T6497 Kerinci Steam Turbine Training Operation and Maintenance

T6497 KERINCI
Steam Turbine Training

Operation and Maintenance
Start-up, Operation and Shut-down
Important Note!
This start-up description is a prelaminary issue. The

final issue will developed and produced during the
commissioning of the turboset. Therefore parts of the
content will be a matter of change if it is required for
the process or plant safety.
Slide 2 2007 - T6497 KERINCI Steam Turbine Operation & Maintenance Training Dieter Meyer PG I14314 Training
Plant Overview
Area
Lube Oil System
(example for training purposes only!)
Work Area
Button Area
HP Control Oil
Steam
Control
Drain System
Condensate System
Control
Function Diagram Turbine Controller

Overview T6497
Function Diagram Turbine Controller
Legend and Explanations
Generator
Bearing Temperature
Relative Shaft Vibration, Relative Casing Expansion, Axial Shaft Position

Curves
Messages
Introduction
¾ The starting operation may have a decisive effect on the possible

curtailment of turbine life. Major thermal and mechanical stresses are
going to be experienced in the course of starting. This hazard will
arise particularly with starts from the cold.
¾ Therefore, to avoid thermal and mechanical stresses during start-up,

the now presented diagrams should be used:
1. Pressure build-up in valve casing

2. Increase of turbine speed
3. Increase of turbine power
4. Allowable load increase out of thermal steady state conditions
5. Allowable load decrease out of thermal steady state conditions
Temperature Measuring Points
1. Live steam
temperature TE001
2. 50 and 100 %
measuring at HP steam
main stop valve (TE
038)
3. Flange temperature
(TE176)
Explanation of 50% and 100%
Temperature Measurement
S – wall thickness
100 % measuring point at the inside of the wall
50% measuring point in the middle of the wall
Thermowell Thermocouple
Start-up and Shutdown Operation 1

Checks prior to start up
Checks when Plant is at Standstill
Note!
Beginning of operational readiness
Operational readiness of the plant should be established two
hours prior to the planned startup time of the turbomachinery.
Lubricating Oil and Control Oil System

Prerequisites
Familiar with P+I flow charts
– P&I Lube oil 0-0640-6497-00
– P&I Lube oil unit 0-0640-6497-01
– HP control oil 0-0636-6497-00
– Control oil diagram 0-0641-6497-00
Measures
In the PCS7 operator control and monitoring system select the process
display Oil system
Lube oil system
The oil pump 4221 and emergency oil pump 4241 are shut down and
their autocontrols are switched off.
Oil vapor extractor 4341 is switched off.
The duplex lube oil coolers 4400/4420 are switched such that only one
cooler is in operation.
Cooling water is being supplied to the oil coolers and the water chambers
are vented.


Oil level in the lube oil tank is normal
The duplex lubricating oil filters 4500/4501 are switched such that only one
filter is in its operating position.
Isolating valves to the differential pressure switch PDIS 363 are open.
Oil purifier is switched off
Drain valve of purifier is closed
Isolation valves in suction and discharge line of purifier are open
Oil vapour separator is not in operation
Jacking Oil System

Jacking oil pump 4711 is set to Manual and is not in operation.
Isolation valve before jacking oil pump 4711 is open

Measures
display HP Control Oil
Control oil system
The oil pumps 4279, 4280, and cooling oil pumps 4284, 4285 are shut
down and their autocontrols are switched off.
Cooling water is being supplied to the oil coolers 4410, 4412 and the
water chambers are vented.
The duplex control oil filters 4530 are switched such that only one filter is
in its operation position.
Isolating valves to the differential pressure switch PDIS 367 are open.
Isolating valve to the oil accumulator 4605 and 4606 are open
the drain valve of the oil accumulato 4605 and 4606 are closed

