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STEAM TURBINE
0PERATION & MAINTENANCE
INSTRUCTIONS

NO.STE-
NO.STE-TF-
TF-277-
77-MS

MAITHAN-MPL, 2X525 MW
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BHARAT HEAVY ELECTRICALS LIMITED
RANIPUR, HARIDWAR – 249403 (INDIA)
 Steam Turbine Preface
General

This manual contains information on the turbine. Bharat Heavy Electricals Limited
operation and maintenance of steam turbine. can not be responsible for any malfunction
The information has been prepared with the occurring as a result of operation beyond
assumption that the O&M personnel have rated limits and such operation, if
basic knowledge of power plant engineering undertaken by utilities, must be at their own
and operation. risk.

It is an essential prerequisite for satisfactory The part numbers of components, indicated

operation and maintenance of the steam in the Description section of the manual
turbine that the operating and maintenance should not be used for ordering spare parts.
personnel are fully familiar with the design of Please refer the chapter on Ordering of
the steam turbine plant and receive thorough spares for that purpose.
training in operating and maintaining the Effort has been made to include adequate
unit. information in this manual. For any further
Extensive operation beyond rated design information or clarification please contact:
values will eventually result in increased Field Engineering Services, Steam Turbine
maintenance expenses or a corresponding Engineering, BHEL, Haridwar– 249403,
reduction in the useful life of the steam Uttarakhand, India.

MAITHAN-MPL, 2X525MW: Document No. STE-TF-277-MS

KJ SM VS SRP PCK
Prepared Approved
Checked
by by
by

Issued by STE (FES), BHEL, Haridwar Issue

Date

BHEL Haridwar 5.0-0001-77

 Steam Turbine Contents
Description

Subject Document No Subject Document No

GENERAL ■ Journal bearing IP rear 5.1-0345-01/2
■ Preface 5.0-0001-77/1 ■ Casing supports and guides 5.1-0350-01/2
■ Contents 5.0-0002-77/3 LP Turbine
DESCRIPTION ■ Casing 5.1-0410-00/4
Brief Description ■ Atmospheric relief 5.1-0420-00/1
■ Sectional arrangement 5.1-0001-04/1 diaphragm
■ General description 5.1-0002-04/2 ■ Blading, drum stages 5.1-0430-01/1
■ Fixed points 5.1-0003-01/2 ■ Blading, LP stages 5.1-0440-01/2
Technical Data ■ Shaft seals 5.1-0450-01/1
■ Construction, speed & 5.1-0100-77/3 ■ Rear bearing pedestal 5.1-0460-02/1
Steam pressure ■ Journal bearing 5.1-0470-00/2
■ Steam and casing 5.1-0101-77/2 Turning Gear
temperatures ■ Hydraulic turning gear 5.1-0510-01/1
■ Bearing metal temperatures, 5.1-0102-77/1 ■ Manual turning gear 5.1-0520-01/1
vibration, weights ■ Hydraulic lifting device 5.1-0530-77/2
Control System
■ Oil supply, oil pumps 5.1-0103-77/2
■ Control fluid system and 5.1-0104-77/4 ■ General description 5.1-0600-01/2
control fluid pumps ■ Start-up procedure 5.1-0610-01/2
■ Limit curves: HP stop & 5.1-0110-01/1 ■ Speed control 5.1-0620-01/2
control valve casing ■ Electrical speed measuring 5.1-0621-02/1
■ Limit curves: HP casing 5.1-0111-01/2 ■ Protective devices 5.1-0630-01/2
■ Limit curves: HP shaft 5.1-0112-01/2 ■ Over speed trip test 5.1-0631-01/1
■ Limit curves: IP shaft 5.1-0113-01/1 ■ Testing of stop valves 5.1-0632-02/1
■ Steam purity values 5.1-0120-01/1 ■ LP bypass System (General) 5.1-0640-00/1
■ Oil specification standard 5.1-0130-04/2 ■ Extraction check valve 5.1-0650-01/1
■ Fire resistant fluid (FRF) for 5.1-0140-04/2 ■ Swing check valve (CRH) 5.1-0651-01/1
turbine control system ■ Testing of check valves in 5.1-0652-02/1
HP Turbine cold reheat line
■ Valve arrangement 5.1-0205-00/1 ■ Automatic turbine tester 5.1-0660-00/1
■ Casing 5.1-0210-01/3 general
■ Blading 5.1-0220-02/1 ■ Automatic turbine tester 5.1-0661-00/7
■ Shaft seals and balance 5.1-0230-01/2 for protective devices
piston ■ Automatic turbine tester 5.1-0662-01/4
■ Front bearing pedestal 5.1-0240-01/2 stop and control valves
■ Rear bearing pedestal 5.1-0250-02/2 ■ HP actuator 5.1-0665-00/1
■ Combined journal and thrust 5.1-0260-01/2 ■ Electro hydraulic seal steam 5.1-0670-01/4
bearing pressure control
■ Journal bearing, HP front 5.1-0270-01/2 ■ Governing scheme 5.1-0680-02/1
■ Casing supports and guides 5.1-0280-01/2 ■ Control system diagram 5.1-0681-02/5
IP Turbine legend
■ Lubrication chart 5.1-0690-02/3
■ Casing 5.1-0310-01/3
Control System Parts
■ Blading 5.1-0320-02/1
■ Shaft seals 5.1-0330-01/2 ■ Hydraulic speed governor with 5.1-0710-00/2
■ Rear bearing pedestal 5.1-0340-02/1 starting and load limiting device
■ Adjusting gear 5.1-0720-00/1

BHEL Haridwar 5.0-0002-77/1

 Subject Document No Subject Document No
■ Electro hydraulic converter 5.1-0730-03/3 ■ Solenoid valve for temperature 5.1-0950-00/1
for turbine control system controlled interlock
■ Hydraulic amplifier for 5.1-0740-02/3 ■ Vacuum breaker 5.1-0960-02/2
turbine control system ■ Changeover valve for 5.1-0980-00/1
■ Electrical speed pick-up 5.1-0760-01/1 testing device
■ Pressure converter 5.1-0761-00/1 Oil Supply
Steam valves and ■ Oil supply system 5.1-1000-77/4
accessories ■ Oil vapor extraction system 5.1-1001-77/2
■ Combined main stop and 5.1-0810-01/2 ■ Oil discharge & vent system 5.1-1002-77/2
control valve ■ Oil purification system 5.1-1003-77/1
■ Servomotor for main & 5.1-0811-00/1 ■ Main oil tank 5.1-1010-01/2
reheat stop valves ■ Main oil pump with hydraulic 5.1-1020-01/2
■ Hydraulic servomotor for 5.1-0812-00/2 speed transmitter
main & reheat control valves ■ Auxiliary oil pump 5.1-1030-01/1
■ Test valve for emergency 5.1-0813-00/1 ■ DC emergency oil pump 5.1-1040-01/1
stop valve ■ Jacking oil pump 5.1-1050-00/2
■ Combined reheat stop & 5.1-0814-00/2 ■ Oil throttle 5.1-1080-00/1
control valves ■ Oil throttle 5.1-1081-00/1
■ Hangers for reheat stop & 5.1-0815-01/1 ■ Three way control valve for 5.1-1090-01/1
control valves Lubricating oil temp. control
■ Steam strainer 5.1-0816-00/1 Control Fluid Supply
■ Changeover valve for 5.1-0840-00/1 ■ HP control fluid pump with 5.1-1110-00/1
bleeder check valve LP extraction
■ Auxiliary valve of extraction 5.1-0841-00/2 ■ Plate-type filter 5.1-1120-00/1
check valve ■ Duplex filter for pilot control 5.1-1130-00/3
■ Rotary vane actuator for 5.1-0853-01/1 of control valves
reheat swing check valve ■ Regenerating plant 5.1-1140-00/3
■ Pilot valve for rotary vane 5.1-0854-00/1 Other Systems
actuator of swing check valve ■ Drain system (MAL) 5.1-1210-77/2
■ Auxiliary pilot valve for 5.1-0855-00/1 ■ System diagram index 5.1-1220-77/3
rotary vane actuator of ■ Component diagram index 5.1-1230-77/11
reheat swing check valve ■ Shaft seal system 5.1-1240-77/5
■ Gland steam control valve 5.1-0860-02/1 Operation
■ Leakage steam control valve 5.1-0870-02/1 ■ Introduction 5.2-0001-01/1
Protective Devices ■ Specification of steam, oil & 5.2-0002-00/1
■ Main trip valve 5.1-0910-00/2 control fluid
■ Emergency trip valve for 5.1-0911-00/1 ■ Testing of turbine 5.2-0020-00/1
manual trip out Components - General
■ Solenoid valve for remote 5.1-0912-00/1 ■ Turbine systems testing
trip out testing intervals
■ Over speed trip 5.1-0920-00/1 □ Controllers 5.2-0021-01/1
■ Over speed trip releasing 5.1-0921-00/2 □ Automatic turbine tester 5.2-0022-01/1
device □ Automatic turbine tester 5.2-0023-01/1
■ Over speed trip test device 5.1-0922-00/2 □ Protective devices 5.2-0024-01/1
■ Low vacuum trip 5.1-0935-00/1 □ Safety devices 5.2-0025-01/1
■ Condenser safety device 5.1-0940-00/1 □ Valves 5.2-0026-01/1

5.0-0002-77/2
 Subject Document No Subject Document No
□ Monitoring devices 5.2-0027-01/1 ■ Automatic turbine tester 5.2-0455-00/9
□ Operating parameters 5.2-0028-01/1 ■ Oil system 5.2-0460-00/6
Start-up ■ Control fluid system 5.2-0470-00/3
■ Starting the turbine 5.2-0110-01/1 ■ Gland steam system 5.2-0480-01/1
■ Startup & shutdown 5.2-0111-00/1 ■ Bypass System 5.2-0490-00/3
diagrams, symbols MAINTENANCE
■ Startup diagram ■ Introduction 5.3-0001-01/1
□ General 5.2-0112-00/2 ■ Inspection schedule 5.3-0010-04/3
□ Preparation for startup 5.2-0113-00/1 ■ Maintenance schedule
□ Operating position of 5.2-0120-00/1 □ Turbine 5.3-0021-02/1
manually operated valves □ Oil system, seal steam 5.3-0022-01/3
□ Oil System & Turning Gear 5.2-0130-02/5 system, drains
□ Control fluid system 5.2-0135-02/4 □ FRF system 5.3-0023-01/2
start-up diagram ■ Testing during start-up 5.3-0030-02/7
□ Condensing Plant 5.2-0140-02/4 ■ Testing during power 5.3-0035-02/5
□ Bypass System 5.2-0150-00/3 operation
□ Warm-up & startup of turbine 5.2-0160-02/6 ■ Acquisition & archiving of 5.3-0037-03/3
□ Temperature criteria 5.2-0170-01/4 operating data
□ Controllers 5.2-0180-00/4 ■ Remedial actions for off- 5.3-0040-01/6
On-load Running normal operating conditions
■ Load operation, Introduction 5.2-0200-00/1 ■ Measurement of internal 5.3-0050-02/3
■ Synchronization and loading 5.2-0210-00/5 efficiency
■ Power operation, controllers 5.2-0220-00/9 ■ Testing during shut down 5.3-0060-01/5
■ Actions to prevent 5.2-0230-00/4 ■ Testing during standstill 5.3-0061-02/6
unallowable heat-up ■ Testing of safety valves 5.3-0062-01/1
through blade wind age ■ Testing of signaling devices 5.3-0063-00/2
Shut-down ■ Testing of TSC 5.3-0064-01/4
■ Introduction 5.2-0300-00/1 ■ Steam washing of turbine 5.3-0070-02/3
■ Shutdown diagram ■ Turbine Oil care 5.3-0080-03/11
□ General 5.2-0310-01/1 ■ Grease and Oil lubrication 5.3-0081-00/1
□ Turbine-generator 5.2-0320-02/5 ■ Care of control fluid 5.3-0082-02/9
□ Condensing plant 5.2-0330-01/2 ■ Determination of FRF purity 5.3-0083-01/2
□ Oil system 5.2-0340-01/2 ■ Vibration dampers 5.3-0100-00/2
■ Fast cooling down of turbine 5.2-0350-01/1 ■ Instructions for overhaul 5.3-0200-05/8
■ Preventing corrosion in 5.2-0360-00/2 ■ Turbine restart after boiler 5.3-0210-00/1
idle turbine repairs
Fault Tracing ■ Turbine restart after major 5.3-0220-00/3
■ Introduction 5.2-0400-00/1 inspections or repairs
■ Serious faults 5.2-0410-00/8 ■ Environmental protection 5.3-0250-00/1
■ Vibration 5.2-0420-00/5 □ Fluorelastomer products 5.3-0251-00/1
■ Bearing temperature 5.2-0421-01/1 safety notice
■ Casing temperatures 5.2-0423-02/2 □ Safe disposal of turbine oil 5.3-0252-00/1
■ Turbine stress controller: 5.2-0430-01/5 ■ Ordering of spares 5.3-0300-00/1
measures to avoid
impermissible operation
■ Stop & control valves 5.2-0440-01/2
■ Protective devices 5.2-0450-01/7

5.0-0002-77/3
 Steam Turbine Preface
General

This manual contains information on the turbine. Bharat Heavy Electricals Limited
operation and maintenance of steam turbine. can not be responsible for any malfunction
The information has been prepared with the occurring as a result of operation beyond
assumption that the O&M personnel have rated limits and such operation, if
basic knowledge of power plant engineering undertaken by utilities, must be at their own
and operation. risk.

It is an essential prerequisite for satisfactory The part numbers of components, indicated

operation and maintenance of the steam in the Description section of the manual
turbine that the operating and maintenance should not be used for ordering spare parts.
personnel are fully familiar with the design of Please refer the chapter on Ordering of
the steam turbine plant and receive thorough spares for that purpose.
training in operating and maintaining the Effort has been made to include adequate
unit. information in this manual. For any further
Extensive operation beyond rated design information or clarification please contact:
values will eventually result in increased Field Engineering Services, Steam Turbine
maintenance expenses or a corresponding Engineering, BHEL, Haridwar– 249403,
reduction in the useful life of the steam Uttarakhand, India.

MAITHAN-MPL, 2X525MW: Document No. STE-TF-277-MS

SM VS SRP PCK SB
Prepared Approved
Checked
by by
by

Issued by STE (FES), BHEL, Haridwar Issue 19.08.09

Date

BHEL Haridwar 5.0-0001-77

 Steam Turbine Contents
Description

Subject Document No Subject Document No

GENERAL ■ Journal bearing IP rear 5.1-0345-01/2
■ Preface 5.0-0001-77/1 ■ Casing supports and guides 5.1-0350-01/2
■ Contents 5.0-0002-77/3 LP Turbine
DESCRIPTION ■ Casing 5.1-0410-00/4
Brief Description ■ Atmospheric relief 5.1-0420-00/1
■ Sectional arrangement 5.1-0001-04/1 diaphragm
■ General description 5.1-0002-04/2 ■ Blading, drum stages 5.1-0430-01/1
■ Fixed points 5.1-0003-01/2 ■ Blading, LP stages 5.1-0440-01/2
Technical Data ■ Shaft seals 5.1-0450-01/1
■ Construction, speed & 5.1-0100-77/3 ■ Rear bearing pedestal 5.1-0460-02/1
Steam pressure ■ Journal bearing 5.1-0470-00/2
■ Steam and casing 5.1-0101-77/2 Turning Gear
temperatures ■ Hydraulic turning gear 5.1-0510-01/1
■ Bearing metal temperatures, 5.1-0102-77/1 ■ Manual turning gear 5.1-0520-01/1
vibration, weights ■ Hydraulic lifting device 5.1-0530-77/2
Control System
■ Oil supply, oil pumps 5.1-0103-77/2
■ Control fluid system and 5.1-0104-77/4 ■ General description 5.1-0600-01/2
control fluid pumps ■ Start-up procedure 5.1-0610-01/2
■ Limit curves: HP stop & 5.1-0110-01/1 ■ Speed control 5.1-0620-01/2
control valve casing ■ Electrical speed measuring 5.1-0621-02/1
■ Limit curves: HP casing 5.1-0111-01/2 ■ Protective devices 5.1-0630-01/2
■ Limit curves: HP shaft 5.1-0112-01/2 ■ Over speed trip test 5.1-0631-01/1
■ Limit curves: IP shaft 5.1-0113-01/1 ■ Testing of stop valves 5.1-0632-02/1
■ Steam purity values 5.1-0120-01/1 ■ LP bypass System (General) 5.1-0640-00/1
■ Oil specification standard 5.1-0130-04/2 ■ Extraction check valve 5.1-0650-01/1
■ Fire resistant fluid (FRF) for 5.1-0140-04/2 ■ Swing check valve (CRH) 5.1-0651-01/1
turbine control system ■ Testing of check valves in 5.1-0652-02/1
HP Turbine cold reheat line
■ Valve arrangement 5.1-0205-00/1 ■ Automatic turbine tester 5.1-0660-00/1
■ Casing 5.1-0210-01/3 general
■ Blading 5.1-0220-02/1 ■ Automatic turbine tester 5.1-0661-00/7
■ Shaft seals and balance 5.1-0230-01/2 for protective devices
piston ■ Automatic turbine tester 5.1-0662-01/4
■ Front bearing pedestal 5.1-0240-01/2 stop and control valves
■ Rear bearing pedestal 5.1-0250-02/2 ■ HP actuator 5.1-0665-00/1
■ Combined journal and thrust 5.1-0260-01/2 ■ Electro hydraulic seal steam 5.1-0670-01/4
bearing pressure control
■ Journal bearing, HP front 5.1-0270-01/2 ■ Governing scheme 5.1-0680-02/1
■ Casing supports and guides 5.1-0280-01/2 ■ Control system diagram 5.1-0681-02/5
IP Turbine legend
■ Lubrication chart 5.1-0690-02/3
■ Casing 5.1-0310-01/3
Control System Parts
■ Blading 5.1-0320-02/1
■ Shaft seals 5.1-0330-01/2 ■ Hydraulic speed governor with 5.1-0710-00/2
■ Rear bearing pedestal 5.1-0340-02/1 starting and load limiting device
■ Adjusting gear 5.1-0720-00/1

BHEL Haridwar 5.0-0002-77/1

 Subject Document No Subject Document No
■ Electro hydraulic converter 5.1-0730-03/3 ■ Solenoid valve for temperature 5.1-0950-00/1
for turbine control system controlled interlock
■ Hydraulic amplifier for 5.1-0740-02/3 ■ Vacuum breaker 5.1-0960-02/2
turbine control system ■ Changeover valve for 5.1-0980-00/1
■ Electrical speed pick-up 5.1-0760-01/1 testing device
■ Pressure converter 5.1-0761-00/1 Oil Supply
Steam valves and ■ Oil supply system 5.1-1000-77/4
accessories ■ Oil vapor extraction system 5.1-1001-77/2
■ Combined main stop and 5.1-0810-01/2 ■ Oil discharge & vent system 5.1-1002-77/2
control valve ■ Oil purification system 5.1-1003-77/1
■ Servomotor for main & 5.1-0811-00/1 ■ Main oil tank 5.1-1010-01/2
reheat stop valves ■ Main oil pump with hydraulic 5.1-1020-01/2
■ Hydraulic servomotor for 5.1-0812-00/2 speed transmitter
main & reheat control valves ■ Auxiliary oil pump 5.1-1030-01/1
■ Test valve for emergency 5.1-0813-00/1 ■ DC emergency oil pump 5.1-1040-01/1
stop valve ■ Jacking oil pump 5.1-1050-00/2
■ Combined reheat stop & 5.1-0814-00/2 ■ Oil throttle 5.1-1080-00/1
control valves ■ Oil throttle 5.1-1081-00/1
■ Hangers for reheat stop & 5.1-0815-01/1 ■ Three way control valve for 5.1-1090-01/1
control valves Lubricating oil temp. control
■ Steam strainer 5.1-0816-00/1 Control Fluid Supply
■ Changeover valve for 5.1-0840-00/1 ■ HP control fluid pump with 5.1-1110-00/1
bleeder check valve LP extraction
■ Auxiliary valve of extraction 5.1-0841-00/2 ■ Plate-type filter 5.1-1120-00/1
check valve ■ Duplex filter for pilot control 5.1-1130-00/3
■ Rotary vane actuator for 5.1-0853-01/1 of control valves
reheat swing check valve ■ Regenerating plant 5.1-1140-00/3
■ Pilot valve for rotary vane 5.1-0854-00/1 Other Systems
actuator of swing check valve ■ Drain system (MAL) 5.1-1210-77/2
■ Auxiliary pilot valve for 5.1-0855-00/1 ■ System diagram index 5.1-1220-77/3
rotary vane actuator of ■ Component diagram index 5.1-1230-77/11
reheat swing check valve ■ Shaft seal system 5.1-1240-77/5
■ Gland steam control valve 5.1-0860-02/1 Operation
■ Leakage steam control valve 5.1-0870-02/1 ■ Introduction 5.2-0001-01/1
Protective Devices ■ Specification of steam, oil & 5.2-0002-00/1
■ Main trip valve 5.1-0910-00/2 control fluid
■ Emergency trip valve for 5.1-0911-00/1 ■ Testing of turbine 5.2-0020-00/1
manual trip out Components - General
■ Solenoid valve for remote 5.1-0912-00/1 ■ Turbine systems testing
trip out testing intervals
■ Over speed trip 5.1-0920-00/1 □ Controllers 5.2-0021-01/1
■ Over speed trip releasing 5.1-0921-00/2 □ Automatic turbine tester 5.2-0022-01/1
device □ Automatic turbine tester 5.2-0023-01/1
■ Over speed trip test device 5.1-0922-00/2 □ Protective devices 5.2-0024-01/1
■ Low vacuum trip 5.1-0935-00/1 □ Safety devices 5.2-0025-01/1
■ Condenser safety device 5.1-0940-00/1 □ Valves 5.2-0026-01/1

5.0-0002-77/2
 Subject Document No Subject Document No
□ Monitoring devices 5.2-0027-01/1 ■ Automatic turbine tester 5.2-0455-00/9
□ Operating parameters 5.2-0028-01/1 ■ Oil system 5.2-0460-00/6
Start-up ■ Control fluid system 5.2-0470-00/3
■ Starting the turbine 5.2-0110-01/1 ■ Gland steam system 5.2-0480-01/1
■ Startup & shutdown 5.2-0111-00/1 ■ Bypass System 5.2-0490-00/3
diagrams, symbols MAINTENANCE
■ Startup diagram ■ Introduction 5.3-0001-01/1
□ General 5.2-0112-00/2 ■ Inspection schedule 5.3-0010-04/3
□ Preparation for startup 5.2-0113-00/1 ■ Maintenance schedule
□ Operating position of 5.2-0120-00/1 □ Turbine 5.3-0021-02/1
manually operated valves □ Oil system, seal steam 5.3-0022-01/3
□ Oil System & Turning Gear 5.2-0130-02/5 system, drains
□ Control fluid system 5.2-0135-02/4 □ FRF system 5.3-0023-01/2
start-up diagram ■ Testing during start-up 5.3-0030-02/7
□ Condensing Plant 5.2-0140-02/4 ■ Testing during power 5.3-0035-02/5
□ Bypass System 5.2-0150-00/3 operation
□ Warm-up & startup of turbine 5.2-0160-02/6 ■ Acquisition & archiving of 5.3-0037-03/3
□ Temperature criteria 5.2-0170-01/4 operating data
□ Controllers 5.2-0180-00/4 ■ Remedial actions for off- 5.3-0040-01/6
On-load Running normal operating conditions
■ Load operation, Introduction 5.2-0200-00/1 ■ Measurement of internal 5.3-0050-02/3
■ Synchronization and loading 5.2-0210-00/5 efficiency
■ Power operation, controllers 5.2-0220-00/9 ■ Testing during shut down 5.3-0060-01/5
■ Actions to prevent 5.2-0230-00/4 ■ Testing during standstill 5.3-0061-02/6
unallowable heat-up ■ Testing of safety valves 5.3-0062-01/1
through blade wind age ■ Testing of signaling devices 5.3-0063-00/2
Shut-down ■ Testing of TSC 5.3-0064-01/4
■ Introduction 5.2-0300-00/1 ■ Steam washing of turbine 5.3-0070-02/3
■ Shutdown diagram ■ Turbine Oil care 5.3-0080-03/11
□ General 5.2-0310-01/1 ■ Grease and Oil lubrication 5.3-0081-00/1
□ Turbine-generator 5.2-0320-02/5 ■ Care of control fluid 5.3-0082-02/9
□ Condensing plant 5.2-0330-01/2 ■ Determination of FRF purity 5.3-0083-01/2
□ Oil system 5.2-0340-01/2 ■ Vibration dampers 5.3-0100-00/2
■ Fast cooling down of turbine 5.2-0350-01/1 ■ Instructions for overhaul 5.3-0200-05/8
■ Preventing corrosion in 5.2-0360-00/2 ■ Turbine restart after boiler 5.3-0210-00/1
idle turbine repairs
Fault Tracing ■ Turbine restart after major 5.3-0220-00/3
■ Introduction 5.2-0400-00/1 inspections or repairs
■ Serious faults 5.2-0410-00/8 ■ Environmental protection 5.3-0250-00/1
■ Vibration 5.2-0420-00/5 □ Fluorelastomer products 5.3-0251-00/1
■ Bearing temperature 5.2-0421-01/1 safety notice
■ Casing temperatures 5.2-0423-02/2 □ Safe disposal of turbine oil 5.3-0252-00/1
■ Turbine stress controller: 5.2-0430-01/5 ■ Ordering of spares 5.3-0300-00/1
measures to avoid
impermissible operation
■ Stop & control valves 5.2-0440-01/2
■ Protective devices 5.2-0450-01/7

5.0-0002-77/3
BHEL Haridwar 5.1-0001-04
 Steam turbine General Description
Description

Construction, Steam Flow LP Turbine

The turbine is a tandem compound machine with The casing of the double-flow LP cylinder is of
separate HP,IP and LP sections. The HP section three-shell design. The shells are horizontally
being a single-flow cylinder and the IP and LP
split and are of rigid welded construction. The
sections double-flow cylinders. The turbine
innermost shell, which carries the first rows of
rotors and the generator rotor are connected by
stationary blades, is supported so as to allow
rigid couplings.
thermal expansion within the intermediate shell.
The HP turbine is throttle controlled. The initial
The intermediate shell rests at four points on
steam is admitted ahead of the blading via two
longitudinal girders, independent of the outer
main stop and control valve combinations. A
shell. Guide blade carriers, carrying the last
swing check valve is installed in the line leading
from HP turbine exhaust to the Reheater to stationary blade rows are also attached to the
prevent hot steam from the reheater flowing intermediate shell.
back into the HP turbine. Blading
The steam coming from the Reheater is passed The entire turbine is provided with reaction
to the IP turbine via two reheat stop and control blading. The stationary and moving blades of the
valve combinations. Cross around pipes connect HP and IP sections and the front rows of the LP
the IP and LP cylinders. Connections are turbine are designed with integrally milled
provided at several points of the turbine for inverted T -roots and shrouds. The last stages of
feedwater extraction purpose. the LP turbine are fitted with twisted drop -forged
moving blades with fir-tree roots engaging in
HP Turbine, Barrel Type Casing grooves in the shaft with last stage stationary
The outer casing of the HP turbine is of the blades made from sheet steel.
barrel type and has neither an axial nor a radial Bearings
flange. his prevents mass concentration which The HP rotor is supported on two bearings, a
would have caused high thermal stresses. The
journal bearing at its front end, and a combined
almost perfect asymmetric design of the casing
journal and thrust bearing immediately next to
permits moderate and nearly uniform wall
the coupling to the IP rotor. The IP and LP rotors
thickness at all sections. The inner casing is
have a journal bearing each at rear end. The
axially split and supported so as to be free to
combined journal and thrust bearing
move in response to thermal expansion. As only
incorporates a journal bearing and a thrust
slight pressure differences are effective, the
horizontal flange and joint bolts of the inner bearing which takes up residual thrust from both
casing can be kept small. The barrel type casing directions. The bearing metal temperatures are
permits flexibility of operation in the form of short measured by thermocouples directly under the
start-up times and a high rate of change of load babbit lining. The temperature of the thrust
even at high initial steam conditions. bearing is measured in two opposite thrust pads.
IP Turbine The bearing pedestals are anchored to the
The IP turbine section is of double flow foundation by means of anchor bolts and are
construction with horizontally split casings. fixed in position.
Allowance is made for thermal movement of the The HP and IP turbines rest with their lateral
inner casing within the outer casing. The inner support horns on the bearing pedestals at the
casing carries the stationary blading. The turbine centerline level. The HP and IP casings
reheated steam enters the inner casing from top
are connected with the bearing pedestals by
and bottom. The provision of an inner casing
confines high steam inlet conditions to the casing guides, which
admission section of this casing, while the joint establish the centerline alignment of the turbine
flange of the outer casing is subjected only to casing.
the lower pressure and temperature effective at The axial position of the HP and IP casings is
the exhaust from the inner casing. fixed at the support brackets on HP-IP bearing
pedestal.
BHEL Haridwar
5.1-0002-04/1
The fixed point for the LP casing is at the front Turbine Control System
point of support on the longitudinal girder. The turbine has an electrohydraulic control
Thermal expansion of the casings originates system. An electric system measures speed and
from the fixed points. output and controls them by operating the
control valves hydraulically via an
Shaft Seal and Blade Tip Sealing electrohydraulic converter. The electrohydraulic
All shaft seals, which seal the steam in the controller ensures controlled acceleration of the
casings against atmosphere, are axial-flow turbine-generator up to rated speed and limits
type. They consist of a large number of thin seal speed overshoot in the event of sudden load
strips which, in the HP and IP turbines are rejection. The linear power frequency
caulked alternately into grooves in the shafts droopcharacteristic can be adjusted in fine steps
and the surrounding seal rings. In the LP even
turbine, the seal strips are caulked only into the when the turbine is running.
seal rings. Seal strips of similar design are also
used to seal the radial blade tip clearances. Turbine Monitoring System
Valves In addition to measuring and display instruments
for pressure, temperatures, valve lifts and
The HP turbine is fitted with two main stop and speed, the monitoring system also includes
control valves. One main stop valve and one instruments for measuring and indicating the
control valve with stems arranged at right angles following parameters:
to each other are combined in a common body.
The main stop valves are spring-action single-  Rotor expansion measured at the rear-
seat valves; the control valves, also of single- bearing pedestal of the LP turbine
seat design, have diffusers to reduce pressure  Axial shift measured at the HP-IP pedestal
losses.  Bearing pedestal vibration, measured at all
turbine bearings
These valve combinations are located at both  Shaft vibration measured at all turbine
sides of the turbine with their stems horizontal. bearings
The HP valves are connected to the turbine by
easily separable collar couplings, which contain Oil Supply System
self-sealing U-rings as sealing elements.

The IP turbine has two reheat stop and control A common oil supply system lubricates and
valves. The reheat stop valves are spring-action cools the bearings . The main oil pump is driven
single-seat valves. The control valves, also by the turbine shaft and draws oil from the main
spring-loaded, have diffusers. The control valves oil tank. Auxiliary oil pumps maintain the oil
operate in parallel and are fully open in the supply on start-up and shutdown, during turning
upper load range. In the lower load range, they gear operation and when the main oil pump is
control the steam flow to the IP turbine and faulted. DC Emergency oil pump supplies oil to
ensure stable operation even when the turbine- the bearings during AC power failures.
generator unit is supplying only the station load.
A Jacking oil pump forces high-pressure oil
The reheat stop and control valves are under the shaft journals to prevent boundary
supported free to move in response to thermal lubrication during turning gear operation. The
expansion on the foundation cover plate below Jacking oil pump also supplies the high pressure
the operating floor and in front of the turbine- oil to the Hydraulic Turning gear motor. The
generator unit. All valves are actuated by lubricating and cooling oil is passed through oil
individual hydraulic servomotors. coolers before entering the bearings.

The control fluid pumps situated on a control

fluid tank supply the hydraulic turbine and
bypass control system and the protective
devices and valve actuators with HP and LP
control fluid.

5.1-0002-04/2
 Steam Turbine
Description Fixed Points

Design of the supports for the turbine has to Centering of LP outer casing is provided by
allow for the expansion of the turbine during guides which run in recesses in the foundation
thermal cycling. Constrained thermal expansion cross beam. Axial movement of the casings is
would cause overstressing of the components. unrestrained.
The method of attachment of the turbine Hence, when there is a temperature rise, the
components is also critical to the magnitude of outer casings of the HP turbine expand from
the differential expansion between the rotor and their fixed points towards Front pedestal. Casing
turbine casings which is given careful attention of IP Turbine expand from its fixed point towards
in the determination of internal clearances. the generator.
LP Casing expands from its fixed point at front
end, towards the generator.

Rotor Expansion
The following components form the fixed The thrust bearing is housed in the rear bearing
points for the turbine: pedestal of the HP turbine. The HP turbine rotor
expands from the thrust bearing

The HP, IP and LP turbine bearing pedestals
towards the front bearing pedestal of the HP

The horn supports of the HP and IP
turbine and the IP turbine rotor from the thrust
turbine at
bearing towards the generator.
HP- IP Pedestal
The LP turbine rotor is displaced towards the

At turbine end of longitudinal girder of the
generator by the expansion of the shaft
LP Turbine
assembly, originating from the thrust bearing.

The thrust bearing in the HP turbine rear
bearing pedestal Differential Expansion
Differential expansion between the rotors and
Casing Expansion
casings results from the difference between the
The bearing pedestals are anchored to the
expansion of rotor and casing originating from
foundation by means of anchor bolts and are
the HP-IP pedestal. The largest differential
fixed in position. The HP and IP turbines rest
expansions of the HP and IP turbines thus occur
with their lateral support horns on the bearing
at the ends farthest from the thrust bearing.
pedestals at the turbine centerline level. The HP
Differential expansion between the rotor and
and IP casings are connected with the bearing
casing of the LP turbine results from the
pedestals by casing guides which establish the
difference between the expansion of the shaft
centerline alignment of the turbine casings. The
assembly, originating from the thrust bearing
axial position of HP and IP casings is fixed at the
and the casing expansion, which originates from
HP-IP pedestal. Thermal expansion of the
the fixed points on the LP turbine longitudinal
casings originates from the fixed points. The LP
beams.
Turbine outer casing is held in place axially, at
turbine end of longitudinal girder by means of
fitted keys. Free lateral expansion is allowed.

BHEL, HARIDWAR 5.1-0003-02/1

5.1-0003-02/2
 Steam Turbine Technical Data
Description Construction, Speed
& Steam Pressure

Load

Rated Load 525 MW

Maximum Load under valve wide open (VWO) condition 546.7MW

Construction

Three cylinder reheat condensing turbine

Single flow HP Turbine with 17 reaction stages Type : H30-100-2

Double flow IP Turbine with 12 reaction stages per flow Type : M30-63

Double flow LP Turbine with 6 reaction stages per flow Type : N30-2x10-2

2 Main Stop and Control valves (HP casing mounted) Type : EV 320-1

2 Reheat Stop and Control Valves (Floating) Type : IV 560

1 Swing Check Valve in cold reheat line DN-800

Make : BHEL, Trichy

2 LP Bypass Stop and Control Valves with actuators & HPSU To be Ordered
(High pressure EHA Based)

Extraction Swing Check Valves

Extraction 1 : No valve

Extraction 2 : 1 Swing Check Valve with actuator and DN 800

1 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 3 : 1 Swing Check Valve with actuator and DN 500

1 Swing Check Valve without actuator Make : BHEL, Trichy

Extraction 4.1 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 4.2 : 2 Swing Check Valves with actuator DN 500

Make : BHEL, Trichy

Extraction 5 : 1 Swing Check Valve with actuator and 1 Swing DN 400

Check Valve without actuator Make : BHEL, Trichy

Extraction 6 : No valve

BHEL Haridwar 5.1-0100-77/1

Speed

Rated speed 50.0 c/s

Speed limitation in load and station operation

Max. Speed, no time limitation 51.5 c/s
Min. Speed, no time limitation 47.5 c/s
Permissible for maximum 2 hours during the life of LP blading
Speed below 47.5 c/s
Speed above 51.5 to 60 c/s

Speed exclusion range at operation without load * 7 to 47.5 c/s

Standard over speed trip setting Max. 55.5 c/s

* This speed range should be passed through in one smooth operation to avoid endangering the
blades due to resonance

Steam Pressures
♦ ♣ ♥ Unit
Rated Long time operation Short time operation

Initial Steam 166.7 175.0 200 bar

st
Before 1 HP drum stage 154.4 169.8 169.8 bar
HP cylinder exhaust 44.02 50.63 ♠ bar
52.83
IP cylinder stop valve inlet 39.63 45.97 ♠ bar
47.55
Extraction 6 44.02 50.63 52.83 bar
Extraction 5 16.32 19.26 19.26 bar
Extraction 4 7.36 8.84 8.84 bar
Extraction 3 2.910 3.55 3.55 bar
Extraction 2 1.547 1.90 1.90 bar
Extraction 1 0.358 0.44 0.44 bar
LP cylinder exhaust 0.104 0.3 0.3 bar
♦ These values correspond to 525 MW load with 3 % make-up and 33deg.C CW pressure with
all heaters in service and rated steam conditions.
♠ The safety valves must be set so that short time values are not exceeded.
♣ Long time operation: Upper limit value, permissible without time limit.
♥ Short time operation: Permissible momentary value. The aggregate duration of such swings
must not exceed 12 hours in any one year
All pressures are absolute pressures

5.1-0100-77/2
Low vacuum trip, standard setting

Hydraulic low vacuum trip 0.3 bar

Electrical low vacuum trip 0.3 bar

Electrical low vacuum trip bypass operation 0.6 bar

Seal steam supply system

Pressure in seal steam header (above atmospheric) 35 mbar

Axial shift

Alarm ± 0.5 mm

Trip ± 1.0 mm

Direction of rotation

Anti clock wise when viewed from Front Pedestal towards the Generator

5.1-0100-77/3
 Steam Turbine Technical Data
Description Steam & Casing Temperatures

Steam Temperatures

Rated value, Long-term 400 hrs. 80 hrs. per year

Annual value, subject to per year Max. 15 min in
average annual average individual case Unit

Main steam at HP 537.0 545.3 551.0 565.0 °C

stop valve inlet

HRH steam at IP 537.0 545.3 551.0 565.0 °C

Stop valve inlet

Steam Temperatures
Rated value Long term 80 hrs. per year, In special
♦ operation Max. 15 min. in cases at no
Unit
individual case load

HP turbine exhaust 335.7 337.7 427.7 ♥ °C

500.0
Extraction 6 335.7 337.7 427.7 ♥ °C
500.0
Extraction 5 423.2 428.2 463.2 °C
Extraction 4 294.8 304.8 344.8 °C
Extraction 3 195.4 208.4 255.4 °C
Extraction 2 136.9 156.9 201.9 °C
Extraction 1 73.2 93.2 143.2 °C
LP turbine exhaust 46.2 70.0 70.0 °C
Long-term operation : upper limit value permissible without time limit.
♦ These values correspond to 525 MW Load with 3% makeup and 33deg.C pressure with all
heaters in service and rated steam conditions.
♥ Only valid for the no load period with high reheat pressure after trip-out from full load
operation. For individual case approx. 15 minutes.
The turbine is immediately re-loaded or the boiler immediately reduced to minimum load if no
load operation is maintained.

Casing Metal Temperatures

Wall Temperatures Alarm at Machine must be shut down at Unit

HP turbine casing exhaust 485 500 °C

Outer casing of LP cylinder 90 110 °C

0
Spray water to LP turbine must be switched on at 90 C

BHEL Haridwar 5.1-0101-77/1

Casing Metal Temperature Differences

Temperature Difference Alarm at Machine must be tripped at Unit

Between upper & lower casing ± 90 ± 100 °C
halves of HP turbine, middle
Between upper & lower casing ± 30 ± 45 °C
halves of IP turbine, front & rear

Permissible differential temperature between parallel steam supply lines

No time limitation 17 °C
Short time period (15 min) 28 °C
In the hottest line the limitations indicated for main and reheat steam temperature must not be exceeded

Feedwater Heater out of service

Operation with feedwater heaters out of service Main steam flow, Kg/s Load,
(indicative) MW

Extraction A6, A5 (Both strings out) 399 525

Output Limit during Testing with Automatic Turbine Tester

Testing of main steam stop and control valves < 300 MW

Testing of HRH steam stop and control valves 300 MW

Motoring
Motoring is the condition in which the turbine is driven by the generator at rated speed with the
stop and control valves closed. In this operating mode, certain turbine components are heated up
by windage power of the blading.
To prevent heat-up beyond permissible temperatures, motoring must not be allowed to continue
for longer than one minute. If the condenser low vacuum limit of 0.3 bar is exceeded, motoring
must not be allowed to continue for more than 4 seconds.

5.1-0101-77/2
 Steam Turbine Technical Data
Description Bearing Metal Temperatures
Vibration, Weights

Bearing babbit metal temperatures

Alarm at Machine must be shut down at

Operation temperature below 75 °C 90 °C 130 °C

Operation temperature 75 to 85 °C 100 °C 130 °C

Operation temperature 85 to 90 °C 110 °C 130 °C

Operation temperature above 90 °C 115 °C 130 °C

Vibration
Absolute bearing housing vibration Absolute shaft vibration

Standard alarm setting 50 µm above normal level

Maximum alarm setting 84 µm 200 µm

Limit value for tripping 106 µm 320 µm

The normal level is the reproducible vibrational behaviour typical for the machine &
dependent on the operating conditions.

Vibration readings indicated in control room are peak to peak. The above values are also
given in peak to peak.

Weights
HP turbine, completely assembled 95 T

IP turbine, top half outer casing 26 T

IP turbine, top half inner casing, complete with blading 16 T

LP turbine, top half outer casing complete 43 T

LP turbine, top half inner outer casing, complete with blading, guide blade carriers & 37 T
diffusers
HP turbine rotor, complete with blading 16 T

IP turbine rotor, complete with blading 23 T

LP turbine rotor, complete with blading 100 T

Main stop and control valve, complete with servo motors, without bend & pipe section 22 T

Reheat stop and control valve, complete with servo motors, without bend & pipe 32 T
section
All weights have been calculated with safety allowances. Slings chosen must provide sufficient
security.

BHEL Haridwar 5.1-0102-77

 Steam Turbine Technical Data
Description Oil Supply, Oil Pumps

OIL supply
3
Main oil tank, rated capacity 25/40 M
3
First oil filling (estimated) 53 M
3
Flushing oil quantity (estimated) 32 M

Oil cooler for operation, number 1 No.

Oil cooler for reserve, number 1 No.

Min. 38 °C
Oil temperature at cooler outlet, unit in operation Normal 45
Max. 47

Oil temperature at cooler outlet, unit shut down Max. 75 °C

Temperature rise of oil in bearings Normal 20 °C

Max. 25
3
Estimated oil requirement for Bearing 1 0.8 dm /s
3
Estimated oil requirement for Bearing 2 15.4 dm /s
3
Estimated oil requirement for Bearing 3 4.55 dm /s
3
Estimated oil requirement for Bearing 4 9.29 dm /s
3
Estimated oil requirement for Generator front bearing 7.92 dm /s
3
Estimated oil requirement for Generator rear bearing 7.92 dm /s
3
Estimated oil requirement for Exciter bearing 0.70 dm /s
3
Estimated oil requirement for Hydraulic Barring at 4.5 – 5.0 bar 57.4 dm /s

Duplex oil filter- full flow, Type: 2.68.2, size 355/750, Nb 150 1 No.

Filtration particle size of duplex filter element as per specification 37 µm

Filtration particle size of main oil tank filter element 250 µm

Safety valve in jacking oil system, setting 200 bar

Pressure limiting valve in jacking oil system, setting 178 bar

No
Duplex oil filter for jacking oil, Type: DFDK 330 D40 W/HC/-V-So212 1

Filtration particle size of jacking oil filter 37 µm

5.1-0103-77/2
Jacking oil pump, cut-in and cut-out speeds

Jacking oil pump must be in operation at turbine speeds below approx. 510 rpm to avoid
damage to bearings.

Jacking oil pump should be cut-out at speeds above approx. 540 rpm.

Oil pumps

Main oil Auxiliary oil DC emergency Jacking oil pump

pump pump oil pump

Quantity 1 2 1 AC: 1 DC: 1

Type BOI BOI BOI BOI

Quality Make Rated Discharge Speed

Capacity
Main oil Pump 1 BHEL 350 9.1 3000

5.1-0103-77/2
 Steam Turbine Technical Data
Description Control Fluid System &
Control Fluid Pumps

CONTROL FLUID SYSTEM

A Fire Resistant Fluid (FRF) is used for the control system

3
Control fluid tank, rated capacity 10/16 M
3
First fill quantity (estimated) 15 M
3
Flushing fluid quantity (estimated) 12 M

Control fluid cooler for operation 1 No.

Control fluid cooler for reserve 1 No.

Control fluid regeneration system

Gear pump Make: Tushaco

3
Fluid flow 0.25 dm /s

Gauge pressure 3 bar

speed 1405 rpm

Motor power 0.55 KW

Control fluid purification system Make: Rotring, Type: PR 100.1

1 No. Drying filter
2 Nos. Fueller’s earth filter
1 No. Fine filter

BHEL, HARIDWAR 5.1-0104-77-1

 Control Fluid Pumps

Control fluid pumps 2 Nos.

Manufacturer KSB, Type: WKVM80/1+3

Speed 2982 rpm

Drive A.C. motor, Manufacturer – Siemens AG Type: ILG4313-2AB94-Z

Enclosure IP 55

Voltage 415 V

Frequency 50 Hz

Motor rating (at 50ºC) 121 KW

Motor rating (at 40ºC) 132 KW

Rated current 224 A

Starting current 1614 A

Control fluid pumps operating characteristics Fluid flow Discharge

3
(dm /s) Pressure (bar)

Operating point I (normal operation)

Low pressure leakage fluid 7.60 11.5

High pressure leakage fluid 6.16 38.5

Operating point II (during start & opening of stop valve servomotors)

Low pressure leakage fluid & low pressure control fluid 20.60 10.8

High pressure leakage fluid 6.16 37.8

Operating point III (during opening of CV servomotors)

Low pressure leakage fluid 7.60 10.0

High pressure leakage fluid & high pressure control fluid 16.16 31.0

All pressures are gauge pressures.

5.1-0104-77-2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the wall of HP stop and control valve

casing during Sliding Pressure Operation Mode

140

120 ∆θ = f(θm )
Heating up
100
F
80

N
60

40 S
∆θ[K] OPERATION MODE
F=Fast
20 N=Normal
S=Slow

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600
θm [°C]

∆θ = (θi - θm) on the wall temperature sensor

θi = temperature of inner layer
θm = temperature of middle layer

BHEL Haridwar 5.1-0110-01

 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the wall of HP casing during

Sliding Pressure Operation Mode

140

120 ∆θ = f(θm)

100 Heating up

80 F

60

N
40
OPERATION MODE
∆θ[K] F=Fast S
N=Normal
20 S=Slow

-20

-40
Cooling down

-60

-80
0 100 200 300 400 500 600
θm [°C]
∆θ = (θi - θm) on the wall temperature sensor
θi = temperature of inner layer
θm = temperature of middle layer

BHEL Haridwar 5.1-0111-01/1

 Permissible temperature difference ∆θ in the wall of the HP casing during
Constant Pressure Operation Mode

140

120 ∆θ = f( θm )

100
Heating up

80 F

60
N

40
OPERATION MODE
S
F=Fast
20 N=Normal
S=Slow
∆θ[K]
0

-20

-40
Cooling down
-60

-80
0 100 200 300 400 500 600
θm [°C]

∆θ = (θi - θm) on the wall temperature sensor

θi = temperature of inner layer
θm = temperature of middle layer

5.1-0111-01/2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the HP turbine shaft during

Sliding Pressure Operation Mode
200
180
∆θ = f (θm)
160
Heating up
140
120 F
100
80 N
∆θ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

220

200

180

160

∆θ[K]
140

120

100

80

60
θax [° C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL Haridwar 5.1-0112-01/1

 Permissible temperature difference ∆θ in the HP turbine shaft during
Constant Pressure Operation Mode

180
160
∆θ = f (θm)
140
Heating up
120
100 F
80
60 N
∆θ[K]
40
S
20 OPERATION MODE
0 F = Fast
N = Normal
-20 S = Slow
-40
-60
Cooling down
-80
-100
θm [°C]
0 100 200 300 400 500 600

200

180

160

140

120
∆θ[K]

100

80

60

40
θax [° C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

5.1-0112-01/2
 Steam Turbine Technical Data
Operation Limit Curves

Permissible temperature difference ∆θ in the IP turbine shaft during

Sliding Pressure Operation Mode
200
180
∆θ = f (θm )
160
Heating up
140
120 F
100
80 N
∆θ[K]
60
S
40 OPERATION MODE
20 F = Fast
N = Normal
0 S = Slow
-20
-40
Cooling down
-60
-80
θm [°C]
0 100 200 300 400 500 600

220

200

180

160

140

∆θ[K] 120

100

80

60
θax [°C]
0 20 40 60 80 100 120

∆θ = (θo - θm) on the wall temperature sensor

θo = outer layer temperature of the shaft
θm = temperature of middle layer in the shaft (calculated)
θax = temperature of axis in the shaft (calculated)

BHEL Haridwar 5.1-0113-01

 Steam Turbine Steam Purity values
Description for main steam condensate

The deposits which occur in turbines due to achieve the values in the normal operation
impurities in the steam can lead to column.
thermodynamic and mechanical inefficiencies
and, with the presence of salts, especially A recording instrument may be used to
chlorides, and sodium hydroxide also cause continuously monitor the electrical
damage to turbine parts. The corrosion conductivity of the main steam and turbine
stressing caused by active deposits, for condensate following a strongly acid cation
example, has an adverse effect on the fatigue exchange unit. In order to determine slight
strength of the blade material when the steam impurities, the sodium concentration should
is in the transition zone between the be measured in addition to this. Should
superheated and the saturated state. saline contamination occur, the turbine is to
be immediately washed with saturated
Compliance with the target values is steam to remove salt deposits.
mandatory in continuous operation, with the
values in the normal operation column Whether an alkaline, neutral or combined
preferable. With the commissioning of a new method is used for conditioning, the water
plant and starting-up operation, however, steam circulation is for the customer to
these values cannot be attained with an decide. If an alkaline method is used, the
economical outlay. The values listed in the oxygen content in the main steam
column “starting-up operation “are then valid. condensate can be max. 0.02 mg/kg and the
pH value in the turbine condensate max.9.3
It should be pointed out that adherence to the with brass condenser piping. When the
target values does not rule out deposition in condenser piping is of copper-nickel alloys,
the turbine with absolute certainty. Wherever the pH value must not exceed 9.5. There is
possible every effort should be made to no limitation for the pH value with non-
corroding steel or titanium.

Recommended values for main steam condensate

Quantity Target Value Normal Start Up
* Operation **
Conductivity at 25°C, down stream of highly µS/cm < 0.2 0.1 < 0.50
acidic sampling cation exchanger,
continuous measurement at sampling point
Silica (SiO2) mg/kg < 0.020 0.005 < 0.050

Total iron (Fe) mg/kg < 0.020 0.005 < 0.050

Total copper (Cu) mg/kg < 0.003 0.001 < 0.010
Sodium (Na) mg/kg < 0.010 0.002 < 0.020
* To avoid any drop in efficiency, it is recommended that values be kept below the target values
and into the range of the values for normal operation.
** The target values must show a noticeable downward trend. On initial start-up of new plants the
values given for normal operation must be achieved within 2 to 3 days and within 2 to 3 hours
for other start-ups.

BHEL Haridwar 5.1-0120-01

 Steam Turbine Oil Specification
Description Standard

Introduction Compatibility
This standard specifies the turbine oil For topping up of the oil system, it is
recommended for use in governing and preferable if the oil used is of the same
lubrication systems of BHEL make steam brand and quality as that already in the
turboset. system. However, if the same brand of oil is
not available and where it is intended to mix
Description in different products that individually conform
Oil of viscosity class ISO VG 46 shall be to this standard, a compatibility test should
used. The oil shall be a petroleum product be conducted before actually mixing the oils.
with or without additives to meet the Samples of both the oils in equal volume
requirement of this standard. The finished oil should be mixed and centrifuged for about
shall be clear and free from water, 40 hrs. and then mixture must comply fully
suspended matter, dust, sediment and other with the requirements of this standard.
impurities.
Properties
The turbine oil shall not contain additives The oil should comply with the
having any negative effect on the materials requirements given in table below when
of the oil system. The turbine oil must be tested according to the test methods given
capable of withstanding bearing temperature in the respective standards mentioned
of max. 130°C and oil tank temperature of against each property. For obvious
max. 80°C without physical and chemical reasons, we do not give any special
degradation. recommendation to a particular brand of oil
to be used in the oil system of our turbo
The properties of the oil shall not be affected sets. Any brand of the oil complying with
by centrifuging, water washing or filtering. the above standards may be used.

Properties of turbine oil ISO VG 46 shall be as follows:

Sl. No. Properties Value Unit Test Method
1. Kinematic Viscosity at 40ºC 41.4 – 50.6 cst IS: 1448, P-25 ASTM D445
Kinematic Viscosity at 50ºC 28 cst
2. Viscosity Index 98 Min. IS: 1448, P-56 -----

3. Neutralization No. (Total ≤ 0.20 mg IS: 1448, P-1 ASTM D974

acidity) KOH/g
4. Colour ≤2 Max. IS: 1448, P-12 ASTM D1500

5. Specific gravity at 50 ºC 0.85 --- IS: 1448, P-32 ASTM D1298

Specific gravity at 15 ºC 0.90 ---
6. Flash point (Cleveland > 200 °C IS: 1448, P-69 ASTM D92
open cup)
7. Copper strip corrosion test at Not worse --- IS: 1448, P-15 -----
100 ºC for 3 hrs. than No.1

8. Pour point ≤-6 °C IS: 1448, P-10 ASTM D97

9. Rust preventing ≤ 0-B --- DIN: 51585 ASTM D665

characteristics

BHEL Haridwar 5.1-0130-04/1

Properties contd.
Sl. No. Properties Value Unit Test Method
10. Emulsion characteristics ≤ 20 minute DIN: 51599 ASTM D1401

11. Total acidity after 2500 ≤ 0.2 mg DIN: 51587 ASTM D943
hrs oxidation KOH/g
12. Foaming characteristics at ----- ASTM: D892
25°C
3
- Foaming tendency ≤ 400 cm
- Foaming stability ≤ 450 s s
13. Deaeration capacity at 50°C ≤4 minutes DIN: 51381 ASTM: D3427

14. Ash (by weight) ≤ 0.01 % IS:1448, P-4 -----

15. Water content by weight ≤ 0.01 % DIN: 51777-1 ASTM: D1744

16. Solid particles by weight ≤ 0.05 % DIN: 51592 -----

17. Particle distribution -/17/14 Minimum ISO: 4406

(Class-8) (NAS: 1638)
18. Water release ≤ 300 s DIN: 51589-1

Following brands of oil are acceptable

Supplier Brand Supplier Brand

lOC Servo Prime 46 Castrol lndia Ltd. Castrol Perfecto T-46-Superclean

Gulf Oil India Ltd Gulf Crest 46 Bharat Petroleum Turbol 46
Apar Ltd. Power Turbo-46 Indo Mobil Ltd. Mobil DTE Medium / DTE798
Caltex Regal R&O 46 Savita Chemicals Daphne Super Turbine oil 46
HPCL Turbinol 46 Bharat Shell Ltd. Shell Turbo oil T46
TOTALFINAELF Total Preslia 46

Also refer to the following sections:

[1] 5.3-0080: Turbine oil Care

5.1-0130-04/2
 Steam Turbine Fire Resistant Fluid (FRF)
Description for Turbine Control System

This specification is valid for Fire Resistant should be no deterioration of the FRF in
Fluids (FRF) recommended for BHEL presence of such trace quantities.
make steam turbine control system. The air release of the FRF should not
According to ISO 6743/4, FRF is a fluid deteriorate in presence of fluoroelastomer
based on triarylphosphate ester marked seals and packing used in the FRF system.
ISO-L-HFDR.
The FRF must be free of ortho-cresol
compounds.
General Requirements
The FRF must not pose a safety or health
The FRF shall not cause corrosion to Steel, hazard to the persons working with it,
Copper and its alloys, Zinc, Tin or provided that the requisite hygiene
Aluminum. regulations are observed.
The FRF must provide sufficient corrosion
protection to the materials used in the FRF
system. Limit values
The FRF shall be continuously regenerated The following limit values are not to be
with Fuller’s earth or an equivalent exceeded during the life time :
regeneration agent. Kinematic viscosity - maximum variation
Note: Before using regeneration agents ± 5% with reference to delivery condition.
other than Fuller’s earth (e.g. ion Neutralisation number - maximum increase
exchangers) BHEL and FRF manufacturer 0.20 mg KOH/g with reference to delivery
or supplier shall be contacted. condition.
The FRF must not cause any erosion or Air release -maximum 12 minutes.
corrosion on the edges of the control
elements. Foaming at 25 °C -Tendency maximum 200
ml, Stability maximum 450 sec.
The FRF must be shear-stable. It should not
contain any viscosity index improver.
Disposal
FRF leaking from the system, if any, must
not ignite or burn in contact with hot Supplier to be contacted for ‘Buy Back’ of
surfaces (up to 550 ºC). used fire resistant fluid.
The FRF must be capable of withstanding In consultation with supplier, liquid material
continuous operating temperatures of 75 °C should be incinerated and material absorbed
without physical or chemical degradation. on sand should be disposed off as
hazardous solid waste.
The FRF must be miscible with traces (max.
3 % by vol.) of TXP of another brand. There

BHEL Haridwar 5.1-0140-04/1

Recommended Properties of new batches of FRF
Property Numerical Unit Test method
Value
DIN / ISO ASTM
2
Kinematic Viscosity at 40 °C 41.4 - 50.6 mm /s DIN 51 562-1 D 445
(ISO VG 46)
Air release at 50 °C ≤3 minutes DIN 51 381 D 3427
Neutralisation number ≤ 0.1 mg KOH/g DIN 51 558-1 D 974
Water content ≤ 1000 mg/kg DIN 51 777-3
Foaming at 25 °C Tendency ≤ 100 ml D 892
(Seq. 1)
Stability ≤ 450 sec
Water separability ≤ 300 sec DIN 51 589-1
Demulsification ≤ 20 minutes DIN 51 599 D 1401
3
Density at 15 °C ≤ 1250 kg/m DIN 51 757 D 1298
Flash point (Cleveland open cup) > 235 °C DIN/ISO 2592 D 92
Ignition temperature > 550 °C DIN 51 794
Wick flame persistance time ≤5 sec DIN/ISO 14935
Pour point ≤ −18 °C DIN/ISO 3016 D 97
Particle distribution * ≤ 15/12 Code ISO 4406
Chlorine content ≤ 50 mg/kg DIN 51 577-3
Oxidation stability ≤ 2.0 mg KOH/g DIN 51 373
Hydrolytic stability ≤ 2.0 mg KOH/g DIN 51 348
Change of neutralisation number
Electrical resistivity > 50 MΩm IEC 247
* The required system cleanliness is dependent upon the system design. Suitable measures (e.g.
filtration, separation) have to be taken to achieve this cleanliness level.

Following fire Resistant Fluids are approved:

Brand Supplier
1. Reolube Turbofluid 46XC M/s. Chemtura, UK
2. Fyrquel EHC-N M/s. Supresta, USA

Also refer to the following sections:

[1] 5.3-0082 : Care of control fluid

5.1-0140-04/2
 Steam Turbine HP Turbine
Description Valve Arrangement

General Arrangement
The short length of the admission section
The HP turbine has 2 main stop valves and 2 between the control valves and the casing
control valves located symmetrically to the right results in a very low steam volume in this
and left of the casing. The valves are arranged section, which has a beneficial effect on the
in pairs with one main stop valve and one shutdown characteristics of the turbine-
control valve in a common body. generator unit.

Valve Actuation
Steam flow
Each main stop valve and control valve has a
The main steam is admitted through the main dedicated hydraulic servomotor(3;5). The
steam inlet passing first the main stop valves servomotors are mounted above floor level so
and then the control valves. From the control that they are accessible and can be easily
valves the steam passes to the turbine maintained.
casing(1).

5.1-0205-00
BHEL Haridwar
 Steam Turbine
Description HP Turbine
Casing

Barrel type Casing

are relieved by the high pressure acting from the
The HP outer casing is designed as a barrel- outside and can thus be kept small. For this
type casing without axial joint. An axially split reason, turbines with barrel type casing are
inner casing (4) is arranged in the barrel-type especially suitable for quick start-up and loading.
casing(3) Seals
The pretensioned U-shaped seal ring(12),
Because of its symmetrical construction, the that is forced against the axial sealing surfaces
barrel - type casing retains its cylindrical shape by the steam pressure and the I shaped seal
and remains leakproof during quick changes in ring (16), that allows axial displacement of the
temperature (e.g. on start-up and shut down, on inner casing (4), seal the space between the
load changes and under high pressures). The inner casing (4) and the barrel type outer casing
inner casing too is almost cylindrical in shape as (3) from the adjacent spaces.
the joint flanges

Fig. 1 HP Turbine
BHEL Haridwar 5.1-0210-01/1
 Fig.2 Inlet Connection

3 Outer casing
4 Inner casing
valves are connected to the inlet connections
6 U seal ring of the outer casing by Breech Nuts(8) (Fig.2)
7 Cylindrical pin through buttress threading. Sealing is achieved
8 Breech nut by U-seal rings(6) which is forced against the
9 Inlet pipe from main stop and control valve outer sealing surface by inlet steam pressure.
The annular space around the sealing ring is
connected to the condenser through a steam
Connection to Main Stop and Control Valves leak-off line. Cylindrical pins(7) located at the
joint flange prevent rotation of the inlet pipe with
The steam lines from the main stop and control respect to the outer casing.

3 Outer casing 3 Outer casing

4 Inner casing 4 Inner casing
11 Fitted Key 10 Fitted Key

Fig. 3 Centering and support of Fig.

Fig.4 Centering and support
4 Centering of
and support of
inner casing (Exhaust side)
Inner casing (Admission side) Inner casing (Exhaust side)

5.1-0210-01/2
 Attachment of Inner Casing

The inner casing (4) is attached in the

horizontal and vertical planes in the barrel-type
casing(3) so that it can freely expand radially in
all directions and axially from a fixed point when
heating up while maintaining concentricity
relative to the turbine rotor.
On the admission side, four projections of the
inner casing (4) and on the exhaust side three
projections fit into corresponding grooves in the
barrel-type casing (3). In the horizontal plane
these projections rest on fitted keys (10) and in
the vertical plane they are guided by the fitted
keys (11) (Fig.3&4). Radial expansion is
therefore not restricted by this suspension.

As shown in fig.6 the axial fixed point of the

inner casing is provided by a shoulder in the
3 Outer casing
barrel-type casing (3) against which a collar of
4 Inner casing
the inner casing(4) rests. The axial thrust to
16 I-seal ring
which the inner casing is subjected is
17 Holding ring
transmitted to and absorbed by the thrust ring
18 Hexagon head screw
(14) via thrust pads(13). The thrust ring is held
in position by support ring (15).

Outlet Connections
The exhaust end of HPT has single outlet
Fig. 5 I-Ring seal (Detail A from Fig. 1)
connection from bottom. At the flange
connection a U-seal ring (19) is provided to
prevent any leakage (Fig.1)

3 Outer casing 13 Thrust pads

4 Inner casing 14 Thrust pads
12 U- seal ring 15 Support ring

Fig. 6 Axial Retention ofInner casing and Centering in vertical plane (Detail E from Fig.1)

5.1-0210-01/3
 HP Turbine
Steam Turbine Blading
Description

Moving and Stationary Blades

The HP turbine with advance blading consists of

17drum stages. All stages are reaction stages
with 50% reaction. The stationary and moving
blades of all stages (Fig.1) are provided with
inverted T-roots which

A 2
3

B .

The moving and stationary blades are

inserted into corresponding grooves in the
shaft( 4) and inner casing (1) and are caulked
5 at bottom with caulking piece (5) .The
insertion slot in the shaft is closed by a
locking blade which is fixed by taper pins or
grub screws. End blades are used at the joint
plane in L/H & U/H of inner casing along with
predetermined interference.

Gap sealing
Fig. 1 Drum Stages
Sealing strips(6) are caulked into the inner
casing(1) and the shaft (4) to reduce leakage
1 Inner casing 4 Turbine shaft losses at the blade tips. Cylindrically
2 Guide blade 5 Caulking piece machined surface on the blade shrouds are
3 Moving blade
opposite the sealing strips. The surfaces have
stepped diameters in order to increase the
also determine the distance between the
turbulence of the steam and thus the sealing
blades. The shrouds are machined integral with
effect. Should an operational disturbance
the blades and forms a continuous shrouding
cause the sealing strips to come into contact
after insertion.
st th with opposite surfaces, they are rubbed away
From 1 . to 8 . stages are provided with ‘3DS’
th th without any considerable amount of heat
blades, 9 . to 13 . stages with ‘TX’ blades and
th being generated. They can easily be renewed
14 . to 17 th. stages with ‘F’ blades.
at a later date to provide the specified
clearance.

BHEL Haridwar 5.1-0220-02

 Steam turbine HP Turbine
Description Shaft seals and Balance Piston

Function diameter is suited to the requirements for

balancing the axial thrust.
The function of shaft seals is to seal the interior Gap Seals
of the casing from the atmosphere at the ends of Sealing between the rotating and stationary
the shaft on the admission and exhaust parts of the turbine is achieved by means of seal
sides.The HP Turbine has shaft seals in front strip(6) caulked into seal rings (2,7,9) and into
and rear. The front shaft seal is of labyrinth type, the rotor (3) (details D and E). The pressure
while the rear shaft seal is of ‘see through’ type. gradient across the seal is reduced by
The difference in pressure before and after the conversion of pressure energy into velocity
raised part of the shaft seal on the admission energy which is then dissipated as turbulence as
side serves to counteract the axial thrust caused the steam passes through the numerous
by steam forces.The raised part is called compartments according to the labyrinth
Balance piston. The effective seal principles.

Fig. 1 Shaft Seal Admission side Seal Rings

The seal rings (2), the number of which
1 Inner casing 2 Seal ring depends on the pressure gradient to be sealed
3 Turbine rotor are divided into several segments as shown in
4 Shaft seal cover
5 Caulking wire
Section A-A, B-B and C-C and mounted in
6 Seal strip T -shaped annular grooves in the inner casing
(1 ) and shaft seal cover (4) such that they are
free to move radially. Each segment is held in
position against a shoulder by helical springs
(11). This provides the proper clearance for the
seal gaps. Should rubbing occur, the segment
concerned can retreat. The heat developed by
light rubbing of the thin seal strip (6)

Fig. 2 Shaft seal Exhaust side

BHEL Haridwar 5.1-0230-01/1

 is so slight that it cannot cause deformation of expansion at the exhaust end, see through
the rotor (3). When the turbine is started from seals are used in which the seal strips are
the cold or warm state, the seal rings naturally located opposite each other, caulked into the
heat up faster than the casing. However, they shaft and into seal rings centered in the outer
can expand freely In the radial direction against casing (Detail E).
the centering force of the helical spring (11). The outer seal rings can be removed for
The shaft seals are axial-steam flow non- inspection and if necessary, seal strips can be
contacting seals. replaced during short turbine shut down.
In the region subjected to the low relative Steam Spaces
expansion in the vicinity of the combined Steam spaces are provided within the shaft
journal and thrust bearing, the seal strips are seals. From spaces ‘Q’ and ‘R’ leakage is drawn
caulked alternately into the shaft and into off to another part of the turbine for further use.
spring-supported segmented sealrings in the The steam seal header is connected to space
casing, forming a labyrinth to impede the ’S’. The slight amount of leakage steam which
outflow of steam (Detail D). are still able to pass the seal ring are conducted
In the region subject to greater relative from the space ‘T’ into the seal steam
condenser.

5.1-0230-01/2
 Steam Turbine HP Turbine
Description Front Bearing Pedestal

Arrangement Connection of Bearing Pedestal and

Foundation
The front bearing pedestal is located at the
turbine- The bearing pedestal (1) is aligned to the
side end of the turbine generator unit. Its foundation
function is to support the turbine casing and by means of hexagon head screws that are
bear the turbine rotor. It houses the following screwed into it at several points. On completion
components and instruments. of alignment, the space beneath the bearing
pedestal is filled with special non-shrinking

Journal bearing [1] grout. The bearing pedestal is anchored to the

Hydraulic turning gear [2] foundation by means of anchor bolts (13). The

Main oil pump with hydraulic speed anchor bolt holes are filled with gravel, which
transducer [3] gives a considerable vibration damping effect.

Electric speed transducer [4] The defined position of the bearing pedestal on

Overspeed trip [5] the foundation is established by a projection in

Shaft vibration pick-up the middle of the bearing pedestal base

Bearing pedestal vibration pick-up engaging in a recess in the Foundation. On
Details of casing supports and casing guides are completion of alignment, the remaining space
given in description 5.1-0280. in this recess is likewise filled with grout .

1 Bearing pedestal 7 Hydraulic turning

7 Hydraulic gear
turning gear
2 Main oil pump 8 Bearing
8 Bearing
pedestal
pedestalvibration
vibration
pick-up
pick-up
3 Hydraulic speed transducer 9 Shaft vibration
9 Shaft pick-up
vibration pick-up
4 Electric speed transducer 10 10
Journal bearing
Journal bearing
5 Gear coupling 11 11
HPHPturbine rotor
turbine rotor
6 Over speed trip 12 12
Foundation
Foundation

Fig.1 Axial Section through HP Turbine Front

Bearing Pedestal
5.1-0240-01/1
BHEL Haridwar
 Fig. 2 Cross section of main oil pump

Fig. 3 Cross Section of Journal Bearing

[4] 5.1-0760 Electric Speed Transducer

Also refer to the following information
10 Journal bearing [1] 5.1-0270 Journal Bearing
Also refer to the following information [2] 5.1-0510 Hydraulic Turning Gear
12 Foundation [3] 5.1-1020 Main Oil Pump with Hydraulic
13 Anchor bolts Speed Transducer
[1] 5.1-0270 Journal Bearing
14 Hex head screw [4]
[2]5.1-0760
5.1-0510Electric Speed
Hydraulic Transducer
Turning Gear
[5]
[3]5.1-0920
5.1-1020Overspeed
MainOilPumptrip with Hydraulic Speed Transducer
5.1-0240-01/2 [5] 5.1-0920 Overspeed trip
 Staem Turbine
Description HP Turbine
Rear bearing Pedestal

Arrangement
The bearing pedestal is located between the
HP and IP turbines. Its function is to support the
turbine casing and bear the HP and IP turbine
rotors.

The bearing pedestal houses the following

turbine
components:

 Combined journal and thrust bearing

 Shaft vibration pick-up
 Bearing pedestal vibration pick-up
 Thrust bearing trip (electrical)
Details of casing supports and casing guides
are given in descriptions 5.1-0280 and 5.1-0350.

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by means of hexagon head screws
that are screwed into it. On completion of
alignment, the space beneath the bearing
pedestal is filled-in with special non-shrinking
grout. The bearing pedestal is anchored to the
foundation by means of anchor bolts. The
anchor bolt holes are filled with gravel, which
gives a considerable vibration damping effect.
The defined position of the bearing pedestal on
the foundation is established by a projection in
the middle of the bearing pedestal base
engaging a recess in the foundation. On 1 HP turbine rotor
2 Combined journal and thrust bearing
8
completion of alignment, the remaining space in
the recess is likewise filled with grout. 3 Bearing pedestal vibration pick-up
4 Shaft vibration pick-up
5 Thrust bearing trip (electrical)
6 Coupling bolts
7 IP turbine rotor
8 Foundation

Fig. 1 Axial Section through the HP Turbine

Rear Bearing pedestal

BHEL Haridwar
5.1-0250-02/1
2 Combined journal and thrust bearing 9 8
8 Foundation
9 Hex head screw

Fig. 2 Cross Section through Combined

Journal and Thrust Bearing
10 Straight pin
11 Anchor bolt
12 Plate
13 Round nut
14 Hex nut
15 Guard cap

Fig. 3 Connection between Bearing Pedestal

and foundation

5.1-0250-02/2
 Steam turbine Combined Journal and Thrust
Description Bearing

Function The journal bearing is constructed as

elliptical sleeve bearing. The bearing liners are
The function of the combined journal and provided with a machined babbit face; additional
thrust bearing is to support the turbine rotor and scraping is neither necessary nor allowable.
to take the residual axial thrust. The magnitude In order to prevent the bearing from exerting
and direction of axial thrust to be carried by the a bending moment on the shaft, it is pivot-
bearing depends on the load conditions of the mounted on spherical support (16). The
turbine. This bearing is located in the bearing spherical block (14) with shims (13,15), is bolted
pedestal between HPT & IPT. The thrust bearing to the lower bearing shell (12). A transverse
maintains desired axial clearances for the projection in the upper part of the cap (2) and
combined turbine generator shaft system. the fitted key (3) prevent the bearing shells from
rising.
Construction and Mode of Operation The bearing shells are located laterally by
The combined journal and thrust bearing keys (10). The bearing is supported axillay
consists of the upper and lower bearing shells against the bearing pedestal (1,9) by means of
(4, 12), thrust pads (6), cap (2), spherical blocks keys (17, 18) (Section H-H). This fixing is of
(14, 16) and keys (10, 17). The upper and lower great importance for axial clearance in the whole
halves (4, 12) of the bearing shell are bolted and turbine.
doweled at the horizontal joint by means of 4 Located at each end of the bearing shell,
taper pins and 4 stocket-head screws. babbitted thrust pads (6) form two annular
surfaces on which the integralily machined shaft
Section A-A collars run.
Section B-B

12 Bearing shell,lower
1 Bearing pedestal, upper 7 Bearing liner
13 Shim
2 Cap 8 Turbine shaft 14 Spherical block
3 Key 9 Brg. pedestal 15 Shim
4 Bearing shell upper lower 16 Spherical support
5 Cowling with all baffle 10 Key 25 Key
6 Thrust pad 11 Oil line “a” Shaft jacking oil

BHEL Haridwar 5.1-0260-01/1

These collars and thrust pads permit equal
19 Thermocouple
loading of the thrust bearing in either direction.
20 Thermocouple
As shown in section N-N, the thrust pads are of
the tilting type, secured in place by pins (23) and
Oil Supply
flexible mounted on split spring element (21).
Lubricating oil is admitted to the bearing
shells from one side via oil line (11) from where
Temperature Measurement
it flows to the oil spaces milled into the upper
Metal temperature of the journal bearing and
and lower bearing shells at the horizontal joint.
thrust pads is monitored by the thermocouples
(19,20) (Section E-E and G-G).

Oil leaving the journal bearing flows to the two

annular grooves adjacent to the bearing surface
and then to the thrust pads (6). Through the two
oil return cowlings (5), oil is discharged into the
drain area in the pedestal (9)

JackingOil

Passages are located at the lowest point in the

lower bearing shell through which high pressure
jacking oil is supplied under the journal at low
speed of the turbine rotor (on start up or
shutdown). Thus dry friction is prevented and
the breakaway torque on start-up with turning
gear is reduced.

High pressure oil “a” flows under the journals

via
the oil line and via openings in the lower bearing
shell (12). O-ring (24) located between the
bearing liner (7) and the lower bearing shell (12)
prevents any oil from penetrating between the
4 Bearing shell upper 21 Spring two elements (Detail “C”).
element
Any leakage passing the seal will drain off to
6 Thrust pad 22 Key
the
12 Bearing shell, lower 23 Dowel pin
bearing pedestal through a groove in the lower
bearing shell. This arrangement ensures that no
oil penetrates between the bearing liner and the
bearing shell.
5.1-0260-01/2
 Steam Turbine Journal Bearing
Description HP front

Construction bearing shells. Keys (8) are fitted on both

sides of the projection.
The function of the journal bearing is to The bearing shells are fixed laterally by key (11)
support the turbine rotor. Essentially the journal which are bolted to each other. Each key is held
bearing consists of the upper and lower shells in position in the bearing pedestal (10) by two
(3,6), bearing cap (1), spherical block (7), lateral collars. The temperature of the bearing
spherical support (14) and the key (11) .The bodies is monitored by thermocouples (19) as
bearing shells are provided with a babbit face. shown in section c-c.
The babbit surface of the bearing is precision
machined and additional scraping is neither Oil Supply
necessary nor permissible. Both bearing shells
are fixed by means of taper pins and bolted Lubricating oil is admitted to the bearing shells
together. from one side and flows to oil spaces that are
In order to prevent the bearing from exerting a milled into the upper shell at the horizontal joint
bending moment on the rotor (5), it is pivot- and are open to the rotor. The rotor (5) picks up
mounted in the spherical support (14). For this oil from oil pocket machined into the babbitting
purpose the spherical block (7) with shims .The oil emerges from the bearing shell where it
(12,13) is bolted to the bearing shell (6) . A is collected in the oil return cowling (4) and
projection in cap (1) with shims (9) fits into a drained into the bearing pedestal(10).

corresponding groove in the bearing shell (3)

and prevents vertical movement of the

1 Cap 6 Lower baering shell 11 Key

2 Tab Washer 7 Spherical block 12 Shim
3 Upper bearing shell 8 Key 13 Shim
4 Oil return Cowling 9 Shim 14 Spherical support
5 Turbine Rotor 10 Bearing pedestal 15 Shim

BHEL Haridwar 5.1-0270-01/1

Jacking oil

As shown in Detail B, a threaded nozzle( 17)

is arranged at the lowest point of the lower
bearing shell (6) through which high pressure lift
oil is supplied to the space below the journals
when the rotor is turning at low speed (on start-
up and shutdown).This high pressure oil floats
the shaft to prevent dry friction and overcome
breakway torque during start-up on the hydraulic
turning gear.

A seal (18) prevent high pressure oil from

penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.
16 Ring
17 Threaded nozzle
Removal of Bearing Shells 18 Sealing ring
19 Thermocouple
Not only the upper shell(3) but also the lower
bearing shell(6) can be removed without the
removal of rotor (5). To enable this to be done
the shaft is lifted slightly by means of jacking
device but within the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.

5.1-0270-01/2
 Steam Turbine HP Turbine
Description Casing Supports and Guides

Supports The turbine casing (2) is supported with its two

front and two rear support horns on the horn
The turbine casing is supported on the support supports of the bearing pedestal (1,3) at the
horns such as to make allowance for the thermal turbine centerline level. This arrangement
expansion. It is essential for the casing to retain determines the height of the casing and also
concentric alignment with the rotor, which is allows thermal expansion to take place in the
supported independently. horizontal plane by the support horns

1 Front bearing pedestal

2 HP turbine
3 Rear bearing pedestal

Fig.1 Connection between Turbine Casing

and Bearing Pedestals

BHEL Haridwar 5.1-0280-01/1

sliding on the sliding pieces (6) of the bearing to the turbine centerline is provided by the
pedestals (1 ;3). To prevent lift-off of the turbine guides shown in section B-B and E-E. These
casing (2), holders (4) hold down projections of guides allow the turbine casing to expand freely.
the support horns which engage in mating
recesses in the bearing pedestal.
Fixed Point
When the turbine is being erected, a clearance The fixed point for the turbine casing (2) is
’s’ is maintained between the thrust bar(5) and located at the horn support on HP-IP pedestal at
the turbine casing support horn projection. the turbine centerline level and is formed by the
parrallel keys (16). Axial expansion of the
Guides turbine casing (2) originates from this point.

The central location of the turbine casing at right

angle

1 Front bearing pedestal

2 HP turbine 10 Sliding piece
4 Holder 11 Plate
5 thrust bar 12 Parallel key
6 sliding piece 13 Scale indicating casing expansion
7 Plate 14 Sliding piece
8 parallel key 15 Plate
9 plate 16 Parallel key

Fig. 2 Details of Casing Supports and guides

5.1-0280-01/2
 Steam Turbine IP Turbine
Description Casing

Double Shell Construction The provision of an inner casing confines

the steam inlet conditions to the admission
The casing of the IP turbine is split section of this casing. While the joint flange
horizontally and is of double shell construction. of the outer casing is subjected only to the
A double-flow inner casing (3,4) is supported lower pressure and temprature effective at the
in the outer casing (2,5) (Fig.1) Steam from exhaust from the inner casing. This means
the HP turbine after reheating enters the inner that the joint flange can be kept small and
casing from top and bottom through two material concentrations in the area of the
admission branches which are integral with the flange reduced to a minimum. In this way,
mid section of the outer casing. This difficulties arising from deformation of a casing
arrangement provides opposed double flow in with flange joint due to non uniform
the two blade sections and compensates axial temperature rise e.g. on start-up and shut
thrust. The centre flow prevents the steam down, are avoided. The joint of the inner
inlet temperature from affecting the support casing is relieved by the pressure in the outer
horns and bearing sections. casing so that this joint has to be sealed only
against the resulting differential pressure.

