditions must be examined in the event of

mineral deposits The drum internals must also be checked for proper
functioning.
Frequently, mineral deposits occur in conjunction with foaming and spitting

of the boiler. Formation of foam on the surface of the water, which extends
up to the steam space, entrains fine particles of liquid from the steam. The
minerals contained in these particles can then be deposited in the
superheater and in the turbine. The following primary causes have been
determined for this in conjunction with foaming:
Organic substances which form into complex colloid dispersoids via

molecularly disperse microbes. Also, suspensoids and hydrated colloids.
Differences in concentration between the interior and surface of the water
and reduction of surface tension.
Heterogeneous composition of the boundary layer.
Sodium hydroxide solution and phosphate aid foaming. Sodium sulfate and
sodium chloride counteract foaming.
The amount of organic substances must also be reduced to prevent

foaming. In addition, the alkalinity and the phosphate content must be kept
within defined limits.
Minerals can also ingress into the turbine as a result of boiler spitting. In
contrast to foaming, spitting is caused by abrupt "bubbling" of the water as a
result of delayed boiling. Spitting can not be rectified using chemical means.
Traces of hardness that ingress into the boiler react with silicic acid with
formation of calcium and/or magnesium silicate if there is not an ample
amount of trisodium phosphate present. Trisodium phosphate tends to
counteract the formation of hardened silicate, meaning that calcium and/or
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magnesium phosphate of reduced solubility is formed and SiO2 remains in

solution.
The silicic acid is dissolved in the steam at high temperatures and is no

longer included in the aforementioned solution. The following rules must be
observed to achieve a low content of residual silicic acid in demineralization
plants:
Complete clear filtration of the raw water;

Complete dealkalization of the water to be desilicified;
Low operating temperature but high regeneration temperature;
Use of very basic resins;
Presence of a sufficient regenerant surplus;
Usage of a capacity adapted to current operating conditions;
Countercurrent regeneration;
Mixed bed filter for fine filtration;
Filtering of fouled condensate from operation via a softener filter.
When these guidelines are observed it is possible to obtain the highest

degree of purity for any raw water, with regard to mineral content, in an ion
exchange unit.
Mineral or silicate deposits occur within certain pressure and temperature

ranges. In turbines with a main steam pressure of up to around 40 bar,
mineral deposits primarily occur; silicic acid deposits at higher main steam
pressures.
Experience has shown that a major portion of water-soluble mineral deposits

are flushed out when the unit is restarted, as a restart after an outage acts
as a rinsing process. The more the turbine casing temperature has fallen
during the outage, and the more frequently the startup and shutdown
processes are repeated, the greater the efficacy of this natural rinsing effect.
If soiling can not be prevented due to inadequate feedwater treatment, or

other plant deficiencies, the plant must be monitored to establish the best
time to eliminate the soiling.
Water-soluble deposits can be flushed out with condensate or wet steam.

Elimination of water-soluble components by condensate flushing normally
requires more effort than saturated steam washing and should, due to
economic aspects, only be considered second to wet steam washing. Non-
water-soluble deposits must be removed mechanically. The special
instructions provided by the manufacturer must be observed for this.
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It is recommended to first perform wet steam washing. Frequently, non-

water-soluble compounds are embedded in water-soluble ones. After
washing out the soluble components, the remaining framework of non-
soluble components will collapse and can then be rinsed out. This is the
same effect achieved by startup and shutdown, albeit somewhat diluted.
Saturated steam washing The steam cooler and the requisite piping, with the exception of the flushing
steam connection on the main steam line, can be prepared for wet steam
washing during turbine operation. When the turbine has been shut down,
two to three hours will be required for preparatory work. This does not
include cooling of the casing with main steam for around two hours, the
actual washing process itself, which depends on the type of deposits that are
present, lasting around a half to one whole day. A well prepared washing
process hence requires an outage time of around 12 to 24 hours.
Special cases notwithstanding in which Cu or Fe deposits have been

established on the blading which then require condensate flushing, we
always recommend wet steam washing for removing deposits.
Prior to steam washing, the turbine casing should be brought to a

temperature close to that of the steam used for washing in order to prevent
any impermissible deformation. Insofar as no casing temperature measuring
points are available, the casing temperature is best measured using a stem
thermometer. For this, the thermometer must be inserted as deeply as
possible between the insulation on the casing.
If the turbine is to be washed directly after shutdown, it is recommended to

reduce the casing and rotor temperatures as much as possible during the
shutdown procedure by lowering the main steam temperature in order to
shorten the subsequent cooling period. This option is only available for block
units, i.e. if the turbine is not supplied with motive steam from a header.
Otherwise, the cooling process can be accelerated using the washing
equipment, provided the main steam connection on the steam cooler has
roughly the same steam temperature as the main steam.
Condensate rinsing Condensate rinsing involves filling the turbine with condensate and turning
the turbine rotor.
Condensate rinsing is only used in exceptional cases.
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Rinsing using sodium Rinsing with a sodium hydroxide solution must only be used in exceptional
hydroxide solution cases and after consultation with the turbine manufacturer. More detailed
information can be obtained about this process on an individual case basis
when required.
Removing deposits Removal of deposits containing copper must only be performed in

containing copper exceptional cases and after consultation with the turbine manufacturer. More
detailed information can be obtained about this process on an individual
case basis when required.
Cleaning with the turbine open