Seal Steam Control System
Prerequisites
Familiar with the P+I flow chart
Turbine steam and drains system 0-0642-6497-00
Measures
The main steam isolating valve before the pneumatic seal-steam control
valves 7201 is closed
Open the isolation valves upstream and downstream of the pneumatic seal-
steam control valve 7201 and close the associated bypass valve for
emergency operation.
Open drain valve before the steam trap
Open the isolation valves upstream and downstream of the seal steam cooler
5465
Instrument air supply must be available for the pneumatic control valves
Seal steam controller is set to Manual and the output signal is 0%.
Local drain valve check
Condensate Injection
Isolating valves up- and downstream of solenoid valve 6020 are open
Drain Check
The following drain valves are opened manually at the location of the
valves:
Drains of main steam line
Warm-up line near the ESV's partly
Drains on extraction non return valves 2350, 2351
Bypasses with steam traps:
E036, E038, E008, E1, E009, E2, E015, A1, E050 at the drain collector
E198 and E199
Start-up 7
Evacuation and condensing system
¾ Condensate pumps are not in operation

¾ Check the cooling water supply to the surface condenser
¾ Check the valves up- and down-stream of the condensate pumps
are open
¾ Check the valves of the pressure compensation line are open
¾ Check the valves up- and down-stream of air ejector coolers are
open
¾ Check valves up- and downstream of the condensate control and
recycle valves are open and the bypass valves are closed
¾ Check instrument air supply to the condensate control and recycle
valves are available
Start-up 8
Evacuation and condensing system
¾ Check both isolating valves in the air suction lines at the condenser
are open
¾ Check hand wheels of the pressure relief valve are in the closed
position
¾ Check that all steam and air gate valves at the steam ejectors are
closed
¾ Check drains of inter/after coolers: valves up- and downstream of
the condensate traps must be open, the bypass valves must be
closed
¾ Check that the condensate valves up- and downstream of inter/after
coolers are open
Startup Automatic
Start-up 9
Lube oil system
Set oil tank heater in Auto Control Mode

Start the oil mist separator
Start auxiliary oil pump and set pump to AUTO
Set emergency oil pump to AUTO
Start jacking oil pump
Start the turning gear
Start-up 10
Seal steam supply
¾ Set the condensing pumps to AUTO

¾ Warming-up the seal steam line upstream of the seal steam
control valve via drain valve HV3010
¾ Set seal steam controller to AUTO and adjust the set point to
10 mbar
¾ Open the isolating valve downstream of the seal steam control

valve
¾ Open stepwise the upstream isolating valve until the seal

steam pressure system is pressurized. The control valve
closes and the pressure controller maintain the seal steam
pressure at 10 mbar
Start-up 11
Condensing system
¾ Warming-up the steam line upstream of the steam ejector group
¾ Check the seal water supply to the condenser pressure relief

valve when the condesate pump is started
The evacution system starts automatically from the Automatic Start

Sequence if the required steam conditions are fulfilled.
The condensate pumps are operated from the Automatic Start
Sequence
Start-up 12
Seal steam supply
Note!
The maximum permissible period for operation of the turbine with the
sealsteam supply system activated and without operating steam is four (4)
hours. During this period, the turbine must be in turning gear operation
however. At the end of this period, operation with seal steam must be ceased
at least until the rotor and gland casing system has cooled adequately.
The turbine manufacturer will not be liable for any damages resulting when
these guidelines are not observed.
Start-up 13
Warming-up main steam line
The Emergency stop valve opens automatically by means of the

Automatic Start Sequence
¾ Open the main steam header valve and warming up the main steam
line 30 to 50 °C higher than saturated steam temperature
¾ Raise the main steam up to header pressure gradually until the

pressure up- and down-stream is nearly equalized
¾ Adjusting or closing the drain valves.
The main supply pressure (PT001) is built up (according to

document “Start up instructions” automatically by means of the
Automatic Start Sequence (valves HV3012, HV3013 and warm-
up HV3009)
Pressure Build-up In Valve Casing
Main stop valve casing temperature TE038 before start-up
Start-up 15
Start-up curve
The Automatic Start Sequence starts the turbine controller

if the casing temperature TE176 is g.t. 140 °C
The slowest start is determined by the cold-start startup
curve, the fastest startup is determined by the hot-start
startup curve. Between these curves the ramp rates and
hold delays are interpolated.
The ramp rates and hold delays are configured in the
TURBINE CONTROLLER.
The ramp rates as well as the hold delays are calculated
by using the casing wall temperature TE176 (wheel
chamber area).
Start-up curves depending on casing temperature