BHEL Haridwar 5.1-0310-01/1

Steam Inlet and Extraction Connection While providing a tight seal, this arrangement
The angle ring (9) are provided at the connection permits the inner casing to move freely in all
of admission and extraction branches with the inner directions.
casing (3,4) (Detail ‘D’ Fig. 2 & 3). One leg of the
angle ring (9) at such a connection bears against the Attachment of Inner Casing
back of the collar of the threaded ring (7) in the outer Due to the different temperatures of the inner
casing while the other fits into an annular groove in casing relative to the outer casing, the inner casing is
the inner casing. The threaded ring (7) is fitted in attached to the outer casing in such a manner as to
such a way that the short leg of the angle ring can be free to expand axially from a fixed point and
slide freely between the collar of the threaded ring radially in all directions, while maintaining the
and the outer casing. The steam pressure prevailing concentricity of the inner casing relative to the shaft.
on the inside, forces the angle ring against the face The steam admission connections and the extraction
of the outer casing. . connections are designed to avoid any restrictions
The tolerances of the annular grooves in the inner due to thermal expansion. The inner casing is
casing are dimensioned to allow the long legs of the attached to the outer casing in the horizontal and
angle ring (9) to slide in the groove. The angle rings vertical plane.
are flexibly expanded by the pressure on the inside
and their outer areas forced against the annular
grooves to provide the desired sealing effect

5.1-0310-01/2
 In the horizontal plane, as shown in details E and casing (4) and together with the fitted keys (14)
F (Fig. 4 & 5) the four support horns of the top half provide a centering system for the inner casing (3, 4)
inner casing (3) rest on plates (13) which are in the transverse plane This arrangement allows axial
supported by the joint surface of the bottom half outer and radial expansion of the inner casing relative to
casing (5). The shoulder screws (12) are provided the outer casing while the fitted keys (14) maintain
with sufficient clearance to permit the inner casing to transverse alignment.
expand freely in all directions in the horizontal plane.
Thermal expansion in the vertical direction originates
from the point of support at the joint. This ensures
concentricity of the inner casing relative to the rotor
(1) in this plane.
The support horns provided at the bottom half
inner casing (4), project into the recesses in bottom
half outer casing (5) with clearance on all sides.
Located on top of each support horn is a spacer disc
(11) whose upper surface has a clearance ’s’ to the
flange face of the top half outer casing (2). This
clearance thus determines the lift of the inner casing.
As shown in details E, the inner casing is located
axially by the fitted keys (10) arranged on both sides
of the support horns of the bottom half inner casing
(4). Thermal expansion in the axial direction
originates from these points. Radial expansion is not
prevented by these fitted keys, as they are free to
slide in the recesses of the bottom half outer casing.
Shoulders on the bottom half outer casing (5)
project into corresponding recesses in the bottom
half inner

5.1-0310-01/3
 Steam Turbine IP Turbine
Description Blading

Gap SealIng
Moving and Stationary Blades Sealing strips (7) are caulked into the inner
casing (1) and the rotor (4) to reduce leakage
The IP turbine with advance blading consists of losses at the blade tips. Cylindrically machined
2x12 (double flow) drum stages. All stages are surfaces on the blade shrouds are opposite the
reaction stages with 50% reaction. The stationary sealing strips. These surfaces have stepped
and moving blades of all stages are provided with diameters in order to increase the turbulence of
inverted T -roots in moving blade and hook type the steam and thus the sealing effect. In case of
roots in Guide blade which also determine the an operation disturbance, causing the sealing
distance between the blades. All these blades are strips to come into contact with opposite surfaces,
provided with integral shrouds, which after they are rubbed away without any considerable
installation form a continuous shroud. The moving amount of heat being generated. They can then
and stationary blades are inserted into easily be renewed at a later date to provide the
appropriately shaped grooves in the rotor (4) and specified clearances.
in the inner casing (1) and are bottom caulked
with caulking material (5). The insertion slot in the
rotor is closed by a locking blade which is fixed by
grub screws. End blades, which lock with the
horizontal joint are used at the horizontal joint of
the inner casing (1).

1 Inner Casing
2 Guide Blade 5
3 Moving Blade
4 Turbine Shaft
5 Caulking piece 2
6 Sealing strip
7 Caulking wire

7
5

BHEL Haridwar 5.1-0320-02

 Steam Turbine
Description IP Turbine
Shaft Seals

Function
The function of the shaft seals is to seal the caulked into the shaft and into seal rings
interior of the turbine casing against the centered in the outer casing.
atmosphere at the front (thrust bearing end) and The outer seal rings can be removed for
rear shaft penetrations of the IP turbine. inspection and if necessary seal strips can be
The shaft seals are axial-steam-flow non- replaced during a short turbine shut down
contacting seals. keeping module in place.
In the region subject to low relative
expansion in the vicinity of the combined journal Gap Sealing
and thrust bearing, the seal strips are caulked Sealing between the rotating and stationary
alternatively into the shaft and into spring- elements of the turbine is achieved by means of
supported segmented rings in the casing, seal strip (9) ,caulked into seal rings (3;5) and
forming a labyrinth to impede the outflow of into the rotor (4) (details A and C). The pressure
steam. gradient across the seal is reduced by
In the region subject to greater relative conversion of pressure energy into velocity
expansion at the exhaust end, see-through seals energy which is then dissipated as turbulence as
are used, in which the seal strips are located the steam passes through the numerous
opposite each other, compartments according to the labyrinth
principle.

BHEL Haridwar 5.1-0330-01/1

Seal Rings When the turbine is started from the cold or
warm state, the seal rings naturally heat up
The seal rings (3), the number of which faster than the mounting rings. However. they
depends on the pressure gradient to be sealed can expand freely in the radial direction against
are divided into several segments as shown in the centering force of the helical springs (6).
Section BB and mounted in grooves in the rings
such that they are free to move radially. Each Steam Spaces
segment is held in position against a shoulder by Steam spaces are provided within the shaft
helical springs (6) and by the steam pressure seals. From space ‘P’ leakage is drawn off to the
above the seal rings (3). This provides the steam seal header. The slight amount of
proper clearance for the seal gaps. Should leakage steam which are still able to pass the
rubbing occur the segments concerned can seal ring are conducted from the space ‘R’ into
retreat. The heat developed by light rubbing of the seal steam condenser.
the thin seal strips (9) is so slight that it cannot
cause deformation of the rotor (4).

5.1-0330-01/2
 Steam Turbine IP Turbine
RearBearing Pedestal
Description

Arrangement

The bearing pedestal is located between the

IP and LP turbines. Its function is to support the
turbine casing and bear the weight of IP and LP
rotors.

The bearing pedestal houses the following

turbine components:

• Journal bearing
• Shaft vibration pick-up
• Bearing pedestal vibration pick-up
• Hand barring arrangement

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by means of hexagon head screws
that are screwed into it at several points. On
completion of alignment the space beneath the
bearing pedestal is filled with special non
shrinking grout. The bearing pedestal is
anchored to the foundation by means of anchor
bolts. The anchor bolt holes are filled with gravel
which gives a considerable vibration damping
effect.

BHEL Haridwar 5.1-0340-02

 Steam Turbine IP Rear Journal Bearing
Description

Construction The bearing shells are fixed laterally by spacers

The function of the journal bearing is to support (10) which are bolted to each other. Each spacer
the turbine rotor. Essentially, the journal bearing is held in position in the bearing pedestal (11) by
consists of the upper and lower shells (3, 6), two laterall collars. The temperature of the
bearing cap (1), torus piece (7), cylindrical bearing bodies is monitored by thermocouples
support (14) and the keys (10). The bearing (15) as shown in section C-C.
shells are provided with a babbit face which is
precision machined. Additional scraping is
neither necessary nor permissible. Both bearing
shells are fixed by means of taper pins and Oil Supply
bolted together. Lubricating oil is admitted to the bearing shells
from both sides, from where it flows to oil spaces
In order to prevent the bearing from exerting a milled into the upper and lower shells at the
bending moment on the rotor (5), it is pivot- horizontal joint that are open to the rotor end. Oil
mounted in the cylindrical support (14). For this from the oil space machined in the babbitting is
purpose, the torus piece (7) with shims (12, 13) carried through the rotor (5) and emerges from
is bolted to the bearing shell (6). A projection in the bearing shell from where it is collected in the
cap (1) with key (9) fits into a corresponding oil return cowling (4) and drained into the
groove in the bearing shell (3) and prevents bearing pedestal (11).
vertical movement of the bearing shells.
Centering of the bearing shells in the vertical
plane is achieved by means of keys (8).

BHEL Haridwar 5.1-0345-01/1

Jacking Oil

As shown in section B-B, two threaded

nozzles (17) are arranged at the lowest point of
the lower bearing shell (6) through which high
pressure oil is supplied to the space below the
journal when the rotor is turning at low speed
(on start-up and shutdown). This high pressure
oil floats the shaft to prevent dry friction and
overcome breakaway torque during startup, thus
reducing torque requirements of the hydraulic
turning gear.
A seal (18) prevents high pressure oil from
penetrating the space between threaded nozzle
and ring (16) and thus from lifting the babbit.
Any leakage oil can drain through passages in
the bearing shell below the ring.

Removal of Bearing Shells

Not only the upper shell (3) but also the lower
bearing shell (6) can be removed without the
removal of rotor (5). To enable this to be done,
the shaft is lifted slightly by means of jacking
device but with in the clearance of the shaft
seals. The lower bearing shell can then be
turned upwards to the top position and removed.

5.1-0345-01/2
 Steam Turbine
Description IP Turbine
Casing Supports and Guides
The turbine casing is supported on the support It is essential for the casing to retain
horns such as to make allowance for the thermal concentric alignment with the rotor which is
expansion. supported independently

1 HP Turbine rear bearing pedestal Fig.1 Connection between turbine casing and
2 IP turbine bearing pedestal
3 IP turbine rear bearing pedestal

BHEL Haridwar 5.1-0350-01/1

 The turbine casing (2) is supported with its
two front and two rear support horns on the
bearing pedestals(1,3) at the turbine centerline
level. This arrangement determines the height of
the casing and also allows thermal expansion to
take place in the horizontal plane by the support
horns sliding on the sliding pieces (6;16) of the
bearing pedestals (1,3). To prevent lift off the
turbine casing (2), holders (4;15) hold down
projections of the support horns which engage in
mating recesses in the bearing pedestal.
When the turbine is being erected, a
clearance ’s’ is established between the thrust
bars (5;14) and the turbine casing (2) support
horn projection.

Guides Fixed Point

The fixed point for the turbine casing (2) is
The central location of the turbine casing at right located at the front horn support at the turbine
angles to the turbine centerline is provided by centerline level and is formed by the parallel
the guides shown in section B.B .These guides keys ((7;10). Axial expansion of turbine casing
allow the turbine casing to expand freely. (2) originates from this point

5.1-0350-01/2
 Steam Turbine LP Turbine
Description Casing

Construction
Inlet Connections
The LP turbine casing consists of a double- Steam admitted to the LP turbine from the IP
flow unit and has a triple shell welded casing. turbine flows into the inner casing (4,5) from
The outer casing consists of the front and rear both sides through steam inlet nozzles before
walls, the two lateral longitudinal support the LP blading Expansion bellows are
beams and the upper part. The front and rear provided in the steam piping to prevent any
walls as well as the connection areas of the undesirable deformation of the casings due to
upper part are reinforced by means of circular thermal expansion of the steam piping.
box beams. The outer casing is supported by
the ends of the longitudinal beams on the base
plates of the foundation.

1 Outer casing, upper half 5 Inner inner casing, lower half

2 Diffuser, upper half 6 Inner outer casing lower half
3 Inner outer casing upper half 7 Diffuser lower half
4 Inner- inner casing, upper half 8 Outer casing lower half
Fig. 1 LP Turbine (Longitudinal
section)

BHEL Haridwar 5.1-0410-00/1

Arrangement of Inner Casing in Outer Two guide plates are welded vertically to
Casing the lower inner bend of each of the beams.
The guiding piece (12) which is rigidly
The LP casing has a double-flow inner connected to the foundation crossbar, fits
casing. This inner casing is a double shell between these plates. Fitted pieces(11)
construction and consists of the outer part inserted between the square guiding piece(12)
(3,6) and the inner part (4,5). The inner shell is and the plates maintain alignment of the
suspended in the outer shell to allow thermal casing in the centre plane and permit
movement and carries the front guide blade expansion transverse to the axis of the
rows. machine.
Support and Guiding of Inner Casing in
The rear guide blade rows of the LP stage Outer Casing
are bolted to the outer shell of the inner
casing. The complete inner casing is The complete assembled inner casing rests
supported in the LP outer casing (1,8) in a in the horizontal plane with 4 brakets on the
manner permitting free radial expansion sliding piece(15, 18) placed in the plates
concentric with the shaft and axial expansion bolted to the longitudinal support beam of the
from a fixed point (Fig.2). casing. The two brackets (detail C Fig.5) on
the turbine side are fixed in the axial direction
Support and Guiding of Outer Casing by fitted keys (16) as opposed to the brackets
on the generator side (detail D Fig.6) which
The outer casing rests with the brackets at are not fixed. Any thermal expansion in the
the end of the longitudinal beam on the base axial direction thus originates from here.
plates fixed to the foundation crossbeam. The
outer casing of the LP turbine is axially fixed at The spacer bolts( 17) prevent lifting of the
the respective front brackets (Fig.2). inner casing. The clearance of these spacer
bolts in the holes of the brackets is
In the lower area of the circular beams dimensioned to permit the inner casing to
which reinforce the front and rear walls of the expand horizontally on sliding piece (15) of the
outer casing, the casing is guided in the fixed support transverse to the axis of the
vertical centre plane (Fig.1, 3) which takes machine, and on sliding piece (18) of the non-
the radial and axial expansion into account. fixed support transverse and parallel to the
machine axis. As thermal expansion in the
vertical direction originates at approximately
the level of the horizontal.

5.1-0410-00/2
Fig.3 Guiding of the Outer Casing

joint, the concentricity of the inner casing with

the shaft is ensured in this plane. As shown in
detail E (Fig.2,4) two casing guides are
located at the lower half (6) of the outer shell
to prevent any transverse displacement of the
inner casing from the centerline of the turbine.
Radial and axial expansions is not prevented
by fitted keys(14) in these casing guides

Suspension of the Inner Shell

The inner shell (4,5) is suspended in the

outer shell (3,6) in the horizontal plane and is serve to align the inner shell, lower half (5) in
guided axially in the vertical plane (Fig.7and the outer shell, lower half (6) by the use of
8). In the horizontal plane, the upper half (4) of jacking bolts during erection. On the IP turbine
the inner shell is supported by four brackets side, 2 fitted keys (19) are inserted between
resting on the support plates (21,22) located at each bracket and recess. As shown in detail L,
L and M of the joint face of the lower half of these fitted keys fix the inner shell in the axial
the outer shell (Fig.9 & 10). The brackets of direction and thermal expansion thus
the upper part (3) of the outer shell which originates from here
project over the cover plates (20) , prevent
lifting of the inner shell. The slight clearance
between these cover plates and the brackets
permits free horizontal expansion of the inner
shell in all directions at the support points.
Thermal expansion in the vertical plane
originates at the joint face. This ensures
concentricity of the inner shell with the shaft in
this plane.

The brackets of the inner shell, lower half (5)

project into recesses of the outer shell, lower
half (6) These brackets are provided with
clearance on all sides and

5.1-0410-00/3
3 Outer shell, upper half
4 Inner shell, upper half
5 Inner shell, lower half
6 Outer shell, lower half
Fig. 7 Inner Casing, Longitudinal Section

In the vertical plane 4 centering pins (26)

which are guided in bushings (25) are
provided for the suspension as shown in detail
A Fig. 11. The lower ends of the centering pins
are fitted into keys (27) which slide in axial
grooves in the inner shell. This arrangement
permits axial displacement of the inner shell
relative to the keys (27) and vertical
displacement along the axis of the centering
pins(26) while displacement transverse to the
axis of the unit prevented by the keys. Thermal
expansion transverse to the axis of the unit
originates from these keys so that
concentricity of the inner shell with the shaft is
also maintained in this plane. The bushings
(25) have an eccentric bore and by turning
them during alignment of the inner casing, the
inner shell can be moved laterally. After the
alignment has been completed, the bushings
are fixed in position by grub screws.

5.1-0410-00/4
 Steam Turbine Atmospheric Relief Diaphragm
Description

Atmospheric relief diaphragms are provided in consists of a thin rolled lead plate. To insure
the upper half of each LP exhaust end section that the remnants of the diaphragm and
to protect the turbine against excessive rupturing disc are not carried along by the
pressure. In the event of failure of the low blow-off steam a cage with brackets (5) is
vacuum trips the pressure in the LP turbine provided. As long as there is a vacuum in the
exhaust rises to an excessively high level until condenser the atmospheric pressure forces
the force acting on the rupturing disc (1) the breakable diaphragm and the rupturing
ruptures the breakable diaphragm (2) thus disc against the supporting flange (3).
providing a discharge path for the steam. The
diaphragm

BHEL Haridwar 5.1-0420-00

 Steam Turbine LP Turbine
Description Blading, Drum Blading

Arrangement

The drum blading stages 1 to 3 of the double

flow LP turbine are of reaction type with 50%
reaction. They are Located in the inner-Inner
casing and form the initial stages of the LP
blading. The LP stages following these drum
stages are described in detail in next chapter.

Guide and moving blades

All guide and moving blades of drum stages

have integral shrouds, which after installation
form a continuous shrouding. The moving
blades (7) of the last drum stage are tapered
and twisted. All stationary and moving blades
have T -roots which also determine the
distance between the blades. They are
inserted into the matching grooves in the
turbine shaft (5) and inner casing (1) and are
caulked in place with
caulking material (6). The insertion slot in the
rotor is closed by means of a locking blade
which is secured in its position by means of
grub screws between shaft and lock blade .In
casing, blades at joint planes are fixed by
means of grub screws.

Inter stage Sealing

In order to reduce blade tip losses, tip to tip

sealings are provided in these stages. Thin
sealing strips (9) are caulked in inner casing
(1) and turbine rotor (5). The sealing fins are
machined on the shrouds of moving and
stationary blades opposite to the sealing strips
in inner casing or rotor (Detail A). In the event
of rubbing due to a fault , little heat will be
generated due to rubbing of thin sealing strips.
These can be renewed at a later date to
provide the correct radial clearances.

BHEL Haridwar 5.1-0430-01

 Steam Turbine LP Turbine
Description Blading, Low Pressure Stages

from steel sheets to form hollow blades.

Guide and Moving Blades Suction slits are provided in the blades of row
The last three stages of the LP turbine are (7). Through these slits water particles on the
also reaction stages. Each stage is made up of surface of these last stage guide blades are
guide and moving blades. drawn away to the condenser.
The moving blades (3) of first LP stage are
tapered,

The stationary blade rows (2, 5, 7) are made twisted and have integral shrouds with T -root.
by welding inner ring, blades and outer ring The last two stages of moving blades (6,8)
together to form Guide Blade Carriers in two have curved fir-tree roots (View-X) which are
halves, that are bolted to inner outer casing inserted in axial grooves in the turbine shaft
(1). The blades of rows 2 & 5 are of precision (4) and secured by means of clamping pieces
cast steels and the blades of row 7 are made (11). Axial movement of the blades

5.1-0440-01/1
BHEL Haridwar
is prevented by segments of locking plate Inter stage sealing
segments (12) and the end segments are spot In order to reduce blade tip
welded at joint. The difference in losses at the stationary blade rows
circumferential speed at the root and tip of the (2,5,7). sealing strips (9) are caulked
moving blades is taken into consideration by into turbine shaft. Opposite to this,
the twisted design of the blades. sealing strips are also caulked on the
inner ring of stationary blade rows as
shown in Detail A. This arrangement
permits favourable radial clearances
to be attained. In case of rubbing, the
thin seal strips are worn away without
generating much heat. They can be
easily replaced at a later date to
restore the required clearances.

5.1-0440-01/2
 Steam Turbine LP Turbine
Description Shaft Seals

Function

The function of the axial shaft seals situated

between the bearing casings and the LP
exhaust casing is to seal the inner space of
the LP exhaust casing against atmospheric
pressure at the passages through the shaft.

Gap Sealing

The sealing effect between the moving and

stationary parts of the turbine is achieved by
means of sealing strips (4) which are caulked
into the individual seal rings (2), The prevailing
pressure is reduced according to the labyrinth
principle by conversion into velocity with strips (4) due to this light pressure are so slight
subsequent turbulence in many sections. that it cannot cause deformation of the rotor
(5). When the turbine is started from the cold
or semi-warm state, the sealing rings naturally
heat up more quickly than the steam seal
casings. They can then expand radially without
hindrance against the centering force of the
helical springs.

Steam Spaces
Steam spaces are provided within the shaft
seal. When the plant is started up and in
operation, sealing steam enters space “Q” to
prevent air penetrating the space, which is
under a vacuum. The slight amount of steam
that passes the center seal ring is drawn off
from space “R” into the seal steam condenser.

Sealing Rings

The sealing rings (2), the number of which

depends on the pressure existing in the
turbine, are split into several segments as
shown in section A-A and arranged in T-
shaped annullar grooves in the steam seal
casing (1) so that they can move radially.
Several helical sprir1gs (3) force each
segment against a shoulder and hold it in this
position. This permits the correct clearance in
the sealing gaps. Should rubbing occur, the
segments concerned retreat. The frictional
heat developed by the thin

BHEL Haridwar 5.1-0450-01

 Steam Turbine LP Turbine
Description Rear Bearing Pedestal

Arrangement

The bearing pedestal is situated between

the LP turbine and generator. Its function is to
bear the weight of LP rotor.

The bearing pedestal contains the

following turbine components:

Bearing pedestal vibration pick-up

• Journal bearing
• Shaft position measuring device
• Shaft vibration pick-up

Connection of Bearing Pedestal and

Foundation

The bearing pedestal is aligned on the

foundation by hexagonal screws that are
bolted into the bearing pedestal. To overcome
friction resistance, balls are arranged under
the heads of these hexagonal screws. After
alignment the space under the bearing
pedestal is filled in with special nonshrink
grout, resistant to expansion and contraction.
The bearing pedestal is also connected to the
foundation by means of anchor bolts.

BHEL Haridwar 5.1-0460-02

 Steam Turbine Journal Bearing
Description

Construction The bearing shells are fixed laterally by the

keys (10) which are bolted to each other. Each
The function of the journal bearing is to key is held in position in the bearing pedestal
support the turbine rotor. Essentially, the (11) by two lateral collars. The temperature of
journal bearing consists of the upper and lower the bearing is monitored by thermocouples
shells (3, 6), bearing cap (1), torus piece (7), (15) as shown in section C-C.
cylindrical support (14) and the keys (10). The
bearing shells are provided with a babbit face. Oil Supply
The bearing bore is precision machined and
additional scraping is neither necessary nor Lubricating oil is admitted to the bearing
permissible. Both bearing shells are fixed by shells from both sides, from where it flows to
means of taper pins and bolted together. oil spaces milled into the upper and lower
shells at the horizontal joint that are open to
In order to prevent the bearing from the rotor end. Oil from the oil space machined
exerting a bending moment on the rotor (5), it in the babbitting is carried through the rotor (5)
is pivot-mounted in the cylindrical support (14). and emerges from the bearing shell from
For this purpose, the torus piece (7) with where it is collected in the oil return cowling (4)
shims (12, 13) is firmly bolted to the bearing and drained into the bearing pedestal (11).
shell (6). A projection in cap (1) with shims (9)
fits into a corresponding groove in the bearing Lift Oil
shell (3) and prevents vertical movement of As shown in section B-B threaded nozzles (17)
the bearing shells.. Centering of the bearing are arranged at the lowest point of the lower
shells in the vertical plane is achieved by bearing
means of keys (8).

1 Cap 5 Rotor 9 Shim 13 Shim

2 Tab washer 6 Lower bearing shell 10 Key 14 Cylindrical support
3 Upper bearing shell 7 Torus piece 11 Bearing Pedestal
4 Oil return cowling 8 Key 12 Shim

5.1-0470-00/1
BHEL Haridwar
shell (6) through which high pressure oil is
supplied during start-up. This high pressure oil
relieves the bearing to overcome breakaway
torque and prevent dry friction, thus reducing
the torque requirements of the hydraulic
turning gear.
The lift oil flows into the above mentioned
threaded nozzles (17) through passages in the
lower bearing shell (6). A seal (18) prevents
high pressure oil from penetrating the space
between threaded nozzle and ring (16) and
thus from lifting the babbit. Any leakage oil can
drain through passages in the bearing shell
below the ring.

Removal of bearing shells

Not only the upper shell (3) but also the
lower bearing shell (6) can be removed without
the removal of the shaft (5). To enable this to
be done, the shaft is lifted slightly by means of
the jacking device but within the clearance of
the shaft seals. The lower bearing shell can
then be rotated to the top position and
removed.

15 Termocouple
16 Ring
17 Threaded nozzle
18 Sealing ring

Also refer to tne following sections

[1] 5.1-0510 Hydraulic Turning Gear

5.1-0470-00/2
 Steam Turbine
Description Hydraulic Turing Gear

Arrangement
Function
The hydraulic turning gear is situated The function of the hydraulic turning gear is
between the main oil pump and the journal to rotate the shaft system at sufficient speed
bearing in the HP turbine front bearing pedestal. before start-up and after shut-down in order to
avoid irregular heating up or cooling down and
thus avoid any distortion of the turbine rotors.
The air flow set up by the blades along the inner
wall of the casing during turning operation
provides good heat transfer conducive to
temperature equalization between upper and
lower casing halves.

Operation
During turning gear operation, the shaft
system is rotated by a blade wheel which is
driven by oil supplied by the auxiliary oil pump.
This oil passes via a check valve into the nozzle
box (1) and from there into the nozzles (2) which
direct the oil jet in front of the blading.

Return Oil Flow

After passing the blading, the oil drains into
the bearing pedestal and flows with the bearing
oil into the return flow line.

Manual Turning Gear

A manual turning gear is provided in addition
to the hydraulic turning gear to enable the
combined shaft system to be rotated manually.

Lifting of Shaft
To overcome the initial break-away torque on
start-up and to prevent dry friction, the bearings
are relieved during turning gear operation by
lifting oil supplied from below i.e. the shafts are
lifted slightly.

BHEL Haridwar 5.1-0510-01

 Steam Turbine Mechanical Barring Gear
Description

Function Operation
Take the following steps to make the
The turbine generator is equipped with a barring gear ready for operation: Remove
mechanical barring gear, which enables the cover (2) unlatches at (7) and attach a bar to
combined shaft system to be rotated manually lever (1).
in the event of a failure of the normal hydraulic Barring of lever (1) will rotate the
turning gear. combined turbine generator shaft system.
It is located at IP - LP pedestal
After barring has been completed, return
lever (1) and pawl (6) to the position shown in
figure and secure lever (1) by means of latch
Construction (7) Replace cover (2).
The barring gear consists of a gear
machined on the rim of the turning gear wheel The barring gear may only be operated
(10) and pawl (6). This pawl engages the ring after the shaft system has been lifted with
gear and turns the shaft system when high-pressure lift oil. If it is hard to start turning
operated by means of a bar attached to laver by means of the mechanical barring gear, this
(1). The pawl (6) is shown disengaged and the may be due to incorrect adjustment of the
lever (1) resting against a stop. The lever (1) is jacking oil system or due to a rubbing shaft.
held in position by latch (7). Before steam is admitted to the turbine.
corrective action must be taken

BHEL Haridwar 5.1-0520-01

 Steam Turbine Hydraulic Jacking Device
Description

Function
When the turbine is started up or shut to protect the jacking oil system from damage
down, the hydraulic jacking device is used to due to improper switching ON of the jacking oil
maintain the oil film between rotor and pump when the check valve (12) is closed, a
bearings. The high-pressure oil is forced under spring-loaded safety valve (11) is situated in
the individual bearing, thus raising the rotor. the piping between the jacking oil pump (13)
The necessary torque from the hydraulic and the check valve (12). The necessary
turning device or from the manual turning pressure in the system is kept constant by
device is reduced in this way. The high- means of the pressure-limiting valve (8). The
pressure oil also provides motive force to pressure-limiting valve can be relieved by the
hydraulic turning gear motor installed in front bypass valve (9). The superfluous flow from
bearing pedestal. the pump is conducted into the main oil tank.

Speed Limit Values The necessary jacking oil pressures are

In order to avoid damage to the bearings, set for each bearing by the fine control valves
the jacking oil pump must be switched on (7) in the oil pipes. Check valve (6) in the
below a certain speed. The exact speeds for jacking oil pipes prevent oil from flowing out of
switching on and off can be seen in the the bearings into the header during turbine
Technical data 2-0103. operation when the jacking oil system is
naturally switched off.
Jacking Oil Pump
The jacking oil pumps, one number AC Valve Arrangement
(13) and one number DC(14) are jack-screw
immersion pumps situated on the tank (10) The fine control valve (7) of the turbine
supply the high pressure oil for the lifting bearings, the check valves (6) and the
device. The oil is drawn off directly by one of pressure gauges are arranged in boxes, which
the two pumps. The pressure oil piping of the are connected laterally to the bearing
jacking oil pump that is not in operation is pedestals.
closed by the check valve (12). In order

1 HP turblne 6 Check Valve 11 AC Motor driven lifting oil pump 16 Valve

2 IP turblne 7 Fine control valve 12 DC Motor driven lifting oil pump c Drain
3 LP turblne 8 Pressure Limiting Device 13 Spring loaded safety valve
4 Generator 9 Bypass Valve 14 Check valve
5 Exciter 10 Main Oil Tank 15 Duplex filter

BHEL Haridwar 5.1-0530-01-1

5.1-0530-77-02
 Steam Turbine General Description
Description

The turbine control system description for The special operating conditions existing in
500 MW steam turbine comprises the reheat condensing turbines necessitate
following: additional control elements. On start-up of
General Description the high-pressure boiler it is necessary to
Start-up Procedure start up the turbine straight away with a
Speed Control considerable steam rate and, due to the high
Electrical Speed Measuring temperature in the reheater to admit steam
Protective Devices to the reheater immediately.
Overspeed Trip Test As long as the HP section of the turbine is
Testing of Stop Valves unable to accommodate all the steam
Bypass Control System (General) supplied by the boiler, the rejected steam is
Electro-hydraulic Bypass Control (Electrical routed directly to the reheater via HP bypass
System) valve. The steam from the reheater which
Electro-hydraulic Bypass Control (Hydraulic cannot be accommodated by the IP section
System) with its control valves MAB10+20AA002 and
Extraction Check Valve reheat stop valves MAB10+20AA001 is
Swing Check Valve in CRH line routed into condenser MAG10BC001 by way
Testing of Swing Check Valves in the Cold of LP bypass stop & control valves
Reheat Line MAN11+12AA001 and MAN11+12AA002.
Automatic Turbine Tester, General
Automatic Turbine Tester, Protective The IP turbine must be fitted with its own
Devices control valves to prevent steam remaining in
Automatic Turbine Tester, Stop Valves the reheater from entering the turbine via the
HP Actuator IP and LP section and causing further
Electro-hydraulic Gland Steam Pressure acceleration of the turbine after the main
Control steam control valves have been closed in
Control System Diagram the event of load rejection or trip. In addition,
List of Parts the steam pressure in the main steam line
Lubrication Chart would increase after sudden closure of the
Lubrication Chart, Index main steam control valves, thus causing the
HP by pass valve to open, with the result
Turbine generator unit MAA50HA001 that even more steam would flow into the IP
MAB50HA001and MAC10HA001 comprises section of the turbine.
three-cylinder reheat condensing turbine
with condenser MAG10BC001 and a direct- It is the function of main oil pump MAV21
driven three-phase a.c. generator. AP001, driven directly by the turbine shaft,
to supply oil for bearing lubrication, for the
The turbine has a hydraulic speed governor oil circuit for the overspeed trip test, and for
MAX46BY001 and an electric turbine the primary oil circuit, pressure in which is
controller. The hydraulic speed governor generated by hydraulic speed transmitter
adjusts control valves MAA10+20AA002 and MAX44AP001.Two Electrically driven
MAB10+20AA002 by way of hydraulic auxiliary oil pumps are provided for auxiliary
amplifier MAX45BY011 whilst the electric oil supply. The LP control fluid circuit (8 bar)
turbine controller acts on these control and the HP actuators of the main steam
valves by way of electro-hydraulic converter control valves, reheat control valves, LP
MAX45BY001. bypass stop & control valves (32bar) are
Hydraulic amplifier MAX45BY011 and supplied by two full-load control fluid pumps
electro-hydraulic converter MAX45BY001 installed in the control fluid tank.
are switched in parallel to form a minimum The turbine is equipped with an electro-
gate. The system not exercising control is in hydraulic seal steam control system, an
its maximum position. electro-hydraulic bypass control system, an

BHEL Hardwar 5.1-0600-01/1

automatic turbine tester for the protective
devices, main and reheat “Stop & Control
Valves” and an automatic functional group
control.

5.1-0600-01/2
 Steam Turbine Start-up Procedure
Description

Mode of Operation transiently the fluid supply to solenoid valve

MAX48AA202 from the connection
The turbine is started up and brought up to
downstream of filters MAX42BT001 and
speed with the assistance of the control
MAX42BT 002 during latching in of main trip
valves MAA10+20AA002 and MAB10+20
Valves MAX51AA005 and MAX51AA006 by
AA002. If the hydraulic controller is to
means of start-up and load limiting device
govern start-up, the reference speed setter
MAX47BY001, because the pressure drops
MAX46BY001 must be set to minimum
in this line considerably for a short time as a
speed during this process. In this case the
result of the high flow of fluid required to fill
speed reference from the electric controller
the drained trip fluid system during this
is at maximum. If conversely, start-up is to
latching in-period. The pressure upstream of
be governed by the electric controller,
solenoid valve MAX48AA202 is maintained
reference speed setter MAX46 BY001 is set
via orifice MAX42BP022 during this period.
to maximum and the speed reference from
This ensures that the solenoid valve remains
the electric controller to minimum. The
in the position shown. The auxiliary start-up
combined stop and control valves are closed
fluid circuit at the start-up and load-limiting
because the trip fluid circuit is not yet
device MAX47BY001 is fed from the system
pressurized. Turning hand-wheel KA01
down stream of filter MAX42BT003 (fluid
clockwise or operating motor
supply during testing), since the pressure in
MAX47BY001M of start-up and load limiting
the system is subject to no significant
device MAX47BY001 in the close direction
change during start-up. It is not possible to
releases spring KA06 in auxiliary follow up
supply the hydraulic fluid connection of
piston KA08 via the linkage, thereby
solenoid valve MAX48AA202 from this
preventing a buildup of auxiliary secondary
system, as this would have an in admissible
fluid pressure. The hydraulic amplifier
effect on the trip fluid system while the
MAX45BY011 with follow-up pistons KA01
latching operation with the solenoid valves
and KA02 is now in the control valves closed
MAX48AA201 and MAX48AA202 during
position so that a buildup of secondary fluid
testing is taking place.
pressure is prevented when main trip valves
MAX51AA005 and MAX51M006 are latched After latching in, the trip fluid circuit is
in. closed. The trip fluid now flows to the space
above servomotor piston KA01 of stop
Further turning of hand-wheel KA01 moves
valves MAA10+20AA001 and MAB10+20
pilot valve KA02 of start-up and load limiting
AA001 forcing it down against piston discs
device MAX47BY001 further downwards,
KA002. Operation of the start-up and load-
admitting control fluid first into the start-up
limiting device is continued until their lower
fluid circuit and then into the auxiliary start
limit position is reached.
up fluid circuit. The start-up fluid flows to the
space above the pilot valve of test valves When hand-wheel KA01 is turned back or
MAX47AA011+012 and MAX47AA021+ motor MAX47BY001M of start-up and load
022, forcing them down against the action of limiting device MAX47BY001 is operated in
the springs. The auxiliary start-up fluid the open direction, the control fluid is
raises the pilot valves of main trip valves allowed to drain first from the auxiliary start-
MAX51AA005 and MAX51AA006, thereby up fluid circuit and then from the start-up
moving them into their normal operating fluid circuit. The pilot valve of test valves
position and permitting trip fluid to flow to MAX47AA011+012 and MAX47 AA021+022
test valves MAX47AA011+012 and are forced upwards by the springs,
MAX47AA021+022 of the main stop valves whereupon the trip fluid above servomotor
and reheat stop valves. At the same time, piston KA01 slowly drains off. The pressure
overspeed trip release devices difference thus created lifts both pistons
MAY10AA001 and 002 are latched in if they together into their upper limit position, thus
have been tripped. The function of non causing main stop valves MAA10+20 AA001
return valve MAX42AA011 is to interrupt and reheat stop valves MAB10+20 AA001 to

BHEL Hardwar 5.1-0610-01/1

open. Main trip valves MAX51AA005 and setter has the effect of changing turbine
MAX51AA006 are now held in their output.
operating position by the fluid pressure
beneath the differential piston.
Load Limitation
Once the main & reheat stop valves are Start-up and load limiting device
open, further turning of hand-wheel KA01 or MAX47BY001 engages mechanically in
operation of motor MAX47BY001M of the controller bellow KA09 of hydraulic speed
start -up and load limiting device in the open governor/controller MAX46BY001 so that it
direction will after passing through a certain can serve simultaneously as a load-limiting
dead range, cause lever KA03 and sleeve device. This means that opening of the
KA04 to move further downwards, as a control valves MAA10+20AA002 and
result of which the auxiliary secondary fluid MAB10+20 AA002 is limited to an adjustable
pressure begins to increase and acts via setting. This setting is made manually or
hydraulic amplifier MAX45 BY011 and follow from the control room via motor
up pistons KA01 and KA02 to gradually MAX47BY001M.
open control valves MAA10+20AA002 and
MAB10+20AA002. This brings the turbine
up to about 85 to 90% rated speed. Speed Electro-hydraulic Turbine Controller
controller MAX46BY001 now cuts in to If the turbine is to be started up with the
maintain turbine speed. Start-up and load electro-hydraulic turbine controller, the
limiting device MAX47BY001 is then brought reference signal from the electric speed
into the fully open position. A pressure controller must first be set to minimum so
gauge MAX44CP501 and electric speed that this takes over running up the turbine -
transducer MYA001CS011-013 are used to generator unit from turning speed. Start-up
measure speed. and load limiting device MAX47BY001 is
brought into its open position once the stop
Reference speed setter MAX46BY001 is
valves have been opened. Slowly raising the
used for further speed run-up for connecting
speed reference from the electric controller
the turbine-generator unit in parallel and for
cuts in the electric speed control system,
bringing it on load. Turning hand-wheel
and the turbine-generator unit is brought up
KA01 of the reference speed setter or
to rated speed and synchronized.
operation of motor MAX46BY001M increase
the tension of speed setting spring KA02 to Further loading is governed by the electric
increase speed. Since in interconnected power controller by increasing the load
operation speed is determined by grid reference within the admissible rate of load
conditions, actuation of the reference speed change.

5.1-0610-01/2
 Steam Turbine Speed Control
Description

Speed control may be exercised either secondary medium pressures in the follow-up
hydraulically or electro-hydraulically. pistons of the hydraulic amplifier.
The secondary medium circuits and the
Hydraulic Control auxiliary secondary medium circuits are
Main oil pump MAV21AP001 supplies the supplied from the trip medium circuit by way
bearing and primary oil circuits with control of orifices.
oil whilst hydraulic speed transmitter The varying secondary medium pressure in
MAX44AP001 acts as a pulse generator for the follow-up pistons of the hydraulic amplifier
the control circuit, providing a primary oil in turn effects changes in the positions of
pressure proportional to the speed. This oil their associated control valves or other
pressure can also be read directly from control devices.
speed indicator pressure gauge
MAX44CP501. This primary oil pressure
acts on diaphragm KA09 of hydraulic speed Electro-hydraulic Control
governor MAX46BY001 against the force of The speed of the turbine is measured
speed setting spring KA02 which is digitally. For this purpose electrical speed
tensioned by reference speed setter transducers MYA01CS011 to 013 are
MAX46BY001.The travel of diaphragm mounted on the high-pressure end of the
KA09, which can be limited by starting and turbine shaft.
load limit device MAX47BY001, is
transmitted by linkage KA03 to sleeves The electro-hydraulic converter constitutes
the link between the electrical and hydraulic
KA04 of auxiliary follow-up pistons KA08,
parts of the governing system. The electro-
the pistons KA05 of which are held against
hydraulic converter consists of the speed
the medium pressure by spring KA06.
control converter MAX45BY001 and a
Medium drains off according to the amount
of port overlap between piston and sleeve plunger coil system CG001T. The signal from
and a medium pressure corresponding to the electro-hydraulic controller actuates the
control sleeve via the plunger coil system.
the tension of spring KA06 is built up. This
The control sleeve determines the position of
auxiliary secondary medium pressure acts
pilot valve KA07 in the manner of a follow-up
as a pulse signal via pilot valve KA07 of
hydraulic amplifier MAX45 BY011. piston. The further mode of action is the
same as that of the hydraulic speed
Piston KA08 of this hydraulic amplifier governor. Two differential transmitters
assumes a position corresponding to the CG001A and CG001K are located at piston
auxiliary secondary medium pressure and KA08 of electro-hydraulic converter MAX45
operates the sleeves of follow-up piston BY001 as feedback transmitters to the
KA01and KA02 via a linkage system. A electro-hydraulic controller. This stabilizes the
feedback system stabilizes the position of control process.
pilot valve KA07 and piston KA08 of
hydraulic amplifier MAX45BY011. As
Change-over from Hydraulic to Electro-
already described for auxiliary follow-up
hydraulic Control
piston KA08, a secondary medium
pressure corresponding to the position of As already mentioned, Change-over from one
the sleeves and to the related spring control system to the other is possible even
tension builds up in the follow up pistons of during operation as the two controllers are
hydraulic amplifier MAX45BY011. Any connected in parallel downstream of the
change in the position of linkage KA03 associated follow up piston batteries, which
results in a proportional change of the form a minimum value gate. This means that

BHEL Hardwar 5.1-0620-01/1

it is always the controller with the lower set regulating cylinders MAX45BY001 KA10 and
point, which leads. MAX45BY011 KA10 by way of energizing
If the turbine is operated with the hydraulic solenoid valve MAX42AA051, whereby the
governor, the speed set point of the electro- pistons move into their upper end positions
hydraulic controller is set at “maximum against the force of the spring and, via a
speed” which prevents the electro-hydraulic linkage, tension the springs of follow-up
control system from coming into action. To pistons KA02 of the control valves in such a
bring in the electro-hydraulic control way that this produces the desired setting
system, the speed set point of the electro- response of the IP control valves in relation to
hydraulic controller must be reduced slowly the HP control valves.
until the secondary medium pressures drop If the condition “Turbine load less than set
slightly. When this occurs, the electro- minimum load and the ratio of HP exhaust
hydraulic controller has taken over. Then steam pressure to main steam pressure
the reference speed setter of hydraulic greater than a set value is fulfilled”, e.g.
governor speed MAX46BY001 is set to after a load rejection, solenoid valve
“maximum speed”. The electro-hydraulic MAX42AA051 is de-energised, thereby
controller is then fully effective and can cutting off the flow of control medium to the
operate over the entire load range. The regulating cylinders and allowing the control
hydraulic speed governor also acts as a medium under the pistons to drain off. The
speed limiter in the event of failure of the pistons are moved into their lower end
electro-hydraulic controller. In this case, position by the restoring springs and the
operation of the turbine may immediately springs of follow-up pistons KA02 are
be continued by means of the hydraulic adjusted so that the IP control valves do not
speed governor. begin to open until the HP control valves
have opened to a greater extent, with the
Change-over from Electro-hydraulic to result that the HP exhaust steam temperature
Hydraulic Control is lowered.
Change-over is performed in the reverse For operation of the plant without the HP and
sequence. First reduce the set point at LP bypass stations, a manual adjusting
reference speed setter MAX46BY001 until mechanism KA11 is also provided for
the secondary medium pressures drop adjusting the relationship between the valves
slightly. This indicates that the hydraulic such that the reheat valves open before the
speed governor has taken over. Then set main steam valves. Under these operating
the set point of the electro-hydraulic conditions, solenoid valve MAX42AA051 is
controller to maximum. The hydraulic energised and an interlock is provided to
speed governor is then completely effective prevent de-energisation.
and can operate over the entire load range.
This adjustment may only be performed
manually and must always be performed on
Adjusting Device for Valves both follow-up piston batteries MAX45BY001
An adjusting device, which makes it and MAX45BY011, to ensure that change-
possible to change the setting response of over from hydraulic to electro-hydraulic
the HP and IP control valves, is provided control and vice versa is possible at all times.
for limiting the HP exhaust steam This manual adjustment must always be
temperature. reversed before the HP or LP bypass station
In normal operation, control medium is is brought into operation.
admitted to the space below the pistons of

5.1-0620-01/2
 Steam Turbine Control System
Description Electrical Speed Measuring

The electrical speed signals originate from remaining speed probes. The output is then
the electrical speed transducers which fed to the speed measuring unit, electro-
consist of four ferromagnetic type speed hydraulic controller and speed target unit.
probes, MAY01CS011 to 014 (one as spare)
The speed-measuring unit incorporates two
and a toothed wheel with 60 teeth made
speed ranges. The lower range covers 0-
around its circumference located on the
360 rpm and the upper range 0-3600 rpm.
main oil pump shaft.
The changeover from one range to the other
The teeth of the wheel act upon the four is completely automatic.
stationary speed probes. When turbine
A speed indicator mounted on the hydraulic
rotates, square wave signals are generated
control equipment rack provides local
in the probes. The frequency of these
speed-readings. Indicating lights located
voltages is proportional to the rotational
near the speed indicator show which range
speed of the turbine. The output of these
is engaged.
speed probes are fed to the input modules
which provide digital output signals. From the speed-measuring unit, speed
signals are also provided to the turbine
The three values for the rotational speed
stress evaluator/controller, automatic turbine
obtained by this process are continuously
tester and recorders. Output signals are
monitored for failures. If one of the speed
available for purchaser’s remote speed
probes fail, the control circuit continues to
indicators and functional group automatic
operate without interruption, using two
(FGA).

BHEL Hardwar 5.1-0621-02

 Steam Turbine Protective Devices
Description

Overspeed Trip Low-Vacuum Trip for Turbine Protection

Two overspeed trips MAY10 AA001 and 002 An increase of pressure in the condenser
are provided to trip/shut down the turbine in causes the valve of low-vacuum trip MAG01
the event of overspeed. Each trip device AA011 to move downwards from its upper
consists of an eccentric bolt/striker fitted in position under the force of the pre-tensioned
the emergency governor shaft with its center spring. This action depressurizes the space
of gravity displaced from the axis of rotation below the right-hand valve. The right-hand
and held In position against centrifugal force valve is moved into its lower position by a
by a spring up to an adjustable preset speed spring and thus opens the auxiliary trip fluid
of 10 to 12 % above the normal turbine circuit. Opening the auxiliary trip fluid circuit
operating speed. At the preset overspeed, depressurizes the fluid below the differential
centrifugal force overcomes the spring force pistons of main trip valves MAX51AA005
and the eccentric bolt/striker flies outwards and MAX51AA006 and the differential
into its extended position. In doing so it pistons are activated by a spring. This
strikes the pawl which releases the piston of closes the control fluid inlet to the trip fluid
the overspeed trip release device KA01. circuit and at the same time opens the main
Through combined spring force and fluid trip fluid circuit to drain, causing the trip fluid
pressure, the piston opens the auxiliary trip pressure to drop and all stop and control
fluid circuit to the main trip valves MAX51 valves of the turbine to close. Limit switch
AA005 and MAX51AA006. MAG01CG011B signals to the control room
that the low-vacuum trip is not in its normal
operational position. Limit switch MAG01
Thrust-Bearing Trip
CG011C indicates in the control room that
Thrust bearing trips MAD12CY011/012/013 turbine trip has been initiated by the low-
are tripped electrically in the event of vacuum trip.
excessive axial displacement of the turbine
shaft. To make it possible to latch-in the trip
devices and thus to build up trip fluid
pressure for adjusting and testing the control
Pressure Switch loop or similar purposes when the turbine is
Installed in the trip fluid circuit are two shut down and no vacuum exists, the low-
pressure switches MAX51CP011 and vacuum trip has an auxiliary piston which is
MAX51CP012 which bridge the longtime loaded with primary oil pressure above the
delayed relays of the reverse-power adjustable compression spring. When the
protection system in such a way that the turbine is shut down there is no primary oil
generator is shut down by response of the pressure and so the auxiliary piston is
short-time delayed relays as soon as it unable to tension the adjustable
begins to motor. The annunciation Turbine compression spring arranged above the
trip initiated is transmitted simultaneously to diaphragm system. The spring below the
the control room. diaphragm system lifts the valve, closing the
auxiliary trip fluid circuit so that the trip
devices can be latched in.
Remote Solenoid Trip
Remote solenoid trip is activated via As soon as the turbine is started up and
solenoid valves MAX52 AA001 and MAX52 brought up to speed, primary oil enters the
AA002. The remote solenoid trip may be space above the auxiliary piston, forcing in
initiated manually from the control room by into its lower end position at a turbine speed
push button, by the electrical low-vacuum far below rated speed. Thus the low-vacuum
trip or the thrust bearing trip or other trip is reset for initiation of turbine trip before
protective devices. the turbine has reached rated speed.

BHEL Hardwar 5.1-0630-01/1

Solenoid Valves for Load Shedding Relay via main trip valve MAX51AA005 and
Solenoid valves MAX45 AA001 and MAX46 MAX51AA006 and flows both to the
AA011 are provided to prevent the turbine secondary fluid circuits and to the stop
from reaching trip-out speed in the event of valves MAA10+20AA001 and
a sudden load rejection. These solenoid MAB10+20AA001. The main trip valves
valves are actuated by the load shedding serve to rapidly reduce the fluid pressure in
relay if the rate of load drop relative to time the trip fluid circuit. If the pressure below the
exceeds a predetermined value. Solenoid differential piston of main trip valves MAX51
valve MAX45AA001 opens the IP secondary AA005 and MAX51AA006 drops below a
fluid circuit directly. Solenoid valve MAX46 preset adjustable value, the piston in each
AA011 opens the auxiliary secondary fluid valve is forced downwards by the spring,
circuit. Pilot valve KA07 of hydraulic opening the drain passage for the trip fluid
converter MAX45BY011 moves upward and and closing the control fluid inlet.
allows the control fluid to flow to the area If the pressure in the trip fluid circuit drops
below piston KA08 of the converter. Piston below a predetermined value, spring loading
KA08 moves to its upper end position, separates the upper and lower pistons of
thereby depressurizing all secondary fluid main stop valves MAA10+20 AA001 and
circuits. reheat stop valves MAB10+20 AA001, and
Since the reheat IP secondary fluid circuit all the stop valves close very rapidly. At the
opens directly, the IP control valves (which same time, the control valves and extraction
control the major portion of the power check valves also close, as the secondary
output) close without any appreciable delay. fluid circuits are fed from the trip fluid circuit.
A small delay is involved in closing all other Thus on trip initiation, all turbine stop and
control valves by depressurizing the control valves close.
auxiliary secondary fluid circuit, but his
action is still performed before an increase Manual local Trip Method of Initiating
in turbine speed causes the speed controller Turbine Trip
to respond. At the same time, the extraction
Manual local initiation of turbine trip is
check valves, which are dependent on
performed by way of local trip valve MAX52
secondary fluid via extraction valve relay
AA005. The valve must be pressed
MAX51AA011, close.
downwards manually, thus opening the drain
After an adjustable interval, the solenoid passage for the auxiliary trip fluid. The two
valves are reclosed, permitting secondary limit switches MAX52CG005C and MAX52
fluid pressures corresponding to the reduced CG005E indicate in the control room that trip
load to build up again. has been initiated locally by hand.

Turbine Trip Gear

The trip fluid is taken from the control fluid

5.1-0630-01/2
 Steam Turbine Overspeed Trip Test
Description

Testing with Turbine under Load When this happened, pilot valve KA02 must
Condition be pushed downwards to admit control
Overspeed trips MAY10 AA001 and 002 can medium into the auxiliary start-up medium
be tested using test device MAX62AA001 circuit to the differential pilot valve of the
with the turbine running under load or no- overspeed trip device. The pilot valve moves
load conditions. To operate the test device, towards the right and latches the overspeed
pilot valve KA03 is first pushed downwards trip device in again.
and held in this position. This isolates the The buildup of pressure in the auxiliary start-
auxiliary trip medium circuit from the up medium circuit between the overseed trip
overspeed trips and prevents the main trip test device and the overspeed trip release
being initiated by the overspeed trips. device can be followed at pressure gauge
Subsequent operation of hand-wheel KA01 MAX48CP501. When pilot valve KA02 is
moves the center pilot valve downwards. then released, the auxiliary start-up medium
This action blocks the drain and allows the pressure returns to 0 pressure. The auxiliary
control oil to flow through the center bore of trip medium pressure must then remain at its
the pump shaft into overspeed trips. The full value (readable at pressure gauge
control oil pressure thus builds up and MAX52CP501). If this is the case, pilot valve
moves the eccentric bolts/strikers outwards KA03 may be released. The test is
against the spring force, releasing the pawls completed. If, when valve KA02 is released,
of the overspeed trip releasing device, as a the auxiliary trip medium pressure collapses,
results of which the pilot valve moves rapidly pilot valve KA02 must be pushed
inwards. The pressure in the auxiliary rip downwards again and must be held in this
medium circuit, up to the over speed trip test position a little longer. It is essential that the
device, then collapses. Operation is followed auxiliary trip medium pressure must remain
by observing the reading at pressure gauge steady before valve KA03 is released.
MAX52CP501.
The trip pressure is read off at pressure Testing with Turbine under No-Load
gauge MAX62CP501. If during operation at Condition
rated speed, this pressure should deviate
Overspeed trips MAY10AA001 and 002
from the baseline value as recorded in the
must be tested at regular intervals by
test report, a defect in the overspeed trip
running the unloaded turbine up to trip
may be assumed. If the trip pressure is too
speed. This is done by operating lever KA07
high, the bolt may be made to move freely
of hydraulic speed governor MAX46BY001,
by rapidly operating the pilot valve by means
which presses linkage KA03 downwards,
of hand-wheel KA01 several times in
thus increasing the secondary medium
succession. If this measure does not have
pressures. This causes the control valves to
the desired result, the turbine must be shut
open and the turbine starts to overspeed.
down and the emergency governor to be
The actual speed at which trip occurs can be
inspected.
read off at pressure gauge MAX44CP501.
As soon as the auxiliary trip medium
Limit switches MAY10CG001&002C of
pressure drops to 0 at pressure gauge
overspeed trip release device MAY10
MAX52CP501, the center pilot valve must
AA001 and 002 indicate in the control room
be returned to its original position using
that main trip valves MAX51AA005 and
hand-wheel KA01. The pressure in the test
MAX51AA006 have been actuated by
line should then return to 0, as can be read
overspeed protective device.
off at pressure gauge MAX62CP501. The
bolts/strikers of the overspeed trips should
return to their original position.

BHEL Hardwar 5.1-0631-01

 Steam Turbine Testing of Stop Valves
Description

Main Steam Stop Valves

The main control valves may be closed for
The stop valves can be tested for freedom of testing purposes for not longer than 4 to 5
movement independently of each other even minutes so that the unbalanced steam flow
during operation with the aid of the test is only present for a short period to avoid
valves MAX47AA011 to 012 attached to significant effects on the HP turbine casing.
each of them. The main stop valves MAA10
and 20AA001 may only be tested at a load It is a precondition for testing the main stop
that is less than 80% of the maximum valves that there should be a mixing header
output. in the steam leads between the boiler and
the stop valves.
If the test is conducted with the initial
pressure controller out of operation, the
main stop valves may only travel out of the Reheat Stop Valves
open position to about 50% closed at the Testing of a reheat stop valve must be
most and are to be reopened immediately. If conducted at a power output at which the
the initial pressure controller is in operation reheat control valves MAB10 and 20 AA002
complete closure of a main stop valve may are fully open. First the associated reheat
be performed. This, however, is conditional control valve is to be closed by pressing of
upon the response time of the initial pushbutton in the supply unit. Then the
pressure controller being high enough to reheat stop valve MAB10 or 20 AA001 is
keep the initial pressure constant even closed by actuating test valve MAX47AA021
during the testing procedure. and 022 and reopened. On completion of
the test the reheat control valve is to be
First the main control valve concerned
reopened.
MAA10 or 20AA002, is to be closed by
pressing of pushbutton in the supply unit. If As for the main steam stop valves it is a
in operation, the initial pressure controller precondition for testing the reheat stop
opens the other main control valve valves that there should be a mixing header
accordingly. Once the control valve has in the steam leads between the boiler and
been closed the stop valve can be closed. It the stop valves.
is to be reopened immediately.

BHEL Hardwar 5.1-0632-01

 Steam Turbine LP Bypass System
Description (General)

Function Electro-hydraulic Actuator for LP Bypass

The function of the LP bypass control Control Valve
system (EHA Type) is to monitor the The LP bypass control valve actuator is an
pressure in the reheat system and to control electro-hydraulic actuator with an external
it under certain operating conditions. During control fluid supply from centralized
start-up and shutdown, and at operation Hydraulic Power Unit (HPSU). The control
below minimum boiler load, the volume of block converts the electrical signal from the
steam not utilized by the IP and LP cylinders controller into flow of hydraulic fluid. It
of the turbine must be bypassed to the controls the intake and discharge of
condenser via the LP bypass valves. This hydraulic fluid to and from the piston
requires the bypass control system to chambers of the actuator in a continuous
maintain the pressure in the reheater mode, thus permitting very precise
constant in accordance with the preset positioning of the actuator. The control block
reference value. In the event of will position the valve as well as block the
disturbances, e.g. load shedding or trip out, cylinder in case of hydraulic fluid failure.
the amount of excess reheat steam
bypassed to the condenser. Water Injection System
During LP Bypass operation a part or entire
Hydraulic Power Supply Unit (HPSU) steam flow produced by boiler is routed to
the condenser. In order that the condensate
The hydraulic unit serves to supply the
pumps do not have to supply the injection
necessary pressurized fluid to the actuators.
water flow required for the full boiler capacity
The hydraulic power unit has two pumps. and to prevent the amount of excess water
One pump is always in operation and the flow becoming too high, under normal start-
other is stand-by. up and shut down conditions, a regulating
type water injection system to optimize the
Two nos. filtration circuits are provided in
water quantity to be mixed with LP Bypass
order to maintain the cleanliness of system
steam is provided.
for proper functioning of hydraulic system.
Actuator for water injection valve may be
Hydraulic fluid, a phosphate ester is chosen
hydraulic or pneumatic type.
for high pressure hydraulic system, which
ensures good fire protection. The fluid has A separate flow controller is provided to
good lubricating properties and allows a regulate the spray water valve.
comparatively easy maintenance.
A regeneration unit for hydraulic fluid is
Note:- This is a general description of LP
provided to maintain its properties/quality.
Bypass System (EHA Type). Refer O&M
Electro-hydraulic Actuator for LP Bypass manual supplied alongwith equipments
Stop Valve by vendor for detail description.
The LP bypass stop valve actuator is an
electro-hydraulic actuator with an external
control fluid supply from centralized
Hydraulic Power Supply Unit (HPSU). The
unit is designed to operate a single acting
cylinder with a spring in closing direction.
The unit has a solenoid valve for opening &
closing of stop valve and two trip solenoid
valves for fail close/positive close function.
Operation of any one trip solenoid valve is
sufficient to close the stop valve.

BHEL Haridwar 5.1-0640-01-1

 Steam Turbine Extraction Check Valve
Description

The function of extraction check valves there is a danger that the contents of the
LBQ50, LBS21, LBS31, LBS41 and LBS42 feed water heaters will flash into steam. In
AA001and 002 is to prevent the backflow of this case, closure of the swing check valves
steam into the turbine from the extraction is assisted for a short time by means of
lines and the feed water heaters. pistons KA01 of auxiliary slide valve MAX51
AA011. In normal operation pilot valve KA01
Two free-swinging check valves are
passes trip oil to pilot valve KA02. In the
installed in each extraction lines A2, A3, A4
event of an abrupt output drop, the pressure
and A5. In the event of flow reversal in the
on the top side of pilot valve KA01 drops,
extraction lines, the valves close
where as depressurization beneath the
automatically, whereby actuator KA01
piston is delayed by a check valve and the
assists the closing movement of the disc.
pressure in fluid accumulator MAX45BB001.
The mechanical design of the swing check The resulting differential pressure moves the
valves is such that they are brought into the piston upward to interrupt the trip fluid supply
free -swinging position by means of trip fluid to the swing check valves, whose closing
pressure via actuator KA01 and the disc is movement is assisted by the spring force of
moved into the steam flow by means of actuator via a flow restrictor. The pilot valve
spring force acting via the lever, shaft and moves back into its original position to open
disc lever and closes if differential pressure the way for the trip fluid to release the swing
is either lowered or reversed. check valves.
The trip supply to actuator KA01 is Turning the handwheel on the changeover
controlled by extraction valve relay MAX51 valves MAX51AA048, MAX51AA051 etc.
AA011, changeover valves MAX51AA028, close the associated swing check valves
MAX51AA031 etc. within the bounds of the effectiveness of the
spring.
Extraction valve relay MAX51 AA011
actuates the swing check valves in The swing check valve in extraction lines A4
accordance with the secondary fluid can also be triggered by differential pressure
pressure, suitable adjustment of the spring switch LBS42CP002. This differential
in relation to piston KA02 sets the turbine pressure switches energizes solenoid valves
load at which the swing check valves are MAX51AA028 and MAX51AA031 if the
released for opening or assisted in closing. steam flow drops below a preset rate
The release setting for opening cannot be (differential pressure), thereby further
arbitrarily adjusted towards higher turbine assisting the closing action of the swing
output, as the swing check valve will open check valve.
even without the release action if the steam
The position of all swing check valves is
pressure difference exerts a greater force
indicated via position transmitters-CG001A
than the closing spring.
and CG002A.
In the event of major output drops above
the opening point of the swing check valves,

BHEL Hardwar 5.1-0650-01

 Steam Turbine Swing Check Valve
Description Cold reheat steam line

In order that the turbine may be completely check valve is closed by the actuator KA01
separated from the steam when it is and prevent the steam in the cold reheat line
stationary, an additional check valve from returning to the turbine. By removing the
LBC10 AA001 is fitted in the line between valve from the steam flow during operation
the HP cylinder and the reheater and above 5 to 10% of maximum power,
operating through pilot valve MAX42AA001 additional pressure losses during normal
+002 and the rotary actuator KA01 operation are avoided. If, during start-up, the
depending on the pressure in the steam pressure on the inlet side of the valve
associated secondary medium circuit. The and at the same time the secondary medium
swing check valve opens fully when the pressure is not yet sufficient to open the
control valves reached approx. 5 to 10% of valve, the steam pressure will open the swing
their full-power travel. Only when the check valve against the medium pressure in
control valves reach this point again as the manner of a safety valve.
they are being closed, the swing check The Open and Control position of the swing
valve brought into steam flow again by the check valve are indicated in the control room
hydraulic actuator. Thus when the steam via the limit switches.
flow in the normal direction ceases, the

BHEL Hardwar 5.1-0651-01

 Steam Turbine Testing of Check Valves
Description in Cold Reheat Line

The check valve LBC10AA001 in cold can be brought only in an intermediate

reheat line is wide open during normal position.
operation by its associated rotary When the check valve starts moving, the
servomotor KA01. For testing the movability, open position limit switch will change
the check valve can be moved in closing position, which is indicated in the control
direction by interrupting the connection room. With this indicator the regular
between pilot valve MAX42 AA002 and HP movement of the check valve can be
secondary fluid line with closing of shut-off checked after closing shut-off valve
valve MAX45AA566 (pilot valve and shut-off MAX45AA566 nearby upto this value. After
valve are installed in the turbine hydraulic this check the shut-off valve has to be
control rack). reopened. The check valve is moved then in
By closing the shut-off valve the pilot valve its wide-open position. At the position
MAX42AA002 is reversing and rotary indicator in the control room it can be
servomotor is moving the check valves in checked if the check valve has reached
closing direction. Because the torque of again its wide-open position.
these servomotor is limited, the check
valves can not be closed completely. This

BHEL Hardwar 5.1-0652-01

 Steam Turbine Automatic Turbine Tester
Description General

Function
Healthiness of the protective devices and the 1. Protective devices
stop and control valves is vitally important for
Description: “Automatic Turbine
the operational reliability and availability of
Tester, Protective device”.
the turbine. Hence, it is essential that these
equipments are always kept in a fully 2. Main stop and control valves
serviceable condition. Economy has dictated Description: “Automatic Turbine tester,
longer intervals between turbine overhauls, stop and control valves”.
with the result that testing of the equipments The complete testing of all components
and devices is now necessary at regular which must operate when an automatic trip
intervals during normal operation. becomes necessary is assured, despite the
There are manually operated devices for subdivision into two testing groups
testing the free operation of the stop and (protective devices, stop and control
control valves. However, these tests do not valves), because the main trip valves which
cover all components involved in an store the trip signal by mechanical hydraulic
automatic trip with the result that the means are operated together with each
conditions only party corresponds to those protective device and subsequent
prevailing during a real trip. satisfactory reduction of the trip oil pressure
after the valves are monitored.
The system
Nature of the description
Any possible mal-operation associated with
manually operated devices are avoided with The descriptions mentioned above contain
fully automatic tests by means of the the practical sequence of the tests on the
automatic turbine tester. Full protection for individual devices and gives details of
the turbine during testing is also assured by possible irregularities. The description of
suitable circuit arrangements. This increases equipment contained in the automatic
the operational reliability and availability of control cubicle (stepping switches, interlock
the plant. modules, etc), the control panel in the
control room and schematic circuit diagrams
The automatic turbine tester is realised in are contained in the separate electrical
digital technology. section of the “Operating Manual” for the
automatic turbine tester.
System adaptation For the understanding of the automatic
The system is subdivided into functional turbine tester from these descriptions it is
groups for each device. Each group contains assumed that the reader is fully conversant
the device itself and all necessary with the functioning of the individual
transmission elements for initiation of a protective devices and valves within the
normal trip. overall turbine governing and protection
system.
The automatic turbine tester is divided into
the following 2 subgroups:

BHEL Hardwar 5.1-0660-00

 Steam Turbine Automatic Turbine Tester
Description for Protective Device

Scope of Testing
The Automatic turbine tester (ATT) Trip Initiation during Testing
subgroup for the protective devices is To provide normal protection for the turbine
divided into a preliminary test and the during testing, any trip initiation signals from
following four individual testing systems. the protective devices will de-energize the

Remote trip solenoid MAX52AA001 solenoid valves for remote trip during testing
and the same time initiate the reset

Remote trip solenoid MAX52AA002 program. This also applies to all normal

Over speed trips MAY10AA001/MAY10 electrical remote trips such as generator
AA002 protection, etc. For the duration of testing,
two electrical speed signals are formed to

Low vacuum trip MAG01AA011 provide protection against turbine
One or more systems can be selected for overspend.
testing at the control panel and the selection During all electrical testing of the protective
is stored. The start of the test program devices, the electric trip action is prevented
automatically causes a preliminary test to be however, all annunciations are activated as
carried out on the protective channels which for actual trip. The appropriate section of the
are to be effective during actual testing and alarm annunciation system is thus also
then establishes the test circuit. Once the tested.
first test selected has been completed and
the protective device has latched in again,
the test circuit is restored to its normal Features of the Automatic Turbine Tester
operational configuration. Further selected The automatic turbine tester is distinguished
tests must be started individually by by the following features:
pressing the Test push-button to start the

Individual testing of each turbine
program.
protective device.

Automatic testing, upon selection of a
General
test, of the devices that protect the
During normal operation, the protective turbine during that test.
devices act via main trip valves MAX51
Testing of the protective devices for
AA005 and MAX 51AA006 on the stop and
normal turbine operation can only be
control valves and extraction swing check
performed if the preliminary test has run
valves. The remote trip solenoids MAX52
without fault and the protection of the
AA001 and MAX52 AA002, over speed trips
turbine during testing is assured.
MAY10AA001/MAY10AA002 and low
vacuum trip MAG01AA011 actuate main trip
Monitoring of all program steps for
valves MAX51AA005 and MAX51AA006 by execution within a certain time.
opening the auxiliary trip fluid circuit.

Interruption if the running time of any
For the duration of testing of the protective program step is exceeded or if trip is
devices, a test circuit is established .In order initiated.
to keep the trip fluid circuit effective, it is

Automatic reset of the test program after
isolated from main trip valves MAX51 AA005
a fault.
and MAX51AA006 by means of change-over
valve MAX51AA211 and supplied with fluid
Protection of the turbine during testing
via solenoid valves MAX51AA201 and provided by special test protective
MAX51AA202 (remote trip during testing). devices.

BHEL Hardwar 5.1-0661-00/1

Setting Data Individual Tests
The setting data for the pressure switches The individual test is performed after
are listed in the setting record Measuring completion of the preliminary test and after
Point List. The actually set values are the test circuit has been established.
logged in the Commissioning Test Successful completion of each individual
Record.The test running times, etc. are test is annunciated by the limit switches on
entered in the functional diagrams. main trip valves MAX51AA005 and MAX51
AA006, pressure switch MAX52CP211 in
Test Sequence the auxiliary trip fluid circuit and pressure
switch MAX 51CP209 in the trip fluid circuit
Start of Testing between change-over valve MAX51AA211
The test begins with the selection of the and the main trip valve MAX51AA006. The
protective devices subgroup. This is associated limit switch also annunciates
performed by pressing the subgroup On/Off when a protective device (except for the
push button. remote trip solenoids) has been activated.
On completion of each individual test, all
The subgroup remains on until switched off
activated protective devices are returned to
when the program has been completed.
their normal operating position by reset
While the protective devices subgroup
solenoid valves MAX48AA201 and MAX48
program is running, the other subgroups are AA202 and the test circuit is deactivated.
blocked.
Whenever several of the same types of
The On/Off push-button is also used to
protective device are provided, only one will
acknowledge alarms.
be described in the following, as the test
procedure is the same for all.
Selection
After the subgroup has been switched on, Preliminary Test
the protective device to be tested is selected Pressing the Test push-button automatically
by pressing the selection push button for the
initiates a test of the protective circuits to be
individual device.
effective during testing.
A separate selection push-button is provided
for each protective device. Only one
Function
selection may be made at a time. Selection
of a further test is possible only once all The function of the preliminary test is to
other programs have ended detect any faults in the protective circuits to
be used during testing, and, if any are
detected, to inhibit testing of the protective
Test Push-Button device, as this would leave the turbine
The automatic test program is started by without protection.
pressing the Test push-button
Test Sequence
Cancel Push-Button
In the course of the preliminary test,
This push-button can be used to terminate solenoid valves MAX51AA201 and MAX51
the test program running at any time and to AA202 (remote trip during testing) are
initiate the reset program. The reset automatically tested before the test circuit is
program has priority over the test program. established. These valves (MAX51AA201
and MAX51AA202) are first energized,
Lamp Test Push-Button resulting in a buildup of control fluid
upstream of changeover valve MAX51AA
All the signal lamps on the control panel can 211.lnitiation of Schmitt triggers (in the
be tested by pressing the Lamp Test Push- speed measuring unit) de-energizes
Button. solenoid valve MAX51AA201 and the control

5.1-0661-00/2
 fluid up stream of changeover valve MAX51 actuating limit switch MAX51CG211C which
AA211 is drained. Successful completion of annunciates this status.
testing is annunciated by pressure switch
MAX51CP207 between solenoid valve MAX De-activating the Test Circuit
51AA201 and changeover valve MAX51AA
211. Subsequently, solenoid valve MAX51 The test circuit is deactivated in the reverse
AA202 is de-energized via the second order on completion of the selected test and
channel of its Schmitt trigger, thereby after automatic latching of the protective
depressurizing the control fluid still present device concerned in its normal operating
between solenoid valves MAX51AA201 and position.
MAX51AA202. This process is monitored by Hydraulic Test Signal Transmitters
pressure switch MAX51CP205. On
successful completion of the preliminary The function of the hydraulic test signal
test, the test circuit is automatically transmitters is to activate the related
established, which permits realistic testing of protective device (with the exception of the
the protective devices without initiating remote trip solenoids). Each protective
turbine trip. device has an associated test signal
transmitter. For testing the over speed trip
Solenoid valves MAX51AA201 and MAX51 device, the associated test signal transmitter
AA202 (for remote trip during testing) are builds up a test pressure relatively slowly
again energized whereupon control fluid is and passes it to the overspeed trips, for
supplied to change over valve MAX51 testing the low vacuum trip, an air pressure
AA211. Then solenoid valve MAX61AA201 signal is introduced to the device via an
is energized, effecting changeover from trip orifice. The testing signals to remote trip
fluid to control fluid. The control fluid in this solenoids MAX52AA001 and MAX52AA002
line drains off, and the pressure difference
drives changeover valve MAX51AA211 into
its test position (lower end position), thereby

are formed within the automatic turbine

tester itself and not by a test signal
transmitter.

5.1-0661-00/3
Main Trip Valves Pressure switches MAX48CP201 and
MAX48CP202 monitor the orderly pressure
MAX 51 AA005 and MAX 51 AA006 collapse of auxiliary start-up fluid circuit after
Only one of the two main trip valves is latching-in of main trip valves.
described in the following, as they are Attention: The lever for manual actuation of
constructional and functionally identical. the main trip valve must not be test operated
during turbine automatic testing operation,
as the electrical trip action is always initiated
Function via the manual trip-out limit switch.
The function of the main trip valve is to Remote Trip Solenoids
amplify and store the hydraulic or
mechanical (manually initiated local) trip MAX52 AA001 and MAX52 AA002
signal. It must respond in the course of The twin electrical remote trip feature
every successful protective device test. consists of the two remote trip solenoid
valves MAX52AA001 and MAX52AA002.
Operation
0ne trip channel is described here, as the
Each main trip valve is kept in its position by test procedure is the same for both.
auxiliary trip fluid pressure. If a protective
device is actuated, the auxiliary trip fluid
circuit is depressurized and the main trip Function
valve is activated. This connects the trip fluid The function of the remote trip solenoids is
and auxiliary trip circuits to drain and shuts to depressurize the auxiliary trip fluid circuit
in the shortest possible time, thereby
bringing main trip valves MAX51AA005 and
MAX51AA006 into their trip positions, in the

off the control fluid supply to the turbine

valves. At the same time, limit switch 1 is event of a malfunction requiring electrical
actuated. trip initiation.

Auxiliary start-up fluid pressure forces During normal operation, the remote trip
differential piston (3) into its normal solenoid isolates the auxiliary trip fluid circuit
operating position. Control fluid IV is then from the drain. For testing, the automatic
free to pass through to buildup the pressure turbine tester switches over the
in the trip fluid and auxiliary trip fluid circuits.

5.1-0661-00/4
solenoid valve so that the auxiliary trip fluid drain, thereby depressurizing it. The loss of
circuit is connected to drain. Trip initiation is auxiliary trip fluid pressure causes the main
monitored downstream of the main trip trip valve to drop which in turn causes the
valves by pressure switches MAX51CP209 trip fluid pressure to collapse.
and MAX52CP211 in the auxiliary trip fluid To activate the over speed trip at rated
circuit. In addition, the limit switch of each speed, as the test routine performed by the
main trip valve must annunciate successful automatic turbine tester requires, a specific
completion of the test. force, equivalent to the increase in
centrifugal force between rated speed and
Latching -in preset trip over speed, is needed .For
testing, this force is exerted by the test oil
On successful completion of testing, remote
pressure, acting on the flybolt /striker (2) .On
trip solenoids MAX52AA001 and MAX52
the basic of the existing defined geometry,
AA002 are de-energized. The reset program
the test oil is reproducible measure for the
is then started.
trip speed, and can therefore be used to
check whether the over speed trip responds
at the desired setting.
Overspeed Trips Test Sequence
MAY10AA001/MAY10AA002 The test oil pressure is produced using the
Function hydraulic test signal transmitter, which is
also used for manual testing. First the
The two over speed trips are provided to
command is given to the actuator motor to
protect the turbine against over speeding in
go into the trip position (down). After a
the event of load rejection coincident with
certain idling time, the test oil pressure
failure of the speed controller. As they are
builds up to act on the two over speed trip
particularly important to the protection of the flybolts/strikers (2).
turbine, they can also be locally tested by
manually with the aid of the over speed trip If the two bolts are functioning correctly, they
test device MAX62AA001 (hydraulic test will fly outwards into the trip position when
signal transmitter) during turbine operation the defined pressure is reached, thereby
at rated speed. (For description see Over activating the main trip valve via pawl (4),
Speed Trip Test). piston (5) and the auxiliary trip fluid circuit.
The two over speed trips are monitored for
activation at the given test oil pressure by

Operation the two pressure switches MAX62CP211

and MAX62CP212 in the test oil line, and
When the preset over speed is reached, the
the limit switch (6). Pressure switches MAX
eccentric flybolt/striker (2) of each over
62CP211 and MAX62CP212 are preset to
speed trip activates piston (5) and limit
respond at a certain level (approx.O.15 bar)
switch (6) annunciate via pawl (4). This
below and above the test oil reference
connects the auxiliary trip fluid circuit to

5.1-0661-00/5
pressure respectively. This test oil reference operation, the pressure in the turbine
pressure is determined during condenser exceed a preset valve.
commissioning and entered in the
commissioning test record. Limit switch (6) Operation
must respond within the pressure range
When the condenser pressure exceeds the
between the settings of pressure switches
adjusted limit, the piston (6) is moved
MAX62CP211 and MAX62CP212. A slow
downwards by this pressure, which acts
buildup of pressure is required for this
against diaphragm {4), and the spring force
operation, that is why a relatively long
(3). Thereby pressure below piston (7) drops
monitoring period equivalent to the running
and this piston moves in its lower end
time of the actuator, has to be selected.
position by spring force connecting the
Premature response of the over speed trips
auxiliary trip fluid circuit to the drain. The
is annunciated.
resultant depressurization of the auxiliary
trip fluid circuit actuates main trip valves
Latching-in MAX51AA005 and MAX51AA006, thereby
closing all turbine valves.
Once the trip has been initiated, the actuator
of the hydraulic test signal transmitter is
driven back until the limit switch annunciates
that normal position has been reached.
Monitoring must be continued until the test
oil pressure at pressure switch MAX62
CP213 is less than 0.1 bar.
This double check-back of the hydraulic test
signal transmitter having returned to normal
position ensures that, after completion of
testing, the over speed at which the turbine
will trip is not reduced due to test oil
pressure remaining effective and that the
over speed trip will not be set off
prematurely in the event of load reduction.
While test oil pressure is decreased, the two
over speed flybolts/strikers spring back into
their normal positions at a pressure well
above 0.5 bar.
Subsequently, piston (5) is brought back into
its normal position by the pressure of
auxiliary start-up fluid II and latched-in with
pawl (4). At the same time, piston (5) shuts
off drain channel IV, so auxiliary trip fluid III
can build up pressure. Once this has been
done, the auxiliary start-up fluid can be
Test sequence
depressurized.
After energizing of test signal transmitter
(solenoid valve) MAG01AA201, fitted in the
signal line to the condenser, this signal line
Low Vacuum Trip is blocked off and simultaneously the space
MAGO1 AAO11 above diaphragm (4) is connected to
Function atmosphere. The air flow via orifice causes a
slow increase of pressure by which the
The function of the low vacuum trip is to pistons (6) and (7) move to their trip position
operate the main trip valve if, during normal
connecting the auxiliary trip fluid circuit to
the drain.

5.1-0661-00/6
The low vacuum trip is monitored for Dispersion of the auxiliary start-up fluid
operation within the specified vacuum range pressure is monitored by pressure switch
by observing pressure switches MAG01 MAX48CP201. The second reset solenoid
CP202 and MAG01CP204. MAX48 AA202 is then de-energized to
disperse the pressure between the two-
solenoid valves. This is monitored by
Latching-in pressure switch MAX48 CP202. The use of
When test signal transmitter (solenoid valve) two reset solenoids ensures that main trip
MAG01AA201 has been de-energized and valve MAX51AA005 and MAX51AA006 and
the connection between low vacuum trip and over speed trip will always be sure to be
the condenser re-established, condenser actuated if either one of the two reset
pressure builds up again above diaphragm solenoids is de-energized.
(4). Piston (6) moves into its upper end
position thereby opening the passage for the
control fluid flow to piston (7). When piston
(7) is in its upper end position, the auxiliary
trip fluid circuit is closed again. Restoration
of normal operating configuration is
annunciated by the limit switch of the low
vacuum trip and by pressure switches
MAG01CP201

Reset Solenoids
MAX48 AA201 and MAX48 AA202

Function
The function of the reset solenoids is to
restore the tripped protective devices to their
normal operating positions during the ATT
reset program.

