_we_d300n-000106asm(turbine start-up and operation manual)

REV: A

东方汽轮机厂

DONG FANG STEAM TURBINE WORKS

PROJECT: REFERENCE ONLY JOB. NO:

E03033

CLIENT: PT. SUMBER SECARA PRIMADAYA LOCATION: KARANG TALUN VILLAGE, CILACAP, ENTRAL JAVA, INDONESIA

CONTRACTOR: CHENGDA ENGINEERING CORPORATION OF CHINA

N300-16.7/537/537-8型

汽轮机启动、运行说明书

Start-up and Operational Manual for Steam Turbine

STD NO. (WE) D300N-000106ASM


DES CHECK VER MFG STD ENGR APP


DES CHECK VER

MFG STD ENGR APP

（注:该页不外供）

Start-up and Operational Manual for Steam Turbine (WE)D300N-000106ASM

1

Content

No. Chapter-Section Name Page Remark

1 Preface 2

2 1 Essential Conditions for Start-up 1

3 1-1 Inspection before Start-up 2

4 2 Start-up with IP casing (IP) 1

5 2-1 Start-up under Cold State (IP) 7

6 2-2 Start-up under Warm State (IP) 5

7 2-3 Start-up under Hot State and Extremely Hot State (IP) 6

8 3 Combined Start-up of HIP Casing (HIP) 1

9 3-1 Start-up under Cold State (HIP) 14

10 3-2 Start-up under Warm State (HIP) 5

11 3-3 Start-up under Hot State and Extremely Hot State (HIP) 6

12 4 Operation 1

13 4-1 Normal Operation 2

14 4-2 Varying Duty Operation 2

15 4-3 Abnormal Operation 2

16 5 Shutdown 1

17 5-1 Slide Parameter Shutdown 2

18 5-2 Rated Parameter Shutdown 1

19 5-3 Emergency Shutdown 2

20 6 Restrictions for Start-up and Operation 1

21 6-1 Restrictions for Prohibiting Start-up and Operation 1

22 6-2 Limits for Start-up and Operation 5

23 6-3 General Precautions 2

24 6-4 Regular Check and Test 2

25 7 Auxiliary Operation of Start-up and Shutdown 1

Start-up and Operational Manual for Steam Turbine (WE)D300N-000106ASM

2

26 7-1 Pre-warming of HP casing 2

27 7-2 Heating System of HP casing Interlayer 2

28 7-3 Water Spray System of LP casing of Steam Turbine 1

29 7-4 Emergency Discharge System 1

Start-up and Operational Manual for Steam Turbine (WE) D300N-000106ASM

1

Preface

The start-up mode described in this manual is proposed according to the structural features of main body of 300MW steam turbine made by our factory and by referring to the technical characteristics of imported digital electro-hydraulic control system (DEH) for HP hydraulic oil, which applies to our new generation of full electronic control type of 300MW steam turbine.

There are three kinds of start-up operation modes for the steam turbine, namely "Self-Starting Mode", "Operator Automatic Mode" and "Manual Mode". The operating personnel may choose one of them according to the actual conditions.

Under " Self-Starting Mode ", the ATS of DEH control system is under " Control State ". The ATS controls the steam turbine based on the state of assembling unit to automatically complete the start-up process including turbine rolling, raising speed, synchronous incorporating in power network, picking up initial load. The detailed operational and monitoring requirements about the " Self-Starting Mode " can be found in the " Operation Instruction for Digital Electro-Hydraulic Control System (DEH) for HP Hydraulic Oil " (provided by the supplier of DEH).

Under " Operator Automatic Mode", the ATS of DEH control system is under “Monitoring Mode” instead of participating in controlling. The operator manually sets the target values and rates of change for the speed or load on the operation board according to the condition of main body of steam turbine and the start-up operation procedure provided in the manual. The basic control system of DEH automatically completes the operations of turbine rolling, raising speed, synchronization and picking up the load according

to the target values and rates of change set by the operator. The DEH system automatically monitors the start-up parameters through the CRT display, sends out the signal "Alarm" or " Shutoff" when exceeding the limits, guides the operator and prints the current data and historical data for the operator to study and analyze.


2

Under “Manual Mode”, the valve position multi-functional processing of DEH control system controls the set according to the button of “VALVE LOWER” or “VALVE RAISE” on the operation board controlled by the operator. Under this operation condition, the set shall be controlled by skilled operating personnel according to relevant limits and operating procedures in the manual as well as relevant rules of power plant. The operator shall closely monitor various changes of parameters displayed on the CRT and alarm signals to ensure the safe operation of set.

The procedures for start-up and shutdown specified in this manual only apply to “Operator Automatic Mode” (i.e. ATS monitoring state). The user shall compile the site operation regulations according to the manual and correct them during the actual operation based on the accumulated operating experience. However, each control parameter in the start-up operation shall follow the requirement in the manual. For a new machine, the initial start-up shall properly reduce the rates of raising speed and increasing load. Stable operating time shall be extended properly for each load point.

When a new machine is put into operation, the evenness between the contact surfaces and the glidability between the glide surfaces of various parts need certain operating time to improve. Therefore, when a new machine is put into operation, it must experience at least 6 months operation under the complete cycle mode until the set reaches the stable state.

Refer to the technical documentation, drawings and manuals supplied with the machine by us for relevant technical data, structural features, etc. about the steam turbine (refer to “Delivery List”).

The start-up state of steam turbine is determined by the metal temperature of inner wall (stage adjusting place) of upper half of HP inner casing. Specifically as follows:

Start-up under cold state: ≤150℃

Start-up under warm state: 150℃～300℃

Start-up under hot state: 300℃～400℃


Start-up under extremely hot state: ≥400℃

The set has two operating modes: IP casing start-up as well as HP and IP casing combined start-up. It is recommended that the IP casing start-up be considered first. If the boiler and by-pass system are not adaptable, it is possible to only use the HP and IP casing combined start-up; if the IP casing start-up is adopted, the user needs to buy the VV valve and by-pass system required by the IP casing start-up.

When the new machine is going to perform the load rejection test, the manufacturer shall be notified. The test requirements shall be discussed by the manufacturer and user jointly.

The steam pressure in the manual is absolute pressure and the oil pressure is gauge pressure. The vacuum is converted according to the standard atmosphere, i.e.:

Vacuum Mercury Column (mmHg)=760(mmHg)-Exhaust Absolute Pressure (MPa)×7500(mmHg/MPa)

The user shall make corrections to the following formula according to local sea level height and the climate condition at that time:

Vacuum Mercury Column (mmHg)=Local Atmosphere (mmHg)-Exhaust Absolute Pressure (MPa)×7500(mmHg/MPa)

The curve attached in the manual is only for ModelN300-16.7/537/537-8 instead of other types.


Prepared by Checked by Reviewed by Standardized by Entered by 1-1

1 Essential Conditions for Start-up

a. Each part shall be complete. Each part and system shall be installed, rinsed and adjusted according to the drawings, documentation and installation requirements from the manufacturer. Each part and system shall be firmly connected without looseness and leakage. Each kinetic part shall act flexibly without get stuck. The cleanness of each part and system must reach relevant requirements in JB/T4058-1999 “ Steam Turbine Cleanness Standard”.

b. When a new set is installed or the operational set completes inspection and repairing, before it is put into operation, the oil system must be rinsed by oil. The rinse acceptance must meet relevant regulations in “ Operation Instruction for Rinsing Oil System”. The acceptance for the hydraulic oil system must meet relevant regulations in “ Operation Instruction for Adjustment and Security System”.

c. Parts and systems need to be separately tested must pass the tests and meet the installation test requirements of manufacturer.

d. All the instruments, meters and measuring points for the set shall be complete. Installation and connection shall be correct and firm. All the instruments, meters and cables shall be inspected and qualified.

e. The set must have good heat preservation. The turbine proper shall have heat preservation according to the “Design Specification for Steam Turbine Heat Preservation” provided by the manufacturer. The heat preservation for the pipeline and auxiliary devices shall be done according to relevant regulations for the power industry. The insulating layer shall not have the phenomena such as crack, come off, water and oil immersion. There shall be sufficient expansion gap reserved between the insulating layer and the foundation or other fixed parts.

f. There shall not have any temporary facilities that hinder the operation (according to the safety rules for the power industry)

g. The operating and maintenance personnel must go through special training and get familiar with the position, structure, principle, performance, operating method and emergency action of each responsible device.


Prepared by Checked by Reviewed by Standardized by Entered by 1-1-1

1-1 Inspection before Start-up

The inspection applies to HIP casing combined start-up (HIP) and IP casing start-up (IP). The time between the completion of inspection and formal start-up shall not be too long (normally not exceeding 10 days).

a. Supply power to the DEH system and check whether the functions of each functional module are normal. Check whether the I/O interface communication with the CCS system and TBS system (by-pass control system) is normal.

b. Check the functions of TSI system.

c. Check whether the central control room and local instruments work properly.

d. Check the oil level in the lubricant box and hydraulic oil box. The oil indicators shall indicate the highest oil levels and the test of oil level alarm shall be performed.

e. Check the working performance of each auxiliary oil pump. The electric control system must ensure various kinds of auxiliary oil pump can be switched properly.

f. Check the working performance of each oil pump in the hydraulic oil system. The electric control system must ensure various oil pumps can be switched properly.

g. Check whether the lubricant oil temperature, pressure and level are normal.

h. Check whether the temperature, pressure and level of hydraulic oil are normal.

i. Check the working performance of jacking oil pump. The jacking test shall be performed at the initial start-up: adjust the opening of throttle valve according to the jacking oil pressure and pushed up height in the “Specification for Oil Pipeline of Jacking Device” and record the pushing up oil pressure and pushed up height of each bearing pad.

j. Start the smoke discharge fan and check its working performance. When the fan is working， the negative pressure in the oil box shall keep within 196～245Pa and the


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negative pressure in the bearing box shall keep within 98～ 196Pa. The negative pressure in the oil box shall not be too high. Otherwise, water can easily get into the oil and dust can be sucked into.

k. Check whether the working performances of various parts in the adjusting and security system meet the requirements.

l. Check whether the working performances of various parts in the oil supply system of hydraulic oil meet the requirements.

m. Start the jacking oil pump and confirm the rotor is jacking before performing turning gear engagement and disengagement. Adopt the reverse mode of turning gear motor for disengagement.

