COMMISSIONING OF STEAM

TURBINE AND ASSOCIATED SYSTEM

03/27/2021 Gyanendra Sharma - NPTI Delhi 1

 DEFINITION

03/27/2021 Gyanendra Sharma - NPTI Delhi 2

 Pre-commissioning

 Pre-commissioning means preparation for

commissioning.
 Commissioning means set to work the equipment or
system with optimised parameter as envisaged
 commissioning of an equipment is pre commissioning
of a sub system or a system

 Commissioning of a sub system is pre commissioning of

larger system

03/27/2021 Gyanendra Sharma - NPTI Delhi 3

 Commissioning
 Commissioning of steam turbine means to put the steam turbine
into on load operation with optimised parameters and with all
its interlock and protection for equipment and personals.

 For a thermal power plant commissioning means to set up and

optimise all its equipments and systems to get output, efficiency,
auxiliary power consumption and emission on sustained basis
as envisaged to drive the benefit.

03/27/2021 Gyanendra Sharma - NPTI Delhi 4

 EXPECTATION FROM COMMISSIONING
OF A THERMAL POWER PLANT

 Out put
 Heat Rate ( Efficiency )
 Auxiliary power consumption
 Emission level
 Sustained generation

03/27/2021 Gyanendra Sharma - NPTI Delhi 5

 SYSTEMS , SUB SYSTEMS AND MAJOR
EQUIPMENTS OF STEAM TURBINE

• Turbine oil lubrication system

• Turbine governing system
• Turbine glands and sealing system
• Barring gear system
• Turbine protection and interlock system
• Alarm and annunciation system

03/27/2021 Gyanendra Sharma - NPTI Delhi 6

 Contd…
• Air extraction system
• Condensate system
• Feed water system
• Vacuum system
• Main steam, Hot reheat , cold reheat and HP/LP by Pass
system
• steam extraction system
• Turbine drainage system
• Other supportive system are service and instrument air,
fire fighting, air cooling and ventilation and lighting

03/27/2021 Gyanendra Sharma - NPTI Delhi 7

 THERMODYNAMICS
• IT IS A SCIENCE THAT STUDIES THE
TRANSFORMATION OF ENERGY INTO HEAT AND
POWER
• MEDIA USED FOR TRANSFORMATION IS FLUID
THEREFORE IT IS ESSETIAL TO UNDERSTAND THE
BEHAVIOUR AND PROPERTIES OF FLUID FOR
THERMODYNAMICAL STUDIES.
• STEAM IS USED FOR STEAM TURBINE CYCLE
(RANKINE CYCLE) AND AIR FOR GAS TURBINE CYCLE
(BRAYTON CYCLE)
03/27/2021 Gyanendra Sharma - NPTI Delhi 8
 BASICS
BASICSOF
OF
THERMODYNAMICS
THERMODYNAMICS
 1ST LAW OF THERMODYNAMICS
 2ND LAW OF THERMODYNAMICS
 THRMODYNAMICAL PROCESSES
 FLUID PROPERTIES AND PHASE STEAM PROPERTIES
 CARNOT AND RENKINE CYCLES
 RENKINE CYCLE EFFICIENCY
 OPTIMISATION OF RENKINE CYCLE
 SUBCRITICAL,SUPERCRITICAL AND ULTRASUPERCRITICAL
POWER PLANTS

03/27/2021 Gyanendra Sharma - NPTI Delhi 9

 THERMODYNAMICS LAWS
 
(1 LAW)
st CONTENTS
• Lorem ipsum dolor sit amet,
Conservation of Energy:
consectetuer adipiscing elit.
“The flow of energyVivamus
into and outet
of magna. Fusce
a process must sedaccounted
be fully sem for;
energy cannot be created or destroyed in a process. In a steady flow process
seda magna
the total mass entering suscipit
system must egestas.
be equal, to the total mass leaving the
system”.
• Lorem ipsum dolor sit amet,
consectetuer adipiscing elit.
Vivamus et magna. Fusce sed sem
sed magna suscipit egestas.

03/27/2021 Gyanendra Sharma - NPTI Delhi 10

 THERMODYNAMICS LAWS (2ndLAW)
CONTENTS
 

The 2nd Law, states the processes proceed in a “certain” direction. The first law
• on the direction
places no restrictionLorem ipsum of dolor
a process.sit amet,will not occur
A process
consectetuer
unless it satisfies both adipiscing
the first (1st ) and (2nd elit.
) laws of thermodynamics.

Vivamus et magna. Fusce sed sem

sed magna suscipit egestas.
• Lorem ipsum dolor sit amet,
consectetuer adipiscing elit.
Vivamus et magna. Fusce sed sem
sed magna suscipit egestas.

03/27/2021 Gyanendra Sharma - NPTI Delhi 11

 CONTENTS
 
THERMODYNAMIC PROCESSES

•
Reversible Any process that can proceed from state 1 to state 2 and then
Lorem ipsum dolor sit amet,
be made to proceed in reverse back to state 1.
ca

consectetuer adipiscing elit.

Isothermal A process where the temperature of the fluid does not change.
Vivamus et magna. Fusce sed sem
Adiabatic A process where
sedthere is no heat
magna added or removed.
suscipit egestas.
Entropy A measure of•theLorem ipsum
disorder of a systemdolor sit amet,
(dS = dQ/T)

Isentropic A reversible,consectetuer adipiscing

adiabatic process where elit.
the entropy remains
constant. Vivamus et magna. Fusce sed sem
sed
Polytropic A process that magna
follows suscipit egestas.
the relationship:
Pvn= Constant
Where: P is Pressure
v is the specific volumeGyanendra Sharma - NPTI Delhi
03/27/2021 12
n is the ratio of specific heats, (cp/cv)
 CONTENTS
 
Carnot Cycle Efficiency
• Lorem ipsum dolor sit amet,
The Carnot cycle efficiency is a maximum since all the heat added is added at t
maximum cycle temperature,consectetuer adipiscing
and all heat rejected elit.at the lowest cyc
is rejected
temperature.
Vivamus et magna. Fusce sed sem
The discussion of other sed
cycles magna suscipit
will illustrate egestas.
this premise to be valid. In steam turbi
cycles, the use of regenerative feedwater heating enhances cycle efficiency. In g
• Lorem
turbine applications, the ipsum will
use of a regenerator dolor sit amet,
also improve efficiency but is seldo
used in practice. Economics governs the mechanism used to improve cycle performanc
consectetuer adipiscing elit.
Vivamus et magna. Fusce sed sem
sed magna suscipit egestas.

03/27/2021 Gyanendra Sharma - NPTI Delhi 13

 CONTENTS
Fluid Properties & Phases

Any two properties of a fluid or gas can be used to define the state of a
• Lorem ipsum dolor sit amet,
fluid or gas. At the saturated state of a fluid only one property is
consectetuer
required to determine it’s state. adipiscing elit.
Vivamus et magna. Fusce sed sem
Pressure sed magnaInternal Energyegestas.
suscipit
Temperature• Lorem ipsum dolor sit amet,
Enthalpy

Specific Volumeconsectetuer adipiscing elit.

Entropy
Vivamus et magna. Fusce sed sem
sed magna suscipit egestas.

03/27/2021 Gyanendra Sharma - NPTI Delhi 14

03/27/2021 Gyanendra Sharma - NPTI Delhi 15
03/27/2021 Gyanendra Sharma - NPTI Delhi 16
03/27/2021 Gyanendra Sharma - NPTI Delhi 17
 Steam Properties

Any two independent properties define thermodynamic state.

Press and temp usually define energy level.

Energy level referred to as enthalpy.

Steam properties are usually presented in tables--- ASME steam tables. The tables
facilitate the ease of finding the property and increase the accuracy.