Operation
The reset solenoids are two 2/3-way 1 Compression I Aux. start-up fluid
solenoid valves, fitted in the auxiliary start- spring II Aux. start-up fluid
2 Coil to protective devices
up fluid line. Both solenoid valves are
3 Valve disc III Control fluid
energized in the course of the reset program
conducted after each subtest, so that Fig. 7 –Reset Solenoid
auxiliary start-up fluid II is supplied with
control fluid III. The control fluid pressure
forces all protective devices back into their
normal operating positions and the trip fluid
and auxiliary trip fluid pressure can build up
again.
When the protective devices have latched-in
again, reset solenoid MAX48AA021 is de-
energized first to shut oft the control fluid
supply through this value.

5.1-0661-00/7
 Steam Turbine Automatic Turbine Tester
Description Stop and Control Valves

The following description refers to a by means of a motor operated actuator

standard stop and control valve assembly. (-AA002M) acting on pilot piston (KA06)
The same text applies analogously to both parallel to pilot value (KA05). This result in
the main stop and control valves and the a closing movement simulating that which
reheat stop and control valves. The valve occurs when the associated secondary
assembly described is drawn in the closed fluid pressure drops. The resultant,
position (ready for start-up). constant slow closing movement is
necessary in order to keep the output
constant. Thus the conditions for actuation
General of the valve are the same during testing as
The stop and control valves of the turbine during normal actuation by the controller.
are the final control elements actuated by
The stop valves, which are held in the
the protective devices arid it is, therefore,
open position by trip fluid pressure during
equally important that these, as well as the
normal operation, are subjected to exactly
protective devices, should function
the same hydraulic conditions during
reliably. The testing of these valves in
testing as would be the case in the event
conjunction with testing of the protective
of actual turbine trip, as the action of the
devices, as already described in
protective devices is simulated by the
Automatic Turbine Tester, General
solenoid valve (MAX61AA211 and 212).
ensures that all elements which must
The steam side conditions during testing
respond on turbine trip are tested for their
are somewhat more severe than during
ability to function reliably.
actual trip, as the pressure downstream of
Each stop valve is tested together with its the stop valve can not drop off during
associated control valve. The automatic closure because the control valve is
turbine tester is designed so that only one closed. This means that the steam
valve assembly may be selected and pressure acting against the spring closure
tested at any time. force is greater than in the event of normal
trip.
Test Requirements The automatic turbine tester intervenes
To avoid turbine output changes and initial only in the fluid circuits normally used to
pressure variations due to the closing of control the valves and uses only trip fluid
the control valve under test during ATT, to actuate the test valves (MAX47AA011
the electro-hydraulic turbine controller and 012) and to reset and open the stop
must be in operation prior to testing. To valves. Thus closure of the valves cannot
facilitate compensation by the controller, be impeded in the event of a genuine trip
the closing time of the control valves is during testing, regardless of the stage,
relatively long, and to enable initial which the test has reached. This also
pressure to be maintained constant, applies to the control valves, as the ATT
testing is only permissible when the does not interrupt the secondary fluid
turbine output is below a certain value. circuit and secondary fluid can thus be
depressurized in the normal manner in the
event of a trip.
Special Conditions during Testing
The main stop and control valves may only Features of Automatic Turbine Tester
be tested if no other ATT subgroup is
running. The ATT has the following features:
During testing the selected control valve
Separate part-testing of each valve
(MAA10+20AA002) is closed completely assembly.

BHEL Hardwar 5.1-0662-01/1


Time-related monitoring of all program concluded. When one subgroup program
steps, and their implementation. is running, the other subgroup is blocked.
The On/Off push button also

Interruption due to running time
acknowledges signals:
exceeded or turbine trip.

Automatic reset of test program after a
Selection
fault.
If the test requirements have been fulfilled,

Protection of the turbine during testing the valve, assembly (e.g. main stop and
provided by special test protective control valve (LHS)) to be tested is
circuits. selected by switching in the subgroup by
pressing title selection push-button.
Setting Data A separate selection push-button is
The setting data for the pressure switches provided for each combination of stop and
used to monitor the individual valve control valve assembly. Only one selection
movements are listed in the setting record may be made at a time. Selection of a
Pressure Switch settings. The actual set further test is not possible until the
values are logged in the Commissioning programme already selected has ended.
Test Record. The test running times, etc.,
are entered in the functional diagram.
Operation Push-button
The test run is started by pressing the
Test Selection Units Operation push- button in the Stop and
There are two nos. of combined main Control valves tile.
steam and control valves” and two nos.
of combined reheat stop and control
Shutdown Push-button
valves, each of which is tested as a
separate unit and has a separate selection This push-button can abort the current unit
push-button on the ATT control panel. test and introduce the reset program,
They are as follows: which has priority over the test
programme.
Selection1:
Main stop and control valve (LHS)
Lamp Test Push-button
Selection 2: All lamps on the panel are tested by
Main stop and control valve (RHS) pressing the Test push-button.

Selection 3:
Closure of Control Valve
Reheat stop and control valve (LHS)
If all the test requirements have been
Selection 4: fulfilled and the selection and operation
Reheat stop and control valve (RHS) push buttons pressed, the control valve
(MAA10 and 20AA002) is closed by
means of the associated actuator (test
Test Procedure
motor –AA002M). Operation of the
Start of Test actuator (KA01) is continued until limit
The test starts with the selection of switch (-CG002C) and limit switch (-
subgroups by pressing the On/Off push- AA002M S72, S73) on the actuator is
button. tripped to annunciate that the control valve
being tested is in closed position.
The subgroup remains on until it is
switched off after the programme is

5.1-0662-01/2
During this time, the turbine output pressure switch MAX51CP222, 227. If all
controller compensates for the effects of conditions are fulfilled within this relatively
closure of the valve being tested on the long monitoring period, solenoid valve
turbine output by opening the remaining MAX61AA211 and 212 is de-energized
control valves. (operating position), so that trip medium is
once again able to flow to test valve
The running time for closure of the control
MAX47AA011 and 012 and the drain is
valve is monitored. If the control valve is
blocked off again. The buildup of trip
functioning properly, it will close within the
medium pressure is monitored by pressure
preset running time.
switch MAX51CP221, 226.
When the pressure is sufficiently high, the
Closure of Stop Valve
stop valve is opened by de-energizing
Then the solenoid valve (MAX61AA211 solenoid valve MAX47AA211 and 212
and 212) energized. This allows trip fluid (operating position). Test valve MAX47
to flow to the space below changeover AA011 and 012 switches over, admitting
slide valve (MAX61AA011 and 012), which trip medium to the underside of the piston
moves into its upper end position and disc KA02 and after a certain amount of
connects the space below piston disc further travel, slowly connects the space
(KA02) with the drain. The pressure in this above piston KA01 with the drain. The
space drops rapidly and is monitored by resultant pressure difference causes the
pressure switch (MAX51CP223,228). tensioned piston relay to open the stop
When the pressure at this pressure switch valve. As soon as the open position is
has dropped slightly below the breakaway reached, the full trip medium pressure
pressure of piston disc (KA02), monitoring builds up. This is monitored by pressure
of the stop valve closure time starts. The switch MAX51CP221, 228 and by limit
associated limit switch (-CG001E) switch –CG001D. Testing of the stop valve
annunciates entry of the valve into its is now completed.
closed position, thus making it possible to
monitor the valve closing action for
completion within the maximum Re-Opening of Control Valve
permissible running time. If the conditions are fulfilled within the
specified monitoring period, the control
valve is reopened. The motor of positioner
Opening of Stop Valve
–AA002M is operated in the opening
Next, solenoid valve MAX47AA211 and direction. Positioner –AA002M moves the
212 is energized (test position) and trip control valve into its original position in the
medium is admitted to the control surface reverse sequence to the closing action.
of the piston in the test valve MAX47 Again the initial pressure and output are
AA011 and 012. The pilot moves into its kept constant by the appropriate controller.
lower end position against the spring Operation of positioned -AA002M is
force, thus permitting trip medium to flow continued until, after a certain amount of
to the space above piston KA01 of the over travel, it has positively ceased to
stop valve. This piston is forced influence the controller. This position is
downwards by pressure of the medium, detected by limit switch –AA002 MS61 or
thereby tensioning the spring between –AA002 MS62. If the control valve is
piston KA01 and piston disc KA02 and functioning properly, it will open within the
finally pressing against piston disc KA02. preset running time.
Up to this point the medium pressure
above piston KA01 is relatively low, being
equal to the spring force acting against it. Cancellation of Selection
The spontaneous pressure rise when On conclusion of testing of each
piston KA01 has made contact with piston combination of valve assembly, the
disc KA02, and thus on completion of the selection is automatically cancelled and
spring tensioning action, is detected by the programme is shut down.

5.1-0662-01/3
Interruption due to Running Time Interruption due to Turbine Trip
Exceeded If electrical turbine trip is initiated during
The reset program is automatically testing, all solenoid valves are de-
initiated if the running time for any step in energized and positioner –AA002M is
the test program is exceeded. If any returned to its extreme position and the
running time is exceeded during the reset programme cancelled. All equipments
program, the program halts. In either case, associated with the automatic turbine
the alarms Fails signal and Time overrun tester are automatically returned to their
generated. If the Faults in ATT alarm is normal position.
displayed, the fault lies in the automatic
tester itself.

5.1-0662-01/4
 Steam Turbine HP Actuator
Description

The actuator is of the two-stage the signal fluid pressure changes, pilot valve
amplification type, i.e. it incorporates pilot KA05 is displaced which results in
and main control mechanisms. The movement of auxiliary pilot piston KA06. The
actuating forces for movement of the HP movement of piston KA06 is transmitted via
control valve are generated, in the opening the resetting linkage of the pilot mechanism
direction, by main actuator piston KA02 to the resetting spring, causing spool valve
under the force of the control fluid and, in KA05 to return to the central position which
the closing direction, by the disc spring establishes proportionality between the
column. During actuation main pilot valve signal fluid pressure and the travel of
KA07 acts as a 3-way valve to allow the auxiliary pilot piston KA06.
control fluid to flow to the space behind main
At the same time, main pilot valve KA07
actuator piston KA02. Main pilot valve KA07
displaced via the resetting linkage system by
is actuated via the resetting linkage by
auxiliary pilot piston KA06, effects
means of auxiliary pilot piston KA06 which is
displacement of main actuator piston KA02
subject to control fluid pressure on both
whose movement returns main pilot valve
sides.
KA07 to the central position via the resetting
The actuating signal given by the signal fluid mechanism. Consequently the position of
pressure acts on the face of pilot valve KA05 the pilot and main actuator pistons are
pressing it against the resetting spring on proportional to the secondary fluid pressure
the opposite side. Acting as a 4-way valve, in the steady state (on completion of the
the pilot valve allows fluid to flow to both control action).
sides of auxiliary pilot piston KA06. When

BHEL Hardwar 5.1-0665-00

 Steam Turbine Electro-hydraulic Seal
Description Steam Pressure Control

Function hydraulic converter comprises a control

With all shaft seals subject to a positive coil, which adjusts the position of the
pressure difference, the escaping steam is impingement plate of the hydraulic
throttled to a low pressure and fed into a preamplifier.
header 1.1, which is common to all shaft
seals. Those seals, which are under Controller
vacuum, must be supplied with seal steam
The function of the electric controller 1.9 in
to prevent the ingress of air. The supply of
conjunction with the transducer 1.6 and
steam is taken from the header 1.1. The
the actuating elements (control valves) is
amount of leakage steam and seal steam
to maintain a controlled variable at a
required depends on the pressure at the
preset valve by adjusting the final
seals, which, in turn, is primarily
controlling elements. The actual valve of
dependent on the turbine load.
the control system is acquired
The function of the control system is to continuously by the transducer 1.6 and
maintain the pressure at the bleed-off compared against the set value in the
points of all seals at the same preset electric controller 1.9. If the actual value
pressure. This is effected by exhausting deviates from the set value, one of the
steam from the header (e.g. to the final controlling elements (either the leak-
condenser) or supplying extra steam to the off or steam supply control valve) is
header 1.1, according to operating adjusted until the actual value again
conditions. agrees with the set value. Only if there is a
large control deviation, e.g. during a full-
load trip, are all valves operated
Arrangement
simultaneously. The electric controller is
Leak-off control valve 1.3 is used for realised in digital technology.
discharging surplus steam from the header
1.1 and seal steam supply control valve
1.4 for admitting extra steam to it. All Mode of Operation
valves are actuated by type HSA-1-K The input signal coming from the controller
electro hydraulic actuators. The actuators flows through the solenoid (31). The
1.11 are under the continuous control of magnetic field of the solenoid together with
an electric controller 1.9 each via an the magnetic field of the permanent
electro hydraulic converter. The electro magnet system (42) exercises a force on
the freely pivoted armature (30). This force
reacts against the force generated by the

BHEL Hardwar 5.1-0670-01/1

tension of the return spring. If the input upon the magnitude of an input signal
signal is changed, the equilibrium will be change. The greatest amount of deflection
disturbed and, therefore, there will be a and, therefore, the fastest change in the
deflection of the armature retained by the Hydraulic cylinder’s position is already
spring (32) and return spring (36). The achieved with an input signal change of
baffle plate (29) then covers the two- delta I ≥ 3 mA.
rebound nozzle tips (15) to an unequal Following smaller changes in signal, the
extent. In the oil flow that flows through hydraulic cylinder operation is
two-choke valves (21) to the rebound correspondingly slower. The servo-valve
nozzles (16), a pressure differential is enables an extremely sensitive control by
created. The oil pressure existing in the virtue of its special construction. The main
rebound nozzles is applied to the face of cylinder piston moves and in so doing
the slide gate (1a). The slide gate is changes the position of the coupled
deflected and releases the oil flow to or actuator. At the same time, the tension in
from the hydraulic cylinder (5.1). The the return spring (36) changes via the
deflection of the slide gate is dependent return rod (44) and the adjustment lever

5.1-0670-01/2
(39), until the tension of the springs and Electric manual control
magnetic forces reach a state of The controller can be switched off by the
equilibrium. The armature returns to its push button “Controller on/off”. Then the
mid position, the pressures on the faces of valves can be controlled directly by hand
the slide gates (1a) are of equal by means of the push-button
magnitude. The slide gate moves to its “Higher/Lower” below the valve position
mid position, the oil flow to the cylinder is display with the aid of the remote-control
initially reduced and, when the slide gate manual control setter of the electrical
(1a) reaches its middle setting it is equipment. The inscription “Higher/Lower”
completely shut off, and the main piston of refers to the change in pressure when the
the hydraulic cylinder is in its set position. push-button is operated, e.g. “Higher”
The position of the main piston or rather means increasing the pressure (the leak-
the actuator is directly proportional to the off steam control valve closes or the seal
input signal on the servo valve. steam control valve opens). Manual
control is disconnected during automatic
control; the manual control setter is then
Double Blocking Valve
automatically tracked to the controller
A double blocking valve is connected to output voltage by the equalizing controller
the outlet side of the servo-valve. The so that when changing over from
pump pressure opens the hydraulically automatic control to manual control the
operated check valve (8). the connections manual control setter is already in the
to the hydraulic cylinder (5.1) are free. If correct position. Under manual control the
the oil supply fails, both hydraulically equalizing controller automatically tracks
operated check valve close. The hydraulic the output voltage of the disconnected
cylinder’s piston will be retained in its last controller 1.9 to the manual control
position. voltage. If the control deviation has been
reduced to zero by positioning the valves
Display of control deviation /Adjusting before the controller is switched on, the
the set value change-over from manual control to
automatic control will be bump less;
The control deviation is displayed on each otherwise the controller regulates the
of the two desk tiles for the valves. The pressure to the preset value after it has
two instruments are connected in parallel.
been switched on. Thus, it is quite easy to
The set value for steam pressure in the switch the controller on and off during
header can be adjusted between 0 and 22 operation.
mbar at the controller by means of the set
value push-button.

5.1-0670-01/3
5.1-0670-01/4
5.1-0680-02
 Steam Turbine Control System
Description Diagram Legend

Power Plant iden- Title Coor- Power Plant iden- Title Coor-
tification System dinete tification System dinete

KA06 Relay Piston for Pre Control Pilot ValveC7

KA07 Main Pilot Valve C7
KA09 Hand wheel for Testing Device B7
LBC10 AA001 Swing Check Valve of CRH E7 M Electrical Motor for Testing Device B7
KA01 Rotary Servomotor E7 AA002 MS61 Torque limit Switch,
LBC10 CG001 B Limit Switch, Open Position E7 Testing Device 100% ATT B7
C Limit Switch, Closed Position E7 MS62 Travel Limit Switch,
D Limit Switch, Open Position E7 Testing Device 100% ATT B7
E Limit Switch, Closed Position E7 MS72 Torque Limit Switch,
Testing Device 0% A TT B7
LBS21 AA001 Extraction Check Valve A2 E12,13 MS73 Travel Limit Switch, B7
KA01 Servomotor E12,13 Testing Device 0% ATT
LBS21 CG001A Remote Position Indicator E12,13
MAA10 + 20
LBS31 AA001 Extraction Check Valve A3 E13 CG002 A Remote Position Indicator C7
KA01 Servomotor E13 C Limit Switch, Closed Valve Position ATT C7
LBS31 CG001A Remote Position Indicator E13
MAB10 +20
LBS31 AA002 Extraction Check Valve A3 E13 AA001 Reheat Stop Valve ABC9
LBS31 CG002 A Remote Position indicator E13 KA01 Piston A9
KA02 Piston Disc A9
LBS41 AA001 Extraction Check Valve A4 C10
KA01 Servomotor C10 MAB10 + 20
LBS41 CG00 1A Remote Position Indicator C10 CG001 B,F,H, Limit Switch, Open Valve Position A9
C,G,J Limit Switch, Closed Valve Position A9
LBS41 AA002 Extraction Check Valve A4 C10 D Limit Switch, Open Valve Position ATT A9
KA01 Servomotor C10 E Unlit Switch,Closed Valve Position ATT A9
LBS41 CG002A Remote Position Indicator C10

LBS42 AA001 Extraction Check Valve A4 AB11 MAB10+ 20 Main Control Valve BC9,10
KA01 Servomotor A 11 AA002
LBS42 CG001A Remote Position Indicator B 11
KA01 Servomotor C10
LBS42 AA002 Extraction Check Valve A4 AB1 1,12 KA02 Piston C10
KA01 Servomotor A12 KA05 Pre Control Pilot Valve C10
LBS41 CG002A Remote Position Indicator B12 KA06 Relay Piston for Precontrol Pilot ValveC10
KA07 Main Pilot Valve C10
LBQ50AA001 Extraction Check Valve A5 E9 KA09 Hand wheel for Testing Device B10
KA01 Servomotor E9 M Electrical Motor for Testing Device B10
LBQ50CG001 A Remote Position Indicator E9 MS61 Torque Limit Switch,
Testing Device 100% ATT B10
LBQ5OAA002 Extraction Check Valve A5 E9 MS62 Travel Limit Switch,
LBQ50 CG002A Remote Position Indicator E9 Testing Device 100% ATT B10
MS72 Torque Limit Switch,
MAA10 + 20 Testing Device 0% ATT B10
AA001 Main Stop Valve ABC7 MS73 Travel Limit Switch, B10
KA01 Piston AB7 Testing Device 0% ATT
KA02 Piston Disc B7
MAB10 + 20
MAA10 + 20 CG002 A Remote Position Indicator C10
CG001 B,F,H Limit Switch, Open Valve Position B7 C Limit Switch, Closed Valve Position C10
C,G,J Limit Switch, Closed Valve Position B7 ATT
D Limit Switch, Open Valve PositionATT B7 MAD12
E Limit Switch, Closed Valve PositionATTB7 CY011,012,013 Electrical Thrust Bearing Trip D8

MAA10+ 20 MAG01 AA011 Low Vacuum Trip. B5

AA002 Main Control Valve BC7,8 MAG01CG01 B Limit Switch, Not Reset B5
KA01 Servomotor C7,8 C Limit Switch, Alarm B5
KA02 Piston C7 E Limit Switch, Alarm ATT B5
KA05 Pre Control Pilot Valve C7 MAG01AA016 Condenser Safety Device
(Bypass Control) G9

BHEL Haridwar 5.1-0681-02/1

 Power Plant iden- Title Coor-
Power Plant iden- Title Coor-
tification System dinete
tification System dinete
MAX32BT021 Fluid Filter for Pre Control,
MAV21 AP001 Main Oil Pump E1 Reheat Control Valves A10

MAV21BT001 Oil Filter MAX32BT081 Fluid Filter for Pre Control,

(Hydraulic Control Equipment Rack) D4 Bypass Control Valves C11

MAX31
MAX41 CP50l Pressure Gauge. Control Fluid
BB011, 016 Accumulator for HP Servomotor,
Main Control Valves B7 (Hydraulic Control Equipment Rack) C2

MAX31 Accumulator for HP Servomotor, MAX42AA001 Slide Valve for Swing Check Valve
BB21, 26 Reheat Control Valves B9 Cold Reheat D7

MAX31 BB021 Accumulator for HP Servomotor, MAX42AA002 Slide Valve for Swing Check Valve
BB041,049 Bypass Control Valves C11 Cold Reheat D8
MAX32
MAX42AA011 Non-Return Valve B1
BT011 +012 Fluid Filter for Pre Control.
Main Control Valves A7
MAX42BT001 Fluid Filter
(Hydraulic Control Equipment Rack) C1

MAX42BT002 Fluid Filter

(Hydraulic Control Equipment Rack) C2

MAX42BT003 Fluid Filter

(Hydraulic Control Equipment Rack) B4

MAX42BT021 Fluid Filter (Hydraulic

Bypass Control Equipment Rack) G6

MAX42BT022 Fluid Filter for Water Injection Valves

(Hydraulic Bypass Control
Equipment Rack) A12

MAX42CP501 Pressure Gauge, Control Fluid

(Hydraulic Bypass Control
Equipment Rack) F6

MAX42CP511 Pressure Gauge, Control Fluid Water

Injection Valve Open B12

MAX42CP512 Pressure Gauge. Control Fluid Water

Injection Valve for Sequential Water
Injection Open B13

MAX44AP001 Hydraulic Speed Transmitter E1

MAX44CP501 Pressure Gauge, Primary Oil A5

MAX45BB001 Accumulator for Extraction Valve

Relay E4

MAX45BY001 Electro-Hydraulic Converter F4

KA01 Follow-Up Piston for Main
Control Valves F5
KA02 Follow Up Piston for Reheat
Control Valv8S F5
KA04 Sleeve F4
KA05 Piston F4
KA06 Helical Spring F4
KA08 Piston F4
KA10 Adjusting Device Control Valves F5
KA11 Manual Adjusting Device F5

5.1-0681-02/2
Power Plant iden- Title Coor- Power Plant iden- Title Coor-
tification System dinete tification System dinete
MAX45 MAX47CG001F Limit Switch, 56% G1
CG001 A Remote Position Indicator F4 MAX47CP501 Pressure Gauge, Start-up Fluid G1
K Remote Position Indicator F4 MAX48 CP501 Pressure Gauge,
T Solenoid F4 Auxiliary start-up fluid E3
B Limit Switch Operating Without Bypass
Valves and Adjusting Device Blocked F5
C Limit Switch, Displacement of MAX51
Control Valves F5 AA005 +006 Main Trip Valve B2

MAX45BY011 Hydraulic Converter F2 MAX 51

KA01 Follow-up Piston for Main Control Valves F3 CG005+006 C Limit Switch, Alarm B2
KA02 Follow-Up Piston for Reheat Control F3 E Limit Switch, Alarm, ATT B2
valve
KA04 Sleeve G3 MAX51 AA011 Extraction Valve Relay D5
KA01 Valve D5
KA05 Piston G3
KA02 Valve D5
KA06 Helical Spring F3
KA07 Pilot Valve G2 MAX51AA041 Slide Valve for Extraction
KA08 Piston G3 Check Valve A2 E12
KA09 Proportional Band Adjustment G2
KA10 Adjusting Device Control Valves F4 MAX51 AA044 Slide Valve for Extraction
KA11 Manual Adjusting Device F4 Check Valve A3 E13
MAX45CG011 B Limit Switch, Operation without Bypass MAX51 AA047 Slide Valve for Extraction
Valves and Adjusting Device Blocked F3 Check Valve A4 C12
C Limit Switch, Displacement of control
valves F4 MAX51 AA048 Slide Valve for Extraction
Check Valve A4 A 11
MAX45CP501 Pressure Gauge Secondary Fluid
Main Control valves F2 MAX 51 AA 050 Slide Valve for Extraction
Check Valve A4 C12
MAX45CP511 Pressure Gauge, Secondary Fluid
Reheat Control Valves E2 MAX 51 AA051 Slide Valve for Extraction
Check Valve A4 A11
MAX46BY001 Hydraulic Speed Governor G1
MAX 51 AA056 Slide Valve for Extraction
KA01 Hand wheel F2
Check Valve A5 E9
KA02 Speed Setting Spring F1
KA03 Link F1 MAX51AA211 Changeover Valve B3
KA04 Sleeve F2
KA05 Piston F2 MAX51 CG211B Limit Switch, up Normal Position ATT B3
KA06 Helical Spring F2 C Limit Switch, Down- Test Position ATT B3
KA07 Overspeed Tester Lever F2
KA08 Auxiliary Follow-up Piston F2 MAX51CP501 Pressure Gauge, Trip Fluid A3
KA09 Governor Bellows G1
M Electrical Motor F1 MAX51 CP522 Pressure Gauge, Trip Fluid above piston
527 Main Stop Valve A6
MAX46CG001 A Remote Position Indicator F2
B Limit Switch 100% MAX 51 CP523 Pressure Gauge, Trip Fluid below piston
(Start-Up Automatic) F2 528 Disc Main Stop Valve B6

MAX46CP501 Pressure Gauge. MAX51 CP542 Pressure Gauge, Trip Fluid above Piston
Auxiliary Secondary Fluid F2 547 Reheat Stop Valve A9

MAX51 CP543 Pressure Gauge, Trip Fluid below Piston

MAX47
548 Disc Reheat Stop valve B9
AA011 +012 Test Valve for Main Stop Valves B6
MAX52AA005 Local/Manual Trip Valve B2
MAX47 MAX52 CG005 C Limit Switch, Alarm B2
AA021 +022 Test Valve for Reheat Stop Valves A9 E Limit Switch, Alarm ATT B2

MAX47BY001 Starting and Load Limit Device F1 MAX 52 CP501 Pressure Gauge, Aux, Trip Fluid D3
KA01 Hand wheel F1
KA02 Valve F1
M Electrical Motor F1

MAX47CG001 A Remote Position Indicator F1

B Limit Switch, 100% G1
C Limit Switch, 0% G1
D Limit Switch, 42% G1

5.1-0681-02/3
Power Plant Iden- Title Coor- Power Plant Iden- Title Coor-
tification System dinate tification System dinate

MYA01
CS011-013 Electrical Speed Transmitter E1
MAG01 AA201 Solenoid Valve for Testing
Low Vacuum Trip B4
MAX42AA001 Solenoid Valve, Adjustment of
Control Valves F5

MAX45AA001 Solenoid Valve for Load Shedding Relay

in Secondary Fluid to Reheat
Control Valves E5

MAX46AA011 Solenoid Valve for Load Shedding Relay

in Auxiliary Secondary Fluid G2

MAX47
AA211 +212 Solenoid Valve for start -up Fluid,
Main Stop Valve B5
MAX 47
AA221 +222 Solenoid Valve for Start-up Fluid,
Reheat Stop Valves B8

MAX48
AA201 +202 Solenoid Valve for Auxiliary
Start-Up Fluid B1,2

MAX51AA021 Solenoid Valve for Extraction

Check Valve E12

MAX51AA024 Solenoid Valve for Extraction

Check Valve E13

MAX51AA027 Solenoid Valve for Extraction

Check Valve A4.1 C 12

MAX51 AA028 Solenoid Valve for Extraction

Check Valve A4.2 A10

MAX51 AA030 Solenoid Valve for Extraction

Check Valve A4.1 C12

MAX51AA031 Solenoid Valve For Extraction

MAX61 Check Valve A4.2 A11
AA011 +012 Test Valve for Main Stop Valves B6
MAX51 AA036 Solenoid Valve for Extraction
MAX61 Check Valve A5 E9
AA021 +022 Test Valve for Reheat Stop Valves B8
MAX51 AA201 Solenoid Valve for Control Fluid
MAX62AA001 Overspeed Trip Test Device C4 Supply during Test B3
KA01 Valve for Test oil C4
KA02 Valve for Auxiliary Start-up Fluid C4 MAX51AA202 Solenoid Valve for Control Fluid
KA03 Valve For Auxiliary Trip Fluid C4 Supply During Test B4
KA001M Electrical Motor C4
MAX52AA001 Remote Trip Solenoid C2
MAX62CG001 B Limit Switch, up-Normal position ATT C4
C Limit Switch, Down- Test Position ATT C4 MAX52AA002 Remote Trip Solenoid C2

MAX62CP501 Pressure Gauge, Test Oil Overspeed D1 MAX53AA051 Solenoid Valve for Sequential
Trip Water Injection C13
MAY10
AA001 +002 Overspeed Trip E2 MAX61AA201 Solenoid Valve for Changeover from
KA01 Releasing Device E2 Trip Fluid to Control Fluid C3

MAY10
CG001 +002 C Limit Switch, Alarm E3
E Limit Switch Alarm ATT E3

5.1-0681-02/4
 Power Plant iden- Title Coor-
Power Plant iden- Title Coor-
tification System dinete
tification System dinete
MAX48 CP202 Pressure Switch for Auxiliary
MAX61
Start-up Fluid Between Solenoid
AA211 +212 Solenoid Valve for Testing of Valves MAX48AA201 and202 B1
Main Stop Valves C5,6
MAX51
MAX61 CP001 +002 Pressure transmitter for Trip fluid A1
AA221 +222 Solenoid Valve for Testing of
Reheat Stop Valves C8
MAX51
CP205 +206 Pressure Switch for Trip Fluid Between
Solenoid Valves MAX51 AA201
and 202 B3
LBS42 CP002 Differential Pressure Monitor for
Extraction Check Valve-A4 MAX51
(Batron -Cell) B11
CP207 +208 Pressure Switch for Trip Fluid Ahead of
Changeover Valve MAX51 A211 B3

MAX51
CP209 +210 Pressure Switch for Trip Fluid Ahead of
MAG01CP201 Pressure Switch, low-Vacuum Trip, Changeover Valve MAX51 AA211 B2,3
Vacuum min. B4
MAX51CP 221 Pressure Switch for Trip Fluid ahead of
MAG01CP202 Pressure Switch, low-Vacuum Trip, +226 Main Stop Valve, Test Valve B6
Vacuum max. B4
MAX51CP222 Pressure Switch for Pressure above
MAG01CP203 Pressure Switch, low-Vacuum Trip, +227 Piston of Main Stop Vale B7
Vacuum min. B5
MAX51 CP223 Pressure Switch for Pressure below
MAG01CP204 Pressure Switch, low-Vacuum Trip
+228 Piston Disc of Main Stop Vale A7
Vacuum max. B5
MAX51CP242 Pressure Switch for Trip Fluid above
MAG10CP011 Pressure Switch, Electrical Low
+247 Piston of Reheat Stop Valve A9
Vacuum Trip.
Signal Pressure to high E13 MAX51 CP243 Pressure Switch for Trip Fluid Below
+248 Piston Disc of Reheat Stop Valve B9
MAG 10CP012 Pressure Switch, Electrical low
Vacuum Trip, Alarm E13 MAX52CP211 Pressure Switch for Auxiliary
Trip Fluid B3
MAG10CP013 Pressure Switch Electrical low Vacuum
Trip Interlocking MAG10CPO12 E14 MAX62 CP 211 Pressure Switch for Test oil of
overspeed Trip max D1
MAG10CP016 Pressure Switch for Energizing of
Vacuum Breaker E13 MAX62 CP 212 Pressure Switch for Test oil of
overspeed Trip max. D1
MAX45 CP211 Pressure Switch For Reheat Control
Valves Secondary Fluid E2 MAX62 CP 213 Pressure Switch for Test oil of
overspeed Trip Pressure Collapsed D2
MAX48 CP201 Pressure Switch For Auxiliary C2
Start-up Fluid MAX45 AA031 Pressure Converter for IP secondary
Oil E4

5.1-0681-02/5
 Steam Turbine Lubrication Chart
Description

No. Lubrication Filling Lubricant Lubrication Top-up Remarks

Point Quantity Interval Quantity

1 Overspeed test Turbine oil* Every 1 to 2

device months
2 Reduction gear of 200g Grease Every 1 to 2 ≈ 10g
overspeed trip Servogem-2 months
test device
3 Bearing of low Turbine oil* Every 1 to 2
vacuum trip months
4 Main control valve Molykote U After every Use no oil
stem dismantling or grease
5 Main stop valve Molykote U After every Use no oil
stem dismantling or grease
6 Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main stop valve
7 Limit Switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
main control valve
8 Hinge of main Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
9 LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of main SF7-026 Operating
control valve hours
10 Reheat control Molykote U After every Use no oil
valve stem dismantling or grease
11 Reheat stop valve Molykote U After every Use no oil
stem dismantling or grease
12 Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat stop valve
13 LAWA actuator 0.4 kg Calypsol Every 104 0.4 kg
VR 16 of reheat SF7-026 Operating
control valve hours
14 Hinge of reheat Molykote Every 1 to 2 Use no oil
control valve M30 months or grease
position indicator
15 Limit switch Molykote Every 1 to 2 Use no oil
attachment on M30 months or grease
reheat control
valve
16 Hinge of Molykote U After every Use no oil
extraction swing dismantling or grease
check valve
17 Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
starting and load Servogem-2 months
limit device

BHEL Haridwar 5.1-0690-02/1

No. Lubrication Filling Lubricant Lubrication Top-up Remarks
Point Quantity Interval Quantity

18 Journal for Turbine oil* Every 1 to 2

hydraulic speed months
governor
19 Adjusting gear of 200g Grease Every 1 to 2 ≈ 10g
reference speed Servogem-2 months
setter
20 Bearing of Turbine oil* Every 1 to 2
trimming device months
21 Hinge of cold Molykote U After every Use no oil
reheat swing dismantling or grease
check valve
22 Stem guides of Molykote U After every Use no oil
shaft seal steam dismantling or grease.
valve Lubrication
point not
shown
23 Shaft seal steam 7 to 9 kg Hydraulic oil 1stoil change 7 to 9 kg Lubrication
valve actuators to DIN 51517 after 6 point not
and VDMA months, shown
24318 H-LP thereafter
oils** every12
months.

* Turbine oil 46/Servoprime 46 of IOC, Turbinol 47 of HPCL or equivalent

** HLP 46 (VG) ISO of IOC

5.1-0690-02/2
5.1-0690-05/3
 Steam Turbine Hydraulic Speed Governor
Description with Starting and Load
Limiting Device

Function
The function of the hydraulic speed governor Mode of Operation
is to operate the control valves to give the If the primary oil pressure falls (as a result of
appropriate turbine steam throughput for the increasing load and the resulting drop in
particular load condition. The arrangement speed), the link (11) and the sleeve (5)
and functioning of the governor within the sliding on the follow-up piston (4) are moved
overall governing system is described in the downwards by the speed setting spring (13)
section on governing. so that the overlap of the ports in the sleeve
and the follow-up piston is reduced. This
Construction causes the pressure in the auxiliary
secondary fluid circuit to rise and the follow-
The principal components of the speed
up piston follows the movement of the
governor are the bellows (8), the link (11),
sleeve against the increasing force of the
the speed setting spring (13), the sleeve (5)
tension spring (3) until normal overlap of the
and the follow-up piston (4). The primary oil
ports and equilibrium are restored. The lift of
supply from the hydraulic speed transmitter
the control valves is increased in this
is available at connection ‘a1‘. A fire
manner by the increased secondary fluid
resistant fluid is used as the hydraulic fluid in
pressure.
the governing system. An additional bellows
(9) prevents primary oil getting into the Conversely, a rise in primary oil pressure
control fluid circuit if there be a leakage in causes the lift of the control valves to be
the governor bellows (8). In this case, the reduced.
leakage oil can be drained off via connection
When the pre-compression of the speed
‘c1 ‘. In case a leak in the bellows (9) occur,
setting spring (13) is varied with the
the control fluid that has leaked in will also
reference speed setter it changes the
be drained off via connection ‘c1’.
relationship between the primary oil
The primary oil pressure (connection ‘a1‘) is pressure and the secondary fluid pressure
dependent on the speed and determines the and hence the relationship between speed
position of the link (11) via the bellows (8) and power output.
and the push rod (10). The speed setting
Lever (12) allows the link (11) to be
spring (13) opposes the primary oil
depressed by hand to give a lift signal to the
pressure. Its pre-compression can be varied
governor, e.g. to provide a second means of
either by hand or remotely by the motor (16).
overspeeding the machine for testing the
The sleeve (5) which can slide on the
overspeed trips in addition to the overspeed
bottom end of the follow-up piston (4) is
trip tester.
attached to the link (11). The follow-up
piston is held against the auxiliary
secondary fluid pressure (connection ‘b’) by Starting and load limiting device
the tension spring (3). The follow-up piston Before start-up, the pilot valve (21) is
and the sleeve have ports, which at normal brought to its bottom limit position either by
overlap allow sufficient fluid to escape to hand or remotely by the motor (20). This
produce equilibrium between the auxiliary causes the bellows to be compressed via
secondary fluid pressure and the force of the the lever (6) and the pin (7) until the
tension spring (3). governor assumes the position “Control
Each steady-state position of the link (11) valves closed”. With the pilot valve (21) in
and hence of the sleeve (5) corresponds to the bottom limit position, control fluid from
a specific force from the tension spring (3) connection ‘a’ can flow simultaneously to the
and hence to a specific secondary fluid auxiliary start-up fluid circuit (connection
pressure which in turn determines the ‘u1‘) and as start-up fluid via connection ‘u’
position of the control valves.

BHEL Haridwar 5.1-0710-00/1

 to the stop valve to prepare these for causes the pin (7) to release the bellows as
opening. When the pilot valve (21) is moved with falling primary oil pressure and the
back the auxiliary start-up fluid circuit is control valves are opened. The release of
depressurized and subsequently the start-up the bellows can be limited by the pin (7) so
fluid connection ‘u’ is opened to the return that the control valves do not open any
‘c’. This opens the stop valves. Further further despite a further reduction in primary
upward movement of the pilot valve (21) oil pressure.

5.1-0710-00/2
 Steam Turbine Adjusting Gear
Description

Function
spindle to slide axially in the bushing (4),
The adjusting gear is used for manual or which can rotate in cover (19). Spring (6)
motor operation of the reference speed forces the thrust rings (18) against bushing
setter and the starting and load limiting (4) which prevents bushing (4) and spindle
device. (16) from turning. Spindle (16) however, can
be moved axially by turning the worm wheel
Mode of Operation (15).

The speed/load adjusting gear is operated Spindle (16) can be moved up or down
either manually or by means of motor (28). depending on which direction worm- wheel
The rotary movement of the motor shaft is (15) turns. The limit of travel is set by limit
transmitted to worm wheel (15) via worm rings (14 and 17). If either stop has been
wheel (9) and the worm attached to it. reached the thrust rings operates as a slip
Wormwheel (15) is located axially on the coupling. The thrust rings also protect the
threaded portion of the hand wheel spindle motor (28) from overload in the event of
(16) by insert (5) and the gear casing (11). restrictive movement within the adjusting
The spindle (16) is connected with bushing gear.
(4) by a feather key so as to permit the

BHEL Haridwar 5.1-0720-00

 Steam Turbine Electro-hydraulic Converter
Description for Turbine Control System

Function
The electro-hydraulic converter is the The secondary fluid circuits, which are fed
connecting element between the electrical from the trip fluid circuit via throttles and
and hydraulic parts of the turbine control supply the various actuating devices, are
system. It converts the signals from the connected at point ‘b’. The secondary fluid
electric controller into the hydraulic signals pressures are determined by the tension of
and amplifies them before transmitting them springs (22) which counter balance the fluid
to the actuating devices. pressure acting on the follow-up pistons
(21). Each follow-up piston and sleeve (20)
Construction has ports, which control the secondary fluid
The principal components of the converter flow according to their overlap. When the
are proportional valve (1), Manifold plate throttling area is changed by the movement
(12), EHC Piston (7), Casing (4), position of the sleeve (20), it also changes the
transmitter (2), follow-up pistons (21) and pressure in the follow-up piston causing it to
actuator (17). Bushings and follow-up follow the movement of the sleeve. This
pistons ‘A’ are connected to each other via varies the tension of springs (22) until
the adjusting screws (24), spring end pieces equilibrium is regained between the spring
and the springs (22). The control signals force and the new secondary fluid pressure.
from the electro-hydraulic controller Each position of the EHC piston (7) thus
operates on proportional valve(1) through a corresponds to a specific position of the
matching amplifier module. The control fluid sleeves (20) and, therefore, the follow-up
from connection ‘a’ is admitted to the space pistons (21). The position of the follow-up
above or below the piston (7)with the piston is the determining factor for the
opposite side of the piston opened to the secondary fluid pressure at point ‘b’.
fluid drain. The resulting motion of the piston The initial tension of the follow-up piston
(7) is transmitted via lever (13) to the springs can be varied by means of the
sleeves (20) which in turn can slide on the setscrews (24).
follow-up pistons (21).

BHEL Haridwar 5.1-0730-03/1

Controlling action with the Elctro-
hydraulic Converter
When the electric controller gives a
command to open the turbine control valves, When a command is given to close the
the proportional valve enables the control control valves, the controlling action is
fluid to flow through port ‘B’. The fluid flows similar but in the reverse sequence.
to the space below the piston (7) via
manifold plate (12). This moves the piston
(7) upwards.
The following movement of the piston (7)
then slides the sleeves (20) downwards over
the levers (13,19) reducing the drain area
between the sleeves and the follow-up
pistons (21), causing the pressure in the
follow-up pistons and secondary fluid circuits
to rise.
The motion of the piston (7) produces a
simultaneous feedback action on the
proportional valve (1) via the position
transmitter (2). The control command gets
modified and in the equilibrium position
there is no flow through the proportional
valve neither to port ‘B’ nor to port ‘A’.

5.1-0730-03/2
Adjusting Device for Valves Setting Device for start-up without
Bypass Valves
The follow-up pistons ‘B’ and the lever (14)
of the rotary shaft (15) situated above it are If the plant is started up without bypass
connected by the springs (22) of follow-up system, the IP/reheat stop and control
pistons ‘B’, the guide pin (16) and the valves must open before the main steam
setscrews (30). During normal operation an stop and control valves. For this purpose,
energized solenoid valve allows control fluid the hand wheel (32) is set in the upper end
‘a1’ to flow under the piston (25) of the position. Signal from limit switch (33):
actuator (17). The piston (25) is moved Setting device in operation without
upwards against the forces of the spring bypass system position.
(26). Stop (34) locked in normal position by
pin and the initial tension of the tension
springs (22) of the follow-up pistons ‘B’ is
adjusted by means of the lever (28, 14)
which results in the IP control valves
opening in relation to the HP control valves
as intended for this operation.
If the condition turbine load less than a set
minimum load and the ratio of HP
exhaust steam pressure to main steam
pressure greater than the set pressure
ratio is fulfilled, for example after load
shedding, the solenoid valve will be de-
energized. This blocks the flow of control
fluid to the actuator (17) and allows control
fluid under the piston (25) to flow into the
return pipe. The force of the spring (26)
moves the piston into the lower end position
and the tension springs (22) of the follow-up
pistons ‘B’ are adjusted so that the IP control
valves do not begin to open until the HP
control valves are wider open. The lever (28)
then rests on the precisely set stop (34).
Limit switch (29) indicates: Setting device
engaged.

5.1-0730-03/3
 Steam Turbine Hydraulic Amplifier
Description for Turbine Control System

Function
auxiliary secondary circuit and the force of
The function of the hydraulic amplifier is to
spring (8) are in equilibrium. The pilot valve
amplify the signals from the hydraulic speed
is kept in rotation by control fluid flowing
governor (connection ‘b1’) so that they are
from tangential holes in an integral collar to
sufficient for the actuating devices.
give greater freedom of reciprocal motion
and high response sensitivity.
Construction When the pilot valve is deflected from its
The principal components of the amplifier center position control fluid from connection
are amplifier piston (1), pilot valve (7), ‘a’ is, admitted to the space above or below
follow-up piston (2) with sleeves (3), the amplifier piston (1) with the opposite side
mechanical feedback system (6) and of the piston opened to the fluid drain. The
actuator (21). Bushings and follow-up resulting motion of the amplifier piston is
pistons ‘A’ are connected to each other via transmitted via lever (5) to the sleeves (3)
the setscrews (10), spring end pieces and which in turn, slide on the follow-up piston
springs (11). Auxiliary secondary fluid flows (2). The secondary fluid circuits, which are

over the pilot valve (7) via connection ‘b1’. In fed from the trip fluid circuit via throttles and
the steady-state condition, the pilot valve is supply the various actuating devices, are
in its center position and the pressure in the

BHEL Haridwar 5.1-0740-02/1

connected at point ‘b’. The secondary fluid The initial tension of the follow-up piston
pressures are determined by the tension of springs can be varied by means of the
springs (11), which counterbalance the fluid adjusting screws (10, 14), and the levers
pressures acting upon the follow-up pistons. (15, 16).
Each follow-up piston (2) and sleeve (3) has
ports, which control the secondary fluid flow Controlling action with the Hydraulic
according to their overlap. When the Governor
throttling area is changed by movement of The pressure above the pilot valve (7) is
the sleeve (3), it also changes the pressure varied by the hydraulic governor via varying
in the follow-up piston causing it to follow the the auxiliary secondary fluid pressure
movement of the sleeve, This varies the connected at ‘b1’. An increasing auxiliary
tension of spring until equilibrium is regained secondary fluid pressure causes the
between the spring force and the new secondary fluid pressure at the connection
secondary fluid pressure. Each position of ‘b’ to rise and open the actuating devices; a
the amplifier piston (1) corresponds to a
specific position of the sleeve (3) and the
follow-up piston (2). The position of the
follow-up piston is the determining factor for
the secondary fluid pressure at point ‘b’.

5.1-0740-02/2
reduction in the secondary fluid pressure If the condition Turbine load less than a
causes the actuating device to close. The set minimum load and the ratio of HP
motion of the amplifier piston produces a exhaust steam pressure to main steam
simultaneous feedback via lever (6) and pressure greater than the set pressure
causes the pilot valve to assume its center ratio is fulfilled, for example after load
position when the new position of the shedding, the solenoid valve will be de de-
amplifier piston is reached. Each auxiliary energized. This blocks the flow of control
secondary fluid pressure corresponds to a fluid to the actuator (21) and allows control
certain position of the piston (1) which, in fluid under the piston (20) to flow into the
turn, results in a certain secondary fluid return pipe. The force of the spring (19)
pressure at connection ‘b’ with each moves the piston into the lower end position
auxiliary fluid pressure. The degree of and the tension springs (11) of the follow-up
proportionality of the hydraulic governor can pistons ‘B’ are adjusted so that the IP control
be adjusted by varying the position of lever valves do not begin to open until the HP
pivot (6) with the setscrew (9). control valves are wider open.
The follow-up piston ‘B’ and the lever (15) of The lever (16) then rests on the precisely set
the rotary shaft (12) situated above it are stop (25). Limit switch (17) indicates:
connected by the springs (11) of follow-up Setting device engaged.
pistons ‘B’, the guide bolts (13) and the
setscrews (14).
Setting Device for Start-up without
During normal operation, an energized bypass valves
solenoid valve allows control fluid ‘a1’ to flow If the plant is started up without bypass
under the piston (20) of the actuator (21). system, the IP/reheat control valves must
The piston (20) is moved upwards against open before the main steam control valves.
the force of the spring (19). Stop (25) locked For this purpose, the hand wheel (24) is set
in normal position by pin and the initial in the upper end position.
tension of the tension spring (11) of the Signal from limit switch (23): Setting device
follow-up piston ‘B’ is adjusted by means of in operation without bypass system
the lever (15, 16) which result in the IP position.
control valves opening in relation to the HP
control valves as intended for this operation.

5.1-0740-02/3
 Steam Turbine Electrical Speed Pick-Up
Description

Construction and Mode of Operation toothed wheel, which rotates, with the
The electrical speed pick-up located in the rotation of the turbine shaft. On rotation of
front bearing pedestal indicates the exact the toothed wheel (1), electrical impulses
speed through all speed ranges of the are generated as a result of alternating
turbine. The measuring procedure effect between the speed probe (3) and
functions as follows: - the toothed wheel (1). The output
frequency is conducted to the speed-
A toothed wheel (1) is mounted on shaft measuring unit.
(2) of main oil pump. The speed probes
are installed around the periphery of the

BHEL Haridwar 5.1-0760-01

 Steam Turbine Pressure Converter
Description

Function
The pressure converter is installed in the IP
secondary oil circuit. It does not permit to
raise the IP secondary oil pressure beyond
certain value.

Construction
The pressure converter is provided with a
follow up piston (3), which slides in the
bushing (6) at the top, and in the sleeve (2)
at the bottom. The bushing and follow up
piston are connected to each other via the
set screw (9, 10) and the spring (4). There
are drainage slots in the follow up piston (3)
and sleeve (2), through which a larger or
smaller amount of fluid can flow into the fluid
return line ‘c’ depending on how much they
overlap. The fluid pressure prevailing in the
follow up piston (3) is connected to the
reheat control valves for speed control via
connection ‘x’.

Mode of Operation
When the setscrew (9) of the pressure
converter has been appropriately set, IP
secondary fluid pressure is permitted to
increase to certain value.

1 Ring 8 Cap
2 Sleeve 9 Set Screw
3 Follow up piston 10 Set Screw
4 Spring
5 Casing
6 Bushing c Return flow
7Cover x IP secondary fluid

BHEL Haridwar 5.1-0761-00

 Steam Turbine Combined Main Stop
Description and Control Valves

Function and Arrangement Stop Valve

One stop and one control valve are The steam enters the valve casing (13) via
combined in a common body. The main stop the Inlet connection and remains above the
valve provides a means of isolating the stop disc (1). The main valve disc
turbine from the main steam line and can incorporates a pilot disc formed from the end
rapidly interrupt the supply of steam to the of the valve steam (3). The valve stem is
turbine. The function of the control valve is sealed by packing rings (6). On the back of
to regulate the flow of steam to the turbine the valve disc is a raised seat which comes
according to the prevailing load. into contact with a neck bush (4) when the

BHEL Haridwar 5.1-0810-01/1

valve is fully open and so provides extra Control Valves
sealing at this point for the stem. Both stem The stem and disc (16) of the control valve
and disc are secured against torsion. The are in one piece. Balancing holes in the
valve body cover (2) is held in the valve valve disc reduce the operating force
casing (13) by a threaded ring (8). There is a required. The valve stem and disc (16) are
U-shaped gasket (5) between cover and guided in the cover (17) and the stem is
casing. The two legs of the gasket are sealed by packing rings (20). When the
pressed against the sealing face to give a valve is fully opened, the raised seat of the
tight joint .The stop valve is opened valve disc rests against the neck bushing
hydraulically and closed by spring force. (18) and provides additional sealing. As with
the stop valve, the valve body cover (17) is
held in the casing by a threaded ring (21)
Testing Main Stop Valve
and is sealed by U-shaped gasket (19). The
Each stop valve must be tested at regular control valve is actuated by the piston of the
intervals to ensure proper functioning. A servomotor (26) that is operated by a cup
testing valve is provided for this purpose. spring in the closing direction and
hydraulically in the opening direction.

5.1-0810-01/2
 Steam Turbine Servomotor for Main
Description and Reheat Stop Valves

The operative part of the servomotor the piston and the piston disc connected to
consists of a two-part piston, the lower disc- the valve stem moves to close the valve.
shaped part of which is connected via piston Just before the valve disc seats, the piston
rod to the valve stem. The other part of the disc enters a part of the cylinder where the
piston is bell-shaped and moves within the diametral clearance is reduced. This
housing, which is in the form of a cylinder. arrangement restricts the flow of fluid past
Two spiral springs are placed between the the piston disc and so produces a braking
two halves of the piston at the lower end a action, which causes the valve disc to seat
spring plate is interposed between the gently.
springs and the piston disc. When trip fluid
All fluid connections are routed through a
is admitted to the space above the bell-
test valve. All operations can be controlled
shaped part of the piston, it moves this half
by means of the test valve and the starting &
of the piston downwards, compressing the
load limiting device and main trip valve.
springs, until it seats against the piston disc.
After the main stop valves have been
opened, the turbine is started by the control
valves. Before the main stop valves can be
opened, however, they must be
“pressurized”, i.e. prepared for opening, by
admitting trip fluid from the trip fluid circuit to
the space above the piston to press it down
against the piston disc after overcoming the
resistance of the springs. The edge of the
bell-shaped half of the piston is designed to
produce an fluid tight seal with the piston
disc.
To open the valve, fluid from the trip fluid
circuit is admitted to the space below the
piston disc and, simultaneously, the space
above the bell-shaped half of the piston is
opened to drain. This causes both halves of
the piston to move together in the direction,
which opens the valve. In order to reduce
fluid leakage past the bell-shaped part of the
piston when the valve is open, a back seat is
provided in the housing against which the
collar of the piston can seat.
When the valve is tripped, the pressure in
the trip fluid circuit, and hence in the space
below the piston disc, falls, with the result
that the springs separate the two halves of

BHEL Haridwar 5.1-0811-00

 Steam Turbine Hydraulic Servomotor for
Description Main and Reheat Control Valves

The flow of steam to the turbine is regulated order to ensure that the valve moves freely
by varying the lift of the control vale by at all times.
means of its servomotor. Main Control System
The control valve is actually moved by the The movement of the pilot piston (4) deflects
piston (9), which is loaded, on one side by the main pilot valve (3) from its center
the disc springs (10) and on the other side position by means of lever (5) so that either,
by hydraulic pressure. The position of the control fluid from connection ‘a’ is directed to
valve is determined by the secondary fluid the underside of piston (9) and the control
pressure, which is controlled by the valve opens, or the underside of piston is
governor. Since large operating forces are opened to drain so that the disc springs can
required, the servomotor is of the high- close the control vale. Shortly before the
pressure type (approx. 32 bar) and has a main valve disc actually comes into contact
pilot control system. The supply of with the seat, the servomotor piston (9)
secondary fluid (connection ‘b’) controls the enters a recess turned in the body and
auxiliary pilot valve (14) which directs control throttles the flow of fluid draining from the
fluid from connection ‘a1’ to the appropriate underside of the piston. This slows down the
side of the pilot piston (4). The pilot piston valve closing motion and the disc seats
operates the main pilot valve (3) through gently. The spring (1) pre-loads the linkage
lever (5) so that when the valve is being and prevents any slackness or lost motion at
opened, control fluid from connection ‘a’ is the pivots. The straight feedback cam (7)
directed to the underside of piston (9). When mounted on the end of the servomotor
the valve is being closed, fluid drains piston rod (8) returns the main pilot vale (3)
through the main pilot valve. to its center position by means of a lever
system. The slope of the feedback cam is in
Pilot Control System
two stages to give two degrees of
When the turbine is running and the valve is proportionality, which produce good linearity
steady at any particular value of lift, the of the steam flow characteristics.
auxiliary pilot valve (14) will be in the center
position shown in the drawing. In this Testing Device
position the force exerted by the spring (13) The control valve can be operated either by
and the secondary fluid pressure acting on hand or under power independently of the
the auxiliary pilot valve are in equilibrium. governor by means of the testing device (11)
When the governor varies the secondary in order to check the free movement of the
fluid pressure to open or close the control valve. The testing device acts on the lever
valve, the auxiliary pilot valve is deflected (5) in the same manner as the pilot piston
from this center position. This allows control (4); the system demanding the smaller valve
fluid (connection’ a1 ‘) to flow to one side of lift being in control,
the pilot piston (4) while the other side of the
Damping Device
piston is opened to drain. The movement of
the pilot piston returns the auxiliary pilot Fig.2 illustrates the auxiliary pilot valve (14)
valve to its center position by means of the and the damping device in the secondary
feedback linkage (12) thus giving fluid circuit. Any signals in the secondary
proportionality between secondary fluid fluid circuit are damped out by passing the
pressure and pilot piston travel. The degree secondary fluid through capillary tube (16)
of proportionality of the pilot control system before it enters the auxiliary pilot vale (14).
can be adjusted by varying the position of Any air carried by the secondary fluid is
the feedback lever pivot (12). The auxiliary conducted to the free space in the actuator
pilot valve is continuously rotated by the via the screw plug (18) and holes in the
action of fluid issuing from tangential casing of the damping device and pilot
drillings in a disc mounted on its spindle in valve.

BHEL Haridwar 5.1-0812-00/1

5.1-0812-00/2
 Steam Turbine Test Valve
Description for Emergency Stop Valve

Function lowering the pressure in the start-up fluid

The function of the test valve is to open and circuit or by manually turning the hand wheel
close the emergency stop valve, either by (3). The trip fluid can now flow from
start-up fluid circuit or manual operation connection ‘x’ to connection ‘x2’ via the
especially when the emergency stop valve is auxiliary valve (5) and ducts in the casing,
being checked for easy movement. and thus under the piston disc.

Arrangement Testing the Emergency Stop Valves

Each test vale (6) and auxiliary valve (5) is For testing the emergency stop valve, the
arranged in series behind a solenoid valve valve (6) is moved slowly downwards by
(1, 2). means of the hand wheel (3). In this way,
trip fluid is admitted to connection x1, and
Each emergency stop valve is served by then connection x2 Iinked to drain c, which
one test valve, whereby a test valve (6) is closes the emergency stop valve. After this,
combined with an auxiliary valve (5) in a the hand wheel (3) is slowly turned back and
common casing. These blocks of test valves the emergency stop valve opens again. This
are arranged in frames immediately next to procedure is accordingly the reverse of the
the relative emergency valve groups. closing procedure.

Opening of the Emergency Stop Valve Closing the Emergency Stop Valve by
In order to open the emergency stop valve, Automatic Testing Device
the valve (6) must first be forced downwards When trip fluid is admitted under the
against the force of the spring (7). This can auxiliary valve (5) via connection v, this will
either be done by start-up fluid (connection be forced upwards against the force of the
‘u’) or manually with the hand wheel (3). Trip spring (4). This links connection x2 with
fluid (connection ‘x’) can then flow to drain ‘c’ via valve (5). Fluid thus drains
connection ‘x1’ and on over the piston in the under the piston disc in the emergency stop
emergency stop valve. The valve must then valve and the valve closes suddenly.
be returned to the upper position, either by

BHEL Haridwar 5.1-0813-00

 Steam Turbine Combined Reheat Stop
Description and Control Valves

Function and Construction inlet of the valve body (2) and remains
One stop and one control valve are above the valve disc (7) when the stop
combined in a common body with their valve is closed. A pilot valve, integral with
stems arranged at right angles to each the valve stem (6) is provided for relieving,
other. The stop valve can interrupt the thereby reducing the force necessary for
supply of steam from the reheater to the opening. The valve disc (7) slides in the
IP and LP turbines extremely quickly. The bushing of the valve cover (4) and has a
control valve controls the steam flow to bead on the back which lies against the
the IP and LP turbines on load rejection, base bushing (5) and provides additional
start-up & shutdown and remains fully sealing at this point. Metal packing rings (3)
open in the upper load range to eliminate seal the valve stem. The stop valve is
any throttling losses. Further details of the opened hydraulically and closed by spring
arrangement of the valve combination in force.
the control system can be seen under
section “Governing system”.
Testing Stop Valves
Each stop valve must be checked for
Reheat Stop Valve correct operation at regular intervals. A test
The stop valve is a single seat valve with valve is provided for this purpose. The
integral pilot valve. Steam enters via the checking procedure is described in section
“Test valve”.

BHEL Haridwar 5.1-0814-00/1

Control Valve
The control valve has a pipe-shaped when the valve is fully open.
valve disc (14) that is bolted to the valve Asbestos/graphite packing rings (10) seal
stem (13) and slides in the bushing in the the valve stem (13) in the valve cover (11).
valve cover (11) The valve disc is The control valve is operated by the piston
provided with relieving holes to reduce the of the servomotor (9) i.e. is opened
necessary controlling force. A ring fixed in hydraulically and closed by disc springs.
the bushing of the valve cover prevents
In the event of a disturbance in the system
the valve disc from rotating. This valve
or on trip-out, both stop valve and control
disc also has a back sealing that operates
valve close rapidly.

5.1-0814-00/2
 Steam Turbine Hangers for Reheat Stop
Description and Control Valves

The reheat stop and control valves arranged directions. Tensile forces are taken up via
beneath the turbine operating floor in front of the disk spring (8) and tie rod (6) by girders
the turbine-generator unit are suspended at (1) that rest horizontally on shims in a
three points from girders in the upper recess in the foundation and are connected
foundation plate in such a way that they can to the foundation via clamping plates.
follow thermal expansion of the steam lines.
Tie rod (6) is screwed into rod cap (5) and
The ball-and-socket design of the tie caps when the correct elevation of the reheat stop
(5) and spring body (9) and the disk spring and control valve (3) has been established,
stack (8) arrangement permit free movement is secured to prevent turning.
of the reheat stop and control valve (3) in all

BHEL Haridwar 5.1-0815-01

 Steam Turbine Steam Strainer
Description

Function parts. The end turns of the corrugated strip

are then tacked to the T -section
Steam Strainers are installed in the main
intermediate rings (3). The maximum mesh
steam lines and in the hot reheat lines from
size of the strainer, which inner diameter
the boiler. They protect the admission
determined by the height of the
elements of the HP and IP turbines from
corrugations, is 1.6 mm. The effective area
foreign objects, which could be picked up in
is made atleast three times the cross-
the boiler or associated piping.
sectional area of the pipe. The strainer is
used for both initial commissioning of the
Construction turbine and for regular operation.
The strainer screen (2) is made of
corrugated strip wound on a frame. This

design offers a high degree of resistance,

even to particles impinging at high velocity. Fig. 3 Corrugated metallic` strip
The frame consists of two rings (1, 6) and a
number of rods (5) welded between the
rings. The rods are additionally held by
reinforcing rings (4) welded inside them. The
strainer is designed for a single direction of
flow from the outside inwards. For longer
strainers, the screen is made up of several

BHEL Haridwar 5.1-0816-00

 Steam Turbine Changeover Valve
Description for Bleeder Check Valve

Function
The function of the changeover valve is to
manually operate the actuator of the
bleeder check valve.

Mode of Operation
The trip fluid (connection x) holds the valve
(10) in the upper end position (illustrated)
against the force of the spring (8). The trip
fluid flows via the holes in the valve to
connection x 1 and then on to the actuator
of the bleeder check valve. The valve can
be moved downwards by means of hand
wheel (1). In this way connection x1 is
connected to the fluid drain ‘c’ and the fluid
drains away from the actuator of the bleeder
check valve. The spring of the actuator can
then initiate the closing of the check valve. If
the pressure drops at the trip fluid
connection x, the spring (8) pushes the
valve (10) downwards. In this way the fluid
drain of the actuator is also freed.

1 Hand wheel 6 Cover

2 Spindle 7 Bush
3 Cap nut 8 Spring
4 Bush 9 Ball
5 Lip ring 10 Valve
11 Cover
c Drain fluid
x Trip fluid
x1 Trip fluid to actuator

BHEL Haridwar 5.1-0840-00

 Steam Turbine Auxiliary Valve
Description of Extraction Check Valve

Function
The auxiliary valve controls the fluid supply With this position of the valve, the trip oil
to the extraction check valve actuators and ‘x’ can flow to the other valves and as
its function is to give the check valves a soon as these valves have been
signal to close in the case of a drop in load switched to the upper position by
or trip-out so that steam can not flow out of secondary fluid from follow-up piston of
bleeder lines back to the turbine. The reheat control valves-on to the change-
auxiliary valve serves several check valves. over valves of the extraction check
valves (connection ‘x1‘). The check
valves are then free to open. On a
Mode of Operation reduction in load, as mentioned above,
Trip fluid is admitted through connection ‘x’ the pressure above the valve (11) is
on the body (10) (section A-B). Secondary reduced accordingly while the Pressure
fluid from follow-up pistons of main control below the valve is retained for a while.
valves is admitted to the spaces above and This is made possible by the fact that the
below the valve (11) through connection ‘b2’ pressure reduction below the valve is
As the pressure above and below the valve retarded by the ball (15) and the
(11) are equal under normal conditions, the pressure in the accumulator (connection
valve is held in the lowest position by the ‘b’) until the equilibrium is re-established
force of the spring (7).

BHEL Haridwar 5.1-0841-00/1

between the pressure in the accumulator upwards against the action of the springs
and the new pulse fluid pressure and open the path for the trip fluid to the
(connection ‘b2’) via the equalizing passage changeover valves of the extraction check
in the cover (12). Owing to the brief valves. The lift of the valves is limited by a
differential surge, the valve (11) is forced collar at their lower end. By appropriately
upwards against the action of the spring (7), setting the springs (14) to the valves, it can
thus cutting off the trip fluid supply to the be ascertained at which secondary fluid
check valves and opening the fluid return. pressure i.e, at which turbine load, the check
As a result of this, the check valves receive valves open or receive an impulse to close.
a closing impulse and close at reduced or If the pressure in the secondary fluid circuit
reversed differential steam pressure. drops, the valves are pushed downwards by
The valves (16), (section C-D) are acted the force of the springs and the inlet ports
upon from below (connection ‘b1’) by the from the trip fluid circuit are cut off, the bleed
load -dependent secondary fluid pressure of valves thus receiving an impulse to close.
the control valves. If the secondary fluid The fluid in the line to the changeover valves
pressure exceeds the value set by adjusting can drain off through the opened fluid return
the springs, these valves are forced ‘c’.

5.1-0841-00/2
 Steam Turbine Rotary Vane Actuator
Description for Reheat Swing-Check Valve

Function
The function of the rotary vane actuator segments (1). This rotary movement,
flanged to the swing-check valve is to transmitted by actuator shaft (8) to shaft (3)
open or close the swing-check valve fitted of the swing-check valve via coupling (5;6)
in the cold reheat line. closes the swing-check valve. Conversely,
the swing-check valve is opened when
control fluid is admitted through
Operation connections ‘d1’
When the pilot valve operated by the
transformer of the speed controller
Seals, Fixing
passes control fluid via connections ‘d’ to
the interior of the actuator, the adjacent Actuator shaft (8) is guided in bushings
connection ‘d1’ is depressurized. The (11) at both ends of the segments (1) and
control fluid then flows through bores in is sealed off by seal ring (10). The
the body into the two diametrically segments (1) are fixed in body (12) and in
opposite chambers turning rotary vane (2) cover (13) by means of fitted pins. Leaking
on actuator shaft (8) into contact with the fluid ‘c’ is drained to the header.

BHEL Haridwar 5.1-0853-01

 Steam Turbine Pilot Valve for Rotary Vane
Description Actuator of Swing-Check Valve

Function
The function of the pilot valve is to control
the admission of control fluid to the moving
vane actuator in such a way that the swing-
check valve is operated in accordance with
the pressure in the secondary fluid circuit.

Mode of operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value. If
signal fluid enters the body via connection
‘b’, the valve (10) is lifted against the action
of the spring (5). The initial tension of this
spring and thus the point at which the swing-
check valve opens can be adjusted. If the
valve (10) is lifted beyond the center position
illustrated, the control fluid entering at
connection ‘a’ flows on to a chamber of the
actuator via connection ‘a2’ to open the
swing-check valve. Connection ‘a1’ then
communicates with the fluid return ‘c’ via
passages in the body, permitting the fluid to
drain away from the actuator chambers not
supplied with control fluid. If the valve (10)
drops below the center position illustrated,
the control fluid will then be conversely
admitted to the actuator chambers in such a
way that the swing-check valve closes.
To prevent the valve (10) from seizing in its
sleeve (9) during operation control fluid is
passed through the center bore and out
through the tangential bores at the wheel
disc (8) to impart rotary movement to the
valve (10). For this reason, a thrust ball
bearing (7) and a ball (13) is fitted for this
purpose.
1 Throttle capillary tube 12 Slotted nut
2 Cap nut 13 Ball
3 Setscrew
4 Hood
5 Compression spring
6 Spring disc
7 Thrust ball bearing
8 Wheel disc
9 Valve bush
10 Valve
11 Bush c Return
a Control fluid b Signal fluid
a1 Control fluid(closes swing check valve)
a2 Control fluid(opens swing check valve)

BHEL Haridwar 5.1-0854-00

 Steam Turbine Auxiliary Pilot Valve
Description for Rotary Vane Actuator
For Reheat Swing-Check Valve

Function
The function of the auxiliary pilot valve for
the pilot valve for the reheat check valve
actuator is to control the admission of
control fluid to the pilot valve in such a way
that the swing-check valve is actuated in
accordance with the pressure in the
secondary fluid circuit.

Operation
The swing-check valve is kept open as long
as the pressure in the secondary fluid circuit
does not drop below a definite limit value.
Secondary fluid entering body (9) via
connection ‘b’ lifts spool (7) against the
action of the spring (3). The initial tension of
this spring and thus the point at which the
swing-check valve opens can be adjusted. If
spool (7) is lifted beyond its central position
as illustrated, the control fluid entering at
connection ‘a’ flows on via connection ‘a1” to
connection ‘b’ of the pilot valve to open the
swing- check valve via the rotary actuator. If
spool (7) drops below its central position as
illustrated, control fluid is admitted to the
opposite chambers of the rotary actuator, so
that the swing-check valve closes.
To prevent spool (7) from seizing in its
sleeve (6) control fluid is passed through the
center bore in the spool during turbine
operation and out through tangential bores
in the upper part of spool (7) to impart rotary
motion to the spool. A deep-groove ball
bearing (5) between spool (7) and spring
retainer (4) reduces friction from the rotary
motion.

BHEL Haridwar 5.1-0855-00

 Steam Turbine Gland Steam Control Valve
Description along with Actuator

Function
One function of the gland steam control
valve, which is situated in the grand steam
pipe of the seal steam system, is to supply
the shaft seals with seal steam during start-
up and in the lower load range. A further
function is to keep the set pressure in the
header constant in order to prevent air
penetrating the vacuum of the shaft seals.

Construction and Mode of Operation

The gland steam control valve is operated
by the pneumatic actuator which is moved in
the open direction by air pressure and in
closed direction by the spring force.
The gland steam pressure controller feeds 4
to 20 mA control signal to the positioner
which in turn gives the corresponding air
pressure to the actuator for the operation of
gland steam control valve.
The cross section view of gland steam
control valve alongwith actuator of gland
steam system is also given here.
1-Body 26-Bonnet Bush
2-Seat 27-Extended Bonnet
3-Plug 28-1½ “ -6UNC-2B Nut
4-Bush 29-1½ “ -6UNC-2A Stud
5-Packing 30-Flow Divider
6-Spring
7-Washer
8-Threaded Bush
9-Washer
10-Body Gasket
11-Adaptor
12-Nut
13-Yoke Bonnet
14-Travel Indicator
15-Wiper Ring
16-Oil Seal Supplier’s catalogue may be referred for
17-Coupling complete details. Valve alongwith actuator is
18-Diaphragm Plate supplied by M/S Samson Controls Pvt. Ltd.
19-Diaphragm B-43, Wagle Industrial Estate, Road No. 27,
20-Actuator Thane (Maharashtra)
21-Spring
22-Actator Nut
23-Bush
24-Hand Wheel Position Indicator
25-Needle Roller Bearing

BHEL Haridwar 5.1-0860-02

 Steam Turbine Leakage Steam Control Valve
Description along with Actuator

Function
The function of the leakage steam control
valve, which is situated in the leakage steam
pipe of the seal steam system, is to drain
excessive steam from the header in order to
keep the set pressure in the seal steam
header.

Construction and Mode of Operation

The leakage steam control valve is operated
by the pneumatic actuator. Valve is moved
in the open direction by the air pressure and
moved in closed direction by spring force.
The gland steam pressure controller feeds 4
to 20 mA control signal to the positioner
which in turn gives the corresponding air
pressure to the actuator for the operation of
leakage steam control valve.
The cross sectional view of leakage steam
control valve alongwith actuator of gland
steam system is given here.

1-Body
2-Seat
3-Plug
4-Bush
5-Packing
6-Plug stem
7-Lock Nut
8-Threaded bush
9-Retainer Ring
10-Body Gasket
11-Adaptor
12-Ext. Bonnet
13-Yoke
14-Travel Indicator
15-Coupling (Clamp)
16-Diaphragm plate
17-Diaphragm Supplier’s catalogue may be referred for
18-Actuator casing complete details. Valve alongwith actuator is
19-Spring supplied by M/S Samson Controls Pvt. Ltd.
20-Actuator nut B-43, Wagle Industrial Estate, Road No. 27,
21-1 ½ “ – 6UNC-2B Nut Thane (Maharashtra)
22-1 ½ “ – 6UNC-2A Stud

BHEL HarIdwar 5.1-0870-02

 Steam Turbine Main Trip Valve
Steam Description

Function
(12) are designed as differential pistons
The Function of the main trip valve is to being forced tightly against the body
open the trip fluid circuit in the event of assemblies (10) by the rising pressure of the
abnormal conditions, thereby closing the fluid. Control fluid flows into the casing (11)
valves and thus shutting off admission of via connection ‘a’ and with a tripping device
steam to the turbine. latched in (in the position shown), into the
trip fluid circuit via connection ‘x’. The trip
Construction fluid circuit leads to the stop valves and the
secondary fluid circuits. Via passage drilled
The main trip valve consists of mainly two
in the body (11) (Section A-A) fluid flows to
valves (12) that slide in the casing (11) and
the auxiliary trip fluid circuit, which leads to
are loaded by the springs (5,6). The valves
the hydraulic protection devices.

BHEL Haridwar 5.1-0910-00/1

Operation
When starting the unit, the valves (12) are (12) move downwards due to the spring
lifted by the aux. start up fluid (connection force and their own weight, thus connecting
‘u1 ‘) against the force of the springs (5,6) connections ‘x’ and ‘x1’ with the fluid back
and forced tightly against the assemblies flow ‘c’. This depressurizes the trip fluid
(10). In this way pressure is build up in the circuit which causes the main and reheat
trip fluid circuit (x) and the auxiliary trip fluid stop valves to close. The fluid supply to the
circuit (x1). The pressure in the auxiliary trip secondary fluid circuits is also shut off, thus
fluid circuit keeps the valve in the position causing the control valves to close.
shown while the aux. start up fluid drains
The two valves (12) work independently of
through the start up device.
each other so that even if one valve fails the
Should the fluid in the pressure in the function of the tripping device is not
auxiliary trip fluid circuit drop below a impaired. The limit switches (1) transmit
specific value for any reason (e.g. by electrical signals to the control room.
tripping of a protection device) the valves

5.1-0910-00/2
 Steam Turbine Emergency Trip Valve
Description for Manual trip out

The emergency trip valve enables the

machine to be manually tripped out.
The valve consists of the valve cone (8),
which slides in the bushing (9) and is
loaded by the spring (7), and the ball head
(1) with the spindle (4).
During normal operation the valve (8) is
forced tightly against the bushing (6) by
the pressure of the auxiliary trip fluid
arising at connection ‘x1 ‘. To actuate the
trip, the ball head (1) is pushed
downwards. This opens the valve and
connects the auxiliary trip fluid circuit
(connection ‘x1 ‘) with the fluid back flow
‘c’, The drop in pressure in the auxiliary
trip fluid circuit actuates the emergency
tripping device. The limit switch (2) shows
the tripping of the valve.
On start-up, before the auxiliary trip fluid is
pressurized, the valve (8) is forced
upwards against the bushing by the
auxiliary start-up fluid (connection ‘u1‘).
1 Ball head
2 Limit switch
3 Cover
4 Spindle
5 spring
6 Bushing
7 Spring
8 Valve cone
9 Bushing
10 Casing
11 Cover

x1 Auxiliary trip fluid

u1 Auxiliary start-up fluid
c Return fluid

BHEL Haridwar 5.1-0911-00

 Steam Turbine Solenoid Valve for
Description Remote Trip-out

Function
The solenoid valve is installed in the
auxiliary trip fluid line to the automatic trip
gear and, when operated, causes the
auxiliary trip fluid circuit to be opened and
the turbine stopped, The solenoid valve is
remote-controlled electrically, e.g. from the
control room or from a protective device.

Construction
The directions of flow are indicated by
arrows on the body. The solenoid sleeve (4)
is bolted to the casing (6) and is inserted in
the magnet casing (1) with the armature (3).
The complete valve element is placed in the
body (6) and held by the plug (11). The two
valve discs (8) seal the valve seats (9). The
solenoid valve and the line to the automatic
trip gear are ventilated by means of the
screw (12).

Mode of Operation
When the solenoid (1) is not energized, the
armature (3) is moved downwards by the
spring (2) so that the valve disc (8) is
pressed against the valves seats (9) to
provide sealing. The solenoid valve is
operated by energizing the solenoid (1). The
armature and the valve discs are drawn
upwards against the force of the spring (2)
so that the auxiliary trip fluid ‘a’ is linked with
the drain ‘c’ and the pressure in the line to
the automatic trip gear collapses.

1 Magnet casing
2 Spring
3 Armature
4 Solenoid sleeve
5 Hexagonal nut
6 Casing
7 Ring
8 Stem with two valve discs
9 Valve seat
10 O-ring
11 Plug
12 Ventilation screw
a Auxiliary trip fluid to automatic trip gear
c Drain

BHEL Haridwar 5.1-0912-00

 Steam Turbine Over speed Trip
Description

Function and Construction

The function of the overspeed trip is to stop
the turbine when the permissible speed is
exceeded. It is fitted in the turbine rotor (7)
and consists of the eccentric bolt/striker (4),
adjusting screw (6), spring (5) and the screw
plug (1).

Mode of Operation
The overspeed trip mechanism is set by the
adjusting screw (6). By appropriate
adjustment of the screw, the center of
gravity of bolt/striker (4) is positioned
eccentrically to the turbine shaft so that
below the tripping speed the bolt is held in
the position shown by the spring (5) against
the centrifugal force. In this position, the bolt
bears against the screw plug (1). If the
turbine rotational speed exceeds the
overspeed setting, the centrifugal force
overcomes the force of the spring (5) and
forces the bolt/striker (4) out of the turbine
rotor (7). This activates the turbine 1 Screw plug 5 Spring
2 Guide bushing 6 Adjusting screw
automatic stop mechanism.
3 Guiding foil 7 Turbine rotor
4 Bolt/striker 8 Guide ring

Fig. 1 Arrangement of overspeed trip in

turbine rotor

BHEL Haridwar 5.1-0920-00

 Steam Turbine Overspeed Trip Releasing Device
Description

Function Turbine Trip by Overspeed Trip Device

The function of the overspeed trip releasing When the overspeed trip operates, the
device is to open the auxiliary trip fluid circuit eccentric bolts/striker fly out radially and
and thereby shut down the turbine when an strike pawls (12). The impact of the
overspeed is reached which would subject bolt/striker rotates the pawls outwards
the rotor to high centrifugal force. against the force of torsion springs (11). The
latches of the pawls release rod (8) which, in
turn, moves towards the shaft (13) due to
Construction
the force of spring-loaded pilot valve (3) and
The overspeed trip releasing device located force of the auxiliary trip fluid ‘x1’. This
in the bearing pedestal consists of valve movement opens fluid drain ‘c’ to the
bodies (4,10), pilot valve and rods (3,5,7,8), auxiliary trip fluid and the resulting loss in
pawls (12) and limit switch (1). The bellows pressure and trips the turbine. The electrical
16) on the pilot valves and rods prevent trip signal is transmitted to the control room
hydraulic control fluid from entering bearing by the limit switches (1).
pedestals and lubrication system. When the
turbine is started up, the pilot valve, rods
and pawls are latched by auxiliary start-up
fluid ‘u1 ‘.

BHEL Haridwar 5.1-0921-00/1

Testing the Overspeed Trips for Free Start-up
Movement Before restarting the turbine following a trip,
Proper functioning of the overspeed trips is latch in the overspeed trip. This is done by
important since severe damage may result admitting auxiliary startup fluid ‘u1’ into pilot
from excessive over speeds. The overspeed valve body (4) and forcing the respective
trip test device makes it possible to check pilot valve (3) outwards until rod (8) engages
the bolts/strikers as well as pilot valves and the latch of the pawl. The auxiliary start-up
rods (3, 5, 7, 8) without interrupting fluid flow is interrupted and auxiliary start-up
operation of the turbine. fluid flows via a hole to fluid drain ‘c’.

5.1-0921-00/2
 Steam Turbine Overspeed Trip Test Device
Description

Function functioning of the overspeed trip is of the

The function of the overspeed trip test utmost importance.
device is to test and exercise the overspeed Construction
trip. The overspeed trip consists of
The overspeed trip test device consists of
bolts/strikers which protrude against the
three pilot valves (4,10, 11) combined in
force of a spring under the effect of
valve block (12). Pilot valve (11) is held in
centrifugal force during an overspeed
the position by spring (9), which bears
condition. The bolt/striker strikes a pawl and
against guide piece (15) and rod (7). In this
thus opens the auxiliary trip fluid circuit and
position auxiliary trip fluid can pass to the
in turn trip fluid circuit so that the stop and
overspeed trip release device via connection
control valves immediately interrupt the
‘x’ and ‘x1‘. If the pilot valve (11) is pushed
admission of steam to the turbine. Perfect

BHEL Haridwar 5.1-0922-00/1

inwards and held by means of the knob (6), bore of the pilot valve. By means of
the auxiliary trip fluid circuit (connection ‘x’ handwheel (5), the pilot valve (10) can be
and ‘x1’) is separated from the overspeed moved inwards so that the passage from
trip release apart from a small quantity of connection ‘a2’ is blocked from drain ‘c1’.
fluid which is permitted to pass to fill up the Control oil can now flow from connection ‘a1’
empty pipe after the test operation. This via the bushing (13) and the pilot valve (10)
prevents the emergency trip from being to connection ‘a2’ and the bolts/strikers of
actuated by the overspeed trip. the overspeed trip.