Increase of turbine speed
casing wall temperature TE176 before start-up
Start-up live steam

condition:
138 bar / 538 °C
The curves in this diagram

represent the increase of
speed as a function of the
minimum start-up time.
Start-up 17
Rotor Sticking Protection and Critical speed band
Rotor sticking protection

When the signals from all speed pick ups are below a minimum (n < 500
rpm) while the valve lift is above a minimum value (Pos. HP valve > 30
%) the turbine is tripped.
Final adjusting of “Pos. HP valve” during commissioning!
Critical speed band

The TURBINE CONTROLLER also takes care of critical speed ranges;
It is not possible to halt the set-point in the range of the critical speed
band (800 – 2720 RPM).
With the commands HALT / CONTINUE it is possible to interrupt

resp. continue the start sequence if the turbine speed is not in the
barred range.
Loading
The Automatic Start Sequence starts
1. starts the excitation system of the generator and raising the voltage.
2. starts the synchronsing system to adjust the speed (frequency), voltage and
phas angle to the existing grid parameters
3. closing the generator breaker
4. applying a small amount of load to avoid the response of the reverse power
protection
5. changes from speed to load control
Start-up curves depending on casing temperature
Increase of turbine load
casing wall temperature TE176 before start-up
Start-up live steam

condition:
138 bar / 538 °C
The curves in this diagram

represent the increase of
turbineload as a function of
the minimum start-up time.
Allowable Load Changes out of

thermal steady conditions
Initation of HP inlet pressure controller
Initiation of HP inlet pressure control

If only a limited amount of main steam is available in the system, changeover
can be made from speed or load control to inlet pressure control.
Activate the operator faceplate for the inlet pressure controller.
In the operator control window, the setpoint and actual value for the
inlet pressure are displayed for the load that is currently set in the
"Manual limiter mode".
The required setpoint is specified for the boiler by making several small
step changes in the setpoint.
The HP steam control valves are opened and/or closed in accordance

with the inlet pressure setting.
Set the inlet pressure controller to "Automatic" when the required actual
value has been reached.
The controller that was previously in operation switches automatically to

"Manual"; the SGC symbol color changes from green to white.
Checks and Measurents during operation
Checks and Measures during Operation

The shift personnel checks all of the operating data by selecting the
process displays:
Steam,
Control system,
Oil system,
Vibration,
Bearing temperature,
Generator
Alarms, messages.
Lube oil temperature and filter diff.-press.
The oil temperature to the bearings is regulated automatically by the
oil temperature control valve 5550 to 45 ±6 °C. To accomplish this,
cold oil is mixed with hot oil at port B (bypass) via port C.
Soiling of the filter elements of lubricating oil filter 4500 or 4501 is

signaled when the differential pressure switch PDIS 363 issues an
alarm at p > 0.6 bar.
Hot oil is routed to the standby filter via the filling valve to heat
the vent line.
Switch to the standby filter.
Clean the soiled strainer elements immediately.
Danger!
Risk of escaping oil - potential burn hazard!
The filling valve must be closed and the body drained via the discharge
cock with the vent is open before opening the casing.
Lube oil temperature and filter diff.-press.
The body can be filled via the filling valve after the filter elements
have been cleaned. Warming up of the vent line is an indication
that filling has been adequate and successful.
Note!
Leave the filling valve open
It has proven useful in the past to always leave the filling valve open so
that in the event of a fault hot oil can flow to the bearings while switch-over
is made to the standby filter.
Shutdown
Shutdown concept
The "SHUTDOWN" step program has the task of shutting down the
turbine from power operation to a defined state of turbine standstill.
The SHUTDOWN program can be initiated
- From the unit control level
- By initiation of a turbine trip or
- Manually from the control room
Coast down and turning
The turbomachinery reduces its speed in accordance with the coastdown

curve.
Controlled via the speed, the jacking oil pump and the hydraulic turning gear
cut in.
The turning gear begins turning operation of the turbomachinery when the
overrunning clutch engages:
This prevents bowing of the turbine rotor as the turbine is cooling

down;
Observe this procedure in the process display "Oil system".
The supply of seal steam to the shaft seals is discontinued as soon as there
is no longer a vacuum present in the turbine.
Shut down the condensing system, as it is no longer necessary to