The following steam tables show properties of water for :

•The saturated phase

•The superheated and sub-cooled phases

03/27/2021 Gyanendra Sharma - NPTI Delhi 18

03/27/2021 Gyanendra Sharma - NPTI Delhi 19
 Steam Turbine Cycles

• Rankine Cycle

• Enhancing Cycle Performance

03/27/2021 Gyanendra Sharma - NPTI Delhi 20

 Basic Rankine Steam-Power Cycle

Four Basic Components

1-2 Water at low pressure has pressure increased by feed water pump
to state 2. Work (Wa) is added to the cycle.

2-3 Heat (Qa) is added in the boiler to form superheated vapor.

3-4 Vapor expands in the turbine, producing useful work (Wr).

4 1 Vapor is condensed in the condenser and flows back to the pump

(Qr).
03/27/2021 Gyanendra Sharma - NPTI Delhi 21
03/27/2021 Gyanendra Sharma - NPTI Delhi 22
03/27/2021 Gyanendra Sharma - NPTI Delhi 23
03/27/2021 Gyanendra Sharma - NPTI Delhi 24
03/27/2021 Gyanendra Sharma - NPTI Delhi 25
03/27/2021 Gyanendra Sharma - NPTI Delhi 26
03/27/2021 Gyanendra Sharma - NPTI Delhi 27
03/27/2021 Gyanendra Sharma - NPTI Delhi 28
03/27/2021 Gyanendra Sharma - NPTI Delhi 29
 Improving the Steam Turbine Cycle

 Increase Throttle Pressure

 Increase Throttle Steam Temperature

 Use Reheat

 Incorporate Feed water Heating

03/27/2021 Gyanendra Sharma - NPTI Delhi 30

03/27/2021 Gyanendra Sharma - NPTI Delhi 31
 COMMISSIONING AND PRECOMMISSIONING
ACTIVITIES
 CHEMICAK CLEANIG
 Oil flushing
 Steam blowing
 Restoration of system
 Barring gear
 Vacuum system check
 Commissioning of gland sealing system
 Commissioning of turbine drainage system
 Commissioning of HP/LP bypass system
 Steam dumping

03/27/2021 Gyanendra Sharma - NPTI Delhi 32

 COMMISSIONING AND
PRECOMMISSIONING ACTIVITIES

 Control gear setting

 Checking of turbine and generator protection
 Rolling and synchronizing
 Loading and trial run
 Performance guarantee test

03/27/2021 Gyanendra Sharma - NPTI Delhi 33

 CHEMICAL CLEANING

• THE PURPOSE OF CHEMICAL IS TO REMOVE

OIL,GREASE,PROTECTIVE COATING, RUST AND
MILL SCALE
• NEUTRALISING AFTER CHEMICAL CLEANING

03/27/2021 Gyanendra Sharma - NPTI Delhi 34

 PROCEDURE
• MAKE PREPARATION BY REMOVING EQUIPMENTE WHICH MAY
GET EFFECTED BY CHEMICALS AND PROVIDING BLANKS AND
SPACER AS PER THE SCHEME PREPARED AT SITE
• SYSTEM TIGHTNESS TEST
• INITIAL RINGE AND FLUSH
• ALKALINE FLUSH
• RINGE
• CHEMICAL CLEANING AND RINSE
• NEUTRALISATION AND PASSIVATION
• RESTORATION OF PIPING
• OIL CICULATION

03/27/2021 Gyanendra Sharma - NPTI Delhi 35

 PROCESS
• INITIAL RINSE AND FLUSH
- FLSH THE SYSTEM WITH HOT WATER AND DRAIN
• ALKALI FLUSHING
- CIRCULATE THE HOT CHEMICALS THROUGH THE
SYSTEM AND DRAIN AS PER CHEMIST ADVISE
• RINSE
- CIRCULATE HOT WATER TO REMOVE CHEMICAL

03/27/2021 Gyanendra Sharma - NPTI Delhi 36

• CHEMICAL CLEANING AND RINSING
- CIRCULATE HOT HCL OF RECOMMENDED CONCENTRATION
THROUGH THE SYSTEM AND DRAIN
- RINGE WITH WATER TILL PH OF DRAIN REACHES 7
• NEUTRALISATION AND PASSIVATION
-CIRCULATE THE NEUTRALISING CHEMICAL OF REQUIRED
CONCENTRATION AND CONTINUE AS PER CHEMISTADVISE
• DRAIN AND DRY
• RESTORE THE SYSTEM
• CIRCULATE OIL IN OIL SISTEM TO WET ALL CHEMICALLY
TREATED SURFACE

03/27/2021 Gyanendra Sharma - NPTI Delhi 37

 CHEMICALS AND EQUIPMENT REQUIRED
• HCL
• INHABITOR (RHODINE)
• TRISODIUM PHOSPHATE
• DOWELL F-33
• SODA ASH
• SODIUM NITRATE
• CLEAN OIL TANK
• DIRTY OIL TANK
• HEATERS ACID FILL PUMP
• FITERED WATER
03/27/2021 Gyanendra Sharma - NPTI Delhi 38
 Oil flushing

 Lubricating oil system

 Seal oil system
 Jacking oil system
 Governing oil/ control fluid system

03/27/2021 Gyanendra Sharma - NPTI Delhi 39

 OBJECTIVE OF OIL FLUSHING

To clean and remove any foreign material from the

oil system

03/27/2021 Gyanendra Sharma - NPTI Delhi 40

 preparation
 Completion of oil piping
 Installation of temporary piping after proper cleaning
 Cleaning of main oil tank and bearing pedestal
 Oil throttles in the bearing supply lines must be removed and dummy
provided
 Duplex filter element in oil supply line to thrust bearing should be removed
initially however it may be installed during final stage of flushing
 Flushing devices are installed in the bearing pedestal to bypass the
bearings
 MOP must be removed and flushing device installed
03/27/2021 Gyanendra Sharma - NPTI Delhi Cont..
41
 Jacking oil system is isolated and it should be flushed
separately.
 Turning gear nozzle box is removed and replaced with flushing
device.
 Suitable oil heating arrangement must be available to raise
the oil temperature to around 75 °C.
 Oil cooling arrangement should also be there to cool the oil for
giving thermal shocks.
 Arrangement for analysis of oil sample should be available.

03/27/2021 Gyanendra Sharma - NPTI Delhi 42

 Precaution
 Use of cotton waste is prohibited for cleaning the oil system. Markin cloth to
be used.

 For checking the direction of rotation of the oil pumps oil must be filled in
the oil tank
 Provision must be made for stopping the oil pumps from local as well as
from UCB
 Fire fighting arrangement must be available during flushing
 Arrangement for cleaning the spilled oil should be available before starting
the oil flushing.
 Motor current of the oil pumps specially the auxiliary oil pump should not
exceed the rated value.