Note: When the lubricant pressure is less than 0.08Mpa and the pressure of jacking piping-main is less than 9.8Mpa, the auto and manual auto engagement at zero speed of the turning gear will not work. This is realized by the pressure switch through electric interlock so as to prevent the friction of bearing Babbitt caused by inadequate oil supply. The details can be found in the “Operation Instruction of Turning Gear”.

n. When the turning gear is engaged, check and record the eccentricity of rotor, compare with the original value of rotor (the variance shall not exceed 0.03mm), confirm that the rotor does not bend as well as monitor whether there is friction sound in the through flow part.

Note: The original value of rotor is the eccentricity of rotor measured at a specific position by a mechanical type rotor bend meter when rotating the rotor initially after the connection of axis series on the site, i.e.excircle runout. The value shall not exceed 0.02mm.


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o. Close the vacuum breaking valve, add water to the hot well of steam condenser, engage the main vapor extractor to run the steam condenser and check whether the devices in the steam condensing system work properly.

p. Check whether the steam supply regulating station, temperature control station and overflow station of each steam source in the self-seal gland seal system work properly.

q. Check whether each electric stop valve in the drainage system works properly and perform the regular switch test for the system.

r. Check whether the HP exhaust non return valve f and all the check valves of steam extraction work properly. Perform the linkage test.

s. Check whether the RFV, ventilator valve(VV), emergency blowdown valve(BDV) and electric stop valve for interlayer heating work properly and perform the regular switch test. Check whether the working characteristics of electromagnetic valve of ventilator valve works properly.

t. When the condense pump is engaged, the parameters for the sprayer of LP casing shall be reset. The reset values shall be: automatic engagement when the

exhaust temperature ≥80℃ ; automatic removal when the exhaust temperature ≤65℃ . The regular switch test for the cooling system of LP casing sprayer shall also be performed.

v. The HP main stop valve, IP reheat stop valve and HP control valve and IP control valve shall go through static test and be reset.

w. Before turbine rolling, the protection test for axial displacement and other electric test shall be performed.

All the inspections and tests above shall be performed according to relevant instructions.



2 Start-up with IP Casing (IP)

Start-up with the IP casing is to utilize the reheat steam that has higher temperature and bigger flow to raise the temperature of IP casing more rapidly. This makes the IP exhaust temperature exceed the fragility transforming temperature of rotor so as to avoid the fracture of rotating shaft due to fragility, reduce the heat impact of HP casing, prevent the exhaust temperature of HP casing from exceeding the limit, realize the matching between the temperature of main steam and reheat steam as well as the metal temperature at the HP control stage and IP Stage 1, and achieve the purpose of shortening the start-up time and reducing the life loss of set. Start-up with the IP casing has better flexibility and is in favor of peaking operation in two shifts.

For start-up with the IP casing, it is required that the by-pass capacity shall meet the requirement of ≥35%MCR and the by-pass system shall be engaged normally. It is best to set it under the automatic state.



2-1 Start-up under Cold State (IP)

1 Preparation before Turbine Rolling

a. Supply power to the DEH. The panel and system shall all be in normal condition;

b. Start the lubricant pump and jacking oil pump and confirm whether the lubricant system and jacking system are in normal working conditions;

c. Start the hydraulic oil pump;

d. Engage the turning gear and ensure that before turbine rolling the turning gearing time is no less than 4h;

e. Recheck the lubricant system, hydraulic oil system, DEH, TSI system and turning gear according to Section 1-1;

f. After confirming there is no water in the gland seal steam pipeline, engage the auxiliary steam source of gland seal system. The pressure of gland seal

piping-main shall be 0.123Mpa and temperature shall be under 150℃～260℃；

g Create the vacuum for the steam condenser. The pressure in the condenser shall be below 16.7kPa.

h. Press the “LATCH” button and the set will be turned on;

i. Press the “PREWARM” button to pre-warm the HP casing, main steam pipe and valve shell. See Section 7-1;

j. Open the drain valves in the HP, IP and LP sections (refer to Section 3-1 for the drainage in various sections);

k. Confirm whether the HP exhaust non return valve is closed completely;

l. The TSI measured data display is in the permissible range;

m. Confirm Steam Parameters for Turbine Rolling（ refer to Section 3-1 for the


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definition principle） ;

(1) Main steam pressure: 3.45MPa;

(2) Reheat steam pressure: 0.686MPa;

(3) Main steam temperature: 300℃ ;

(4) Reheat steam temperature: 237℃

n. Define Change Rate of Steam Temperature During Start-up

See Item n in Article 1 of Section 3-1;

p. Operating Requirements for LP By-pass before Turbine Rolling

Along with the start-up of boiler, the valve opening of LP by-pass increases gradually. When the reheat steam pressure increases to 0.686MPa, the LP by-pass shall get the auto control of pressure feedback engaged.

2 Turbine Rolling

a. Confirm whether the slide valve of emergency governor is engaged;

b. Confirm whether the “HP＆ IP START/IP START” button is under the “HP＆IP START” state;

c. Press the “RUN” button and start the HP and IP reheat stop valves;

d. Confirm whether the ventilator valve (VV valve) is at the closed state;

e Select the speed of 500r/min for “TARGET”; the accelerating rate of 100r/min/min for “ACCELERATE”;

f. After pressing the “GO” button, the HP control valve opens gradually until the speed increases to 500r/min. The set increases the speed according to the given accelerating rate; when the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall disengaged be


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and the machine shall be stopped.

3 Inspection at 500r/min

At this speed, perform overall inspection for the set. Mainly inspect whether there is friction between the static and dynamic parts, whether the ventilator valve is at the close position, whether the HP exhaust non return valve is at the open position. The stop time shall not exceed 5 min.

Note: When inspecting various start-up states at 500r/min in the situation of start-up with the HP casing, the HP and IP control valves shall be closed. The inspection shall be done at the idling speed. Re-charge before the speed is more than 50r/min.

a. Select the speed of 1200r/min for “TARGET”;

b Press the “GO” button, slightly open the HP control valve until the speed increases to 500r/min;

c When the speed increases to 500r/min, the opening of HP control valve is locked and the equilibrated valve of IP control valve opens gradually to increase the speed of steam turbine to 1200 r/min at the original accelerating rate;

4 Warming up at Medium Speed of 1200r/min

a. Confirm whether the jacking oil pump is stopped;

b. Check all the monitoring instruments;

c. At this speed, warm up for 30min. During the warming up, the speed of steam turbine is controlled by the equilibrated valve of IP regulation. During the period, the metal temperature of the HIP casing exhaust shall be monitored. When the

metal temperature of HP exhaust lower half inner wall of reaches 200℃ , the VV valve shall be opened and adjusted for its manual door opening to control the metal temperature around 200℃ .

d. Completion of Warming up


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(1) If the metal temperature of HP exhaust lower half inner wall reaches 200℃ and the metal temperature of IP exhaust lower half inner wall reaches 130℃ , “TARGET” can directly select 3000r/min.

(2) After the completion of warming up, check and confirm whether the HP control valve is closed completely and the ventilator valve is fully opened.

(3) If the metal temperature of HP and IP exhaust lower half inner wall fail to reach the above requirements, the "TARGET" selects the speed of 2000r/min for high speed warming up.

During the process of raising speed afterwards, the set shall rapidly and steadily pass each step critical speed of axis series. The vibration of bearing cover at the critical speed shall be no more than 0.10mm (peak-peak value). Otherwise, the brake shall be disengaged and the machine shall be stopped.

Warming up at the high speed can be done through adjusting the opening of manual valve after the ventilator valve to control the metal temperature of lower half

inner wall to reach 200 ℃ around. If the temperature still can not reach the requirement at this time, the manual valve before the reverse warming valve can be opened properly.

When the metal temperature of HP exhaust lower half inner wall reaches 200℃ and the metal temperature of IP exhaust lower half inner wall reaches 200℃ , the warming up shall continue for 30min. Then the warming up at the high speed finishes.

“TARGET” selects the speed of 3000r/min.

e. Press the “GO” button to increase the speed.

5 Rated Speed 3000r/min

At this speed, perform warming up under zero load for 30min;

a. The pressure of steam condenser shall be less than 13kPa and the vacuum


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protection shall be engaged;

b. When the exhaust temperature is ≥80℃ , the sprayer of LP casing shall engage automatically. Otherwise, it shall be started manually.

c. The TSI monitoring items shall be within the permissible range;

d. Check Lubricant System

(1) The switch between the main oil pump and AC lubricant pump shall be completed;

(2) The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2;

(3) The lubricant pressure shall be at the normal value. See Article a in 1.2 of Section 6-2;

(4) The inlet temperature of lubricant shall be at the normal value. See Article c in 1.2 of Section 6-2.

e. Check Hydraulic Oil System

The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2.

f. Requirements for Parameters

(1) The main steam pressure shall reach 5.88MPa;

(2) The change rates of main steam temperature and reheat steam temperature shall not exceed the selected value before turbine rolling;

g. Operating Requirements for HP and LP By-pass

When the pressure of main steam reaches 5.88MPa, the HP by-pass shall have the auto control of pressure feedback engaged;


2-1-6

6 Perform following system tests before incorporating in power network (for new machine start-up or after heavy repair of set):

a. Oil spray test of emergency governor;

b. On-line test of HP emergency governor IC (HPT) electromagnetic valve;

c. On-line test of overspeed limit IC (OSP) electromagnetic valve;

d. Manual shutdown button test;

e. Speed acceleration test of emergency governor (before performing the acceleration test, the set shall run no less than 3h for warming up with20% load);

f. Electric overspeed protection test

The specific requirements for various tests above can be found in the “Specification for Adjusting and Security System”, “Specification for Safety Monitoring Device of Steam Turbine” and “Specification for Electrical Appliance Monitoring and Protection System of Steam Turbine”

7 Incorporating in Power Network

After the completion of test and inspection of steam turbine generator set, inform the operator that it is permissible to incorporate the set in power network.

Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network).

After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase.

Maintain the pressure in front of HP main stop valve during the process

of accelerating, incorporating in power network and picking up the load.

8 Load Increase


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a. Select the final stable operating target load for "TARGET"; select the load increase rate of 1.2MW/min for "LOAD RATE";

b. Press the "GO" button to increase the load;

Afterwards, the by-pass valve closes gradually.

9 Switching HP and IP casings

a. Before switching the HP and IP casings, pay attention to the matching of steam temperature and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method;

Under normal condition, the followings shall be controlled:

Main Steam: 5.88MPa 400～430℃

Reheat Steam: 0.686MPa 350～380℃

b. When it is changed from the sole steam admission through the HP casing to the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically.

c. When the by-pass valve is fully closed, (at this time, the load is about 40MW) the TBS system sends signals to the DEH to maintain the load;

d. When the by-pass is fully closed, perform warming up at low load. Monitor the metal temperature of HP exhaust lower half inner wall. It shall reach 170℃ . Adjust the opening of manual valve in the back of ventilator valve to control the

metal temperature of HP exhaust lower half inner wall within 220--250℃ for 30min;

When all the above items are completed, the operator presses the "VALVE CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then;

e. After the change is over, （at the rate of 3MW/min） increase the load to


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42MW and warm up for 30min;

f. Check the following items during the change over period:

(1) The ventilator valve (VV valve) is closed;

(2) The HP exhaust non-return valve opens automatically.

g. When the change is over, engage the interlayer heating device based on the concrete situation of HP casing temperature and expansion difference.

h. When warming up is completed, the DEH system sends signals to the TBS and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback.

10 Increase Load to Target Value

a. When the load reaches the downslide point, the DEH system sends signals to the CCS system. The set starts to slide the parameters and increase the load along with the boiler.

b. The set gets to the downslide point when the load is about 105MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment (i.e. not participate in the load control) until the load approachs to 90% ECR.

c Stop using the heating system of cylinder interlayer at any time according to Section 7-2.

d. Check the closing sequences of drainage system under the following operating states:

(1) At 15% rated load, close the drainage of HP section;


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(2) At 20% rated load, close the drainage of IP section;

(3) At 30% rated load, close the drainage of LP section.

e. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.

f. When the steam turbine runs stably upwards of 225MW and the air extractor works properly, it is possible to perform the tightness test of vacuum system.

(1) Close the inlet electric door of air extractor, the vacuum of steam condenser shall drop slowly.

If the drop rate ≤0.13kPa/min (1mmHg/min), excellent

If the drop rate ≤0.27kPa/min (2mmHg/min), good

If the drop rate ≤0.4kPa/min (3mmHg/min), qualified

When the drop rate of vacuum is more than 0.67kPa/min (5mmHg/min), the machine shall be stopped for identifying the root cause. Restart the machine when the trouble is eliminated.

(2) During the test, if the IP exhaust pressure increases to 17.86kPa (or vacuum decreases to 626mmHg) and the temperature is higher than 58℃ , the test shall be stopped.

When the test is finished, open the electric valve immediately to recover the rated vacuum value.



2-2 Start-up Under Warm State (IP)

1 Preparation Before Turbine Rolling




d. Engage the turning gear and ensure that the turning time is no less than 4h before turbine rolling;

e. Before turbine rolling, the auxiliary steam source of gland seal system shall be engaged. It is required that the pressure of gland seal piping-main shall be

0.123Mpa and the temperator shall be under 150℃～260℃ .

f. When the gland seal system runs properly, the vacuum of steam condenser shall be created. It is required the pressure of steam condenser shall be below 16.7Kpa;

g. Press the “LATCH” button and the set will be turned on;

h. Open the drain valves for the HP, IP and LP sections;

i. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met.

j. Confirm whether the HP exhaust non-return valve has closed completely;

k. Define Steam Parameters for Turbine Rolling:

（1） main steam pressure: 5.88MPa;

（2） reheat steam pressure: 0.686MPa;


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（3） recommended temperature for main steam: 370℃ ;

（4） Selection of Reheat Steam Temperature: refer to (2) in Item m of Section 3-1.

l. Define change rate of steam temperature during start-up: refer to Item n in Article 1 of Section 3-1.

m. Operating Requirements for HP and LP By-pass before Turbine Rolling

With the start-up of boiler, the openings of HP and LP by-pass valves increase gradually. When the main steam pressure increases to 5.88MPa, the auto control of pressure feedback shall be engaged in the HP by-pass; when the reheat steam pressure increases to 0.686MPa, the auto control of pressure feedback shall be engaged in the LP by-pass.

2 Turbine Rolling




d. Confirm whether the ventilator valve（VV valve） is closed;

e. Select the speed of 500r/min for "TARGET"; select the accelerating rate of 200r/min/min for "ACCELERATE";

f. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the machine shall be stopped.


At this speed, perform overall inspection for the set. Mainly check whether there


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is friction between the static and dynamic parts. The stop time shall not exceed 5 min.


b. Press the “GO” button to increase the speed;

Based on the metal temperature of HP exhaust lower half inner wall, control the temperature to reach 200℃ or so through adjusting the opening of manual valve in the back of ventilator valve.


a. The pressure of steam condenser shall be less than 13kPa and the vacuum protection shall be engaged;




(1) The change over between the main oil pump and AC lubricant pump shall be completed;




(5) Stop the jacking oil pump when the speed reaches 1200r/min.



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The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2;

g. Requirements for Steam Parameters

The change rates of main steam temperature and reheat steam temperature shall not exceed the selected values before turbine rolling;


After the completion of inspection of steam turbine generator set, inform the operator that it is permissible to incorporate the set in power network.



6 Load Increase

Select the load of 30MW for “TARGET” and the load increase rate of 3MW/min for “LOAD RATE”;

Afterwards, the LP by-pass valve closes gradually.

7 Change over between HP and IP Casings

a. Before changing over between HP and IP casings, pay attention to the matching of steam temperature and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method;

b. When it is changed from the sole steam admission through the HP casing to the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically.

c. When it is changed from the sole steam admission through the HP casing to


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the combined steam admission through the HP and IP casings, the parameters and flows of main steam and reheat steam shall be kept stable basically.

d. When the by-pass is fully closed, perform warming up at low load. Monitor the metal temperature of IP exhaust lower half inner wall. It shall reach 170℃ . Adjust the opening of manual valve in the back of ventilator valve to control the

metal temperature of HP exhaust lower half inner wall within 220--250℃ for 15 min;

e. When all the above items are completed, the operator presses the "VALVE CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then;

f. Check the following items during the change over period:

(1) The ventilator valve (VV valve) is closed;

(2) The HP exhaust non-return valve opens automatically.

g. When the change is over, engage the interlayer heating device based on the concrete situation of HP casing temperature and expansion difference.

h. When the change over is completed, the DEH system sends signals to the TBS and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback.



b. The set gets to the downslide point when the load is about 135MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with


2-2-6

the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment (i.e. not participate in the load control) until the load approachs to 90% ECR.

c. Stop using the heating system of cylinder interlayer at any time according to Section 7-2.

d. Check the closing sequences of drainage system under the following operating states:







2-3 Start-up Under Hot State and Extremely Hot State (IP)




c. Start the hydraulic oil pump

d. During the period from shutdown to restart, the set shall be at continuous turning gearing state;

e. Before turbine rolling , steam shall be sent to the gland seal. Then the vacuum of steam condenser shall be extracted. It is required that the pressure of

gland seal piping-main shall be 0.123MPa and the temperator shall be under 250℃～

350℃；

f. Create the vacuum for the steam condenser after the gland seal system runs normally. The pressure for the condenser shall be below 16.7kPa;


h. Open the drain valves in the HP, IP and LP sections;

i. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning shall be continued before start-up until the requirements are met;

j. Confirm whether the exhaust non-return valve is closed completely;

k. Define the steam parameters for turbine rolling: pay attention to the matching of reheat steam temperature after the work done by IP Stage 1 and metal temperature.

(1) Pressure of Main Steam: hot state 7.85MPa, extremely hot state 9.81MPa;


2-3-2

(2) Reheat Steam Pressure: 0.883MPa;

(3) Temperature of Main Steam: hot state 450℃ , extremely hot state 460℃ ;

(4) Selection of Reheat Steam Temperature: refer to (2) in Item m in Article 1 ofSection 3-1;

m. Define the change rate of steam temperature during start-up: refer to Item n in Article 1 of Section 3-1.

n. Operating Requirements for HP and LP By-pass before Turbine Rolling

Along with the start-up of boiler, the valve openings of HP and LP by-pass increase gradually. When the main steam pressure increases to 7.85MPa for hot state and 9.81MPa for extremely hot state, the HP by-pass shall get the auto control of pressure feedback engaged.

When the pressure of reheat steam increases to 0.883MPa, LP by-pass shall also get the auto control of pressure feedback engaged.

2 Turbine Rolling




d. Select the speed of 500r/min for “TARGET”;

Selection for “ACCELERATE”: hot state: 200r/min/min and extremely hot state: 300r/min/min

e. After pressing the “go” button, the IP control valves open gradually. The set increases the speed according to the given accelerating rate. The ventilator valve is opened. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the machine shall be stopped.


2-3-3


At this speed, perform overall inspection for the set. Mainly check whether there is friction between the static and dynamic parts. The stop time shall not exceed 5 min.