Pilot valve (10) performs the function of Pilot valve (4) is used for resetting the
admitting test oil to the eccentric overspeed trip release device after the test
bolts/strikers of the overspeed trips, causing operation. When pilot valve (4) is pushed
them to protrude from the turbine shaft inwards against the force of spring (3),
during the overspeed trip test operation. control fluid can flow from connection ‘a’ to
Pilot valve (10) is guided in guide bushings ‘u1, thus latching in the overspeed trip
(13,14). A center bore with radial openings device. During start-up, connections ‘u’ and
is provided in the pilot valve. An annular ‘u1’ provide a passage for auxiliary start-up
chamber in the bushing (13) is connected to fluid for latching in the overspeed trip release
test oil connection ‘a1’. In the position device. After the test operation, the pilot
shown oil is prevented from entering the valves (4,11) are blocked.

5.1-0922-00/2
 Steam Turbine Low Vacuum Trip
Description

Function depressurized and the main trip valve

operates. Concurrently, valve (11)
The purpose of the low vacuum trip is to
actuates the limit switches (15), which
operate the main trip valve when a failure
initiates an alarm contact.
of vacuum occurs in the condenser, thus
tripping out the main and reheat stop and The range in which the vacuum safety
control valves and shutting off the supply device operates can be varied by adjusting
of steam to the turbine within the shortest the initial tension of the spring (7) by
possible time. means of the adjusting screw (5).
In order to isolate the auxiliary trip fluid
Operation circuit during starting, auxiliary pilot valve
The condenser vacuum is connected via ‘I’ (9) is lifted by means of the spring (10) so
(connection to condenser) to the top side that drain ‘c’ is shut off, thereby
of the diaphragm (8). The space below the establishing pressure in the auxiliary trip
diaphragm is at atmospheric pressure. fluid circuit when no vacuum exists.
Upon failure of the condenser to maintain As primary oil pressure builds up with the
proper vacuum, diaphragm (8) is forced increase in turbine speed, piston (2) is
downwards by the increase in pressure forced into the lower position. This lower
and the force of the spring (7) against the position is reached when the speed is still
force of spring (10), thus moving valve (9) far below the rated value at which time the
downwards. This establishes a connection low vacuum trip safety device is ready to
between ‘x1’ (control fluid) and drain ‘c’ so operate.
that the auxiliary trip fluid circuit is

BHEL Haridwar 5.1-0935-00

 Steam Turbine Condenser Safety Device
Description

Function
The function of the condenser safety device
situated in the control fluid circuit of the
bypass control system is to protect the
condenser, when there is an excessive
increase in pressure in the condenser, by
opening the control fluid lines so that the
resulting drop in pressure causes the
bypass valves to close.

Mode of Operation
The steam space in the condenser is
connected with the spring space above the
diaphragm (5) via connection ‘I’. The space
below the diaphragm is at atmospheric
pressure. If the pressure in the condenser
increases excessively, the diaphragm (5),
and thus the valve (6), is forced downwards
out of the upper end position by the
increasing pressure and the force of the
spring (4). This shuts off the connection ‘a1”
to the bypass valve from connection. ‘a’
which is from the converter and connects it
to drain ’c’.
The pressure range in which the vacuum
safety device operates can be varied by
adjusting the initial tension of the spring (4)
by means of the adjusting screw (2).
During commissioning the valve (6) is
automatically moved into the upper end
position, where it keeps the control fluid
circuit closed, as soon as the negative
pressure in the condenser falls below the
preset value. In order to be able to close the
control fluid circuit when there is still
insufficient vacuum in the condenser, the
valve is lifted via the lever (10) and cam (9)
but is not yet brought into its upper end
position. As already mentioned, this end
position is not reached until there is
sufficient vacuum.
After this, the lever (10) and cam (9) drop
down and do not impair the functioning of
the vacuum safety device. Any leakage fluid
can drain off through passages in the valve
sleeve (7) and the casing (8).

BHEL Hardwar 5.1-0940-00

 Steam Turbine Solenoid Valve for Temperature
Description Controlled Interlock

Function
When there is an unallowable rise in
condenser temperature due to lack of
injection water a temperature sensor
situated in the condenser dome sends
electric signals to the solenoid valve which
open the signal fluid circuit of the bypass
valve actuators, thereby closing the bypass
valves so that the steam flow to the
condenser is interrupted.

Mode of Operation
During normal operation, the control fluid ‘a’
holds the main control valve (7) against the
force of the compression spring (8) in the
center position as shown here, This provides
the connection between the signal fluid from
pressure switch for injection water ‘b’ and
the stop and control valve operator of the
bypass stop valve ‘b1 “, If the temperature in
the condenser rises to an unallowable value,
the solenoid valve (3) is moved downwards
against the force of the compression spring
(4) so that the control fluid ‘a’ arising before
the main control valve (7) is connected with
the drain ‘c’.
Simultaneously, the control fluid ‘a’ can flow
behind the main valve (7) so that the main
valve moves forwards against the force of
the compression spring (6) and the signal
fluid circuit ‘b1’ is opened and connected to
the drain ‘c’ and the bypass stop and control
valve closed’.

BHEL Hardwar 5.1-0950-00

 Steam Turbine Vacuum Breaker for
Description Reducing the Running Down
Time of the Turbine

Function
With normal shut down or tripping of the
machine, the function of the vacuum breaker
is to cause an increase in condenser
pressure by conducting atmospheric air into
the condenser together with bypass steam
flowing into the condenser from the bypass
station. When the pressure in the condenser
increases, the ventilation of the turbine
blading is increased, which causes the turbo
set to slow down so that the running down
time of the turbo set and the time needed for
passing through critical speeds are
shortened.
Partial and Total Vacuum Breakers
The partial vacuum breaker is used when
the running down time is to be shortened
with normal shut down and plant conditions
are free of disturbance. Taking blade stress
into consideration, the permissible
operational condenser pressure of 0.3 bar
should not be exceeded. For this reason the
limiting value for the condenser pressure
has been set at 0.2 bar.
In special cases requiring a rapid shut down 1- LP Turbine
of the turbo set, the total vacuum breaking is 2- Pressure Transmitter
employed. 3- Solenoid Valve
4- Vacuum Breaker Valve with actuator
5- Condenser
Electrical Control of Partial Vacuum Breaker
6- Condensate Pump
The vacuum breaker valve is actuated to 7- Water Injection Valve
open once by a manual key. It closes
automatically when the pressure in the d Steam from IP Turbine
condenser rises. This control achieves a d1 Bypass Steam
rapid passing through the speed range up to k Condensate
hydraulic shaft turning operation. The I Atmospheric air
pressure transmitters installed in the c Drain
condenser for registering the pressure
increase is set at 0.18 bar so that the
condenser pressure will not exceed 0.2 bar
after the valve has closed.
This control enables a complete equalization
Electrical Control of Total Vacuum of condenser and ambient pressure.
Breaker
Automatic Control
So that the vacuum can also be broken
The vacuum breaker is also actuated
without limitation due to condenser
automatically by the turbine fire protection
pressure, a manual key is provided. This key
system to shut the turbo set down more
opens the vacuum breaker valve. However,
quickly. It is switched back manually using
it can not go into the closing position until
the close key in this case.
the close key provided for closing is used.

BHEL Haridwar 5.1-0960-02/1

Mode of Operation of Vacuum Breaker
Solenoid Valve (SV):-When the solenoid
valve is energized, it used to provide the
signal air to the volume booster to supply
enough air to the actuator to open the
vacuum breaker valve.
Volume Booster (VB):-This is used to
supply exact volume of air to the actuator to
meet the required time for opening of the
vacuum breaker valve.
Quick Exhaust Valve (QEV):-This is used
to close the vacuum breaker valve (when
supply to solenoid valve fails or solenoid
valve gets de-energized to close the vacuum
breaker valve) by exhausting the air
supplied to the actuator of vacuum breaker
valve within the allowable time for its
closing.
Air Filter Regulator (AFR):-This is used to
supply air to SV and VB.
Note:-The vacuum breaker valve is always
in closed condition during normal operation
of turbine.

Working Arrangement:-
Opening Process:-
When the magnet of solenoid valve is
excited/energized then the signal air is
supplied to volume booster for its operation.
Pressurized air from volume booster through
quick exhauster valve is supplied to the
actuator to open the vacuum breaker valve.
Closing Process:-
When the magnet of solenoid valve is not
excited/de-energized then the vacuum
breaker valve is closed as air gets
exhausted from the actuator through quick
exhauster valve as well as volume booster
and at the same time further signal air
supply from solenoid valve is also cut-off.

5.1-0960-02/2
 Steam Turbine Changeover Valve
Description for Testing Device

Function
The function of the changeover valve is to
shut off the flow of trip fluid into the trip
fluid circuit while the protective devices
are being tested for proper operation by
means of the Automatic Turbine Tester
(ATT) and to allow control fluid ‘a’ to flow
in so that the stop valves do not close
when the safety devices respond.

Mode of Operation
During normal operation, the control fluid
‘a1’ in the space under the lower piston
(8) of the changeover valve keeps the
valve in the upper end position shown
here. In this way, connection ‘x’ is
connected with connection ‘x1’ and trip
fluid can flow into the trip fluid circuit. The
space above the piston (6) (connection
‘a’) remains depressurized during normal
operation.
When safety devices are checked for
proper operation, the space below the
lower piston (8) is depressurized by
means of a solenoid valve and control
fluid ‘a’ enters the space above the upper
piston, which moves the valve into the
lower position. Due to the connection now
made between connections ‘a’ and ‘x1’,
control fluid ‘a’ can flow freely into the trip
fluid circuit, which keeps the stop valves
open for the duration of the test. Two limit
switches (1) transmit the position of the
valve to the control room.

1 Limit switch 9 Body

2 Piston rod 10 Cover
3 Seal
4 Bushing a Control fluid
5 Inset a1 Control fluid
6 Upper piston c Fluid drain
7 Sliding bushing x Trip fluid from
8 Lower piston tripping device
x1 Trip fluid to trip
fluid circuit

BHEL Haridwar 5.1-0980-00

 Steam Turbine Oil Supply System MAV
Description System Description

Accompanying system diagram

Description and function of components of the
(Drawing No. 2-13100-91101 on Sheet No. hydraulic and lubricating oil system
On Sheet No.5.1-1000-77/4)
Process engineering functions of the The components of the hydraulic and lubricating oil
hydraulic and lubricating oil system system and their function are described below:
The hydraulic and lubricating oil system has
Main oil tank
the following process engineering functions: The oil necessary for operation is stored in the
• Lubrication and cooling of the turbine and main oil tank. The oil pumps draw the turbine oil
generator bearings with turbine oil drawn from the main oil tank and forward it to where it is
from the main oil tank by the oil pumps and needed. Large solid contaminants in the returning
forwarded via cooler and filter to the oil are removed by the strainers in the main oil tank
bearings; pressures and flow rates are set before the oil reaches the suction section of the
with throttle valves. main oil tank.
Air and oil vapour are drawn out of the main oil tank

Supplying motive oil to turning gear. by the oil vapour extractor.

Backflow of the turbine oil to main oil tank. The main oil tank level is monitored.
The turbine oil can be drained from the main oil
Components of the hydraulic and tank.
lubricating oil system • Injector MAV21 BN001
MAV21 BN002
Injector is located upstream of the main oil pump,
In addition to piping, manually operated which is driven by the turbine shaft. The injector is a
valves, and monitoring equipment, the submersible pump, which draws the turbine oil
following tanks, pumps, drives, coolers, filters directly from the main oil tank using turbine oil and
and valves are necessary for operation of the forwards it to the main oil pump under positive
hydraulic and lubricating oil system: pressure.
• Main oil pump MAV21 AP00I
• Main oil tank and oil pumps The main oil pump is driven by the turbine shaft
Main oil tank and assumes the function of oil supply just before
Injector feeder pump MAV 21 BN001 the turbine generator unit reaches rated speed.
Injector feeder pump MAV 21 BN002 • Auxiliary oil pumps
Main oil pump driven by MAV 21 AP001 auxiliary oil pump 1 MAV22 AP001
the turbine shaft auxiliary oil pump 2 MAV23 AP001
Auxiliary oil pump 1 MAV22 AP001 The auxiliary oil pumps are submersible pumps,
Auxiliary oil pump 2 MAV23 AP001 which draw oil directly from the main oil tank.
Emergency oil pump MAV24 AP001 One of the two auxiliary oil pumps supplies the
hydraulic and lubricating oil system with turbine
• Turning gear oil supply valve MAV51 AA001 oil as long as the main oil pump is unavailable
when turbine generator speed is too low for

Oil coolers and oil filters supplying oil, e.g., during start-up or shutdown of
.Oil cooler 1 MAV41 BC001 the turbine. generator or during turning gear
Oil cooler 2 MAV41 BC002 operation
Double multiport butterfly MAV41 AA521
Emergency oil pump MAV24 AP001
valve The emergency oil pump is a submersible
Oil temperature control valve MAV41 AA001 pump, which draws oil directly from the main 'oil
Lubricating oil filter MAV42 BT001 tank. The turbine oil is forwarded by the
emergency oil pump while bypassing the oil
cooler and oil filter in the lubricating oil system

Lubricating oil supply to bearings when the auxiliary oil pumps are unavailable for
lubricating oil valve MAV42 turbine oil supply due to a fault in three-phase
AA502 power supply.
upstream of turbine bearing 1
lubricating oil valve see below
upstream of turbine bearing n
lubricating oil valve see below
upstream of generator bearing n
There is a lubricating oil throttle valve (coded
according to the system diagram) in the
lubricating oil line upstream of every turbine or
generator bearing.

BHEL,HARDWAR 5.1-1000-77/1
• Motive oil valve of the MAV51 AA001 The bearing-specific oil flow rates are set with
turning gear the throttle valves in the lubricating oil lines
The motive oil valve of the turning gear is actuated upstream of the turbine and generator bearings.
by the associated motor.

Piping and valves
• Oil coolers
oil cooler 1 MAV41 BC001 The turbine oil is supplied to where it is needed
oil cooler 2 MAV41 BC002 through piping. The dimensions of the oil lines are a
function of oil velocity and the oil pressure during
One oil cooler is always in operation to remove operation.
the heat generated by the turbine and generator
bearings from the turbine oil. The second oil Piping, oil coolers, and oil filters are equipped with
cooler is on standby. Changeover to the standby drain valves. Oil coolers and oil filters can be filled
oil cooler must be made when the oil cooler in and vented.
operation clogs or leaks., Air and oil vapour is extracted from the return lines.
Sampling valves are provided for taking oil samples.
The maximum flow rate of the cooling water
.through the oil cooler in operation must be Passive turbine fire protection
maintained for good heat transfer and preventing
deposits in the cooler tubes. The main oil tanks, oil pumps, oil coolers, oil
filters, and important oil system valves are

Double multiport butterfly MAV41 AA521 installed in separate compartment of the turbine
valve building. This compartment is designed with a
The double multiport butterfly valve is the sump for catching leak oil. The sump volume is
changeover valve for the oil coolers. the same as that of the main oil tank.
The oil lines are laid in ducts, which can collect

Oil temperature control MAV41 AA001 leak oil and prevent it from contacting machine
valve parts on which it can ignite.
The lubricating oil temperature upstream of the
turbine and generator bearings is maintained by Information for operation and maintenance
the oil temperature control valve.

Technical Data
The oil temperature control valve is a multiport
valve in which hot and cold turbine oil is mixed to The Technical Data contain the following
obtain the desired lubricating oil temperature of
information:
approx. 45-degree C downstream of the control
valve. - nominal capacity of the main oil tank

Duplex lubricating oil filters - reference values for the capacity of the
lubricating oil filter MAV42 BT001
lubricating oil system including the oil-side
volume of the system tanks, coolers, filters, and
One element of the switchable duplex lubricating piping, which are filled during operation
oil filter is always in operation to protect the - highest and lowest oil level in the main oil tank
turbine and generator bearings against solid during turbine generator operation at rated ,s-
contaminants. .peed
- reference values for the amount of oil which
The differential pressure across the lubricating oil must be filled into the main oil tank for operation
filter in operation is a measure of filter clogging. of the hydraulic and lubricating oil system and
for the amount of oil necessary for flushing the

Double multiport butterfly valve oil system during commissioning or inspection
and overhaul
The double multiport butterfly valve is the - manufacturer, type designation, and design data
changeover valve for the lubricating oil filters. of oil pump motors
- setpoint and limit values of the lubricating oil

Lubricating oil throttle valves upstream of temperature for operation and shutdown of
turbine and generator bearings the turbine generator unit

5.1-1000-77/2

-
 - manufacturer, type designation , and fineness auxiliary oil pump must be switched off.
of the lubricating oil system filter
Extended parallel operation of the main and auxiliary
- reference values for oil heatup in the bearings oil pumps shall be avoided.
and bearing-specific oil requirement

Sub-loop controls of the hydraulic and

Dimensioning of the main oil tank lubricating oil system.

The main oil tank is dimensioned so that the total oil - Sub-loop controls for the oil Pumps
in the tank is not recirculated more than 8-10 times
per hour. The turbine oil in the system takes up air All oil pumps of the hydraulic and lubricating oil
during every recirculation. This air is released from system driven by electric motors are controlled
by the switching commands of the associated
the turbine oil in the course of the dwell time in the
sub-loop controls. The oil pumps should always
main oil tank. Large amounts of air in the turbine oil be switched on in a certain sequence to ensure
are either due to an excessive turbine oil recirculation the lubricating oil supply to the turbine and
rate or due to an inadequate air release property of generator bearings in the event of a drop in oil
the turbine oil. pressure in the hydraulic or lubricating oil
system. The sub-loop controls of the oil pumps

Setting of the throttle valves of the hydraulic must be in AUTO mode as long as the line of
and lubricating oil system shafting is driven by steam or the turning gear.
The throttle valve settings for the hydraulic and
Changeover of oil coolers and filters
lubricating system are optimised during initial start- Standby oil coolers and standby lubricating oil
up when the turbine generator unit is running at filters must be filled and vented before
rated speed: changeover.
- The INJECTOR (MAV21BN001 /
Venting of the oil coolers
MAV21BN002) ensure a positive pressure of
approx. 0.2 bar in the suction line immediately The oil-side vent of the oil cooler in operation
upstream of the main oil pump.
must be open.
- Lubricating oil throttle valves upstream of the
turbine and generator bearings, e.g.,
lubricating oil throttle valve upstream of the
first turbine bearing MAV42 AA501.

The mass flows of the oil necessary for

lubricating and cooling are set using the
lubricating oil throttle valves upstream of the
turbine and generator bearings in accordance
with the reference values given in the Technical
data. The lubricating oil throttle valve upstream
of every bearing should be adjusted so that the
turbine oil in the bearing heats up to approx. 20
K.

Characteristics of the main and auxiliary oil

pumps are designed with respect to one another
so that the main oil pump assumes the oil supply
just before the turbine generator unit reaches
rated speed. If the auxiliary oil pump is still in
operation when the takeover criteria of the main
oil pump are fulfilled, the

5.1-1000-77/3
5.1-1000-77-4
Steam Steam Turbine Oil System MAY
Description Oil Vapour Extraction System
System Description

Accompanying system diagram Oil vapour extractors

(Drawing No. 2-13100-91103 on Sheet No. 5.1- oil vapour extractor 1 MAV82 AN001
1001-77/2) oil vapour extractor 2 MAV82 AN002
check valve of MAV82 AA001
Process engineering function of the oil vapour
oil vapour extractor 1
extraction system
Oil vapour forming, for example, due to turbulent flow check valve of MAV82 AA002
of turbine oil in the bearing pedestals and due to release oil vapour extractor 2
of entrained air in the oil return lines and main oil tank is One of the two single-stage oil extractors, whose
removed by one of the two extractors of the oil vapour characteristic is matched to volumetric flow of oil-
extraction system. enriched air, must be in operation as long as the
The negative pressures above the oil surface in the generator is filled with hydrogen.
bearing pedestals, oil return lines, and main oil tank The check valves downstream of the oil vapour
prevent turbine oil or vapour from escaping into the extractors prevent the extractor in operation from
atmosphere. drawing in air tough the standby extractor.
Turbine oil and oil vapour are separated in the oil
Oil separator MAV82 BT001
separator of the oil vapour extractors so that the air Virtually all of the turbine oil in the vapour phase is
released into the atmosphere is virtually free of oil. removed by the oil separator. Inadequate oil
separation is usually caused by excessive
Components of the oil vapour extraction system volumetric flow of oil vapour. Consequently, the
In addition to piping the following equipment is necessary throttle valves in the oil vapour extraction lines
for operation of the oil vapour extraction system : must not be opened too far and the lid of the main
oil tank must be airtight.

Adjustable throttle valves in the oil vapour

Oil vapour extractors and oil separator extraction lines
oil vapour extractor1 MAV82 AN001 Volumetric flow in the oil vapour extraction lines is
oil vapour extractor2 MAV82 AN002 adjusted with throttle valves so that negative
throttle valve upstream of MAV82 AA511 pressures in the bearing pedestals equal the
oil vapour extractor1 reference value of approx. 5-10 mm of water column.
throttle valve upstream of MAV82 AA512 The negative pressures in the oil return lines and
oil vapour extractor2 main oil tank must be matched to this reference value
check valve of MAV82 AA001 without degrading oil separation in the oil separator
oil vapour extractor1 due to excessive volumetric flow.
check valve of MAV82 AA002 If the pressure in one bearing pedestal or in the main
oil vapour extractor2 oil tank is considerably lower than the reference
oil separator MAV82 BT001 value, there is a risk of dust, moisture, or leak off

Throttle valves downstream of bearing steam from the immediate atmosphere being drawn
pedestals into the oil system.
bearing pedestal 1 MAV81 AA501
bearing pedestal 2 MAV81 AA503 Notes on operation of the
bearing pedestal 3 MAV81 AA505 oil vapour extraction system
gen. brg. pedestal MAV81 AA507 During extended shutdowns the oil system fills with
exciter bearing pedestal MAV81 AA511 air as the oil slowly flows back into the main tank. When

Throttle valves of oil return lines the system is started up again by activating the pump,
throttle valve MAV81 AA521 resuming oil flow, the air is driven out and accumulates in
throttle valve MAV81 AA522 the bearing pedestals. Pressure build-up in the bearing
pedestals and discharge of oil through the seal rings can
Description and function of components of the oil be prevented by filling the system using the emergency
vapour extraction system oil pump.
The components of the oil vapour extraction system
and their function are described in the following :

BHEL, Hardwar 5.1-1001-77/1

5.1-1001-77-2
 Steam Turbine Oil System MAV
Description Oil Discharge and Vent System
System Description
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Accompanying system diagram:
(Drawing No. 2-13100-92103 On sheet 5.1-1001-77/2) turbine oil to the main oil tank. Under normal operating
conditions, all oil drain valves must be closed in order
to avoid interruption of the oil supply.
Process engineering functions of the oil Oil drain valves of the oil tank, the oil coolers and the
discharge and vent system oil piping system are to be locked against unauthorised
The valves and pipes of the oil discharge and or accidental opening.
vent system are used to discharge the turbine oil
Draining the jacking oil system
from the components of the oil system, and to vent Note that the jacking oil filter system is drained using
certain components. the drain line of the jacking oil filter. The appropriate
The discharged turbine oil is temporarily stored valves must be aligned to route oil flow to the jacking
and then refilled into the main oil tank. The turbine oil filter used for drainage.
oil is purified either before or during the refill
Vent valves
process. The vent valves, the ID codes of which are given in the
system diagram, must be used to vent the following oil
Components of the oil discharge and vent system components:
system - Oil cooler 1 MAV41 BC001
The oil discharge and vent system contains - Oil cooler 2 MAV41 BC002
valves with ID codes as shown on the system The valves in the vent lines of the oil coolers
diagram, and the piping required for discharging must be open at all times.
the turbine oil and venting the oil system -Lubricating oil filter MAV42 BT001
components. - Jacking oil filter MAV35 AT001
The filter housing of the switchable duplex filters of the
Description and function of components of the operating oil systems must be filled and vented after
oil discharge and vent system the filter elements have been cleaned.

Oil drain valves The vent lines feed into the oil return line or into the oil
The oil drain valves, the ID codes of which are tank of the oil discharge system, to avoid oil loss during
given in the system diagram, are used to drain the venting.
following oil system components :
- Main oil tank MAV10 BBOO1
The main oil tank is drained if the entire turbine Information for operation and
oil fill is to be discharged, or if the main oil tank is maintenance
to be cleaned during inspection and overhaul. Incorrect valve positions, inadequate
The entire oil fill is discharged if the oil system, protection of valves against unauthorized
including all components thereof, is to be cleaned actuation, incorrect turbine oil fill and discharge
or if the turbine oil is to be reconditioned or procedures, and failure to isolate valves can
replaced. result in faulty operation, damage,
-Oil cooler 1 MAV41 BC001 contamination of waste water or buildings, and
-Oil cooler 2 MAV41 BC002 loss of turbine oil. For this reason, all
The turbine oil must be discharged from one of information on this subject in this system
description must be observed. In particular, the
the oil coolers if a check on leak tightness or
following information must also be complied with:
condition is to be performed or if the oil cooler is to
be cleaned.
- lubricating oil filter 1 MAV42 BT001
Complete drainage of the oil system before
- Jacking oil filter MAV35 AT001 changing the turbine oil fill when changing the
Oil filters must be drained on each cleaning turbine oil fill, the used oil must be fully
operation or whenever the filter elements are removed from the system so that the
changed. properties of the new turbine oil are not
adversely affected.
-Oil piping systems If necessary, flanges and threaded joints must
The turbine oil in the oil piping systems is be disconnected and valve bonnets removed,
discharged when the oil system is drained so that the used oil can be completely
completely, or before corrective action is removed. Once discharged, the used oil must
undertaken to eliminate leaks. The turbine oil must be disposed of properly.
be discharged into a clean oil tank or into clean oil
Isolation of oil system components
drums. Before an oil drain valve is opened, there must
If the entire turbine oil fill is to be discharged, an be oil-side isolation of the component to be
appropriately sized stationary or mobile oil tank drained.
must be provided. An oil pump is used to return Before the main oil tank is drained, the operating

BHEL,HARDWAR 5.1-1002-77-1
 Steam Turbine Oil System MAV
Description Oil Discharge and Vent System
System Description
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

oil pumps which draw the turbine oil from the transportation effort involved, turbine oil should only be
main oil tank must be deactivated to prevent the discharged into drums if neither stationary nor mobile oil
oil pumps from running dry. tanks are available.

Discharging the turbine oil into drums
To allow rouse of the turbine oil, drums into
Oil level in the main oil tank
which the oil is discharged must be free of The oil level in the main oil tank must be topped
contaminants of any kind. up while the turbine generator unit is operating
at rated speed, since this operating condition is
Drums must not overflow when being filled with
used as the basis for defining the reference
the discharged oil, nor must they be damaged operating level for the oil.
during transportation.
Due to the amount of time and the large Care should be taken that the reference
operating level is not exceeded.

5.1-1002-77/2
 Steam Turbine Oil System MAY
Oil Conditioning (Purification)
Description System Description

Accompanying system diagram: Description of the oil conditioning system

(Drawing No. 2-13100-92103 On sheet 5.1-1001-77/2) arrangement
A multipurpose oil conditioning station is available
Process engineering function of the oil for turbine oil conditioning.
conditioning system
Turbine oil is subjected to stringent requirements
in terms of purity, since the properties of the turbine Information for operation and maintenance
oil and the condition and proper functioning of the • Valve positioning during normal
turbine generator components which come into operation
contact with that oil can be adversely affected by The positions of the manually operated valves of
solid or liquid contaminants. the oil conditioning system during normal
The function of the oil conditioning system, operation are given in the position list for
which can be kept in continual operation manually operated valves appended to the
independently of the operating oil systems, is to operating instructions.
either maintain or restore the purity of the turbine
Operation and maintenance of the oil
oil. conditioning system.
ID codes of the oil conditioning system For all questions regarding the operation and
components maintenance of the oil conditioning station,

Multipurpose oil conditioning station please refer to the manufacturer's instructions..

BHEL, Hardwar 5.1-1003-77

 Steam Turbine Main Oil Tank
Description

Function 3 D.C emergency oil pump 10 Inspection port

4 Jacking oil pump 11 Oil vapour Ehauster
The main oil tank contains the oil necessary for 5 Oil level indicator 12 Level switch
the lubrication and cooling of the bearings, for the 6 Riser section drain 13 Oil strainer
jacking system and for the hydraulic turning gear. It 7 Main section drain .

not only serves as a storage tank also for deaerating

the oil. Oil Flow in Tank
The capacity of the tank is such that the full quantity
of oil is circulated not more than 8 times per hour. Oil returning to the tank from the oil supply
This results in a retention time of approx. 7 to 8 system first flows through a submerged inlet (8) into
minutes from entry into the tank to suction by the the riser section “of the tank where the first stage of
pumps. This time allows sedimentation and deaeration takes place as the oil rises to the top of
detrainment of the oil. the tank. Oil overflows from the riser section through
the oil strainer (13) into the adjacent section of the
1 Suction pipe (injector) 8 Oil inlet tank where it is then drawn off on the opposite side
2 A.C. auxiliary oil pump 9 Riser section inlet by the suction pipe or the oil pumps.

BHEL Hardwar 5.1-1010-01/1

Oil pumps Oil Strainer

The main oil pumps draws the oil through a The basket type oil strainers (13) are mounted in the
suction pipe (1) situated at the flow end of the tank tank. They are of brass wire mesh of 0.25 mm
(1). This suction pipe is constructed as an injector to filtration particle size and can be exchanged by
aid the suction of the main oil pump which has to opening the tank cover.
overcome a certain suction head. Power oil is
conducted to the injector via an injection pipe. This Oil Vapour Exhaust
injection pipe also fills the suction pipe of the main
oil pump when the plant is being started up. The whole tank is made as airtight as possible.
Oil vapour exhausters (11) produce a slight negative
The auxiliary oil pumps (2,3) arranged on the pressure in the tank, in the return drain lines and in
tank are electrically driven rotary oil pumps(2). The the spaces in the bearing pedestals so that oil
jacking oil pumps(4) also situated on the tank, are vapour arising is drawn off.
electrically driven jack-screw immersion pumps (3).
All pumps immerse in the oil contained in the tank Oil Level Indicator
and draw oil from the deepest point in order to
obtain oil as free of air as possible. The driving The main oil tank has a direct reading oil level
elements of the pumps are fixed to the base plates indicator and a fluid limitswitch. This permits signals
of the tank covet. to be transmitted when maximum and minimum
levels have been reached. Extra tank volume is
provided between the normal operating level and the
tank cover to accept oil from the entire oil supply
system when the turbine is shut down, The tank is
constructed with a sloping bottom with drain
connections at the lowest point (6,7).

Also refer to the following sections

(1) 5.1-1020 Main oil Pump
(2) 5.1-1030 Auxiliary oil Pump
(3) 5.1-1040 D.C Emergency oil pump
(4) 5.1-1050 Jacking oil pump

5.1-1010-01/2
 Steam Turbine Main Oil Pump with
Description Hydraulic Speed Transmitter

Function pump shaft (5) runs in the journal bearing (1) and the
The main oil pump is situated in the font bearing combined journal and thrust bearing (7). Both
pedestal and supplies the entire turbine with oil that is bearings are lubricated with filtered 011. If the
used for bearing lubrication, cooling the shaft journals overspeed trip test device, which is described
and as primary and test oil. The main oil pump is separately [2] is actuated, overspeed trip test oil ‘a’
driven direct from the turbine shaft via the coupling flows to the overspeed trip devices via the oil tube
(11). If the turbo-set is out of operation or the main oil (16) built into the pump shaft (5).
pump fails, auxiliary oil pumps take over the Hydraulic Speed Transmitter
necessary oil supply. These pumps also convey oil The pump shaft (5) also carries the hydraulic
into the suction branch of the main oil pump until the speed transmitter (14) which runs in the bearing (7)
main oil pump has started to draw from the main oil and in rings (13). The hydraulic speed transmitter
tank which is situated at a lower level [1]. operates on the same principle as a centrifugal pump
Construction impeller. Any change in speed gives rise to a
the double flow impeller (5) is an integral part of pressure change in primary oil circuit ‘a1’ which
the pump shaft. The pressure and suction chambers serves as a control impulse for the hydraulic speed
are sealed off from each other by seal rings (4) which controller. The hydraulic speed transmitter (14) is
are split and secured against turning at the joint. The supplied with control oil from the hydraulic control

BHEL Hardwar 5.1-1020-01/1

equipment rack via the oil supply reservoir (9). ! \n
annular bead in the speed transmitter ensures that its
interior is atways covered with a thin layer of oil to
maintain a uniform initial pressure. Excess oil drains
into the bearing pedestal.

Electrical Speed Plck-up

The pick-up for the electrical speed transmitter
(12) is a nonmagnetic disc into which small magnets
are inser1ed around the circumference. When the
disc rotates as the pump runs, ~h8 alternating effect
between the magnets and the Hall generators, not
shown here, gives rise to a voltage signal which is
forwarded to the electrical speed display [3].

Fig. 2 Hydraulic Speed Transmitter, Cross Section

5.1-1020-01/2
 Steam Turbine Auxiliary Oil Pump
Description
Description removed from the tank as a complete unit. After the
The auxiliary oil pump is a vertical one-stage suction casing (14) has been removed and the shaft
rotary pump with a radial impeller and spiral casing. It nut (16) loosened. The impeller can be extracted. It is
is fixed to the cover of the oil tank and submerges advisable to renew the split rings (17) when
into the oil with the pump body. It is driven by an exchanging the impeller. The now clearance between
electric motor that is bolted to the cover plate (1). The split ring and impeller neck is 0.3 mm in diameter.
oil enters the suction connection from underneath and
is supplied to the oil system via the pressure pipe Exchanging the Bearings
(18). The pump shaft has: a sleeve bearing (12) in the When dismantling the pump must be removed as
pump casing and a grooved ball bearing (7) in the above. Loosen the pump casing from the pressure
bearing yoke. The bearings are lubricated from the line and suspension pipe from cover plate. Remove
pressure chamber of the pump; the sleeve bearing coupling halves from the shaft by means of an
via a bore in the casing; the grooved ball bearing ‘,ia appropriate device. Remove retaining ring (6), loosen
a lube line. bearing nut (6) and detach grooved ball bearing.
Extract pump shaft after the unscrewing of impeller.
Assembly The pump is reassembled in reverse order.
The pump is assembled before dispatch and can
be mounted on and bolted to the oil tank as a Adjusting Pump Rotor
complete unit. When connecting, care must be taken During assembly, the rotor rests on the sealing
the piping is not stressed when bolted. ring of the suction casing. Lift the rotor by means of
the bearing nut (5) until the rotor sits firmly with the
Dismounting shoulder of the shaft and the distance ring (8) at the
Exchanging the Impeller inner ring of the grooved ball bearing. Secure the
After the motor has been disassembled and the bearing nut with threaded pin.
pressure pipe disconnected. the pump must be

BHEL Hardwar 5.1-1030-01

 Steam Turbine D.C. Emergency Oil Pump
Description

Function The vertical pump shaft (9) is connected to the motor

The emergency oil pump is of the vertical, shaft by a flexible coupling equipped with rubber -
centrifugal, submerged type and serves for lubrication sleeved coupling studs. The radial ball bearing (7)
and cooling of the bearings during emergency carries the downward thrust load of the pump and with
conditions. the lower babbitted sleeve bearing 112) guides the
shaft. The lower sleeve bearing is mounted in volute
Location 113). Pressure lubrication is provided to both
The unit is located on top of the main oil tank and bearings. The lower bearing is supplied with oil
driven by a D.C. motor. The complete pump -motor through a drilled oil passage from the discharge side
assembly is attached to mounting plate (1) which is of the pump. The upper bearing is oil fed by pipe (10)
bolted to the top of the main oil tank. which connects to the pump discharge. Seal rings (17)
form a seal between the impeller suction and the
Construction pump discharge.
Oil is delivered by impeller (15) via the intake (141
to volute (13) from where the oil flows through
discharge pipe (18) to the oil supply system.

BHEL Hardwar 5.1-1040-01

 Steam Turbine Jacking Oil Pump
Description

Function pressure pipe (3).

The jacking oil pump is a self-priming screw- The driving spindle (16) and the two moving
spindle pump with three spindles and internal spindles (20) run in the inner casing (13). The fluid
bearings The pump supplies the jacking oil that is pressure to which the spindle thread is subjected on
needed for lifting the shafting at low speeds [1]. the pressure side is compensated by the driving
spindle by means of the balancing piston (shrunk-on
Construction, Mode of Operation sleeve) running in the throttle bushing (11). With the
The screw-spindle pump is connected vertically to hollow moving spindles, the axial thrust is
the cover plate (2) of the main oil tank via a support compensated by the balancing pistons arranged on
(5) and immerses with the suction casing (15) into the the suction side which run in the balancing bushings
oil, The drive is an electric motor that is bolted to the (21).
cover plate (2). The oil now into the suction branch of The throttle bushing (11) and the driving spindle
the suction casing (15) from underneath and is (16) form a throttling gap that separates the pressure
supplied to the lifting oil system by the pump via the area from the following area. The oil that leaves the

BHEL Hardwar 5.1-1050-00/1

throttle gap. flows via the grooved ball bearing (7) into Due to the special profile given by the sides of the
the support and from there back into the main oil tank. threads the three spindles form sealed chambers, the
The grooved ball bearing is lubricated with this oil. contents of which are continuously being moved
The driving spindle is fixed by means of the grooved axially from the suction side to the pressure side of
ball bearing in the bearing carrier (9) that is bolted to the pump as the spindles rotate.
the pressure casing (12) of the pump.

Also refer to the following sections

[1] 5.1-0100 Technical Data
[1] 5.1-0510 Hydraulic Turning Gear
[1] 5.1-0530 Hydraulic Lifting Device

5.1-1050-00/2
 Steam Turbine Oil Throttle
Description

Arrangement
The oil throttles arranged immediately before
the bearing in the lubricating lines serve for
adjusting the necessary amount of oil for the
bearings. While the left half of the sectional view
represents the oil throttle during oil flushing, the
right half shows the oil throttle in normal operation.

Construction
The main parts of the oil throttle are the body
(8), in which either the oil strainer (7) which is held
in place by the screw plug (6), for the flushing
process or the adjustable throttle piece (5) with
parts (1, 2, 3) for normal operation are inserted.

Operation
The flushing process is carried out before the
turbine is taken into service. After the flushing, the
oil strainer (7) as well as the screw plug (6) are to
be exchanged with the throttle piece (5) and the
screw plug (3) with the capped nut (11. By means
of the adjustable throttle piece, the cross section
of the passage is then adjusted for normal
operation, according to the necessary amount of
the lubricating oil and consequently the lubricating
oil flow adapted to the required oil exit temperature
of the bearing.

BHEL Hardwar 5.1-1080-00

 Steam Turbine Oil Throttle
Description

Arrangement installed in final stage of flushing. The oil strainer

The oil throttles arranged immediately before (7) as well as the blind cover (6) are to be
the bearings in the lubricating lines inside the exchanged with the throttle spindle (1), cap nut
bearing pedestals serve for adjusting the (2), nut (3) and cover (4). By means of adjustable
necessary amount of oil for the bearings. While throttle, the cross section of the oil passage is then
the Fig. 1 represents the oil throttle during normal adjusted for normal operation. according to the
operation, Fig. 2 shows the oil throttle during final necessary amount of the lubricating oil and
stage of oil flushing. consequently the lubricating oil flow adapted to the
Operation required oil exit temperature of the bearing.
The flushing process is carried out before the
turbine is taken into service. The strainer (7) is

BHEL Hardwar 5.1-1081-00

 Steam Turbine Three-way Control Valve
Description For Lubricating Oil Temp. Control

Description

The three way temperature control valve has the

function of regulating the lubricating oil temperature
at 45 °C. Possible oil flow paths for regulating the oil
temperature are:

 All lubricating oil flows through oil cooler.

 Lubricating oil flows through oil cooler and
bypass piping.
 All lubricating oil flows through bypass piping.

Valve Type

Three way Angle Valve with Electric Actuator.

BHEL Hardwar 5.1-1090-01

 Steam Turbine
H.P. Control Fluid Pump
Description
With LP Extraction

Description
The extraction or dual pressure pump is a
vertical rotary pump in multiple stages. It is attached
to the cover of the fluid tank and submerges in the
control fluid. Drive is provided by an electric motor
located on the cover plate (1). Control fluid enters
the suction casing (10) from below and is conducted
into the LP control fluid circuit via the pressure pipe
(19) and into the HP control fluid circuit via pressure
pipe (23). The pump shaft is guided by a sleeve
bearing (11) in the suction casing and by ball
bearings (25) in the bearing support (4). The ball
bearings and the bevel gear coupling are lubricated
by oil from the 1st stage pressure chamber via
lubricating pipe (22).The sleeve bearing is lubricated
via a passage in the casing.

Assembly
The pump is delivered in assembled state and
can be placed as a unit on the tank and bolted to it.
When connecting the pressure pipe care must be
taken that the piping is not stressed when bolted.

Exchanging the Rotors

When the motor has been dismantled and the
pressure piping removed. the pump must be
extracted as a unit from the tank. After the suction
casing has been removed and the rotating wheel nut
loosened, the 1 st stage rotating wheel can be
extracted. In order to dismantle the other stages, the
baffle ring and then the stage casing are removed. It
is expedient to renew the seal rings when
exchanging the rotating wheels. The new clearance
between seal ring and the neck of the rotating wheel
is 0.3 mm in diameter. The pump is assembled in
the reversed sequence.

Exchanging the Bearings (11 and 25)

The pump is first taken apart; loosen pump
casing from pressure piping and bearing support
from the cover plate; remove coupling half from the
shaft by means of special device; remove bearing
securing device; loosen nut (2) and ball bearings
(25). The pump is assembled in the reversed
sequence.

Adjusting Pump Rotor

During assembly the shaft is supported by the
sealing ring of the suction casing. The shaft is lifted
by means of the nut (2) until the rotor with shaft
shoulder and distance ring (24) sits firmly on the
inner ring of the ball bearing. Bearing nut is then
secured with threaded pin.

BHEL Hardwar 5.1-1110-00

 Steam Turbine Plate-type Filter
Description

The plate type filter cleans the oil or fluid

used in the governing system.

Construction
The plate type filters are installed in
Governing and LP Bypass racks. Single stage
plate type filters are used in LP Bypass racks
while in Governing rack the filter has three
stages. The filtering elements are arranged in
parallel inside the casing. The main components
of the filter are: handwheel (1), filter top (2), filter
element (3), body (4) and sludge drain plug (5).

Mode of Operation
The control fluid enters the body at the right
hand arrow and passes through the filter
element (3). The sludge gets arrested on the
surface ot the cartridges. The clean fluid flows
out to the machine.

Operation and Maintenance

To clean the plate type filter, use the
handwheel (1) to turn the filter cartridges. The
sludge and dirt removed collect at the bottom of
the body (4) in the sludge collection chamber.
The handwheel (1) should be turned 2 or 3
revolutions daily. Accumulated sludge is to be
removed at fairly long intervals when the plant is
shut down by removing the screw plug (5). The
filter cartridges need not be removed.

Disturbance Do not take the cartridges apart. After the filter

If the filter is not given due attention and the element has been cleaned, place it back in the
handwheel not turned regularly, it may happen position. It is possible that the gland in the filter
that the cartridges become so clogged that it is top may become loose or sticky. In such cases
impossible to turn the main spindle, and there is tighten the gland nut or replace the packing. Be
only a very slight flow of fluid through the filter. sure not to tighten the nut too much so as to
In such cases no force should be applied under prevent the cartridges from being turned.
any circumstances. It is relatively easy to correct
this kind of trouble when the machine is
shutdown: Remove the element from the body
carefully. The cartridges can now be cleaned
thoroughly by using a noncorrosive cleaning
fluid and with the aid of a brush.

BHEL Haridwar 5.1-1120-00

 Steam Turbine Duplex Filter
Description for Pilot Control of Control Valves

Function Mode of Operation of Differential pressure

Duplex filters permit the dirty fiter elements to be Gauge
cleaned during operation. The casing is divided into two pressure chambers by
a diaphragm sealed piston. The first chamber is
Construction connected with the filter enterance and the other
The Duplex filter consists of two filter bodies and with the exit. In the normal case ( p = O ), the
is fitted with a change-over device which enables the piston is held in the zero position by a tension
filter to be switched as desired. The filter bodies are spring. On an increase in the differential pressure,
designed according to the pressure stage and the the piston is pushed against the tension spring. Each
relevant codes and the filter itself is designed to alteration in pressure corresponds to a certain
provide safety taking into account the differential
piston setting. This position is transferred

pressures. magnetically i.e. with low friction,

Installation of Duplex Filters to the indicating disc and the two contacts
When the filter is being bolted to the foundation, the outside the pressurized area. At certain red portion
casing must not be subjected to any external of the two viewing windows of the indicating disc
stresses. This also applies when the piping is being which occures for example when filter contamination
connected .Care must be taken that the fluid flows increases and at specified switching points a
through in the correct direction. The directin of flow particular contact, thus correspond to the prevailing
is normally marked on the flanges of the filter bodies. differential pressure.

Differential Pressure Gauge

The function of the device is to measure and give a
visual indication of’the variation in the differential
pressure

Fig.3 Differential Pressure Gauge

Valve Changeover Device

The changeover device consists of two
changeover valves arranged one above the other.
Valve discs (4) that control the path of flow in the
valve casing are moved by means of a star-wheel
via spindle that has a left and right hand thread.
This construction guarantees synchronized
movement of the two valves discs whereby one
filter chamber is switched on before the other
Fig.2 Cylindrical Filter
chamber is switched off, Without causing the
flow to be interrupted .A visual indicator on the
upper valve casing shows the prevailing
direction of flow and switching.

BHEL Hardwar
5.1-1130-00/1
Operating the Changeover Valve
The large arrow on the switching gauge (1) gives
the direction of flow and the small arrow the
switching direction. Before operating the changeover
device, the pressure equalizing coak (2) must be
open.
The duplex filter is switched to the other filter
chamber by turning the star-wheel (3) in the given
direction. By means of a turning lever, the valve
discs can be easily loosened. The star-wheel (3) is
also tightened to the end position by means of this
turning lever. The valve discs (4) open in the
appropriate direction of flow and the change-over
process is then completed. The cock of the pressure
equalizing pipe must then be closed so that one filter
chamber is hermetically sealed.
Start-up and Cleaning

 Change-over device in intermediate position;

both filter chambers in operation
 Open vents in both chambers
 Start-up plant slowly
 Close vents when air has escaped and fluid
begins to come out
 Block one filter chamber by opening changeover
device. While the first filter chamber is filtering
,the shut off chamber is in reserse until the
permissible differential pressure has been
reached due to contamination. When the
permissible differential pressure has been
reached ,one must switch over to the clean filter
chamber as follows:
 Open pressure equalizing cock and check
whether the reserve chamber is full by opening
the vents for a short time
 Change over
 Close pressure equalizing cock.
 Open vent in shut-off half ; this relieves the
control fluid and gives the possibility of checking
whether the changeover device has blocked the
flow to the filter chamber.
 Disassemble the casing cover of the shutoff filter
chamber.
 Remove filter element vertically in an upwards
direction,
 Clean mesh of filter element with appropriate Fig.4 Changeover Valve
cleaning material and by blowing through the
mesh from the clean side (see filter cleaning 1 Switching position indicator
instructions). 2 Pressure equalizing cock
 Re-insert cleaned filter element. 3 Star-wheel
 Close casing through cover; vent is still open. 4 Valve disc
Before replacing cover take care that condition
and position of seal are perfect. If necessary  Unscrew switching gauge.
change seal.  Loosen valve discs by turning star-wheel
 Open pressure equalizing cock until filter half is  Disassemble upper cover.
deaerated.  Unscrew valve stem with valve disc(4).
 Close vent. Filter half is ready as reserve again.  Check sealing rings and renew if necessary.
 Screw valve stem with valve disc(4) back again.
Removal and Installation of Changeover  Close casing with cover.
Valve  Assemble switching gauge.
Belore removing the changeover valve, care  Disassemble lower cover.
must be taken that the fluid in the casings is not  Unscrew Valve stem with valve disc.
under pressure.
5.1-1130-00/2
Cleaning the Filters
1. Normal Cleaning
1.1 With multi-part filters, each element is cleaned
in dividually.
1.2 Brush the individual elements with a not too
hard brush and suitable cleaning agent over a
bath or container and rinse.
1.3 Blow compressed air from the clean side
through the filter that has been cleaned in this
way in order to remove any dirt particles
caught in the filter mesh. The cleaning
process can be carried out with filter cleaning
apparatus (Fig. 5).
Application according to Item 2.3

2. Cleaning Obstinate Dirt

2.1 Place complete filter in a container with a
cleaning agent for several hours or spray
repeatedly at short intervals.
2.2 Treat filter elements as described under 1.2
and 1.3.
2.3 Using filter cleaning apparatus (Fig.5) and
suitable agent, blow through filter thoroughly
from clean side.
Fig. 5 CIeaning device for filter element
3. Cleaning Disassembled Filter Elements
(Only with bolted construction) 4. Cleaning Agents
Only when absolutely necessary to be Suitable cleaning agents are e.g. air,
performed with great care. water, steam, Tri-Perchlorethylene,
3.1 loosen all nuts (a) on respective filter element petrol, benzene, diesel oil, etc.
and remove.
3.2 Detach lower filter plate (b)
The application depends on their cleaning
3.3 Detach filter casing (c)
3.4 Remove support pipe (d) capacity and their compatibility with the
3.5 Clean strainer basket as in Item 2 media to be filtered.
3.6 Clean all parts. also upper filter plate (g) and
stay rod (e)
3.7 Check all seals (f) and strainer basket for
damage and renew if necessary
3.8 Assemble filter elements and bolt firmly. Care
must be taken here that strainer basket and
seals sit properly.

5.1-1130-00/3
 Regenerating Plant
Steam Turbine
Description
General The Fuller’s earth needed for regenerating
Of the various types of fire resistant fluid, the the fire resistant fluid must be dry with a residual
only ones suitable for use with our turbines are water content of not more than 1% of the weight.
phosphoric esters of the group HS-D which have If required Fuller’s earth must be dried at a
a low water and chlorine content. temperature not exceeding 105 C.
Their chemical composition and structure The US strainer number 30/60 mesh is the
necessitate certain measures and alterations granular size to be used (or this must
compared with an oil system. correspond to the details from the fluid
Fire resistant fluid systems for our turbines manufacturer). The dust proportion of the
are provided with a bypass regenerating plant. granulate must not be used. The amount of
The design of this plant is made to the earth must not be too little and must be stamped
specifications of the fluid manufacturer. Any or shaken to avoid the formation of gaps and
acids and ageing products are removed during channels which would reduce the effectiveness
operation by continuous filtering through of the Fuller’s earth.
Fuller’s-earth and mechanical filters. The efficiency of the regenerating plant is to
The mode of operation of this natural earth be controlled by an exact record of the
treatment is based on a ion-exchange reaction. neutralization value and the degree of purity.
In addition to the precautions against acidifying
of the fluid, continuous care is taken that any Construction of Regenerating Plant
solid particles are separated by the fine filter so The filter group consists of one dry filter (10),
that they can not speed up the reaction. The fine 2 Fuller’s earth filters (6) and a mechanical Filter
filter of this plant retains particles of Fuller’s (7). The cleaning and deacidifying takes place in
earth as well as providing the essential a separate circuit. A pump (4) conducts a
cleanliness of the whole system and increasing constant amount of fluid through the filter group
the life of the filters. and back into the tank (1). When the filter is
contaminated there is an increase

5.1-1140-00/1
BHEL Haridwar
in the fluid pressure. A spring safety valve (3) is
installed to protect the system against an
excessively high increase in pressure.
Dry Filter
Fluid first enters the dry filter . The cartridges
inside the filter remove dirt and water from the
fluid.The outer media layer filters out silt, rust
and other particular contaminants. The inner
layers absorb water and will chemically bond it
so that no water will release downstream.When
the cartridge reaches its water holding limit, the
media swells and the differential pressure
rapidly increases. The differential pressure
indicator reaches the all-red range.This signals
the operator that the cartrdge must be changed.

Fuller’s earth Filter (Fig. 2)

The Fuller’s earth filter contains three
sections with a special granulate which binds
any acid present in the fluid. Two filters work in
parallel and can not be switched over.

Mechanical Fine Filter (Fig. 3)

Following the Fuller’s earth filters is a fine Fig. 2 Fuller’s Earth Filter
filter with textile inserts of finest mesh. These
inserts retain the finest particles of dirt, both 1 Connection for pressure gauge
metallic and nonmetallic impurities. In this way 2 Connection for air exhaust
the fine filter also serves the safety of the control 3 Connection for safety valve
fluid system by trapping any particles of 4 Control fluid Inlet
granulate that may be circulating. The fine filter 5 Contrul fluid outlet
also separates water particles and other ageing 6 Connection to drain tank
7 Filter basket with gauge
materials which would make it necessary so
renew the control fluid too soon.

Lift cover taking care not to damage seal
Commissioning and Maintenance of the
Loosen drain pipe screws and lift basket
Filter Plants cover

The filters are to be continuously deaerated
Extract filter basket (7) carefully and centrally
by slightly opening the vent valve.
Clean inside of filter casing

Observe pressure increase on pressure
Clean filter basket (7)
gauge
After cleaning care must be taken that the

The acid content must be checked by parts are completely dry
examining the fluid in the laboratory at certain Fill filter basket and Insert. The earth must be
intervals. carefully pressed down without use of

If there is a constant increase in the acid excessive force so that the sections are filled
value. the granulate is exhausted and must compactly in order to prevent later settling of
be replaced earlier than originally intended. the earth and the possible formation of

The increasing contamination of the filter can channels
be measured by the constant increase in
Insert clean basket cover and tighten well
pressure. The differential pressure indicators with screw so that no Fuller’s earth can
installed in the system show optically the escape
degree of contamination. When the white-red
Close drain (6).
segments are only showing red, the filter
Replace cover carefully and tighten uniformly
material must be changed. by means of screws (pay attention to seal)

Switch on pump (4).
Exchanging the Earth Filling (Fig. 2)

Switch off pump

Open filter drain (6). Drain Filter (Flg.2)

Loosen cover bolts

5.1-1140-01/2
Instructions for Installation of Filter
Cartridges
of Fine Filter (Fig.3)
The filter cartridges (8) are to be immersed in
the control fluid before the first commissioning
and installed in the filter. The cartridges must be
placed above the standpipes such that the large
opening of the filter cartridge faces downwards.
By inserting the rubber and metal discs and the
clamping springs in this sequence, the filter
cartridges are stressed by means of the
clamping screws to equalize an alteration in the
length of the filter cartridge column.

Means of Cleaning
The following are to be used for cleaning:
Textile and paper cloths without threads,
benzine, white spirit, trichloroethylene,
perchloroethylene and compressed air.
When using these, the respective accident
prevention rules are to be observed.
Remains of cleaning materials are to be
Carefully removed (when chlorinated
hydrocarbon is used there must be no increase
in the chlorine content of the FRF).
Each newly cleaned surface is susceptible to
corrosion. In order to protect the surfaces,
therefore, they must be moistened with FRF or a
corrosion protection medium compatible with
FRF immediately after cleaning.

1 Connection for pressure gauge

2 Connection for air exhaust
3 Connection for safety valve
4 Control fluid inlet
5 Connection for thermometer
6 Control fluid outlet with flow gauge
7 Connection for sludge outlet and
Fig. 3 Mechanical Fine Filter
drainage
8 Filter cartridges

5.1-1140-01/3
 Steam Turbine Drain System MAL
Description System Diagram
Index

System Diagram

MAL Turbine Drains System Drawing No. 1-13100-91131 on sheet No. 5.1-1210-77/2
MAG Turbine Drains System Drawing No. 1-13100-91131 on sheet No. 5.1-1210-77/2

BHEL, Hardwar 5.1-1210-77/1

5.1-1210-77/2
 Steam Turbine System Diagram
Description Index

System Diagram

MAA HP-IP-LP Scheme Drawing No. 1-13100-91142 on sheet 5.1-1220-77/2

MAB HP-IP-LP Scheme Drawing No. 1-13100-91142 on sheet 5.1-1220-77/2
MAC HP-IP-LP Scheme Drawing No. 1-13100-92142 on sheet 5.1-1220-77/2

MAN Condenser Spray System Drawing No. 2-13100-91141On sheet 5.1-1220-77/3

LCE Condenser Spray System Drawing No. 2-13100-91141On sheet 5.1-1220-77/3

BHEL, Hardwar 5.1-1220-77/1

5.1-1220-77/2
5.1-1220-77/3
 Steam Turbine Component Diagram
Description Index

Component Diagram

MAA HP Stop & Control Valves Drawing no. 4-18000-51021 on sheet 5.1-1230-77/3

MAB IP Stop & Control Valves Drawing no. 4-18000-51021 on sheet 5.1-1230-77/4

MAN LP Bypass Valve (ETA Type) Drawing no. 4-18000-51021 on sheet 5.1-1230-77/5

MAW Seal Steam /Leak off Steam Valve Drawing no. 4-18000-51021 on sheet 5.1-1230-77/6

MAD Measuring Points on Turbine – Generator Drawing no. 4-18000-51022 on sheet 5.1-1230-77/7
Bearings

BHEL, HARDWAR 5.1-1230-77-1

5.1-1230-77-2
5.1-1230-77-3
5.1-1230-77-4
5.1-1230-77-5
5.1-1230-77-6
5.1-1230-77-7
5.1-1230-77-8
5.1-1230-77-9
5.1-1230-77-10
 Steam Turbine Shaft Seal Steam System MAW
Description System Description
ACOMPANYING SYSTEM DIAGRAMS
Leakage steam system
Drg nos. 1-13100-91121 & 3-13100-91122 on Sheet nos. Butterfly valves in the leakage steam lines of the shaft
5.1-1240-51/4 & 5.1-1240-77/5 seals
st
Process engineering function of the shaft seal steam - 1 casing front MAW82 AA501
system - 1st casing rear MAW81 AA501
nd
The process engineering function of the shaft seal - 2 casing front MAW83 AA501
nd
steam system is to prevent the escape of shaft seal - 2 casing rear MAW84 AA501
rd
steam from the turbine to the atmosphere and the ingress - 3 casing front MAW85AA501
rd
of air into the turbine and the condenser. The provision is - 3 casing rear MAW86AA501
also made for drawing the leak off steam from U-Ring, in Isolation valve upstream of the MAW80AA001
case of failure, the spindles of Main Steam Stop & Control seal steam condenser MAW80AC001
valves, HRH Steam Stop & Control Valves and LPBP Isolation valve upstream of MAW80AA011
Stop & Control Valves under leak off steam system. leakoff steam condenser exhauster 1
The subsystems of the shaft seal steam system have Leakoff steam condenser MAW80AN001
the following functions: exhauster 1

Seal and leakoff steam system Isolation valve upstream of MAW80AA012
- exhausting of leakoff steam from shaft seals Leakoff steam condenser exhauster 2
having a positive internal pressure and from valve Leakoff steam condenser MAW80AN002
stem seals. exhauster 2
- supplying the shaft seals having a sub- Valve upstream of seal steam MAW10AA011
atmospheric internal pressure with seal steam. Supply control valve
- admission of excess leakoff steam to the The control of this valve is temperature dependent
condenser. and the valve is open as long as the temperature of

Leakage steam system steam before this valve is more than pre-set value.
- exhausting of leakage steam from the leakage
Description and function of the components of
steam chambers of the shaft seals. the shaft seal steam system
- condensing of leakage steam in the seal steam The components of the shaft seal steam system
condenser. and their function are described in the following.:
- exhausting of leakage steam to atmosphere
Valve upstream of the seal steam control valve
during faulted seal steam condenser operation. MAW10AA011
- extraction of air from the seal steam condenser The control of this valve is temperature dependent
using one of the leakoff steam condenser and the valve is open as long as the temperature of
exhausters.
steam before this valve is more than pre-set value.

Leakage steam condensate system

Seal steam control valve
- exhausting of leakage steam condensate to the
MAW10AA001
waste water system.
The seal steam control valve is positioned by the
Components of the shaft seal steam system shaft seal steam controller. The valve opens if the
In addition to piping, monitoring equipment and amount of leak-off steam is not sufficient to satisfy
manually operated valves, the following equipment and seal steam requirements. During start up & shut
valves are necessary for operation of the shaft seal steam down and at low load operation range up-to 35%,
system: steam from auxiliary source is supplied to system
through seal steam control valve. The pressure in the

Seal steam supply System header is maintained at slightly higher than the
Seal steam control valve MAW10AA001 atmospheric pressure at a pre-set value (1.023 ata)
Motor-operated bypass valve MAW15AA001 by seal steam pressure controller. An electrical
Valve upstream/downstream of seal steam control pressure controller connected to a valve lift controller
valve acts on the actuator of the seal steam leak-off and
-upstream of seal steam MAW10AA010 supply valves. Each valve is equipped with an elctro-
control valve hydraulic actuator. If the electro hydraulic actuating
-downstream of seal steam MAW10AA512 fails, the seal steam leak-off and supply valves may
control valve be moved to required position with the help of built-in

Leakoff steam discharge system manual pump.
Leakoff steam control valve MAW50AA001
Motor-operated bypass valve MAW15AA001
Motor-operated bypass valve MAW55AA001 The bypass valve can be opened from the control
Valve upstream/downstream of leakoff control valve room if the seal steam control valve is not able to
- upstream of leakoff steam MAW50AA010 satisfy seal steam requirements, e.g., as a result of
of control valve faulted seal steam control valve operation, or if the
- downstream of leakoff steam MAW50 AA512 steam pressure upstream of seal steam inlet valves
control valve

BHEL,HARDWAR 5.1-1240-77/1
5.1-1240-77/2

Keeping the seal steam line upstream of the
seal steam control valve warm

The warmup valve is used to keep the seal steam line

upstream of the seal steam control valve warm.
Opening and closure of the warmup valve is
dependent on the steam temperature upstream of the
seal steam control valve.

Exhausting the leakage steam to
atmosphere
Under normal operating conditions, the leakage
steam is condensed in the seal steam condenser.
If the seal steam condenser is not available, the
leakage steam must be exhausted to
atmosphere.

5.1-1240-77/3
5.1-1240-77/4
5.1-1240-77/5
 Steam Turbine Operation of the Turbine
Description Introduction

In the Operation section of the manual computing channels perform on going

the steps of startup, power operation and calculations of material fatigue. This allows
shutdown of the turbine are given. turbine operation within a set envelope
Also, the activities that must be against various permitted stress types or
performed during shutdown to maintain loading combinations. Temperature
operability are described. margins are indicated on CRT during all
Basic knowledge of operation and operating conditions.
monitoring of turbines are taken for The turbine can be operated in line with
granted. Further knowledge gained during three different stress limits or operating
the commissioning period gives the modes viz. Fast, Normal and Slow, which
operating staff a more complete are selected by operator action. To
understanding of turbine generator safeguard shaft material, switch over from
operation. slow to normal or fast mode is not
permitted until the temperature in shaft
Role of Turbine Stress Controller center line exceeds 100 °C . Beyond this
(TSC) point, it is possible to switch over from S
(slow) to N (normal) mode or from N to F
The function of TSC is to continuously (fast) mode at any time. However. Before
monitor and evaluate the main components the TSC enables switch over from F mode
of turbine viz. Main steam stop and control to back to N mode or from N to S mode, it
valve, HP rotor, HP casing and IP rotor in automatically checks whether there will still
respect of their material limits and fatigue be a positive temperature margin of 15 °C
life. It monitors the operational non steady in the new mode once this change over has
state thermal stresses affecting the steam been affected.
admission area, and the turbine dedicated

BHEL Hardwar 5.2-0001-01

 Steam Turbine Specification of Steam, Oil and
Operation Control Fluid

The efficiency of turbine and functioning of its maintenance instruction on Oil Care [4] should be
components depend, among other things, on followed. Regular sampling and laboratory checks
whether the steam quality and the properties of the will indicate that the turbine oil complies with the
operating fluids fulfil the requirements listed in the specifications.
Description section of this manual. Particular care
should always be taken during startup that the The purity (freedom from liquid and solid
purity and the physical & chemical properties impurities), air-release properties and foaming
comply with the turbine manufacturer’s guidelines. characteristics of the oil are important to the
functioning of the turbine generator unit’s
Steam Purity components.
The steam purity must comply with the guideline
on ‘Steam Purity’ (1) before startup and power Control Fluid
operation is begun. The guideline ‘Control Fluid’ [5] has the
requirements for this operating fluid. The
Blade deposits reduce the efficiency. Deposits maintenance instruction ‘Care of Control Fluid’ [6]
can only be removed by time-consuming processes should also be followed. Regular sampling and
[2] and occur during power operation when normal laboratory checks will indicate that the control fluid
values are exceeded. complies with the specifications.

Immediate corrective action must be taken to The purity (freedom from liquid and solid
restore the required steam Quality specified in the impurities), neutralization coefficient as a
guideline [1]. characteristic for aging, air-release properties and
foaming characteristics of the fluid are important to
Turbine Oil the functioning of the turbine generator unit’s
Oil Specifications guideline [3] lists the components.
requirements for the operating fluid. Also

Also refer to the following sections

[1] 5.1-0120 Steam Purity Required Values

[2] 5.3-0070 Steam Washing of Turbine
[3] 5.1-0310 Oil Specification
[4] 5.3-0080 Oil Care
[5] 5.1-0140 Fire Resistant Fluid
[6] 5.3-0082 Care of Control Fluid

BHEL Hardwar 5.2-0002-00

 Steam Turbine Testing of Turbine Components
Operation General

Introduction
Countermeasures for Abnormal Conditions
The operational reliability and availability of a
turbine is assured only if all the vital components and It is recommended that all abnormal conditions
monitoring equipment for operation are in the specified detected in the course of testing be eliminated by the
condition at all times. countermeasures specified in the remedial action and
maintenance instructions in the turbine manual.
This applies particularly to :
In some cases the desired condition may be

controllers restored sooner or prevented from deteriorating if the

protective devices testing intervals are shortened. Use of this opportunity

safety devices is recommended. Shorter testing intervals also make it

stop and control valves and other important turbine easier to detect and monitor any progressive
valves deterioration in the condition of component.

monitoring equipment
On this basis, the optimum timing for the
The unit’s operating parameters can provide necessary remedial actions may be determined in the
important information on the condition and reliability of light of other factors, requiring consideration.
the turbine unit and its systems,
Performance of Tests
Testing Intervals Tests are generally performed by the operator’s
The following recommendations, for time Intervals properly qualified plant personnel.
between tests have been compiled, on the basis of As a rule the performance testing should be
experience gained by the turbine manufacturer and the executed immediately after maintenance or overhaul
operators. activities, such as major inspection, in the presence of
concerned qualified personnel form BHEL.

BHEL Hardiwar 5.2-0020-00

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals - Controllers

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Turbine Governor
- function 1 X X X
- setting X X

Load Shedding Relay

- function X X
- setting X X

Bypass Controller
- function 3 X X X
- setting X X

Seal Steam Controller

- function X X

Fluid Temperature
Controller
- function
X X
Oil Temperature
Controller
- function X X

BHEL Hardwar 5.2-0021-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals –
Automatic Turbine Tester

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Automatic Turbine
Tester for Protective
Devices

- functioning of remote 2 X X X
trip solenoid
- functioning & setting of
overspeed trips
- functioning & setting of
hydraulic low
vacuum trip

BHEL Hardwar 5.2-0022-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals –
Automatic Turbine Tester

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly

Automatic Turbine
Tester for Stop & Control 2 X X X
valves
- free movement of stop
valves
- free movement of
control valves

BHEL Hardwar 5.2-0023-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals- Protective Devices

Component Test Cycle Plant

- Type of test After start -Up Status

During or after overhaul

After shutdown>1

shutdown
Monthly

running
Weekly

month
Yearly
Main Trip Valves
- functioning and breakaway pressure x x x

Overspeed Trips
- functioning and setting during testing with x x x
hydraulic test signal transmitter
- functioning and setting during testing by Overspeed 1 x x

Thrust Bearing Trips

- functioning x
x

Hydraulic Low Vacuum Trip

- functioning and setting x x

Electrical Low Vacuum Trip

- functioning and setting 6 x x

Bypass Mode Low Vacuum Trip

- functioning and setting x x

Reverse Power Protection

- functioning at each shutdown 1 x x x
- functioning and setting x x

Oil Starvation Trip

- functioning and setting 1 x x

Turbine Fire Control System

- functioning 1 x x x
- alarms 1 x x x

Alarms from Protective Devices

.functioning and setting of binary signal transmitters 3 x x

BHEL Hardwar 5.2-0024-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals-Safety Devices

Component Test Cycle Plant

- Type of test After start Up Status

After shutdown>1 month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Safety Valves
- functioning and set pressure x

Rotary Pump Relief Valves .

- functioning and set pressure x x

Subloop Control for Auxiliary and Emergency Oil Pumps

*
- functioning 3 X x x
- setting of pressure switches x x

Automatic Changeover Units for Control Fluid Pumps

*
- functioning 3 X x x
- setting of pressure switches x x

Extraction NRV Checks

- functioning 1 x x
- setting of differential pressure switches x x x

* At each shut-down and startup

BHEL Hardwar 5.2-0025-01

 Steam Turbine Turbine Systems Testing
Operation Testing Intervals- Valves

Component Test Cycle Plant

- Type of test After start -Up Status

After shutdown>1month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Stop Valve
- free movement x x x
using starting and load limiting device.
test valve or trip actuation
- breakaway pressure x x
- leak tightness at each startup x x x

Control Valve
- free movement x x
using starting and load limiting device.
test gear or trip actuation
- leak tightness 1 x x
(in conjunction with test of reverse power protection at
each shutdown)
- free movement x x
(observe control valves lift at each load change) 1 x

Extraction Valves
- free movement 2-4 x x x
by observation of position indicators

Vacuum Breaker
- functioning at each shutdown 1 x x x

CRH NRV
- free movement 2 x x x
by operating pushbutton on desk

BHEL Hardwar 5.2-0026-01

 Steam Turbine Turbine Systems - Testing
Operation Testing Intervals – Monitoring Devices

COMPONENT Test Cycle Plant Status

- Type of test After start-up

After shutdown > 1 month

During or after overhaul

shutdown
Running
monthly
weekly

yearly
Alarms
- functioning X X

Binary Signal
Transmitters X X
- functioning and setting

Speed Indicators
Temperature Gauges
Expansion Measuring
Devices
Vibration Measuring
Devices
liquid Level Measuring
Devices
Valve lift Transducers
- accuracy of indication 3 X X X

BHEL Hardwar 5.2-0027-01

 Steam Turbine Turbine Systems-Testing
Operation Testing Intervals- Operating Parameters

Component Test Cycle Plant

- Type of test After start -Up Status

After shutdown>1 month

During or after overhaul

Shutdown
Running
Monthly
Weekly

Yearly
Steam Pressures
Steam Temperatures
Steam Mass Flow Rates
Casing Temperatures
Bearing Metal Temperatures
Expansion
Vibration
liquid Levels
Oil Pressures
Oil Temperatures
Control Fluid Pressures
Control Fluid Temperatures
- recording of operating values for long term monitoring 3 x x
purposes

BHEL Hardwar 5.2-0028-01

 Steam Turbine Starting the Turbine
Operation

Introduction the turbine generator unit can be started up

from the control room by operating the
Startup of the turbine and auxiliary systems
control devices by watching the analog
must always be performed to ensure
displays.
operational reliability and economy.
The schematics have added instructions
Startup is a phase where almost all
that must be followed during startup or
operating values are subject to change.
operation of the system. Instrumentation
Monitoring of these transient operating
and control functions are given in ATRS
state by the monitoring instrumentation
functional schematics. To maintain
demands close attention.
operational reliability and economy, certain
It is very important that all control tests must be performed during all phases
operations are always performed in the of turbine operation. This furnishes
recommended sequence. information on the condition of turbine
generator components.
To fulfill these requirements, startup
schematics are prepared to show all control Since some tests must be carried out
operations and monitoring criteria for the before or during the startup phase, a list of
turbine and its auxiliary systems. the tests and their intervals [1] is given at
the beginning of the system- startup
The startup schematics of the turbine schematics.
manual are compiled so that with their help

BHEL Hardwar 5.2-0110-01

 Steam Turbine Startup and Shutdown Diagrams
Operation Symbols

values recorded in the logs and from the

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

BHEL Hardwar 5.2-0111-00

 Steam Turbine Start of Turbine/Generator
Operation Startup Diagram (General)
(01) + TURBINE/GENERATOR START UP PREPARE REF. TO 5.2-0133
+ PREPARATION FOR START UP COMPLETED
(02) + EXTERNAL SYSTEMS READY FOR OPERATION CHECK
CIRCULATING WATER FOR CONDENSER AVAILABLE
COOLING WATER FOR COOLERS AVAILABLE
AUXILIARY STEAM AVAILABLE
DEMINERALIZED WATER SUPPLY AVAILABLE
CONDENSATE SYSTEM READY FOR OPRN.
VACUUM PUMP READY FOR OPRN.
THE EXTERNAL SYSTEMS DO NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAMS OF SYSTEMS.
INSTRUCTIONS OF EXTERNAL SYSTEMS MUST
COMPLY WITH TURBINE OPERATION.
+ EXTERNAL SYSTEMS READY FOR OPRN.
(03) + OIL SYSTEM AND TURNING GEAR START REF. TO 5.2-0130
START OF OIL SYSTEM APPROX.6 HOURS
PRIOR TO TURBINE START.EXTEND
TIME IN ADVANCE OF TURBINE START IF
OIL TEMPERATURES ARE EXTREMELY LOW.
WITH FGA (OIL SUPPLY)
OR
MANUAL OPERATION AT OPER. CONSOLE
FGA=FUNCTIONAL GROUP AUTOMATIC
+ SHAFT TURNS
– CF-RECONDITIONING-PLANT AND HEATERS IN OPERATION
PRIOR TO CONTROL FL PUMP OPERATION THE
CONTROL FLUID TEMPERATURE SHOULD BE > 20°C
TEMP. RATE DURING HEATER OPERATION 1-2° K / HOUR
START OF OPERATION OF RECONDITIONING
AND HEATERS IN ACCORDANCE WITH INITIAL
TEMPERATURE AND HEATING RATE.
OPERATE RECONDITIONING PLANT CONTINUOUSLY
IF NEUTRALISATION NUMBER TENDS TO INCREASE
+ TEMPERATURE IN CONTROL FLUID TANK > 20°C
(04) + CONTROL FLUID SYSTEM START REF. TO 5.2-0135
WITH FGA (CONTROL FLUID SYSTEM)
OR
MANUAL OPER.AT OPER.CONSQLE
+ CONTROL FLUID SYSTEM IN OPERATION
(05) + CONDENSING PLANT START REF.TO 5.2-0140
TIMING OF CONDESING-PLANT START MUST
AGREE WITH TIMING OF FIRST STEAM ENTERING
THE CONDENSING PLANT
THE CONDENSING PLANT DOES NOT BELONG TO
THE SCOPE OF SUPPLY (TURBINE/GENERATOR).
POSITION OF VALVES ACCORDING TO SINGLE
LINE DIAGRAM OF SYSTEMS.
INSTRUCTIONS OF THE MANUFACTURER OF THE
CONDENSING PLANT MUST AGREE WITH TURBINE
OPERATION.
+ CONDENSATE PUMPS ON
WITH FGA (CONDENSING PLANT)
OR
MANUAL OPER.AT OPER.CONSOLE

BHEL Hardwar 5.2-0112-00/1

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

+ SEAL SYSTEM SUPPLY ON

WITH SLC (SEAL STEAM)
OR
MANUAL OPER, AT OPER,CONSOLE
+ VACUUM < P AMB
+ SEAL STEAM PRESSURE > P AMB
(06) + STATE OF OPERATION OF STEAM GENERATOR CHECK
+ STEAM GENERATOR IN OPERATION
+ CRITERIA FOR BYPASS OPERATION FULFILLED

(07) + START OF BYPASS OPERATION OBSERVE REF. TO 5.2-0150

(08) + MAIN STEAM (MS) LINE WARM UP REF. TO 5.2-0160
WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ MAIN STEAM (MS) LINE WARMED UP
(09) + CRITERIA FOR WARMING UP TURBINE CHECK

(10) + TURBINE WARM UP REF. TO 5.2-0160

WITH FGA (TURBINE CONTROL)
OR
MANUAL OPER. AT OPER. CONSOLE
+ TURBINE WARMED UP
+ CRITERIA FOR SPEEDING UP TURBINE/ FULFILLED
GENERATOR

(11) + TURBINE/GENERATOR TO RATED SPEED SPEED UP REF. TO 5.2-0160

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

(12) + GENERATOR BREAKER ON REF. TO 5.2-0210

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

+ LOADING CRITERIA FULFILLED

(13) + TURBINE/GENERATOR LOAD REF. TO 5.2-0210

5.2-0112-00/2
 Steam Turbine Preparation for Startup
Operation Startup Diagram

(01) - PRESERVATION DEVICES REMOVE

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

(02) - INSPECTION OPENINGS CLOSE

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

(03) + VOLTAGE SUPPLY SWITCH ON

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

(04) + LIGHT BULBS FOR PANEL AND ALARMS CHECK

+ DEFECTIVE LIGHT BULBS REPLACED

(05) + MEASURING EQUIPMENT READY FOR OPERATION CHECK

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

(06) + LIQUID LEVELS CHECK

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

(07) - FILTERS CLEAN

(08) + TEST PROGRAM (STANDSTILL) CARRY OUT REFER TO 5.3-0061

TESTING INTERVALS OBSERVE REFER TO 5.2-0020

(09) + TEST PROGRAM (STARTUP) CARRY OUT REFER TO 5.3-0030

TESTING INTERVALS OBSERVE REFER TO 5.2-0020

(10) + GENERATOR READY FOR OPERATION CHECK

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

BHEL Hardwar 5.2-0113-00

 Steam Turbine Operating Position of
Operation Manually Operated Valves

Introduction = manually on the local control

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

Lead Sealing of Valves Open

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

BHEL Hardwar 5.2-0120-00

 Steam Turbine Oil System and Turning Gear
Operation Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES )GENERAL) CHECKED
AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
VALVES BEFORE / AFTER PUMPS OPEN
PERMANENT VENTS OPEN
VENTS OF COOLERS OPEN
VALVES IN FILLING LINES (PERMANENT) OPEN
VALVES BEFORE / AFTER FANS IN SERVICE OPEN
VALVES BEFORE/AFTER STAND BY FANS CLOSED
DRAIN VALVES OF COOLERS CLOSED
DRAIN V ALVES OF TANKS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN TEMPORARY V~NTS CLOSED
VENTS OF COOLERS (WATER SIDE) CLOSED
VENTS OF FILTERS CLOSED
VALVES IN TEMPORARY FILLING LINES CLOSED
V ALVES OF PRESSURE TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE PIPES FOR TESTING CLOSED
MULTI WAY VALVES OF COOLERS IN SERVICE
MULTI WAY VALVES OF FILTERS IN SERVICE
THROTTLE VALVES IN VAPOUR LINES ADJUSTED

SPEC. MAN. OPER. VALVES OF SYSTEM CHECKED

AND IN POSITION
THROTTLE VALVES IN JACKING Oil LINES ADJUSTED
RELIEF VALVE OF JACKING Oil SYSTEM ADJUSTED
COOLING WATER VALVES OF STANDBY CLOSED
OIL COLER
DRAIN OF OIL COOLER WATER SIDE OPEN
FILLING LINE OF STANDBY OIL COOLER OIL SIDE OPEN
VALVE POSITION OIL PURIFYING PL!ANT ADJUSTED

+ OIL PUMPS READY FOR OPRN MAV22 APOO1

MAV23 APOO1
MAV24 APOO1
MAV31 AP 0 01
MAV32 APOO1
MAV33 APOO1
OIL PUMPS ON MANUAL CONTROL SWITCH ON
OR
OIL PUMPS ON SUBLOOP CONTROL SWITCH ON
OIL PRESSURES NORMAL

+ OIL VAPOUR FAN (TURBINE) ON MAV82 ANOO1

OR MAV82 AN002
OR READY FOR OPRN MAV82 ANOO2
OR MAV82AN-OO1
+ OIL VAPOUR FAN (GENERATOR) ON MKO31 ANOO1
OR MKO32 ANOO1
OR READY FOR OPRN MKO32 ANOO1
OR MKO31 ANOO1

+ SUBLOOP CONTROL OIL VAPOUR FAN GEN. ON ----------------------

BHEL Hardwar 5.2-0130-02/1

 ONE OUT OF TWO VAPOUR FANS OF THE
TURBINE OIL TANK AND THE GENERATOR
MUST BE IN OPERATION AS LONG AS THE
GENERATOR IS FILLED WITH HYDROGEN.