03/27/2021 Gyanendra Sharma - NPTI Delhi 43

 CHARGING OIL TANK
• CHECK THAT OIL TANK IS CLEANED ,INSPECTED AND
ENSURED ABSENCE OF ANY FOREIGN MATERIAL
• RECOMMENDED OIL IS FILLED IN THE TANK
• OIL TANK BOTOM DRAIN VALVE IS CLOSED AND LOCKED
• OIL GAUGE GLASS IS COMMISSIONED
• LEVEL INDICATION IS ALSO AVAILABLE IN CONTROL ROOM
• SET THE MAIN OIL TANK LEVEL HIGH/LOW LEVEL ALARM

03/27/2021 Gyanendra Sharma - NPTI Delhi 44

 COMMISSIONING OF OIL CENTRIFUGE
• CHECK INSTALLATION COMPLETION INCLUDING ELECTRICAL
CONNECTION
• CHECK THAT FIRE FIGHTING SYSTEM IS AVAILABLE
• CHECK THAT WATER CONNECTION TO CENTRIFUGE IS AVAILABLE
• CHECK THAT ALL THE VALVES ARE INDENTIFIED AND TAGGED
• ENSURE THAT CENTIFUGE SUCTION IS CONNECTED TO NEAR THE
BOTOM OF TANK
• CHECK THAT OIL IS FILLED IN THE CHECK UP TO NORMAL LEVEL
• CHECK THAT HEATER CONNECTIONS ARE MADE IN CENTRIFUGE
• Check the direction of rotation
• Run the centrifuge and check that water and impurities are
separating out by centrifugal action

03/27/2021 Gyanendra Sharma - NPTI Delhi 45

 COMMISSIONING OF OIL PUMPS
• CHECK INSTALLATION OF OIL PUMPS WITH MOTOR ON THE TANK
• CHECK DIRECTION OF ROTATION BEFORE COUPLING
• CHECK THE NORMAL LEVEL IN THE OIL TANK
• CHECK THAT PUMP DISCHARGE VALVE IS CLOSED
• ENSURE ELECTRIC SUPPLY TO THE MOTOR
• ENSURE THAT DISCHAGE PRESSURE MEASUREMENT IS AVAILABLE LOCALLY
• CHECK THAT MOTOR CURRENT MEASUREMET IS AVAILABLE.
• START THE PUMP WITH AND CHECK THE DISCHARGE PRESSURE WITH
DISCHAR GE VALVE CLOSED. RECORD THE VALUE . THIS IS SHUT UP
PRESSURE OF THE PUMP.
• WHEN SYSTEM IS READY FOR FLUSHING, DISCHARGE VALVE CAN BE
GRADUALLY OPENED TO CHARGE THE SYSTEM

03/27/2021 Gyanendra Sharma - NPTI Delhi 46

 Process/operation

During flushing oil flow is maximized through the system .by

removing the restrictions.

Oil centrifuge is kept in continuous operation to remove the

mechanical impurities and moisture

Oil flushing is effective when oil temperature is around 75°C.

To remove weldments from inside the pipe line thermal shock
and mechanical means are some time employed .

Oil filter installed in the MOT is regularly cleaned

03/27/2021 Gyanendra Sharma - NPTI Delhi 47
03/27/2021 Gyanendra Sharma - NPTI Delhi 48
 Evaluation of result/termination of oil
flushing
 Oil flushing is considered complete when there is no
mechanical impurities and traces of moisture as catched from
oil sample.

 Duplex filter remains clean after 24 hours of flushing.

 Particle count is also some time used to declare completion

of oil flushing.

 Recommendation of turbine supplier should be a guiding

factor.

03/27/2021 Gyanendra Sharma - NPTI Delhi 49

 Evaluation of result/termination of oil
flushing
 Oil flushing is considered complete when there is no
mechanical impurities and traces of moisture as catched from
oil sample.

 Duplex filter remains clean after 24 hours of flushing.

 Particle count is also some time used to declare completion

of oil flushing.

 Recommendation of turbine supplier should be a guiding

factor.

03/27/2021 Gyanendra Sharma - NPTI Delhi 50

FLUSHING OF JACKING OIL SYSTEM
• DURING FLUSHING OF BEARING LUBRICATION
SYSTEM JACKING OIL SYSTEM IS KEPT ISOLATED.
• JACKING OIL LINES ARE KEPT OPEN IN BEARING
PEDESTAL FOR FLUSHING THE JACKING OIL LINES.
• RELIEF VALVES IN THE JACKING OIL LINE IS KEPT
FULLY OPENED.
• JACKING OIL LINES ARE FLUSHED BY
CONNECTING THE JACKING OIL SYSTEM TO
AUXILIARY OIL PUMP SUPPLY LINE
03/27/2021 Gyanendra Sharma - NPTI Delhi 51
03/27/2021 Gyanendra Sharma - NPTI Delhi 52
 RESTORATION
 After oil flushing the system is restored to original position.

 All the temporary piping and flushing devices are removed.

 All the orifices/ restrictions are restored.

 All instrumentation pressure, temperature ,flow devices etc. are normalized.

 Blanks installed during flushing are removed.

 Main oil tank is drained , oil tank cleaned and recharged with fresh oil .

 Bearing pedestals are cleaned before boxing up

 Coolers are normalized

03/27/2021 Gyanendra Sharma - NPTI Delhi 53

 COMMISSIONING OF OIL SYSTEMS
• OIL SYSTEMS CONSISTS OF:
--BEARING LUBRICATION SYSTEM
--JACKING OIL SYSTEM
-- GENERATOR HYDROGEN SEAL SYSTEM
--GOVENING OIL(RELAY OIL) SYSTEM

03/27/2021 Gyanendra Sharma - NPTI Delhi 54

 COMMISSIONING OF BEARING LUBRICATION
OIL SYSTEM
• BEFORE COMMISSIONING THE BEARING OIL SYSTEM ENSURE ,
- SYSTEM IS NORMALISED AFTER FLSHING
- - ENSURE ALL BLANKS ARE REMOVED
-- ORIFICES ARE RESTORED
-- INSTRUMENTATION INSTALLED
- OIL TANK CHARGED AFTER CLEANING
- OIL COOLERS ARE NORMALISED
- ROTORS ARE COUPLED AFTER ALIGNMENT,
ALL SENSERS INSIDE THE PEDESTAL ARE INSTALLED
AND BEARING PEDESTAL BOXED UP
-ENSURE LUB OIL TEMPERATURE AFTER COOLER IS MORE THAN 35
DEGREE CENTIGRADE

03/27/2021 Gyanendra Sharma - NPTI Delhi 55

 CONTD…
• RUN ONE OF THE AUXILIARY OIL PUMP WITH DISCHAGE VAVE CLOSED.
• CHECK UP AND RECORD SHUT UP PRESSURE
• GRADUALLY OPEN THE DISCHARGE VALVE AND CHARGE ENTIRE
LUBRICATING SYSTEM INCLUDING OIL COOLERS
• PRIME THE OIL COOLERS TO REMOVE THE ENTRAPPED AIR
• CHARGE THE COOLERS FROM WATER SIDE AND PRIME IT TO REMOVE
ENTRAPPED AIR .
• CHECK THE INSTALLATION OF LUB OIL TEMEPERATURE CONTROL VALVE
AFTER Calibration AND SETTING
BUILD UP BEARING OIL HEADER PRESSURE BY ADJUSTING BEARING OIL
PRESSURE RELIEF VALVE
• ADJUST THE THROTALS IN THE BEARING OIL SUPPLY LINE AND SET OIL
SUPPLY PRESSURE IN INDIVIDUAL BEARING

03/27/2021 Gyanendra Sharma - NPTI Delhi 56

 Interlock and protection of oil system
• Set lub.oil header pressure low alarm
• Set auto start of standby auxiliary oil if oil pressure
further falls.
• Set auto start of DC lub .oil and DC seal oil pump pump
on AC power failure
• Set high lub .oil header temperature
• Set high differential pressure across duplex strainer
• Set auto start of stand by seal oil pump if seal oil inlet
pressure falls
• Set oil/gas differential high/low alarm
03/27/2021 Gyanendra Sharma - NPTI Delhi 57
 COMMISSIONING OF VAPOUR EXTRACTION
SYSTEM
• CHECK THE VAPOUR EXTRACTION FAN INSTALLATION
AND ELCTRICAL CONNECTION TO ITS ELECTRIAL MOTOR .
• CHECK THE SUCTION AND DISCHARGE PIPING
• ENSURE THAT EXHAUST PIPING IS LED TO OUT SIDE
BUILDING AND DRAIN LINE IS PROVIDED TO DRAIN
CONDENSED OIL BACK TO TANK
• RUN THE FAN CHECK THAT SLIGHT VACUUM IS CREATED
AND MAINTAINED IN OIL THE PEDESTAL AND IN MOT
• CHECK THAT VAPOU FAN TRIP ALARM APPERS IN
CONTROL ROOM