The outlet oil pressure of main oil pump shall be at the normal value. See Article a in 2.1 of Section 6-2;


(4) The lubricant pressure shall be at the normal value. See Article c in 1.2 of Section 6-2;





2-3-4

f. Requirements for Steam Parameters

The change rates of main and reheat steam temperature shall not exceed the selected values before turbine rolling;



Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase.

6 Load Increase

Select the final stable operating target load for “TARGET”; selection for “LOAD RATE”: hot state: 4.8MW/min extremely hot state: 7MW/min

Afterwards, the LP by-pass valve closes gradually.

7 Change over between HP and IP casings

a. Before changing over between HP and IP casings, pay attention to the matching of steam temperature

and metal temperature of main steam after the work done by the HP control stage. Refer to (2) in Item m of Section 3-1 for the calculation method;

b. After the LP by-pass valve is fully closed, the TBS system sends signals to the DEH to maintain the load;

c. When all the above items are completed, the operator presses the "VALVE CHANGE" button to change the valves. The HP control valve gradually opens in the mode of single valve. After about 1 min, the HP and IP control valves start to enter into proportional relationship and the change is over by then;


2-3-5

d. Check the following items during the change over period:

（1）The ventilator valve (VV valve) is closed;

（2）The HP exhaust non-return valve opens automatically.

When the change over is completed, the DEH system sends signals to the TBS and the set starts to increase load. With the increase of load, the HP by-pass closes gradually. When the load reaches the downslide point, the HP by-pass valve releases the auto control of pressure feedback.



b. The set gets to the downslide point when the load is about 165MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment (i.e. not participate in the load control) until the load approachs to 90% ECR.

c. Check the closing sequences of drainage system under the following operating states:

(1) At 10% rated load, close the drainage of HP section






3 Combined Start-up of HIP Casing (HIP)



3-1 Start-up under Cold State (HIP)



b. Start the lubricant pump and jacking oil pump etc and confirm whether the lubricant system and jacking system are in normal working conditions;


d. Engage the turning gear and ensure that before turbine rolling the continuous turning gearing time is no less than 4h;

e. Recheck the lubricant system, hydraulic oil system, DEH, TSI system and turning gear according to Section 1-1;

f. Create the vacuum for the steam condenser. The pressure for the condenser shall be below 16.7kPa;

g. After confirming there is no water in the gland seal steam pipeline, engage the auxiliary steam source of gland seal system. The pressure of gland seal piping-main shall be 0.123MPa and the temperature shall be under 150℃～260℃ ;

h. Press the “LATCH” button and the set will be turned on;

i. Press the “PREWARM” button to pre-heat the HP casing, main steam pipe and valve shell. See Section 7-1;

j. Open the drain valves in the casing proper and steam pipeing:

a) HP Section

1）upper valve body drainage of HP main stop valve;

2） lower valve body drainage of HP main stop valve;


3-1-2

3）drainage of HP main steam pipe;

4）drainage of HP inner casing;

5) drainage of casing interlayer heating connection with steam combination box and its inlet tube;

6）drainage of interlayer between HIP inner and outer casings

7）drainage of exhaust check valves at Stage 1 and 2 and valve front;

b) IP Section

1）Drainage of IP steam admission chamber;

2）Drainage of valve front and back of HP exhaust check valve;


4）drainage of IP combined steam valve;

5）drainage of steam drain of IP casing;

c) LP Section


2）drainage of self-seal system and shaft seal steam supply pipe;

All the drainage valves in the HP, IP and LP sections mentioned above must be opened when the set is under cold, warm, hot and extremely hot states to prevent water hammer during turbine rolling. The specific close sequences can be found in Paragraph 11 of this section.

k. The TSI measured data display is within the permissible range. Following major records shall be noted before turbine rolling:

1）absolute expansion of cylinder;


3-1-3

2）expansion difference;

3）axial displacement;

4）shaft eccentricity and turning current;

5）upper and lower half inner wall temperature at HP inner casing adjusting stage;

6）each bearing pad temperature and return oil temperature;

7） temperature of inner and outer wall of valve shell of HP main stop valve;

8） temperature of inner and outer wall of valve shell of HP control valve;

m. Define Parameters of Turbine Rolling Steam

1) main steam pressure: 3.45MPa;

2) Selection of turbine rolling steam temperature

The selection criteria is to make the temperature of main steam and reheat steam after the HP control stage or doing work at HP Stage 1 match the metal temperature.

Selection of main steam temperature: determine the steam temperature after the HP control stage according to the metal temperature after the HP control stage before turbine rolling and the temperature difference between the metal and steam in Article 2.4 of Section 6-2. Then based on Fig.3-1-1, determine the temperature of main steam according to the pressure of main steam and steam temperature after the control stage


3-1-4

For example:

Calculation Procedure Calculation Basis Calculation Result

Metal temperature after the control stage and pre-warming of HP casing before turbine rolling

Measured 150℃

According to Article 2.4 of Section 6-2

t（selected） 90℃

Steam temperature after the control stage

t+ metal temperature after the control stage

240℃

Temperature of main steam Find in Fig.3-1-1 320℃

Selection of reheat steam temperature: determine the steam temperature after IP Stage 1 according to the metal temperature after IP Stage 1 before turbine rolling and Article 2.4 of Section 6-2 (temperature difference between the metal and steam). Then determine the reheat steam temperature according to the temperature drop

(about 37℃ ) of IP Stage 1.

For example:


Metal temperature after MP Stage 1 before turbine rolling

Measured 50℃

According to Article 2.4 of Section 6-2

t（selected） 150℃

Steam temperature after IP Stage 1

t+ metal temperature after IP Stage 1

200℃

Reheat steam temperature

Steam temperature after IP Stage 1 + temperature drop （37℃）after IP Stage 1

237℃


3-1-5

n. Define Change Rate of Steam Temperature During Start-up

When the ATC does not get the control engaged, it is necessary to select a rational change rate of metal temperature (equivalent to the change rate of steam temperature) by adopting the rotor life loss curve so as to ensure the safe operation of set.

(1) Selection of Change Rate of Main Steam Temperature:

Before start-up, the operator sets a target stable operating load for the set, calculates the temperature after the HP control stage according to Fig. 3-1-2, Fig.3-1-3 or Fig.3-1-4, determines the change of metal temperature of HP casing (change of metal temperature in short), and then selects the change rate of metal temperature after the HP control stage according to the HP rotor life loss curve.

For example:


Steam temperature after the HP control stage at a target stable operating load

Set the target load as 50%ECR and main steam pressure as 10.79MPa, and adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537 ℃-temperature drop at control stage

500℃

Metal temperature after the HP control stage before turbine rolling

Measured 150℃

Change of metal temperature

Steam temperature after the control stage-metal temperature after the control stage

350℃

Change rate of main steam temperature

Find the normal loss in Fig.3-1-5. 57℃ /h

(2) Selection of Change Rate of Reheat Steam Temperature


3-1-6

The steam temperature after IP Stage 1 under various working conditions is the difference between the IP steam admission temperature and the temperature drop at IP Stage 1 under the rated working condition. Compare it with the metal temperature at IP Stage 1 before turbine rolling to get the change of metal temperature of MP casing. Then select the change rate of metal temperature at IP Stage 1 according to the IP rotor life loss curve (Fig. 3-1-6) (equivalent to the change rate of reheat steam temperature).

For example:


Metal temperature after IP Stage 1 before turbine rolling

Measured 50℃


（537-37）℃ 500℃


Steam temperature after Stage 1-metal temperature after IP Stage 1

450℃

Change rate of reheat steam temperature

Find the normal loss in Fig.3-1-6. 84℃ /h

2 Turbine Rolling


b. Engage the heating for the cylinder interlayer and refer to Section 7-2 for details;

c. Confirm whether the “HP＆ IP START/IP START” button is under the “HP＆ IP START” state;

d. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGLE VALVE” state;


3-1-7

e. Press the “RUN” button and start the HP and IP reheat stop valves;

Select the speed of 500r/min for “TARGET”; the accelerating rate of 100r/min/min for “ACCELERATE”;

g. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the machine shall be stopped.


At this speed, perform overall inspection for the set. Mainly inspect whether there is friction between the static and dynamic parts, whether the ventilator valve is at the close position, whether the HP exhaust non return valve is at the open position. The stop time shall not exceed 5 min.

Note: under various start-up states for the HIP combined start-up, when performing inspection at 500r/min, the HP and IP control valves shall be closed and it shall be done at idling speed. Before the speed is more than 50r/min, re-open the HP and IP control valves and raise the speed to 1200r/min according to the accelerating rate.


b. Press the “GO” button;

4 Warming up at Medium Speed of 1200r/min

Warming up at the speed for 30min.

a. Stop the oil pump for jacking;

b. Inspect all the monitoring instruments;

c. Select the speed of 2000r/min for the "TARGET”;


3-1-8

d. Press the “GO” button to increase the speed;

During the process of raising speed afterwards, the set shall rapidly (at the accelerating rate of 250～300r/min/min) and steadily pass the critical speed at each step in the axis series. The vibration of bearing cover at the critical speed shall be no more than 0.10mm (peak-peak). Otherwise, the brake shall be disengaged and the machine shall be stopped.

5 Warming up at High Speed of 2000r/min

At this speed, monitor the metal temperature of IP exhaust lower half inner wall no more than 130℃ and keep warming up for 60 min. After the completion of warming up, the following values shall be met:

Metal temperature after the control stage of upper half inner wall of HP inner casing: more than 250℃ ;

Expansion of HP and IP casings: more than 7mm;

Expansion of HP and IP less than 3.5mm and getting stable;


b. Press the “GO” button to increase the speed.