condense any steam.
Emergency shut-down 1
In the event of danger, the turboset can be shutdown irrespective of

the power output by emergency tripping by means of the solenoid
valve for remote emergency tripping.
Immediate emergency shutdown can be necessitated by:
sudden rise of vibration amplitude;
reaching or exceeding the limit values of the bearing metal

temperatures at the axial or radial bearings;
failures of auxiliary units, without further operation of the turboset

is not possible.
In the case of less severe danger to the turboset, the turbine can be
also be unloaded by reduction of the speed or load setpoint at the
turbine controller
Emergency shut-down 2
The decision as to whether the turbine should be

shutdown immediately by emergency trippping or
should be shutdown after previous unloading, must
be based on the degree of endangerment of the
turboset. In case of doubt, immediate emergency
tripping should be initiated.
Note!
Measures subsequent to emergency tripping
All the necessary measures described in the
operating instructions for "Shutdown" must also be
carried out or be initiated subsequent to emergency
tripping.
Manual Synchronization 1
Synchronization of the generator, speed controller active
Select the process display "Generator".
Turbomachinery is running at rated speed.
In the operator panel "Voltage regulator", activate excitation and set to

"Auto".
If the voltage regulator is in the "Automatic" mode, the generator is excited up

to rated voltage.
The level of the generator voltage and the voltage downcircuit of the machine
transformer are shown in the process display.
Manual Synchronization 2
When voltage is nearly the same downcircuit and upcircuit of the generator
circuit-breaker, press the button "Start" in the synchronization window, after
previously pressing the button "Syn".
If no faults or blocking conditions are present, the field "running" will then
show the execution of the automatic synchronization procedure.
The generator circuit breaker is closed when all of the synchronization

conditions are fulfilled.
This is shown in the process display by the symbol for the generator
circuit-breaker.
Manual Loading of Turbomachinery 1
Loading of the turbomachinery using the load controller
A slight load is applied automatically after successful synchronization so

that the generator circuit-breaker is not immediately re-opened via the
turbine protection system against windage "Reverse power coming from
grid".
Select the process display "Control system" to apply further loading.
The subgroup control (SGC) "Load" for the load controller is set to
"Automatic".
the SGC symbol changes to green,
the SGC symbol for the speed control changes to white.
After selecting the faceplate for the load controller the load setpoint can
be set to the required load.
Manual Loading of Turbomachinery 2
The load controller modifies the load applied to the turbine using the
load increase gradient that is calculated and given in the startup
curve; this gradient is a function of the temperature measured at
measuring point TE 176 and is displayed in MW/min under the load
control symbol.
Note!
Limiting of load increase
Limiting of the load increase when applying a load to the turbine prevents
the defined temperature change rates from being exceeded in thick-walled
items, such as turbine rotors, inlet end section, outer casing.
If the load controller remains active, assuming steady-state operation

under load, limiting curves for load step increases and reductions are
stored in the load controller.
Allowable Load Changes out of
thermal steady conditions
Time [min] Time [min]
Manual Unloading
Removing the Load from the Turbomachinery

The load can be removed from the turbomachinery in the following manner:
specific, separate unloading of turbomachinery, or
unloading in conjunction with the boiler and the process steam
loads.
Normally, the turbine is shut down to perform inspection and overhaul work
on the turbomachinery, for example during a scheduled outage
Attention!
Observe the load change rates
The load change rates specified in 0-2040-6497-51, Load Changes, may
not be exceeded.
Testing of Reverse Power Protection 1
Removing the Load and Testing of Turbine Reverse Power Protection
Loading of the turbomachinery can be reduced by entering lower
setpoints for load control and higher ones for inlet pressure control.
The long-term reverse power protection, as the most important turbine
protection system, is tested as follows:
Switch from inlet pressure to speed control;
Reduce the load by entering stepwise lower speed setpoint SP values,
e.g. –5 rpm per step down to 1 MW; the speed control still operates as
a P-action controller whose setpoint is considerably higher than the
process speed PV. Note the value of the SP.
Now, enter a speed setpoint that is markedly lower than the rated
speed 3000 rpm, e.g. 2900 rpm, to force the generator to
accommodate reverse power.
The turbine control valves then close completely due to the great
divergence between the setpoint and actual value.
After a trip time of around 20 seconds, the generator circuit
breaker opens and a corresponding message is issued.
Testing of Reverse Power Protection 2
Note!
Generator circuit-breaker fails to open
In the event that the generator circuit-breaker does not open, the
control valves must be re-opened by entering a higher speed
setpoint as displayed and noted at 1 MW
Danger!
Do not initiate turbine trip - risk of windage in the turbine!
In the event that the reverse power protection system fails, do not
initiate turbine trip, as the turbine is held at rated speed by the
generator and, since the control valves are closed, no cooling steam
can flow through the turbine
As an emergency measure you can open the generator circuit-