03/27/2021 Gyanendra Sharma - NPTI Delhi 58

 COMMISSIONING OF JACKING OIL PUMP
• CHECK THAT JACKING OIL PIPING ARE RESTORED AFTER
FLUSHING: BLANK IS REMOVED FROM THE SUPPLY LINE AND
JACKING OIL PIPE IS CONNECTED TO THE BOTOM OF ALL BEARING.
• ENSURE ELECTRIC SUPPLY TO JACHING OIL PUMPS.
• RUN THE JOP AND SET JACKING OIL RELIEF VALVE TO GET JACKING
OIL PRESSURE IN ALL THE BEARING
• CHECK THE LIFT IN BEARINGS
• CHECK THE RESTART OF STAND BY PUMP IN CASE OF RUNNING
TRIPPING.
• CHECK THE AUTO START OF DC JACKING OIL PUMP IN CASE OF AC
POWER FAILURE

03/27/2021 Gyanendra Sharma - NPTI Delhi 59

 STEAM BLOWING
 MAIN STEAM
 COLD REHEAT
 HOT REHEAT
 HP BYPASS
 LP BY PASS
 AUXILIARY STEAM AND PRDS HEADER
 GLAND SEALING
 OTHER SMALL BORE LINES

03/27/2021 Gyanendra Sharma - NPTI Delhi 60

 OBJECTIVE

The objective of steam blowing is to remove scales, loose

material, iron cuttings etc, that might have been entrapped in
Super Heaters, Steam piping, re heaters during manufacture,
storage, erection at site. Failure to remove the debris may
result in damage to turbine blades. Valves etc.

03/27/2021 Gyanendra Sharma - NPTI Delhi 61

 PROPOSAL
 The steam blowing is done in four stages. Viz Stage 1(1a,1b) Stage 2
(2a & 2b), Stage 3 (3a & 3b) & stage 4. Loop pipes from ESV and IV to
turbine are to be taken care for cleanliness before erection and not to
be steam blown.

 Steam blowing is carried out by adopting puffing method for stages

1a, 2a 2b,&3a,3b. in which, boiler pressure is raised to 40 Kg/cm2
and released through a quick opening valve and steam blowing done
till the Drum pressure drops from 40 Kg/cm2 to 20 Kg/cm2

 Steam blowing for stages 1b & 4 are carried out by continuous

method. Steam blowing by continuous method shall be done at 40-
50% of normal operating pressure of the respective system for period
of 20 to 30 minutes. Blowing repeated after a time gap of 2 Hrs.
 

03/27/2021 Gyanendra Sharma - NPTI Delhi 62

 System covered in each stage are as follows:
 Stage1a: SH, MSL, ESV, temporary line from ESV to EOTV and EOTV to exhaust with
temporary piping will be concluded by observing the indents on the target plate.

 Stage1b:SH,MSL,Aux PRDS, Atomizing Steam lines & FO heating/tracing lines.

 Stage – 2a SH, MSL, ESV, temporary lines from ESV to EOTV, EOTV to CRH line, CRH lines up
to boiler end with temporary exhaust pipe. Tap off lines from CRH for deaerator, , auxiliary
PRDS, HP heater 6a & 6b, gland sealing, etc. shall be remain closed/isolated. Stage 2a end
point will be concluded by observing the indents on the target plate .

 Stage – 2b : 2a plus HP bypass inter connection, hand operated valve mounted in place of HP
bypass valve and CRH lines up to Boiler end with temporary exhaust piping. In this stage 6 to
8 blows will be given through HP bypass to ensure cleanliness of the limb. Boiler MS stop
valve will be used for stage 2b. EOTV will be kept closed. Manually Operated Isolation Valves
in HP bypass lines will be kept opened fully.

 Stage – 3a : 2a plus reheater, HRHL, IV and temporary pipe.

CRH line along with attemperator shall be welded with reheater before start of stage 3a. LP
bypass lines shall be blanked during stage 3a. Stage 3a end point will be concluded by
observing the indents on target plates .

03/27/2021 Gyanendra Sharma - NPTI Delhi 63

 Stage-3b: Stage 3a plus LP Bypass lines.

Stage-4 :

4a) APRDS to Gland seal steam

4b) CRH to turbine extraction line (HPHS &LPHS).

4c) CRH to Extraction – 4 to Deaerator

4d) CRH to Deaerator / FST

4e) CRH to HP Heaters.

4f) CRH steam line to Turbine gland sealing line

4g) CRH to APRDS

03/27/2021 Gyanendra Sharma - NPTI Delhi 64

 PREPARATION
 BLANKING DEVICES ARE INSTALLED IN TURBINE MAIN TOP AND CONTROL
VALVES AND SIMILARLY IN ESV
 TARGET PLATE IS INSTALLED BEFORE THE STEAM EXHAUST.
 TEMOPORARY PIPING ARE ERECTED FROM MAIN STOP VALVE TO OUTSIDE
BUILDING
 TEMPORARY PIPING ARE ERECTED FROM ESV TO OUT SIDE BUILDING
 ARRANGEMENTS ARE MADE TO BLOW COLD REHEAT PIPE LINE TOWARDS
BOILER END
 LOOPS ARE ERECTED TO BLOW HP BYPASS AND LP BY PASS
 TEMPORARY ARRANGEMENTS ARE MADE TO BLOW GLAND SEALING AND OTHER
SMALL BORE LINES

03/27/2021 Gyanendra Sharma - NPTI Delhi 65

 PROCESS/OPERATION
 The purpose of steam blowing of all critical piping, the steam blowing
valve will be opened at 40 kg/Sq.Cm. and closed at 20 kg/sq.cm drum
pressure.

 All the steam lines are purged as per various stages and it is a standard
practice to limit number of blows per day to( 8-10) with an interval of 1-1
½ hours.

 Blowing is carried out during the day and system is left cooling during
night

 While blowing stage 3a, suitable dummies will be put at LPBP outlet
temporary line. Required flange provisions are made in these temporary
lines for installation of dummies.

03/27/2021 Gyanendra Sharma - NPTI Delhi 66

 PRECAUTIONS
 All instruments coming in the steam flow are isolated or removed

 Temporary pipings are properly supported and insulated

 Steam exhaust is led to outside building to a safer place so as not to

cause damage to equipment or person

 Steam blowing should be done preferably during day time due to

noise pollution

 Sufficient quantity of dm water is stored

03/27/2021 Gyanendra Sharma - NPTI Delhi 67

 COMPLETION CRITERIA OF STEAM
BLOWING
 Steam blowing is considered complete when target plate remains
clean (2-3) small dots in three consecutive steam blows after
overnight cooling.

 for stages 1, 2a, & 3a Disturbance factor value at selected locations

should be greater than unity.

 More than 5 (five) pitting and shall not have any deformed edges.
Besides, there shall be no pitting in the rim zone, i.e., area other than
central zone

 Gland steam and other small bore pipings are blown for 1-2 hours and
blowing is terminated on visual operation

03/27/2021 Gyanendra Sharma - NPTI Delhi 68

 PROCEDURE FOR CALCULATIONS OF
DISTURBANCE FACTORS
Disturbance Factor = Qb2 x Vb
 
Q2 MCR x VMCR

Qb - Steam flow during blowing

QMCR - Steam flow at MCR
Vb - Sp. Volume of steam during blowing
VMCR - Sp. Volume of steam at MCR
 
Qb = Sonic Velocity During blowing x Area x 1

Vb
Where
 
Qb = St. flow in kg/sec
 
Sonic Velocity= KP Vb g =M/sec
 
Area = Sq.M
Vb = Cu.m/Kg
K = Constant = 1.3
P = Pressure at the exit pipe = Kg/Sq.m
Vb = Sp. Volume =Cu.M/Kg
g = Acceleration due to gravity = M/Sec2
 
 
03/27/2021 Gyanendra Sharma - NPTI Delhi 69
 RESTORATION
 After steam blowing the system is restored to original position.
 All the temporary pipings and temporary supports are removed.
 All the orifices/ restrictions are restored.
 All instrumentation pressure, temperature ,flow devices etc. are
normalized
 Blanking arrangements are removed and valves restored .
 Blanks installed during steam blowing for system isolation are
removed and system normalized.