ONE OIL COOLER OIL SIDE IN SERVICE MAV41 BCOO1

OR MAV41 BC002

CHECK OIL COOLER(S)IN SERVICE AT THE

INDICATOR AT THE CHANGE-OVER VALVE(S).
DO NOT ADJUST ANY INTERMEDIATE POSITION
OF CHANGE-OVERVALVE.
- COOLING WATER”’FOR OIL:COOLER(S) AVAILABLE
OPERATION OF THE COOLING WATER SYSTEM
ACCORDING TO SEPARATE INSTRUCTIONS NOT
INCLUDED IN THE TURBINE MANUAL
- SERVICE O!L COOLER (WATER SIDE) FILLED MAV41 BCOO1
AND VENTED OR MAV41 BCOO2
- COOLING WATER PIPE VENTED
- STAND BY OIL COOLER WATER SIDE DRAINED MAV41 BCOO1
IF THE OIL COOLER IN STANDBY CAN NOT BE AND DRIED OR MAV41 BCOO2
DRIED BY OIL FLOWING VIA THE FILLING
AND THE VENT LINE, THE OIL COOLER IN STAND
BY MUST BE EXPOSED TO THE FULL FLOW OF
THE COOLING WATER ONCE WEEKLY TO
PREVENT DEPOSITS CAUSING CORROSIVE
ATTACKS TO THE MATERIAL
+ SLC OIL TEMPERATURE CONTROL ON
THE OIL TEMPERATURE CONTROLLER CAN BE
SWITCHED DN/OFF MANUALLY. IT ALSO GETS
ON/OFF COMMANDS FROM FGA ON FULFILLMENT
OF CERTAIN CRITERIA
- OIL LEVEL IN TANK NORMAL MAV10 CL521
COMPARE ACTUAL VALUES WITH STAND-
STILL CONDITION VALUES OF OIL PUMPS.
- OIL FILTERS INCLUDING STANDBY FILTERS READY FOR OPRN
FILTER ELEMENTS CLEANED OR REPLACED
- OIL PROPERTIES NORMAL
OIL CLEAR.
NO COLLECTION OF WATER AT THE BOTTOM
OF THE OIL TANK.

(02) + GENERATOR READY FOR OPERATION CHECK

+ MANUAL OPERATED VALVES GENERATOR ADJUSTED
REFER TO GENERATOR MANUAL
+ GENERATOR HYDROGEN FILLED
+ HYDROGEN PURITY > 95% MKG25 CQO01
+ SEALL OIL PUMP AIR SIDE ON MKW11 APOO1
OR MKW21 APOO1
+ STANDBY SEAL OIL PUMP AIRSIDE OFF MKW21 APOO1
OR MKW11 APOO1
AND MKW31 APOO1
+ SEAL OIL PUMP GAS SIDE ON MKW13 APOO1
THE DC SEAL OIL PUMP WILL ONLY BE
OPERA TED IF THE AC POWER SUPPLY
IS FAULTY

+ SUBLOOP CONTRSCOF SEAL OIL PPS. ON --------------------

THE SEAL OIL PLANT MUST ALSO BE IN AND -------------------
OPERATION IF THE TURNING GEAR
WILL BE OPERATED EVEN THE GENERATOR
IS NOT FILLED WITH HYDROGEN.

5.2-0130-02/2
 + SEAL OIL SYSTEM NO ALARM
+ LIQUID IN GENERATOR NO ALARM -----------------
AND MKA22 CLOO1
AND MKA23 CLOO1
AND MKA23 CL 011

(O3) + CRITERIA FOR BEGIN OF START UP CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE STARTED UP FROM
STANDSTILL
+ AUXILIARY OIL PUMP OFF MAV22 APOO1
AND MAV23 APOO1
+ EMERGENCY OIL PUMP OFF MAV24 APOO1
THE DC EMERGENCY OIL PUMP WILL OPERATE
IF AC POWER SUPPLY FAILS
+ TURNING GEAR OIL VALVE CLOSED MAV51 AAO01
AND
+ SUBLOOP CONTROL TURNING GEAR OFF MAV51 EEO01
+ SUBLOOP CONTROL OF AUX OIL PUMPS OFF MAV22 EEOO1
AND
+ SUBLOOP CONTROL EMERGENCY OIL PUMPS OFF MAV24 EEO01
+ JACKING OIL PUMPS OFF MAV31APOO1
AND MAV32 APOO1
AND MAV33 APO01
AND
+ SBULOOP CONTROL JACKING OIL PUMPS OFF MA V30 EEOO 1
AND MAV33 EEO01

(04) + FGA OIL SYSTEM START

FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THE FGA
OR
+ OIL SYSTEM MANUAL OPERATED START
.
(05) + AUXILIARY OIL PUMP SWITCH ON MAV22 APO01
OR MAV23 APO01
+ AUXILIARY OIL PUMP ON MAV22 APO01
OR MAV23 APO01
OR WITH FGA OIL SUPPLY

(05/S) + AUXILIARY OIL PUMP 1 ON MAV22 APO01

OR AUXILIARY OIL PUMP 1 FAULTED MAV22 APO01
+ AUXILIARY OIL PUMP 2 MANUAL OPERATION ON MAV23 APO01
+ OIL PRESSURE > 5 KG/CM2 MAV21 CPO01
+ LUB OIL PRESSURE >1.2 KG/CM2 MAV42 CPO01
+ OIL LEVEL IN TANK NOALARM MAV1O CLOO1
’ + FILTER LUB OIL SYSTEM NO ALARM
DIFERENTIAL PRESSURE ACROSS FILTER NOT HIGH MAV42 CP013
PRESSURE BEHIND FILTER NOT LOW MAV42 CPO14
LOCAL INDICATOR NOT INITIATED MAV42 B1001
CHECK STAND BY FILTER BY LOCAL
CHANGE OVER

(06) + TURNING GEAR OIL VALVE OPEN MAV51 AAO01

+ TURNING GEAR OIL VALVE OPEN MAV51 AAOOl
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL TURNING GEAR SWITCH ON MA V 51 EEOO1
+ SUBLOOP CONTROL TURNING GEAR ON MAV 51 EEO01
+ OR WITH FGA (OIL SUPPLY)

5.2-0130-02/3
(06/S) + SUBLOOP CONTROL TURNING GEAR ON MAV51 EEO01
SUBLOOP CONTROL OPENS AND CLOSES THE
TURNING GEAR OIL VALVE DEPENDING ON
TURBINE/GENERATOR SPEED.
TURNING GEAR OIL VALVE (OPEN) < 210 RPM
TURNING GEAR OIL VALVE (CLOSED) > 240 RPM
TURNING GEAR OIL VALVE CLOSES DURING
STARTUP AND OPENS WHEN THE TURBINE
IS COASTING DOWN AFTER SHUTDOWN.
DO NOT SWITCH OFF SUBLOOP CONTROL
AS LONG AS TURBINE IS IN OPERATION TO
MAKE SURE TURNING GEAR CUTS IN IF
TURBINE WILL BE SHUTDOWN.

+ TURNING GEAR OIL VALVE OPEN MAV 51 AAO01

+ OIL LEVEL IN TANK NO ALARM MAV 10 CLO01

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

AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH ON
+ SUBLOOP CONTROL OF AUXILIARY Oil PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY Oil PUMPS ON
OR WITH FGA (OIL SUPPLY)

(07/S) *+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON

AND

+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON

THE SUBLOOP CONTROLS START THE AUXILIARY
OIL PUMPS AND THE DC EMERGENCY OIL PUMPS
DEPENDING ON PRESSURE.
AUXILIARY Oil PUMP 1 < 4.8 KG/CM2 MAV21 CPO11
AUXILIARY Oil PUMP 2 < 4.5 KG/CM2 MAV21 CP012
AC EMERGENCY Oil PUMP < 1.1 KG/CM2 MAV42 CP011
DC EMERGENCY OlL PUMP < 1.1 KG/CM2 OR MAV42 CPO 12
SIMULTANEOUSLY ALARMS WILL BE ACTUATED.
LUBRICATING OIL PRESSURE MAV 21 CP011
AND/OR
LUBRICATING OIL MAV42 CP011
THE SUBLOOP CONTROLS OF EMERGENCY OIL PUMPS
AND JACKING OIL PUMPS MUST NOT BE SWITCHED
OFF UNTIL THE SHAFT STOPS COMPLETELY.

(08) + SEAL OIL PRESSURE GENERATOR END CHECK

+ SEAL OIL PRESSURE AIR SIDE TURBINE END > P MIN MKW71 CP511
+ SEAL OIL PRESSURE AIR SIDE EXCITER END > P MIN MKW71 CP521
+ SEAL OIL PRESSURE GAS SIDE TURBINE END > P MIN MKW73 CP511
+ SEAL OIL PRESSURE GAS SIDE EXCITER END < P MIN MKW73 CP521
= SUBLOOP CONTROL OF SEAL OIL PUMPS ON
THE SUBLOOP CONTROL OF THE SEAL OIL PUMPS

START THE PUMPS DEPENDING ON SEL OIL PRESSURE.

P MIN ACCORDING TO ACTUAL H2 PRESSURE.

(09) + JACKING OIL PUMP SWITCH ON MAV31 APO01,

OR MAV32 APO01
+ JACKING OIL PUMP ON MAV31 APOOl
OR MAV32 APO01
OR WITH SUBLOOP CONTROL

5.2-0130-02/4
+ SUBLOOP CONTROL OF JACK1NG OIL PUMP SWITCH ON MA V30 EEOO1
AND MAV33 EEOO1
+ SUBLOOP CONTROL OF JACKING OIL PUMP ON MAV30 EEOO1
AND MAV33 EEOO1
OR WITH FGA(OIL SUPPLY)
(09/S)*+ SUBLOOP CO~TROL OF JACKING OIL PUMP ON MAV30 EEO01
AND MAV33EEOO1
+ JACKING OIL PUMP ON MAV31 APOO1
OR JACKING OIL PUMP FAULTED MAV31 APO01
+ JACKING OIL PUMP MANUAL OPERATION ON MAV32 APO01
OR MAV33 APO01
SUBLOOP CONTROL STARTS AND STOPS THE
JACKING Oil PUMP 1 DEPENDING ON
TURBINE/GENERATOR SPEED CRITERIA.
JACKING OIL PUMP 1 ON < 510 RPM
JACKING OIL PUMP 1 OFF > 540 RPM

AND
SUBLOOP CONTROL STARTS THE JACKING OIL
PUMP 2 DEPENDING ON JACKING OIL PRESSURE

5.2-0130-02/5
 Steam Turbine Control Fluid System
Description Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES (GENERAL) CHECKED CHECKED

AND IN POSITION
ROOT VALVES IN IMPULSE PIPES OPEN
VALVES AHEAD OF TRANSMITTERS OPEN
PERMANENT VENTS OPEN
ISOLATING VALVES BEF/BEH CON- OPEN
TROL VALVES
ISOLATING VALVE IN CONTROL FLUID LINES OPEN
VALVES AHEAD OF HYDRAULIC ACCUMULATORS OPEN
VENTS OF COOLERS OPEN
DRAIN VALVES OF COOLERS CLOSED
DRAIN VALVES OF FILTERS CLOSED
VALVES IN DRAINS OF PIPING CLOSED
VALVES OF PRESSURE-TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VENTS OF COOLERS (WATERSIDE) CLOSED
VENTS OF FILTERS CLOSED
MULTI-WAY VALVES OF COOLERS ADJUSTED
MULTI-WAY VALVES OF FILTERS ADJUSTED

- SPEC.MAN.OPER. .OF SYSTEM CHECKED

AND IN POSITION
COOLlNG WATER VALVES OF CLOSED
STANDBY CONTROL.FLUID COOLER
DRAIN OF STANDBY CF- COOLER OPEN
WATERSIDE

VALVES IN RECONDITIONING PLANT ADJUSTED

+ CF-RECIRCULATION PUMP READY F OPE RAT MAX91APOO1

CF-PUMPS MANUALLY SWITCH ON

OR CF-PUMPS WITH SUBLOOP CONTROL SWITCH ON
CONTROL FLUID PRESSURESS NORMAL

CF-COOLER CF-SIDE IN SERVICE MAX41 BCOO1

OR MAX41 BCOO2
CHECK CF-COOLER IN OPERATION
AT LOCAL INDICATOR OF CHANGE
OVER VALVE.
DO NOT ADJUST ANY INTERMEDIATE
POSITION OF CHANGE OVER VALVE

- COOLING WATER FOR CF-COOLER AVAILABLE

- CF COOLER IN OPER. WATERSIDE FILLED MAX41 BC001

AND VENTED OR MAX41 BCOO2

- COOLING -WATER PIPE VENTED

BHEL Hardwar 5.2-0135-02/1

 STANDBY CF-COOLER WATER SIDE DRAIND MAX41 BCO01
AND DRIED OR MAX41 BCO02
IF THE CF-COOLER IN STANDBY
CANNOT BE DRIED BY WARM
CONTROL FLUID FLOWING VIA
THE FILLING AND VENT-LINES
THE CONTROL-FLUID COOLER
IN STANDBY MUST BE FLUSHED
BY FULL WATER FLOW ONCE
WEEKLY TO WASH OUT-DEPOSITS
TO AVOID CORROSION ATTACK
OFTHETUBES.

+ CF- TEMPERATURE -CONTROL ON MAX01 DTO01

THE CF- TEMPERATURE CONTROL
CAN ALWAYS BE SWITCHED ON.
IF THE FUNCTIONAL GROUP
AUTOMATIC WILL RECHECK THE
MODE OF OPERATION OFTHE
CONTROLLER OR THE COMMAND
<ON> WILL BE GIVEN THE
CRITERIUM IS FULFILLLED AND
THE PROGRAM CONTINUES.

+ SETPOINT CF- TEMPERATURE CONTROL 50±2º CEL MAX11 CTO01/2

FIX SETPO1NT

+ CF-TEMPERATURE CONTROL VALVE CLOSED MAX41AAO01

CF- TEMPERATURE IN TANK <50 º CEL

+ LEVEL IN CONTROL FLUID TANK NORMAL MAX11 CL521

COMPARE ACTUAL VALUES WITH
TEST REPORT VALVES DURING
STAND STILL OF CF-PUMPS

+ CF-FILTERS IN SERV.AND STANDBY

FILTER-INSERT CEANED READY F OPE RAT
OR
FILTER REPLACED .
FILTER CODE NO REFER TO
SINGLE LINE DIAGRAM.

- CF-RECONDITIONING PLANT READY F OPE RAT

FILTER EARTH NOT EXHAUSTED.
SAMPLES OF THE CONTROL FLUID
MUST BE TAKEN AND ANALYSED
FOR PROPERTIES OF FLUID.
THE FILTER EARTH MUST BE
REPLACED IN REGULAR INTERVALVES
GIVEN IN INSTRUCTION
5.3-0082 OR IN SPECIFICATION.
MECHANICAL FINE MESH FILTER
NOT EXHAUSED OBSERVE DIFFERENTIAL
PRESSURE WHEN OPERATING
RECONDITIONING PUMP,
EARTH-AND MECHANICAL FILTER
FILLED AND VENTED

5.2-0135-02/2
 -START RECONDITIONING PUMP
-VENT FILTERS
-SHUT-DOWN RECONDITIONING PP
- DEAERATION OF CF- TANK READY F OPE RAT
AIR-FILTER: NO CHANGE IN
COLOUR.
EXHAUSTER FAN <ON>
- CONTROL FLUID PROPERTIES NORMAL
REFER TO 5.3-0082
- CONTROL FLUID HEATER READY F OPERA T

(02) + CRITERIA FOR BEGIN OF STARTUP CHECK

IF THE FOLLOWING CRITERIA
ARE FULFILLED THE SYSTEM
WILL BE STARTED-UP FROM
< STANDSTILL> .
+ CONTROL FLUID PUMPS (CF-PUMPS) OFF MAX16APOO1
AND MAX16APOO2

+ SUBLOOP CONTROL OF CF-PUMPS OFF MAX16EEOO1

+ SUBLOOP CONTROL CF-HEATERS OFF MAX91EEOO1

+ CF-RECONDITIONING PUMP OFF MAX91 APO01

+ CF-TEMPERATURE IN TANK < 20 CEL MAX11CTO01A

(03) + SUBLOOP CONTROL CF-HEATERS SWITCH ON MAX91EEO01

AND
+ CF-RECONDITIONING PUMP SWITCH ON MAX91APO01
+ CONTROL FLUID HEATER ON MAX91AHOO1
AND
+ CF-RECONDITIONING PUMP ON MAX91 APOO1
THIS STEP HAS TO BE CARRIED
OUT IN DEVIATION FROM THE
FGA-PROGRAM TO SATISFY THE
CRITERION
CF-TEMPERATURE IN TANK > 20 CEL MAX11CT001A
TO START CF. PUMPS
(04) + CF-PUMP. FOR OPERATION PRESELECT MAX16APO01
OR MAX 16APO02
+ CF-PUMP. FOR OPERATION PRESELECTED MAX16APOO1
OR MAX16APO02
(05) + CONTROL. FLUID SYSTEM MANUAL START

OR WITH FGA < CONTROL. FLUID SYSTEM>

+ FGA < CONTROL-FLUID SYSTEM> START

OPERATION OF PUSH BUTTONS

REFER TO MANUAL FOR THE FGA-
FGA = FUNCTIONAL GROUP AUTOMATIC

+ CF-TEMPERATURE IN TANK >20CEL MAX11CTO01A

(06) + ONE CONTROL FLUID PUMP SWITCH ON MAX16APOO1

OR MAX 16APO02
+ ONE CONTROL FLUID PUMP ON MAX 16APOO 1
OR MAX16APOO2
OR WITH FGA < CONTROL FLUID SYSTEM>

5.2-0135-02/3
(06/S)*+ ONE CONTROL FLUID PUMP ON MAX16APOO1
OR MAX16APO02

+ CONTROL FLUID PRESSURE > 28 BAR MAX31CPOO1

+ CONTROL FLUID PRESSURE > 5 BAR MAX41CPOO1

+ FILTER SUPERVISORY EQUIPMENT NO ALARM

+ LEAKAGE SUPERVISORY EQUIPMENT NO ALARM

- LEVEL IN CONTROL FLUID TANK NORMAL MAX 11 CL621

(07) + SUBLOOP CONTROL OF CF-PUMPS SWITCH ON MAX16EEO01

+ SUBLOOP CONTROL OF CF-PUMPS ON MAX16EEOO1

SUB LOOP CONTROL OF CF-PUMPS
STARTS THE STANDBY PUMP IF
THE CF-PRESSURE BEHIND PUMP
DROPS TO < 28 BAR

(08) + SUBLOOP CONTROL CF-HEATER SWITCH ON MAX91AHO01

+ SUBLOOP CONTROL CF-HEATERS ON MAX91AHOO1
THE SUBLOOP,CONTROL OPERATES
THE HEATER DEPENDENT ON THE
FOLLOWING CRITERIA:
<ON> AT CF-TEMP. IN TANK < 48 CEL MAX1 1CTOO1
<OFF> AT CF-TEMP. IN TANK > 52 CEL MAX1 1CTO01
OR
< ON> AT THE HEATER < 50 CEL MAX91 CTOO1
<OFF> AT THE HEATER > 65 CEL MAX91CTOO1
THE HEA TER- TEMPERA TURE-PRO-
TECTION WILL BE INITIATED
AT A TEMPERATURE AT HEATER > 75 CEL MAX91CTO02
THE SUBLOOP CONTROL INTER-
LOCKS THE HEATER, IF THE
CF- TEMPERATURE CONTROL VALVE
IS NOT CLOSED.
OR WITH FGA < CONTROL. FLUID SYSTEM>

(08/5)* + SUBLOOP CONTROL CF-HEA TERS ON MAX91 AHOO1

(09) + CF-RECONDITIONING PUMP SWITCH ON MAX91 APO01

+ CF-RECONDITIONINGPUMP ON MAX91 APOO1

OR WITH FGA < CONTROL. FLUID SYSTEM>

(09/5)* + CF-RECONDITIONING PUMP ON MAX91APOO1

(10) - FILTER OF RECONDITIONING PLANT VENT

THE STEPS (08) AND (09) MUST NOT

BE CARRIED OUT IF THE CF-
HEATER AND/OR THE RECONDITIONING
PLANT OPERATES PRIOR TO CONTROL
FLUID PUMP OPERATION.

5.2-0135-02/4
 Steam Turbine Condensing Plant
Operation Startup Diagram

(01) + SYSTEM READY FOR OPERATION CHECK

MANUAL OPERATED VALVES (GENERAL) CHECKED
AND IN POSITION

ROOT VALVES IN IMPULSE PIPES OPEN

VALVES AHEAD OF TRANSMITTERS OPEN
PERMANENT VENTS OPEN
VALVES IN FILING-LINES OPEN
(PERMANENT)
VALVES BEF/BEH FANS IN SERVICE OPEN
VALVES BEF/BEH STANDBY FANS CLOSED
ISOLATING VALVES BEF/BEH CONTROL VALVES OPEN
VALVES IN TEMPERARY VENTS CLOSED
VALVES IN TEMPERARY FILING LINES CLOSED
VALVES IN BYPASS LINES CLOSED
VALVES OF PRESSURE-TEST CONNECTIONS CLOSED
VALVES IN SAMPLING LINES CLOSED
VALVES IN IMPULSE-PIPES FOR TESTING CLOSED
VALVES IN DRAIN-LINES CLOSED

- SPEC.MAN.OPER.VVLS .OF SYSTEM CHECKED

AND IN POSITION
VALVE AHEAD OF SEAL-STEAM CONDENSER OPEN
VALVE IN SEAL STEAM LINE TO ATMOSPHERE CLOSED
ISOLATING VALVES BEF/BEH SEAL STEAM SUPPLY LINE OPEN
BYPASS VALVE OF SEAL STEAM SUPPLY LINE CLOSED
BYPASS VALVE OF SEAL STEAM LEAK-OFF VALVE CLOSED
THROTTLE VALVES IN VAPOUR LINES ADJUSTED
VALVES IN AIR SUCTION LINES OPEN
ISOLATING VALVES IN AIR SUCTION LINES CLOSED
VALVES IN AIR SUCTION LINES OPEN
FROM AIRCOOLER OF CONDENSER
VALVES IN SEALING WATER-LINES OPEN
FOR VACUUM VALVES
VALVES IN SEALING WATER-LINES OPEN
FOR VACUUM BREAKER
VALVES IN SPRAY-WATER-LINES OPEN
FOR STAND- PIPES OPEN
VALVES BEHIND VACUUM BREAKER OPEN
LEVEL OF CONDENSER NORMAL
- LEVEL IN U-LOOPS NORMAL
U-LOOPS FILLED BY MEANS OF
+ FILLING VALVES
SET-POINT SEAL STEAM CONTROLLER >P AMB
FIX SETTING

BHEL Haridwar 5.2-0140-02/1

 (02) + EXT SYSTEMS READY FOR OPERATION CHECK
+ CIRCULATING WATER OF CONDENSER AVAILABLE

CIRCULATING WATER SYSTEM

DOES NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
SPECIAL INSTRUCTION FOR
- CIRCULATING WATER PUMPS
- VENTING OF THE CIRCULATING
WATER SYSTEM MUST AGREE WITH TURBINE-
OPERATING AND HAVE TO BE FOLLOWED
NOTE-
MAXIMUM CIRCULATING WATER
SPEED IN CONDENSER TUBES
MUST NOT BE EXCEEDED

+ CONDENSING SYSTEM IN OPERATION

THE CONDENSATE SYSTEM
DOES NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
SPECIAL INSTRUCTION FOR CONDENSING PUMPS
- CONDENSER LEVEL CONTROL
- MINIMUM FLOW CONTROL
- HEATER
MUST AGREE WITH TURBINE-
OPERATING AND HAVE TO BE FOLLOWED

+ VACUUM PUMPS READY FOR OPERATION

THE VACUUM PUMPS
DO NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
OPERATIONAL READINESS ACC.
TO SPECIAL INSTRUCTIONS

+ AUX. SYSTEM FOR SHAFT SEALS AVAILABLE

THE AUX. SYSTEM
DO NOT BELONG TO THE SCOPE OF
SUPPLY<TURBINE/GENERATOR>
POSITION OF VALVES AHEAD OF
- SEAL STEAM SUPPLY VALVE
ACCORDING TO SINGLE LINE DIAGRAM
IF APPLICABLE REFER TO
SPECIAL INSTRUCTIONS

(03) + CRITERIA FOR BEGIN OF START UP CHECK

IF THE FOLLOWING CRITERIA
ARE FULFILLED THE SYSTEM
WILL BE STARTED-UP FROM
< STANDSTILL> .
+ TURNING GEAR IN OPERATION REF TO S.2.0130
+ CONTROL FLUID SYSTEM IN OPERATION REF TO S.2.0135

+ DRAIN OF SEAL STEAM HEADER CLOSED MAL81AA001

+ SEAL STEAM CONTROL AND OFF
+ WARM UP VALVE SEAL STEAM CLOSED MAW11AA001
AND VACUUM BREAKER CLOSED MAW10AA001
AND SEAL STEAM EXHAUST FAN OFF MAW80AN002
+ VACUUM PUMPS AND OFF
+ AIR SUCT-VALVE PUMP CLOSED

5.2-0140-02/2
(04) + DRAIN OF SEAL STEAM HEADER OPEN MALe-1AA011
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL DRAINS SWITCH ON MALOOEEO01
+ DRAIN OF SEAL STEAM HEADER OPEN MAL81AA011
POSITION OF DRAIN VALVE(S)
DEPENDING ON TEMPERATURE
CRITERIA IN HEADER
VALVE(S) <OPEN> STEAM-TEMP. < 120 CEL
VALVE(S) <CLOSEQ> STEAM-TEMP. >150 CEL

(05) + AIR SUCTION EQUIPMENT START

AND
+ SHAFT SEAL STEAM SUPPLY START
OR WITH FGA <CONDENSING PLANT>
+ FGA <CONDENSING PLANT> START
OPERATION OF PUSH BUTTONS
REFER TO MANUAL FOR THE FGA.
FGA=FUNCTIONAL GROUP AUTOMATIC

(06) + SEAL STEAM EXHAUST FAN SWITCH ON MAW80ANO01

OR MAW80AN001
+ SEAL STEAM EXHAUST FAN ON MAW80ANO01
OR MAW80ANO02
AND
+ SEAL-STEAM CONTROL SWITCH ON
+ SEAL-STEAM CONTROL ON
AND
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP VALVE SEAL STEAM OPEN MAW11AA011
+ WARM-UP CONTR. <SEAL-STEAM> SWITCH ON
+ WARM-UP CONTR. <SEAL-STEAM> ON
SLC <SEAL-STEAM
SLC=SUBLOOP CONTROL
(06/S)*+ SEAL STEAM EXHAUST FAN ON MAW80ANO01
OR MAW80ANO02
AND

(06/S)*+ SEAL-STEAM CONTROL ON

AND

(06/S)*+ WARM-UP CONTR. <SEAL-STEAM> ON

BY STEAM FLOW THROUGH THE
WARM-UP VALVE THE STEAM-
TEMPERATURE UPSTREAM OFTHE
SEAL-STEAM SUPPLY VALVE
WILL BE INCREASED UNTIL THE
REQUIRED TEMPERATURE WILL
BE REACHED.
THE SEAL STEAM SUPPLY VALVE
MUST NOT BE OPENED UNTIL
THE TEMPERATURE CRITERIA
IS FULFILLED AND A MINIMUM
VACUUM IS REACHED IN THE
CONDENSER.
CRITERIA FOR OPENING THE
SEAL STEAM SUPPLY VALVE
STEAM-TEMPERATURE > 220 CEL
VACUUM < 0.7 BAR

5.2-0140-02/3
 (07) + VACUUM-PUMPS SWITCH ON
THE VACUUM PUMPS DO NOT BELONG
TO THE SCOPE OF SUPPLY OF THE
<TURBINE/GENERA TOR>.
OPERATION OF PUMPS AND VALVES ‘.
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION ,\CCORDING
TO SPECIAL INSTRUCTIONS. .
IOPERATION OF PUMPS AND VALVES
FOR AIR REMOVAL PRIOR TO AND
DURING OPERATION REFER
TO PLANT-MANUAL

+ VACUUM-PUMPS ON MAJ60ANO01
AND MAJ70ANO01

(08) + AIR-SUCT -VALVE VACUUM PUMP OPEN

+ AIR-SUCT-VALVE VACUUM PUMP OPEN

(08/S)*+ VACUUM PUMP ON MAJ60ANO01

AND MAJ70ANO01
+ VACUUM < 0.7 BAR MAG10CPO01

+ TEMP. AHEAD OF SEAL-ST. SUPPLY VLV > 220 CEL MAW10CTO01

(09) * + OPENINGOFSEAL-STEAMSUPPLYVLV OBSERVE MAW11AAO01

+ SEAL STEAM PRESSURE >P AMB MAW20CPO01

+ VACUUM < 0.15 BAR

(10) + VACUUM PUMP OPERATION CHANGEOVER

CHANGE IN OPERATION OF VACUUM-
PUMPS SERVES THE PURPOSE TO
HAVE ALL VACUUM PUMPS IN OPER-
ATION WHICH ARE NECESSARY
TO REMOVE AIR AND GAS FROM
THE CONDENSER DURINGOPER-
ATION. OBSERVE ALL CRITERIA -
INVOLVING VACUUM PUMP-OPER-
ATION.

GENERAL OUTLINE:

+ SERVICE VACUUM PUMP ON

AND
+ STARTUP A. STANDBY VACUUM PUMPS CFF

5.2-0140-02/4
 Steam Turbine Bypass-System
Description Start of Operation

(01) + SYSTEM READY FOR OPERATION CHECK

- MANUAL OPERATED VALVES CHECKED
ACCORD. TO LIST OF
VALVE-POSITION
AND IN POSITION
+ BYPASS-CONTROLLER ON
+ BYPASS-CONTROLLER NOT FAULTED

+ FIXPRESSUREREFERENCEVALUE KG/CM2
THE SETTING OF THE FIX
PRESSURE REFERENCE VALUE
DEPENDS ON THE REQUIREMENTS
OF THE STEAM-GENERATOR
F.E. THE SYSTEM FLOW THROUGH
THEREHEATER.
THE SETPOINT HAS TO BE
RAISED DURING STARTUP TO
MEETTHE DESIGN-VALUE FOR
MINIMUM LOAD OF THE STEAM-
GENERATOR.
FIX PRESSURE REFERENCE
VALUE AS DESIGNED. ...KG/CM2

+ HYDRAULIC PRESSURE SWITCH DELOCKED

THE H’(DRAULIC PRESSURE
SWITCH MUST ONLY BE
BLOCKED FOR THE PURPOSE
OF TESTING.

(02) + EXT. SYSTEM READY F. OPERATION CHECK

EXTERNAL SYSTEMS = SYSTEMS
BEYOND THE SCOPE OF SUPPLY
OF THE TURBINE/GENERATOR

+ CIRCULATING WATER OF CONDENSER AVAILABLE

+ CONDENSATE PUMPS IN OPERATION

+ VACUUM-PUMPS IN OPERATION

+ VACUUM < 0,6 KG/CM2

(03) + INT. SYSTEM READY FOR OPERATION CHECK

INTERNAL SYSTEMS = SYSTEMS
WITHIN THE SCOPE OF SUPPLY
OFTHETUR8JNE/GENERATOR.

BHEL Hardwar 5.2-0150-00/1

 + Oil SYSTEM IN OPERATION

+ TURNING GEAR IN OPERATION

+ CONTROL FLUID SYSTEM IN OPERATION

+ VACUUM-PUMPS IN OPERATION

+ VACUUM < 0,6 KG/CM2

(04) + STATE OF OPERAT. STEAM- CHECK

GENERATOR

+ STEAM-GENERATOR IN OPERATION

+ REHEAT PRESSURE/FIX PRESS. RELATION < 1

REF. VALUE

(05) + CRITERIA FOR BEGIN OF STARTUP CHECK

+ BYPASS STOP VALVE CLOSED MAN11AAO01

AND MAN12AAO01

+ BYPASS CONTROL VALVE CLOSED MAN11AAO02

AND MAN12AAO02

+ HYDR. SIGNAL OF BYPASS CONTROL < 1.0. KG/CM2

+ SP RAY WATER PRESSURE < 1.0 KG/CM2

+ REHEATPRESSURE/FIXPRESS. RELATION = 1
REF. VALUE

(06) + START OF BYPASS-OPERATION OBSERVE

BYPASS OPERATION STARTS IF
THE STEAM PRESSURE UPSTREAM
OF THE BYPASS VALVE MEETS
THE PRESS-REFERENCE VALUE.

* + BYPASS STOP VALVE OPENS MAN11AAO01

AND MAN12AAO01

* + SPRAY WATER VALVES (STAGE 1) OPEN

DESIGNATLON OF THE SPRAY.
WATER VALVES ACCORDING TO
SINGLE LINE DIAGRAM.

* + BYPASS CONTROL VALVE OPENS MAN11AAO02

AND MAN12AAO02

+ INTERLOCKS OF BYPASS-CONTROLS NOT INITIATED

THE BYPASS-CONTROL AND
STOP VALVES CLOSE IF THE
FOLLOWING CRITERIAARE
FULFILLED:
VACUUM > 0.6 KG/CM2
SPRAYWATERPRESSURE < 9,5 KG/CM2

5.2-0150-00/2
 + LIMIT VALUE OF STEAM FLOW NOT INITIATED

THE LIFT OF THE BYPASS-

CONTROL VALVES WILL BE
LIMITED. IF THE LIMIT
PRESSURE IS REACHED
THE BYPASS-CONTROL VALVE
CLOSE. .

+ LIFT OF BYPASS-CONTROL-VALVES 100%

(07) + FIXPRESSURE REFERENCE VALUE SETHIGHER

+ FIXPRESSURE REFERENCE VALVE HIGHER

+ LIFT OF BYPASS-CONTROL-VALVES < 100%

THIS CASE CAN OCCUR IF
THE FIXPRESSURE REFERENCE
VALUE HAS BEEN REDUCED
BELOW THE DESIGN VALUE
DURING STARTUP.

5.2-0150-00/3
 Steam Turbine Warm up and Startup of Turbine
Operation Startup Diagram

(01) + TURBINE READY FOR STARTUP CHECK

AND
+ MAIN STEAM LINES READY FOR WARMUP CHECK
+ MANUAL OPERATED VALVES OPEN.
(POSITION ACCORDING TO LINE DIAGRAM)
TEST VALVES OF STOP VALVES OPEN
HYDRAULIC VALVES OF EXTRACTION NRV OPEN
+ ELECTROHYDRAULIC TURBINE CONTROL ON
+ ELECTROHYDRAULIC TURBINE CONTROL NOT FAULTED
+ SPEED REFERENCE VALUE < N TURN GEAR
NORMALLY THE TURBINE WILL BE CONTROLLED
BY THE ELECTROHYDRAULIC CONTROLLER.
REFER TO 5.2-0180 FOR CHANGE OVER TO AND
OPERATION OF HYDRAULIC GOVERNOR
+ STARTING AND LOAD LIMIT DEVICE 0% MAX47 BYOO1
+ SPEED SETTER HYDRAULIC GOVERNOR 100 % MAX46 BYOO1
+ TURBINE STRESS EVALUATOR/CONTROLLER (TSE/TSC) ON
+ TSE/TSC NOT FAULTED
TSE/TSC TEST POSITIVE
NO ALARM
.NO FAULT INDICATOR ILLUMINATED
NO UNREASONABLE POSITION OF DISCS
+ TSE/TSC INFLUENCE ALWAYS ON
EXEMPTION: TSE/TSC FAULTY
CHANGE OVER WHEN DISTURBED. REFER TO 5.2-0430
IF THE TSE/TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURE AT THE MEASURING POINTS
WHICH REPRESENT THE THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED. REFER TO 5.1-011.
REF 5.2-0430 IF TSE/TSC ALLOWANCE IS REDUCED.
APPLIES TO ALL MODES OF OPERATION
+ TRIPPING DEVICE TURBINE PROTECTION NO ALARM
OVERSPEED TRIP MAY10 AAO01
AND MAY10 AAO02
IF STARTING AND LOAD LIMIT DEVICE > 20 %
+ ELECTRICAL TRIP NO ALARM
+ CASING DIFFERENTIAL TEMPERATURES NO ALARM
HP TURBINE CENTER TOP/BOTTOM < 90°C MAA50 CT051
AND MAA50 CT052
OR IP TURBINE FRONT TOP/BOTTOM < 30°C MAB50 CT0 43
AND MAB50 CT044
OR IP TURBINE REAR TOP/BOTTOM < 30°C MAB50 CT06 1
AND MAB50 CT062
CASING DIFFERENTIAL TEMPERATURES DETERMINE
THE DISTORTION OF THE TURBINE CASINGS

(02) + GENERATOR READY FOR OPERATION CHECK

ALL REQUIREMENTS AS PER GENERATOR MANUAL
FULFILLED BEFORE STARTUP
+ GENERATOR BREAKER OFF
+ EXCITATION BREAKER OFF
+ SEAL OIL PLANT IN OPERATION
+ H2 PRESSURE P DESIGN MKG25 CPO03
+ HYDROGEN PURITY > 95% MKG25 CQO01
+ H2 TEMPEARTURE CONTROL ON

BHEL Hardwar 5.2-0160-02/1

 + H2 TEMPERATURE CONTROL NOT FAULTED
+ PRIMARY WATER PUMP ON MKF12 APO01
OR MKF22 APO01
+ STANDBY PRIMARY WATER PUMP OFF MKF22 APO01
OR MKF12 APO01

+ PRIMARY WATER PRESSURE > P MIN MKF12 CPOOl

+ SUBLOOP CONTROL PRIMARY WATER PUMPS ON
+ PRIMARY WATER CONDUCTIVITY < 1,5 MYS/CM MKF35 COOOl
+ PRIMARY WATER TEMPERATATUREV CONTROL ON
+ PRIMARY WATER TEMPERATURE CONTROL NOT FAULTED
THE CRITERIA FOR THE GENERATOR HAVE TO
BE FULFILLED FOR ALL MODES OF OPERATION
WHICH CAN OCCURR,

+ DRAIN UPSTREAM OF MCV OPEN MAL11AA011

AND MAL AA011
+ DRAIN HP OUTER CASING OPEN MAL22 AAOll
CRITERION: TEMPERATURE HP TURBINE < 300 °C
OR
+ DRAIN HP OUTER CASING CLOSED MAL22 AAOll
CRITERION: TEMPERATURE HP TURBINE > 320 °C
+ DRAIN AHEAD OF SWING CHECK CRH NRV OPEN MAL65 AAOll
CRITERION: CRH NRV CLOSED
+ DRAIN BEFORE IP CONTROL VALVE OPEN MAL26 AAOll
AND MAL27 AAOll
+ DRAIN DOWN STREAM IP CONTROL VALVE OPEN MAL31 AAOll
AND MAL32 AAOll
CRITERION: VALVE CASING TEMPERATURE
MINUS SATURATION TEMPERATURE OF STEAM <-20 °C
OR
+ DRAIN BEFORE IP CONTROL VALVE CLOSED MAL26 AA011
AND MAL27 AAOll
+ DRAIN DOWN STREAM IP CONTROL VALVE CLOSED MAL31 AAO 11
AND MAL32 AAOll
MINUS SATURATION TEMPERATURE OF STEAM > 50 °C ‘
CRITERION: EXTRACTION VALVE CLOSED

(05) + CRITERIA FOR BEGIN OF START UP CHECK

IF ALL CRITERIA AS LISTED BELOW ARE
FULFILLED THE TURBINE/GENERATOR WILL
BE STARTED FROM
-TURNING GEAR IN OPERATION
-STOP VALVES CLOSED
+ MAIN STEAM STOP VALVES CLOSED MAA10 AAOOl
AND MAA20 AAOO 1
+ REHEAT STOP VALVES CLOSED MAB10 AAOOl
AND MAB20 AAOOl
+ HP CONTROL VALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
+ IP CONTROL VALVES CLOSED MAB 10 AAO02
AND MAB20 AAO02
+ SWING CHECK VALVE COLD REHEAT L4NE CLOSED LBC10 AAOOl

+ EXTRACTION VALVE CLOSED

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

(07.) + PREWARMING OF TURBINE START

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

5.2-0160-02/2
 OPERATION OF PUSH BUTTONS
REFER TO MANUAL FOR THE FGA

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

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

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

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

(10) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 5.2-0170
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REFER TO 5.2.0170
OR
+ MAIN STEAM VALVE TEMPERATURE < 100 °C
RELEASE OF STEP(05) OF THE FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PROGRAMME
HA VE BEEN FULFILLED

(11) + STATE OF OPERATION OF STEAM GENERATOR CHECK

+ STEAM GENERATOR IN OPERATION

(12) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BYO01
OR WITH OF FGA (TURBINE CONTROL)

(12/S) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47 BYO01
STARTING AND LOAD LIMIT DEVICE > 42% MAX47 BYO01
+ MAIN STEAM STOP VALVES OPEN MAA10 AAO01
MAA20 AAO01

(13) + STEAM TEMPERATURE CRITERIA CHECK

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

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

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

(15) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX4B.YO01

OR WITH FGA (TURBINE CONTROL)
(15/S)+ STARTING AND LOAD LIMIT DEVICE RAISE MAX47 BYO01
+ STARTING AND LOAQ. LIMIT DEVICE > 56 % MAX47 BYOO 1
+ REHEAT STOP VALVES OPEN MAB10 AAO01

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

5.2-0160-02/3
 OPERATION OPERATE DRAIN VALVES OF THE HP
CONTROL VALVES MANUALLY. CLOSE ON DECREASING
TSE/TSC ALLOWANCE. OPEN ON INCREASING TSE/TSC
ALLOWANCE. IF THE TSE/TSC IS FAULTY OPERATE
DRAIN V ALVES ACCORDING TO WALL TEMP
AT THE TSE/TSC RECORDER. REFER TO TECHNICAL
DATA FOR LIMITS OF DIFFERENTIAL
TEMPERATURES OF THE TSE/TSC.

(17) + DRAINS MAIN STEAM LINE CLOSE

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

(18) + STEAM TEMPERATURE CRITERIA CHECK

+ MAIN STEAM TEMPERATURE CRITERIA FULFILLED REF. 5.2-0170 FIG.1,4
+ REHEAT STEAM TEMPERATURE CRITERIA FULFILLED REF. 5.2-0170 FIG.L.5
THE RELEASE OF STEP (12) OF FGA (TURBINE
CONTROL) OCCURS AFTER THE SLIDING TEMP.
CRITERIA INCLUDED IN THE FGA PRO(1RAMME
HAVE BEEN FULFILLED

(19) + LOAD REFERENCE VALUE CHECK MYA01 DUO01

+ LOAD REFERENCE VALUE > 10 % MYAOL DUOOL

(20) + SPEED REFERENCE VALUE SET HIGHER

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

+ SPEED OF TURBINE/GENERATOR > 240 APM

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

+ SPEED OF TURBINE/GENERATOR > 540 RPM

22) + JACKING OIL PUMP SWITCH OFF MAV31 APOOL
OR MAV32 APO01
+ JACKING OIL PUMP OFF MAV31 APOO1
AND MAV32 APOO1

5.2-0160-02/4
OR WITH SUBLOOP CONTROL

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

AND MAV32 APOO1

(23) + STEAM TEMPERATURE CRITERIA CHECK

AND
+ OPERATIONAL VALUES OF TURBINE CHECK
+ STEAM TEMPERATURE CRITERIA FULFILLED REF. 5.2-0170 FIG,6
+ TURBINE STRESS MARGIN > 30 OK
+ BEARING VIBRATION NORMAL
+ SHAFT VIBRATION NORMAL
DEFINITION OF NORMAL VALUES OF VIBRATION:
VIBRATION PREVIOUSLY OBSERVED WHEN OPERATING
WITH SAME SPEED AND OTHER PARAMETERS

(24) + WARM-UP CONTROL SWITCH OFF

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

(25) + SPEED REFERENCE VALUE SET HIGHER MYAO1 DUO01

+ SPEED REFERENCE VALUE > 3000 RPM MYA01 DUOO1
OR WITH FGA (TURBINE)
(25/S)* + SPEED REFERENCE VALUE > 3000 RPM

(26) + WAIT
THE LIMITED SPEED REFERENCE VALUE FOLLOWS
THE SPEED REFERENCE VALUE WITH THE PRESET
GRADIENT. DO NOT HOLD THE TURBINE IN THE
CRITICAL SPEED ZONE. THE SPEED GRADIENT
WILL BE REDUCED IF REDUCTION OF THE TSE/TSC
ALLOWANCE OCCUR. THE TSE/TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.
IF A SIGNIFICANT REDUCTION OF THE TSE/TSC .
ALLOWANCE OCCURS, THE TURBINE SPEED WILL BE
REDUCED TO WARM UP SPEED. IF THE TSE/TSC IS
FAULTED THE DIFFERENTIAL TEMPERATURES AT
THE MEASURING POINTS WHICH REPRESENT THE
THERMAL STRESSES OF CASING AND ROTOR MUST
BE EVALUATED REFER TO 5.1-011..
REDUCE SPEED REFERENCE VALUE TO WARMUP
SPEED WHEN OPERATING WITHOUT TSE/TSC
INFLUENCE AND THE TSE/TSC ALLOWANCE
REDUCED TO ZERO.

+ SPEED REFERENCE VALUE 3000 RPM

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

(28) + DRAIN AHEAD OF HP CONTROL VALVES CLOSE MAL 11 AAO11

5.2-0160-02/5
 AND MAL 12 AA011

+ DRAIN AHEAD OF HP CONTROL VALVES CLOSED MAL 11 AA011

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

(29) + AUXILIARY OIL PUMP SWITCH OFF MAV22 APO01

AND MAV23 APO01

OR WITH FGA (TURBINE CONTROL)

+ STEAM TEMPERATURE CRITERIA CHECK

+ GENERATOR SYNCHRONIZE REFER TO 5.2-0210

5.2-0160-02/6
 Steam Turbine Warming-up and Starting the Turbine
Description Temperature Criteria

Warming-up and Starting the Turbine Des

The admission steam temperature should
meet the metal temperature as shown in the
diagram below in order to start and load the
turbine in shortest possible time.

Note : The following criteria represent

approximate values, which can be optimized
by operational experience.

Turbines with Automatic Turbine Runup

System (ATRS) should under go optimizing.

Criteria for the opening of stop valves

When opening the main stop valves the

main steam parameters should meet the
following recommended values.

 Minimum main steam temperature

θms>θs Fig.1

θms = Main steam temperature at

steam generator outlet

θs = Temperature of saturated
steam (depending on main
steam pressure)
and
θms>f(θmcv50%) Fig.2

θms = Main steam temperature at

steam generator outlet

θmcv50% = Middle wall temperature of

main control valve casing

BHEL Hardwar 5.2-0170-01/1

  Maximum main steam saturation
temperature ahead of the turbine

θs>f(θmcv50%) Fig.3

θs = Maximum main steam saturation

temperature ahead of the turbines

θmcv 50% = Middle wall temperature of

main control valve

Starting Cretaria

When the main control valves are opened

the main steam and reheat steam
temperatures should fulfill the following criteria:

 Minimum main steam temperature

θms>θs Fig.1

θms = Main steam temperature

ahead of the turbine

θs = Temperature of saturated
steam (depending on main
steam pressure)

and

θms>f(θHT50%) Fig.4

θms = Main steam temperature

ahead of turbine

θHT 50% = Middle wall temperature of HP-

casing or simulated middle
phase shaft temperature

5.2-0170-01/2
 Minimum reheat temperature

9Reh > f (9IT 50%)

Fig. 5

9Roh = Steam temperature in the hot

reheat line

9IT 50% = Simulated midwall temperature

of the IP-shaft

Speeding up criteria

Before the turbine is brought to rated speed

the main steam temperature 9MS ahead of the
turbine should fulfill the following criteria:

9MS < f ( 9HT 50% ) Fig. 6(a) & (b)

9MS = Main steam temperature

ahead of the turbine

9HT 50% = Middle wall temperature of the

HP-turbine casing or simulated
midwall temperature of HP
shaft

5.2-0170-01/3
Loading criteria

Before the turbine is loaded the reheat

temperature, ahead of the turbine should fulfill
the following criteria

9Reh > f (9IT 50%) Fig. 7

9Reh = Steam temperature in the hot

reheat line

9IT 50% = Simulated midwall

temperature of the IP-turbine
shaft

5.2-0170-01/4
 Steam Turbine Warming up and Starting the Turbine
Operation Controller

1 Operating modes of the control systems and of

the starting and load limit device
The turbine generator Unit is accelerated and
 Electrical speed Control
maintained at constant warmup speed
- Warmup operation
accelerate unit to rated speed
- Running up the turbine I generator unit
maintain unit at rated speed
- Rated speed operation
The turbine generator unit is accelerated and
 Hydraulic governor
maintained at constant warm-up speed by manual
- Warm-up operation
actuation of the starting and load limit device

When the reference speed setter is in the 0% position,

- Running up the turbine generator unit
the hydraulic governor takes over speed control at
approx. 8O% rated speed
so, run -up of the turbine generator unit from
approx. 8O to 100% rated speed is controlled by
the hydraulic speed governor.

Maintain unit at rated speed

- Rated speed Operation
Acceleration to 107% of rated speed by the governor;
overspeed trip test
speed is increased to trip speed using acceleration
lever on casing of hydraulic governor;
During overspeed trip test ,the electrical speed
controller must be disengaged and switched off.

The main trip valves are brought into operating

 Starting and load limit device
position when the starting and load limit device is
- setting operating configuration of main trip valve
in the 0% position.
- Opening the stop valves
When the starting and load limit device is in
approx 4 0% open position, the stop valves should
be open;
the test valves of the stop valves must be in the
operating position for the opening procedure.
- Warm up operation
See Hydraulic speed governor
2 Electrical speed control
0-107% (limitation by hydraulic speed governor)
 Control range in % rated speed
 Setpoint control
The actual setpoint follows the target setpoint
- Target setpoint /actual setpoint
along preset gradients.
The preset gradient is reduced according to a
- Limitation of setpoint by turbine, stress evaluator (TSE)
Predeterminaned characteristic to confirm to the
margin generated by the TSE
- Application of the TSE signal
The TSE signal must always be present if the TSE
is not faulted.
- Oparation with TSE faulted
The actual setpoint no longer follows the target
setpoint if the TSE is defaulted
the actual and target setpoint must be matched up
before the TSE signal can be switched off. When the
signal from TSE is not present, the thermal
stress in the turbine components must be figured
out by comparing. The actual temperature and their
differences with the curves for permissible
temperature margins as given in Technical Data 5.1-011

BHEL Hardwar 5.2-0180-00/1

  Limitation by higher-level or alternative
controllers or other devices
- Minimum value selection Effecive controller = controller with the lowest
setpoint setting at any time (also applies to other
devices influencing the opening characteristic)
- Hydraulic speed governor Limit setpoint by hydraulic minimum
(speed setting device approx.80%) value selection;
- Starting and load limit device Limit setpoint by hydraulic minimum
valve selection;
excessive control valve opening can be prevented
by using the starting and load limit device to
limit valve travel.
 Operation
- Operating elements and monitoring see arrangement of control desk as described in
instruments controller manual. Pay attention to notes on operation
of release pushbuttons!
- Operating logic sequences for changing See Appendix (for changing the operating mode during
the operating mode no-load operation see
Power Operation, Controller 5.2-0180
3 Hydraulic Speed Governor
 Setpoint control
- Target setpoint factual setpoint The actual setpoint immediately follows the target
setpoint (no influence from turbine stress evaluator),
During operation with the hydraulic speed governor,
the thermal stresses in the turbine components must
be figured out on the basis of the TSE display or,
if the TSE is faulted, by comparing the actual
temperatures and their differences with the curves
for permissible temperature margins as given in
Technical Data 5.1-011.
 Limitation by higher-level or
alternative controllers or other device
- Minimum Value selection Effective controller = controller with lowest
setpoint setting at any time (also applies to other
devices influencing the control characteristic)
- Electrohydraulic controller Limits setpoint by hydraulic minimum
<100% value selection
- starting and IQad limit device Limits setpoint by hydraulic minimum
value selection
 Operation
- Operating elements and monitoring See arrangement of control desk as described in
instruments in controller manual
- Operating logic sequences for See next page
changing operating mode

5.2-0180-00/2
 + Turbine generator unit speed = Turning gear speed
+ Stop valve position = 0%
+ Control Valve position = 0%
+ Main trip valves = depressurized
+ Starting and load limit device = 40% open
+ Reference speed setter = 0%
+ Electrical speed reference = 0%

(1) + Electrical speed reference raise

+ Electrical speed reference = 100%

(2) + Plunger coil deenergize

+ Plunger coil deenergized

(3) + Starting and load limit device lower

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

(4) + Starting and load limit device raise

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

(A) + Main Steam lines warm-Up

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

(5) + Starting and load limit device raise

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

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

(B) + Turbine Warm-up

+ Run-up criteria fulfilled
+ Steam generator output adequate

(7) + Starting and load limit device raise

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

(8) + Starting and load limit device raise

+ Starting and load limit device = 100% open

(9) + Reference speed setter raise

+ Turbine generator unit speed = rated speed

Operating logic sequence 1: Starting up the turbine generator unit with the
starting and load limit device and the hydraulic
speed governor
A see Warming up the Main Steam Line
B see Warming up Starting up the Turbine

5.2-0180-00/3
 + Turbine generator unit speed > turning gear speed and
< 75% rated speed
+ Electrical speed reference = turbine generator unit speed
+ Reference speed setter = 100%

+ Starting and load limit device = 56 to 100%

(1) + Starting and load limit device lower

+ Starting and load limit device effective

(2) + Electrical speed reference raise

+ Electrical reference = 100%

(3) + Plunger coil deenergize

+ Plunger coil deenergized

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

(5) + Reference speed setter lower

+ Reference speed setter = 0%

Operating logic sequence 2: Transition from operating with electrical speed controller to
operating with starting and load limit device
(Speed approx, 80% rated speed)

+ Turbine generator unit speed > Turning gear speed and

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

(1) + Plunger coil energize

+ Plunger coil energized

(2) + Electrical speed reference lower

+ Turbine generator unit speed = electrical speed reference

(3) + Starting and load limit device raise

+ Starting and load limit device 56 to 100 %

(4) + Reference speed setter raise

+ Reference speed setter = 100%

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

5.2-0180-00/4
 Steam Turbine Load Operation
Operation Introduction

runs the risk of reductions in availability and

Power operation begins by
reliability.
synchronizing of the generator. The turbine
generator load may then be raised or The operating staff must detect all
lowered according to the commands from operating conditions that is a danger to tile
the monitoring/controlling equipment, in turbine generator and must immediately
particular the load margins from the turbine correct them.
stress evaluator (TSE) / turbine stress
Regular checking of protection equipment,
controller (TSC), to meet the grid power
long-term monitoring of operating variables
requirement.
and operational maintenance are very
During power operation, monitoring is important for early detection and elimination
essential for the economic operation of the of system faults.
turbine generator. Neglecting this principle

BHEL Hardwar 5.2-0200-00

 Steam Turbine Synchronization and Loading
Operation Startup Diagram

(01) + GENERATR READY TO BE CHECK

SYNCHRONIZED

+ SPEED OF TURBINE/GENERATOR 3000 RPM

+ DRAIN OF SEAL STEAM HEADER NORMAL

+ H2-SUPPL Y SYSTEM NO ALARM

+ SEAL-OIL PLANT NO ALARM

+ PRIMARY WATER SYSTEM NO ALARM

+ LIQUID IN GENERATOR NO ALARM

+ STEAM TEMPERATURE CRITERIA FULFILLED

(02) + EXCITATION BREAKER SWITCH ON

+ EXCIT ATION BREAKER SWITCHED ON

OR WITH FGA (TURBINE CONTROL)

(02/S)* + EXCITATION BREAKER SWITCHED ON

(03) + GENERATOR VOLTAGE SET HIGHER

+ GENERATOR VOLTAGE HIGHER

OR WITH FGA (TURBINE CONTROL)

(03/S)* + AUTOMATIC SYNCHRONIZER ON

(04) + GENERATOR VOLTAGE CONTROL CLOSED

+ GENERATOR VOLTAGE CONTROL SWITCHED ON

OR WITH (AUTOMATIC SYNCHRONIZER)

(04/S)* + GENERATOR VOLTAGE CONTROL SWITCHED ON

(05) + SYNCHRONOSCOPE SWITCHED ON

OR WITH (AUTOMATIC SYNCHRONIZER)

+ SYNCHRONOSCOPE SWITCHED ON

BHEL Hardwar 5.2-0210-00/1

(07) + GENERATOR VOATAGE ADJUSTED
BY MEANS OF REFERENCE
VALUE OF VOLTAGE CONTROL

+ GENERATOR/LINE-VOLTAGE MET
OR WITH (AUTOMATIC SYNCHRONIZER)

(07/5)* + GENERATOR/LINE-VOLTAGE MET

(08) + GENERATOR FREQUENCY ADJUSTED

BY MEANS OF REFERENCE
VALUE OF SPEED CONTROL

+ GENERATOR/LINE-FREQUENCY MET

OR WITH (AUTOMATIC SYNCHRONIZER)

(08/5)* + GENERATOR / LINE-FREQUENCY MET

GENERATOR FREQUENCY MUST
BE ADJUSTED IN SUCH A WAY
THAT THE NEEDLE OF THE
SYNCHRONOSCOPE TURNS
SLOWLY IN THE DIRECTION
GENERATOR FREQUENCY HIGHER
THAN LINE FREQUENCY =
FAST SYNCHRONIZING.
FAST SYNCHRONIZING ENSURES
THAT THE GENERATOR Will
BE LOADED IMMEDIATELY
AFTER SYNCHRONIZING
THUS PREVENTING REVERSE
POWER RELAY TO BE ACTUATED.

(09) + SYNCHRONIZING DEVICE START

+ GENERATOR BREAKER SWITCHED ON

IF THE BREAKER WILL BE
SWITCHED ON MANUALLY
ADJUSTED PHASE ANGLE TO
NEEDLE OF SYNCHRONOSCOPE
MUST METT THE ZERO-ANGLE
MARK ON THE SCALE WHEN
SWITCHING IN BREAKER.

OR WITH (AUTOMATIC SYNCHRONIZER)

(09/5)* + GENERATOR BREAKER SWITCHED ON

(10) + SPEED REFERENCE VALUE SET HIGHER MYA01DU001

+ GENERATOR LOAD > 10%

5.2-0210-00/2
(11) + STARTING AND LOAD LIMIT DEVICE SET HIGHER MAX47BYO01

+ STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01

OR WITH FGA (TURSINE CONTROL)

(11/S)* + STARTING AND LOAD LIMIT DEVICE 100% MAX47BYO01

+ TURBINE STRESS EVALUATOR (TSE) CHECK

+ TURBINE STRESS EVALUATOR (TSE) CHANGED OVER

AT A PRESENT MINIMUM LOAD
THE TSE CHANGES OVER FROM
TEMPERATURE-TO LOAD SCALE

+ GENERATOR LOAD > 10%

LOAD CONTROLLER SWITCHED ON

THE LOAD CONTROL WILL BE
SWITCHED ON AT A PRESET
MINIMUM LOAD.

(12) + LOAD REFERENCE VALUE SET HIGHER MYA01 DUO01

+ LOAD REFERENCE VALUE TARGET LOAD MYA01 DUO01

(13) + WAIT

(13/S)* + LIMITED LOAD REFERENCE VALUE HIGHER MYA01DUO01

THE LIMITED LOAD REFERENCE
VALUE FOLLOWS THE TARGET
LOAD REFERENCE VALUE
WITH THE ADJUSTED
LOAD GRADIENT.
THE LOAD GRADIENT WILL
BE REDUCED, IF REDUCTION
OF THE TSE ALLOWANCE OCCUR.
THE TSE INFLUENCE WILL BE
EFFECTIVE VIA THE REFERENCE
LIMITER.

IF THE TSE IS FAULTED THE

DIFFERENTIAL- TEMPERATURES
AT THE MEASURING POINTS
WHICH REPRESENT THE
ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST
BE EVALUATED.

REFER TO 5.2-0430 IF
TSE-ALLOWANCE IS
REDUCED.

5.2-0210-00/3
(14) + DRAIN DOWNSTREAM RCV CLOSE

OR WITH SUBLOOP CONTROL (DRAINS)

POSITION OF DRAINS CHECK

+ DRAIN DOWNSTREAM OF HP-CONTR. CLOSED MAL 15AAO01

VLV AND MAL 16AAO01

CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATURATION
TEMPERATURE OF STEAM

+ DRAIN OUTER CASING CLOSED MAL 22AA011

CRETERIUM:
TEMP.HP-CASING TOP >320 CEL

+ DRAIN AHEAD OF SWING-CHECK CRH CLOSED MAL65AA011

CRITERIUM: LBC10AAO01
NON RET.CHECK VLV COLD REH. OPEN

+ DRAIN UPSTREAM RCV CLOSED MAL26AA011

AND MAL27 AA 11

CRITERIUM: > 50 CEL

VALVE CASING TEMPERATURE
MINUS SATURATION
TEMPERATURE OF STEAM

+ DRAIN DOWNSTREAM RCV CLOSED MAL31AA011

AND MAL32AA011
CRITERIUM:
VALVE CASING TEMPERATURE > 50 CEL
MINUS SATURATION
TEMPERATURE OF STEAM

(15) + HEATER OPERATION CHECK

+ HEATERS IN OPERATION
+ EXTRACTION VALVE > 0% LBO50AAO01
AND LBS41AAO01
AND LBS42AAO01
AND LBS31AAO01
AND LBS21AAO01

(16) + DRAINS OF EXTRACTIONS CLOSE MAL47AA011

AND MAL51AA011
AND MAL54AA015
AND MAL55AA011

5.2-0210-00/4
 + DRAINS OF EXTRACTIONS CLOSED MAL47AAO11
AND MAL51AAO11
AND MAL54AAO15
AND MAL 55AAO11

IF THE EXTRACTION STEAM

FLOW WILL BE REDUCED,
CAUSING THE EXTRACTION
VALVE TO CLOSE THE
RESPECTIVE DRAIN MUST
BE OPEN.

+ BOILER/TURBINE LOAD RELATION 1

(17) + BYPASS CONTROL VALVE CHECK

+ BYPASS CONTROL VALVE CLOSED MAN11AAOO2

AND MAN12AAOO2

+ BYPASS STOP VALVE CLOSED MAN11AAOO1

AND MAN12AAOO1

5.2-0210-00/5
 Steam Turbine Power Operation
Operation Controllers

1 Control System Operating Modes

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

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

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

- Constant pressure operation without positioning control valves.
frequency influence As above, turbine generator assists in grid frequency
- Constant pressure operation with stabilization when frequency changes.
frequency influence as given by the
proportional setting of the frequency
control and by the thermal storage
capacity of the steam generator Maintenance of constant load;{steam generator con-
- Variable pressure operation without trol system takes over control when max. control
frequency influence valve lift reached).
Maintenance of constant load;
Turbine generator assists in grid frequency stabilization
- Variable pressure operation with frequency when frequency changes.
influence as given by the proportional
setting of the frequency control unit
and the thermal storage capacity of the
steam generator by controlled throttling of
the control valves

Initial pressure control by the electrical

load controller (alternative to limit initial
pressure control) Maintenance of constant pressure in steam generator
- Constant pressure operation as given by proportional settings characteristics of”
(with or without frequency influence) pressure reference value.

Limit initial pressure control by the electrical load controller

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

BHEL Hardwar 5.2-0220-00/1

2 Electrical Speed Control

Control range
- Speed (as % 9f rated speed) 0-170%
(limited by hydraulic governor)

- Valve lift 100%

- load at design pressure. 100%

Reference limiter
- Target reference value/actual The actual reference value tracks the target
reference value reference along a preset gradient.
- Limitation of reference limiter by TSE The present gradient Is reduced in accordance with
(turbine stress evaluator) component a predetermined characteristic to conform to the
load margin generated by the TSE.
- Application of TSE signal The TSE signal must always be present unless the
TSE is faulted. .
- Operation with TSE faulted The actual reference value no longer tracks the
target reference value if the TSE is faulted;
Actual and target reference value must be matched
up before the TSE signal can be switched off.
The thermal stresses In the turbine components
must be assessed by comparison of the actual tem-
peratures and their differences with the curves for
permissible temperature margins given in
TechnicaI Date 5.1-011.

limitation by priority or alternative
controllers or other equipment
- Minimum value selection Controller in effect = controller with lowest
setpoint;
(also applicable to other equipment that affects
the controller output signal.
- Hydraulic governor < 100% limits reference value by means of hydraulic minimum
value selection.
- Starting and load limit device < 100% limits reference value by means of hydraulic minimum
value selection.
Control valve lift overshot can be prevented by
means of starting and load limit device

Operation
- Control and monitoring devices See desk allocation diagram in controller manual.
Note instructions on use of release pushbuttons I
-Control logic for changing operating See appendix
mode

Instructions for control and operational
monitoring
- speed reference value after changeover After changeover to load control the speed
to load control reference value is to be set such that speed will
revert to approx. 0.6% above rated speed in the
event of load shedding.
3 Hydraulic Governor

Control range
- Speed 80-107%
- Valve travel at rated speed 100%
- load at design pressure 100%

Reference limiter
- Target reference value/actual Actual reference value tracks target reference
reference value value directly (no TSE component).
During operation with the hydraulic governor in
control, the thermal stresses in the turbine com-
ponents must be assessed by referring to the TSE
display or, if the TSE is faulted, by comparing
the actual temperatures and their differences with
the curves for permissible temperature margins as
give in Technical Data 5.1-011.

Limitation by priority or alternative
5.2-0220-00/2
controllers or other equipment
 - Minimum value selection Controller in effect == controller with lowest
reference value;
(also applicable to other equipment that affects
the controller output signal).
- Electrohydraulic controller < 100% Limits reference value by means of hydraulic
minimum value selection.
- Starting and load limit device < 100% Limits reference value by means of hydraulic
minimum value selection.

Operation
- Control and monitoring devices See desk allocation diagram in controller manual.
- Control logic for changing operating See appendix
mode

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

Control range
- Valve travel 100%
- Load at design pressure 100%

Reference limiter
- Target reference value/actual The actual reference value tracks the target
reference value reference value along a preset gradient.
- Limitation of reference limiter by TSE The present gradient is reduced in accordance with
a predetermined characteristic to conform to the
load margin generated by the TSE.
- Application of TSE signal The TSE signal must always be present unless the
TSE is faulted.
- Operation with TSE faulted The actual reference value no longer tracks the
target reference value if the TSE if faulted;
Actual and target reference value must be matched
before the TSE signal can be switched off.
The thermal stresses in the turbine components
must than be assessed by comparison of the actual
temperatures and their differences with the curves
for permissible temperature margins given in
Technical Data 5.1-011.

Limitation by priority or alternative
controllers or other equipment
- Minimum value selection Controller in effect = controller with lowest
reference value;
(also applicable to other equipment that affects
the controller output signal).
Absolute limit load reference value Limit reference values by means of electric minimum
selection;
Active in the event of unit malfunctions.

5.2-0220-00/3
 - Hydraulic speed governor < 100% Limits reference value by means of hydraulic
minimum value selection
- Starting and load limit device < 100% See above

Operation
- Control and monitoring devices See desk allocation diagram in controller manual.
Note instructions on use of release pushbuttons
-Control logics for changing operating See appendix
mode

Instructions for control and operational
monitoring
- Changeover from speed to load and from Valve lift reference value must be matched up prior
load to speed control To changeover..
- Switching off load controller in the Changeover from load to speed control is effected
event of load shedding When the load falls below a preset value;
Changeover back to load control is effected if the
actual load rises above the lower limit within
approx. 2s.
- Cut in of initial pressure controller The pressure control deviation must be 0 before
the initial pressure can cut in.

5.2-0220-00/4
 APPENDIX

+ Turbine generator speed = rated speed

+ Turbine generator load = Zero MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = rated speed
+ Speed changer = 100%
+ Starting and load limit device = 100%

(1) + Speed changer lower

+ Speed changer reference value < electrical speed reference value

(2) + Electrical speed reference value raise

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

(3) + Plunger coil switch off

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

(4) + Speed changer raise or lower

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

+ Turbine generator speed =rated speed

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

(1) + Plunger coil Switch on

+ Plunger coil on

(2) + Electrical speed reference value lower

+ Electrical speed reference value < speed setter reference value

(3) + Speed changer raise

+ Speed changer = 100%
+ Required speed higher or lower

(4) + Electrical speed reference raise or lower

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

5.2-0220-00/5
 + Turbine generator load >0MW
+ Individual valve controller in operation
+ Plunger coil on
+ Electrical speed controller in operation
+ Electrical load controller in operation
+ Electrical speed reference value = rated speed + load component
+ Speed Changer = 100%
+ Starting and load limit device = 100%

(1) + Speed changer lower

+ Speed changer reference valve < electrical speed reference value

(2) + Electrical speed reference value raise

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

(3) + Plunger coil switch off

+ Plunger coil off
+ Load reference value higher or lower

(4) + Speed changer raise or lower

+ Hydraulic frequency control not required

(5) + Starting and load limit device lower

+ Starting and load limit device in effect

(6) + Speed changer raise

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

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

Control logic 3: Changeover from electrical to hydraulic speed control during speed controlled Power operation
(procedure (5) onwards: Switching off hydraulic frequency influence)

5.2-0220-00/6
 + Turbine generator load > OMW
+ Plunger coil off
+ Electrical speed controller not in operation
+ Electrical load controller not in operation
+ Electrical speed reference value = max. speed
+ Speed changer = 100%
+ Starting and load limit device = in effect

(1) + Speed changer lower

+ Speed changer in effect

(2) + Starting and load limit device raise

+ starting and load limit device = 100%

(3) + Plunger coil switch on

+ Plunger coil on

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

(5) + Speed changer raise

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

(6) + Electrical speed reference value raise or lower

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

5.2-0220-00/7
 + Turbine generator load > a MW
+ Plunger coil on
+ Electrical speed controller in operation
+ Pressure component on
+ Pressure controller in operation
+ Electrical load reference value = actual # pressure component
+ Electrical speed reference value = approx 1.005 x rated speed
+ Speed changer = 100%
+ Starting and load limit device = 100%

(1) + Electrical initial pressure controller switch off

+ Initial pressure controller off
+ Limit initial pressure controller on

(2) + Initial pressure component switch off

+ Initial pressure component off

(3) + Speed changer lower

+ Speed changer reference valve < electrical load reference value

(4) + Electrical speed and load reference values raise

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

(5) + Plunger coil switch off

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

(6) + Speed changer raise or lower

+ Hydraulic frequency control off

(7) + Starting and load limit device lower

+ Starting and load device in effect

(8) + Speed changer raise

+ Speed changer = 100%
+ Turbine generator load reference value higher or lower

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

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

5.2-0220-00/8
 + Turbine generator load > 0 MW
+ Plunger coil A off
+ Electrical load controller not in operation
+ Electrical load reference value = max. load
+ Electrical speed reference value = max. speed
+ Speed Changer = 100%
+ Starting and load limit device in effect

(1) + Speed changer lower

+ Speed changer in effect

(2) + Starting and load limit device raise

+ Starting and load limit device = 100%

(3) + Plunger coil switch on

+ Plunger coil on

(4) + Electrical load controller switch on

+ Electrical load controller on

(5) + Electrical reference value lower

+ Electrical reference value = approx. 1.005 x rated speed

(6) + Electrical load reference value lower

+ Electrical load reference value < speed setter reference value

(7) + Speed changer raise

+ Speed changer = 100%
+ Load higher or lower

(8) + Electrical load reference value raise or lower

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

(9) + Initial pressure component switch on

(10) + Initial pressure controller control balance

+ deviation
+ Initial pressure controller control balanced
deviation

(11) + Initial pressure controller switch on

+ Initial pressure controller on
+ Load higher or lower

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

Control logics 6: Changeover from hydraulic to electrical load control in power operation
Procedure (1) + (2) Switch off hydraulic frequency cornball
Procedure (9) + (10) Switching on pressure condoner

5.2-0220-00/9
 Steam Turbine Actions to Prevent Unallowable Heat up
Operation Through Blade Wind age
Procedural Instruction
Introduction
During startup and shut-downs, there can be iong Owing to the proportional relationship between steam
period during which Steam turbines are operated at very density and steam pressure, the steam pressures in
low volumetic flows. This operating mode can result in
blade windage in individual stages of multi-stage expansion sections undergoing windage can be used to
turbines. determine the degree of heatup due to windage.
The direction of the energy conversion cycle at the
affected blade stages is reversed. The mechanical General actions to prevent unallowable heatup of the
energy transmitted by the turbine shaft is converted to steam turbine due to windage
thermal energy, which in turn result in an increase in the
temperature of both the steam and the turbine
Limitation of the period of ‘motoring’ operation Blade
components. windage can occur in expansion sections of a steam
Unallowably high temperatures can occur as a result turbine if volumetric flow drops to zero, resulting in
of blade windage, leading to loosening of the blade the turbine being driven by the generator which acts
assembly of drum stages through plastic deformation. as a motor driven by the public power system.
Turbine casings can undergo deformation due to the - Activation of short-time reverse power protection
effects of high temperatures. following turbine trips
During steam turbine operation, the operating mode After turbine trip, which can be initiated during any
and limiters and protective devices must be used to keep operating mode of the turbine generator unit. the
heatup due to blade windage within the prescribed Imits. generator must be isolated from the public power
system after no more than four seconds through
Thermodynamic and operating factors affecting activation of the short-time reverse power
blade windage protection.
The following factors can lead to blade windage: in order to prevent motoring of the generator at

Volumetric flow Blade windage can occur as a result high speed beyond this time period owing to the
of insufficient volumetric flow through a multistage interruption in volumetric flow and high steam
expansion section of the steam turbine. pressure in one expansion section.
The lower the volumetric flow through a blade stage, Activation of long-time reverse power protection
the lower the turbine efficiency will be in the case of during a (schedule) turbine generator shut-down,
very low volumetric flows, steam flow through the the control valves of the turbine generator unit are
stage is not directed and the steam has to be closed, to allow the generator to be isolated from
accelerated up to the average speed of the rotating the public power system through activation of the
blades, which creates a deceleration effect. long-time reverse power protection.
As the volumetric flow decreases, and the turbine The maximum time delay for activation of the
starts to operates at zero load, blade windage result long-time reverse power protection specified in the
in transition from power transfer from the blades to Technical Data must not be exceeded. The long-
power transfer to the blades. time reverse power protection must be functionally
Blade windage starts in the final blade stages of an tested in conjunction with leak testing of the
expansion section, and extends towards the first control valves each time the turbine generator unit
stages as flow decreases. is shut down.

Steam density, steam pressure and turbine generator
Turbine trip after limit values have been reached
speed. Blade windage causes temperature increases at
The degree of windage-induced heatup Which occurs certain exhaust-steam or casing -temperature
as a result of low volumetric flow through an measuring points. The limit values of the
expansion section of the steam turbine depends on temperature at which turbine trip is to be initiated are
the windage power. specified in the Technical Data. if, under particularly
The higher the steam density and the turbine speed unfavorable conditions, these temperatures are
to the third power, the greater will be windage power, reached, turbine trip must be initiated, either
and therefore the heatup, in one blade stage. manually from the control room, or automatically by
tripping of a protective device.

BHEL Hardwar 5.2-0230-00/1

Blade windage in the HP expansion section of a The limit conditions for reheat steam pressure can be
steam turbine with reheat established on the basis of setpoint values for the
At low volumetric flows, blade windage can main steam and IP/LP bypass controllers.
occur towards the exhaust end of the HP expansion
Draining the HP turbine by opening the drain valves
section if the steam pressure in or downstream other HP in the case of low volumetric flow combined with high
turbine section is high. reheat steam pressure, the HP turbine must be
Blade windage can occur during the following modes drained by opening the valves in the drain lines
of operation: located downstream of the HP control valves, at the

No-load or low-load operation during startup of the turbine outer casing and upstream of the non return
tubine generator unit. valve(s) downstream of the HP turbine.

No-load or a auxiliary-power operation following load These drain valves are actuated on the basis of a
rejection. load signal (p<approx. 5%) or the opening signal of
The risk of unallowable heatup due to windage ,is the HP turbine dump valve, which can be installed as
particuarly high following load rejection, since this an additional limiter.
may coincide with a high reheat steam pressure, If necessary, the drains sub loop control must be
meaning that turbine generator speed temporarily switched immediately the MANUAL mode and the
exceeds rated speed. drain valves must be opened using a remote manual

Motoring operation prior to activation of the long- time command.
reverse power protection during shut-down of the
Back fitting an HP turbine dump valve
turbine generator unit If under unfavorable conditions the cross sections of

At overspeed during overspeed trip testing the drains compared to the volume of the space
constituted by the HP turbine and the HP
Actions to be taken to prevent unallowable heatup of exhaust steam lines up to the non return valve (s) is
the HP turbine due to windage not a large enough to ensure sufficiently fast

Optimization of the volumetric flow through the HP drainage, the plant operator can arrange with the
turbine by staggered operation of the main steam and turbine supplier for an HP turbine a dump valve to be
reheat control valves. beck fitted (e.g. to reduce the time required for

By Specifying a staggered control valve operating pressure reduction).
sequence in which the main steam control valve open
Actions to be taken in the event of fault-induced
before the reheat control valves, the volumetric flow closure of the main steam stop and/or control valves
through the HP turbine during no-load or low-load One particular fault which can arise occur during
operation is optimized so that unallowable heatup power operation when the volumetric flow through the
due to windage can only occur under the most HP turbine approaches zero as a result of fault-
unfavorable conditions e.g. if the pressure induced closure of the main steam stop and/or control
downstream of the HP section is too high. valves, but the turbine generator unit continues to

Optimization of the volumetric flow through the HP operate because the reheat control valves are still
turbine by means of trimming device open. In the event of such a fault, further operation of
During turbine operation at low volumetric flow, the the turbine generator unit is not allowed, and must be
trimming device adjusts the staggered operating stopped through remote manual initiation of a turbine
sequence of the main steam and reheat control trip.
valves on the basis of HP turbine exhaust steam The occurrence of this type of fault is indicated by a
temperature, thus ensuring that the largest possible load surge, opening of the HP bypass station and an
volume of steam flows through the HP turbine. increase in the HP exhaust steam temperature.

Proper observance of limit conditions for reheat
Actions to be taken in the event of backflow of steam
steam pressure through the check valve(s) downstream of the HP
The steam pressure ration PMS / PRS as a function of turbine. Blade windage can occure as a result of non-
power ratio must not drop below that specified in leak tightness or faulted operation of the check valve
Data Sheet. (s) down stream of the HP turbine if pressure in the
If the turbine generator unit at a volumetric flow reheated is high.
approaching zero e,g. during turbine generator shut- Non-leak tightness or faulted ‘operation’of1he check
down prior to activation of the long-time reverse valve(s) occurs if the steam pressure down steam of
power protection or during operation at overspeed for the HP turbine cannot be reduced to less than the
overspeed trip testing, the maximum reheat steam reheat steam pressure down steam of the check
pressure PRS MAN specified in Data Sheet [1] must not valve (s) must be subjected to regular checks for
be exceeded. freedom of movement and leak tigtness, in order to

5.2-0230-00/2
prevent adverse effects in terms of blade windage. After the alarm “LP casing temperature high” has been

Actions to the taken in the event of a high steam initiated the spray valve of the LP condensate injection
temperature downstream of the HP turbine system must be opened, either automatically or
If blade windage occurs in the HP turbine, there will manually, in order to prevent unallowable heatup due to
be an increase in steam temperature at1he windage.
measuring point down steam of the HP turbine.
The limit value of maximum allowable exhaust steam Settings and Tests
temperature specified In the Technical Data must not
Settings of the staggered operating sequences for
be exceeded. main steam & reheat steam control valves in
After the alarm “HP exhaust temperature high” has accordance with the relevant setting diagram.
been issued the following actions must be
Settings of the settings for the staggered operation
implemented immediately to prevent unallowable of main steam & reheat steam control valves
heatup due to windage: following inspections and overhauls.

The control valve opening signals and lifts are

- establish a steam pressure ratio P MJP AS which recorded as a function of a common opening signal
lies above the characteristic curve specified in and the staggered operating sequence is checked
Data Sheet (1) on the basis of the curve generated.
- reduce steam pressure in the HP turbine by
lowering the constant-pressure setpoint for the IP/
Functional testing of trimming device for main steam
LP bypass control system and rehat control valves after inspections and
- reduce the main steam temperature overhauls on the basis of the C&I functional
- if the generator is connected to the public power diagrams.
system, increase the turbine load
On-line testing for freedom of movement of check
valve (s) downstream of HP turbine at six-weekly
Blade windage in IP turbines intervals during turbine – generator unit operation.