breaker by hand on the board.
It is imperative that you inform the responsible electrical engineer to
effect fault rectification.
Manual Startup and Function Tests
of Lube Oil System (1)
display "Oil System".
Switch on the he oil tank heater, set it to "AUTO" and heat the oil in the
tank up to 35°C.
Switch on the oil vapor extractor.
Check AC oil pump 1 and 2 and DC emergency oil pump are in

"MANUAL" and shut off
Set DC emergency oil pump to "AUTO".
The emergency oil pump must start due to the low lube oil pressure
Preselect oil pump 1 or 2 as main oil pump and set the standby oil pump
to "AUTO".
the standby oil pump must start due the low lube oil pressure
Manual Startup and Function Tests

of Lube Oil System (2)
Set the emergency oil pump to "MANUAL", STOP the pump and set it
back to "AUTO"
Set preselected main oil pump to "AUTO", set the standby oil pump to
"MANUAL" and STOP the standby oil pump
the preselected main oil pump must start due the low lube oil
pressure
Set the standby oil pump to "AUTO".

The function test of the oil pump automation system is OK
Refer to the commissioning data record for the requisite lubricating oil
pressures; the switch set point for the auxiliary and emergency oil pumps
are listed there also.
Manual shutdown of oil system
Shutdown of the Lubricating Oil System
Do not shut down the lubricating oil system before the hydraulic turning
gear has been switched off and it has been established that the
turbomachinery has come to a complete standstill.
Set the jacking oil pump to "Manual" and switch it off.
Set the auxiliary oil pump autocontrols to "Manual" and switch it off
The emergency oil pump starts up,
Set the emergency oil pump to "Manual" and switch it off.
The oil tank heater remains at "Automatic" to provide oil at operating

temperature at any time it may be required.
Select the oil vapor extractor and switch it off.
Manual Starting of Turning Gear
Danger!
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.
Clear the turbine and generator rotor for turning gear operation.
Switch the hydraulic turning gear from "MANUAL" to "AUTO".
Set jacking oil pump to "AUTO".
The jacking oil lifts the turbine and generator rotor.
If the jacking oil pressure exceed the 70 bar, the hydraulic turning gear
starts up and accelerates the turbomachinery to the specified speed.
Function test for hydraulic rotor turning gear "OK".
Manual Shutdown of Turning Gear
Shutting down the hydraulic turning gear and opening the

internal turbine drains
Shut down the hydraulic turning gear once the temperature at the HP
outer casing (see measuring point TE 176) has fallen below 150°C:
This cooling process may required several days, depending on the

size of the turbine and the quality of insulation.
Limit Monitoring
The turbine plant is equipped with monitoring, limiting and protective

equipment and devices. The task of these devices is to avoid, or make
apparent, any operating conditions that are not permitted or not economical
for the turbine.
• Monitoring devices visualize operating conditions of the plant and/or
report any deviation from the specified conditions.
• These devices are designed and set such, that they intervene in advance
of the corresponding protective devices and their associated trips in an
attempt, to prevent disruption of operation where at all possible. The
devices are designed and adjusted such that they act before the
corresponding protective devices and, where possible, prevent protective
devices being tripped, thereby causing an outage.
• The task of protective devices is to shut down the turbine itself, or other
sections of the plant, as soon as conditions occur which pose a risk to
the turbine.
Important criteria for recognizing during normal
operation
Potential risk for the turbine plant are:
¾ the oil and babbitt metal temperatures,
¾ the bearing housing and / or shaft vibration levels,
¾ the relative shaft expansion and absolute casing expansion,
¾ the steam and component temperatures,
¾ the steam pressures,
¾ the speed.
Babbitt metal and oil temperatures
¾ The temperature is measured at the journal bearings and thrust bearing