03/27/2021 Gyanendra Sharma - NPTI Delhi 70

 BARRING GEAR
 The function of barring gear is to rotate the shaft at low speed to
remove the temporary bend during start up and after shut down to
prevent hogging.

 Barring gear are :

Electric motor operated

 Hydro motor operated
 Hydraulic barring gear

 All turbines have manual barring gear provision

03/27/2021 Gyanendra Sharma - NPTI Delhi 71

PREREQUISITE FOR BARRING GEAR
 Alignment of rotor train completed
 Rotors coupled
 Oil flushing completed
 Instrumentation inside the bearing pedestals completed.
 Bearing pedestals boxed up
 Generator work is completed and generator boxed up.
 Exciter is coupled.
 Insulation of generator bearing is checked before generator bearing
pedestal box up.
 Condenser floated and joint between turbine and condenser made.

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont..

72
 Lube oil and seal oil system commissioned
 Jacking oil pumps are available
 All the turbovisory , local and control room instrumentation are
installed, calibrated and available for monitoring
 Interlock and protection for oil tank, oil pump and barring are
tested and available
 Dc emergency power as well as DG set are commissioned and are
available
 Shaft lift is checked in all the journals and is ok
 Direction of rotation of the shaft is checked.

03/27/2021 Gyanendra Sharma - NPTI Delhi 73

PROTECTION AND INTERLOCK OF BARRING
• AUTO STARTING OF STANBY AOP IN CASE LOW DICHARGE
PRESSURE OR FAILURE OF RUNNING AOP.
• AUTO START OF EOP IN CASE BOTH AOP NOT RUNNING
• AUTO STOPPING OF EOP WHEN ONE OF THE AOP COMES
IN OPERATION
• AUTO START OF JOP IN CASE RUNNING JOP TRIPS
• BARRING GEAR NOT STARING IF AOP AND OR JOP NOT IN
OEPRATION
• ALARM IN CONTROL ROOM IF BARRING NOT RUNNING

03/27/2021 Gyanendra Sharma - NPTI Delhi 74

 BARRING GEAR OPERATION
 ESTABLISH THE LUBE OIL SYSTEM
 ENSURE LUBE OIL TEMPERATURE AFTER OIL COOLER IS >35 °C
 ENSURE PRESSURE IN ALL BEARING OIL SUPPLY LINE AND FLOW IS SITE
GLASSES
 ENSURE PRESSURE IN SEAL OIL SUPPLY LINE AND FLOW IN SITE
GLASSES.
 ENSURE DIFFERENTIAL PRESSURE REGULATOR IS FUNCTIONING.
 DC SEAL AND DC LUBE OIL PUMPS ARE ON AUTO START MODE AN CASE
OF AC FAILURE
 SWITCH ON THE SUPPLY TO SUPPLY TO TURBOVISORY.

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…

75
 START JACKING OIL PUMP AND CHECK THE JACKING OIL PRESSURE
AN ALL THE BEARINGS .

 TURN THE SHAFT MANUALLY WITH THE HELP OF MANUAL BARRING

GEAR AND CHECK THE FREENESS OF THE SHAFT

 MOTIVE OIL CAN BE ALLOWED TO ENTER BARRING GEAR WHEEL

CHAMBER BY OPENING THE ELECTRICALLY OPERATED MOTIVE OIL
VALVE

 JACKING OIL PUMP IS KEPT RUNNING AS LONG AS SHAFT IS TURNING.

03/27/2021 Gyanendra Sharma - NPTI Delhi 76

 CHECKS DURING BARRING GEAR
OPERATION
 ANY ABNORMAL IS NOISE IN THE TURBINE GLANDS OR BEARINGS.
 RETURN OIL FLOW FROM THE BEARINGS AND TEMPERATURE OF
OIL.
 TURBOVISORY READINGS.
 GENERATOR SEAL OIL TEMPERATURE AND LINER METAL
TEMPERATURE.
 COSTING DOWN TIME FROM FULL BARRING SPEED TO ZERO

03/27/2021 Gyanendra Sharma - NPTI Delhi 77

 VACUUM SYSTEM

 Presence of air in the condenser causes poor heat transfer,

resulting in poor vacuum and subsequently loss of efficiency.
 All leak tightness test is conducted by filling the vacuum
space with dm water and attending the leaky points
 After leak tightness actual vacuum is created by charging the
gland sealing system and running the vacuum
pumps/ejectors.

03/27/2021 Gyanendra Sharma - NPTI Delhi

Cont…78
 LEAK TIGHTNESS TEST

PREPARATIONS

 Ensure completeness of turbine system pipings i.e turbine integral

piping, heaters, extraction pipings, flash tanks, HP/LP bypass pipings
all drains, suction to condensate pumps etc.

 All the atmospheric drain valves are kept closed

 Condenser springs are kept locked during the test.

 Steam space of all heaters gland steam condenser, drain cooler are
connected to condenser.

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…

79
 All vacuum gauges are kept isolated

 Manhole cover on cooling water side are kept open

 Gauge glasses for condenser, heaters, gland steam condenser,

drain cooler are installed.

 CEP suction and deaeration valves are kept open

 Condenser air evacuation line are kept open

 Float valves for condenser, heaters, drain cooler, GSC, are

mounted.
03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…
80
 vacuum breaker valve is kept open.

 all drain line valves connecting to vacuum system are kept

open.

 Gland sealing steam inlet valve is kept closed.

 Isolation valves of GSC, vapour exhauster are kept closed.

 IP cylinder bottom insulation is not done.

 Interlock system of regenerative system is completed.

03/27/2021 Gyanendra Sharma - NPTI Delhi 81
 AIR EVACUATION SCHEME

03/27/2021 Gyanendra Sharma - NPTI Delhi 82

 LEAK TIGHTNESS

 pH and conductivity of dm water is checked before

water admission
 if leak detected during filling it should be attended
before further filling
 water level in the system to be monitored from gauge
glass of condenser, heaters, GSC, drain cooler and
additionally from temporary manometer connected to
vacuum system
 The system may be filled one meter above the condenser
tube nest.
 Functioning of heater level switches can be checked
during filling process
03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…
83
 System is completely checked for any leakages and after
attending to leakages water is kept for 24 hours and watch the
drop in the level. if level drops and there are no leaks passing of
atmospheric drains are to be checked and eliminated.

 After test is completed the water to be drained upto condenser

normal level and system normalized.

 Condenser springs to be unlocked

03/27/2021 Gyanendra Sharma - NPTI Delhi 84

 GLAND SEALING SYSTEM
COMMISSIONING

 Barring gear in operation.