6 Rated Speed 3000r/min:

At this speed, perform warming up under zero load for 30min;





3-1-9







The pressure of hydraulic oil shall be at the normal value. See Article b in 1.2 of Section 6-2.

f. Requirements for Steam Parameters

(1) The main steam pressure shall reach 5.88MPa and main steam temperature shall reach 370℃ ;

(2) Before incorporating in power network, the difference between the main steam temperature and reheat steam temperature shall meet Article c in 2.3 of Section 6-2;

(3) The change rates of main steam temperature and reheat steam temperature shall not exceed the selected value before turbine rolling;

7 Perform following system tests before incorporating in power network (for new machine start-up or after heavy repair of set)

a. Oil spray test of emergency governor;

b. On-line test of HP emergency governor IC (HPT) electromagnetic valve;


3-1-10

c. On-line test of overspeed limit IC (OSP) electromagnetic valve;

d. Manual shutdown button test;

e. Speed acceleration test of emergency governor (before performing the acceleration test, the set shall run no less than 3h for warming up with 20% load);

f. Electric overspeed protection test

The specific requirements for various tests above can be found in the “Specification for Adjusting and Security System”, “Specification for Safety Monitoring Device of Steam Turbine” and “Specification for Electrical Appliance Monitoring and Protection System of Steam Turbine”


After the completion of test and inspection of steam turbine generator set, inform the operator that it is permissible to incorporate the set in power network.



9 Load Increase

a. Select the load of 30MW for “TARGET”, the load increase rate of1MW/min as the “LOAD RATE”;

b. Press the “GO” button to increase the load.

10 Warming up Under Low load


3-1-11

Perform steadily under the low load of 30MW, ensure the metal temperature of IP exhaust lower half inner wall more than 176℃ and keep warming up for 30 min;

a. Select the final stable target operating load for “TARGET”;

the load increase rate of 1MW/min as the “LOAD RATE”;



a. The set gets to the downslide point when the load is about 105MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment (i.e. not participate in the load control) until the load approachs to 90% ECR.

b. Stop using the heating system of cylinder interlayer at any time according to Section 7-2.





d. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.

e. When the steam turbine runs stably upwards of 225MW and the air extractor works properly, it is possible to perform the tightness test of vacuum system.


3-1-12

(1) Close the inlet electric door of air extractor, the vacuum of steam condenser shall drop slowly.

If the drop rate ≤0.13kPa/min (1mmHg/min), excellent

If the drop rate ≤0.27kPa/min (2mmHg/min), good

If the drop rate ≤0.4kPa/min (3mmHg/min), qualified

When the drop rate of vacuum is more than 0.67kPa/min (5mmHg/min), the machine shall be stopped for identifying the root cause. Restart the machine when the trouble is eliminated.

(2) During the test, if the exhaust pressure increases to 17.86kPa (or vacuum decreases to 626mmHg) and the exhaust temperature is higher than 58℃ , the test shall be stopped.

(3) When the test is finished, open the electric valve immediately to recover the rated vacuum value.


3-1-13

Mai

n St

eam

Tem

pera

ture

Parameters on the left sideand line are prohibited

Main Steam Pressure

Para

met

ers

abov

e th

e li

ne a

re

proh

ibit

ed d

urin

g tu

rbin

e ro

llin

g

Steam Temperature after Control Stage ℃

Fig.3-1-1 Relation Curve of Steam Temperature Under Steam Pressure during Initial Turbine Rolling and Steam Temperature after Control Stage



3-2 Start-up Under Warm State (HIP)

1 Preparation Before Turbine Rolling

a Supply power to the DEH. The panel and system shall all be in normal condition;



d. Engage the turning gear and ensure that the turning time is no less than 4h before turbine rolling;

e. Before turbine rolling, the auxiliary steam source of gland seal system shall be engaged. It is required that the pressure of gland seal piping-main shall be

0.123MPa and the temperature shall be under 150℃～260℃ .

f. When the gland seal system runs properly, the vacuum of steam condenser shall be created. It is required the pressure of steam condenser shall be below 16.7Kpa;


h. Open the drain valves for the HP, IP and LP sections;

i. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met.

j. Define Steam Parameters for Turbine Rolling

(1) Recommended pressure for main steam: 7.84MPa;

(2) Refer to (2) in Item m of Article 1 of Section 3-1 for the selection of steam temperature for turbine rolling.


3-2-2

Selection of Main Steam Temperature:

For example:


Metal temperature after the control stage of HP casing before turbine rolling Measured 180℃

According to Article 2.4 in Section 6-2 t（selected） 130℃

Steam temperature after the control stage t+ metal temperature after the control stage 310℃

Main steam temperature Find in Fig.3-1-1 410℃

Selection of Reheat Steam Temperature:

For example:


Metal temperature after IP Stage 1 before turbine rolling Measured 140℃

According to Article 2.4 in Section 6-2 t（selected） 150℃

Steam temperature after IP Stage 1 t+ metal temperature after IP Stage 1 290℃

Reheat steam temperature Steam temperature after IP Stage 1+ temperature drop after IP Stage 1（37℃）

327℃

k. Define the change rate of steam temperature during start-up: refer to Item n in Article 1 of Section 3-1

(1) Selection of Change Rate of Main Steam Temperature


3-2-3

For example:



Set the target load as 100% ECR and main steam pressure as 16.67MPa, and adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537 ℃-temperature drop at control stage

504℃


Measured 180℃

Change of metal temperature Steam temperature after the control stage-metal temperature after the control stage

324℃

Change rate of main steam temperature Find the normal loss in Fig.3-1-5. 57℃ /h


For example:


Metal temperature after IP Stage 1 before turbine rolling Measured 140℃

Steam temperature after IP Stage 1 （537-37）℃ 500℃

Change of metal temperature Steam temperature after Stage 1-metal temperature after IP Stage 1 360℃

Change rate of reheat steam temperature Find the normal loss in Fig.3-1-6 84℃ /h


3-2-4

2 Turbine Rolling


b. Engage the heating for the cylinder interlayer according to the expansion difference of set;

c. Confirm whether the “HP＆ IP START/IP START” button is under the “HP＆ IP START” state;

d. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGLE VALVE” state;

e. Press the “RUN” button and start the HP and IP reheat stop valves;

f. Select the speed of 500r/min for “TARGET”; the accelerating rate of 100r/min/min for “ACCELERATE”;

g. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically. Otherwise, the brake shall be disengaged and the machine shall be stopped.


Running at this speed, perform overall inspection for the set. Mainly check whether there is friction between the static and dynamic parts, whether

the ventilator valve and emergency blowdown valve are at the closed position, whether the HP exhaust non-return valve is at the opened position. The stop time shall not exceed 5 min.





3-2-5


b. When the exhaust temperature of LP casing is ≥80℃ , the sprayer of LP casing shall engage automatically. Otherwise, it shall be started manually.







(5) Stop the oil pump for jacking when the speed reaches 1200r/min.



f. Confirm Steam Parameters

(1) Main steam pressure: 7.84MPa;

(2) Before incorporating in power network, the difference between the main steam temperature and reheat steam temperature shall meet Article c in 2.3 of Section 6-2;


3-2-6

(3) The change rates of main steam temperature and reheat steam temperature shall meet the selected value before turbine rolling;



Select “AUTO SYNC IN”(DEH internal automatic incorporating in power network) or “AUTO SYNC OUT”(external electric incorporating in power network). After incorporating in power network, the control system will add 3% ---minimum load, and then get into the control of load increase.

6 Load Increase

a. Select the load of 30MW for “TARGET”, the load increase rate of 3MW/min as the “LOAD RATE”;


7 Warming up under Low Load

Operate steadily under the low load of 30MW, ensure the metal temperature of IP exhaust lower half inner wall more than 176℃ and keep warming up for 20 min;

a. Select the final stable target operating load for “TARGET”;

b. Select the load increase rate of 3MW/min as the “LOAD RATE”;

c. Press the “GO” button to increase the load.


a. The set gets to the downslide point when the load is about 135MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment until theload approachs to 90% ECR.


3-2-7

b. Stop using the heating system of cylinder interlayer at any time according to Section 7-2.





d. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.



3-3 Start-up Under Hot State and Extremely Hot State (HIP)



b. Start the lubricant pump and jacking oil pump etc and confirm whether the lubricant system and jacking system are in normal working conditions;

c. Start the hydraulic oil pump and enable it under normal working condition;

d. During the period from shutdown to restart, the set shall be at continuous turning gearing state;

e. Before turbine rolling, steam shall be sent to the gland seal. Then the vacuum of steam condenser shall be extracted. It is required that the pressure of gland seal piping-main shall be 0.123MPa and the temperature shall be under 250℃～350℃ ;

f. Create the vacuum for the steam condenser after the gland seal system runs normally. The pressure for the condenser shall be below 16.7kPa;


h. Confirm the difference between the rolling steam temperature and the main

stop valve metal temperature of inner wall. If it is more than 120℃ , the valve shall be pre-heated;

i. Open the drain valves in the HP, IP and LP sections;

j. The TSI measured data display shall be in the permissible range. The eccentricity shall not exceed 0.03mm of original value. Otherwise, the turning gearing shall be continued before start-up until the requirements are met;

k. Define Steam Parameters for Turbine Rolling

(1) Main steam pressure: hot state: 9.81MPa extremely hot state: 11.76MPa

(2) Refer to (2) in Item m of Article 1 of Section 3-1 for the selection of steam


3-3-2

temperature for turbine rolling

Selection of Main Steam Temperature:

For example:

Calculation Result Calculation Procedure Calculation Basis

Hot State Extremely Hot State

Metal temperature after the control stage of HP casing before turbine rolling

Measured 310℃ 420℃

According to Article 2.4 in Section 6-2 t（selected） 30℃ 10℃

Steam temperature after the control stage

t+ metal temperature after the control stage 340℃ 430℃

Main steam temperature Find in Fig.2-1-1 450℃ 510℃

Note: The pressure of main steam shall not exceed 11.7Mpa during start-up

under the extremely hot state. The temperature of main steam shall not exceed 510℃ as much as possible. In the meanwhile, attention shall be paid to the constraints of load compatibility in Article 2.4 of Section 6-2.