directly below the babbitt metal lining for the bearing shell and for the
thrust bearing segments. Only in exceptional cases is the temperature of
the draining oil measured downstream of the bearings.
¾ The level of residual thrust is the decisive factor for the thrust bearing.
¾ Changes may occur at the journal bearings which can lead to the direction
and magnitude of bearing loading of the bearing journals being affected by
the steam flow conditions.
¾ Bearing damage, with the associated increase in temperatures, occur
rapidly and over short periods. Here, it is important to remember that
temperature increases are frequently only temporary and that the
temperature can return to near normal at the bearing support system after
damage occurs. A check of the oil strainer in the oil tank should at least be
made immediately after a severe temperature fluctuation in violation of
defined limits to determine whether fragments of babbitt metal, resulting
from bearing damage, are present in the strainer.
Monitoring of Journal Bearings
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.
Reliable functioning of essential factors:

¾ continuous flow of lubricant and complete filling of all sleeve bearing
cavities; in conjunction therewith, an assured oil level in the tank;
¾ incompressibility of the lubricating oil;
¾ adhesion of the lubricating oil to the sleeve surfaces, i.e. the adhesion
must be considerably larger than the cohesive force.
¾ continuous and adequate dissipation of the friction heat losses, in order
to limit the lubrication gap temperature and the lubricating oil viscosity.
¾ 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.
Temperature Influence of Oil
The bearing ability of the lubricating oil film is dependent mainly on the
viscosity of the oil employed. This is strongly dependent on the
temperature of the oil film.
Even if 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 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
Pressure Distribution in an elliptical bearing
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 incompetent 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.
Scoring at Tilting Pads
Scoring by dirt entering the

bearing at start-up.Particle
movement is more irregular
than if it had occurred at
high speed.Dirt was likely
already present at
assembly.
Severe scoring at high
speed.Embedded particles
were identified as ferrous.
If a mating shaft is a steel
containing > 1%chromium
or manganese and the
sliding speed is more than
20 m/s very severe scoring
can occur. Sometimes
called “Wire wool fatigue”.
Hard chrome plating is an
effective remedy.
Cracking
Inter-granular craze
cracking on white metal
due to overheating and
partial seizure.
Overload on a small
steam turbo-generator
thrust bearing due to
water passing through the
turbine.
Pitting
Electrical discharge
erosion on a thrust pad
Pitted zone
Unaffected zone
Excessive temperature
Thrust pad subjected to excessive

temperature causing deformation of
white metal without wiping. White
metal temperature 170 °C
Vibration
Vibration measurement provides an insight into
changes in the running condition, caused by:
¾ Blade fracture,
¾ deposits,
¾ erosion,
¾ changes in alignment,
¾ shaft bowing,
¾ temperature-related imbalance;
¾ Dynamic overloading, in particular at the bearings. This leads to
premature decline of the load-bearing capacity.
¾ Reduction of radial clearances that are significant during non-steady-
state operating conditions, especially during startup.
Assessment of the vibration magnitude is based primarily on the deviation

from normal operating values, followed by the level of the measured value.
Comparison with earlier and above all, with the measured values obtained
during commissioning has priority.
Steam and component temperatures
Excessive temperatures reduce the strength values for the components

materials and, hence, lower the margin of safety and service life for the
components concerned.
• 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.
Changes in temperature also cause additional thermal stress in the

components that combines with the fundamental stress; rapid temperature
changes therefore result in overloading of the components and reduce
their active service life.
In addition, rapid changes in temperature brought about by differing

expansion behavior in the rotor and casing also result in relative
expansion which can pose a risk to the overall turbine plant.
Steam Pressure
Main steam pressure is reduced in stages to the exhaust steam pressure in