 Condensate system in operation.
 Condenser cooling water system in operation.
 Gland steam condenser is charged from condensate side.
 Gland steam exhauster fan is in operation.
 Gland steam seal regulator is commissioned.
 Gland steam excess dump to condenser is commissioned.
 Ensure that gland steam pressure is just above the atmosphere and
steam pressure in last seal chamber is between 0 to -5 mmwc.
03/27/2021 Gyanendra Sharma - NPTI Delhi 85
 VACUUM BUILDING

FOR ACTUAL VACUUM RAISING FOLLOWING SYSTEM MUST IN OPERATION

 BARRING GEAR
 CONDENSER COOLING WATER
 CONDENSATE CONTROL AND INSTRUMENTATION
 VACUUM BRAKER VALVE IS COMMISSIONED AND KEPT FULLY CLOSED
 CONDENSER HOT WELL LEVEL IS NORMAL AND CONDENSER IS PRIMED FROM
COOLING WATER SIDE
 DRAIN VALVES ON COLD REHEAT AND HOT REHEAT PIPES ARE KEPT CLOSED
 HP HEATERS ARE KEPT ISOLATED VACUUM SIDE
 CONDENSATE CIRCUIT IS CHARGED THROUGH GSC,DRAIN COOLER,LP HEATERS
TO DEAERATOR
 03/27/2021
CONDENSATE Gyanendra
PUMP IS KEPT ON Sharma - NPTI Delhi
RECIRCULATION Cont…
86
 Seal water is charged to vacuum pump
 Initially vacuum pump is started on hogging mode
 When vacuum is reached around 0.7kg/cm2 gland sealing
system is put in operation after ensuring removal of
condensate and seal steam temperature around 200 °C
 Second vacuum can also be started to achieve full vacuum
 Now vacuum pump operate on holding mode

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…

87
 Vacuum achieve is recorded and one pump can be stopped
and vacuum should hold. for a leak tight system

 One pump is adequate to hold design vacuum at full load.

 Measurement of air should be done using the flow meter.

 In case vacuum is not holding air ingress in the system must

be located and arrested
03/27/2021 Gyanendra Sharma - NPTI Delhi 88
 POSSIBLE AIR LEAK LOCATION

 Turbine explosion diaphragms

 Gland body joint
 Gland sealing
 Horizontal joint
 Condenser welding joint
 IP heater flange on condenser
 Condenser manhole
 Water box joint
03/27/2021 Gyanendra Sharma - NPTI Delhi 89
Cont…
 Vacuum system valves
 Heater joints
 Valve gland packing
 Cross around pipe joints
 Drain and vent from gland steam cooler to condenser
 Vacuum system drain to atmosphere

03/27/2021 Gyanendra Sharma - NPTI Delhi 90

 COMMISSIONING OF MOTOR OPERATED
VALVES
• CHECK INSTALLATION OF VALVE ACTUATORS AS PER
SCHEMATIC DRAWINGS AND LAY OUT.
• ENSURE PROPER SUPPORTING OF ACTUATOR
• CHECK ELECTRICAL SUPPLY
• CHECK FULL OPENING AND CLOSING OF VALVE
MANUALLY AND BY ELECTRICAL POWER
• CHECK INSTALLATION OF LIMIT SWITCHES
• CHECK THE OPEN CLOSE INDICATION IN CONTROL ROOM
• CHECK CUT OFF OF BY TORQE SWITCH AFTER VALVE IS
FULLY OPENED

03/27/2021 Gyanendra Sharma - NPTI Delhi 91

 CONTROL GEAR SETTING

After restoring the control fluid system, Control gear components

are set as per manufacturer’s instruction.

Following system are commissioned

 Electro hydraulic converter.
 Hydraulic starter –up and load limiting device.
 Hydraulic speed governor.
 Electro hydraulic amplifier and follow up piston.
 Commissioning of HP-IP stop valves.
 Commissioning of HP-IP control valves.
 Commissioning of cold reheat NRV.
 Commissioning of quick closing NRV’s in extraction lines.

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…

92
 commissioning of HP/LP by pass valves
 commissioning of HP and LP by pass spray system
 commissioning of exhaust hood spray
 commissioning of turbine protection and interlock

03/27/2021 Gyanendra Sharma - NPTI Delhi Cont…

93
 TURBINE PROTECTION AND
INTERLOCK
Remote trip from UCB
Manual trip from local
Low vacuum trip
Low vacuum trip -hydraulic
Low lube oil pressure
Axial shift
Over speed striker 1 and 2
Fire protection channel -1
Fire protection channel-2
MOT low level
Low lub oil pressure
Boiler fire out
Main steam temperature low
Generator protection
03/27/2021 Gyanendra Sharma - NPTI Delhi 94
 STEAM DUMPING
 Steam dumping is carried out before steam admission to
turbine

 During steam dumping operation, quality of steam is

improved by turbine supplier

 HP/LP by pass system is used for steam dumping

 Turbine is kept on barring gear

 Full vacuum is raised

03/27/2021 Gyanendra Sharma - NPTI Delhi 95

 Max flow is stabilized through HP/LP by pass with rated
steam parameter.

 Steam dumping is carried out till quality of condensate at

CEP discharge is same as inlet to hot well make up.

 After steam dumping hot well, deaerator & Boiler drum are
drained, clean and inspected before recharging.

03/27/2021 Gyanendra Sharma - NPTI Delhi 96

 TURBINE STARTUP

03/27/2021 Gyanendra Sharma - NPTI Delhi 97

 PREPARATION
• LINE CLEAR RETURNED
• POWER SUPPLY READY
• INSTRUMENT, RECORDERS, DAS, AIR CONDITIONER OF UCB ON
• DM PLANT GENERATION ON
• COMPRESSORS IN SERVIVE
• H2 ,CO2 CYLINDERS AVAILABLE
• COOLING TOWERS IN OPERATION
• COOLING WATER SYSTEM IN OPERATION
• ELECTRICAL ACTUATORS POERATION CHECKED
• LEVEL IN HOT WELL, DEAERATOR,DRUM NORMAL

03/27/2021 Gyanendra Sharma - NPTI Delhi 98

 CONTD..
• MOT LEVEL OK.INDICATION AVAILABLE IN
CONTROL ROOM
• CONDENSATE SYSTEM ESTABLISHED
• FEED SYSTEM ESTABLISHED
• PROTECTION OF BFP ,CEP CHECKED
• IR VALUES OF HT MOTOR CHECKED
• DG SET READY FOR OPERATION

03/27/2021 Gyanendra Sharma - NPTI Delhi 99

 OIL SYSTEM
• CENTRIFUGE IN OPERATION
• ANALYSIS OF OIL SAMPLE
• VAPOUR EXRACTION FAN ON
• AUXILIARY OIL PUMP IN SERVICE
• OIL TEMPERATURE CONTROL ON AUTO
• OIL COOLER WATER SIDE CHARGED
• SEAL; OIL SYSTEM PUT IN OPERATION
• OIL TEMERATURE REACHED 45 DEGREE C
• PROTECTION INTERLOCK CHECKED
• GATE GEARING VALVE OPENED
• JOP ON
• TURBINE ON BARRING GEAR

03/27/2021 Gyanendra Sharma - NPTI Delhi 100

 VACUUM SYSTEM
• CHECK ON SPRING , LOCKS RELEASED
• CICULATING WATER SYSTEM IN OPERATION
• TURBINE ON BARRING GEAR
• VACUUM BRAKER CLOSED
• AUXILIARY PRDS CHARGED
• WARM UP TO GLAND STEAM CONTROLLER
- OPEN DRAIN VALVE
- OPEN GLAND STEAM HEADER DRAIN VALVE
- CHARGE GSC STEAM SIDE
START GLAND STEAM EXHAUSTER FAN
• VACUUM PUMP STARTED
• GLAND STEAM CONTROLLAR ON AUTO
• VACUUM LESS THAN 0.12 KG/CM2 LOAD GRATER THAN 5%
• STOP ONE OF THE VACUUM PUMP

03/27/2021 Gyanendra Sharma - NPTI Delhi 101

 DRAINS OPERATION
• MAIN STEAM LINE CHARGED
• MS AND HRH STRAINER DRAINS OPEN
• CRH DRAIN OPEN
• DRAINS BEFORE CRH NRV OPEN
• HP BY PASS DRAIN OPEN
• ESV SEAT DRAINS, IV SEAT DRAINS OPEN
• DRAINS BEFORE IV VALVE OPEN

03/27/2021 Gyanendra Sharma - NPTI Delhi 102

 CONTD…
• DRAIN BEFORELP BY PASS STOP VALVE OPEN
- BY PASS OPERATION STARTS
- OPEN HP LP BY PASS
- AUTOMATIC CONTROLLAR INTER FACE
- LP BY PASS CONTROLLER ON AUTO
- STEAM DUMPING OPERATION
- STEAM PURITY OK