（3） Selection of Reheat Steam Temperature:

For example:

Calculation Result Calculation Procedure Calculation Basis Hot State Extremely

Hot State



According to Article 2.4 in Section 6-2

t（selected） 90℃ 10℃


3-3-3


t+ metal temperature after IP Stage 1 380℃ 450℃

Reheat steam temperature

Steam temperature after IP Stage 1+ temperature drop after IP Stage 1（37℃）

417℃ 487℃

m. Define the change rate of steam temperature during start-up: refer to Item n in Article 1 of Section 3-1.

(1) Selection of Change Rate of Main Steam Temperature

For example:

Calculation Result Calculation Procedure Calculation Basis Hot

State Extremely Hot State


Set the target load as 100% ECR and main steam pressure as 16.67MPa, and adopt single valve for steam admission. Find the temperature drop at the control stage in Fig.3-1-2 and 3-1-3. 537℃ -temperature drop at control stage

504℃ 504℃




Steam temperature after the control stage-metal temperature after the control stage

194℃ 84℃

Change rate of main steam temperature

Find the normal loss in Fig.3-1-5. 62℃ /h 80℃ /h


For example:


3-3-4

Calculation Result

Calculation Procedure Calculation Basis Hot State

Extremely Hot State




（537-37）℃ 500℃ 500℃


Steam temperature after Stage 1-metal temperature after IP Stage 1

210℃

60℃

Change rate of reheat steam temperature

Find the normal loss in Fig.3-1-6

95℃ /h

>300℃ /h

2 Turbine Rolling



c. Confirm whether the “SINGLE VALVE/SEQ VALVE” button is under the “SINGLE VALVE” state;

d. Press the “RUN” button and start the HP and IP reheat stop valves; select the speed of 500r/min for “TARGET”;

e. Selection for “ACCELERATE”: hot state: 200r/min/min and extremely hot state: 300r/min/min

f. After pressing the “go” button, the HP and IP control valves open gradually. The set increases the speed according to the given accelerating rate. When the speed is more than the turning speed, the turning gaer shall come away automatically.


3-3-5

the brake shall be disengaged and the machine shall be stopped.


Running at this speed, perform overall inspection for the set. Mainly check whether there is friction between the static and dynamic parts, whetherthe ventilator valve and emergency blowdown valve are at the closed position, whether the HP exhaust non-return valve is at the opened position. The stop time shall not exceed 5 min.












3-3-6









6 Load Increase

a. Select the final stable operating target load for “TARGET”; selection for“LOAD RATE”: hot state: 4MW/min extremely hot state: 6MW/min



a. The set gets to the downslide point when the load is about 165MW. At this time, the HP control valve approachs to 90% rated valve position. The DEH control system sends signals to the CCS system. The set starts to increase the load along with the pressure increase of boiler. At this time, the DEH control system does not participate in the adjustment until the load approachs to 90% ECR.


3-3-7

b. Check the closing sequences of drainage system under the following operating states:




c. When the target load is reached and the temperature of each measuring point of proper gets stable, press the “SEQ VALVE” button to change to the control state of sequence valve for better economical efficiency.



4 Operations



4-1 Normal Operation

1 When the steam turbine is in the normal operation period, the following items shall be within the normal value ranges defined in Section 6-1 “ Limited Values for Set Start-up and Operation”:

a. controlling oil pressure (refer to the security and hydraulic oil pressures) and bearing lubricant pressure;

b. shaft and bearing pad vibration;

c. HIP and LP expansion differences;

d. temperatures of bearing inlet oil, return oil and tungsten steel;

e. axial displacement;

f. metal temperature;

g. pressure of steam condenser;

h. exhaust temperature of LP casing;

i. steam temperature of HP casing exhaust;

j. oil levels of main and hydraulic oil tanks.

In order to ensure the set safe operation for long term, regular inspection and test shall be performed according to Section 6-4.

2 Precautions of Normal Operation

2.1 Permissible Variable Ranges for Steam Parameters

a. Pressure of Main Steam（ refer to the pressure before the HP main stop valve）

Rated Pressure Po: 16.7MPa

Mean annual Pressure of Continuous Operation: not exceeding Po


4-1-2

Pressure Permissible for Continuous Operation While Ensuring the Mean annual Pressure: not exceeding 1.05Po

Under abnormal conditions, the permissible pressure variance shall not exceed 1.20Po.

However the total time of this value in any year’s operation shall not exceed 12h.

b. Main and Reheat Steam Temperatures（ refer to the temperatures before the HP and IP reheat stop valves）

Rated Temperature To: 537℃

Mean annual Temperature of Continuous Operation: not exceeding To

Temperature Permissible for Continuous Operation While Ensuring the Mean annual Temperature: not exceeding To+8℃

The total operating time no more than To+14℃ shall not exceed 400h; it is allowed to vary between 551℃ and 565℃ . However, the continuous operating time shall not exceed 15min and the total operating time in any year shall not exceed 80h.

2.2 Partial Periodicity operation

Periodicity： f Permissible Operating Time

Unit： Hz Each Time （sec） Total （min）

f<47.0Hz Non-permissible Operation

47.0Hz≤ f<47.5Hz 15 15

47.5Hz≤ f<48.0Hz 65 65

48.0Hz≤ f<48.5Hz 350 350

48.5Hz≤ f<50.5Hz Continuous Operation


4-1-3

50.5Hz≤ f<51.0Hz 200 200

51.0Hz≤ f<51.5Hz 35 35

51.5Hz≤ f<52.0Hz 5 5

52.0Hz≤ f<52.5Hz 2 2

f>52.5Hz Non-permissible Operation

Note:

Above partial periodicity operation restrictions apply to the process from partial to full load. The partial Periodicities occurred during the period of no load operation, shutdown and overspeed shall not be counted into the restricted time.

Refer to Section 6-2 and 6-3 for others.



4-2 Varying Duty Operation

1 Operating Mode

The set can operate in two modes: constant pressure and constant-slide-constant pressure.

During peaking operation, the operating mode of constant-slide-constant is recommended, i.e. adopt the operating mode of constant pressure when the sets runs at more than 90% rated load; adopt the operating mode of slide operation when the sets runs between 90%-40% rated load; adopt the operating mode of constant pressure when the sets runs under 40% rated load. This operating mode can improve the heat economical efficiency, reduce the temperature difference of steam admission part and temperature change when the load changes, thus reduce the fatigue damage of low periodicity.

When the set adopts the operating mode of nozzle adjustment (i.e. sequential valves), if the load reaches 90% rated load, No.I and II control valves are fully opened and No.III control valve is slightly opened. When the set runs between 90％～40％ , the boiler enters into the operation of slide pressure. The main steam pressure reduces along with the load while the opening of HP valve remains almost the same within this range. When the load is smaller than 40% rated load, the set enters the operation of constant pressure. In this phase, the HP control valve is used to change the load. When the load is smaller than 30% rated load, the IP control valve participates in the load adjustment.

Refer to Fig. 4-2-1 for the variable curve of slide pressure operation.


4-2-2

2 When the mean annual operating time is no less than 7500h, the permissible stable operating time for the peaking operating:

Load (％ECR) Hour/Year

100 4500

75 2000

40 1000

（Note: The operating time for 75% and 40% load is not allowed to exceed the above time）

3 Change Rate of Load:

Under 20% nameplate power, no more than 2％ECR/min;

From 50% to 20% nameplate power, no more than 3％ECR/min;

From 100% to 50% nameplate power, no more than 5％ECR/min and permissible variable range: 20%

4 During the normal operation period under high load, if the load varies frequently and the change rate is bigger, in order to have the minimum temperature change in the HP casing and minimum thermal stress, the throttle-governing mode (i.e. single valve adjustment) shall be used. However, if the set stably runs below the rated load for long term, the nozzle-governing mode (sequential valve governing) shall be used to obtain higher economical efficiency.


4-2-3

Main Steam Pressure

Load

Fig. 4-2-1 Varying Curve of Slide Pressure Operation



4-3 Abnormal Operation

When the steam turbine operates, if one or several limited values in Section 6-2 are out of limit and enter into the alarming state but none of them reaches the shutdown value and the power plant does not want to shut down the machine immediately, the short operation under this state is called as abnormal operation.

When the steam turbine operates abnormally, close attention shall be paid to the trends of various overrun, the root causes shall be found out as soon as possible and proper measures shall be taken to eliminate them. Once the overrun value becomes the shutdown value, the machine shall be shut down immediately.

Followings are the contents to be checked when some of limited values enter into the alarming state.

Overrun Project Major Inspection Content Remark

1 Big Axial Displacement

1) Check whether the parameters of main and reheat steam as well as the vacuum fluctuate greatly.

2) Check the temperature of bearing pad and discharged oil and confirm whether the tungsten steel is worn.

2 Big Expansion Difference

1) Big HIP Expansion Difference

a Confirm the direction of expansion difference（Positive expansion difference or negative expansion difference decreases）

b Maintain the load on the set and reduce the fluctuation of main steam temperature. Check the exhaust temperature of HP casing.

c If the positive expansion difference increases, the temperature of main steam shall be reduced or the load on the set shall be decreased gradually.

d If the negative expansion difference increases, the temperature of main steam shall be increased or the load on the set shall be increased gradually. Or other measures shall be taken to raise the cylinder temperature.


4-3-2

2) Big expansion Difference of LP Casing（Limited value for positive expansion difference only）

a Maintain the load on the set and reduce the fluctuation of reheat steam temperature. Check the exhaust temperature of LP casing.

b Reduce the temperature of reheat steam and gradually reduce the load on the set.

3 Big Vibration

1) Pay attention to the vibration trend of each bearing and ascertain the vibration type.