the turbine. The turbine can be endangered by violation of the permissible
upper/lower limits for main steam, wheel chamber, backpressure or shaft
seal pressure. The essential operating pressures for the turbine must
therefore be monitored continuously using the existing pressure measuring
equipment. If defined limits are reached, the operating personnel must
intervene immediately and eliminate the fault.
A change in the pressure profile in the turbine will usually result in a change
in the axial thrust and, hence, in loading on the thrust bearing.
The pressure profile can be impaired by:
• Soiling of the blading, e.g. by mineral or silica deposits,
• Damage to blading resulting in changes in the cross sections
• Changes in steam flow in the individual stages, deviation from design
conditions.
Steam Pressure and Axial Thrust
Protection against excessive main steam pressure is offered by the

safety valves for the steam generator.
If major mineral deposits are present, or if the swallowing capacity of
the turbine is considerably greater than the steam flow achieved at
rated output, the wheel chamber pressure may increase to a point
which poses a risk to the casing and the blading.
Excessive axial thrust may also occur simultaneously.
The End

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T6497 KERINCI

Steam Turbine Training

This start-up description is a prelaminary issue. The

Lube Oil System

(example for training purposes only!)

Function Diagram Turbine Controller

Relative Shaft Vibration, Relative Casing Expansion, Axial Shaft Position

¾ The starting operation may have a decisive effect on the possible

¾ Therefore, to avoid thermal and mechanical stresses during start-up,

1. Pressure build-up in valve casing

Temperature Measuring Points

100 % measuring point at the inside of the wall

50% measuring point in the middle of the wall

Start-up and Shutdown Operation 1

Checks when Plant is at Standstill

Lubricating Oil and Control Oil System

Checks when Plant is at Standstill

Lube oil system

 Oil vapor extractor 4341 is switched off.

Start-up and Shutdown Operation 3

Checks when Plant is at Standstill

Jacking Oil System

Checks when Plant is at Standstill

Control oil system

Start-up and Shutdown Operation 5

¾ Condensate pumps are not in operation

 Set oil tank heater in Auto Control Mode

¾ Set the condensing pumps to AUTO

¾ Open the isolating valve downstream of the seal steam control

¾ Open stepwise the upstream isolating valve until the seal

¾ Warming-up the steam line upstream of the steam ejector group

¾ Check the seal water supply to the condenser pressure relief

 The evacution system starts automatically from the Automatic Start

 The Emergency stop valve opens automatically by means of the

¾ Raise the main steam up to header pressure gradually until the

¾ Adjusting or closing the drain valves.

 The main supply pressure (PT001) is built up (according to

Pressure Build-up In Valve Casing

Main stop valve casing temperature TE038 before start-up

 The Automatic Start Sequence starts the turbine controller

Start-up curves depending on casing temperature

Start-up live steam

The curves in this diagram

Rotor sticking protection

Critical speed band

With the commands HALT / CONTINUE it is possible to interrupt

The Automatic Start Sequence starts

3. closing the generator breaker

5. changes from speed to load control

Start-up live steam

The curves in this diagram

Allowable Load Changes out of

Initiation of HP inlet pressure control

The HP steam control valves are opened and/or closed in accordance

 The controller that was previously in operation switches automatically to

Checks and Measurents during operation

Checks and Measures during Operation

Soiling of the filter elements of lubricating oil filter 4500 or 4501 is

Switch to the standby filter.

Clean the soiled strainer elements immediately.

Lube oil temperature and filter diff.-press.

Coast down and turning

Oil vapor extractor 4341 is switched off.

Set oil tank heater in Auto Control Mode

The evacution system starts automatically from the Automatic Start

The Emergency stop valve opens automatically by means of the

The main supply pressure (PT001) is built up (according to

The Automatic Start Sequence starts the turbine controller

The controller that was previously in operation switches automatically to

The turbomachinery reduces its speed in accordance with the coastdown

sudden rise of vibration amplitude;

reaching or exceeding the limit values of the bearing metal

failures of auxiliary units, without further operation of the turboset

Turbomachinery is running at rated speed.

If the voltage regulator is in the "Automatic" mode, the generator is excited up

A slight load is applied automatically after successful synchronization so

If the load controller remains active, assuming steady-state operation

The oil tank heater remains at "Automatic" to provide oil at operating

Function test for hydraulic rotor turning gear "OK".

Damage as a result of the influence of overspeed,

Excessive temperatures reduce the strength values for the components

Changes in temperature also cause additional thermal stress in the

In addition, rapid changes in temperature brought about by differing