Causes Interruption of the control medium supply result in a
In the case of IP turbines, blade windage (which can closure command being issued. The check valve (s)
result in unallowable heatup of the blading) has a should leave the fully opened position.
number of causes, including excessively low.
Leak testing of the check valve (s) downstream of
volumetric flow across the balding. the HP turbine during each shut down of the turbine

Actions generator unit.
In the case of annunciation “IP exhaust steam
temperature high” is issued, or if the limit value for the The leak tightness of the check valve (s)
temperature downstream of the IP turbine specified downstream of the HP turbine must be checked
for prolonged operation (see Technical Data Sheet) is each time the turbine generator unit is shut down.
exceeded, the load must be increased. The check valve (s) must close during shut down
and, if the main steam stop valves are closed,
Blade windage in LP turbine reclosure of the turbine drains must not result in an
increase in HP turbine steam pressure while there is
In case of the LP turbine, blade windage (which can still positive steam pressure in the reheater.
result in unallowable heatup of the blading and the
Testing of a activation of long time reverse power
casing) is likewise caused by excessively low protection in conjunction with leak testing of turbine
volumetric flow across the blading. control valves during each shut down of the turbine
generator unit.

Actions to be taken to prevent unallowable heatup The turbine controller is used to reduce the steam
of LP turbine due to windage turbine load so far that the turbine control valve
close and the generator then acts as motor, driving
the turbine. This reverse power operation causes the
The following actions can be implemented to prevent reverse power protection to be activated, which
the unallowable heatup due to windage: isolates the generator from the public power system

Increase the turbine load. after a certain time delay has elapsed.

Cooling by means of condensate injection.

5.2-0230-00/3

Testing of activation of short time reverse power
protection during each shut down of the turbine Isolation of the generator from the public power
generator unit. system after 4 seconds must be monitored and
recorded.

Testing and maintenance of protective device in the
event that a fault has resulted in a stricter
changeover in the protection circuit (annunciation:
“protective device faulted”).

5.2-0230-00/4
 Steam Turbine Startup and Shutdown Diagrams
Operation Introduction

The turbine-generator should be shutdown We recommend accelerated cooling to reduce cool

according to operating instruction shown in the down time when shutting down the turbine-generator
shutdown diagrams. unit for preventive maintenance or repairs.
If an emergency occurs, the turbine generator unit Short shutdowns should be used to perform minor
may be rapidly unloaded and/or be shutdown by maintenance unless large-scale preventive
operating the trip push-button or trip valve from any maintenance programs or repairs are to be performed.
operating condition. It is a good idea to have a list ready of those jobs that
During shutdown, all tests [1] for this must be can be done during short shutdowns.
performed. In particular test the overspeed protection Operational readiness should be maintained during
by overspeeding after the recommended interval has maintenance and testing programs and/or should be
elapsed. This test may be performed when the turbine established after their completion to enable speedy
is at operating temperature, particular attention is restart of the turbine-generator unit.
drawn to this test in this context. During long periods of shutdown the turbine and
If work has to be performed immediately after other components may be exposed to corrosive
shutdown of the turbine on hot parts or if the turning attacks. So care must be taken to ensure all
gear is to be shutdown, instruction for accelerated components are protected against corrosion as
cooling [2] must be followed. described in the specific instructions.

BHEL Hardwar 5.2-0300-00

 Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram (General)

(01) + TURBINE/GENERATOR UNLOAD REF. TO 5.2-0320

OR
+ FGA (TURBINE -CONTROL STANDSTILL) START

(02) + START OF BYPASS OPERATION OBSERVE REF. TO 5.2-0320

(03) + GENERATOR BREAKER TO BE OPENED OBSERVE REF. TO 5.2-0320

REVERSE POWER PROTECTION INITIATED

(04) + TEST PROGRAM (SHUTDOWN) CARRY OUT REF. TO 5.3.0060

(05) + TURBINE TRIP INITIATE REF. TO 5.2-0320

OR WITH FGA (TURBINE-CONTROL)
*+ TURBINE TRIP INITIATED REF. TO 5.2-0320

(06) + START OF AUXILIARY OIL PUMP OBSERVE REF. TO 5.2-0320

(07) + TURNING GEAR OPERATION START REF. TO 5.2-0320

+ SHAFT LIFT OIL SUPPLY SYSTEM IN OPERATION
+ TURNING GEAR OIL SYSTEM IN OPERATION
OR WITH SUBLOOP CONTROL
*+ SHAFT LIFT OIL PUMP ON
*+ TURNING GEAR OIL VALVE OPEN

(08) + STEAM -GENERATOR NOT IN SERVICE

+ BYPASS -OPERATION COMPLETED
+ CONDENSING PLANT SHUT DOWN REF. TO 5.2-0330
+ VACUUM PUMPS OFF
+ SEAL -STEAM SUPPLY SHUT -DOWN
+ CONDENSATE PUMPS OFF
+ CIRCULATION WATER SUPPLY NOT IN SERVICE
OBSERVE

(09) + CONTROL FLUID PUMPS SHUT -DOWN REF. TO 5.2-0320

(10) + OIL SYSTEM WITH FGA (OIL SUPPLY) SHUT -DOWN REF. TO 5.2-0340
OR
MANUAL OPERATION AT OPER. CONSOLE
+ SHAFT STANDSTILL
+ OIL SYSTEM NOT IN SERVICE

BHEL Hardwar 5.2-0310-01

 Steam Turbine Unloading and Shut-Down of
Operation Turbine/Generator
Shut-Down Diagram

(01) + OPERATIONAL CONDITIONS CHECK

+ LOAD CONTROLLER ON
+ LOAD GRADIENT ADJUSTED
ADJUSTMENT ACCORDING TO
- REQUIREMENT OF LOAD DESPATCHER
- STEAM GENERATOR CONTROL
- THERMAL INFLUENCE ON TURBINE
+ BYPASS CONTROL ON
+ FIXED PRESSURE SET POINT BYPASS CONTROL ...KG/CM2
ADJUSTMENT IN AGREEMENT WITH
PRESSURE REQUIREMENTS -
- REHEAT PRESSURE DURING START-UP
AND SHUTDOWN
+ ELECTRO HYDRAULIC TURBINE CONTROL NOT FAULTED
+ BYPASS CONTROL NOT FAULTED
+ TSC -INFLUENCE ON
+ TURBINE STRESS CONTROLLER (TSC) NOT FAULTED
IF THE TSC IS FAULTED THE DIFFERENTIAL
TEMPERATURES AT THE MEASURING POINTS WHICH
REPRESENT THE ADDITIONAL THERMAL STRESSES
OF CASING AND ROTOR MUST BE EVALUATED.
REFER 5.2-0430 IF TSC ALLOWANCE IS REDUCED
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
+ SUBLOOP CONTROL TURNING GEAR OIL VALVE ON
+ SUBLOOP CONTROL DRAINS ON
THE SUBLOOP CONTROLS MUST ALWAYS BE
SWITCHED ON DURING OPERATION
+ TURBINE/GENERATOR LOAD > 0 MW
IT IS ASSUMED THAT THE TURBINE/GENERATOR
WILL BE UNLOADED FROM ANY LOAD TO 0 LOAD
WITHOUT DELAY

(02) + LOAD REFERENCE VALUE LOWER

+ LOAD TARGET VALUE 0 MW
OR WITH FGA (TURBINE -CONTROL)
+ FGA (TURBINE -CONTROL STANDSTILL) START

(02/S) * + LOAD TARGET VALUE 0 MW

(03) + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
THE LIMITED LOAD REFERENCE VALUE FOLLOWS
THE TARGET LOAD REFERENCE VALUE WITH THE
ADJUSTED LOAD GRADIENT. THE LOAD GRADIENT
WILL BE REDUCED IF REDUCTION OF TSC
ALLOWANCE OCCUR. THE TSC INFLUENCE WILL
BE EFFECTIVE VIA THE REFERENCE LIMITER.

+ TURBINE/GENERATOR LOAD: STEAM GENERATOR LOAD <1

(04) * + START OF BYPASS OPERATION OBSERVE
BYPASS VALVES OPEN IF LOAD OF STEAM
GENERATOR IS GREATER THAN
TURBINE/GENERATOR LOAD
*+ BYPASS STOP VALVES OPEN MAN41 AAO01
AND MAN51 AAO01
*+ BYPASS CONTROL VALVES OPEN MAN42 AAOO2
AND MAN 52 AAOO2

BHEL Hardwar 5.2-0320-02/1

 (05) + WAIT
*+ LIMITED LOAD REFERENCE VALUE LOWER
+ AUXILIARY POWER SUPPLY SECURED
CRITERION:
AFTER THE GENERATOR CIRCUIT BREAKER IS OPEN
THE UNIT AUX. POWER SUPPLY IS SECURED
OPERATION OF SWITCH GEARS MUST AGREE
WITH AUXILIARY POWER SUPPLY FACILITIES
*+ TURBINE LOAD CONTROLLER OFF
*+ TURBINE SPEED CONTROLLER ON
AFTER A FIX SET MINIMUM LOAD IS REACHED
THE TURBINE CONTROLLER CHANGES OVER FROM
LOAD TO SPEED CONTROL

(06) + SPEED REFERENCE VALUE LOWER

OR WITH FGA (TURBINE -CONTROL)
(06/S) *+ SPEED REFERENCE VALUE LOWER
+ SPEED REFERENCE VALUE < RATED SPEED
*+ MAIN STEAM CONTROL VALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 10 AAOO2
AND MAB20 AAO02
*+ REVERSE POWER PROTECTION INITIATED
*+ GENERATOR CIRCUIT BREAKER OPEN
MEASURES TO BE TAKEN ON FAILURE.
OF REVERSE POWER PROTECTION REF. TO 5.2-0410

(07) + TEST PROGRAM (SHUT DOWN I CARRY OUT REF, TO 5.3-0060

TESTING INTERVALS OBSERVE REF. TO 5.2-0020
FGA PROGRAM INTERRUPT

(08) + TURBINE TRIP INITIATE

OR WITH FGA
(08/S) *+ TURBINE TRIP INITIATED
+ BEGIN OF COASTING DOWN TIME NOTE
*+ TRIP FLUID PRESSURE 0 KG/CM2 MAX51 CPO 13
*+ MAIN STEAM STOP VALVES CLOSED MAA10 AAO01
AND MAA20 AAO01
*+ REHEAT STOP VALVES CLOSED MAB10 AAOO1
AND MAB20 AAO01
*+ MAIN STEAM CONTROL V ALVES CLOSED MAA 10 AAO02
AND MAA20 AAO02
*+ REHEAT CONTROL VALVES CLOSED MAB 1 0 AAO02
AND MAB20 AAO02
*+ SWING CHECK VALVE COLD REHEAT CLOSED LBC10 AAO01
*+ EXTRACTION NON RETURN VALVES CLOSED
CODE NO. OF EXTRACTION NON RETURN VALVES
REFER TO SINGLE LINE DIAGRAMS
*+ VACUUM BREAKER OPEN MAG10 AAO01
VACUUM BREAKER BRINGS VACUUM DOWN TO O.2KG/CM2 ABS
VACUUM BREAKER CLOSED AT VACUUM > 0.2 KG/CM2 ABS
IN CASE OF DANGER TO THE TURBINE/GENERATOR
THE VACUUM CAN BE REDUCED SO THAT COAST P AMB
DOWN TIME WILL BE REDUCED ACCORDINGLY.
*+ SPEED OF TURBINE/GENERATOR < 3000 RPM

(09) + STARTING AND LOAD LIMIT DEVICE LOWER MAX47BYO01

+ STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01
OR WITH FGA (TURBINE -CONTROL)
(09/s) + STARTING AND LOAD LIMIT DEVICE 0% MAX47BYO01

5.2-0320-02/2
(10) + DE-EXCITATION BREAKER OPEN
+ DE-EXCIT A TION BREAKER OPEN

(11) + VACUUM BREAKER CHECK

+ VACUUM > 0.2 KG/CM2 ABS
+ VACUUM BREAKER CLOSED

(12) + SPEED REFERENCE VALUE LOWER

+ SPEED REFERENCE VALUE 0%

(13) + WARM-UP CONTROL (SEAL STEAM) SWITCH CONTROL

+ WARM-UP CONTROL (SEAL STEAM) OFF

(14) + DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPEN MAL11 AA011
OR WITH FGA AND MAL12 AAO 11
+ DRAIN UPSTREAM OF MAIN STEAM CONTROL VALVES OPEN MAL 11 AA011
AND MAL12 AA011

(15) + START OF AUXILIARY OIL PUMP OBSERVE MAV22 APO01

OR
+ START OF EMERGENCY OIL PUMP OBSERVE MAV24 APO01
+ OIL PRESSURE < 4.8 KG/CM2 MAV21 CPO01
+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV22 APO01
OR
+ OIL PRESSURE < 4.5 KG/CM2 MAV21 CPO01
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
*+ AUX. OIL PUMP BY SUBLOOP CONTROL ON MAV23 APO01
OR
+ LUBE OIL PRESSURE < 1.2 KG/CM2 MA V42 CPO 14
AND
+ AUXILIARY OIL PUMP NOT ON MAV22 APO01
AND MAV23 APO01
*+ EMERGENCY OIL PUMP BY SUBLOOP CONTROL ON MAV24 APO01
+ OIL TEMPERATURE CONTROL VALVE CLOSE MAV41 AAO01
+ OIL TEMPERATURE CONTROL VALVE CLOSED MAV41 AAO01

+ SPEED OF TURBINE/GENERATOR < 510 RPM

(16) + JACKING OIL PUMP SWITCH ON MAV31 AP001

+ JACKING OIL PUMP ON MAV31 AP001

OR BY SURLOOP CONTROL JACKING OIL PUMP

*+ JACKING OIL PUMP ON MAV31 AP001

+ JACKING OIL PRESSURE IN HEADER > 100 KG/CM2 MAV35 CP012

OR
JACKING OIL PRESSURE IN HEADER < 100 KG/CM2 MAV35 CP012
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON
OR
*+ STAND BY JACKING OIL PUMP BY SUBLOOP CONTROL ON MAV33 AP001
ON FAILURE OF AC POWER
+ END OF COASTING DOWN TIME NOTE
THE MEASUREMENT OF COASTING DOWN TIME
WILL GIVE VALUABLE INFORMATION ABOUT
INTERNAL CONDITIONS OF THE TURBINE, ESPECIALLY
WHEN SHUTDOWN OCCURS DUE TO DANGER

5.2-0320-02/3
 + SPEED OF TURBINE/GENERATOR < 210 RPM
(17) + TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
+ TURNING GEAR OIL VALVE OPEN MAV51 AAOO1
OR BY SUBLOOP CONTROL TURNING GEAR
*+ TURNING GEAR OIL VALVE OPEN MAV51 AAO01

(18) + DRAIN VALVES OPEN

+ DRAIN HP OUTER CASING OPEN MAL22 AA011
CRITERION:
TEMPERATURE HP OUTER CASING MIDDLE TOP < 300 °C
OR TURBINE LOAD <2%
+ DRAIN AHEAD OF CRH SWING CHECK VALVE OPEN MAL65 AA011
CRITERION: CRH NRV CLOSED
+ DRAIN UPSTREAM OF EXTRACTION VALVES OPEN
DESIGNATION OF DRAIN VALVES ACCORDING
TO SINGLE LINE DIAGRAM.
CRITERION: EXTRACTION CHECK VALVES CLOSED
+ DRAIN SEAL STEAM HEADER OPEN MAL81 AA011
CRITERION: TEMPERATURE IN SEAL STEAM HEADER < 120 °C
OR WITH SUBLOOP CONTROL
+ SUBLOOP CONTROL OF DRAINS NOT FAULTED
*+ DRAIN VALVES BY SUBLOOP CONTROL OPEN
CRJTERION : REFER TO MANUAL OPERATION

(19) + MODE OF OPERATION STEAM GENERATOR CHECK

AND
+ MODE OF OPERATION BYPASS CONTROLS CHECK
AND
+ MODE OF OPERATION CONDENSING PLANT CHECK
+ STEAM GENERATOR NOT IN SERVICE
+ BYPASS OPERATION COMPLETED
CRITERION:
BYPASS STOP VALVES CLOSED
BYPASS CONTROL VALVES CLOSED
THE BYPASS OPERATION IS COMPLETED IF THE
REHEATER OF THE STEAM GENERATOR IS
DEPRESSURIZED. THE REHEATER WILL BE
DEPRESSURIZED BY LEADING THE STEAM INTO
THE CONDENSER OR BY OPENING THE EXTERNAL
REHEATER DRAIN VALVES. THE BYPASS VALVE
WILL BE USED TO LEAD THE STEAM TO THE
CONDENSER. THE FIXED PRESSURE SET POINT
HAS TO BE LOWERED.
+ CONDENSING PLANT NOT IN SERVICE REF. TO 5.2-0330
VACUUM PUMPS OFF
CONDENSATE PUMP OFF
NOTE
IF THE CONTROL FLUID SYSTEM WILL BE SHUT
DOWN WITHOUT SHUTTING DOWN THE
CONDENSATE PUMP THE BYPASS SPRAY
WATER VALVES WILL OPEN. ON REF. TO 5.2-0330
OR OFF
+ SEAL STEAM PRESSURE P AMB
SEAL STEAM CONTROLLER OFF
SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
FAN OF SEAL STEAM CONDENSER OFF MAW80 ANOO1
AND MA W80 ANOO2

5.2-0320-02/4
 + TEST PROGRAM (STANDSTILL) COMPLETED
+ CONTROL FLUID SUPPLIED DEVICES NOT IN SERVICE
(20) + CONTROL FLUID SYSTEM MANUAL OPERATION SHUTDOWN
OR WITH FGA (CONTROL FLUID SYSTEM)
+ FGA (CONTROL FLUID SYSTEM STANDSTILD START
OPERATION OF PUSH BUTTONS
REFER TO THE MANUAL FOR FGA.

(21) + SUBLOOP CONTROL HP .CONTROL FLUID PUMP SWITCH OFF

+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
+ HP -CONTROL FLUID PUMP OFF MAX16 AP001
OR MAX16 AP002
OR WITH FGA (CONTROL FLUID SYSTEM)
(21/S) *+ SUBLOOP CONTROL HP -CONTROL FLUID PUMP OFF
(21/S) *+ HP -CONTROL FLUID PUMP OFF MAX 16 AP001
AND MAX 16 AP002

NEUTRALIZATION NO. NORMAL

NEUTRALIZATION NO. DOES NOT
TEND TO INCREASE
(22) + CF -RECONDITIONING PUMP SWITCH OFF MAX91 APOO1
+ CF -RECONDITIONING PUMP OFF MAX 91 APOO1
OR WITH FGA (CONTROL FLUID SYSTEM)

(22/S) *+ CF -RECONDITIONING PUMP OFF MAX91 APOO1

+ TEMPERATURE IN CONTROL FLUID TANK < 50 °C MAX11 CTO01

(23) + SUBLOOP CONTROL OF CONTROL FLUID HEATER SWITCH OFF
FLUID HEATER
SWITCH OFF SUBLOOP CONTROL OF CONTROL
FLUID HEA TEA ONLY IF THE CONTROL FLUID SYSTEM
MUST NOT BE OPERATED FOR AN EXTENDED PERIOD ~
OF TIME AND/OR THERE IS SUFFICIENT TIME TO C
HEAT-UP THE CONTROL FLUID IN THE TANK PRIOR
TO RESTART.

5.2-0320-02/5
 Steam Turbine Condensing Plant
Operation Shutdown Diagram

(1) CRITERIA FOR SHUT DOWN CHECK

+ STEAM GENERATOR NOT IN SERVICE
+ BY PASS OPERATION COMPLETED
+ HP BYPASS VALVES CLOSED
+ EXTERNAL DRAINS OF STEAM LINES OPEN
BEFORE THE CONDENSING PLANT Will BE SHUT
DOWN ALL. ADMISSION STEAM SYSTEM HAVE
TO BE DEPRESSURIZED.

(2) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOLLOWING CRITERIA ARE FILLED
THE SYSTEM Will BE SHUT DOWN FROM OPERATION
+ AIR SUCTION VALVE OF VACUUM PUMPS OPEN
+ SERVICE VACUUM PUMP ON
+ VACUUM BREAKER CLOSED
+ SEAL STEAM CONTROL ON
AND
+ SEAL STEAM SUPPLY VALVE OPEN
+ SEAL STEAM EXHAUST FAN ON MAW11 AAO01
MAW80 ANO01
ORMAW80 AN02
+ CONDENSATE SYSTEM IN OPERATION
+ CIRCULATING WATER OF CONDENSER AVALABLE
+ VACUUM BREAKER OPEN
+ WARM-UP CONTROL (SEAL STEAM) ON

(3) + CONSENSING PLANT MANUAL OPERATION SHUT DOWN

OR WITH FGA (CONDENSING PLANT)
+ FGA (CONDENSING PLANT STANDSTILL) START
FOR OPERATION OF PUSH BUTTONS REFER TO
MANUAL FOR THE FGA

(4) + AIR SUCTION VALVE VACUUM PUMP CLOSE

+ AIR SUCTION VALVE VACUUM PUMP CLOSED

(5) + VACUUM PUMPS SWITCH OFF

+ VACUUM PUMPS OFF
THE VACUUM PUMPS DO NOT BELONG TO THE
SCOPE OF SUPPLY OF THE TURBINE/GENERATOR
OPERATION OF VACUUM PUMPS AND VALVES
ACCORDING TO SPECIAL INSTRUCTION.

(6) + VACUUM BREAKER OPEN MAG10 AAO01

+ VACUUM BREAKER OPEN MAG10 AAO01
OR WITH FGA, SUBGROUPS (SEAL STEAM SUPPLY
STANDSTILL)

(06/S) *+ VACUUM BREAKER OPEN MAG10 AAO01

BHEL Hardwar 5.2-0330-01/1

 + VACUUM > 0.8KG/CM2
+ SEAL STEAM CONTROL SWITCH OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSE MAW11AAO01
+ SEAL STEAM CONTROL OFF
AND
+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(07/S) *+ SEAL STEAM CONTROL OFF
AND
(07/S) *+ SEAL STEAM SUPPLY VALVE CLOSED MAW11 AAO01

(08) + SEAL STEAM EXHAUST FAN SWITCH OFF MAW80 ANO01

ORMAW80 AN02
+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2
OR WITH FGA, SUBGROUP (SEAL STEAM SUPPLY
STANDSTILL)
(08/S) *+ SEAL STEAM EXHAUST FAN OFF MAW80 ANO01
AND MAW80 ANOO2

(9) + CONDENSATE SYSTEM SHUT DOWN

+ CONDENSTATE SYSTEM NOT IN SERVICE
THE CONDENSATE SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE-
GENERATOR). SPECIAL INSTRUCTIONS FOR
-CONDENSATE PUMPS
-CONDENSER LEVEL CONTROL
-MINIMUM FLOW CONTROL
-HEATERS
MUST AGREE WITH TURBINE OPERATION AND
HAVE TO BE FOLLOWED.
THE CONDENSATE SYSTEM CAN ALSO BE
SHUT DOWN AFTER STEP (12) IS CARRIED OUT.

(10) + CIRCULATING WATER SYSTEM SHUT DOWN

+ CIRCULATING WATER SYSTEM NOT IN SERVICE
CIRCULATING WATER SYSTEM DOES NOT
BELONG TO THE SCOPE OF SUPPLY (TURBINE
GENERATOR).
THE CIRCULATING WATER SYSTEM SHOULD STAY
IN OPERATION DURING SHORT DOWNS TO
AVOID CORROSION OF THE CONDENSER TUBES,
THE CIRCULATING WATER’SYSTEM CAN£E SHUT
DOWN AFTER STEP (12) IS CARRIED OUT.

(11) + VACUUM BREAKER CLOSE MAG10 AAOO1

+ VACUUM BREAKER CLOSED MAG10 AAO01
OR WITH FGA (SEAL STEAM SUPPLY STANDSTILL)
(11/S) *+ VACUUM BREAKER CLOSED MAG10 AAO01

(12) + WARM-UP CONTROL (SEAL STEAM) SWITCH OFF

+ WARM-UP CONTROL (SEAL STEAM) OFF
OR WITH FGA (SEAL STEAM)
(12/S) +* WARM-UP CONTROL (SEAL STEAM) OFF

5.2-0330-01/2
 Steam Turbine Oil System
Operation Shutdown Diagram

(01) + CRITERIA FOR STANDSTILL CHECK

+ CASING TEMPERATURE < 100 °C MAA50 CT053A
BEFORE THE TURBINE GEAR IS STOPPED, SHAFTS AND MAA50 CT054A
AND CASING MUST COQL DOWN TO 100 °C TO
PREVENT SHAFT DISTORTION DURING STANDSTILL
PERIOD FOLLOWING TURNING GEAR OPERATION.
THE TURNING GEAR MUST BE STOPPED IF ABOVE
TEMPERATURES ARE REACHED, EXCEPT IN CASES
WHERE EXTENDED TURNING GEAR OPERATION IS
REQUIRED e.g. IF THE TURBINE IS TO BE STARTED
IN SHORT TIME.

(02) + CRITERIA FOR BEGIN OF SHUT DOWN CHECK

IF THE FOLLOWING CRITERIA ARE FULFILLED
THE SYSTEM WILL BE SHUT DOWN FROM
TURNING GEAR OPERATION.
+ SUBLOOP CONTROL TURNING GEAR ON
AND
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS ON
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS ON
AND
+ AVXILIARY OIL PUMP ON MAV22 APOOl
OR MAV23 APOOl
+ WAITING TIME FOR COOLING DOWN (K4) EXPIRED
+ SUBLOOP CONTROL OF JACKING OIL PUMPS ON
AND
+ JACKING OIL PUMP ON MAV31 APOOl
OR MAV32 APO01

(03) + FGA (OIL SUPPLY STANDSTILL)

FOR OPERATION OF PUSH BUTTONS REFER
TO MANUAL FOR FGA.
OR
+ TURNING GEAR MANUALLY OPERATED SHUTDOWN

(04) + SUBLOOP CONTROL TURNING GEAR SWITCH OFF

AND
+ TURNING GEAR OIL VALVE CLOSE MAV51 AAO01
+ SUBLOOP CONTROL TURNING GEAR OFF
AND
+ TURNING GEAR OIL VALVE CLOSED MAV51 AAOO1
OR WITH FGA (OIL SUPPLY)
(04/S) *+ SUBLOOP CONTROL TURNING GEAR OFF MAV51AA012

(05) + WAIT
THE WAITING TIME IS EXPIRED WHEN THE
SHAFT COMES TO A COMPLETE STOP.
+ SHAFT STAND STILL

BHEL Hardwar 5.2-0340-01/1

06) + SUBLOOP CONTROL OF AUXILIARY OIL PUMPS SWITCH OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS SWITCH OFF
AND
+ AUXILIARY OIL PUMP SWITCH OFF MAV22 APO01
OR MAV23 APOOl
+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
+ AUXILIARY OIL. PUMP OFF MAV22 APO01
AND MAV23 APO01
AND
+ EMERGENCY OIL PUMPS OFF MAV24 APO01
OR WITH FGA (OIL SUPPLY)
(06/S) *+ SUBLOOP CONTROL OF AUXILIARY OIL PUMPS OFF
AND
*+ SUBLOOP CONTROL OF EMERGENCY OIL PUMPS OFF
AND
*+ AUXILIARY OIL PUMP OFF MAV22 APOOl
AND MAV23 APO01
AND
*+ EMERCJENCY OIL PUMP OFF MAV24 APO01

(07) + WAIT
WAIT FOR SHUTDOWN OF JACKING OIL PUMP UNTIL
THE RELATIVE EXPANSIONS ARE REDUCED AND NO
FURTHER MAJOR AXIAL SHIFTING OF THE JOURNALS
IN THE BEARINGS IS EXPECTED.

(08) + SUBLOOP CONTROL OF JACKING OIL PUMP SWITCH OFF

AND
+ JACKING OIL PUMP SWITCH OFF MAV31 APOOl
OR MAV32 APO01
+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
+ JACKING OIL PUMP OFF MAV31 APO01
OR WITH FGA (OIL SUPPLY) AND MAV32 APO01
(08/S) *+ SUBLOOP CONTROL OF JACKING OIL PUMP OFF
AND
*+ JACKING OIL PUMP OFF MAV31 APO01
AND MAV32 APO01

5.2-0340-01/2
 Steam Turbine Fast Cooling Down of the Turbine
Operation

Introduction
If service activities or repairs have to be carried out
very soon or immediately after shut down of the Fast cooling down during stand still
turbine, it is advisable to reduce the cooling down time.
Fast cooling down is necessary especially if activities During stand still air will be sucked through the
are to be executed at turbine parts, which are exposed turbine by the vacuum pumps resulting in fast cooling
to high operational temperatures. of casing and rotor.

Cooling down of the turbine during operation Arrangement of the air Inlet sockets

The cooling down of the turbine is to be started
HP turbine: Between main steam stop valves and
during load operation as follows: control valves.

Reduce unit power output to the boiler minimum
IP turbine: At the admission pipes between control
load. valves and IP turbine,

Slowly reduce admission temperatures to values,
which can be maintained steady by boiler control. During normal operation the air inlet sockets are
closed by blank flanges.
The HP exhaust temperature may not be reduced to
the saturation point corresponding to the HP exhaust Procedure
pressure.

Open air inlet sockets

Observe the TSE/TSC lower margin.

Set test valve of all stop valves in the position stop
NOTE: Do not reduce load and temperature at valve closed.
the same time because of the danger to exceed the

Operate vacuum pumps
permissible relative expansion and the lower
margin of the TSE/TSC

Observe TSE/TSC lower margin and stop vacuum
pumps if limit values are exceeded.
Load or temperature reduction have to be stopped
or the rate of ‘change to be reduced depending upon
the limiting values of relative expansion and the lower
The fast cooling down of turbine has to be
margins of the TSE/TSC.
limited to those cases where this measure is

Operate the turbine with reduced load and steam unavoidable with respect to the availability of the
temperatures until the lower margin of TSE/TSC do turbine.
not change significantly any more.

Shutdown the turbine in accordance with the

respective instructions after cooling down during
bypass operation has been completed.

BHEL Hardwar 5.2-0350-01

 Steam Turbine Preventing Corrosion
Maintenance in Idle Turbines

Introduction  the condensation produced when the temperature

If a turbine stands idle for a long period it is liable to within the turbine falls below point ( this is the
corrosion attack which if not prevented by appropriate principal source of the water).
means, will cause deterioration of the components. Fig.1 shows the effect of relative humidity on rusting
loss (VA) for a sample of carbon steel.
During long idle periods when the turbine has The rusting loss increase sharply when the relative
cooled to the ambient temperatures, all components humidity is high therefore, to inhabit corrosion attack in
which come into contact with steam vapour, water or an idle turbine, the relative humidity of the enclosed air
damp air are liable to corrosion attack. should be maintain below 50% as far as possible.
FIg. 1 Enect of Relative Humidity on Hustling Loss
The Effect of Corrosion Vr

 Seizure of sliding components due to increased Preventing Corrosion During Idle Periods
volume of the products of corrosion,
If complete effectiveness of the following method of
 Heavier wear of corrosion-damaged surfaces,

 erosion of material reducing sections and producing

notch effects which weaken the components.

 Leaks at valve and fittings,

 fouling of the systems which spreads the corrosion

to other areas.

Factors Contributing to Corrosion

Chamically corrosive gases and vapours are

seldom encountered in normal power stations in
sufficiently high concentrations to cause damage.
However, if a turbine is installed in or near a chemical
plant it would be possible for such gases and vapours
to increase the amount of corrosion.

On the other hand, water-which is responsible for a

high proportion of all corrosion -is found in all turbines
which have cooled down and been idle for some time.

The water originates from: corrosion prevention is to be achieved, it is essential

for no steam at all to enter the turbine while it is idle.
 Residual water in inadequately drained spaces
Any auxiliary steam lines which will remain under
 steam leaking into the turbine and condensing steam pressure during a complete unit shut-down must
be isolated in a manner which ensures that no steam
can enter the turbine.

The turbine itself and its connecting pipe work must  The high relative humidity air inside the turbine can
be well drained through out the idle period. It is also be exchanged for dry air.
advisable to drain the condensate from the condenser.
There are basically two possible methods of For large turbines, therefore, a method of
preventing corrosion attack caused by condensation prevention is recommended employing an Air dryer to
from the air inside the turbine: exchange the high relative humidity air in the turbine
for dry air.
 The turbine components can be heated by means of
a hot air blower to a temperature above that of the
outside air.

BHEL Hardwar 5.2-0360-00/1

 Filtered air from the atmosphere is drawn into the Operation of the air -dryer must be executed in
Air dryer by a fan and moisture is removed from it In a accordance with the instructions of the dryer-
rotating drying wheel before it is delivered to the manufacturer.
turbine. The dying wheel which has absorbed the
moisture is dried by a reverse flow of hot air in the The air dryer does not belong to the scope of supply
regenerating sector which is separate from absorption
sector.
There will an obvious drop in the relative humidity
only a few hours after switching on the Air dryer. It

must be operated continuously while the turbine is idle.

The dryer’s relatively low power consumption does not
involve any great cost.

The filter of the Air dryer must be clean from time to

time depending on the dust content in the air supply. It
is inadvisable to operate the air dryer without the filter
because of the danger of blockage in the fine tubular
ducts of the absorption wheel. Two air dryers are
needed.
of BHEL.
Figure 3 shows the interconnection between air-
dryers and turbine.
Preservation of the Oil System
The wet air escapes at the drains behind HP
Turbine at flanges between IP valves and IP casing The turbine oil contains corrosion inhibitors
and the lowest point of the condensers. therefore it is unnecessary to adopt any special
measures to preserve oil carrying components except
Main steam control valves have to be opened and to operate one of the auxiliary oil pumps for an hour at
blocked in this position. intervals of two to three weeks.

5.2-0360-00/2
 Steam Turbine Fault Tracing
Operation Introduction

The scope and content of the trouble In the instruction Serious Faults [1], the
shooting instructions are limited to criteria or remedial measures are indicated against the
measures that can be performed by the faults that could have severe consequences.
control panel operator or the turbine
The operating staff must be trained to take
operator without specialized help and avert
proper action should such fault occur.
events detrimental to the operation and
availability of the turbine generator unit.

Also refer to the following sections:

[1] 5.2-0410 : Serious Faults

BHEL Haridwar 5.2-0400-00

 Steam Turbine Serious Faults
Operation Fault Tracing

Introduction Many of the criteria refer not only extreme

conditions requiring immediate action but
Many operating faults require the monitoring
also to the trends of the process transients,
staff to take immediate appropriate action if
which must also be taken into consideration.
serious reductions in the availability,
operating reliability and service life of the The turbine is in danger not only when the
turbine are to be averted. specified limits of a process parameter are
reached but also when the process
The following criteria and instruction must be
parameter deviates markedly or rapidly from
included in the intensive schooling and
the normal values otherwise observed.
training program for the monitoring staff.

Fault Cause Remedy

Other symptoms
Load rejection

Turbine generator remains Breaker opens as a result of Control valves and extraction
in operation after short an internal or external fault. valves closed by the turbine
time rise in speed. governor to stop the steam
flow through the turbine.
Manual intervention is not
possible as automatic shut
down is too fast.

Excess steam from steam Normal procedure Reduce steam generator to
generator is dumped to the minimum output immediately, if
condenser through the this is not done automatically
bypass valves. by the unit control.

Prolonged operation at Operation may continue
rated speed with or without indefinitely.
residual load.
Limits specified in 5.1-0101
must not be exceeded.
Set reference speed setter to
rated speed.
Reduce main steam
temperature or load turbine if
HP turbine exhaust steam
temperature approaches to
limits.
General rule: determine cause
of shut-down. Synchronize
generator if permitted by
Load rejection with turbine results of fault tracing.
trip

Turbine speed reaches trip Beaker opens as a result of an See also Turbine Trip.
speed of overspeed trip. internal or external fault. Refer 5.2-0450.

BHEL Haridwar 5.2-0410-00/1

Fault Cause Remedy

Other symptoms
Adverse condition during load Investigate conditions, e.g.
rejection load and speed prior to load
rejection.
Control malfunction Check control and attend
malfunction.
Turbine trip

Turbine trip by protective Stop and control valves and
devices extraction valves close.
Generator disconnected from
system by reverse power
protection relay.
Speed drops;
Auxiliary oil pump cuts in due
to loss of pressure as speed
drops, turning gear operation
commences.

Turbine-generator unit in Reduce condenser vacuum to
imminent danger shorten coast down.
− Open vacuum beaker
− Stop air extraction
− Allow air to condenser
plant.
Reduce steam generator to

Excess steam from steam
generator is dumped to the minimum output immediately if
condenser through the this is not done automatically
bypass valves by the unit control.
General rule: determine cause
of trip. See also 5.2-0450.

Overspeed after load rejection. See load rejection with turbine

trip.
Shaft displacement in thrust Inspect thrust bearing and, if
bearing due to damage to necessary, repair, see also
bearing. 5.2-0421. Refer to fault tracing
instructions and eliminate fault.
Condenser vacuum reduced Refer to relevant fault tracing
due to fault in condenser plant. instructions and eliminate fault.
Remote trip by protective Refer to relevant fault tracing
devices in steam supply instructions and eliminate fault.
system, turbine or generator.

5.2-0410-00/2
Fault Cause Remedy

Other symptoms
Reverse power protection
relay fails to open generator
breaker

Turbine control valves Suspected that steam is still Attention: do not open
closed by control as load entering the turbine. generator breaker manually
removed (danger of impermissible
overspeed).
Check position of control and
extraction valves (Desired
position: 0%).
Trip turbine.
Observe closing of stop
valves, check steam pressure
in turbine, check output
display, reduce condenser
vacuum:
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant
Open turbine drains
Open drains between stop and
control valves
Shut down steam generator;
reduce steam pressure in
steam supply lines.
Fault in reverse power If reverse power protection
protection relay relay is not actuated by all or
some of the above mentioned
measures, it is very probable
that there is a fault in the
reverse power protection relay.
In this case, disconnect the
generator from the supply
system by opening the
breaker.
The following parameters Use load limiting device to
exceed the permissible reduce load on turbine
limits even though remedial generator unit from any
measures have been taken operating mode to no-load
as prescribed in the relevant and/or shut-down unit by
fault tracing instructions actuating main trip valve.

Vibration high See 5.2-0420 Reduce condenser vacuum to
shorten coast down.

5.2-0410-00/3
Fault Cause Remedy

Other symptoms

Casing differential See 5.2-0423 Note: The decision whether
temperatures high the load limiting device should
be used to further reduce load

Bearing metal See 5.2-0421
before the main trip valve is
temperatures high
actuated will depend both on

Temperature differences the seriousness of the danger
between parallel steam and on the amount by which
supply lines high the limits are exceeded.

Rapid, large drop in inlet
stream temperature

Condensate level in
condenser very high

The following parameters

exceed the permissible
limits

Inlet steam pressure high, Steam generator output too Reduce steam generator
pressures and duration of high output or increase turbine load
exposure to excessive
pressures limited as
specified in 5.1-0100.

Inlet steam temperatures Fault in steam generator Change steam generator
high. Temperatures and operation, eliminate fault if
duration of exposure to necessary.
excessive temperature
limited is specified in
5.1-0100.

Steam pressure upstream Load too high Reduce turbine load
of blading and/or extraction
steam pressure high. Irregularities in the turbine e.g. Measure stage pressures and
blade choking. compare with normal values
Pressures and duration of
under identical operating
exposure to excessive
conditions.
pressure limited as
specified in 5.1-0100. Measure internal efficiency.

HP exhaust temperature Reduce main steam
high during no-load or low temperature or increase
load operation. turbine load.
If these measure do not
reduce the temperature,
initiate turbine trip.

LP turbine exhaust Ventilation heating through Start injection into LP turbine
temperature high during no blading. or increase load.
load or low load operation.

Bypass stream Condenser vacuum low. Check condensate pumps.
temperature high during Injection water pressure too Reduce steam generator
bypass operation low. Bypass steam flow rate output.
too high.

5.2-0410-00/4
Fault Cause Remedy

Other symptoms
Control valve or stop valve
fails to open again after
testing with automatic
turbine tester

All measures as Fault in valve or turbine tester. The turbine plant may be
prescribed in 5.2-0455 fail. operated with defective valve
for max.1 week.
If necessary, the output must
be reduced so that the limits
as prescribed in 5.1-0100 are
not exceeded.
Drain steam line upstream and
downstream of defective valve
thoroughly.
Observe limits for temperature
difference between parallel
steam supply lines.
Shaft assembly runs down
without lubricating oil

Fault in auxiliary and Check bearing metal
emergency oil pumps. temperatures, if impermissibly
Jacking oil pumps in high, inspect bearings.
operation

Fault in jacking oil Danger of bearing whipping.
pump(s). Check bearing metal
temperatures. Check bearings.
Fire or fire hazard during Set off fire alarm. Follow fire
operation protection rules. if
necessary, initiate fire
fighting measures.
At the same time:

Escape of control fluid Leakage in piping or other Press fire protection
turbine components pushbutton 1
or
Switch off sub-loop control for
the control fluid pumps
immediately and shut-down
(operating) pump (result:
turbine generator unit trips).

Escape of oil from the Leakage in piping or other Press fire protection
lubricating oil system turbine components pushbutton 2 (pressing fire
protection pushbutton 2
automatically initiate fire
protection 1 measures), result:
turbine generator unit trips.

5.2-0410-00/5
Fault Cause Remedy

Other symptoms
or
Shut down turbine generator
unit. Depressurize control fluid
system (measures as above).
Switch off sub loop control for
jacking oil pumps.
Start up jacking oil pumps.
Switch off subloop control for
auxiliary oil pump. If
necessary, shut down auxiliary
oil pump(s). Check to ensure
that subloop control cuts-in
emergency oil pump as oil
pressure drops. Close turning
gear oil valve. Reduce
condenser vacuum to shorten
coast down.
− Open vacuum breaker
− Stop air extraction from
condenser plant
− Allow air to enter
condenser plant

Shaft comes to a standstill Shut down DC lubricating oil
when fire protection pump. Keep jacking oil pump
measures are initiated in operation if no leakage from
the jacking oil system.
Turn shaft through 180 degree
at intervals of approx. 10
minutes. For treatment of
turbine after complete
standstill shaft see 5.2-0460.
Eliminate leak and perform
hydrostatic pressure test.
Acknowledge initiation of fire
protection measures.
Restart lubricating and control
fluid system.
Commence turning gear
operation.
Replace insulating materials
soaked with escaped fluid.
Start up turbine generator unit.

5.2-0410-00/6
Fault Cause Remedy

Other symptoms
Fire or fire hazard during Set off fire alarm.
turning gear operation
Follow fire protection rules.
If necessary, initiate fire
fighting measures.

Escape of control fluid Leakage in piping or other Measures as for fire or fire
turbine components hazard during operation.

Escape of oil from the Leakage in piping or other Jacking oil pump stays in
lubricating oil system turbine components operation.
Close turning gear oil valve.
Switch off sub-loop control for
auxiliary oil pumps.
Shut down auxiliary oil pumps.
Check to ensure that, sub-loop
control cuts in the lubricating
oil pumps as oil pressure
drops. For further measures
see: Fire or fire hazard during
operation.

Escape of oil from the Leakage in piping or other Shut down jacking oil pump
jacking oil system turbine components (risk of bearing damage is
minor if turning gear stays in
operation).
Isolate and eliminate leak.
Start up jacking oil pump.
Lubricating or control fluid
loss annunciated by level
monitoring circuit

Separate control fluid The system must be checked
system immediately for leakage if this
Alarm: fluid level low or very alarm is generated in rapid
low (2-out-of-3) succession. A leak must be
assumed and appropriate fire
protection measures taken.

Oil system The system must be checked
Alarm: oil level low immediately for leakage if this
alarm is generated.

Oil system
Turbine trip due to oil level Fire protection measures
very low (2-out-of-3) initiated automatically.
Note: The trip system is
inoperative during turning gear
operation.

5.2-0410-00/7
Fault Cause Remedy

Other symptoms
Escape of steam Leakage in piping or other Isolate steam leakage area
turbine components immediately and depressurize
system concerned, if possible.
If there is a rupture hazard
(pre-rupture leak), shut down
turbine generator unit
immediately.
Carefully consider risk of
erosion at sealing surfaces
and decide on time of shut
down.

Earthquake Unload and shut down turbine

generator unit rapidly.
Observe response on bearing
and shaft vibrations.
If necessary, check bearings
and alignment.
Check valve supports.
Check pipe hangers and tank
supports.

5.2-0410-00/8
 Steam Turbine Vibration
Operation Fault Tracing

Despite all design, manufacturing and manufacturer to determine its cause and
erection measures to prevent it, excessive effective measures to be taken to combat it.
vibration can occur and because the various So, it is difficult to give a complete list of
kinds of vibrations are intermingled, the possible causes and proper corrective action
reasons for it are difficult to isolate. to be taken, in this instruction.
If excessive vibration occurs, it is necessary The following data refers to the
to carryout extensive tests together with the characteristics, causes and remedial actions
pertaining to some typical type of vibration.

Fault Cause Remedy

Other symptoms
Rapid or instantaneous
increase in vibration over
the permissible limits or the
range of the measuring
system (alarm or instrument
display)

Loud noises and/or the Suspected damage, e.g. Caution: stop turbine
following operating broken blades or metal to immediately even when
parameters exceed their metal rubbing accuracy of reading is
limits: doubtful.
Casing wall temperature, Clearances eliminated by Check whether increased
because of rapid temperature casing distortion. vibration is maintained after
changes. load is reduce and when
coasting down.
Casing top-bottom differential Clearance eliminated by Measure the time taken to
temperatures. casing distortion. coast down; listen for noises
during this period.
Bearing metal temperatures Bearing damage

Low-frequency vibration. Unstable running due to self Reduce turbine load

Vibration frequency less excited vibration immediately until vibration
than rotational frequency. decreases; examine vibration;
Irregular point trace from load turbine slowly to stability
recording Instrument. limit.

Vibration increases above

normal value for specific
power outputs and operating
conditions

Vibration values less than Many possible causes Carryout the following tests to
permissible limits find out the causes:

BHEL Haridwar 5.2-0420-00/1

Fault Cause Remedy

Other symptoms
Determine main frequency of
vibration.
Measure vibration at all
bearings in three plans:
h - Horizontal
v - Vertical
a - Axial
Measure shaft vibration in two
directions at right angles, if
possible.
Measure the phase relation
ship of the bearings and shaft
vibration.
Measure the foundation
vibration.
Measure the vibration in
relation to all principle
operating parameters and their
variations.
Increased vibration at rated
speed

Increased vibration over
Changes in shaft system
entire load range under Examine magnitude and
balance due to:
steady-state operation. direction of vibrations.
Vibration increased above Rotor condition induced by
previous values, including eccentric coupling. Check the coupling for:
when passing through
- Firm and proper fit of
critical speed ranges.
coupling bolts
- Fit of centering spigot and
recess; redial runout of
coupling faces
- Alignment
Initial corrective action:
- Dynamically re-balance the
rotors (except if coupling
bolts are not tight and
alignment unsatisfactory)
- Correct any discrepancies
found during the checks

Permanent shaft distortion due Measure redial runout of shaft.

to metal to metal rubbing
Initial corrective action:
Dynamic re-balancing of rotor,
if runout is less.

5.2-0420-00/2
Fault Cause Remedy

Other symptoms
Final corrective action: Stress
relieving, thermal stabilisation
and balancing at
manufacture’s works, if runout
is more.

Blade damage Inspect blading.

If blades in the final LP stages
are damaged, a temporary
corrective measure is to
shorten the blade in the 180°
opposite position to damaged
blade or to attach a balancing
weight in the plane of damage
to compensate for the missing
piece (consult manufacturer).
if the blade damage is
suspected elsewhere the
appropriate turbine casing
must be opened.
Modifications or repair on the Dynamic balancing of rotor.
blades during on overhaul

Temporary increase in Temporary shaft distortion due Reduce speed, load and/or
vibration during non steady to temporary non-uniform rate of change of temperature.
state operating conditions temperature distribution during
Wait until vibration improves
(startup, loading and temperature changes.
when steady state conditions
unloading, main steam
are reached.
temperature changes etc.)

Temporary distortion of shaft Reduce speed, load and/or

resulting from metal to metal rate of change of temperature.
rubbing at the seal rings
caused by misalignment due to
temperature changes.
Alignment changes due to Remove restriction to
restricted expansion at turbine expansion by improving sliding
casing and bearing housings. of bearing housings and
casing guides.

Constant relationship Many possible causes Determine relationships by

between vibration and measuring magnitude and
specific changes in direction of vibration under
operating parameters. varied operating conditions.
If possible, vary only one
operating parameter at a time.

5.2-0420-00/3
Fault Cause Remedy

Other symptoms
After, each variation there
must be a delay for steady
state conditions.
Check the following operating
parameters and conditions:
- Speed
- Active load
- Reactive load
- Valve lift
- Steam temperatures
- Casing temperatures
- Steam pressure
- Oil temperatures
- Bearing metal temperatures
- Casing expansion
- Thrust bearing position
- Shaft eccentricity
Check turbine casing and
bearing housing for:
- Freedom of spacing
washers
- Seating and freedom of
expansion of casing palms
- Freedom of movement for
bearing housings
- Freedom of movement for
piping
Note: Changes in vibration
characteristics due to changes
in temperature usually occur
slowly and at a constant rate.

Increased vibration during Warm-up speed near a critical. Change the warm-up speed
warm-up. within permissible ranges.

Increased vibration during Increased vibration while Pass through critical speed
turbine acceleration. passing critical speeds. ranges rapidly.
Vibration is normal at rated
speed.

Increased vibration during Distortion remaining from an Reduce turbine speed to less
turbine acceleration. No interruption of turning gear than 400 rpm. and eliminate
improvement in vibration at operation before start-up. shaft distortion before
rated speed. increasing speed.

5.2-0420-00/4
Fault Cause Remedy

Other symptoms

Increased vibration in LP Balancing pressure of Adjust seal ring balancing

turbine and generator generator axial seal ring not pressure.
area. correctly set.

Sudden sharp increase in

vibration with accentuated
low-frequency components.
Vibration frequency less
than rotational frequency.

Irregular point trace from Many possible causes After finding out the stability
recording instrument limits, identify the operating
parameters affecting vibration:
- Oil temperature
- Load
- Control valve lift
- Expansion
- Shaft displacement
- Bearing metal temperatures

Vibration is related to load Bearing loading too low. Increase bearing loading by
and valve lift. changing the alignment.

Vibration related to Bearing clearance excessive Change oil temperature
lubricating oil temperature
Changes in damping
changes.
properties due changes in
viscosity.

5.2-0420-00/5
 Steam Turbine Bearing Temperature
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Bearing Temperatures High

Rapid rise of one or more If a fault in the temperature Shut down turbine
bearing metal temperatures measuring equipment can immediately to prevent
to the preset alarm level; be ruled out, the bearing is consequential damage.
similar temperature rise not damaged
Check bearing, analyse
observed before under
cause of bearing damage
comparable conditions
and take corrective action.

Inadequate oil supply Check oil pressure upstream
of damaged bearing.
Check throttle valve setting.
Check filters for chocking.

Dirt in oil Check bearings for sign of
wear; take oil samples.

Tilting of bearing Check bearing assembly.

Excessive thrust (in Analyse cause of excessive
thrust bearings) thrust.

Rapid rise of bearing metal Fault in oil temperature Check oil temperature
temperatures control system downstream of cooler.
Switch off controller.
Establish normal oil
temperature.

Fault in oil controller Establish oil temperature
manually

Fault in cooling water Check water flow through
supply cooler.
Shut-down turbine generator
unit, in case oil temperature
reaches the maximum
permissible limit in the event
of cooling water supply
failure.

Cooling water Startup stand-by cooler.
temperature high

Oil cooler chocked Change over to stand by oil
cooler

Slow rise of one or more Misalignment Check alignment
bearing metal temperatures

BHEL Haridwar 5.2-0421-01

 Steam Turbine Casing Temperatures
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Annunciation: Casing
temperature differentials
top/bottom high
+ (positive) = higher
temperature in top half casing
- (negative) = lower
temperature in top half casing

During start-up, ∆θ + / - Uneven heat dissipation due to If possible, increase steam

not enough steam flow through flow through turbine to obtain
casing uniform warm-up.

After load reductions, As above As above

during low power
operation, ∆θ + / -

After load reductions, ∆θ + Steam backflow or entry of Open drain valves in extraction
water into turbine through lines; test functioning and leak-
extraction lines tightness of extraction valves.
Take measures at the feed
water heaters to prevent back
flow.

During power operation, Casing temperatures affected Check condition and measure
∆θ + / - by leaks in sealing elements clearances at sealing elements
inside the turbine during overhaul and refit or
replace leaky elements as
necessary.
notify manufacturer and ask to
calculate if turbine can be
operated at higher temperature
differentials for the time being

During start-up, ∆θ - Casing or steam lines not Check position of drain valves,
properly drained open any close drain valves.

During start-up, ∆θ + Drain valves still open too Close drain valves further or
wide, causing uneven steam completely.
flow through turbine

BHEL Haridwar 5.2-0423-02/1

Fault Cause Remedy

Other symptoms

During standstill or turning Uneven cooling due to air Start turbine very carefully;
gear operation, ∆θ + currents within the foundation wait until the steam admitted
or inside the turbine begins to reduce temperature
differentials before running up
to rated speed.

During standstill or power Uneven heat dissipation due to Repair lagging

operation imperfect lagging

Casing temperature
differentials excessive

In any operating mode Coast down turbine
(additional turbine immediately by tripping;
protection not operative) observe coast down; record
coast down time.

Turbine generator comes Carefully try to turn shaft
to standstill after coast system using manual shaft
down ( in turning gear turning device.
operation)
Warning: Do not rotate the
shaft system forcibly.
Wait until temperature
differential has fallen to
permissible level; set turning
device in operation.

5.2-0423-02/2
 Steam Turbine Turbine Stress Controller
Operation Measures to Avoid Impermissible
Operation

Fault Cause Remedy

Other symptoms

Upper margin of turbine

stress controller restricted
during non-steady-state
operation (Upper margin
becoming O)

Limitation by TSC Admission into main steam line Open warm-up valves (drains)
admission monitoring and main steam stop and between stop and control
channel by TSC detector in control valves too high, i.e. too valves more slowly.
stop valve and/or TSC rapid warm-up reduces the
or
detector in control valve margin.
during warm-up of the Hold warm-up valve position
main steam line and the until a sufficient margin has
stop and control valves. developed.
stop valves open.
or
Continue to close warm-up
valve(s) until a sufficient
margin has developed.

Limitation by TSC Stop valves opened at too high Check whether warm-up
admission monitoring a pressure. valves (drains) between stop
channel by TSC detector in and control valves are closed;
control valve during warm- if not, close-warm up valves;
up of the main steam line wait for sufficient margin
and the main steam valves before re-opening warm-up
immediately after opening valves. If margin is negative,
of the stop valves. repeatedly open and close the
main steam stop valves.
General rule: If main stem
temperature can be reduced
when margins narrow, this
should be done in order to
avoid prolonging warm-up.

Limitation by TSC turbine Steam already entering the Both the admission channel
monitoring channel during turbine, causing reduction of and the turbine channel must
warm-up of the main the margin. be observed and step must be
steam line. taken to avoid reduction of
margin; retard temperature
increase up-stream of turbine
by throttling the warm-up
valves (drains) between stop
and control valves.

BHEL Haridwar 5.2-0430-01/1

Fault Cause Remedy

Other symptoms
Reduce main steam
temperature, if possible.

Limitation by TSC turbine Turbine is being warmed up Reduce supply steam flow by
monitoring channel during too quickly. closing the control valves by
warm-up in wait step below means of the speed set point
critical speed range. controller or the starting and
load limit device.

Limitation by TSC turbine Increase in steam flow during The influence of the TSC on
monitoring channel during acceleration of turbine the set-point controller reduces
turbine run-up to rated diminishes margin. the speed gradient or, at a
speed. certain margin, caused the
speed gradient to tend
towards 0.
A certain TSC margin
(determined empirically) must
be available before the turbine
generator until is run up to
rated speed.
Operation of the turbine
generator unit at constant
speed within the critical speed
range is inadmissible.
The control valves must
therefore be closed and the
turbine generator must be
warmed up at a speed below
the lower boundary of the
critical speed range specified
in the Technical Data 5.1-011..
until an appropriate TSC
margin is available.
The turbine generator unit is
automatically run down to the
set warm up speed by means
of the gradient monitor as soon
as a certain permanently set
minimum speed gradient is not
attained.

Turbine run-up causes an Automatic and/or manual

increase in the supply steam measures as above.
temperature so that the margin
is reduced.

5.2-0430-01/2
Fault Cause Remedy

Other symptoms

The TSC display and the

recorder make it possible to
recognize which turbine
section has the smallest
margin.
It is therefore possible to widen
the margin reducing the
temperature of the supply
steam to that specific section
within the limits permitted by
the steam generator.
If the supply steam
temperature cannot be
reduced, further run-up will
have to be delayed until the
trailing turbine has warmed up
sufficiently.

Margin for IP turbine Warm up operation does not Automatic and/or manual
reduced; temperature of IP warm up the IP turbine measures as above.
turbine low; reheat sufficiently to prevent reduction
temperature high. of the margin. Proper adjustment of the
reheat temperature within the
limits permitted by the steam
generator is recommended.
If the turbine generator unit
can be run up to rated speed,
wait for IP turbine to warm up
sufficiently at rated speed
before synchronizing the
generator, since further margin
reductions are to be expected
when the unit goes on load if
the IP turbine has not been
warmed up sufficiently.

Limitation by TSC turbine Steam flow too high in relation The influence of the TSC on
monitoring channel during to turbine temperature the setpoint controller reduces
power operation. conditions. the speed gradient and/or the
turbine load is reduced and the
generator is possibly
disconnected from the grid by
the reverse power protection
relay.

5.2-0430-01/3
Fault Cause Remedy

Other symptoms

Lower margin of turbine

stress controller restricted
during non-steady-state
operation (Lower margin
becoming 0)

Limitation by TSC Main steam temperature too Do not open main steam stop
admission monitoring low in relation to main steam valves until temperature has
channel during warm-up of line and valve temperature. been adjusted accordingly.
the main steam line and
the main steam stop and
control valves.

Limitation by TSC turbine Main steam temperature too Check steam conditions
monitoring channel during low in relation to turbine upstream of the turbine; raise
warm-up and/or start-up of temperature steam temperature before
the turbine. warming and/or starting up the
turbine.

Limitation by TSC turbine Load change leads to a Reduce load gradient and/or
monitoring channel during reduction of throttle hold load constant until non-
unloading of the turbine. temperature down stream of steady-state condition has
main steam control valves. passed.
Note: Turbine shut-down by
trip actuation is permitted from
any load condition.

Limitation by TSC Rapid, pronounced Immediately adjust turbine

admission and turbine temperature reduction due to output to changed steam
monitoring channels fault in steam generator. generator conditions by means
during disturbances in of load setpoint limiter so as to
steam generator significantly reduce the steam
operation. flow; if the additional influence
due to throttling prevails and/or
if there is no end to the steam
generator malfunction in sight,
the turbine must be tripped.

Limitation by TSC after Normal occurrence as a No particular measures

load rejection with or consequence of the reduction required in the event of
without residual load, or in throttle temperature; will isolated load rejections.
TSC margin becomes reduce turbine life only if
negative. repeated frequently.

5.2-0430-01/4
Fault Cause Remedy

Other symptoms

Fault in turbine stress

controller

Alarm Electrical fault in turbine stress In the event of a fault in the
controller. turbine stress controller during
speed and load operation, the
TSC influence on the turbine
controller is immediately
cutout.
Cut out TSC influence.
Continue monitoring of the
turbine generator unit for
thermal stress by comparing
recorded temperatures with the
permissible temperatures
curves shown in Technical
Data 5.1-011..
Locate and eliminate fault in
turbine stress evaluator as
described in the TSC manual.

5.2-0430-01/5
 Steam Turbine Stop and Control Valves
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Stop valve fails to open

Stop valve system ready Test valve closed Verify opening of stop valves
for operation. Start-up locally. Open test valve.
pressure < valve opening

Stop valve system is made Pressure above piston has not Wait until starting and load
ready for operation by built up sufficiently when test limit device is in 0% position
driving the starting and valve is changed over and pressure above piston of
load limit device towards stop valve has built up.
0%

Stop valve closes when Pressure difference preventing Close drain downstream of
internal pilot valve has main valve from opening stop valve.
reached the end of its
travel. Drains downstream
of stop valve open

Pressure above piston Internal pilot valve jammed Overhaul stop valve and free
drops immediately when inside the main valve internal pilot valve.
pressure builds up below
piston (steam pressure
present)

Control valve fails to open

Secondary oil pressure Cut off valve in secondary line Open cut off valve in
present closed secondary line.
Gear of test valves not in Bring gear of test valves into
operating position operating position.

Control valve opens and

closes erratically

Slight changes in Defect in feedback system of Check feedback system for
secondary pressure actuator blockages.

Control valve fails to

respond to control signals

Starting and load limit Starting and load limit device Bring starting and load limit
device not in 100% limiting hydraulic governor device into 100% position.
position

Reference speed setter not Reference speed setter limiting Bring reference speed setter
in 100% position during hydraulic governor into 100% position.
operation with electro-
hydraulic turbine controller

BHEL Haridwar 5.2-0440-01/1

Fault Cause Remedy

Other symptoms
Change in relationship
between secondary pressure
and control valves

Steady-state operation Many causes possible Check hydraulic governor,
converter and actuators.
Record control characteristics:

Travel of start-up and load
limit device

Travel of converter

Secondary auxiliary
pressure

Secondary pressure

Travel of control valve
and have control setting
corrected by manufacturer

Change in mutual
relationship of control valve
travels

Steady-state operation Many causes possible As above

Restriction in movement of Less clearance between valve Maintain required clearance
valve stem cone & bush between valve cone & bush by
machining ID of bush
Slightly reduce the tightening
Excessive tightening of glands of the glands of the valves
of the valve

5.2-0440-01/2
 Steam Turbine Protective Devices
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Turbine trip

Manual trip-out Main trip valve actuated locally Check condition that was the
or from control room reason for tripping turbine
locally or from the control desk
and find out if turbine
generator unit can be
restarted.

Automatic trip-out Protective device operated. Find out cause of turbine trip
Many causes possible. from recorder plots or
annunciation.
If trip started due to protection
criteria within turbine, check for
damage or irregularities that
would prevent further
operation of the unit.
If trip started due to faults
outside the turbine, check
whether turbine trip operation
was called for in accordance
with the protection concept.
The cause of trip must be
identified and must be rectified
before the unit is started up
again.

Automatic turbine trip

Main trip valves operated The main trip valves operate Check annunciation to find out
whenever trip is started. if both main trip valves
operated.
If only one main trip valve has
operated, test signaling circuit
(limit switches, wiring, lamps)
and repair any mechanical
fault affecting the defective
valve.

Overspeed trips operated The overspeed trips operate Operation of the overspeed trip
when the preset speed limit is is normally prevented by the
reached. turbine governor if load
rejection occurs, i.e., when the
generator breaker is opened.
Check if trip was caused by
these:

BHEL Haridwar 5.2-0450-01/1

Fault Cause Remedy

Other symptoms

Overspeed trips operate too Perform oil pressure test on

early. overspeed trips.
Find out oil pressures when
trips operate and compare
with pressures previously
set.
Perform overspeed test
with turbine is at operating
temperature.
Adjust overspeed trips.
Check if spring fatigued.

Turbine control malfunction. Check free movement of

hydraulic control elements:
− Control valves
− Converter
Remove blockage or other
malfunctions.
Check electrical turbine
controller.

Load rejection relay failed to Check solenoid valves.

respond
Actuate contactor and note
effect on secondary pressure
of solenoid valves opening.
If secondary pressure do not
collapse, test coils of solenoid
valves for operation.
If actuation of load rejection
relay is not annunciated, check
measuring circuit.
Leak in turbine control valves. Check for leaks in turbine
control valves:
Note operation of reverse
power protection if turbine
control valves are closed
during synchronized generator
operation.

Failure of reheat control Exercise reheat control valves.

valves. Extraction check Check position of extraction
valves fail to close or leaking. check valves.

5.2-0450-01/2
Fault Cause Remedy

Other symptoms

Check temperature in
extraction lines.
Rapid temperature drops after
load rejection are probably due
to extraction check valves
leaking.

Thrust bearing trip Excessive play in thrust Check bearing metal

responded bearing temperature.
Check thrust bearing.
Find out cause of high thrust
bearing wear (axial thrust,
damage, lack of oil).

Electrical low vacuum trip Loss of condenser vacuum Identify the cause of
responded condenser vacuum loss.
Fault in circulating water Check circulating water
supply pumps. Check flow of
circulating water through
condenser.

Fault in gland seal steam Check position of control

supply valves.
Check controller.
If fault in controller or if control
valves malfunction, switch of
controller and maintain gland
seal steam pressure manually
or by local operation of valves.

Fault in vacuum pumps Check operation of vacuum

pump.
Air entry into condenser Test for leaks.
Shutdown vacuum pumps and
measure pressure rise.
Locate and repair leaks.
Examine rupture disks for
cracks.

5.2-0450-01/3
Fault Cause Remedy

Other symptoms

Hydraulic low vacuum trip Loss of condenser vacuum As stated earlier

responded

Turbine trip started via Temperature differentials high Check recording instruments,
electrical signal from identify causes as described in
additional turbine instruction 5.2-0423.
protection system because
casing temperature
differential (s) high.

Turbine trip started via Cooling steam flow too low Check valve setting
electrical signal because
temperature of exhaust Pressure of exhaust steam Reduce pressure by suitable
steam from HP turbine from HP turbine too high measures
high. Main steam temperature in HP Reduce main steam
turbine too high temperature

Turbine trip started via Trip by fire protection system See 5.2-0410
electrical signal from the
fire protection system

Faults in protective devices

Main trip valves fail to Jammed Turbine generator unit must
operate not be operated if main trip
valves are not functioning
perfectly.
Locate and repair fault
immediately.

Trip solenoids Fault in solenoids Do not operate turbine

generator unit if trip solenoids
are not functioning perfectly.
Locate and repair fault.

Both overspeed trips fail to Overspeed trip jammed or Repeat testing by test oil
operate during over speed fouled pressure several times until
testing turbine trip starts at normal test
oil pressure values.
Attention : Normal trip speed
must not be exceeded by more If the defective overspeed trip
than 2% still does not operate
satisfactorily, operation of
turbine generator unit must not
been continued.
Trip devices jammed. Locate and repair fault
Incorrect speed reading immediately.

5.2-0450-01/4
Fault Cause Remedy

Other symptoms

Check speed indicator

(compare frequency of excited
generator with system
frequency by means of
synchronizing device).
Adjust speed indicator.

One over speed trip fails to Jammed or fouled Perform testing by test oil
operate during over speed pressure.
testing
Staggering of overspeed trip If testing by test oil pressure
settings reveals that the two overspeed
trips respond at slightly
staggered settings, no further
action is necessary.

Over speed trip operates Turbine generator unit speed Check speed indicator.
at too high a test oil too low when generator not (Compare frequency of excited
pressure when tested by synchronized generator system frequency by
test oil pressure means of synchronizing
device).
Correct speed
Adjust speed indicator.
Movement of over speed trip Repeat testing by test oil
mechanism impaired pressure several times until
turbine trip operates at the test
oil pressure values previously
measured.
Leak in test-oil line inside the Check test oil line at next
bearing pedestal opportunity.

Over speed trip fails to Cause of maloperation may be Adjust test oil pressure.
operate when tested by too high a test oil pressure
test oil pressure
Movement of overspeed trip Increase speed with generator
mechanism impaired unsynchronized and perform
test. If the defective over
speed trip still does not
operate satisfactorily,
operation of the turbine
generator device must not be
continued until fault has been
corrected.

Overspeed trip operates at Turbine generator unit speed Check speed indicator (for too
too low a test oil pressure too high when generator not high a trip speed)
synchronized

5.2-0450-01/5
Fault Cause Remedy

Other symptoms

Drift of trip speed Test overspeed trip by actual

(e.g. spring fatigue) overspeeding at the next
opportunity.
Adjust overspeed trip setting if
necessary.
Turbine generator unit my
continue to be in operation but
may be liable to premature
tripping.

One overspeed trip fails to Movement of one overspeed Test intact overspeed trip daily
operate when tested by mechanism impaired by test oil pressure until fault
test oil pressure. Test oil can be corrected at next
pressure maximum, opportunity.
second trip responds
normally.

Thrust bearing trip fails to Malfunction of test device Check test device and control
operate during testing medium pressure
using the automatic turbine
tester

Hydraulic low vacuum trip Malfunction due to jamming or There is a danger of the
operates too late (at too drift in setting condenser and last-stage
low a condenser vacuum) blades in the LP turbine being
damaged. Therefore correct
malfunction as quickly as
possible or adjust trip setting.
Until this can be done, test
intact low vacuum trip at
frequent intervals.
Speed – dependent release for See above for consequences.
operation faulted by jamming
Overhaul piston for speed
of piston
dependent release for
operation.
See above for interim
measures pending correction
of fault.

Hydraulic low vacuum trip Danger of outage of turbine
operates too early at too generator unit due to
high a condenser vacuum. premature trip.
Drift in setting Correct setting
Diaphragm damaged Check diaphragm and replace.

5.2-0450-01/6
Fault Cause Remedy

Other symptoms

Protection systems operating Fault in signal transmitter Check signal transmitter

largely with electrical signal
or
formation fail to operate or
operate at too high or too low Fault in signal path Check signal path
limit levels.
or
Fault in protective devices Check protective devices

In the fire protection system Fault in signal path Check signal path and
test, one or more fire control devices.
or
protective devices do not
Correct fault or inform and
operate automatically. Device malfunction
instruct shift personnel that fire
protective device must be
manually operated if a fire
occurs.

5.2-0450-01/7
 Steam Turbine Automatic Turbine Tester
Operation Fault Tracing

Fault Cause Remedy

Other symptoms

Fault after selecting and

starting program

Group and individual Electrical or mechanical faults. Find out and record program
alarms on automatic status preliminary test (PT),
turbine tester control test program (TP), reset
panel. program (RP) – and program
step where fault occurs.
Record and decode group and
individual alarms.
Locate fault and check if safety
or functioning of the turbine
generator unit is impaired (e.g.
if the device being tested fails
during testing).
Correct fault as stated in the
description section of the
turbine manual and the
Automatic Turbine Tester
(ATT) manual.
If reset program (RP) runs
without fault (program status
after (RP) = status as before
starting ATT), repeat the test
to get further information on
the nature of the fault.
Continue to perform non-
faulted test programs as
normal.
Program cannot be started

Alarm: No starting Operating condition of the Check starting conditions from
condition turbine generator unit does not the functional diagrams and
correspond to the interlock compare with actual operating
release criteria for the conditions of turbine and
Automatic Turbine Tester. restart test program.
Note: During turbine
shutdown, the starting
conditions for various
programs will not be fulfilled if
testing is to be performed
while the turbine is shut down,
the missing starting conditions
must be simulated.

BHEL Haridwar 5.2-0455-00/1

Fault Cause Remedy

Other symptoms
Fail signal during Protective
Devices Test Program

Alarm: Fail signal and Electrical or mechanical fault in Reset program started
possibly also Time overrun a protective or test device or automatically.
monitoring element.
Check running of program in
the control room and, if
necessary, locally on the basis
of the program status and the
positions of the protective and
test devices.
If possible, return protective
and test devices to normal
operating position
mechanically.
If reset program runs without
fault, repeat individual test to
obtain further information
about cause of fault or to stop
jamming of protective and test
devices.
Fail signal during valve test
program

Alarm Fail signal and Electrical or mechanical fault in Reset program started
possibly also Time overrun a protective device, valve or automatically.
monitoring element (pressure
Check running of program in
switch, position transmitter
the control room and, if
etc.)
necessary, locally also, on the
basis of the program status
and the positions of the valves
and test devices.
Restore to normal operating
condition if possible.
Main stop valve fails to open Close all downstream valves
by remote control (also drain
valves).
Open faulty stop valve using
test valve.
Open downstream valve by
remote control.
Turbine trip due to operating
criteria while test program is
running

Alarm Fail signal and Normal occurrence, since the Reset program started
annunciation from general turbine generator unit will be automatically.
alarm system shut down by the protective
Observe running of reset
devices even during testing if
program.

5.2-0455-00/2
Fault Cause Remedy

Other symptoms
the criteria for turbine trip are Check criteria that caused trip
fulfilled. to make trip conforms to
protection concept.
Locate and remove fault in
Automatic Turbine Tester if trip
was caused by wrong test
procedures.
Running of protective
devices test program
interrupted, program
stopped in faulted program
step

Several annunciation show Fault in electronic circuitry of Test circuit remains in force.
fault in electronic circuitry Automatic Turbine Tester.
Protection of the turbine is
of Automatic Turbine
ensured for the duration of this
Tester
fault by the protective
equipment operative during
testing.
Call in maintenance personnel
for the electronic equipment of
the Automatic Turbine Tester
to repair faults as described in
the ATT manual.

Running of valve test

program interrupted,
program stopped in faulted
program step

Several annunciation show Fault in electronic circuitry of Return valves tested to normal
fault in electronic circuitry Automatic Turbine Tester operating position.
of Automatic Turbine
Tester − Check control valve and
other downstream valves,
and close valves by
remote control, if
necessary.
− Open stop valve using test
valve.
− Open control valve and
downstream valves.
Fault in power supply to
Automatic Turbine Tester for
protective devices

Several annunciation show Fault in power supply Redundant design of the
fault in power supply power supply ensures best
security against outage of the
turbine generator unit.

5.2-0455-00/3
Fault Cause Remedy

Other symptoms
Circuit breaker of test motor, If a circuit breaker has tripped,
solenoid valve, or other actuate test equipment or
electrical equipment tripped. valves locally to restore normal
operating condition.
Identify and remove cause of
fault in power supply as
described in the Automatic
Turbine Tester manual.
Fault during reset program
after testing of protective
devices

Program stopped, Position of protective and test Check position of test or
changeover valve in test devices incorrect due to protective devices locally and
position electrical or mechanical faults. return to operating position by
hand, if necessary.
− Test signal transmitter for Move test signal transmitter for
overspeed trip not in overspeed trip into normal
operating position, e.g. operating position by hand.
because miniature circuit
breaker tripped.
− Main trip valve or trip Actuate contactor for
device not in operating approximately 10s to return
position. main trip valve or trip device
to normal operating position.
If normal operating position
cannot be restored, there is a
mechanical or hydraulic fault
(e.g. jamming of solenoid
valves, worn latching edges,
oil pressure too low for
latch-in) that must be
corrected.
False electrical signals due to Check monitoring equipment
faults in monitoring elements and signal paths.
(pressure switches, position
Check valves of pressure
transmitters, etc.). This type of
switches (desired status:
fault is present if devices are in
open).
operating position but no
checkback signal is generated. Check circuitry of position
transmitter; correct setting if
Incorrect operation of necessary.
protective device during
testing

Trip solenoid valves for Fault in electrical operation or Testing of protective devices is
protecting the turbine mechanical fault in solenoid not permissible if this fault
testing are not actuated. valves. occurs, the test will be

5.2-0455-00/4
Fault Cause Remedy

Other symptoms
Incorrect operation of prevented by the electronic
monitoring equipment circuitry.
− Operating fault Check trip signal.
− Fault in solenoid valves Check operation.
Check power supply.
Check solenoid.
Check freedom of valve
movement.
− Fault in monitoring Check valves of pressure
equipment switches (desired status:
open).
Vent pressure switch.
Check signal path of
checkback signal.
Check functioning of faulted
pressure switch.
Replace pressure switch.

Failure of remote trip Fault in electrical operation or The protection of the turbine
solenoids mechanical fault in solenoid generator unit is not fully
valves. guaranteed.
Incorrect operation of The turbine must be shut down
monitoring equipment unless the fault can be cleared
during operation (e.g. by
switching on the power
supply).
- Fault in operation Check signal path for
formation of trip signal.
Check operation.
- Fault in solenoid valves
Check power supply.
Check freedom of movement
of valve.
- Fault in monitoring Check valves of pressure
equipment switches (desired status:
open).
Vent pressure switch.
Check signal path of
checkback signal.
Check functioning of faulted
pressure switch. If necessary
replace pressure switch.

5.2-0455-00/5
Fault Cause Remedy

Other symptoms

Main trip valves fails to Fault in protective device See trouble shooting
operate instructions for protective
devices.
Main trip valve jammed Turbine generator unit must
not remain in operation.
Fault may be corrected
immediately.
Fault in monitoring equipment Check valves of pressure
switches (desired status:
open).
Check position transmitter,
reset if necessary.

Overspeed trips fail to Actuation fault in test device or Take action if incorrect
operate (running time incorrect operation of operation of the overspeed
exceeded) overspeed trip. trips occur.
See instruction: Protective
Devices. Troubleshooting:
5.2-0450.
Actuation fault in test signal Check if the test signal
transmitter transmitter operates during
test.
Fault in power supply If the test signal transmitter
does not operate, check power
supply and motor.
Check actuation.

Overspeed trips operate at Mechanical blockage of Repeat last several times.

too high a test oil pressure overspeed trips
Determine test oil pressures
where trips respond.
If this does not clear fault, take
action described in 5.2-0450
e.g. set overspeed trips during
overspeed tests.

Overspeed trips operate at Limit switch of test signal Correct setting of limit switch.
normal test oil pressure, transmitter incorrectly set.
but after test signal
transmitter has reached its
limit position.

Overspeed trips operate at Functioning of overspeed trip Danger of premature turbine

too low a test oil pressure impaired trip.
(annunciation only, no
interruption).

5.2-0455-00/6
Fault Cause Remedy

Other symptoms
Check overspeed trip setting
by precise oil pressure testing
or actual overspeed test.
Check setting.

Overspeed trips operate at Fault in functioning, circuitry or Check functioning of pressure

test oil pressures setting of pressure switches for switches.
previously observed monitoring response.
Check circuitry and setting.
Locate fault and repair.
Correct setting if necessary.

Trip mechanism of Latch-in pressure too low Check auxiliary start-up

overspeed trips fails to pressure.
latch-in.
Latch-in edges or trip Repair trip mechanism.
mechanism worn out.

Low vacuum trip fails to Fault in operation of test Check operation.

operate solenoid
Incorrect operation of solenoid Check solenoid.
valve
Air inlet duct obstructed Clear air inlet duct using
probe.
Primary circuit piston not in Repair low vacuum trip device.
normal operating position

Low vacuum trip operates Incorrect operation of low For consequences and steps
too late (at too low a vacuum trip device to be taken, see instruction
vacuum) 5.2-0450.
Check condenser vacuum
where trip device operates.
Repair mechanical fault or
correct setting.

Low vacuum trip operates Incorrect operation of low Availability of turbine generator
too early (at too high a vacuum trip device unit may be reduced due to
vacuum) annunciation premature tripping.
only, no interruption
Check condenser vacuum
where trip device operates.
Repair mechanical fault or
correct setting.

5.2-0455-00/7
Fault Cause Remedy

Other symptoms
Incorrect operation of
valves during testing

Stop valve fails to close Control valve not closed
- Fault in valve test Check power supply and motor
positioner or its actuation of valve test positioner.
Check actuation circuitry.

- Checkback Control valve Check functioning of limit

closed missing switch, signal path and setting
of limit switch.
Repair fault in signal path.
Correct setting of limit switch
Replace limit switch.

- Fault in actuation of stop Check operation of trip

valve solenoid.
Test solenoid;
Check freedom of movement
of valve.

Stop valve closed too Incorrect mechanical Repeat test.

slowly operation of stop valve
Measure time taken for valve
to close.
Repair valve if no other cause.

Malfunction of monitoring Check monitoring equipment.

equipment (pressure
Check functioning and setting
switches, position transmitters
of pressure switches.
etc.)
Check functioning and setting
of limit switches.

Stop valve fails to open Fault in operation of solenoid Check operation solenoid
valves.
Open stop valve with test
valve.
Locate fault in operation.
Check power supply and
solenoid as soon as
downstream valves are closed.

5.2-0455-00/8
Fault Cause Remedy

Other symptoms

Stop valve opens abruptly Jamming of valve positioner Locate fault immediately and
repair valve.
Control valve or other valve Close valve downstream of
downstream of stop valve stop valve.
open
Identify why control valve was
open (step sequence, step
criteria).
Locate fault and repair.

5.2-0455-00/9
 Steam Turbine Oil System
Operation Fault Tracing

Fault Cause Remedy

Other symptoms

Oil properties inadequate

Air release property > limit Oil contamination Examine oil samples, remove
value according to impurities through centrifuge,
Specification remove water.
Water content high Remove water
Improper sealants Check sealants used, do not
use any sealant containing
silicon.
Oil mixed with too much Consult oil supplier
antifoam additive.