2) Check whether the following indications are normal

a Temperature of Bearing Tungsten Steel and Inlet Oil;

b Pressure of Oil Film on Each Pad;

c Whether the unmatched value between the temperature of main and reheat steam vs. temperature of cylinder metal is too big;

d Pressure of steam condenser and LP exhaust temperature;

e Temperature Difference of HIP Cylinder Metal;

f Cylinder Expansion and Expansion Difference;

g Check shaft bend value when shutdown;

h Measure vibration frequency spectrum and axes track, etc.

3） If the vibration is too severe during the start-up period of steam turbine, the set shall not operate in the range of critical speed. If excessive vibration occurs during the load increase period, the load increase shall be stopped and the steam shall operate under the original load. Increase the load again after the cause is found out and eliminated. If the vibration in the accelerating period exceeds the limit, the machine shall be shutdown for inspection. It is not allowed to operate at a reduced speed.

4 Low Lubricant Pressure

1) Check the oil level of main steam oil box;

2) Check whether the lubricant system has leakage;

3) Check whether the main oil pump and oil injector are normal.


4-3-3

5 High Temperature of Supporting Bearing Pad and Return Oil

1) Check the pressure of oil film of bearing;

2) Check the lubricant quality and confirm whether there is any impurity in the oil;

3) Check whether the inlet oil temperature is normal;

4) Check whether the gland seal leakage is severe.

6 High Temperature of Thrust Bearing Pad and Return Oil

1) Check whether the axial displacement is too big;

2) Check lubricant quality and confirm whether there is impurity in the oil;

3) Check whether the inlet oil temperature is normal.

7 High or Low Oil Level of Main Oil Tank

1) When the oil level of main oil tank is low, check whether there is leakage in the lubricant system.

2) When the oil level of main oil box is high, check whether there is water leakage in the oil cooler or whether the pending in the main oil tank is too much.

8 Low Vacuum of Steam Condenser

1) Check whether the LP exhaust temperature is normal;

2) check whether the vacuum breaking valve and emergency blowdown valve are closed;

3) Check whether the feeding pressure for the gland seal before and after the LP casing;

4) Check whether the cycling water temperature and level of steam condenser are normal;

5) If it is under the LP spray state, check whether the water spray is normal.



5 Shutdowns

The set shutdown includes slide parameter shutdown, rated parameter shutdown and emergency shutdown.

Slide parameter shutdown: mainly to reduce the cylinder metal temperature after shutdown to a lower temperature level. Normally it applies to light repair, heavy repair and other planned shutdown.

Rated parameter shutdown: mainly to enable timely start-up after short time trouble-shooting. Therefore, it is desired to maintain a higher temperature level for the cylinder metal to shorten the star-up time.

Emergency Shutdown: mainly applies to the accidents, dangers and sudden nature disasters.

Preparations before the slide and rated parameter shutdown:

a. Test AC and DC lubricant pumps, jacking oil pump and turning gear motor. All shall work properly;

b. Confirm whether the main steam valve, control valve and extraction non return valve are agile without stuck;

c. Heat the pipelines for the shaft seal auxiliary steam source and backup steam source for the deaerator.



5-1 Slide Parameter Shutdown

The steam turbine follows the boiler to slide the pressure to reduce the load according to the slide pressure curve. In the meanwhile, the speed governing port opens gradually and fully. During the load decrease period, the operator shall monitor the metal temperature after the control stage of HP inner casing and metal temperature change gradient of steam admission area of IP casing. Under the “Manual” and “Operator Auto” states, the limited value for the load decrease rate is given by the operation board. Refer to the operating procedures of set start-up for the operating modes.

a. Limitations for the reduction of temperature, pressure and load according to the slide parameter shutdown curve of boiler

descending speed of main and reheat steam temperature: less than 1℃ /min;

descending speed of main and reheat steam pressure: less than 0.098MPa/min;

degree of superheating of main and reheat steam: more than 50℃ ;

b. descending speed of cylinder metal temperature: not exceeding 1℃ /min;

c. When the main steam temperature descends 30℃ or so, the state shall be kept for 5～10min before further temperature reduction. The purpose is to control the temperature difference between the main and reheat steam as well as the heat expansion and expansion difference of steam turbine;

d. When the steam temperature after the control stage is 30℃ lower than the metal temperature of flange inner wall at the control stage of HP inner casing, the reduction of temperature shall be paused;

e. Attention shall be paid to the change of expansion difference of HIP casing during the load reduction process. When the negative expansion difference reaches -1mm, stop reducing the load. If the negative expansion difference continues to increase and no effect is shown by taking measures, which affects the safety of set, the load shall be rapidly reduced to zero;


5-1-2

f. During the load reduction process, engage the by-pass system and the spray cooling system of LP casing according to the operation situation;

g. During the load reduction process, pay attention to the change over of shaft seal and steam source of deaerator;

h. Control of drainage system during the load reduction process

（1） At 30％ rated load, open the drainage in the LP section;

（2） At 20％ rated load, open the drainage in the IP section;

（3） At 10％ rated load, open the drainage in the HP section;

i. When the load is reduced to 50MW, open the condensed water recirculating door to ensure the normal working of condensing pump and water level of steam condenser;

j. When the new steam pressure reduces to 4.9 ～ 5.88MPa and steam temperature reduces to 330℃～360℃ , if reducing the load to 5% rated load under the constant pressure, after the completion of inspection without finding abnormal, the machine shall be shutdown and the HIP reheat stop valve, control valve and exhaust non return valve shall all be closed;

k. When the steam turbine trips, the AC lubricant pump shall start automatically. Otherwise, it shall be started manually and start to record/plot the idling curve of steam turbine;

l. When the speed reduces to 1200r/min, start the jacking oil pump;

m. When the set idles at 300r/min, open the vacuum breaking valve to break the vacuum (if the boiler is not stopped, it is not necessary to open the vacuum breaking valve). When the set speed reduces to zero, engage continuous turning gear, stop the water-jet ejector and record the shaft bend value and turning gear current at the same time;

n. When the vacuum becomes zero, stop the steam supply and blower for the gland seal;


5-1-3

o. When the HP inner casing upper half inner wall temperature of reduces 200℃ , interval turning gear can be used. Turn over 180℃ every half hour. When the temperature reduces below 150℃ , stop the turning gear and jacking.oil pump. After the turning gear is stopped for 8h, stop the lubricant pump;

p. After shutdown, confirm there is no oil smoke in the main oil tank before stopping the smoke discharge fan;

r. Following points shall be monitored during the load reduction and shut down period:

（1）When sliding the parameters to reduce the load, closely monitor the set vibration. Should there by any abnormal vibration, stop the reduction of temperature and pressure. And stop the machine immediately;

（2）During turning gear, if there is any friction sound or other abnormal situations, continuous turning gear shall be changed to regular turning gear. If there is hot bending, use the mode of regular turning gear to eliminate it, and then continuously perform turning gear for over 4 hours;

（3）After shutting down, closely monitor and take measures to prevent cold steam and water from pouring into the cylinder, which will cause shaft bend and cylinder deformation.



5-2 Rated Parameter Shutdown

The rated parameter shutdown normally applies to temporary shutdown. If it is planned to repair the set after shutdown, it is beneficial to adopt the nozzle governing mode. Because the metal temperature is lower if the set is shut down with this mode, the cooling time can be shortened. For the peaking set whose shutdown time only has a few hours or other short temporary shutdown, in order to have higher metal temperature after shutdown to facilitate quick re-start, normally the throttle governing mode is adopted. Based on different shutdown purposes, it is possible to select the valve management mode on the operation board—single valve control or sequential valve control (i.e. throttle governing or nozzle governing).

a. Select 1MW/min as the rate of load reduction on the operation board;

b. Based on the boiler operating situation, engage the by-pass system at any time;

c. When reducing the load, watch the changes of expansion differences of HIP casing and LP casing. If the expansion difference is too big, the load reduction speed shall be slowed down. Check to see whether the steam source for the gland seal needs to be changed over. When the expansion difference reaches –1mm, stop reducing the load and keep stable operation. If the negative expansion difference continues to increase and the measures taken are non-effective, which affect the set safety, the load shall be rapidly reduced to zero; or the set shall be disengaged and shut down;

d. During the load reduction process, pay attention to the change over of steam source for the deaerator;

e. During the load reduction process, refer to Article h in Section 5-1 for the control of drainage system;

f. When the load is reduced to 50MW, open the recycling door of condensed water to ensure the normal working of condensed water pump and water level of steam condenser;


5-2-2

g. When the load reduces to 5% rated load, check whether the set has abnormal. Press the tripping button of steam turbine to disconnect the motor. The HIP reheat stop valve, control valve and exhaust non-return valve shall all be closed;

h. Other operations are the same as the slide parameter shutdown. Refer to Article k to r in Section 5-1.



5-3 Emergency Shutdown

1 Principle of Management for Emergency Shutdown

a. Accident management shall follow the principle of ensuring personal safety, not damaging equipment or damaging equipment as less as possible;

b. When an accident occurs, the faulty equipment shall be stopped immediately and relevant measures shall be taken to prevent the expansion of accident. If necessary, the non-faulty equipment shall continue working;

c. Accident management shall be done quickly, precisely and promptly;

d. The spot shall be maintained, in particular the data recorded in the instruments and meters before the accident and at the time of accident for the references when investigating the root cause and working out corrective measures;

e. When an accident is eliminated, the on-duty personnel shall completely and precisely record the phenomena observed, operating parameters at that time, course of accident management and occurring time to facilitate the inquiries made by relevant people when analyzing the root cause.