03/27/2021 Gyanendra Sharma - NPTI Delhi 103

 CONTD…
• DRAINS AFTER IV VALVE OPEN
• DRAIN BEFORE AND AFTER HPCV OPEN
• HP CASING DRAIN OPEN
• DRAIN BEFORE NRV’S OPEN
• ROLLING STARTS
• SYNCHORONISE AFTER TURBINE AND
GENERATOR TESTING
• LOADING
03/27/2021 Gyanendra Sharma - NPTI Delhi 104
 TROUBLE SHOOTING

03/27/2021 Gyanendra Sharma - NPTI Delhi 105

•

BEARINGS

03/27/2021 Gyanendra Sharma - NPTI Delhi 106

 Rapid rise in one or more bearing
Temperature
• Causes
Instrumentation
tilting of bearing
restriction in oil flow
dirt in the bearing
excessive thirst
misalignment

03/27/2021 Gyanendra Sharma - NPTI Delhi 107

 Rapid rise in one or more bearing
Temperature
• Remedy
check instrumentation
check oil pressure up stream of oil supply
check oil filter
check quality of oil ( check oil sample )
check restriction diaphragm
check bearing for any damage
check cause of excessive thirust
check alignment
03/27/2021 Gyanendra Sharma - NPTI Delhi 108
 Rapid rise of all the bearings metal
temperatures
• Causes
control system malfunctioning
bearing temperature controller problem
cooling water temperature high
cooling water supply inadequate
oil cooler fouled

03/27/2021 Gyanendra Sharma - NPTI Delhi 109

 Rapid rise of all the bearings metal
temperatures
• Remedy
- check oil temperature control system
- in case malfunctioning of controller assume manual
control till controller is rectified.
- change over lub. oil cooler
- check cooling water supply
- check alignment and rectify
- in case of cooling water supply failure and metal
temperature reaching limiting values stop the machine.

03/27/2021 Gyanendra Sharma - NPTI Delhi 110

 OIL SYSTEM PROBLEMS
• OIL CHARACTERISTICS ----- POOR
• -- High water content in oil ---water ingress
• --Foaming in oil tank --- high oil temp.
excessive release of air.
• --inferior air release property of oil
too much anti foaming additives
oil contamination
high moisture content
03/27/2021 Gyanendra Sharma - NPTI Delhi 111
 OIL TANK LEVEL LOW
• DURING TURNING GEAR OPERATION ON
RATED SPEED OPERATION
OIL LEVEL GRADUALLY DROPS OVER A PERIOD
OF TIME
-- LEAKAGE IN OIL SYSTEM
-- PASSING OF OIL TANK DRAIN VALVE
-- CHOCKED STRAINER OIL BUILDS UP IN
RETURN CHAMBER
03/27/2021 Gyanendra Sharma - NPTI Delhi 112
 OIL PRESSURE LOW
• OIL PRESSURE DROPS DURING SHUT DOWN
AUXILIARY OIL PUMP IS SUSPECTED
OIL PRESSURE LOW AFTER REACHING FULL SPEED
AND STOPPING AOP
--- MOP IS SUSPECT
----CHECK VALVE DOWN STREAM OF AOP NOT
CLOSED/PASSING
----BARRING GEAR VALVE NOT CLOSED
CONT.
03/27/2021 Gyanendra Sharma - NPTI Delhi 113
 CONT.
• OIL PRESSURE DROPS DURING RATED SPEED OPERATION
-- FAULTY MOP
-- HIGH AIR CONTENT
-- IF OIL PRESSURE FALLS DURING COOLER CHANGE
OVER– COOLER MAY NOT BE FILLED/VENTED
--IF OIL PRESSURE FALLS DURING FILTER CHANGE OVER
FILLER MAY NOT BE FILLED /VENTED
-- DIFF PRESSURE ACROSS FILTER HIGH –
FAULTY/DAMAGE FILTER

03/27/2021 Gyanendra Sharma - NPTI Delhi 114

 MOP DOES NOT TAKE OVER
• MOT LEVEL LOW
• HIGH AIR CONTENT
• FAULTY MOP

03/27/2021 Gyanendra Sharma - NPTI Delhi 115

 OIL TEMPERATURE HIGH
• OIL TEMPERATURE CONTROL VALVE NOT SET
PROPERLY
• NO COOLING WATER FLOW
• COOLER NOT FILLED/ VENTED
• COOLING WATER INLET TEMPERATURE HIGH
• COOLER FAULED ON WATER SIDE

03/27/2021 Gyanendra Sharma - NPTI Delhi 116

 OIL TEMPERATURE LOW
• EXCESSIVE COOLING WATER
• IF HAPPENS DURING SHUT DOWN
OIL TEMPERATURE VALVE NOT CLOSED

03/27/2021 Gyanendra Sharma - NPTI Delhi 117

 TURNING GEAR DOES NOT START
AUTOMATICALLY
• CHECK SUPPLY/CONTROL OF TURNING GERA VALVE OPEN VALVE MANUALLY
• JOP DOES NOT START CHECK SUPPLY/ CONTROL OF JOP START PUMP
MANUALLY
• JOP PRESSURE LOW IN ALL THE BEARINGS
• CHECK PUMP SUCTION VALVE AND RELIEF VALVE SETTING
• JOP PRESSURE LOW IN ONE OR MORE BEARING , CHECK RELIEF VALVE
SETTINGS
• BARRING GEAR VALVE OPEN AND JOP BUILD UP PRESSURE BUT SHAFT DOES
NOT TURN
RADIAL CLEARANCE LOW
AXIAL CLEARANCE LOW
BEARING DAMAGE
SHAFT JOURNAL DOES NOT LIFT IN THE BEARING

03/27/2021 Gyanendra Sharma - NPTI Delhi 118

 EXPANSIONS

• DIFFERENTIAL EXPANSION - HIGH(POSITIVE)

• DIFFERENTIAL EXPANSION -HIGH (NEGATIVE )
TAKE MEASURES TO REDUCE THE DIFFERENTIAL
EXPANSION . UNIT MAY HAVE TO BE TRIPPED IN
CASE DIFFERENTIAL EXPANSION APPROACHES
LIMITING VALUES.

03/27/2021 Gyanendra Sharma - NPTI Delhi 119

 HP DIFFERENTIAL EXPANSION HIGH
(POSITIVE)
• CHECK MAIN STEAM TEMPERATURE . REDUCE
IT IF REQUIRED
• WAIT FOR TEMPERATURE EQUALISATION
BETWEEN CASING AND SHAFT FOR DIFF.
EXPASION TO RECEDE BEFORE FURTHER
OPERATION.
• CHECK SLIDING OF BEARING PEDESTAL
• CHECK TILTING OF BEARING PEDESTAL.

03/27/2021 Gyanendra Sharma - NPTI Delhi 120

 HP DIFFERENTIAL EXPANSION HIGH
(NEGATIVE)
• CHECK MAIN STEAM TEMPERATURE ,
INCREASEIT IF REQUIRED .
• STABILISE EXPANSION BEFORE PROCEEDING
FURTHER.
• IMPROVE PEDESTAL SLIDING DURING
INSPECTION.

03/27/2021 Gyanendra Sharma - NPTI Delhi 121

 IP DIFFERENTIAL EXPANSION HIGH
(POSITIVE)
• CHECK REHEAT TEMPERATURE, REDUCE IT IF
REQUIRED
• WAIT FOR TEMPERATURE EQUILISATION
BEFORE PROCEEDING FURTHER
• CHECK SLIDING OF BEARING PEDESTALS
• INCREASE SPEED/LOAD WITHIN PERMISSIBLE
LIMIT .BETTER STEAM FLOW WILL REDUCE IP
DIFFERENTIAL EXPANSION.