Foaming on oil surface of Foaming during startup due to Introduce waiting period
oil tank simultaneous release of air between closure of turning
trapped in the oil and air gear oil valve and run-up of the
entrained in the system as a turbine.
result of temperature increase
Check oil level and correct by
in the oil tank.
topping up or draining.

Water content Entry of steam vapour into oil Remove water from oil system
system by separation or draining.
Check vapour pressure in
bearing pedestals.
Locate cause of excessive
leak-off steam from shaft seals
and repair.
Oil level in oil tank low

During rated speed Normal oil loss (oil level drops Top up with oil of the same
operation slowly) make and type.
High oil loss Examine system for leaks. If a
large leak occurs, unload
turbine generator immediately
and/or initiate fire protection
measures. Examine oil coolers
for punctured tubes.
Plug leaky tubes.

BHEL Haridwar 5.2-0460-00/1

Fault Cause Remedy

Other symptoms

During turning gear Measures as for oil level

operation changes during rated speed
operation.
On topping up make allowance
for oil level recorded during
turning gear operation.
Attention: 2-out-of-3 fire
protection ineffective during
turning gear operation.

During rated speed or Oil builds up in return Open oil tank cover
turning gear operation compartment due to choked
Check strainer and if heavily
strainer.
choked, change strainer and
clean.
Examine residues in strainer.
Oil pressure low

In pressure oil system Normal procedure Observes start up of auxiliary
during shut-down of oil pump.
turbine generator unit
If subloop control fails, start
auxiliary oil pump manually
from control desk.

In pressure oil system Main oil pump is not taking See incorrect operation of
immediately after rated over oil delivery. main oil pump.
speed has been reached
Check for leakage through Check pressure downstream
valve downstream of auxiliary of auxiliary oil pumps and
oil pump. pumps for reverse rotation.
Start up and shut down
auxiliary oil pumps with
defective valve once more.
Shut down turbine generator
and ensure freedom of check
valve movement by alternating
auxiliary oil pumps.
Overhaul check valve.

Turning gear oil valve still open Close turning gear oil valve
from control desk or locally by
hand.

5.2-0460-00/2
Fault Cause Remedy

Other symptoms

In pressure oil system Oil level too low Check oil level in oil tank.
during rated speed
Top up if necessary.
operation
Main oil pump faulty Check main oil pump.
Air content of oil too high Examine air release capability
(ARC) (joint investigation by
operator, oil supplier and
turbine manufacturer).

In lubricating oil system Examine as for oil pressure

drops in pressure oil system.
With heavy pressure loss
observe whether turbine trip is
initiated.

In lubricating oil system on Filter not filled and vented Check bearing metal
filter changeover before changeover temperatures.
Check bearings after
temperature increase.

In lubricating oil system on Standby oil cooler not filled Measures as for pressure loss
oil cooler changeover and vented before changeover on filter changeover.
Warning: Danger of bearing
damage is considerably
greater than with improper
filter changeover.

Differential pressure Filter choked Changeover filter properly.

across filter high
Clean filter inserts.

Main oil pump does not take Oil level in tank low See faults: Oil level low
over oil supply on startup
Air content of oil too high See faults: Oil properties
inadequate
Main oil pump faulty Check main oil pump.
Turbine sped may be
temporarily raised to force
main oil pump to take over.
Oil temperature high

During rated speed No flow of cooling water Check positions of cooling
operation after startup through oil cooler in service water isolating valves for oil
(malfunction can also occur on cooler in service. Open if
oil cooler changeovers) closed or throttled.

5.2-0460-00/3
Fault Cause Remedy

Other symptoms

Oil temperature not yet set Set selector valve.

During startup and power Oil cooler not vented on oil Check vents.
operation side or cooling water side.
Cooling water inlet Look for cause of cooling
temperature too high. water temperature increase
and correct.
Oil cooler choked on cooling Changeover oil cooler.
water side.
Note: Follow changeover
instructions
Clean choked oil cooler.
Oil temperature low

During shut-down of Oil temperature control valve Close oil temperature control
turbine generator unit not closed. valve.

During rated speed Oil temperature controller Close oil temperature control
operation after startup faulty. valve manually.

Turning gear does not

startup automatically

Turning gear oil valve Compare actual jacking oil
open, Jacking oil pump on pressures with set pressures.
Correct pressure if necessary.
Check oil temperature, if too
high (> 45 ºC), reduce.
Check using manual turning
gear, whether shaft turns
easily.
Warning: Do not rotate the
shaft system forcibly.

Turning gear oil valve Radial clearance bridged by Let turbine cool down.
open, Jacking oil pump on. casing or rotor distortion.
Jacking oil pump must be
Differential temperature on
operating.
one casing > limit
temperature. Warning: Do not rotate the
shaft system forcibly.
or
Turbine generator unit shut Rubbing of rotor due to Check bearing and replace.
down due to high bearing damage of bearing or shaft
metal temperature. journal in bearing not jacked.

5.2-0460-00/4
Fault Cause Remedy

Other symptoms

Turning gear oil valve does

not close

During startup Turning gear oil valve faulty Close turning gear oil valve
(acceleration to warm-up manually.

Drive
or rated speed)

Control or

AC-power supply

After initiation of fire Turning gear oil valve Acknowledge fire-protection
protection system interlocked. measures.

When shutting down Closure of turning gear oil Allow turbine generator unit to
turning gear valve interlocked via casing cool down further or make
temperature. interlock ineffective.
Note: Record release and
cancel if turbine is to be
restarted.
Turning gear oil valve does
not open

On start up Turning gear oil valve faulty Open turning gear oil valve
manually in place.
or
Drive

On shut down of the
Control
turbine generator

Main oil pump bearing

failure

Test oil pressure built up Failure due to electro-erosion. Replace damaged MOP
during normal operation components.
and turning gear operation
Rotor earthing arrangement Attend rotor earthing
not healthy arrangement.
Poor insulation at generator Improve insulation.
rear pedestal

Oil vapour coming from

bearing pedestal

Vapour fan running Vapour fan faulty Start standby vapour fan.
Wire cloth in the oil stripper is Clean or replace the wire cloth.
choked
Vapour suction Flap valve at Readjust the flap valve.
the bearing pedestal closed

5.2-0460-00/5
Fault Cause Remedy

Other symptoms

Seal steam leaking from

glands

Seal steam pressure Seal steam exhauster fan not Startup one seal steam
normal operating exhauster fan. Check position
of valves upstream of
exhauster fan and correct
(valves of standby exhauster
fan must be closed).
Mechanical or electrical fault in Discharge seal steam to
seal steam exhauster fan atmosphere.

Seal steam pressure high, Seal steam pressure set point Lower set point
no fault in valve or too high
controller functions

Seal steam pressure low

Both control valve Mechanical or electrical fault Open bypass valve and
operating in a sequence maintain constant pressure
faulted manually.

Mechanical fault in seal

steam control valve

Valve fails to follow control Pressurizer valve faulty or set Check pressure, reset
signals too low pressurizer valve.
Filter choked (annunciation) Clean / replace filter and
change oil of the actuator as
specified.
Electrical fault

Valves Many causes possible Determine problem on the
basis of valve and description,
and correct.

Control system Many causes possible Determine problem on the

basis of instrumentation and
control manual and correct.

5.2-0460-00/6
 Steam Turbine Control Fluid System
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Control fluid properties Impure control fluid Examine control fluid samples.
inadequate
Start up bypass regeneration

Rise in neutralization unit immediately.
number (Observed on the
or
basis of constant values
measured continuously Check its operational status.
under the same
conditions). Examine control fluid for water
content, (take sample from
surface).
Change over to other control
fluid cooler.

Fuller’s earth filter exhausted Replace Fuller’s earth filter,

even if replacement not yet
scheduled.
Clean fine mesh filter.

High water content Water entering via cooler Change over to other control
fluid cooler; determine cause
of water entry.

Air release property Take measures as for rise in
diminished neutralization number.

Level in control fluid tank

low

Slowly sinking level in fluid Normal fluid loss not replaced Top up with control fluid of
tank. same make; take sample of
topping-up fluid

Level sinking rapidly (2 out Excessive loss Caution: Stop turbine

of 3 level very low monitor generator immediately. Stop
responds) control fluid pumps and initiate
fire protection measures.

Control fluid pressure low Pump faulty Check control fluid pumps.
Change over to standby pump
or observe start up of standby
pump.

BHEL Haridwar 5.2-0470-00/1

Fault Cause Remedy

Other symptoms

Control fluid differential Filter chocked Change over to other filter,

pressure across clean filter element or insert
interchangeable filter high new filter element.

Control fluid temperature Excessive cooling of system Check temperature controller;

low piping or fault in closed-loop if control valve is open, switch
control off temperature regulator and
close control valve. Switch on
heater when control valve is
closed.

Control fluid temperature Inadequate cooling Check temperature controller;

high check cooling water
temperature, check cooling
water adequately vented,
change over to other control
fluid cooler.
Heater switched on Switch off heater
(fault in open loop control)

Temperature at heater Control fluid heater overheated Switch off control fluid heater
protective tube high

Leak in hydraulic devices

Control fluid/ oil leakage
monitor responds Check carefully which medium
 Leakage of control fluid at is escaping: oil, control fluid or
the hydraulic governor both.
Operation of the turbine
generator may be continued
provided that the escape of
fluid is continuously monitored.

 Leakage of oil or control Diaphragm damaged: Repair leak

fluid and oil at the
hydraulic governor Difficulties in regulating during
operation using hydraulic
governor in the event of both
media escaping.

 Leakage of oil at the trip Operation of the turbine

mechanisms of the over generator may be continued
speed governor or the provided that the escape of
shaft position monitor. fluid is continuously monitored.

5.2-0470-00/2
Fault Cause Remedy

Other symptoms
 Leakage of oil or oil and Diaphragm damaged on the Repair leak
control fluid at the trip control fluid side, danger of
mechanisms of the over turbine trip. If both oils are
speed governor or the leaking, danger of control fluid
shaft position monitor. mixing with oil.

Alarm : Control fluid/water

leakage monitor responds
 Leakage of control fluid Operation of turbine generator
at hydraulic pressure may be continued.
alarm
 Leakage of water at Danger of water mixing with Repair leak
hydraulic pressure alarm control fluid

5.2-0470-00/3
 Steam Turbine Gland Steam System
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Seal steam escaping from
glands

Seal steam pressure normal Seal steam exhauster fan not Start one seal steam
operating exhauster fan.
Check position of valves
upstream of exhauster fan
and correct (valves of
standby exhauster fan must
be closed).
Mechanical or electrical fault in Discharge seal steam to
seal steam exhauster fan atmosphere.

Seal steam pressure high; Seal steam pressure set point Lower set point.
no fault in valve or controller too high
functions

Seal steam pressure low

Both control valves Mechanical or electrical fault Open bypass valve and
operating in sequence are maintain constant pressure
faulty manually.

Mechanical fault in seal steam

control valve

Valve fails to follow control Valve faulty or set too low Check pressure; reset valve.
signals
Filter chocked (annunciation) Clean / replace filter and
change oil of the actuator as
specified.

Electrical fault

Valves Many causes possible Determine problem on the
basis of valve description
and correct.

Control system Many causes possible Determine cause on the
basis of instrumentation and
control manual and correct.

BHEL Haridwar 5.2-0480-01

 Steam Turbine Bypass System
Operation Fault Tracing

Fault Cause Remedy

Other symptoms
Bypass stop and control
valves fail to open

Reheat pressure > Check condensate pressure,
constant or variable condenser vacuum and
pressure setpoint. bypass steam temperature.

Injection water pressure

downstream of injection water
control valves < interlock
pressure

Condensate pump(s) Check operating conditions of
failed. condensate pump or
condensate system.

Pressure downstream of Establish normal conditions.
Condensate pump(s) too
low.

Fault in injection water Check actuators of injection
control valves or their water control valves, e.g. slide
actuators. valves for valve operation.
Condenser vacuum low. See fault tracing instructions
for condenser plant.
Bypass steam temperature See fault tracing instructions
high. for condenser plant.

Reheat pressure < Constant pressure setpoint too Lower constant pressure
constant pressure setpoint high. setpoint.
but > variable pressure
setpoint.

Reheat pressure > Fault in control
Check fault annunciation in
constant or variable
control cabinet.
pressure setpoint.
Interlocks ineffective Attend fault as described in
bypass control manual.
Shut down control until fault is
attended, and control the
reheat pressure manually.
Bypass stop and control
valves close during bypass
operation

Reheat pressure > Injection water interlock
constant pressure setpoint effective.

BHEL Hardwar 5.2-0490-00/1

 Fault Cause Remedy

Other symptoms

Injection water pressure < Check operating conditions of
interlock pressure. condensate pumps or
condensate system.
Establish normal operating
conditions.
Condenser vacuum interlock See fault tracing instructions
effective. for condenser plant.
Bypass system temperature Injection water flow rate too
nd
interlock effective. low, check 2 stage water
injection if bypass steam flow
rate is high.
Bypass control valves close

Reheat pressure > Steam flow rate limitation Reduce steam generator
constant pressure setpoint effective. output.

Bypass stop and control

valves fail to open

Reheat pressure > Fault in injection water control Check signal pressure and
constant pressure set point valves or their actuators. pressure beneath pistons of
injection water control valves.
Condensate pressure
upstream of injection water
control valves normal.
Condensate pressure
Signal pressure not Locate fault in regulator or
downstream of injection water present: Fault in regulator hydraulic control gear and
control valves < interlock or hydraulic control gear. attend.
pressure.

Signal pressure present, Attend fault in changeover
Pressure beneath pistons valve for injection water
of one or more injection control valves.
water control valves not
Open bypass valve until fault
present: Changeover valve
is removed.
defective.

Signal pressure present, Remove blockage in injection
Pressure beneath pistons water control valve
of injection water pilot
valve present: Injection
water control Valve
jammed.
Reheat pressure > constant Fault in interlock elements Check limit pressure control
pressure setpoint. gear.
Condensate pressure Locate and attend fault in limit

Limit pressure control gear
upstream and downstream of pressure control gear.
fails to open: Fault in limit
injection water control valve >
pressure control.
interlock pressure.

5.2-0490-00/2
 Fault Cause Remedy

Other symptoms

Limit pressure control gear Locate and attend fault in
opens: fault in pressure pressure switch.
switch.
If only one of the hydraulic
condensate pressure
monitoring channels is faulty,
the faulty channel may be
blocked and bypass operation
continued.
Attention: No redundant
pressure monitoring effective:
use other criteria, e.g. bypass
steam temperature, to asses
injection water flow rate.
Attend fault as soon as
possible.

Reheat pressure > Fault in interlock elements for
constant pressure setpoint. loss of condenser vacuum.
Condensate pressure

Diaphragm of limit Replace diaphragm;
normal.
pressure control gear
damaged.

Diaphragm of bypass Replace diaphragm.
condenser safety device
damaged. Close cutoff valve upstream of
measuring element.
Insert lever and lock.
Replace diaphragm.
In this case bypass operation
may be continued for the
duration of the repair.

Reheat pressure > Fault in interlock elements for Check temperature measuring
constant pressure setpoint. high bypass steam instrument circuit, actuators of
Bypass steam temperature temperature. solenoid valves and attend
normal. fault.

5.2-0490-00/3
 Steam Turbine In-Service Maintenance
Maintenance Introduction

The availability, reliability and economy of a recording activities as well as procedures to

turbine generator depend on the proper identify the condition of components.
condition of all components. This goal can
only be achieved through a comprehensive The inspection schedule is supplemented by
maintenance program. tables specifying the testing intervals,
instructions and test records for comparison
This maintenance program specifies of the desired and actual conditions.
activities to be performed with the unit in
service to establish the actual condition at Maintenance Schedule
regular intervals (inspection = tests and The maintenance schedule [2] contains all
recording of operating data) and to maintain maintenance activities to be performed
the desired condition (maintenance). during turbine operation or outages at
specified intervals.
Inspection Schedule
The inspection schedule [1] includes all The maintenance work to be performed
essential testing and operating data during prolonged outages, e.g. overhauls,
have been elaborated separately [3].

Also refer to the following sections:

[1] 5.3-0010 : Inspection Schedule
[2] 5.3-002.. : Maintenance Schedule
[3] 5.3-0200 : Instructions for Overhaul

BHEL Haridwar 5.3-0001-01

 Steam Turbine Inspection Schedule
Maintenance

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1.0 Testing of Tests according to:
1.1 Controllers Functioning Ref. 5.2-0021 5.3-0030
& setting 5.3-0035
1.2 Automatic Turbine Tester Functioning Ref. 5.2-0022 5.3-0060
& 5.2-0023 5.3-0061
1.3 Protective devices Functioning Ref. 5.2-0024 during start up,
& setting power operation,
1.4 Safety devices Functioning Ref. 5.2-0025 shut down & stand
& setting still
1.5 Valves Functioning Ref. 5.2-0026
free movement
leak tightness
1.6 Monitoring devices Functioning Ref. 5.2-0027
setting and
accuracy

2.0 Recording and Comparison Ref. 5.2-0028 Also ref. 5.3-0037

documentation of of specified and for long term
operational parameters actual data monitoring
and conditions
2.1 Steady state operation h
2.2 Non-steady state operation every start-up
2.3 Faults every occurrence
2.4 Analysis of steam Purity d Ref. 5.3-0050
2.5 Measurement of internal Internal 3m
efficiency condition of
turbine

3.0 Inspection of LP turbine During Ref Tech. Circular

free standing blades intermediate No. X-68
3.1 Visual inspection Erosion, and major
looseness inspections,
every 50,000
3.2 Blade profile and root Crack
hrs. of
crack examination
operation
3.3 Cleanliness of blade root Cleanliness
and groove
3.4 Blade natural frequency Natural freq.
test

BHEL Haridwar 5.3-0010-04/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
4.0 Inspection of accessible During minor, during shut down
expansion joints in cross intermediate
around and extraction lines and major
4.1 Visual inspection Damages inspections
4.2 Surface crack examination Crack
5.0 Inspection of casing
guides and supports
5.1 Seating of casing on w
support elements
5.2 Cleanliness w
5.3 Integrity of keys & packers Damage During During shut down
5.4 Thermal clearances as per Clearances intermediate
drawing and major
inspections
6.0 Visual inspection for Leakage d
steam-tightness noise
6.1 Casing joints
6.2 Flanges
6.3 Shaft seals
6.4 Valve stems
6.5 Instrument connections
7.0 Inspection of drains
7.1 Internal leak-tightness w
7.2 External leak-tightness w
8.0 Inspection of pumps,
motors and other drives in
continuous operation
8.1 Vibration behaviour d
8.2 Head d
8.3 Bearing temperatures d
8.4 Thrust d
8.5 Leak-tightness d
9.0 Visual inspection of piping
9.1 Leak-tightness d
9.2 Vibration d
9.3 Hangers w
9.4 Expansion w
9.5 Vibration dampers 3m

5.3-0010-04/2
 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
10.0 Inspection of hydraulic
accumulator
10.1 Check charge pressure 2w

11.0 Inspection of Main oil tank

11.1 Level check d
11.2 Foaming characteristics w
11.3 Water collection on bottom 2w
of oil tank
11.4 Level check in bucket filter w
to assess filter chocking
11.5 Water content of oil d
11.6 Solid particle content of oil d
11.7 Analysis of properties Ref. 5.1-0130 Ref. 5.3-0080
12.0 Inspection of FRF tank
12.1 Level check d
12.2 Level check in bucket filter w
to access filter chocking
12.3 Foaming characteristics of w
FRF
12.4 Analysis of fluid properties Ref. 5.1-0140 Ref. 5.3-0082
13.0 Oil / FRF filter
13.1 Check differential pressure d
reading
13.2 Check venting d
14.0 Inspection of TG-deck
springs
14.1 Reference spring heights Ref. Technical After first year
14.2 Alignment check circular No. X-85 of operation
14.3 Catenary check

5.3-0010-04/3
 Steam Turbine Maintenance Schedule
Maintenance Turbine

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of sliding Visual 1m
surfaces inspection

casing supports

spacer bolts and discs
for bearing pedestals and
turbine casings
2. Cleaning of turbine blading measurement as indicated by The criteria
by flushing through with of ηi criteria indicating stage
saturated steam as pressure when
prescribed in 5.3-0070 saturated steam
flushing is
necessary are the
internal efficiency
ηi and the stage
pressures
3. Preservation of turbine relative continuous During shutdowns
using air drying equipment humidity in lasting longer than
as prescribed in 5.2-0360 turbine < 50% 1 week
4. Lubrication of components as prescribed in
of the turbine control and 5.1-0690
turbine protection systems
5. Tightening of turbine 1m
control valve packings
6. Tightening of valve stem 3m or in the
seals event of
leakages
7. Lubrication of valve stems as prescribed
5.1-0690

BHEL Haridwar 5.3-0021-02

 Steam Turbine Maintenance Schedule
Maintenance Oil system, Seal Steam system, Drains

Oil System

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of filters and
strainers

Switch over duplex filters ∆ p across as indicated by
and clean fouled filter filter criteria, max 6m
cartridges as prescribed
in 5.1-1130

Turn plate-type filters d
through two three
revolutions as
prescribed in 5.1-1 120

Clean plate-type filters 6m -1y during
appropriate
shut-downs and
overhauls

Replace filter papers in ∆ p across as indicated by
fine mesh filter filter criteria, max 6 m

Change oil tank oil level in as indicated by during
strainers, clean chocked bucket criteria, appropriate
strainers as prescribed strainers max. 6m - 1y shut-downs and
in 5. 1-1 010 overhauls

Clean wire mesh of oil 6m
stripper
2. Cleaning of oil using solid or liquid continuous, as
centrifuge foreign matter indicated by
in oil criteria
3. Cleaning of centrifuge as deposits in 1m as
specified by the centrifuge indicated by
manufacturer criteria
4. Cleaning of oil tank after deposits in oil 3 -4 y during overhauls
draining oil tank
5. Maintain oil tank level at level in oil tank 1 d (check),
service level; top up with topping up as
oil of same make and indicated by
properties criteria
6. Draining of water from the water collecting as indicated by establish cause
oil tank on oil tank criteria of water
bottom accumulation

BHEL Haridwar 5.3-0022-01/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
7. Oil or grease change in as specified by
valve actuators actuator

Motive oil valve manufacturer

Oil temperature control
valve
8. Lubrication of pump and as specified by
fan motors motor

Auxiliary oil pumps manufacturer

Emergency oil pump

Jacking oil pumps

Oil vapour exhauster
fans
9. Lubrication of oil vapour as prescribed by
exhauster fan bearings fan manufacturer
10. lubrication of valve stem at as prescribed in
the lubrication points 5.3-0081
provided
11. Tightening of valve, steam 3m or in the
seals event of leakages
12. Elimination of oil leakages oil leakages continuous
by tightening of flanges
and bolted joints
13. Check vibration dampers 1y
as prescribed in 5.3-0100
14. Charging of hydraulic charge 1m
accumulators pressure

5.3-0022-01/2
Seal steam system

Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
1. Change of control fluid for 1y
seal steam control valve
actuators as prescribed in
5.1-0690
2. Filter change for seat 1y
steam control valve
actuators as prescribed in
its manual
3. Lubrication of vapour as specified by
exhaust fan motors motor
manufacturer
4. Lubrication of vapour as prescribed by
exhaust fan bearings fan manufacturer
5. Lubrication of valve stems 3m
at the lubrication points as
prescribed in 5.3-0081
6. Tightening of valve stem 3m or in the
seals event of leakages

Drains

Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
1. Oil or grease change in as specified by
drain valve actuators actuator
manufacturer
2. Lubrication of drain valve 3m
stems at the lubrication
points provided as
prescribed in 5.3-0081
3. Tightening of drain valve 3m or in the
stem seals event of leakages
4. Check on drain line sludge 1 -2y
traps

5.3-0022-01/3
 Steam Turbine Maintenance Schedule
Maintenance FRF system

Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of filters ∆ p across filter
and strainers

Switch over duplex
filters; and clean fouled
filter cartridges as
prescribed in 5.1-1130

Turn plate-type filters d
through two three
revolutions

Clean plate-type filters 6m -1y during appropriate
shut-downs and
overhauls

Replace filter papers in ∆ p across filter as indicated by

fine mesh filter as criteria, max 6 m
prescribed in 5.1-1140

Replace fuller’s earth Neutralization 6m or as
filling in regenerating number indicated by
filter as prescribed in criterion
5.3-0082

Change FRF tank FRF level in as indicated by during appropriate
strainers; clean chocked strainers criteria shut-downs and
strainers overhauls

Regenerate air filters or Discoloration of 3m, or as
exchange filter filling filter filling indicated by
criterion

2. Cleaning of FRF tank after deposits in FRF 3-4y during overhauls

draining FRF tank
3. Keeping the FRF in FRF
tank at operating level.

Top up using FRF of the Level in FRF 1 d check; Top
same brand and with the tank up as indicated
same properties by criterion
4. Lubrication of motors of as specified by
pumps and fans the motor

FRF pumps manufacturer

FRF circulating pump

FRF vapour extraction
fan

BHEL Haridwar 5.3-0023-01/1

 Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
5. Lubrication of the bearings as specified by
of the FRF vapour fan manufacturer
extraction fan
6. Lubrication of the valve 3m
stems at the lubricating
points provided
7. Retightening of the valve 3m of if leakage
stem packing detected
8. Elimination of leaks by leakage regularly, as
retightening flanges and indicated by
unions criterion
9. Checking of damping fluid 1 -2 Y
in vibration dampers
as prescribed in 5.3-0100
10. Charging of hydraulic Filling 1m
accumulators pressure

5.3-0023-01/2
 Steam Turbine Testing during Start-up
Maintenance

Introduction main trip valves in operating position, stop

valve closed etc.)
Tests demonstrate the readiness for
operation and the proper functioning of The operation sequence establishing certain
important components. They must be operating conditions is given in the form of
performed before and during start-up of the general instructions to avoid constant
turbine generator unit, irrespective of the repetition in the table of test sequences.
time of the preceding shutdown.
If all prerequisites for performance of the Test Performance
complete test program are not fulfilled, Take care to avoid any risks to people or
reduced testing to ensure the readiness of machines while performing tests.
the auxiliary, emergency and jacking oil
pumps for operation must be performed. Any simulated conditions necessary for the
tests must be cancelled after completion of
The scope of the test program for start-up of tests.
the turbine is to make sure that all tests
required to be performed before start-up Steam inlet valve may only be operated for
after a shutdown period of approx. 4 weeks test purposes if the piping systems upstream
[1, 2] have completed. of the valves are not under pressure and the
systems concerned have been expressly
cleared for testing.
Test procedures
Test performance must be recorded.
Tests, prerequisites, test activities and
criteria in table form is intended to simplify If incorrect operation of the equipment being
testing. The symbols at the head of the tested occurs, take action establishing full
columns in the tables are an aid to operational reliability of the turbine generator
understanding the concise test instructions. unit immediately. Pay attention to fault
tracing instructions.
The tables are also suited to use as
checklists. Whenever no specific test
instructions are prescribed for any test, the
sequences shown in the table must be
followed. Also refer to the following sections:
[1] 5.3-0061: Testing During Standstill
A number of tests require that certain
[2] 5.2-002..: Testing of turbine Component
components be in a definite position (e.g.

BHEL Haridwar 5.3-0030-02/1

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Main trip valves in
operating Position
o Stop valves closed o Starting and load limit device not in 0% position
o Test valves of stop valves in left-hand end
position (=stop valves open)
(1) Move test valve pilot into right-hand end position
using handwheel (= stop valves closed)
(2) Bring starting and load limit device into 0%
position
• Main trip valve in operating position
(3) Bring starting and load limit device into 40%
position
• Main trip valve in operating position and ready to
trip
• Stop valves closed

Main trip valves in o Starting and load limit devices not in 0% position
operating Position
o Test valve of stop valve in left-hand end position
o Stop valves open
(1) Bring starting and load limit device into 0%
position
• Main trip valve in operation position
(2) Bring starting and load limit device into 40%
position
• Main trip valve in operating position and ready to
trip
• Stop valves open

Auxiliary oil pumps

o Pressure-dependent o Shaft at standstill
on command from
o Oil system depressurised
subloop control before
starting turning gear o Auxiliaries and emergency oil pumps off
operation
o Subloop controls on Manual
(1) Switch auxiliary oil pump 1 subloop control to
Auto
• Auxiliary oil pump 1 on
• System oil pressure present
(2) Switch auxiliary oil pump 2 subloop control to
Auto

5.3-0030-02/2
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
(3) Switch auxiliary oil pump 1 subloop 1control to
Manual
(4) Switch auxiliary oil pump 1 off
• Auxiliary oil pump 2 on
• System oil pressure present

D.C. Emergency oil

pump
o Pressure-dependent (1) Switch D.C. emergency oil pump subloop control
on command from on
subloop control before (2) Switch auxiliary oil pump 2 subloop control to
starting turning gear Manual
operation
(3) Switch auxiliary oil pump 2 off
• DC emergency oil pump on
• Lubricating oil pressure present
(4) Switch DC emergency oil pump subloop control
to Manual
(5) Switch DC emergency oil pump off
• Oil system depressurised
• Auxiliary and emergency oil pumps off
Auxiliary and
Emergency oil pumps
o Operational readiness o Shaft at stand still
before starting turning
o Oil system depressurised
gear operation
(testing not required if o Auxiliary and emergency oil pumps off
sobloop controls
o Subloop controls on Manual
have already been
successfully tested) (1) Switch auxiliary and emergency oil pumps in turn
to Manual on
• System oil pressure present
Auxiliary and o Turning gear in operation
Emergency oil pumps
o One auxiliary oil pump operating
o Operational readiness
after starting turning (1) Switch stand-by auxiliary oil pump to Manual on
gear operational • Pressure buildup in system
(2) Switch stand-by auxiliary oil pump to Manual off
(3) Switch emergency oil pump to Manual on
• Pressure buildup in system
(4) Switch emergency oil pump to Manual off

5.3-0030-02/3
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Auxiliary Oil pumps
o Speed-dependent o Turbine generator unit speed = rated speed
cutout when rated
(1) Verify cut out of auxiliary oil pump
speed is reached
Jacking oil pumps
o Speed-dependent on o Shaft at standstill
command of AC
o Jacking oil pumps off
jacking oil pump from
subloop control before o Subloop controls on Manual
starting turning
(1) Switch AC jacking oil pump subloop control to
gear operation
Auto
• AC jacking oil pump on
• Jacking oil pressure present
(2) Switch AC jacking oil pump subloop control to
Manual
(3) Switch AC jacking oil pump off
• AC jacking oil pump off
• Jacking oil system depressurised

Jacking oil pumps

o Manual on of AC o Shaft at stand still
jacking oil pump
(1) Switch AC jacking oil pump to Manual on
before starting turning
gear operation • AC jacking oil pump on
• System oil pressure present
(2) Switch AC jacking oil pump to Manual off
• AC jacking oil pump off
• System depressurised
Jacking oil pumps
o Speed-dependent on o Shaft at stand still
command of DC
o Jacking oil pumps off
Jacking oil pump from
subloop control before o Subloop control on Manual
turning gear operation
(1) Switch DC jacking oil pump subloop control to
Auto
• DC jacking oil pump on
• Jacking oil pressure present

5.3-0030-02/4
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
(2) Switch DC jacking oil pump subloop control to
Manual
(3) Switch DC jacking oil pump off
• DC jacking oil pump off
• Jacking oil system depressurised
Jacking oil pumps
o Operational readiness o Shaft at stand still
of Jacking oil
o Jacking oil pumps off
pumps
o Subloop controls on Manual
(1) Switch jacking oil pumps in turn to Manual on
• Jacking oil pressure present
Control fluid pumps
o Pressure-dependent o Control fluid system depressurised
on command from
o Control fluid pumps off
subloop control
o Subloop control on Manual
(1) Select one control fluid pump (e.g. pump 1)
(2) Switch subloop control to Auto
• Control fluid pump 1 on
• Control fluid system pressure present
(3) Select control fluid pump 2
(4) Switch control fluid pump 1 off
• Control fluid pump 2 on
• Control fluid system pressure present
(5) Switch subloop control to Manual
(6) Switch control fluid pump 2 off
• Control fluid system depressurised
• Control fluid pumps off
Control fluid pumps
o Operational readiness o Control fluid system depressurised
(Testing not required
o Control fluid pumps off
if subloop controls
have already been o Subloop control on Manual
successfully tested)
(1) Switch control fluid pumps in turn to Manual on
• Control fluid system pressure present

5.3-0030-02/5
 Equipment tested o Preconditions Date
() Test Step Result
o Type of test
• Result Tested by

Remote trip initiation

o Push button operation o Main trip valve in operating position
o Stop valves closed
(1) Press trip push button
• Trip annunciated

Stop valves
o Leak test o Main steam pressure present upstream of stop
valves
o Stop valves closed using test valves
(1) Open control valves
• No speed increase
(2) Bring back test valves to operating position
Control valves
o Leak test o Control valves closed using motorised actuator
o Main steam pressure present upstream of turbine
(1) Open stop valves
• No abnormal speed increase
(2) Bring back motorised actuator to open position

Overspeed trip
o Oil injection test o Turbine speed < 2970rpm or
o Unit in low-load operation
(1) Release testing device for operation
(2) Press and hold down test valve for inhibiting trip
(left-hand valve)
(3) Turn handwheel of hydraulic test signal
transmitter to right until test oil circuit is
pressurised
(4) Observe oil pressures where overspeed trip
device operates
• Auxiliary trip circuit depressurised

5.3-0030-02/6
 Equipment tested o Preconditions Date
() Test Step Result
o Type of test
• Result Tested by

(5) Turn handwheel of hydraulic test signal

transmitter to left until test oil circuit is
depressurised
(6) Bring trip device of overspeed trip into operating
position using right-hand valve
• Auxiliary trip pressure built up
(7) Repeat test until overspeed trip operates at the
same test oil pressure in successive tests

5.3-0030-02/7
 Steam Turbine Testing during Power Operation
Maintenance

Test that demonstrate the readiness for Test performance

operation and the proper functioning of Test performance must be recorded. If
important components, must be performed incorrect operation of the equipment tested
during power operation of the turbine occurs, take action establishing full
generator unit. The time intervals between operational reliability of the turbine generator
tests are given in a separate instruction [1]. unit immediately.
Pay attention to fault tracing instructions. [2]
Test Procedures
The table containing tests, prerequisites,
test activities and criteria is intended to
simplify testing. The tables can be used as
checklists. When no specific instructions are Also refer to the following sections:
prescribed for any test, the test sequences [1] 5.2-002.. : Testing of turbine components
shown in the table must be followed. [2] 5.2-0400 : Fault tracing

Equipment tested o Preconditions Date

o Type of test () Test Step Result
• Result Tested by
Turbine controllers
o Functional test o Control valve opening < 100%
(1) Change setpoint of effective controller
• Change in control valve-opening corresponding
to setpoint change

Bypass control
o Functional test o Load approx. 50%
(1) Open HP bypass station slowly by operating
pushbutton on control panel
• Reheat pressure increases
• Injection water pressure present
• Bypass stop valves open
• Bypass control valves begin to open
(2) Close HP bypass station
• Reheat pressure drops
• Bypass control valves close
• Bypass stop valves close
• Injection water pressure reduced

BHEL Haridwar 5.3-0035-02/1

 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Seal steam controller
o Functional test o Seal steam controller on
(1) Seal steam controller off
(2) Induce control deviation by operating control
valves (Pushbutton on control panel)
(3) Seal steam controller on
(4) Verify correction of seal steam pressure
Oil temperature
controller
o Functional test o Oil temperature controller on
(1) Oil temperature controller off
(2) Induce control deviation by operating temperature
control valve (Pushbutton on control panel)
(3) Oil temperature controller on
(4) Verify correction of oil temperature

Auxiliary and
emergency oil pumps
o Operational readiness o Auxiliary and emergency oil pumps off
test
(1) Auxiliary pumps subloop control off
(2) Auxiliary oil pump 1 Manual on
• Pressure buildup downstream of pump
(3) Auxiliary oil pump 1 Manual off
(4) Auxiliary oil pump 2 Manual on
• Pressure buildup downstream of pump
(5) Auxiliary oil pumps 2 Manual off
(6) Auxiliary oil pumps subloop control on
(7) Emergency oil pump Manual on
• Pressure buildup downstream of pump
(8) Emergency oil pump Manual off
Control fluid pumps
o Operational readiness o Service control fluid pump on
test
(1) Stand-by control fluid pump Manual on
• Pressure buildup downstream of tested pump
(2) One control fluid Manual off

5.3-0035-02/2
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Main trip valves
o Ease of movement o Automatic turbine tester available
test
(1) Select and start test program for one protective
device
• Main trip valves respond
• No fault annunciations on automatic turbine tester
Remote trip solenoids
o Functional test o Automatic turbine tester available
(1) Select and start Remote trip solenoids test
program
• Main trip solenoid respond
• No fault annunciations on automatic turbine tester
Overspeed trips
o Functional test and o Automatic turbine tester available
testing of setting
(1) Select and start Remote trip test program
• Overspeed trips respond
(2) If ATT annunciates fault repeat overspeed trip
test
Overspeed trips (1) Release hydraulic test signal transmitter
o Manual functional test (2) Depress left-hand piston of hydraulic test signal
and testing of setting transmitter to limit and hold down
(3) Increase test pressure using handwheel of
hydraulic test signal transmitter
o Overspeed trip(s) respond(s)
(4) Ascertain pressure at which trip(s) respond(s)
and record
(5) Reduce test pressure using handwheel of
hydraulic test signal transmitter
(6) Depress right-hand piston of hydraulic test signal
transmitter to limit
• Auxiliary trip pressure builds up
(7) Release right-hand piston of hydraulic test signal
transmitter
(8) Release left-hand piston of hydraulic test signal
transmitter

5.3-0035-02/3
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

(9) Repeat test as often necessary until trip operates

at the same test pressure as set during
commissioning
Hydraulic low-vacuum
trip
o Functional test and o Automatic turbine tester available
testing of setting
(1) Select and start Low-vacuum trip test program
• low vacuum trip operates
• No fault annunciations on automatic turbine tester
Differential pressure
switch in extraction
lines
o Functional test o Extraction system in operation
o Extraction swing check valve open
o Hydraulic release present
(1) Reduce differential pressure across differential
pressure switch
• Extraction swing check valve closes slightly
Stop and control valves
o Exercising o Automatic turbine tester available
(1) Apply test load
(2) Select and start test program for stop and control
valve unit to be tested
• Control valve closes
• Stop valve closes
• Stop valve opens
• Control valve opens
• No fault annunciation on automatic turbine tester
Extraction swing check
valves
o Exercising o Extraction system in operation
(1) Change load or extraction flow
• Extraction swing check units perform movements

5.3-0035-02/4
 Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Alarms
o Functional test o Alarms generated
(1) Record alarms generated
Speed indicator (1) Compare with grid frequency

Important operating
values
o Recording (1) Record important operating values in accordance
with 5.3-0036 & 5.3-0037
Drains
o Leak test (1) Test temperature condition of drain values

5.3-0035-02/5
 Steam Turbine Acquisition and Archiving
Maintenance of operating data
Procedural Instruction

Introduction
Documents showing the availability

It is in the interest of both the plant operator statistics
and the supplier that the causes of faults,
severe damage and unfavourable inspection Documents from the electronic data
findings be determined, and actions taken to acquisition system
prevent a recurrence of such incidents.

Processing of analog measured values
In order to determine the cause of such
All the data specified in Table-1 should be
faults, it is essential that information be
archived in MAXSTORIAN of electronic data
available, in the form of operating
acquisition system. It should be possible to
documentation, on the operating history of
retrieve data in the form of logs or time
the turbine generator unit both in the past
curves at any time over the course of the
and immediately before and during the fault
intended archiving period. Long-term data
or damage.
archiving is to be done on magnetic tape /
This instruction contains recommendations disc.
on the acquisition and archiving of operating
Only those values for an operating
data.
parameter should be electronically archived
which, after the scanning interval has
Scope of measurement and elapsed, lie outside the scatter band given in
instrumentation Table-1, when compared to the last
The scope of measurements and also, recorded value.
therefore, the instrumentation of the turbine
generator unit are dictated by the
Processing of binary signals
agreements between plant operators and
suppliers. Normally, binary signals resulting from
annunciations and switching operations are
The data are of importance for operations continuously printed out with high time
management. The scope of data resolution by the electronic data acquisition
recommended in Table-1 should therefore system, alarm and switching logs are thus
be available to permit post-event analysis. generated which form an important source
of information for operations management.
Scope of operating documentation For troubleshooting purposes, the alarm and
Operating documentation comprises the switching logs printed immediately before,
following documents: during and after the fault should be retained
and archived.

Printouts from continuous-line printer

Operating data logs or curves based on
Documents for long-term monitoring of
the data archived in the electronic data the turbine-generator unit
acquisition system
Certain operating data should be recorded

Alarm and switching logs ; such logs at long intervals in order to document the
document the histories of faults or long-term behaviour of the turbine generator
damage and should be archived unit, as well as any data relevant in terms of

Logs with handwritten entries are life expectancy considerations.
required in cases where certain data are The associated logs may be of use in
not recorded or archived analysing faults or damages if the cause can

Logs used to document the long-term be traced back to or is indicative of a
behavior of the turbine generator unit gradually developing adverse change.

BHEL Haridwar 5.3-0037-03/1

Documents on availability statistics decide on countermeasures to be
For the purpose of providing information on implemented.
the operating behaviour and the status of
the plant, it is recommended that availability Retention period for documentation
statistics is compiled which show, among
The documents described above must be
other things, the causes and duration of
archived in a magnetic tape for consultation
periods of non-availability.
for a long time after the operating data have
If the statistics show a frequent recurrence been logged in order, among other things, to
of an event which leads to plant non- analyse any correlations between
availability, in-depth investigations should be component status and operating conditions.
performed.

Documents containing operating data
which are relevant in terms of life
Processing of operating documents expectancy considerations must be
archived until the turbine generator unit is

Fault report
taken out of service.
The control room personnel should prepare

It is recommended that all other
reports on fault or damage, showing all
documents be archived until the next
relevant data on the evolution of the event
inspection and overhaul has been
leading to the fault or damage, as well as
completed.
the countermeasures implemented. Copies
of the printouts from the continuous-line
recorder or dotted-line recorder, operating Importance of documents for settling
data tables and curves generated by the guarantee claims
electronic data acquisition system, and the Without the data contained in the documents
fault and damage logs should be appended described above, the supplier of the turbine
to the fault or damage reports. generator unit is not always able to check
the legal validity of guarantee claims in the

Evaluation of the fault report and the
event of damage or a complaint regarding
operating documentation
component defects and may therefore
Faults and damage usually occur when reserve the right to reject any claims for
several adverse influences are present which the requisite documents are not
simultaneously. Because of the multiplicity available.
of conceivable faults and their possible
influencing factors, it is not possible in this
procedural instruction to present a reliable
and complete picture of all the correlations Table-1 lists the required operating data for
involved. acquisition and archiving in accordance with
the operating instruction, in order to permit
It is the duty of the operator’s or supplier’s evaluation of turbine performance. The
own experts to define the correlation requirements will have to be adapted on the
between the event and the adverse basis of the actual measuring point list.
influencing factors and to evaluate them and

Also refer to the following:

[1] BHEL-EDN document on MAX control system

5.3-0037-03/2
 Table – 1

Data acquisition recommended for post event analysis

ID Code Measuring point Measuring Scatter band Retention

cycle Period
Power/Speed
MKA CE Active Power 30 s 0.002 Pnom service life
MKA CE Reactive Power 30 s 0.002 Pnom service life
MYA FS Turbine generator speed 5s 0.05 to 0.1 s-1 inspection cycle
Steam pressure
LBA CP Upstream MS stop valves 30 s 0.01 Pnom service life
MAA CP Upstream HP blading 30 s 0.01 Pnom service life
LBC/MAA CP Downstream HP blading 30 s 1 bar inspection cycle
LBB CP Upstream reheat stop valves 30 s 0.01 Pnom service life
MAB CP Upstream IP blading 30 s 0.01 Pnom service life
LBQ CP HP extractions 30 s 0.005 to 0.01 Pnom inspection cycle
LBS CP LP extractions 30 s 0.02 Pnom inspection cycle
MAG CP Condenser 30 s 0.01 bar inspection cycle
Steam temperatures
LBA CT Upstream MS-stop valves 30 s 2K service life
LBC/MAA CT Downstream HP turbine 30 s 2K inspection cycle
LBB CT Upstream reheat stop valves 30 s 2K service life
MAB CT Downstream IP turbine 30 s 2K inspection cycle
LBO CT HP extractions 30 s 2K inspection cycle
LBS CT LP extractions 30 s 1K inspection cycle
MAW CT Seal steam header 30 s 1K inspection cycle
Casing temperatures
MAA CT MS-SV/CV 100/50% 30 s 2K service life
MAA/MAB CT Turbine casing 100/90/50% 30 s 2K service life
MAA/MAB CT Turbine casing top/bottom 30 s 2K inspection cycle
MAC CT Turbine casing front/rear 30 s 1K inspection cycle
Bearing temperatures
MAD CT Turbine radial/axial bearings 5s 1K inspection cycle
MKD CT Generator/exciter bearings 5s 1K inspection cycle
Vibrations
MAD/MKD CY Turbine / generator bearing 5s 1 µm inspection cycle
casing
MAD CY Turbine shaft abs. or relative 5s 5 µm inspection cycle
MKD CY Generator / exciter shaft 5s 5 µm inspection cycle
absolute or relative

5.3-0037-03/3
 Steam Turbine Remedial Actions for
Maintenance off-normal operating conditions

Turbine

Off-Normal Condition Action Classification of action

Main steam pressure > Pmax Increase turbine load or reduce In-service correction
(Long-term) steam generator output
Main/reheat steam Reduce main / reheat steam In-service correction
temperature > θmax (long- temperature
term)
Main / reheat steam Raise main / reheat steam In-service correction
temperature < θdesign temperature
Steam pressure ahead of Reduce turbine load until pressure In-service correction
turbine blading > Pmax (long- ahead of turbine blading < Pmax
term) (long-term)

HP turbine exhaust steam Take ηi measurements In-service check

temperature or extraction
If internal efficiency ηi degraded Maintenance (saturated
temperatures > normal under
flush through with saturated steam steam washing) during
otherwise comparable
short shut-down
operating conditions Clean blading
Maintenance (cleaning)
during overhaul
Seal steam pressure Check control system; if In-service check and
deviates from setpoint or necessary correct setpoint correction
fluctuates adjuster
Repair during service or
If necessary repair control valves overhaul
Replace filters at seal steam Maintenance during short
control valves shut-down
Seal steam pressure > pnormal Measure temperature in leak-off In-service check
Seal steam leak-off valve steam lines of casings, valves etc.
100%
Check functioning of Gland Steam In-service check
condenser
Check shaft seal and repair Inspection and repair
if necessary during overhaul
Temperature differential , top Check temperature sensors In-service check
and bottom casing > normal
Establish cause of temperature Actions during service or
differential as per 5.2-0423 overhaul depending on
findings
Discrepancies at TSC
- TSC test function not Check TSC and/or temperature In-service check and
correct sensors; check and repair repair
TSC or temperature sensors
- High wall temperature
differentials during steady-
state operation

BHEL Haridwar 5.3-0040-01/1

Off-Normal Condition Action Classification of action

Spacer plates at casing Check for casing lift In-service check

supports not free to move
Clean spacer plates and other In-service check and
fixture elements; establish maintenance (cleaning)
freedom of movement only if casing does
not lift when fixture
elements are removed;
inspection and
maintenance (cleaning) or
repair during overhaul
Check forces exerted by piping, In-service check;
check adjustment of piping correction during shut-
hangers down
Bearing or shaft vibration Perform checks as prescribed in In-service check
> normal under otherwise 5.2-0420 provided vibrations
comparable operating < trip limits
conditions
Actions as appropriate to
finding e.g.
- Rebalance rotor system In-service check
- Check alignment, bearings, In service correction
shaft seals Check during overhaul
or after turbine shut-down

Bearing metal temperatures Perform examinations and checks In-service check

> normal under otherwise as prescribed in 5.2-0421
comparable operating
If temperature changes wide with Immediate inspection and
conditions
rapid rates of change, shut down repair during forced shut-
turbine and inspect bearing down
If temperature changes small and Inspection and repair
slow, inspect and repair at earliest during overhaul
opportunity
Drain valves leaking Open drain, blow through and In-service correction
close again
Loss of integrity of stem Tighten stem seals In-service maintenance
packing of drain valves
LP turbine outlet temperature Leak in internal expansion joint In-service check
> normal under otherwise suspected if high temperature
comparable operating localised
conditions (especially
Perform inspection and if Visual inspection and
condenser vacuum)
necessary repair repairs during overhaul
or after shut-down

5.3-0040-01/2
Oil system

Off-Normal Condition Action Classification of action

Oil system pressures < pnormal Perform examinations and checks Check and remedial
as prescribed in 5.2-0460 and take actions may in many
appropriate action cases be performed
during operation;
otherwise shut down
plant and perform repairs
Lubricating oil pressure Change over filter and clean In-service maintenance
downstream of filter < Pnormal
Control fluid pressure Change over filter and clean or In-service maintenance
< Pnormal replace, or clean filter by rotating
filter plates
Oil temperature downstream Perform examinations and checks In-service checks and
of oil cooler > θnormal as prescribed in 5.2-0460 check maintenance
control system, if necessary
correct setpoint or repair
Check oil cooler vents;
check that no water is
being admitted to standby oil
cooler; check oil cooler for
chocking, where necessary
change over and clean
Oil level in oil tank < normal
- Slow change Top up with oil of same make and In-service check and
type maintenance
Locate leak and take appropriate In-service check and
- Rapid change
actions, e.g. initiate fire protection remedial action
measures
Oil level in tank strainer high Change and clean strainer Maintenance during
service or shut-down
Water collecting on oil tank Drain off water; separate water In-service maintenance
bottom from oil
Establish causes and eliminate Check and repair during
overhaul
Oil escaping at oil guard Check if oil vapour exhauster In-service check and
rings of bearing pedestals fan is in operation correction
Adjust throttle valves on bearing
pedestals
Check leak-tightness of oil tank
covers and if necessary reseal
Oil properties, e.g. air Perform additional oil In-service maintenance
separation capability and examinations; consult on
antifoaming, changed appropriate actions with oil
supplier and turbine manufacturer

5.3-0040-01/3
Control Fluid System

Off-Normal Condition Action Classification of action

Control fluid level in control

fluid tank < normal
- Slow change Top up with control fluid of same In-service check and
make and type maintenance
- Rapid change Locate leak and take appropriate In-service check and
actions; e.g. initiate fire protect- remedial actions
ion measures
Control fluid level in tank Change and clean strainer Maintenance during
strainer high service or shut-down
Control fluid properties, e.g. Operate regeneration plant In-service maintenance
air separation capability or continuously; shorten sampling
neutralisation value, changed intervals; replace Fuller’s
earth in filter
Control fluid temperature Check control system, where In-service checks and
downstream of control fluid necessary adjust setpoint or maintenance
cooler > normal repair
Check control fluid vents
Check that no water is being
admitted to the standby cooler;
check control fluid coolers for
chocking, if necessary change
over and clean
Charge pressures of Recharge accumulators In-service maintenance
accumulators < Pnormal

5.3-0040-01/4
Control System, Protective Devices

Off-Normal Condition Action Classification of action

Change in control system Check control system, if Correction during short

setting necessary reset or correct, shut-downs or overhauls
establish cause of discrepancy
- Control valve lift sequence
and eliminate
- Control valve
synchronisation
- Control valve travel
changed
as function of secondary
pressures
Primary oil pressure Examine antifoaming performance In-service check
fluctuates or < Pnormal of turbine oil
Check oil supply to hydraulic Check during short shut-
speed transducer downs or overhauls
Open main oil pump and check Check and repair during
hydraulic speed transducer overhauls
Control valve streams not
leak-tight
- Control valve opening Replace back seat Repair during overhaul or
100% short shut-downs
- Control valve opening < Replace steam packing rings
100%

Control valve leaking Replace valve stem; rework seat Repair during overhaul
(internal steam leak)
Load shedding relay Repair load shedding relay In-service repair
defective
Faults in valves detected by
automatic turbine tester
- Running time exceeded Adjust limit switch In-service repair
during testing of stop and
control valves
Extraction swing check valve Repair position indicators In-service repair
position indicators defective

5.3-0040-01/5
Pumps and Piping

Off-Normal Condition Action Classification of action

Pump and motor bearing Inspect bearing, renew or In-service maintenance

temperatures > normal replenish grease or oil charge
Pump shaft seals not leak- Tighten and if necessary In-service maintenance
tight repack shaft seals
Performance degraded Switch in standby unit In-service correction
If necessary perform overhaul Repair during overhaul
Discharge head < normal Switch in standby unit In-service correction
under otherwise comparable
Perform system check, if In-service correction
operating conditions
necessary correct system
operation
Pipes vibrating Inspect dampers In-service maintenance
Check and repair piping hangers In-service repair
and supports
Piping and/or piping
connections leaky
- Large-scale escape of Immediately shut down turbine Repair during stoppage
flammable media (initiate fire protection
measures); eliminate leak
- Small-scale escape of Establish cause of leak and Repair during stoppages
flammable media eliminate or overhauls
Valve stem seals not leak- Tighten or replace stem seals In-service maintenance,
tight repair during stoppages
and overhauls

5.3-0040-01/6
 Steam Turbine Measurement of
Maintenance internal Efficiency
Test Instructions

Introduction recommendations given in Table-1 or as

specified by the operator on the basis of
This test instruction describes the procedure
practical experience with the particular plant,
used for measuring the internal efficiency of
which also includes the trend of any
turbines whose expansion line lies within the
changes in efficiency.
superheated steam region.
Principle of measurement
Recommendation for measurement
Prerequisites and limitations
The economic performance of any power The steam conditions in the reference plane
plant unit depends, among other factors, on at the inlet and exhaust of the turbine,
the overall efficiency of the steam turbine whose internal efficiency is to be measured,
and thus, on the internal efficiency of each must lie within the superheated steam
cylinder. region.

Changes in the internal condition of a The internal efficiency of turbines whose

turbine (e.g. due to buildup of deposits on expansion line lies totally or partially within
blades, increased seal clearances, or the wet steam region cannot be measured,
mechanical damage) cause a marked since there is no simple way of measuring
deterioration in internal efficiency. the actual steam content of a flow of wet
steam with sufficient accuracy. This means
Consequently, the internal efficiency of a that the method described here cannot be
turbine cylinder is an important parameter used for measuring the internal efficiency of
with which the effect of the changes in LP turbines, operating under wet steam
internal condition on its performance can be condition.
assessed.

Measuring the steam conditions at the
Measurement of the internal efficiency of turbine inlet and exhaust
each turbine at regular intervals and
The steam pressures and temperatures in
comparison with values recorded previously
the reference plane at the inlet and exhaust
or when the unit was new, are
of a turbine as indicated in Figure-1 are
recommended. This will provide useful
measured, recorded and calculated during
additional information for planning the type,
normal steady-state operation under
scope and timing of maintenance work (e.g.
comparable rated design conditions.
restoring original gaps and clearances,
Carrying out test at identical load and steam
blade repairs etc.).
parameters makes the comparison / trend
The intervals between measurements more realistic.
should be either in accordance with the

Table-1: Test intervals

Type of test Boundary conditions Test interval

Measuring Steady state operation under
6-months
the internal rated design conditions

before and after inspections and overhauls
efficiency comparable with those of
previous measurements.
before and after wet steam washing

BHEL Haridwar 5.3-0050-02/1

 P1
h1 T1

∆h
S1
∆hs P2
h2
T2

hs

Figure-1 : Steam conditions and enthalpies for calculating the internal efficiency of a
turbine cylinder

Notations:
∆h h1 - h2
Internal Efficiency in % = -------- x 100 = ----------- x 100
∆hs h1 - hs

Where,

P1 : Pressure of inlet steam before group stage section

T1 : Temperature of inlet steam before group stage section
P 2 : Pressure of exit steam after group stage section
T2 : Temperature of exit steam after group stage section
h1 : Enthalpy of inlet steam corresponding to P1 & T1
S1 : Entropy of inlet steam corresponding to P1 & T 1
h2 : Enthalpy of exit steam corresponding to P2 & T2

hs : Adiabatic steam Enthalpy corresponding to P2 & S1

Note: Values of h1, S1, h2 and hs are to be worked out from steam table.

5.3-0050-02/2

Determining the enthalpy
Install precision thermocouples or use the
The enthalpies for the steam conditions operational instruments for temperature
measured in the reference plane at the measurement
turbine inlet and outlet are taken from steam
Adjust the inlet steam conditions and the
table. control valve lift to the same values used

Calculating the internal efficiency for previous measurements
The internal efficiency of a turbine cylinder is
Wait until turbine temperatures have
calculated with the ratio of the actual stabilized under steady-state operating
decrease in enthalpy to the isentropic conditions
decrease in enthalpy.

Measure and record the steam pressures

Trend of change in internal efficiency and temperatures
Trend of changes in internal efficiency can
Use steam tables to determine the
be seen when the measurements are plotted enthalpies of the steam condition at the
versus time in a graph. turbine inlet and outlet

Calculate the efficiency
Measuring points and instruments

Compare the measured internal
When taking measurements for calculating
efficiencies with the values recorded
the internal efficiency of a turbine, the
previously or when the unit was new, and
measuring points should be in the same
evaluate
reference plane at the turbine inlet and
outlet as for the acceptance tests.
Duration of testing
The turbine is also provided with test
measuring points for installing precision For reliable measurement, arithmetic
instruments to measure pressures and averages of pressure & temperature
temperatures. measurements should be taken for at least
half an hour duration at stable load condition
Appropriate instruments can be installed in and rated steam parameters.
addition to the operational instrumentation
and used for taking necessary
Reasons for actual conditions deviating
measurements.
from reference condition
If the measurements are to be taken by Changes in internal efficiency can be due to
means of operational instrumentation one or more of the following reasons:
installed in the reference planes, the
instruments must be tested and calibrated
Increased roughness of the blade
regularly in order to eliminate any surfaces due to a build-up of deposits,
inaccuracies due to problems such as drift. corrosion, or solid particle erosion

Increase in clearances in the blading flow
Measuring procedure path
The procedure for measuring the steam
Increased tip clearance losses due to
pressures and temperatures and calculating seal strip wear
the internal efficiency of a turbine is as
follows:
Bypass flow due to internal leaks

Install precision pressure gauges or
Increase of losses in valve seats

recalibrate the operational instrument
Deposits on heat transfer surfaces

Vent the pressure-sensing lines

5.3-0050-02/3
 Steam Turbine Testing during Shut-down
Maintenance

Introduction Test performance

Tests that demonstrate the proper Take care to avoid any risks to people or
functioning of important components, must machines while performing tests.
be performed during shut down of the
Any simulated condition necessary for the
turbine generator unit.
tests must be cancelled after completion of
The scope of the tests performed is listed in tests.
the Test interval instruction [1].
Steam inlet valves may only be opened for
test purposes if the piping system upstream
Test Procedures of those valves is not under pressure and
Test prerequisites, test activities and criteria the system concerned have been cleared for
in tabular form are intended to simplify testing.
testing. Test performance must be recorded.
The tables can also be used as checklists. If incorrect operation of the equipment being
When no specific instructions are given for tested occurs, take action establishing full
any test, the test sequences shown in the operational reliability of the turbine generator
table must be followed. unit immediately.
A number of tests require certain Pay attention to fault tracing instructions.
components be in a definite position (e.g.
main trip valves in operating position, stop
valves closed, etc.).
The operating sequence establishing certain
operating conditions is given in the form of Also refer to the following sections:
general instructions to avoid constant [1] 5.2-002.. : Testing of turbine components
repetition in the tables of test sequences. [2] 5.3-0061 : Testing during standstill

Equipment tested o Preconditions Date

o Type of test () Test Step Result
• Result Tested by
Main trip valves in operating
position

Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand
end position ( = stop valves open)
(1) Move test valve pilot into right-hand
end position ( = stop valves closed)
using hand wheel
(2) Bring starting and load limit device
into 0 % position
• Main trip valves in operating position
(3) Bring starting and load limit device
into 40 % position

BHEL Haridwar 5.3-0060-01/1

Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Main trip valves in operating position

and ready to trip
• Stop valves closed

o Stop valves open o Starting and load limit device not in 0%

position
o Test valves of stop valves in left-hand
end position
(1) Bring starting and load limit device
into 0 % position
• Main trip valves in operating position
(2) Bring starting and load limit device
into 40 % position
• Main trip valves in operating position
and ready to trip
• Stop valves open
Overspeed trip
o Overspeed test after test interval o Generator not synchronised
or after inspections and repairs o Turbine generator unit at rated speed
(See also instruction 5.3-0030)
o Turbine at operating temperature
(1) Raise speed reference to maximum
• Speed approx. 107%
(2) Switch off Electro-hydraulic controller
(3) Run up to trip speed by pressing
mechanical push button on hydraulic
speed governor
(4) Verify operation of overspeed trip
• Trip speed
• Stop and control valves closed
Control valves and reverse power
protection relay
o Leak test valves o Generator synchronised
and o Load > 0 %
o Functional test (reverse power o Speed governor effective
relay)
(1) Lower speed set point

5.3-0060-01/2
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Secondary pressures < opening

pressure for control valves
• Control valves 0%
(2) Verify operation of reverse power
protection relay
• Reverse power protection relay
operated
• Generator breaker tripped
or
• Reverse power protection relay not
operating (see serious faults 5.2-0410)

Auxiliary oil pump

o Pressure dependent on o Stop and control valves closed
command
o Turbine speed dropping
(1) Verify startup of auxiliary oil pump on
pressure-dependent command
• Auxiliary oil pump on

Jacking oil pump

o Speed dependent on command o Stop and control valves closed
o Turbine speed dropping
(1) Verify startup of jacking oil pump on
speed-dependent command
• Jacking oil pump on

Turning gear oil valve

o Speed-dependent open o Stop and control valves closed
command
o Turbine speed dropping
(1) Verify opening of turning gear oil
valve on speed-dependent command
• Turning gear oil valve open

Condenser Safety devices

o Response of electrical o Turbine generator unit not operating
condenser safety device
o Condenser plant operating

5.3-0060-01/3
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Criteria for shut down of condenser

plant fulfilled
o Main trip valves in operating position
o Stop valves closed
(1) Reduce condenser vacuum
(2) Verify operation of electrical condenser
safety device
• Trip initiated
(3) Restore main trip valves to normal
operating position

o Response of hydraulic low o Condenser safety device test

vacuum trip (electrical) performed
o Condenser vacuum > trip vacuum
(hydraulic)
o Main trip valves in operating position
o Stop valves closed
(1) Simulated turbine speed by screwing
in locking bolt on low-vacuum trip
(2) Reduce condenser vacuum
(3) Verify operation of electrical condenser
safety device
• Trip initiated
(4) Restore main trip valves to normal
Operating position
(5) Cancel hydraulic speed simulation
(Unscrew locking bolt on low-vacuum
trip)
(6) Move test valve into operating position

Condenser Safety devices for

bypass operation
o Response of hydraulic low o Condensate extraction pumps
vacuum trip operating
o Condenser pressure Pabs < 0.5 bar
o Criteria for shut down of condenser
plant fulfilled

5.3-0060-01/4
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Bypass operation ended

(1) Press push-button of LP bypass
governor
• Signal pressure for bypass control
valves > 1.7 bar < 2.06 bar
• Bypass stop valves
(2) Operate push-button of LP Bypass limit
controller to inhibit response due to
reduction of condenser vacuum
(3) Reduce condenser vacuum
(4) Verify operation of low vacuum trip
• Signal pressure upstream of bypass
control valves reduced

5.3-0060-01/5
 Steam Turbine Testing during Standstill
Maintenance

Introduction
Tests that demonstrate the proper Test performance
functioning of important components, must Take care to avoid any risks to people or
be performed during stand still of the turbine machines while performing tests.
generator unit.
Any simulated conditions necessary for the
The time intervals between tests are given in tests must be cancelled after completion of
a separate instruction [1]. tests.
Steam inlet valves may only be opened for
Test Procedures test purposes if the piping systems upstream
Test prerequisites, test activities and criteria of those valves are not under pressure and
in tabular form are intended to simplify the system concerned have been cleared for
testing. testing.

The tables are also suited to use as Test performance must be recorded.
checklists. Wherever no specific instructions If incorrect operation of the equipment being
are prescribed for a test, the test sequences tested occurs, take action establishing full
shown in the table are to be followed. operational reliability of the turbine generator
A number of tests require certain unit immediately. Pay attention to fault
components be in a definite position (e.g. tracing instructions.
main trip valves in operating position, stop
valves closed, etc.)
The operating sequence establishing certain
operating conditions is given in the form of Also refer to the following sections:
general instructions to avoid constant [1] 3-001x : Testing of turbine components
repetition in the tables of test sequences.

Equipment tested o Preconditions Date

o Type of test () Test Step Result
• Result Tested by
Main trip valves in operating
position
o Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand end
position ( = stop valves open)
(1) Move test valve pilot into right-hand end
position ( = stop valves closed) using hand
wheel
(2) Bring starting and load limit device into 0%
position
• Main trip valves in operating position
(3) Bring starting and load limit device into 40%
position

BHEL Haridwar 5.3-0061-02/1

Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

• Main trip valves in operating position and

ready to trip
• Stop valves closed

o Stop valves open o Starting and load limit device not in 0%

position
o Test valves of stop valves in left-hand
end position
(1) Bring starting and load limit device into 0%
position
• Main trip valves in operating position
(2) Bring starting and load limit device into 40%
position
• Main trip valves in operating position and
ready to trip
• Stop valves open

Turbine control
o Testing of setting o Main trip valves in operating position
Hydraulic amplifier
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of travel of starting
and load limit device (use starting and load
limit device to change auxiliary secondary
oil pressure by 0.1 – 0.2 bar per reading).
• Travel of starting and load limit device
• Travel of governor bellows
• Auxiliary secondary pressure
• Travel of converter (mm or %)
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer

5.3-0061-02/2
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

o Testing of setting o Main trip valves in operating position

Electro hydraulic converter
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of input voltage of
turbine valve controller
• Input voltage of turbine valve controller
• Travel of converter
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer
Load rejection relay
o Functional test o Main trip valves in operating position
o Control valves open
(1) Use contactor to energize solenoid valves
operated by load rejection relay
• Control valves close for as long as solenoid
valve is energized
Bypass control
o Testing of setting o As per vendor’s recommendation

Main trip valves

o Ease of movement and trip o Main trip valves in operating position
pressure
o Stop valves closed
(1) Reduce control medium pressure of
governor linkage by closing cutoff valve
• Main trip valves close
(2) Measure pressure where main trip valves
close

5.3-0061-02/3
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Remote trip solenoids
o Functional test o Main trip valves in operating position
o Test valves of stop valves in closed
position
(1) Press pushbutton to start remote turbine
trip
• Trip initiated
Low vacuum trip
o Functional test and testing of o Condenser vacuum > response level
setting
or
o Test pump operating and simulated
condenser vacuum > response level
(1) Reduce condenser vacuum or increase
pump pressure
• Low vacuum trip responds
(2) Determine vacuum where trip started
Fire protection system
o Functional test o Shaft at standstill
o Normal operating conditions of oil system
established (exception : jacking oil pump
subloop control off)
o Main trip valves in operating position
(1) Operate fire protection switches 1 and 2 in
succession in the control room and at the
local control stations in the power plant
• Start of fire protection measures in
accordance with functional diagram
• No annunciation “Fire protection measures
not performed”
(2) Acknowledge fire protection measures and
re-establish normal operating conditions for
further testing

5.3-0061-02/4
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Low lub oil pressure trip
o Functional test o Oil system operating
o Main trip valves in operating position
o Stop valves closed
(1) Simulate pressure Transmitters (2 out of 3)
for lubricating oil trip
• Trip started
Stop valve
o Exercising o Oil system operating
o Main trip valves in operating position
o Stop valves open
(1) Actuate main trip valves (manual trip-out
from control system rack or remote trip
• Stop valves closed

o Cut-off pressure o Oil system operating

o Main trip valves in operating position
o Stop valves to be tested open
(1) Reduce trip oil pressure by means of cut-off
valve upstream of control system cabinet
• Stop valve closes
(2) Measure and record trip oil pressure where
valve starts to close

Turbine control valves

o Exercising o Main trip valves in operating position
o Stop valves closed
o No limitation by parallel acting controllers
(1) Open and close control valves by starting
and load limit device
Bypass Stop & Control valves
o Exercising o Bypass interlock criteria not present
or
o Release criteria simulated
(1) Open and close bypass stop and control
valves

5.3-0061-02/5
Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by

Vacuum breakers
o Functional test (1) Operate vacuum breakers

Alarms
o Functional test 4-1190

Binary signal transmitters

o Functional testing of o Remove pressure switches
pressure switches
(1) Test pressure switches with test pump

General measuring
instrumentation
o Functional and annunciation (1) Test and calibrate in accordance with
test manufacturer’s instructions

5.3-0061-02/6
 Steam Turbine Testing of Safety Valves
Maintenance

Introduction The set values must be entered in the

commissioning protocol.
The set pressure of the safety valves of
turbine integral system (e.g. oil or other Bypass valves, which open in the event of
control media) are checked during excessive pressure upstream of turbine
commissioning. components may form part of the over
pressure steam removal system and must
The scope of instruction in the turbine
be likewise set and tested.
manual is, apart from certain exceptions,
strictly limited to the scope of supply of the
turbine factory. Safety valves of the steam
Testing of Safety Valves
and water systems are not normally a part of
the turbine factory’s scope of supply. Thus Regular testing of the safety valves is the
the following instructions may only be responsibility of the turbine generator unit
regarded as recommendations. operator. The testing intervals must comply
with the technical requirements and the
If the pressure in a system increases
recommendations of the valve and turbine
impermissibly from the operating pressure, it
generator unit manufacturer [2] and must be
is the function of the safety valve to reduce
observed.
this pressure to the normal value thus
protecting the system concerned from
damage. Therefore, the turbine
Performance of Testing
manufacturer must approve the valve
settings to be used [1]. Shut-down can be avoided if the testing is
carried out during operation of the turbine.
From the point of view of the turbine
Setting of the Safety Valves manufacturer, however, they can only be
performed if the turbine generator unit is not
The set values recommended by the turbine
endangered.
manufacturer are contained in the Technical
Data [1] of the turbine manual and must be Operation of the turbine with elevated
observed. reheater pressure may lead to impermissible
temperatures or the control and thrust
Setting and testing must be carried out in
characteristics of the turbine being
accordance with the technical requirements
disturbed.
and the instructions of the valve
manufacturer. Furthermore, faults in the safety valves may
cause impermissible load changes or
When the initial setting is performed during
instability of the steam generator. In this
commissioning of the turbine generator unit,
case, it is best to carry out testing when the
a representative of the turbine manufacturer
turbine is not operating.
is to witness the test or be informed of the
set values.

Also refer to the following sections:

[1] 5.1-0100 : Technical data
[2] 5.2-002... : Testing of turbine
components

BHEL Haridwar 5.3-0062-01

 Steam Turbine Testing of Signaling Devices
Maintenance

Introduction Example: A water level can be raised to its

Signaling devices in their various forms are signaling limit by closing the appropriate
important aids to operational supervision. drain valve.
However, they are of value only if they are Care must be exercised with this method to
completely reliable in operation. ensure that the maximum point reached is
Therefore, the signaling devices must be not sufficient to cause an unintentional shut-
tested at regular intervals. down.

These instructions deal with the
Testing during operation by varying the
fundamentals of testing and maintenance of operating condition. When shutting down
signaling devices. and starting up the turbine and its
auxiliaries. and when testing control and
protection equipment, all alarms and
Types of signaling devices condition signals must be carefully
observed and a record made of their
Alarm signaling devices give a visual and
response. It is also important to check
audible indication of operating values
that the signaling actually reflects the
reaching predetermined limits. If this results operating condition accurately.
in automatic intervention in the plant
process. e.g. triggering of the turbine trip, Examples: When shutting down the turbine
then this is also signaled. the “low oil pressure” alarm must come
before the auxiliary oil pump starts
Condition signaling indicates the state of automatically. When testing the overspeed
control devices, e.g. whether a stop valve is trips, the “Overspeed trip operated” alarm
open or closed. must come.
Finally, signaling can provide a reminder

Triggering of the sensor. In this method
that certain action needs to be taken.
the sensor is operated without there
being any change in operating value or
condition.
Basis of signaling device testing
Whenever possible, testing of the signaling Examples: The travel-controlled limit switch
devices should be carried out under a close which signals response of the thrust bearing
approximation to operating conditions. The trip is operated by hand. The pressure
test should also enclose all components of switch for the “condenser vacuum low”
the device. alarm is isolated and then vented to
atmosphere.
In addition to functional testing, the device
settings should also be checked at longer
The response limit value is adjusted so
intervals, especially after inspections. that signaling response occurs. (With this
method it is possible for mistakes to be
made when returning the settings to their
Test procedures original values. Therefore the method
should only be used in exceptional
There are various ways to test the cases.)
functioning of signaling devices.

Signaling response is produced by an

Testing during operation by varying the electrical pulse. If, for some reason, none
operating values. This type of testing is of the previous methods can be used, a
most appropriate when operating values partial test of the signaling device must
can be varied by intervention in the plant be performed by means of an electrical
process. pulse.

BHEL Haridwar 5.3-0063-00/1

Examples: If the level in the oil tank does condition displays, ensure that the correct
not normally fall to its minimum value during colour lamp is used.
operation, the level monitor is disconnected
and the alarm initiated by the application of
an electrical pulse. This method of testing Malfunctions
presupposes that the level sensor itself is Any malfunctioning of signaling devices
not suffering any malfunction. must be rectified Immediately upon
discovery.
Other tests If necessary, the monitored operating values
The lamps of visual signaling devices have or sensor settings must be subjected to
only a limited life. Therefore, they must be critical examination. This is particularly true
tested regularly by means of the lamp test when there is a continuous alarm although
facility to ensure that they are operative and there is no dangerous operating condition in
be replaced if they are blown. When the plant.
replacing coloured lamps in operating

5.3-0063-00/2
 Steam Turbine Testing of
Maintenance Turbine Stress Controller (TSC)

Introduction measured value acquisition and evaluation

functions.
This test instruction describes the plausibility
checks to be carried out on the measured All steam and component temperatures as
values acquired by the temperature sensors well as the calculated margins are either
for turbine stress monitoring, as well as the recorded on dotted-line printers or stored by
recording of measured and calculated the computer.
values for long-term evaluation of
The plausibility of the measured data can be
temperature acquisition and of calculation
checked at a later date using the printed or
circuitry.
stored measured and calculated values. It is
Using the stress monitoring function of the however possible that, by that time, faulty
turbine stress controller (TSC), the non- turbine stress monitoring will result in
steady-state thermal stresses to which the selection of either too fast an operating
steam turbine is exposed during startup and mode, which will have an adverse effect in
shut-down and as a result of changes in terms of the degree of component fatigue, or
heat input to components during power of too slow an operating mode, which will
operation are acquired and compared with have an adverse effect in terms of
the permitted limits. economical operation.
The margins obtained from this comparison For this reason, plausibility checks should
define the stress and set the limits for be carried out on the measured values at
permitted temperature load. the intervals specified in Table-1, in order to
detect and correct any functional defects or
Evaluation of measured temperatures
faulty circuits within the temperature
recording and action of the calculated
acquisition equipment.
margins on the setpoint control for the
turbine controller allow an optimum As part of the long-term monitoring of
operating mode as regards both degree of operating parameters, all measured and
component fatigue and economical calculated TS values should be registered
operation. during steady-state operation under the
same boundary conditions. These values
should then be recorded and archived to
Test recommendations allow comparison at a later date.
A pre-requisite for the proper functioning of Measurement should be performed at the
turbine stress monitoring as described in the intervals specified in Table-1.
introduction is fault-free operation of the

Table-1 : Test Intervals

Type of check or measurement Boundary conditions Test interval

Plausibility checks on Non-steady-state and After inspections and overhauls or
measured values steady-state operation after work on the TS sensor
Recording of measured and Steady-state operation 3 months or after work on the TS
calculated values for long-term sensor or TS monitoring
monitoring purposes equipment

BHEL Haridwar 5.3-0064-01/1

Plausibility checks on measured values
The steam temperatures upstream of
the turbine must be higher than the
When performing plausibility checks on the component temperatures.
measured TS values, the steam and
component temperatures must be compared
The differences that exist between the
with each other, taking certain criteria into main steam temperature and the
consideration. During non-steady-state temperature at the heated surface in
operation, it is also important to evaluate the the main steam valve bodies or the
trend of the measured values over time. steam admission area are only very
slight
If the actual values do not conform to (< 5 K).
expected values, this may be due to
incorrect assignment of measuring points or
During steady-state operation,
to a polarity fault, e.g. at the transducers. temperature differences of
approximately 15 K maximum develop
As regards the criteria to be considered, a between the measuring points on the
distinction must be made between heated surfaces and at the mid-wall of
plausibility checks performed during non- valve bodies or the steam admission
steady-state and steady-state steam turbine area.
operation.

The closer the turbine operating mode
comes to the conditions for purely
Criteria for plausibility checks during constant-pressure operation, the
non-steady-state operation stronger will be the Influence of turbine
output on the differences between main
The temperature at the heated surface of a steam temperatures and the
component must respond faster than that at temperatures at the heated surfaces of
the mid-wall of the component. the turbine casing and the shaft.

The temperature at the heated surface
The temperatures at the heated
of a component is higher during warm- surfaces of the casing and the shaft
up and lower during cooling-down, as cannot be higher than those at the
compared to the temperature at the heated surface of the valve body or the
mid-wall of the component. steam admission area.

During linear changes, the temperature
For the shafts, the differences between
difference ∆θ (in K) arising in the the temperatures at the heated
component is directly proportional to surfaces and the mean integral shaft
the rate of change dθ/dt (in K/min) temperatures are always approximately
0.

During a cold start or startup after an
extended shut-down, the HP turbine
For the barrel-type casing of the HP
warms up rapidly, even while still turbine, differences of upto
operating below rated speed. In the approximately 10 K between
case of the IP turbine however, warm- temperatures at the heated surfaces
up of the shaft takes place to a certain and those at the mid-wall are normal
extent as a sudden step change and during steady state operation.
occurs only just before rated speed is
reached, and then to a greater extent
For the IP turbine, the surface
temperature of the IP turbine shaft is
during subsequent loading.
not measured directly but only at the
heated surface of the inner casing.
Depending on the design-related
Criteria for plausibility checks during
location of the measuring point,
steady-state operation
differences of 10 to 40 K between the

The same absolute temperatures and reheat steam temperature and the
temperature margins must exist for the surface temperatures of the shaft can
same steady-state operating conditions. occur during steady-state operation.

5.3-0064-01/2
Long-term monitoring through recording the turbine stress monitoring equipment.
of all measured and calculated values These must be adapted to plant-specific
requirements.
By registering and recording all measured
and calculated values at the intervals
specified in Table-1 during steady-state Actions to be taken when actual
turbine operation, the thermal behavior of conditions deviate from reference
the turbine and the function of the turbine conditions
stress monitoring equipment can be
monitored on a long-term basis. If actual conditions deviate from reference
conditions, the measured value acquisition
Long-term monitoring can be used to detect function must be carefully checked and any
and rectify any gradually developing faults corrected.
changes.
If the deviations in measured and calculated
If the check on the measured values reveals values are particularly large, it must be
that the margins have changed due to the assumed that the behavior of the turbine
measured absolute temperatures and the plant will be adversely affected. In this case,
differences arising between them, this can action of the TS monitoring equipment on
probably be traced to a fault in the the setpoint control for the turbine controller
calculation circuitry. The cause of the fault must be temporarily deactivated.
must be determined, e.g. by checking the
specified limit curves in accordance with the As long as action of the TS monitoring
procedure described in the manual for the equipment on the set point control for the
TS monitoring equipment. turbine controller is deactivated, the TS limit
curves must be used for evaluation of the
Table-2 contains all measured and thermal stresses imposed on the turbine
calculated values which may be required for components.