Dry cleaning Blade deposits can be scraped off manually using scrapers (very time
consuming), or removed by cleaning with jet air fans (flyash, blasting sand).
Wet cleaning Wet cleaning is performed using solvents, where required. Application of
both procedures - dry and wet cleaning - can save time.
Monitoring the rinsing Water must be analyzed and monitored during any turbine rinsing/washing
process process. This provides information about the amount of impurities that have
been flushed out and, hence, about the remaining duration of the cleaning
process.
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Example of findings made during washing of a steam turbine
It suffices to measure the conductivity of the drained water when rinsing with
pure condensate or saturated steam to establish when the rinsing procedure
can be ceased. The quantity of anions is established in the samples taken,
either as a mixed sample from each turbine filling, or at set intervals during
continuous rinsing, to gain information about the type and degree of soiling
in the turbine. Only the sodium ion should be detected in the cations for
excellent water quality. If other cations are present, such as calcium or
magnesium ions, these must also be determined. The effect of rinsing when
using sodium hydroxide is determined by the residual content of silicic acid.
It is useful to apply the values established during testing in a double

logarithmic scale over time (see diagram with example of findings made
during washing of a steam turbine). This type of representation allows the
duration of washing to be extrapolated at an early stage.
After washing, the steam turbine should be dried, or started up again at the
earliest possible time (standby corrosion). The success of washing becomes
apparent when the stage pressures are measured and when the key data
are calculated.
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Washing shall be performed in accordance with the given instructions. We

also recommend consulting our assembly and commissioning engineers.
Bibliography [1] BASF-Untersuchung der Materialprüfung:

([1] BASF Investigation of Materials Testing:)
Dr. Spähn/Dr. Gräfen (not published)
refer also to
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Salt and Silica deposits [J 46]
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s

Training on Industrial Steam Turbines

Type of Machine: SST800 – EEHNK90/3,2

This Document fits for training puposes

© Siemens Power Generation 2007. Technical data subject to change.

Printed in Germany Siemens Power Generation

1.1 Instructions for operation of the condenser 5

2 Startup and shutdown operation 7

2.1 Checks during plant standstill 7

2.2 Preparations for startup 10

2.3 Start up the Turbine 16

2.4 Testing during plant operation 22

2.5 Uploading the Turbine 24

2.6 Shutdown the Turbine 25

4.1 Overview of operational monitoring 28

4.2 Limit value monitoring 30

4.3 Monitoring of live steam pressure 37

4.4 Temperature monitoring 38

4.5 Monitoring of casing expansion 40

4.6 Monitoring of the internal efficiency 43

4.7 Salt and Silica deposits 46

4.8 Blade Breakages 54

4.9 Monitoring of power output 68

4.10 Speed monitoring 72

4.11 Monitoring of vibrations 76

4.12 Monitoring of turbine radial bearings 83

4.13 Monitoring the turbine's axial bearing 89

4.14 Oil pressure and oil temperature monitoring 91

4.15 Checking of drains 94

4.16 Turbine fouling 95

1.1 Instructions for operation of the condenser

A protective coating must build up in cooling-water-end condenser tubes

The formation and retention of this protective coating depends primarily on

Cooling water velocity

The condenser is designed such that the maximum permissible cooling

Destroying of the protective film or erosion corrosion

A minimum cooling water velocity of 1.5 m/s should be maintained to prevent

Where an automatic tube cleaning system is provided, the limiting conditions

Preventing steam-side corrosion due to ammonia

When the water/steam circuit is conditioned with ammonia it must be

2 Startup and shutdown operation

The following instructions represent a standard description for startup and

Project-specific adaptations are implemented after commissioning of the

2.1 Checks during plant standstill

Introductory remarks to the general startup instructions:

Beginning of operational readiness

Familiar with P+I flow charts

 Lubricating oil: 0-0640-TNo.-00

Control system diagram: 0-0641-TNo.-00

 Oil supply system for driven machine

Lifting Oil System

Familiar with P+I flow charts.

 Jacking oil pump 4712 is set to Manual and is not in operation.

Hydrauic shaft turning gear

Familiar with P+I flow charts

 Turbine steam + drain system: 0-0642-TNo.-00

1. Open the isolation valves upstream and downstream of the pneumatic

Observe the setting for the seal-steam controller

Option: Extraction control system

Evacuation and Condensing System

Familiar with P+I flow charts

 Turbine steam and drains system 0-0642-TNo-00 and

Evacuation using steam-jet air ejectors

Lubricating oil: 0-0640-TNo.-00

Oil supply system for driven machine

Jacking oil pump 4712 is set to Manual and is not in operation.

Turbine steam + drain system: 0-0642-TNo.-00

Turbine steam and drains system 0-0642-TNo-00 and

Water is in continuous circulation through condenser 6000.

Condensate pumps 6110 and 6120 are shut down.

Solenoid valve 6010 to the vacuum breaker is closed.

Main steam line

Wheel chamber (downstream of first control stage)

Testing of electrical trip initiation for Channel 1

Test phase 1 is initiated by switching of valve 2225 (de-energization of

Testing of electrical trip initiation in Channel 2 is started by switching

Testing of electrical turbine trip initiation - Channel 3

Testing of electrical trip initiation in Channel 3 is started by switching