03/27/2021 Gyanendra Sharma - NPTI Delhi 122

 IP DIFFERENTIAL EXPANSION HIGH
(NEGATIVE)
• THIS OCCURES UNDER ABNORMAL OPERATING
CONDITION DURING START UP AFTER A HOT TRIP
OUT.
• DROP IN REHEAT TEMPERATURE.
• USE ROTOR HEATING TO BRING DIFFERENTIAL
EXPANSION WITHIN DESIRED VALUE BEFORE STEAM
ADMISSION.
• THIS CAN ALSO BE CAUSED BY RESTRICTION IN
PEDESTAL SLIDING. IMPROVE IT DURING INSPECTION

03/27/2021 Gyanendra Sharma - NPTI Delhi 123

 CASING TOP/BOTTOM TEMPERATURE HIGH
ALARM
•DURING START UP OR LOW LOAD OPERATION AFTER LOAD REJECTION ,THIS MAY
OCCRE DUE TO UNEVEN DISSIPATION OF HEAT CAUSED BY INADEQUATE STEAM
FLOW.
•ON LOAD REDUCTION, THIS MAY OCCURE DUE TO BACK FLOW OF WATER FROM
EXTRACTION LINE
•DURING ON LOAD OPERATION THIS MAY OCCURE DUE TO LEAKY SEALING ELEMENT
INSIDE THE CASING.
•DURING COLD START UP THIS MAY OCCURE DUE TO INADEQUATE DRAINING.
•DURING TURNING GEAR OPERATION OR STAND STILL CONDITION THIS MAY OCCURE
DUE TO AIR CURRENT WITHIN THE FOUNDATION OR INSIDE TURBINE .
•DURING TURNING GEAR OPERATION OR STAND STILL CONDITION THIS MAY ALSO
OCCURE DUE TO IMPERFECT INSULATION.

..

03/27/2021 Gyanendra Sharma - NPTI Delhi 124

 GLAND SEALING SYSTEM PROBLEMS
• STEAM ESCAPING FROM GLANDS
• SEAL STEAM PRESSURE TOO HIGH DUE TO SEAL STEAM PRESSURE
REGULATOR NOT PROPERLY SET OR MAL FUNCTIONING.
• GLAND STEAM EXHAUSTER NOT FUNCTIONING.
• EXCESSIVE GLAND CLEARANCES
• SEAL STEAM SUPPLY VALVE OPEN AND ALSO SEAL STEAM LEAK
OFF VALVE 100% OPEN. ( ELECTRICAL FAULT IN GLAND STEAM
SUPPLY VALVE.
• SEAL STEAM SUPPLY VALVE AND ALSO SEAL STEAM LEAK OFF
VALVE CLOSED. (ELECTRICAL FAULT IN SEAL STEAM LEAK OFF
VALVE)

03/27/2021 Gyanendra Sharma - NPTI Delhi 125

 GLAND STEAM PRESSURE LOW
MAY RESULT IN DROPING OF VACUUM.
LOW PRESSURE MAY BE DUE TO :
• LOW SET POINT
• SEAL STEAM SUPPLY /LEAK-OFF VALVES
CLOSED ---MECHANICAL/ELECTRICAL FAULT
• SEAL STEAM SUPPLY/ LEAK- OFF VALVES
OPENED ---MECHANICAL/ ELECTRICAL FAULT.

03/27/2021 Gyanendra Sharma - NPTI Delhi 126

 CONDENSING SYSTEM
• LOW CONDENSER VACUUM.
VACUUM FALLS RAPIDLY INSPITE OF COOLING WATER
SYSTEM,AIR EXTRACTION SYSTEM,GLAND SEAL SYSTEM
AND CONDENSATE TRANSFER PUMP WORKING
SATISFACTORILY.THIS MAY HAPPEN DUE TO:
-- EXPLOSION DIAPHRAGM DAMAGED.
--CONDENSATE DRAIN TO ATMOSPHERE OPENED
--LEVEL GAUGE GLASS DAMAGED .
--SUCTION VALVE TO NON-OPERATIONAL PUMP OPENED
--OTHER SEVERE AIR LEAKS IN VACUUM SYSTEM.
03/27/2021 Gyanendra Sharma - NPTI Delhi 127
 CONDENSING SYSTEM
• CONDENSER VACUUM FALLS GRADUALLY
POSSIBLE CAUSES:
--COOLING WATER FLOW TOO LOW
DIFF. BETWEENCOOLING WATER INLET AND
OUTLET TEMPERATURE INCREASED (INADEQUATE COOLING WATER
SUPPLY,WAT DIFFERENCE BETWEEN CONDENSATE AND COOLING WATER
OUT LET TEMPERATURE HAS INCREASED AND DIFF. BETWWEN EXHAUST
STEAM AND COOLING WATER OUTLET TEMPERATURE HAS INCREASEDER
SYSTEM NOT PROPERLY PRIMED )
--GLAND SEAL STEAM PRESSURE TOO LOW
DIFFERENCE BETWEEN CONDENSATE AND COOLING WATER OUT LET
TEMPERATURE HAS INCREASED AND DIFF. BETWWEN EXHAUST STEAM
AND COOLING WATER OUTLET TEMPERATURE HAS INCREASED.

03/27/2021 Gyanendra Sharma - NPTI Delhi 128

--VACUUM PUMP NOT FUNCTIONING
DIFFERENCE BETWEEN CONDENSATE AND COOLING WATER OUT
LET TEMPERATURE HAS INCREASED AND DIFF. BETWWEN EXHAUST
STEAM AND COOLING WATER OUTLET TEMPERATURE HAS
INCREASED.
RECTIFY VACUUM PUMP.
--CONDENSER LEVEL HIGH ALARM HAS APPEARED
DIFFERENCE BETWEEN CONDENSATE AND COOLING WATER OUT
LET TEMPERATURE IS NORMAL BUT DIFF. BETWWEN EXHAUST
STEAM AND COOLING WATER OUTLET TEMPERATURE HAS
INCREASED.
RECTIFY CONDENSATE TRANSFER PUMP

03/27/2021 Gyanendra Sharma - NPTI Delhi 129

 HIGH BEARING/SHAFT VIBRATION
• SOME POSSIBLE CAUSES
• BEARING OIL TEMPERATURE
• BEARING OIL PRESSURE
• SEAL RUB
• HIGH TOP/BOTTOM DIFFERENTIAL
• HIGH DIFFERENTIAL EXPANSION (POSITIVE/NEGATIVE)
• AXIAL SHIFT
• BEARING ASSEMBLY.

03/27/2021 Gyanendra Sharma - NPTI Delhi 130

 HIGH BEARING/SHAFT VIBRATION
• RESTRICTION IN BEARING PEDESTAL SLIDING
• RESTRICTION IN CASING EXPANSION.
• GLAND SEAL TEMPERATURE LOW
• INADEQUATE DRAING OF TURBINE
CASING,TURBINE LOOP LINES
• INADEQUATE DRAINING OF MAIN STEAM, HOT
REHEAT AND COLD REHEAT AND EXTRACTION
LINE DRAINS.
• TEMPERATURE MISMATCH.
03/27/2021 Gyanendra Sharma - NPTI Delhi 131
 HIGH BEARING/SHAFT VIBRATION
• HIGH TURBINE EXHAUST HOOD TEMPERATURE POOR
VACUUM
• HANGERS AND SUPPORT FOR CRITICAL PIPES,EXTRACTION
PIPES AND LOOP PIPES NOT PROPERLY SET
• PROLONGED LOW LOAD OPERATION
• MISALIGNMENT
• OUT OF BALANCE
• BEARING PEDESTAL SECONDARY GROUTING
• TURBINE FOUNDATION

03/27/2021 Gyanendra Sharma - NPTI Delhi 132

• THANK YOU

03/27/2021 Gyanendra Sharma - NPTI Delhi 133