5.3-0064-01/3
 Table-2 : Measured and calculated values for long-term monitoring

Measured and calculated values Terms Unit

Effective power and reactive power

effective power peff MW

reactive power preact MVA
Main steam upstream of HP turbine

mass flow mms kg/s

pressure pms bar

temperature θms ºC
Exhaust steam downstream of HP turbine

pressure pHPexh bar

temperature θHPexh ºC
HP expansion section

differential temperature θms - θexh ∆θ K
Reheat steam upstream of IP turbine

pressure pRS bar

temperature θRS °C
Exhaust steam downstream of IP turbine

pressure pIPexh bar

temperature θIPexh °C
Wall temperatures, MS admission area

surface θi-adm °C

mid metal θm-adm °C
Wall temperatures, HP casing

surface θi-HPC °C

mid metal θm-HPC °C
Temperatures, HP shaft

surface θi-HPS °C

simulated, shaft center θm-HPS °C
Temperatures, IP shaft

surface θi-IPS °C

simulated, shaft center θm-IPS °C
Upper TS margins

steam admission area ∆ ∆ θ adm-u K

HP casing ∆ ∆ θHPC-u K

HP shaft ∆ ∆ θHPS-u K

IP shaft ∆ ∆ θIPS-u K
Lower TS margins

Steam admission area ∆ ∆ θadm-l K

HP casing ∆ ∆ θHPC-l K

HP shaft ∆ ∆ θHPS-l K

IP shaft ∆ ∆ θIPS-l K

5.3-0064-01/4
 Steam Turbine Steam Washing of Turbine
Maintenance

Introduction own time of the turbine. Special measures

should be taken to accelerate cooling [3].
During operation, deposits occur on the
turbine blading to a greater or lesser degree For maximum success, steam washing
depending on the steam purity [1] and the should not be started until the casing
pressures and temperatures of the operating temperatures have dropped to < 100°C.
steam. These deposits cause a reduction of
When Steam Washing the turbine stages,
the turbine generator unit’s efficiency due to:
the initial saturated steam temperatures

Changes in the flow profiles must be as low as possible. Steam Washing
with a constant steam condition is not very

Thicker boundary layers in the steam
effective. After a certain time the turbine
flow as a result of rough surfaces.
blading reaches the temperature of the
In extreme cases the flow area of turbine washing steam and the condensation that
may get reduced with consequent reduction brings about the effect is lost. To get
in the maximum possible steam flow through maximum success in the shortest possible
the turbine, and corresponding output. time, it is necessary to increase the steam
temperature in stages by increasing the
Choking of blade flow path can be detected pressure. As the temperature is raised the
on the basis of internal efficiency (ηi) turbine speed will generally increase (take
measurements [2]. care to avoid critical speed ranges).
If deposit leads to an increase in stage Increased speed will also promote cleaning.
pressures, the maximum stage pressures The steam entering the condenser must be
shown in the Technical Data should not be condensed during the entire process i.e. one
exceeded. If necessary, the output must be circulating water pump must be in operation.
reduced. If possible, the turbine generator unit should
Complex, i.e. water-insoluble, silicate be started up and loaded after steam
deposits occur in a temperature range washing. Any dissolved salt residue
between 500°C and 350°C. Alkali silicates remaining on the blading will be blown out
and silicic acid are deposited between due to the high velocity of the steam under
350°C and 60°C. Salt deposits occur at load conditions.
temperatures ranging from 480°C to the Steam washing with saturated steam will
blading stages where condensation begins. only have the desired success if the steam
Salt deposits are water-soluble and can be has adequate moisture content upstream of
removed by steam washing with saturated the blading.
steam. Depending on their composition,
silicate deposits are either water-soluble The saturated steam is introduced into the
(e.g. alkali silicates) or occur as a hard HP turbine via the connection flanges
Water-insoluble coating. In latter case the provided between the stop and control
deposits can only be removed mechanically valves.
during overhauls. The steam is introduced into the IP turbine
between the control valves and the turbine.
General Instructions Appropriate blind flanges are provided.
The effort required for saturated steam The steam line must be blown-out before
washing is considerably lesser than that saturated steam washing commences.
required for opening the turbine. If efficiency
reduction occurs, saturated steam washing It may be ensured that no external
should be performed first. In that case, the condensate can enter the condenser during
major part of the turbine generator unit steam washing.
downtime is accounted for by the cooling

BHEL Haridwar 5.3-0070-02/1

 Fig. 1 : Flow diagram for saturated steam washing

Steam Washing of IP Turbine After the saturated steam line (Fig.1, item 2)
has been joined up at the connection points
All stop and control valves and all valves in
(3), the washing steam can be routed into
the extraction lines remain closed during
the IP turbine, from there via the cross-
steam washing of the IP turbine. Any
around lines to the IP turbine and then to the
isolating valves present upstream of the
condenser.
feedwater heaters must also be closed.
There are two possible ways of discharging
The drains from the IP turbine between the
the condensate condensing in the
reheat control valves and the IP outlet, the
condenser to the atmosphere. These are:
extraction valves or the swing check valves
in the extraction lines must be vented during
By opening the blind flanges (4) on the
steam washing only to the extent required to condenser. The condenser must be
allow the condensate arising to drain off under atmospheric pressure. With this
whilst preventing excessive loss of steam. method of steam washing samples for
All other drains from the turbine generator finding out the saIt content may also be
must be full open. taken at this point.

5.3-0070-02/2

With the vacuum pump \ ejector Steam Washing of HP Turbine
switched on and the blind flange (4) The main control valves must be open
closed, i.e. with the condenser at sub during steam washing of the HP turbine.
atmospheric pressure, via the
All drains (7, 8) from the HP turbine situated
condensate discharge line of an
between the main stop valves and the HP
operation condensate pump. In this
outlet may be vented during steam washing
case, make sure that the condensate is
only to the extent required to allow the
discharged to the atmosphere
condensate arising to drain off while
downstream of the pump. Samples for
preventing excessive loss of steam.
finding out the salt content are also
taken at this point. All other drains particularly those in the cold
reheat line, must be fully open. Local
The first method of steam washing with the
drainage may also be provided so that no
condenser under atmospheric pressure
steam can enter the Reheater of the Boiler,
guarantees a slight overpressure at the
if at all possible.
drains so that it is possible to perform
additional sampling at these points. For this After the steam line (6) has been joined up
purpose, the appropriate drains may be cut at the connection points (3), the stream can
off at the sludge traps, or the steam inserts be routed into the HP turbine. The steam
of the drain valves may be removed. leaving the HP turbine is exhausted to the
condenser via the drains (9).
It is suggested to record the salt content at
the sampling point continuously throughout The condensate is discharged and samples
the washing Process. Also, water samples are taken to determine the salt content as
should be taken every half an hour for described in steam washing of IP turbine,
deposit analysis. the completion criteria remaining same.
Steam washing may be stopped when the
purity of steam entering the turbine (as Restoring the Turbine to Operating
determined by sampling) is approximately Condition
the same as that of the condensate or steam On completion of steam washing, all
extracted at the discharge sampling point. temporary fittings must be dismantled and
The steam washing may be stopped when the flanges closed off. Any drain lines cut off
the salt content in condensate remains must be rewelded. Controllers and control
constant at a very low level. valves must be returned to normal position.
The temporary lines are to be preserved for
future use.

Also refer to the following sections:

[1] 5.1-0120 : Steam purity
[2] 5.3-0050 : Measurement of internal
efficiency
[3] 5.2-0350 : Fast cooling down of the
turbine

5.3-0070-02/3
 Steam Turbine Turbine Oil Care
Maintenance Maintenance Instructions

Introduction The Turbine Oil Specification [1] contains

Function of the turbine oil is to lubricate and standards and selection criteria for turbine
cool the bearings of the turbine generator oil as well as the requirements in terms of
and to actuate governing system physical and chemical properties.
components. Turbine oil is subjected to high The following oil properties are particularly
physical loads, should have a long service important for turbine oil care:
life and must not have any adverse effect on
the proper functioning of the bearings and
Total-acid number
other turbine oil consumers
Water contents and water separability
The physical and chemical properties of new efficiency
turbine oil must comply with the
Solid contaminant quantities, purity
requirements of the Turbine Oil Specification
[1]. The aim of turbine oil care is to maintain
Air release properties
the properties and the useful service life of
Foaming characteristics
the turbine oil for as long as possible.
Turbine oil properties and the values which
This general maintenance instruction can change those properties are discussed
discusses the necessity for, and the briefly below.
procedures involved in turbine oil care.
Further information can be found in the
The program for the care of turbine oil standards cited in the Turbine Oil
includes regular inspection and analysis of Specification [1] as well as technical
turbine oil samples. In this way changes in literature, including those issued by turbine
turbine oil properties can be determined and oil manufacturers.
the necessary actions can be taken to
remedy the situation. Actions to be taken to rectify typical changes
in turbine oil properties are listed in Table-1.
The filters and strainers in the operating oil
systems retain solid contaminants which can
cause damage and/or impair functioning if Total-acid number of the turbine oil
they ingress into turbine oil consumers. The total-acid number is an easily
By centrifuge (i.e. oil conditioning station) determined reference value for turbine oil
which is independent of the oil operating aging.
systems, contaminants and aging and Catalysts and thermal loading of the turbine
corrosion products which are not soluble in oil can trigger an oxidation process in which
oil are removed from the turbine oil. oleic acids are formed, raising the total-acid
Thorough cleaning of the oil system during number of the turbine oil. The oil ages.
initial startup and after inspections and The oleic acids attack oil system component
overhauls is one of the prerequisites for materials and corrosion products are formed
successful turbine oil care. In addition, the which can, in turn, catalytically accelerate
ingress of contaminants into the oil system the oxidation process.
must be prevented.
Under certain circumstances, contaminants
which ingress into the oil system from
Turbine oil properties outside can promote the oxidation process.
As a rule, turbine oils are paraffin-based
New turbine oil contains additives which,
mineral oils which contain additives to
provided that oil is properly cared for, give
improve their resistance to corrosion and
sufficient protection against agin
their oxidation stability.

BHEL Haridwar 5.3-0080-03/1

The additives become depleted over time. High water contents of the turbine oil can
Under unfavorable conditions, e.g. where also be the result of low water separability of
there is improper or negligent oil care, this the turbine oil. In this case, it is particularly
depletion process can result in premature important that the ingress of water in to the
aging of the turbine oil. oil system be prevented.

In this case, the turbine manufacturer and Solid-contaminant quantities and purity
the turbine oil supplier should be consulted of turbine oil
in order that measures for restoring the Whereas the material property value for
turbine oil can be implemented. solid-contaminant quantity defines the
overall content by weight of solid-
The turbine oil cannot be used if the function
contaminant quantities in a turbine oil
of sensitive turbine generator components is
sample, when defining turbine oil purity only
impaired through corrosion and/or aging
the proportion of solid-contaminants of a
products and if the aging process, i.e., the
specified size is determined. Turbine oil
change in the total-acid number, cannot be
purity is the more reliable criterion.
reversed by treating the turbine oil.
Solid-contaminants can ingress into the
From this highly simplified description of the
turbine oil from outside, or as a result of the
turbine oil aging process, it can be seen that
aging process or corrosion. They contribute,
aging is affected not only by physical loading
along with other factors, to the turbine-oil
of the turbine oil but also by catalysts and
aging process and impair the condition and
aging products, e.g., oleic acids. Treatment
function of the turbine components.
of the turbine oil in the oil conditioning
station removes products of aging and Among the principal areas which can be
corrosion which are not soluble in oil, affected are turbine and generator bearings.
thereby slowing down the aging process. Their load capacity can be reduced due to
scoring caused by solid-contaminants in the
turbine oil. In addition, changes of state and
Water content and water separability of
impaired functioning in control and
the turbine oil
protection equipment can be expected.
With healthy gland sealing & oil vapor
extraction system during normal operation The oil system is thoroughly cleaned during
the moisture content in turbine oil is not initial startup of the turbine generator set.
expected to be more then 100 ppm as in the Flushing of the entire system is included in
turbine oil specification (1). In case the the cleaning process.
moisture content found more then 300 ppm The filters and strainers of the operating oil
during sample testing, the reason is to be systems are used to retain contaminants
investigated. With moisture content value with a particle size larger than the filter mesh
more then 1000 ppm machine should be size, before the turbine oil reaches the oil
tripped and source of water entry is to be consumers. The dwell time of the oil in the
eliminated. filters and strainers will depend on the purity
Water which ingresses into the oil system of the turbine oil.
from an oil cooler, in the form of shaft seal Purity in accordance with the Turbine Oil
steam or leakage water, results in the Specification [1] is achieved through
corrosion in ferrous materials and can continuous filtration or separation of turbine
adversely affect the aging process and oil in the oil centrifuge.
foaming characteristics of the turbine oil.
During inspections and overhauls the turbine
Corrosion causes changes in the surfaces must be drained and the main oil tank, the
and shape of the sensitive turbine generator oil coolers and the bearing pedestals must
components. The corrosion products behave be thoroughly cleaned. It is recommended
in the same as solid contaminants, and lead that the turbine oil be either filtered or
to impaired component functioning. treated in a separator during drainage an
The cause of any increase in turbine-oil refilling.
water contents must be determined and The ingress of solid contaminants into the
remedied. turbine oil must be prevented.

5.3-0080-03/2
Air release properties of the turbine oil with the foam, resulting in a drop in the oil
level in the main oil tank. This change in the
The air release property represents the time
level can cause activation of the level
taken for a specific volume of air to be
monitoring equipment for the main oil tank.
released from the turbine oil sample under
the boundary conditions stipulated in the Increased turbine oil foaming tendency
testing standard of the Turbine Oil occasionally occurs due to high water
Specification [1]. content or increased dust contamination of
the turbine oil.
The turbine oil circulates inside the oil
system and becomes aerated. This air is Silicone-based foam inhibiting additives
-1
released during the dwell time tv = 60n (in have an adverse effect on air release
min) of the turbine oil in the main oil tank, n properties. There is no generally binding
corresponds to the number of passes per evidence regarding any further correlation
hour made by the turbine oil. between foaming tendency and air release
properties, although such a correlation may
If the time required for air release by the exist in individual cases and should be
turbine oil is longer than the dwell time in the investigated.
main oil tank, an oil-and-air mixture will
develop, which will not have as favourable a
density and compressibility as non aerated
Turbine oil care program
turbine oil. This can lead to faults in the
operating oil pumps, fluctuations in oil Owing to correlation between the turbine oil
pressure and impaired functioning of any properties and the factors influencing turbine
control and protection equipment which is oil during operation, the following care
supplied with turbine oil. program for turbine oil must be implemented
during and after initial startup of the turbine
Only in rare cases it is possible to improve
generator set:
the Air release properties of turbine oil with
economically viable treatment methods. For
Regular inspection of turbine oil samples
this reason, any factors which might lead to

Continuous treatment of the turbine oil
deterioration of the air release properties of
the turbine oil, must be avoided.
Protection of the turbine oil system from
the effects of contaminants
It has been proven that the air release
properties of turbine oil are adversely
Drainage of the turbine oil and cleaning
affected by materials containing silicone, of the oil system and the turbine oil
e.g., seal materials or foam inhibiting during inspections and overhauls.
additives.

Inspection of turbine oil samples

Foaming characteristics of the turbine oil
By regularly sampling and inspecting turbine
The material property values for foaming
oil and by evaluating the results, it is
tendency and foam stability of turbine oil
possible to adapt oil care measures
should comply with Turbine Oil Specification
optimally to the particular properties of the
[1].
turbine oil being used.
A certain amount of foaming on the surface
Turbine oil samples are taken
of the oil in the main oil tank can be
simultaneously upstream and downstream
expected as a result of air release. If the
of the oil centrifuge and the inspection
turbine oil shows an increased foaming
results thus permit an evaluation of the
tendency and high foam stability, the space
efficiency of the relevant oil care measures.
above the oil level in the main oil tank
becomes partially or completely filled with The scope and the intervals for turbine oil
foam which can, under certain inspections are listed in the turbine oil
circumstances, result in foam being released maintenance instruction.
from the oil system. Turbine oil is entrained

5.3-0080-03/3
If the turbine oil inspections reveal that or wear to parts such as oil pump seal
alarm levels for certain properties have been ring, etc.
reached or exceeded, it is advisable to
request inspection and evaluation of the Treatment of the turbine oil in the oil
turbine oil by the turbine oil supplier. All data centrifuge
relevant to turbine oil inspection should be
The oil centrifuge can be continuously
sent in together with the turbine oil sample
operated independent of the operating oil
When taking turbine oil samples, care must systems. A small volume of turbine oil is fed
be taken to ensure that sampling bottles are through oil centrifuge with a high separation
clean. efficiency. This achieves a high degree of
purity for the treated turbine oil.
In case of deviation in properties, actions to
be taken as per table 1. As regards the treatment of turbine oil in the
centrifuge, oil filter, dynamic or static
separators, and multipurpose oil purification
Treatment of the turbine oil in the oil
units can be used either independently or in
filters or strainers of the operating oil
combination. In addition, many power plants
systems
have centralised oil purification equipment,

Switchable oil filters either permanently installed or mobile.
The switchable oil filters of the operating The function of the most commonly used oil
oil systems are used to protect purification equipment is described below:
downstream consumers. Contaminants
which, because of their size or
consistency, can cause damage and/or
Fine-mesh filter
impair functioning are retained in the oil The turbine oil can be conditioned in an
filters. Because of their relatively large oil filter with filter elements made of fine-
mesh size, the operating oil filters are pored cloth or filter paper. Since the fine-
not suitable for complete removal of mesh filter has a high separation
contaminants from the turbine oil. The efficiency, a high degree of turbine oil
differential pressure across the oil filters purity can be achieved. Contaminants
is monitored. insoluble in oil which ingress into the oil
system from outside, as well as products
If the differential pressure across an oil
of system-internal aging and corrosion
filter increases, this filter should be
mechanisms are almost completely
isolated from the system and cleaned.
removed from turbine oil.
Fine-mesh filters with cloth or paper

Oil Strainers of the main oil tank
elements can also retain small amounts
The oil strainers of the main oil tank of water. If the turbine oil has a high
have a relatively large mesh size and water content, a dynamic or static
are used to retain contaminants in the separator must be used to reduce the
returning turbine oil and to protect the oil water content in the turbine oil to the
pumps from contaminant damage. value stipulated in the Turbine Oil
If the strainer mesh becomes clogged Specification [1].
during the course of operation, this can
lead to a drop in the level in the suction
Dynamic separator
space of the main oil tank as a result of
The dynamic separator uses centrifugal
an increase in the level in the riser
force to remove either solid or liquid
space.
contaminants as required from the
For this reason, the oil strainers of the turbine oil. The dynamic separator must
main oil tank must be regularly cleaned, be set to operate in either solid
if possible while the oil pumps are shut contaminant or water separation mode
down. Metal particles in the oil strainers in accordance with the manufacturer’s
can be an indication of bearing damage instructions.

5.3-0080-03/4

Static separator different additive packages. For this
reason, when topping up, turbine oil
A static separator is used to remove
which has the same product designation
water from the turbine oil. Since the
and which is supplied by the same
efficiency of the filter elements
manufacturer as was originally filled,
deteriorates due to deposits of solid
should be used.
contaminants, and in view of the
expense of filter elements, it is
recommended that the static separator
Hydraulic oil
be used in conjunction with an upstream Hydraulic oil or control fluid containing
fine mesh filter. phosphoric esters, if in use, must not be
allowed to ingress into the oil system.

Multipurpose oil purification unit
The multipurpose oil purification unit is
Main oil tank
used to remove solid and liquid Openings in the main oil tank must
contaminants from the turbine oil. always be closed and sealed in such a
Operation and maintenance instructions of way that there can be no ingress of
the oil purification unit manufacturer must be contaminants into the main oil tank. The
complied with. cover plates of the main oil tank must be
tightly bolted. There must be no bolts
The maintenance interval for oil filters missing from the plates.
depends on the differential pressure across
the oil filters. For this reason, the differential
pressure instrumentation must be regularly
Oil coolers
checked and corresponding annunciations If the water content of the turbine oil
noted. increases, the leak tightness of the
operating oil cooler must be checked.
Cleaning of the oil system during
inspections and overhauls
Oil return lines
Over the course of time, solid contaminants Inspection holes in oil return lines must
settle in areas of the oil system not be sealed to prevent the ingress of
subjected to high flow velocities, e.g. the contaminants into the oil system.
main oil tank. For this reason, the turbine oil
must be drained via filters during inspections

Oil vapor extraction system
and overhauls, and the main oil tank, the oil
coolers and the bearing pedestals must be The throttle check valves in the oil vapor
thoroughly cleaned. The drained turbine oil extraction system must be set so that
must either be refilled into the main oil tank the pressure in the bearing pedestals
via fine-mesh filters or treated in a and the main oil tank is slightly sub
centralised oil purification unit before atmospheric. This ensures that no
refilling. leakage steam, or airborne water and/or
dust is drawn into the oil system in the
event of turbine oil or oil vapor being
Measures to protect the oil system from released to the atmosphere.
contaminant ingress
Just as important as turbine oil care are

Dirty fluid
measures designed to protect the oil system
from contaminant ingress: Fluid from the dirty-fluid tank must not
be refilled into the main oil tank without
thorough inspection and treatment.

Turbine oil Small amounts of turbine oil which
Problems can arise as a result of the accumulate in the dirty-fluid tank are to
incompatibility of turbine oils from be disposed properly.
different manufacturers and containing

5.3-0080-03/5

Material
The compatibility of materials with the
turbine oil has been taken into account
by the turbine manufacturer during
materials selection. During inspections
and overhauls, care must be taken to
ensure that no incompatible materials
are used. This applies particularly to
gaskets and silicone-based seal
materials.

Leakage steam system

The butterfly valves of the leakage
steam system must be set to prevent
leakage steam from escaping via the
turbine shaft seals since this could result
in water ingress into the oil system.

Disposal of Turbine Oil

For disposal Turbine oil may be send
back to oil company (OEM) for its
recycle.

Also refer to the following sections:

[1] 2-0400 : Oil Specification

5.3-0080-03/6
Table1 : Actions to be taken when actual conditions deviate from reference conditions

Fault Cause Actions

Boundary conditions
The Turbine oil properties
do not comply with the
Turbine Oil Specification

Total-acid number Turbine oil aging Inspect turbine oil samples for:
> mg KOH/g
- Solid contaminant content
- Purity
- Water content
- Air release properties
- Foaming
- Other physical and chemical
properties
Send further oil samples to
turbine oil supplier for inspection
and evaluation. Check operating
performance and condition of
components supplied with
turbine oil, in order to determine
the effect of the change in total-
acid number. Check oil
purification system and intensify
turbine oil maintenance in
accordance with the
recommendations of the turbine
oil supplier and the turbine
manufacturer:
- Keep oil centrifuge in
continuous operation
- Adjust operation of oil
centrifuge to contaminant
content of turbine oil (solid
contaminants or water)
- If necessary install additional
oil purification equipment
- Take turbine oil samples
upstream and downstream
of oil centrifuge and check
separation efficiency (solid
contaminants and/or water)

5.3-0080-03/7
Fault Cause Actions

Boundary conditions
- Reduce intervals for turbine
oil inspections and monitor
evaluation of total-acid
number
Investigate the origin of
contaminants and prevent
contaminant ingress into oil
system.

The solid contaminant The oil centrifuge is not in Put oil centrifuge into operation.
content or the purity of the operation
turbine oil does not comply
The contaminant separation Take turbine oil samples
with the Specification
efficiency of the oil centrifuge upstream and downstream of
does not comply with the the oil centrifuge and determine
requirements the separation efficiency.
Implement measures in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements, replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.

Solid contaminants ingress Check whether and at what

into the oil system point it is possible for air borne
contaminants to ingress into the
oil system.
Check atmospheric pressure in
the main oil tank, the bearing
pedestals and the oil return lines
and, if necessary, correct using
the check valves in the oil vapor
extraction lines.
If necessary, close or reseal the
maintenance covers of the main
oil tank.

High air borne dust content in Reduce airborne dust content in

area around turbine generator area around turbine generator
set set

5.3-0080-03/8
Fault Cause Actions

Boundary conditions

The water content of the There is no permanently Install a dynamic or static
turbine oil does not comply installed dynamic or static separator for removing water
with the specification separator for removing water form the turbine oil. Take turbine
from the turbine oil oil samples upstream and
downstream of the separator
and check water separation
efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.

The permanently installed Put dynamic separator of the

dynamic separator of the oil centrifuge into the operation.
conditioning system is not in
Note that the required
operation
separation temperature must be
complied with in accordance
with the operating instructions of
the separator manufacturer, and
that the separator must be
protected from the effects of
solid contaminants.
Take turbine oil samples
upstream and downstream of
the separator and check water
separation efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.

Water is ingressing into the oil Check whether leakage steam is

system ingressing into the oil system.
If necessary, prevent the escape
of leakage steam from the
steam seals by the correcting
the seal steam pressure or by
adjusting the butterfly valves in
the seal steam lines.
Check the leak tightness of the
operating oil cooler.

5.3-0080-03/9
Fault Cause Actions

Boundary conditions

The air release properties In many cases, there is no Check whether the deterioration
of the oil do not comply specific cause for a in air release properties has an
with the Specification deterioration in air release adverse affect on the operating
properties performance of the systems of
components supplied with
turbine oil.
Involve oil supplier and turbine
manufacturer in inspection
program. If effects are
particularly unfavorable,
consider replacing the turbine
oil.
As a precautionary measure,
care should always be taken to
prevent the ingress into the
turbine oil of materials which
could adversely affect the air
release properties (e.g. silicone-
based materials)

Turbine oil foaming The foam inhibiting additives in Consult oil supplier and top up
characteristics do not the turbine oil have been turbine oil with foam inhibiting
comply with the depleted over time additives.
Specification
As a rule, foam inhibiting
additives have an adverse effect
on the air release properties and
for this reason, the air release
properties must be closely
monitored when topping up with
such additives.

The turbine oil contains Determine the water content of

materials which adversely the turbine oil and, if necessary,
affect the foaming take appropriate measures to
characteristics reduce this. In certain
circumstances it may be
advisable to skim off the foam
from the surface of the turbine
oil.

5.3-0080-03/10
Fault Cause Actions

Boundary conditions
The oil centrifuge is
defective or the operating
conditions for the oil do not
comply with the
requirements

Oil filters
The differential pressure Isolate duplex oil filter and clean
across one oil filter is high filter cartridge
Take oil centrifuge filters out of
operation and replace filter
elements

One oil filter is not sufficiently Open valve in oil filter venting
vented line and adjust

Unit-specific or additional The mode of operation of the Adapt the mode of operation of
dynamic separator dynamic separator does not the separator (solid-contaminant
correspond to the content of separation or water separation)
solid or liquid contaminants in according to the content of solid
the turbine oil contaminants or water in the
turbine oil

Unit-specific or additional The efficiency of the static Replace filter elements.

static separator separator is reduced due to
Implement measures to prevent
clogged filter elements
filter element clogging. e.g.
install an upstream fine-mesh
filter.

Turbine oil temperature If necessary, put heating system

upstream of static separator of oil centrifuge into operation
too low

Oil circulating pump (if The oil circulating pump of the If necessary, put oil circulating
installed) oil centrifuge is not in pump into operation
operation

5.3-0080-03/11
 Steam Turbine Grease and Oil Lubrication
Maintenance

Introduction from the manufacturer’s specification in the

maintenance instructions, it must be clarified
To ensure satisfactory functioning and to beforehand whether this will be universally
limit wear, a small number of components suitable.
on the turbine must be lubricated at regular
intervals.
Application of Lubricants

Scope Before re-lubricating components which are

exposed to the collection of dirt {e.g. shut-off
The following are the individual components, valve stems) they must first be carefully
which require regular lubrication. cleaned.

Control device in accordance with the Over-greasing or overfilling must be
lubrication Chart [1] avoided.

Actuators for remote-controlled Grease guns, which cause no damage to
governing, control and similar devices greasing nipples, etc. should only be used.

Spindles of hand-operated shut-off
devices Lubrication Intervals

Pumps and similar machines The lubrication intervals are stated by the

Drive motors manufacturers in the maintenance
instructions. It is essential for them to be
maintained, especially in the case of motors,
Lubricants pumps and similar equipment.
Only the lubricants stated by the respective It is advisable to prepare lists of items
manufacturers in the maintenance requiring lubrication, noting when the
instructions may be used. various items are to be re-lubricated. This
If for reasons of stocking or for simplifying will ensure that lubrication is carried out at
regular maintenance, it is desired to use the regular, prescribed intervals.
only one particular type of lubricant deviating

Also refer to the following sections:

[1] 5.1- 0690 : Lubrication Chart

BHEL Haridwar 5.3-0081-00

 Steam Turbine Care of Control Fluid
Maintenance

Introduction control fluid for flushing or service. Check for

dust and dirt by first wiping with white filter
The use of fire resistant control fluid for
paper. All traces of detergent must be
turbine control and protection systems
removed.
reduces the risk of fire. This is due to the
higher ignition temperature (compared to Although the control fluid manufacturer must
mineral oil) in case of leaks. ensure that there are no solid or liquid
impurities in the control fluid supplied for the
Phosphoric esters with a low water and
initial filling, the tank must be filled through
chlorine content (HS-D series) are used and
the Fuller’s earth and fine-mesh filter
must be carefully maintained to preserve
equipment.
their properties.
Baseline reference samples for later
This instruction contains the following:
comparison must be taken before filling with

Guidelines for handling control fluid and control fluid for flushing the system and after
for treatment of control fluid systems. regeneration of the fluid used for flushing.

Data on the compatibility of the control
fluid with other materials. Refilling with Control Fluid

Procedures to preserve the control fluid The system must be refilled from lead-
properties. sealed barrels; precautions must be taken to
prevent filling with a control fluid that is not

Data on sampling points in the cycle. identical to the one specified for use or with

Sampling and analysis programs. mineral oil from similar casks.

Maintenance procedures to be followed Changing Control Fluid

if the property characteristics of the fluid
reach the permissible limits. The entire system must be drained when
changing the fluid. New filter elements must
be installed or those present thoroughly
Guidelines for Handling Control fluid and cleaned.
for the Treatment of Control Fluid System
If unavoidable, old control fluid residue (up
Initial filling of system to 3%) may be tolerated.
The control fluid system must be cleaned The system must be refilled and samples
after assembly. The same control fluid may taken for comparison with the initial filling.
be used as service filling as well as for The amount of residue of control fluid within
flushing the system. However, when the the system and the neutralisation number
control fluid has been regenerated by the must be checked by analysing and
manufacturer, especially after filtering comparing the samples taken before filling
through 5 µm fine mesh filters, the property and after the system has been put into
characteristics of the control fluid must operation. If this shows an increase in the
comply with the requirements of the neutralisation number, it must be reduced by
specification [1]. passing the control fluid through the bypass
regenerating system.
All moisture must be carefully eliminated
from the system (e.g. by drying and/or
evacuation) otherwise the control fluid forms Treatment of waste control fluid
acid components when in contact with Biological decomposition of control fluid is
water. The control fluid tank must be difficult; control fluid is heavier than water
thoroughly cleaned before it is filled with and affects it adversely and therefore must

BHEL Haridwar 5.3-0082-02/1

not be passed into the sewage system. The benzene, white spirit and hydrochloric acid
competent Regional Water Authority is based cleaning agents approved for general
responsible for determining the maximum use.
concentration limit in ppm for sewage water. Caution: Observe all safety regulations
when using cleaning agents to clean the
All containers for storing new or used control
tank’s interior.
fluid must be clearly and permanently
marked. A record of the quantity of used
control fluid and of fluid lost due to Precautions to Ensure Compatibility of
maintenance, leakage and damage must be the Control Fluid with other Materials
kept. All components of the control fluid system
For disposal, control fluid may be send back are selected by the turbine manufacturer in
to oil company (OEM) for its recycle. regards to their material to ensure they are
compatible with control fluid and that no
When control fluid is burned, carbon dioxide interactions are to be anticipated between
(CO2) and phosphorus pentaoxide (P4O10) the control fluid and materials used.
are produced, the latter in such small
quantities, making it harmless. To avoid confusion, all spare parts and
materials used in the control fluid system
Disposal must be done by companies must be stored separate from other
authorised and licensed by legislation for the materials and clearly marked.
collection, storage and disposal of waste
materials. Caution: Not all components that are
compatible with control fluid are also
Control fluid leaks must be absorbed by compatible with oil.
using sawdust or oil binding granules and
removed immediately. Where possible, components and materials
for use in the control fluid system should be
Control fluid has the same effect on obtained from the turbine manufacturer. This
concrete as mineral oil. Floors or will make sure compatibility with control fluid
foundations made of asphalt are not by prescribing specifications to be used by
compatible with control fluid. subcontractors and by using suitable
materials. If parts must be obtained from
Preservative Agents in Control Fluid other sources, the chapter referring to the
System compatibility of the control fluid must be
observed.
Spare parts are maintained in serviceable
condition by using anti-corrosion agents Whenever an order is placed with the-
and/or suitable packing (enclosing in plastic turbine manufacturer or with third parties for
foil and use of desiccants); storage in dry parts or materials, it must be expressly
area is recommended. stated that these will be used for the control
fluid system.
When removing anti-corrosion agents, or
cleaning spare parts, take care to ensure the
Health care measures
parts are dry and, above all, that all traces of
solvents containing chlorine have been No special safeguards are required to
removed. Then apply an intermediate protect against toxic properties of the control
protective coating immediately to protect the fluid. Follow manufacturers instructions
freshly cleaned surface against corrosive and/or other legal provisions. Here are some
attacks by the control fluid used. recommendations:
Note: Chlorine presence in the control fluid
All containers for control fluid must be
causes erosion-corrosion at the control kept tightly sealed and permanently
edges of the control components. marked with the Health Hazard danger
sign.
Only the following may be used for cleaning:
Nonfelting textile and paper clothes,

5.3-0082-02/2

Do not eat, smoke or drink when working copper does not apply since the surface
with control fluid or parts in contact with area exposed to control fluid is small.
control fluid. Only austenitic steel may be used for filter

Keep control fluid away from foodstuffs. meshes; brass is unsuitable.

Keep control fluid away from skin, eyes

and clothes. Materials for pumps and electric motors

If control fluid gets into eyes, sponge Bearing and shaft seals and the nonmetallic
carefully and rinse with water. Obtain parts of couplings on pumps and their drive
medical attention if irritation persists. motors most be compatible with control fluid.
Since aerosols of the fluid may reach the

After handing control fluid, wash hands motors windings through the motor
immediately. ventilation system, the windings must be

Wear protective clothes, gloves and designed to be compatible with control fluid.
goggles.

Change any article of clothing that comes Materials for tools
into contact with control fluid. If skin Nonmetallic parts of tools (handles) must be
contact occurs, flush areas with water. made of material compatible with control
Obtain medical attention if irritation fluid or covered with suitable surface
persists. protection (See plastics). Remember this
when ordering new tools.

If control fluid is swallowed, give large
amounts of warm salty water to cause Plastics
vomiting; if unsuccessful tickle inside the
patients throat with a finger. Obtain Plastic materials are susceptible to swelling,
medical attention if stomach discomfort shrinking and surface deterioration.
persists. Plastic incompatible with control fluid may

Avoid inhaling spray clouds (aerosols) or impair the control fluid properties. Following
decomposition products (e.g. use clothes plastics are compatible with control fluid:
to protect respiratory tract). Fluorcarbon elastomers FKM Viton

Wear gas mask if thick clouds of control Butyl rubber IIR Butyl IIR-40
fluid are present. Polytetrafluorethylene PTFE Teflon
Polyethylene PE Hostalene
Polyamide PA Nylon
Compatibility with other materials
Following Plastics are incompatible with
Control fluid’s foaming, air release capability control fluid: PVC plastic, Polycarbonate-
and its resistance to aging are impaired by Makrolon, normal plexiglass.
contact with materials incompatible with
control fluid. Also materials, which are Only glass or Plexidur T may be used for
incompatible with control fluid, can be sight glasses. Protective caps on switches,
attacked. plungers and valves must be of metal or
plastic material compatible with control fluid.
Metallic materials
Sealing material, hose, cable insulation
Phosphoric esters have a negligible effect
and accumulator bladders
on steel, copper alloys, zinc, tin and
aluminum alloys provided the neutralisation Following sealing materials are compatible
number is within the admissible limits. The with phosphoric esters:
solid outer oxide layer of aluminum alloys
For o-rings, packing rings, collars and
must not be destroyed due to friction. diaphragms: viton, teflon, butyl rubber
Pure copper cannot be used due to its and composite material such as cotton-
catalytic effect on the decomposition of the viton, teflon-white asbestos, viton
phosphoric ester. Sealing material made of asbestos.

5.3-0082-02/3

For flat gaskets: viton, teflon, butyl - Stability
rubber and compressed asbestos. Acid and aging products may cause a loss

For hoses and cable insulation: viton, of stability; the speed of aging increase in
teflon and nylon coatings. the manner of a chain reaction, drastically
reducing the service life of the control fluid

For accumulator bladders: butyl IIR-40 (resulting from chemical reactions of the
(up to 80 ºC), viton control fluid with water, air and other

Liquid sealing materials: Hylomar impurities).
SQ32L, Loctite 270, ciba-geigy CY246.
+ Removal of acids and aging products
Caution: Butyl rubber IIR is not compatible The presence of acids and aging products
with oil. Silicon rubber must not be used raises the neutralisation number; the
since it severely impairs the properties of the permissible limit is 0.5 mg KOH/g.
control fluid (reduces its air release
capability). Acid and aging product must be eliminated
from the control fluid by continuous bypass
filtration through a Fuller’s earth filter.
Paints
Only two-component, desmodur / Regeneration through a Fuller’s earth filter is
desmophene (DD) base and epoxy resin based on an ion exchange reaction.
base lacquers may be used. When painting The Fuller’s earth used must be dry (1 % by
the inner surface of containers, make sure weight expellable water at 105 ºC). We
the coating is applied properly. If the paint recommended drying the Fuller’s earth
flakes off, it may cause considerable before filling. The design of the Fuller’s earth
damage. and filter regenerating equipment conforms
to the control fluid manufacturer’s
Caution: Paints compatible with control fluid requirements.
(epoxy resin and desmodur /desmophene
base) give off toxic vapour when exposed to Design and functioning of the filters are
heat. (e.g. during welding or grinding). explained in the Description Section. The
Repair procedures must specify the flow diagram of the regenerating plant is
presence of such paints. Signs on parts, also given in the relevant chapter.
containers with these paints must not be The grain size of the fuller’s earth should be
removed. US screen number 16/30 to 30/60 mesh.
The dust portion must not be used.
Control Fluid properties
When filling the filter, ram down and/or
Requirements shake the earth into the filter elements to
Requirements for control fluid are listed in prevent formation of gaps or channels that
the specifications for control fluid (1). would reduce the efficiency of the Fuller’s
earth.
Special care must be taken during
commissioning and operation to preserve Unnoticed exhaustion of the Fuller’s earth is
control fluid properties. prevented by changing the earth filling at
six- month periods, unless this interval does
Keeping a daily service log is not have to be reduced for other reasons.
recommended; all values from analysis and
details of important events (filter changes Since the control edges of electrohydraulic
and exchange of filter mass, refilling) must servo valves are subjected to erosion-
be entered. All changes and their cause corrosion if the control fluid is not suitably
should be readily detectable on the basis of treated, regular regeneration of the Fuller’s
these records. earth is always necessary, even if there is
no increase in neutralisation number.
Preservation of Properties

5.3-0082-02/4
Regeneration should be started about 48 element being cut out as soon as the limit is
hours before commissioning of the servo reached.
valves. Temperatures above 75°C are admissible
The control element of control circuits for a short period only during flushing
actuated by servo valves must be filled with procedures.
new control fluid through the regeneration
equipment even when the fluid supplied by
the manufacturer has the specified Note: If the temperature rises from 60°C to
neutralisation number. This applied both for 70°C, the speed of oxidation doubles.
initial and refills.
A fine-mesh mechanical filter (polishing + Prevention of influence due to foreign
filter) downstream of the Fuller’s earth filter matter
traps Fuller’s earth particles and other
foreign matter that would act as a catalyst in Measures must be taken to stop the entry of
the control fluid. The fine-mesh filter has the solid or liquid foreign matter or other
added function of establishing the required impurities with a view to maintaining the
purity of the control fluid in the overall stability of the system. All possible
system. measures must be taken to protect the
system from rust.
The fine-mesh filter must be cleaned in the
same way as other fitters in the system. The system is vented and deaerated via a
When changing the filter elements, do not defined opening to stop degeneration of the
remove the protective covers from the new control fluid due to moisture and
elements until just before they are installed. contamination. The opening is sealed by
absorbers or filters to prevent the entry of
Strainers must be cleaned using the moisture and contamination when venting
cleaning agents recommended by the filter and to ensure adequate deaeration.
and control fluid manufacturer; make sure
that dirt does not get onto the clean side. Silica gel absorbers are used to indicate the
buildup of absorbed moisture by changing
Immerse filters in the cleansing fluid only up colour. Evaporating moisture is necessary in
to their upper edge. Filters must always be the absorbers during deaeration. Refill Silica
blown-out from the clean side towards the gel if a permanent change in colour is
dirty side. Use only dry air for blowing-out noticed.
(relative humidity 60% at 20 ºC).
A large absorber or filter is used when the
Confirm absence of oil and dust by using system is vented or deaerated via exhaust
filter paper test. fans to ensure that the control fluid is
Use a magnifying glass to check the separated from the air downstream of the
completeness of the cleansing process. fan.
When deaerating using fans, the system
+ Prevention of thermal influences must not be under a substantial vacuum.
If deaerating valves are used that open
The control system requires a service
when a slight internal over pressure has built
medium viscosity that complies with the
specification at a control fluid service up, make sure the moist air is unable to
temperature of 55±5 ºC. enter into the system.
Accumulated water is annunciated by using
No adverse effects on the stability of the
electrodes. The cause of water
control fluid due to thermal influences are to
accumulation must be located immediately
be expected at this service temperature.
and corrected. Water accumulating on the
A maximum temperature of 90°C is surface of the control fluid tank due to its low
admissible locally, for example, at heating density, must be removed by siphoning or
element / protective pipes with heat pumped off. Condensate occurring in small
conducting oil fillings. Compliance with this amounts evaporates at service temperature.
limit temperature is monitored the heating Increase monitoring the neutralisation

5.3-0082-02/5
number if and after the accumulation of the About 3-4 % mineral oil will dissolve in,
water is detected. control fluid between room temperature and
50°C. If oil enters the control fluid circuit, the
control fluid manufacturer must examine the
- Fire resistance effect this has on the fluid’s fire resistance
Following are the causes of impairing the properties. It is impossible to separate oil
fire resistance properties of the control fluid: from the control fluid since the mixture is a

Mixing of mineral oil by mistake; this can genuine solution. Only when the oil content
be prevented if filling guidelines are exceeds 3-4% does a two-phase liquid
followed. result.

Penetration of mineral oil from the
lubricating oil circuit. - Air release capability
Design measures have been taken to The air release capability of the fluid
prevent oil and control fluid from intermixing. depends on the presence of foreign matter.
Contact points between the lubrication oil The chapters on the subject of stability and
control systems are separated by interface prevention of the influences of foreign matter
made of metal bellows between which there must be observed to ensure the air release
is a drain line to the leakage tanks; the tank capability complies with the requirements.
has a device to annunciate the accumulation
of control fluid due to leaks.
- Purity
The bellows are arranged if one ruptures,
the second takes over its shielding function. SAE guidelines (Table-1) govern the purity
Penetration of one media into the other is requirements for media used in hydraulic
only possible if both dividing elements have systems.
leak.

Magnitude Particles / 100 ml

0 1 2 3 4 5 6
5 – 10 µm 2700 4600 9700 24000 32000 87000 128000
10 – 25 µm 670 1340 2680 5360 10700 21400 42000
25 – 50 µm 93 210 380 780 2510 3130 6500
50 – 100 µm 16 28 56 110 225 430 1000
> 100 µm 1 3 5 11 21 41 92
Table-1: SAE permissible degrees of contamination for hydraulic systems

SAE Class classification applicable for Samples must be taken at sampling points
maintaining the service reliability for from the flowing liquid into clean laboratory
protection and control systems are as bottles. Take care to avoid any secondary
follows: contamination. The sampling bottles must
be permanently marked with these data:
Class-6: Protection and Control systems
facility, sampling point, fluid manufacturer
without servo valves
and type, date, sampler.
Class-3: Protection and Control systems
They must then be sent to a laboratory
with servo valves
(turbine manufacturer, control fluid supplier
or operator) for examination.
Sampling and analysis It is possible to filter the samples at the site
by using the field monitoring method so only
Samples must be taken and examined to be
the diaphragm filter has to be sent for
able to ensure the control fluid meets the
analysis to a laboratory outside the power
purity requirements.
plant.

5.3-0082-02/6
Performing routine analysis of the same fluid mesh filter, before it enters control system
filling involves relating the degree of colour sections susceptible to contamination, and
change of the test filter (relative measuring at the same time to check the function of the
method) to the quantitative degree of fine-mesh filters.
contamination as determined by counting
the contamination particles. Sampling point - Return (PNR)
The precondition for application of the field The PNR is provided in the return line.
monitoring method using diaphragm filters or Analysis of the samples from this point
of the relative measuring method is the makes it possible to determine the degree of
availability of reliable sampling and analysis purity of the fluid in the overall system
equipment at the plant site. without the direct influence of the service
filters.
Sampling and analysis programme
The sampling and analysis program Sampling point - Fluid Tank (PNB)
according to Table-2 makes it possible to The PNB is provided at the tank.
perform the essential assessment of the
control fluid properties and purity at all Sampling points downstream of the
stages of commissioning and during circulation pump (PNU), downstream of
continuous service. Fuller’s earth filter (PNFB) and downstream
of the fine-mesh mechanical filter (PNMF)
Besides, it allows assessing the flushing are provided.
procedures and the condition, efficiency and
regeneration of the filter equipment. Samples from the sampling points (PNU,
PNBF and PNMF are used to determine the
When required, it is possible to compare the efficiency of the regeneration and filtration
results of the routine analysis with the processes.
analysis of the baseline reference samples
taken before filling and completion of The sampling program applies both to the
commissioning. initial filling and to all fillings thereafter.

The samples taken before filling the control

fluid system must be representative of each Maintenance measures to be carried out
consignment delivered; the samples must be to ensure Fluid property characteristics
taken from a collecting container where a Table-3 contains maintenance measures to
certain amount of control fluid mixture from be taken if analysis values obtained for the
each individual container has been retained. samples approach the limits prescribed in
The first control fluid container opened is to the specification [1].
be used as the collecting container to
prevent contamination due to use of a Examination of system components
vessel that was not a part of the control fluid During inspections and major overhauls,
consignment. carefully examine the system components
Table-2 gives the sampling program for SAE for formation of deposits or scale and for
purity grade class-6, which is applicable for erosion-corrosion at the control edges of
this turbine. sensitivity control equipment.

Sampling points are marked as follows: If any deposits are found, they must be
analysed in consultation with the control fluid
manufacturer.
Sampling point - Supply (PNV)
Then checks must be carried out to find out
The PNV is provided within the supply unit. if rust or other forms of corrosion have
Analysis of the samples from this point developed within the system.
makes it possible to ensure the degree of
purity of the fluid downstream of the fine

5.3-0082-02/7
Time of Sampling Degree of purity NZ ASC Water Density Kinem. Anti-
3
Discol Particle KOH min content g/cm Visco corro.
mg/g % by 2 Props.
oration count V mm /s
test vol. (2)
Before filling FRF

Lab sample x x x
x x x

Control sample
Two weeks after filling
FRF, if flushing not yet x x x
started
Before commencing PNB
flushing for record of
as-delivered condition
Continuous sampling PNR
during flushing
Towards end of refilling x x x x
via superfine filter
(3)
Continuous monitoring PNB
during superfine PNU
filtering
PNBF
PNMF
Before commencing
hot operation (Last x x x
sample taken more
than 2 weeks earlier)
24h after
commencing hot x x x x x
operation
One month after
commencing of x x x
operation: weekly
One month after
x x x x x
commencing hot
(1)
operation : monthly
Before handing over PNR x x x x x
with final log
Table-2: Sampling program for SAE purity grade class 6

Entire program applies for refills also.

(1) Continuous monitoring programme after handing over

(2) Anti-corrosion properties to DIN 51585, ASTM D 665-60
(3) Test intervals according to filter capacity

PNB = Tank PNU = downstream of recirculating pump

PNV = supply line PNBF = downstream of fuller’s earth filter
PNR = return line PNMF = downstream of mechanical filter

5.3-0082-02/8
Parameter and Inspection Permissible Inspection Measures to be taken if
dimensions method limit interval limits exceeded
Water content No free water weekly Evaporate, suction-extract,
% by vol. visible to ladle-off, centrifuge using
naked eye special device
Neutralisation DIN 51 558-1 0.5 Monthly, Check regeneration plant,
number ASTM D974 weekly if Replace fuller’s earth, Check
NZ (mg KOH/g) negative effects by frequent
trend measurement of NZ
Kinematic DIN 51562-1 26-50 monthly Replace filling
viscosity at ASTM D445
2
40°C (mm /s)
Solid impurities Particle count SAE purity monthly Check filters for proper
and grade class 6 functioning. If necessary,
discolouration replace filter elements.
test Examine deposits on filter
elements
th
Air separation DIN 51381 Proper every 4 Check fluid for contamination
capability functioning of month (chemical and mechanical,
(min. at 50°C) system must entrained oil)
be assured
th
Density at 15°C DIN 51757 every 4 Check points in system
3
(g/cm ) ASTM D1298 month where oil can enter FRF
system. Examine fluid for
entrained oil, air or water
Fire resistance DIN/ISO 14935 ≤ 5 sec after Replace FRF filling
test determining
oil content
th
Anti-corrosion DIN 51585 no corrosion every 4 Have anti-corrosion additive
properties ASTM D665-60 permissible month analysed by fluid
manufacturer. Replace FRF
filling if necessary.
Oil content nuclear 3% max. see note Replace FRF filling. Perform
% by vol. resonance test, fire resistance test.
density
Table-3: Maintenance Measures

Note : If examination of the points in the system where the oil and FRF loops are structurally
separated reveal that oil has entered the FRF system as a result of structural failure, the
oil content in the FRF must be determined.

Also refer to the following sections:

[1] 5.1-0140 Fire Resistant Fluid
[21 5.1-1110 Control Fluid Pump
[3] 5.1-1120 Plate Type Filter
[4] 5.1-1130 Duplex Filter
[5] 5.1-1140 Regenerating Plant
[6] 5.3-0083 Analysis of Fire Resistant Fluid

5.3-0082-02/9
 Steam Turbine Fire Resistant Fluid
Maintenance Determination of Fluid Purity

Introduction For this reason, the ground glass flasks and

Erlenmeyer flasks must be flushed three
A fire-resistant control fluid (FRF) is used in
times with extra-purified n-heptane.
control and governing systems. The purity of
the fire-resistant fluid is of vital importance to
the reliable operation of the plant and must
Sampling
be monitored continuously.

Always perform sampling at the same
location directly from the system.
Brief Description of the Procedure

Recirculate the fire-resistant fluid long
To determine its purity, a defined quantity of enough prior to sampling to avoid settling
the fire-resistant fluid is dissolved in and give a homogeneous sample.
n-heptane and filtered through a diaphragm

Always perform sampling while the FRF
of pore size 0.45 µm. Size and quantity of
system is in operation.
the separable foreign matter particles are
then determined. A comparison shows
Flush the sampling point prior to
whether the fire-resistant fluid lies within the sampling by draining about 10 litres of
purity requirements established in the fire-resistant fluid into a clean receptacle;
specification [1]. return this into the system after sampling.

Allow about 10 litres of fire-resistant fluid
to pass through the sampling point
Equipment and Chemicals Required
before performing sampling by filling the

Membrane filters, 50 mm dia., 0.1µm and fire-resistant fluid directly into the
0.45 µm pore size cleaned ground-glass flask.

Filtering device and aspirator
Do not use aids such as syringes or
beakers.

n-heptane, p.a., purified by filtration

Always identification-mark the specimens

Filter the quantity of n-heptane p.a. that
uniquely and durably.
is required for dissolving and washing of
the fire-resistant-fluid specimen through
Complete the sampling records and send
a membrane filter of pore size 0.1 µm to the analysing laboratory together with
four times to exclude even the most the FRF sample.
minute impurities.

100 ml ground glass flasks
Determination Procedure

100 ml Erlenmeyer flasks with ground

Measure 20 ml (about 23 g) of fire-
glass stoppers
resistant fluid into an Erlenmeyer flask

Vacuum pump, e.g. water jet pump previously cleaned with purified
n-heptane, p.a., and dissolve in 80 ml of

Microscope slides
purified n-heptane, p.a.

Adhesive tape

Use a clean hair brush to remove any
dust from the membrane filter and clamp
the filter into the filtering device.
Preparation of Sampling Vessels

Connect up the water jet pump to the
Note: Flasks cleaned by a normal cleaning
aspirator and filter the fire-resistant fluid /
procedure still contain far too many minute
n-heptane mixture through the
impurities which can give a false impression
membrane filter.
of purity.

BHEL Haridwar 5.3-0083-01/1


Then flush the Erlenmeyer flask five
After drying the filter, place it between
times with about 50 ml each purified two cleaned microscope slides and seal
n-heptane. p.a. and also pass the the edges with adhesive tape.
n-heptane used for flushing through the
Determine the sizes and quantities of the
filter. separable foreign matter particles.

Also refer to the following sections:

[1] 5.1-0140 : Fire Resistant Fluid
[2] 5.3-0082 : Care of Control Fluid

5.3-0083-01/2
 Steam Turbine Vibration Dampers
Maintenance

Introduction with foreign matter. Another point to watch

are the attachments of the dampers to the
If the piping of the lubricating and control
piping and to any thermal installation plates
fluid system is excited to vibration, the
installed between them, as these
deflections involved could cause
connections may work loose. For these
inadmissible stressing of the piping material.
reasons, regular inspections are necessary
Dampers are used to attenuate piping to ensure that the vibration dampers are in
vibration. These consist essentially of a good condition and functioning properly.
cylindrical casing enclosing a plunger
embedded in a viscous bitumen mass that
performs the actual damping function. The Inspection Intervals, scope of Inspection
upper part of the damper is sealed by a Table-1 gives all important criteria to be
fabric-base plastic guard sleeve. reviewed during vibration damper
This damper design is not subject to wear, inspections. The intervals between
but the damping medium properties may be inspections are given in “y” (years).
impaired by temperature influences or, if the The inspections may also be performed
guard sleeve is damaged, by contamination during plant operation.

Table-1 : Inspection Intervals, Scope of inspections and Criteria

Inspection Scope of Inspection

Intervals - Criteria
1y Damper Attachment
- firm seating of damper components on pipe and support sides (and at
thermal insulation plates, if applicable)
Motion reserve
- cold condition: position of plunger as in support drawing
Guard sleeve
- correct and firm seating
- tension of the clamps
- damage (cracking or perforations)*
External influences
- effects of water, oil or similar *
5y As for 1 y
Condition of the damper medium
- surface appearance
- elasticity
* If found, perform 5-year inspection immediately

BHEL Haridwar 5.3-0100-00/1

Points to Note If cracking, crumbling or loss of elasticity is
If welding work is to be performed close to discovered on the surface of the damper
the piping dampers, take care to protect the medium, or if the plunger has worked itself
dampers (and particularly the guard sleeves) out of the medium, this indicates that
from weld spatter and other potential ambient temperatures in excess of design
damage. have caused deterioration in the damper
medium properties.
To preclude any deterioration due to ingress
of foreign matter such as water, oil, etc., Consult the damper manufacturer if the
replace guard sleeves as soon as any damper medium is unserviceable and has to
damage is discovered. In that event, also be replaced. Damper medium can be
check the condition of the damper medium removed from the casings without leaving
immediately. residue if heated to about 80°C.

5.3-0100-00/2
 Steam Turbine Instructions for Overhaul
Maintenance

In this chapter scope and schedule of Detailed knowledge of the next major
overhaul has been described. overhaul can be gained from the medium
overhaul.
Types of Overhaul The following criteria form the basis for
deciding whether or not to open a casing:

Minor Overhaul (inspection, servicing)
conclusions drawn from long-term
A minor overhaul should be carried out as observation, operating experience and
required simultaneously with shutdowns of manufacturer’s recommendations.
other plant components or during standstill
of the turbine-generator unit due to faults.

Major Overhaul (inspection, servicing,
The purpose of the minor inspection is to repair)
avoid reduction in availability due to forced
A “major overhaul” is a planned shutdown. It
outages by inspection and servicing and, if
permits detailed inspection and the
necessary, by preventive maintenance,
determination of the condition of all
The casings are not opened. components. All casings are opened.
Detailed knowledge of importance for Schedule inspection interval: after 50,000
intermediate overhaul or major overhaul is equivalent operating hours.
gained during minor overhaul.
The term equivalent operation hours is
Scheduled interval: after about 17,000 defined by the following equation:
equivalent hours of operation.
Te = To + ns x 25

Medium Overhaul (Inspection, Where,

servicing, repair) Te = equivalent operating hours
A Medium Overhaul is a planned shutdown,
if possible, simultaneously with other plant To = actual operating hours
components during which a casing may be
ns = the number of starts, without
opened. It covers all work which has a
bearing on the availability of the turbine- differentiation between cold, warm and hot
generator unit. starts.

BHEL Haridwar 5.3-0200-05/1

 TURBINE OVERHAUL
Equivalent Operating hours Variant-1 Variant-2
Minor
Major Overhaul Medium Overhaul
Overhaul

Turbine bearings

Turbine bearings

Turbine bearings
Operating years

Coupling check

Coupling check

Coupling check
Turbine valves

Turbine valves

Turbine valves
HP turbine

HP turbine
LP turbine

LP turbine
IP turbine

IP turbine
8600 01

02
*   *   
25800 03

04
       
43000 05

06
         
60200 07

08

77400 09
       
10

94600 11

12
         
111800 13

14

129000 15
       
16

146200 17

18
         
-Mandatory, -Optional, *Mandatory for turbines with spring mounted TG deck

5.3-0200-05/2
 Medium Overhaul
Minor Overhaul

Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul

For units with spring mounted TG deck, check reference readings of deck * *
spring units, carryout alignment and catenary check and readjust spring
units after first year of operation.

Check guides of inner casing for freedom of movement and wear. Overhaul.  

Measure permanent elongation of bolts in high temperature zone and check  
them for embrittlement, check all bolts for cracks.

Check shaft seals and labyrinth glands for abrasion and scaling. Check  
springs of spring-mounted ring segments. Replace springs of high
temperature zone.

Check shaft for cracks. Perform run out check, eliminate score-marks in  
shaft journals. Inspect coupling.

Visually examine last stage blades of LP turbine (check for cracks if   
necessary).

Clean rotors and casings and examine for damage. Pay particular attention  
to blades and seal strips.

After every 50,000 equivalent hours of operation, remove LP free standing  
blades from fir-tree grooves, clean root & groove, check complete blade
with specific attention to blade root for crack by MPI and carry out NFT.

Check earthling brush contact surface of shaft.   

Open main oil pump, check bearings, seal rings, shaft, impeller etc.   

Open auxiliary, emergency and jacking oil pumps.   

Check control and protective devices. Pay particular attention to parts   
subject to wear or deposits, replace these if necessary.

Perform mechanical, electrical and/or hydraulic functional tests on   
monitoring instrumentation; if necessary, overhaul and re-calibrate.

Disconnect couplings, measure elongation of coupling bolts, check axial *  
and radial alignment, perform run out check, clearance check.

Disassemble bearings, check babbitt surface, measure clearances, check   
seating of bearing in bearing pedestal.

Check, overhaul and, if necessary, replace seal rings of bearing pedestals.   

Check casing guides for deposit, if guides are jammed, remove, clean and   
overhaul keys. Ensure design key clearances.

Check stop valves, control valves, bypass valves; if necessary, replace   
worn parts on the hydraulic and steam sides.

 - If necessary, if applicable,  - Mandatory, * for turbines with spring mounted TG deck

5.3-0200-05/3
 Medium Overhaul
Minor Overhaul

Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul

Remove and check steam strainers for deposits and damage, clean/replace   
if necessary.

Check drains for foreign material, open and clean sludge traps.  

Measure casing distortion, check casing joints for erosion, check for cracks.  

Replace springs of sealing segments in high temperature zone  

Drain main oil / control fluid tank, separate impurities, change oil / control  
fluid if necessary. Inspect tank. Clean strainers.

Check oil / control fluid filters for leaks, remove and clean the inserts, pay   
attention to damage.

Examine oil / control fluid lines for damage, eliminate leaks. Retighten   
flange joints. Change gaskets, if applicable.

Examine steam turbine integral piping for cracks, deformation and  
ballooning. Special attention is to be given to balance piston leak-off line of
HPT.

Check pipe supports and hangers and readjust if necessary. Check casing  
horn drop and eliminate pipe pull by adjusting hangers & supports

Replace TSE/TSC thermocouples fitted in IP inner casing whenever IP  
turbine is overhauled.

 = If necessary, if applicable, = Mandatory, * for turbines with spring mounted TG deck

5.3-0200-05/4
MINOR OVERHAUL If couplings are disengaged it is advisable to
perform a roll check, especially if the
Casings are not opened. Bearing check,
couplings need to be realigned. At the same
coupling check if necessary, mandatory for
time measure the axial displacement of the
spring mounted TG deck after first year of
rotors relative to the casing. If
operation, checks of controls, safety and
disengagement of the couplings is not
protective equipment on steam and oil sides.
performed, coupled run out checks are to be
performed in the vicinity of the bearing as a
Components to be inspected minimum requirement. For accurate runout
− TG deck springs (if applicable) after 1
st
measurement, rotor system temperature
year of operation, alignment & catenary should be close to ambient.
− Casing roll check (if rotors realigned)
− Bearings
Bearings
− Oil guard rings of bearing pedestals Dismantle bearings. It is necessary to check
the babbitt metal lining for damage and
− Sliding pieces in casing guides and looseness by UT. Check seating of bearing
supports in bearing pedestal. Measure clearances of
− Control valves, bypass valves bearings.
− Emergency stop valves and extraction
− non-return valves
Oil guard rings of bearing pedestals
− Control and safety equipment Remove contaminants and abraded
particles on the seal edges to prevent oil
− Piping supports and hangers
leakage. Replace oil guard ring in case of
− Steam strainers excessive clearance.
− Drains
− Oil lines
Sliding pieces in casing guides and
supports
− Pumps (main oil pump, jacking-oil pump,
auxiliary oil pumps and emergency oil Inspect keys and sliding pieces for any
pumps, if necessary) abnormality. If there are indications of
− Oil / control fluid tanks jamming, dismantle and overhaul. Check
and ensure thermal clearances as per
− Oil / control fluid filters design.
− Last stage of LP Turbine
− Monitoring equipment
Control valves, bypass valves
Activities should generally be concerned
Scope of activities with checking of parts subject to wear.

TG deck springs (where applicable) Decisions on further activities and valves to
be covered are to be taken according to the
For units with spring mounted TG deck, the
circumstances on the basis of performance
deck springs are to be inspected and
in the preceding period of operation. Spindle
reference dimensions compared and
seals consisting of packing material are to
adjusted after first year of operation. This
be replaced in all cases. Clearances
will also call for alignment, catenary and roll
between moving and stationary parts should
check.
be checked and corrected.

Couplings
Emergency stop valves
If couplings are to be opened, carry out Emergency stop valves should always be
swing check & coupled runout measurement inspected completely (steam and oil side).
before loosening the coupling bolts, This includes spindle, cone, seat, bush,
measure the pretension of the coupling bolts actuator. With mechanical drives (lever
while loosing and tightening. Check the linkage) in particular, attention is to be give
alignment radially and axially. If deviations to compliance with plays and travel
exceed the permissible tolerance, reserves.
realignment is required.

5.3-0200-05/5

Piping supports and hangers − Inlet and outlet connections
Check and measure alignment dimensions − Casings
in the cold conditions and adjust, if − Inner casing guides
necessary. Verify adjustment by casing horn − Blading
drop test. Check pipes for visible changes. − Glands
− Rotors

Steam strainers − Fasteners
Dismantle and check for foreign bodies and
damage. Replace gasket. Scope of activities

Inlet and outlet connections

Drains Inspect for scale and freedom of movement
The scope of activities depends on at I-and L-seal rings. Inspect U-seal rings
performance during the preceding period of and measure precompression.
operation and susceptibility to malfunctions.
The sludge traps should be opened in all
Casing
cases. Measure for deformation, crack examination.
Rework according to findings. Inspect casing

Oil lines joint plane for erosion
Remove leaked oil, inspect pipes and
mounting for fretting point and strengthen
Inner casing guides
accordingly. Check for freedom of movement and wear.

Pumps
Blading
The main oil pump is to be opened in order Clean entire blading with casing open and
to inspect bearings, sealing rings, shaft, inspect for damage and incipient cracks,
impeller and coupling. Check other pumps in Check shrouds for scale according to
redundancy configuration only as necessary. temperature. Check for blade looseness and
lock blade lift.

Oil / Control fluid tanks
The fir-tree root free standing blades of LP
Clean strainers rotor need special attention. After every
50,000 hours of operation, take out the

Oil / Control fluid filters blades from groove, clean root and groove,
Remove elements and clean. Check for carry out crack detection of the entire blade
damage. including root, check natural frequency in
position with technological pieces.

Last stages of LP turbine
Visual inspection of condition. Crack
Glands and labyrinths
examination where necessary. Check for abrasion and scale (dependent on
temperature). Check condition of springs.

Monitoring equipment
Check that mechanical, electrical and
Rotor
hydraulic monitoring equipment function Check for cracks in fillets. Perform run out
properly and repair or recalibrate as check. Eliminate scoring on the journals.
necessary. Check coupling.

MEDIUM OVERHAUL
TSC thermocouples

At least one casing is to be opened and the Replace TSC thermocouples fitted in IP
rotor lifted out. Otherwise as for minor inner casing, whenever IP Turbine in
overhaul. opened for overhaul. Take advance action
for procurement of the TSC thermocouples
Components to be inspected and associated fittings.
As for minor overhaul but augmented by the
following:

5.3-0200-05/6
5.3-0200-05/7

Fasteners in high temperature zone Depending on the results of the inspection
Replace all fasteners of size upto M64 in the examined components are to be:
high temperature zone after 100,000
Left in the as-inspected condition,
equivalent hours of operation. Carry out because no faults have been found.
destructive test on sample fastener of higher
sizes to determine usability of the lot.
Left in the as-inspected conditions
although damage (e.g. crack formation)
has been found. Continued operation,
MAJOR OVERHAUL either in an unaltered or altered mode, is
All casings are to be opened and the rotors to be justified. The propagation of the
lifted out. Otherwise as for medium damage is to be kept under observation;
overhaul, but instruction if necessary is spare parts, often requiring lengthy
inapplicable. delivery periods, are to be ordered.

Replaced with spare parts (in general
Components to be inspected
small parts subject to wear are normally
As for medium overhaul but instruction “if kept in stock e.g. spindles, fasteners)
necessary” is inapplicable, and augmented
by the following:
Repaired by reworking at site or in the
− Oil / Control fluid tanks works of the supplier
− Steam lines It is necessary to increase the scope of the
− Casing center guides inspection as soon as the units have clocked
more than 100,000 equivalent hours of
Scope of Activities operation. Component integrity assessment
and/or residual life assessment studies are

Oil / Control fluid tanks to be initiated at this stage. Inspection
Drain and clean tank. Purify oil / Control planning must allow for the additional time
fluid, change if necessary. and costs consumed by the inspections.
Apart from this, the intervals between major

Steam lines overhauls necessitate the coverage of
considerably more components by the
Check steam lines exposed to main or
inspection as has been customary hitherto.
reheat steam for expansion, deformation
and crack. When stipulating the scope of the
inspection, the experience gained from

Casing centre guide comparable units should be taken into
account in the plans and/or the
Disassemble and overhaul. Ensure design
manufacturer is to state at which highly
clearances
stressed points the various components are
to be inspected. It is advisable to get the
SUGGESTED INSPECTION & TESTING special checks and tests conducted by the
PROCEDURES specialists from turbine plant.
During inspection of steam turbine generator
units, certain components are required to be
INTEGRITY ASSESSMENT
inspected in-depth to achieve more accurate
evaluation of their condition. The findings During integrity assessment, following
are to be documented (descriptions, check examination / inspection / testing of steam
calculations, drawings and photographs). turbine parts may be done.

Visual Inspection
− With the naked eye and good
Surface crack examination
illumination e.g. 500 Watt − Dye penetration test (DPT)
photographic lamp, mirror
− Magnifying glass − Magnetic particle inspection (cannot
be used on austenitic materials)
− Borescope

5.3-0200-05/7
 − Eddy-current examination − Contact print (Replica) procedure
after etching material surface
− Crack depth determination as far as
possible with capacitance probe or
ultrasound
Hardness test

Ultrasonic examination
Material verification test

− Manual spectroscope

X-Ray examination

Material testing

Detection of permanent deformations − Tensile test to determine yield
strength, tensile strength, elongation
− Out-of-roundness (ovality), angle of
after fracture and necking down.
bend (in pipe elbows), warp
− Notched bar impact test
− Wall thickness measurement
− Chemical composition
− Expansion measurements
(measurement of diameter, length, − Metallographic microstructure
circumference). evaluation

Surface micro-structure examination
Testing of electrical insulation

− Microscopic examination at site against shaft currents

5.3-0200-05/8
 Steam Turbine Turbine Restart
Maintenance After Boiler Repairs

Introduction operation, all solid particles remaining in the

Following extensive boiler repairs, measures system are blown down into the condenser,
must be taken to protect the turbine against which prevents them from causing particle
erosion by solid particles. erosion on the turbine blades Particles
blown down into the condenser must be
removed from the hot well before
Bypass Operation commencement of process operation. The
When extensive repairs have been carried bypass steam mass flow rate must comply
out on the boiler, it is not possible to prevent with the limits (mass flow rate and duration
solid particles remaining in the system in of operation) defined in the specifications.
spite of chemical cleaning. For this reason,
The bypass stop and control valves may
provision must be made for a lengthy period
suffer slight damage to their seats and discs
of bypass operation with the highest
as a result of steam dumping and must,
possible bypass steam mass flow rate at the
where necessary, be checked by sampling.
time of unit restart. During this bypass

BHEL Haridwar 5.3-0210-00

 Steam Turbine Turbine Restart after Major
Maintenance Inspections or Repairs

Introduction Pre-service Inspections

The operational reliability and availability of The functioning and the setting of all of the
a steam turbine unit are determined by, major equipment of the turbine must be
among other factors, the care with which the checked. This applies both to mechanical /
unit was initially started up. The same rule hydraulic components and to
also applies to restarts after large scale instrumentation and control devices. The
maintenance and repair work, e.g. in the scope of inspection and testing of defined in
course of major inspections. instruction 5.2-002x, and covers:

All closed-loop controls
Information Required for Restart
All protective devices
In restarting a turbine it is useful to possess
All sub loop controls and automatic
the following data: changeover controls

The performance of the turbine unit and The characteristics of all electro-hydraulic
its components prior to inspection controllers must be recorded. The test
programs appear in maintenance

The scope of the inspection
instructions 5.3-0030 and 5.3-0061.

Findings and checks made during the
Alarm system and monitoring equipment
inspection
must like wise be overhauled and tested.

Repairs carried out on the basis of the
If the result of operating parameters and
findings
setting checks reveal changes from earlier

Retrofitting and upgrading measures results, new records must be prepared.
taken

Checks planned for the restart period
In-Service Inspections
The information required may be found in
The tests, which could not be carried out in
the following documents:
the pre-service phase because the boundary

Reports on turbine performance prior to conditions had not been fulfilled, must be
inspection performed during the service phase
subsequent to the pre-service inspections.

Operating parameters and setting The essential step-by-step test schedules
records for the unit when new or at the appear in maintenance instruction 5.3-0060.
last restart

Reports on inspections, findings and
repairs
Protective devices

Documents on retrofitting and Service phase testing applies mainly to
modifications those devices which protect the turbine
against over speed. The test programs of
The following are also required: the automatic turbine tester may also be

Diagrams showing current control system executed if required.
setting (in the case of special settings the
Controllers
most recent records are binding)
The performance of the controllers must

Documents from the turbine manual, be observed throughout the restart
such as controller circuit diagrams and phase.
descriptions.

BHEL Haridwar 5.3-0220-00/1

 The control range of the hydraulic which are subjected to large-scale changes
controller must be checked and, if in this phase must be recorded.
necessary, corrected during no-load The operating parameters of the turbine
operation. stress controller must be subjected to critical

Automatic functional group controls analysis, because the start-up time, and
hence the cost-efficient operation of the
The turbine systems and the turbine turbine unit, is largely determined by the
generator unit should be started up with limits set by the TSC.
the aid of the automatic functional group
controls, and checks carried out to
establish whether all criteria for the Evaluation of Tests and Operating
execution of the step programs are Parameter Records
fulfilled.
The test results and the operating parameter

Operating parameters records provide vital information on the
The values of all operating parameters compliance of the turbine and its
must be recorded during steady-state components with the performance
operation when they have remained specifications.
constant for an adequate length of time, Malfunctions and other major discrepancies
and then compared either with the set must be eliminated as far as possible,
point or with previous recorded values. especially when they constitute a hazard to
- Output the operational reliability of the turbine unit.

- Control system characteristics Where necessary, spare parts must be

ordered and/or measures to facilitate future
- Steam mass flow rates elimination of the off-norn1al conditions
- Feed water / condensate mass flow rates detected must be defined.

- Steam pressure and temperatures These measures may include further

measurement of off-normal conditions,
+ Main steam rebalancing and other similar actions.
+ Extraction steam
+ Exhaust steam Re-Commissioning of the set
- Casing temperatures Most of the activities which have to be
- Expansions performed in the course of turbine restarts
go beyond the scope of normal maintenance
- Vibrations work. They call for special knowledge which
- Oil pressure and temperatures is too detailed to be described in full in the
turbine manual, especially where fault
- Bearing metal temperatures elimination is involved.
- Control fluid pressures and temperatures It is therefore expedient to assign
commissioning personnel to assist in
- Circulating water temperatures
restarting the turbine.
+ Condenser
The following is one conceivable allocation
+ Coolers of functions:
- Condensate temperatures
Pre-service inspection and in-service
testing of the unit by one specialist
- Condenser leak tightness (leak test)
engineer each for turbine and generator
During non-steady-state operation, e.g. from the supplier company.
during a cold start, all operating parameters

5.3-0220-00/2

Pre-service inspection and testing of
Report on the findings and checks made
major C&I hardware
Report on repairs and other actions
- Controllers and protective devices
Report on the replacement and spare
- Turbine stress controller parts used or required

- Automatic testers If these special reports are not available,

brief details must be given on these subjects
- Automatic functional group controls under the above headings.

Pre-service inspection and testing of
controls, interlocks and alarms by owner
/ operator’s personnel. The main section of the reports must cover:

The scope and nature of pre-service
inspections
Summary of results from major
inspections and repairs
Findings from the pre-service inspections

Full documentation of the history of a turbine
The scope and nature of in-service
unit includes, among other elements, testing
reporting on turbine restart following major
Evaluation of turbine performance
inspections or repairs.

Findings from in-service testing
The report on restart should make reference
to certain preceding reports, namely:
Matters remaining open (actions,
replacement parts, implementation

Report on the performance of the turbine deadline, etc.)
unit prior to the major inspection

Report on the scope of the inspection

5.3-0220-00/3
 Steam Turbine Environmental protection
Maintenance

It is the social and moral obligation of all Oil leakage does not only pollute the
concerned to ensure adequate protection of environment but is also a potential fire
the environment in every wake of operation. hazard. Oil leakage from any source is to be
quickly attended. In the viscinity of high
During maintenance inspection and capital temperature equipment & pipes, any oil
overhauls, it is of paramount importance to leakage has to be immediately attended,
ensure safety of work force by adhering to even if it calls for unit shutdown.
the applicable safety codes. In addition,
while handling and disposing hazardous Steam leakage from any source is
materials, necessary precautions, as associated with thermal & noise pollution of
published from time to time, are to be the environment. Depending on the source
adhered. & parameters of the leakage steam, it can
be injurious to the associated equipment
Some material, through harmless in normal and also to any individual coming in contact.
regime, may become quite hazardous under Any such leakage is to be quickly attended.
different circumstances. Gaskets made of
Fluorelastomers (viz. Viton), when exposed Proper upkeep & periodic lubrication of all
0
to temperatures in the region of 400 C or rotating equipment as per the
higher due to fire or any other reason, get manufacturer’s instructions goes a long way
decomposed. One of the products of such in ensuring their smooth and noise-free
decomposition is Hydrofluoric acid, which is operation.
highly corrosive and any skin contact with it
must be prevented. To promote environment friendly aesthetic
appearance, the external surface of all the
To protect the natural environment and to equipment should be painted once in two
control pollution from disposed hazardous or years. General upkeep and cleanliness
non-bio-degradable material, a proper standard should be maintained all around,
system of disposal is to be evolved and especially around the turbine floor to
compliance ensured. promote a pleasing look.

Also refer to the following sections:

[1] 5.3-0251 : Fluorelastomer products
safety notice
[2] 5.3-0252 : Safe disposal of Turbine Oil

BHEL Haridwar 5.3-0250-00

 Steam Turbine Fluorelastomer Products
Maintenance Safety Notice

Precautions to be taken during handling equipment should be denied to unauthorised

of Viton synthetic rubber and other or unprotected personnel and warning
Fluorelastomer products after they have notices posted.
been exposed to very high temperatures The affected areas must be decontaminated
Fluorelastomers are synthetic rubber like before either inspection or maintenance is
materials commonly used for making resumed. Do not touch anything in the
gaskets and seals of various kinds. vicinity of the decomposed material until it
has been decontaminated.
‘Viton’ is used extensively in control fluid
(FRF) system due to its compatibility with
phosphate ester fluids. It is also compatible Decontamination procedures for
with mineral oil and can appear in ‘O’ ring decomposed Fluorelastomer products
form in the lubricating oil, jacking oil and
power oil systems. In normal use, fluid Decontamination of equipment exposed
temperature excursions beyond 100 °C are to decomposed Fluorelastomer products
rare and therefore the use of ‘Viton’ seals If decomposed fluorelastomer products are
does not constitute a hazard to safety. suspected, great care must be taken when
However, extreme care should be taken removing the residues from equipment.
when dismantling equipment which may Protective equipment and clothing must be
have been subject to fire damage. used and worn, including heavy duty rubber
When exposed to temperatures in the region gloves and full face protection, to prevent
of 400 °C or higher, fluorelastomers do not accidental skin contact with the Hydrofluoric
burn but decompose into a number of acid (H-F).
materials, one of which is hydrofluoric acid. The residues should be disposed of with
This is corrosive and almost impossible to great care, such as very high temperature
remove once it contaminates the skin. incineration. All containers or bags used to
Personnel who could come into contact with transport the residues must be clearly
degraded ‘Viton’ (or any other marked to ensure careful handling to the
fluorelastomer) should be made aware of its point of disposal.
hazardous nature. Equipment which has H-F residues may be washed away using
been exposed to a very high temperature sufficient quantities of water to dilute them to
(e.g. equipment which has been involved in harmless concentrations.
a fire), and which may contain
fluorelastomer components, should not,
under any circumstances, be touched until it Decontamination of personnel exposed
has been visually inspected for gaskets or to decomposed Fluorelastomer products
seals which have suffered decomposition. If
decomposition has occurred, the component H-F residues should not be handled without
will appear as a charred or black sticky adequate protection. If accidental exposure
mass. occurs, wash well with water and apply an
H-F Antidote Gel as directed. Medical
Supervisory staff should be informed attention should be obtained immediately. A
immediately and inquires made to confirm Calcium Gluconate injection is the normal
whether fluorelastomer components are treatment for Hydrofluoric Acid Burn.
involved. Meanwhile, access to the

BHEL Haridwar 5.3-0251-00

 Steam Turbine Safe disposal of
Maintenance Turbine Oil

Oil of viscosity class ISO VG 46, commonly procedure for safe disposal of used turbine
known as turbine oil, is used for lubrication oil is as follows:
of turbine bearings as well as for hydraulic
turning gear.
To send the discarded oil to
registered refiners who have facilities to
The oil should comply with the requirements reclaim the oil by physico-chemical
given in Operation and Maintenance Manual treatment for further use in non-critical
[1]. It is recommended that the condition of applications.
oil in use, be periodically monitored to
ascertain the quality and properties of
To send the used oil to the parties
turbine oil [2]. All major oil manufacturers who are licensed to handle and dispose
have facility for complete checking of oil used lubricating oil.
properties.

To burn-off the discarded oil in
Turbine oil has to be changed if its boiler furnace by mixing with fuel oil.
properties have crossed discard limits. The

Also refer to the following sections:

[1] 5.1-0130 : Oil specification
[2] 5.3-0080 : Turbine Oil care

BHEL Haridwar 5.3-0252-00

 Steam Turbine Ordering of Spares
Maintenance

While ordering for spares, complete the functioning. For ordering spares, only the
identification details of the required project specific drawings supplied separately
component should be furnished. The details should be referred and following details may
of components described in various chapters be furnished:
of this manual are given only to understand

Enquiry for Steam Turbine O&M Spares

Name of the project :
Capacity :
Unit No. :
Previous enquiry / offer / order reference :

A] BHEL Supplied Spares

Sl.No. Assembly Item No. Qty. Description Part Drg.No. / Application
Drawing Code No. /
No. KKS tag No.
1.
2.
3.
4.
5.

B] Purchase resold items

1. Name of the supplier :
2. Model :
3. Year of manufacturing / supply :
4. Equipment Serial / Fabrication No. :
5. KKS Tag No. :
6. Other details noted from name plate :
7. Supplier’s catalogue reference No.
8. Supplier’s Sketch / Drg. No.
9. Application / location where installed :
10. Details of spares

Sl.No. Description as above Installed Quantity Required Quantity

1.
2.
3.

BHEL Haridwar 5.3-0300-00