2 Under the following circumstances, after the set is disengaged, the vacuum shall be broken for emergency shutdown

a. The set vibrates intensively with the amplitude of pad vibration reaching over 0.10mm;

b. Clear metal friction and impact sound in the steam turbine or generator;

c. Water hammer occurs in the steam turbine or the temperature of main or reheat steam drastically drops over 50℃ in 10min;

d. Return oil temperature of any bearing rises to 75℃ or any bearing runs out of oil and smokes;

e Babbitt alloy temperature of any support bearing rises to 115℃ or Babbitt alloy temperature of thrust bearing rises to 110℃ ;


5-3-2

f. Shaft seal or oil ring rubs seriously and sparks occur;

g. When the lubricant pressure drops to 0.039MPa and no effect occurs even starting auxiliary oil pump;

h. When the oil level of main oil tank drops below the shutdown value of low oil level and no effect occurs even refilling the oil;

i. The oil system catches file;

j. The axial displacement exceeds the tripping value, but the protection device for axial displacement does not act;

k. The speed of steam turbine exceeds 3360r/min, but the emergency governor does not act;

l. The pressure of steam condenser rises to more than 19.7kPa;

m The cycling water discontinued and can not be recovered immediately;

n HP casing exhaust temperature ≥420℃ .

3 Under the following circumstances, after the set is disengaged, it is possible not to break the vacuum for shutdown.

a. The pipelines of main and reheat steam break and the set can not operate;

b. The condensing water pump is in trouble and the water level of steam condenser is too high，but the back-up pump can not be engaged;

c. The set idles after the load is rejected or runs with the plant power for more than 15min;

d. Due to the trouble of DEH system and governing security system, the set can not maintain normal operation;

e. Expansion differences of HIP and LP casings increase and exceed the limited values after non-effective adjustment;


5-3-3

f. The set’s operating time under the motor state exceeds 1min.

4 Precautions for Emergency Shutdown

a. The HP and IP reheat stop valves as well as control valves shall be closed immediately;

b. All the extraction and exhaust non-return valves shall be closed immediately;

c. The AC or DC lubricant pump shall be engaged immediately;

d. All the drainage valves for the steam turbine shall be opened;

e. When the speed drops to 1200r/min, the jacking oil pump shall be started.



6 Restrictions for Start-up and Operation



6-1 Restrictions for Prohibiting Start-up and Operation

Before start-up or during turbine rolling to pick up the load, confirm whether the following circumstances occur. If yes, start-up shall be prohibited or shut down for inspection.

a. Failure of any safety protection device;

b. The protection action value does not meet the requirement;

c. The speed governing system of steam turbine can not maintain no load operation. After the load rejection, the set can not control the speed below that causes the emergency governor acting;

d. Any main steam valve, control valve, exhaust non-return valve is stuck or not closed tightly;

e. The rotor bend value of steam turbine is 0.03mm more than the original value;

f. When turning gear, there is clear metal friction sound or the current for turning gear increases obviously or swings greatly;

g. Main display instruments (such as the sensors and display instruments for measuring speed, vibration, axial displacement, relevant expansion, speed modulation, lubricant pressure, hydraulic oil pressure, outlet oil temperature of oil cooler, temperature of bearing return oil, pressure and temperature of main and reheat steam, vacuum of steam condenser, the pressure switch of governing and security system, the double-branch thermocouple and display instrument for measuring the cylinder metal temperature, etc.) are not complete or out of order;

h. The AC and DC auxiliary oil pump, lubricant system and hydraulic oil supply system are in trouble. The jacking device and turning gaer are out of order;

i. The lubricant and hydraulic oil are not qualified. The inlet temperature of lubricant is abnormal and return oil temperature is too high;


6-1-2

j. In the heat recoup system, the main governing and control systems (such as the water level of deaerator, pressure auto governing, by-pass system protection and auto governing, control system for the steam (electric) feed pump, etc.) are out of order;

k. Water flooding into the steam turbine;

l. Incomplete heat conservation for the set;

m. During start-up and operation, the set exceeds the limited values; (see the limited values for start-up operation in Section 6-2)

n. The water vapor quality does not meet the requirement; for details, refer to “ Water Vapor Quality Standard for Thermal Power Generator Sets and Steam Dynamic Devices” (GB12145-89);

p Trouble of DEH control system.



6-2 Limits for Start-up and Operation

1 Alarming and Shutdown Value

1.1 TSI

a. Axial displacement: (The rotor positions itself at the working pad at the generator side. The displacement of rotor towards to the direction of generator is positive, vise versa, it is negative)

Alarming value: -1.05mm +0.6mm

Shutdown value: -1.65mm +1.2mm

b. Under the state of turning gear, it alarms when the eccentricity exceeds 0.03mm of the original value. If it is more than 0.03mm, continue to turn the gear until it becomes less than 0.03mm before start-up;

c. Expansion difference

Alarming value: HIP expansion difference -3mm +6mm

LP expansion difference / +14mm

Shutdown value: HIP expansion difference -4mm +7mm

LP expansion difference / +15mm

d. Shaft vibration: (peak, peak value)

Normal value: 0.076mm

Alarming value: 0.127mm

Shutdown value: 0.25mm

e. Vibration of bearing cover: (peak, peak value)


6-2-2

Normal value: 0.025mm

Alarming value: 0.05mm

Shutdown value: 0.08mm(manual)

1.2 Oil System

a. Lubricant pressure （value at bearing midsplit surface）

Normal value: 0.0785～0.0981MPa

Alarming value: 0.049MPa

Shutdown value: 0.039MPa

Stop turning gear: 0.029Mpa

b. Pressure of hydraulic oil

Normal value: 14MPa

Alarming value: 11.2MPa

c. Lubricant temperature

Normal working range of inlet oil temperature 40℃～45℃

Oil return temperature:

Normal value: less than 65℃

Alarming value: 65℃

Shutdown value: 75 (℃ manual)

d. Babbitt temperature of support bearing


Shutdown value: 115℃


6-2-3

e. Thrust pad temperature of thrust bearing



f. Oil level of lubricant tank

Highest oil level:

Lowest oil level:

Alarming value: see《Specification for Lubricating System》

Alarming value for low oil level:

Shutdown value for low oil level:

g. Oil level of hydraulic oil tank

Highest oil level:

Lowest oil level:

Alarming value: see the operation instruction for hydraulic oil system from the supplier

Alarming value for low oil level:

1.3. Pressure of Steam Condenser

Normal value: 5.8kPa

Alarming value: 14.7kPa

Shutdown value: 19.7kPa

1.4. Steam Temperature at Steam Drain of HP Outer Casing

Normal value: less than340℃


6-2-4



1.5. Exhaust Temperature of LP Casing:

Normal value: less than 36℃

Alarming value: 80℃（engaging the water spray）

Shutdown value: 110 (℃ manual)

1.6. When operating at the rated load, if the temperatures of main and reheat steam are lower than 520℃ , the set shall reduce the load. During the load reduction, if the steam temperature recovers, the load reduction shall be stopped. Otherwise, the load reduction shall continue. When the steam temperature reduces to 450℃ , the load shall be reduced to zero. If the steam temperature continuously drops to 430℃ and cannot be recovered, the set shall be manually stopped.

1.7. During start-up, load variation and shutdown, the dropped values for the temperatures of main and reheat steam shall be less than 50℃ in the period of continuous 15 min. If it reaches over 80℃ , the set shall be manually stopped.

2 Operation Surveillance

2.1 Oil System

a. Outlet Oil Pressure of Main Oil Pump

Normal Working Range: 1.9～2.05MPa

b. Temperature of Hydraulic Oil

Normal Working Range: 35℃～54℃

When the oil temperature is lower than 18℃ , start-up is prohibited.


6-2-5

2.2 Metal State

When a failure is found during the ATS’s rotor stress surveillance, the following restrictions on start-up operation shall be monitored for the set proper:

a. Temperature rising rate of HIP cylinder wall metal less than 1.5℃ /min (inner wall metal at Stage 1 of HP and IP casings);

b. Temperature differences between the HP and IP outer casings as well as the inner and outer walls of HP inner casing less than 50℃ respectively;

c. Temperature difference between the inner and outer walls of HP main stop valve casing;

d. Temperature difference between the inner wall of HIP casing and outer wall of HP inner casing less than 50℃ ;

e. Temperature difference between the upper and lower half of outer wall of HIP outer casing less than 50℃ ;

f. Temperature difference between the upper and lower half of outer wall of HP inner casing less than 35℃ ;

g. Temperature difference between the inner and outer wall of flange of HIP outer casing less than 80℃ ;

h. Temperature difference between the left and right flanges of upper half of HIP outer casing less than 10℃ ;

Temperature difference between the upper and lower half flanges of HIP outer casing less than 10℃ .


6-2-6

2.3 Steam

a. Temperature rising rate of main steam not exceeding 1.5℃ /min;

b. Temperature rising rate of reheat steam 2℃ /min;

c. The limited value for the temperature difference between the main steam (in front of main steam valve) and reheat steam (in front of IP combined steam valve) is in Fig.6-2-1;

e. The difference of steam temperature of each main steam pipeline and that of each reheat steam pipeline shall not exceed 17℃ ;

f. When the temperature difference between the flooding proof thermocouples on each section of extraction pipeline is more than 40℃ , it can be regarded as the flooding of cylinder. Measures shall be taken immediately to remove the ponding;

g. When the set operates at 5%-10% rated load, the maximum permissible exhaust pressure of LP casing of steam turbine shall be 13kPa and the exhaust

temperature of LP casing is not more than 52℃ . In this load section, long term operation is prohibited;

h. When the set is allowed to run at 30%-100% rated load for long term, at this time the maximum exhaust pressure shall be 14.7kPa. When exceeding the value, the condensing system shall be checked; if exceeding the value but not exceeding the shutdown value, the operating time shall be less than 60min. Otherwise, the set shall be stopped;

i. The highest permissible exhaust pressure during idling after the load rejection shall be 13.8kPa, the exhaust temperature shall be less than 80℃ and operating time shall be less than 15 min. Otherwise, the set shall be stopped;

j. Limite value for each section of extraction pressure and control stage pressure during the start-up and operation period


6-2-7

After the control stage: 13.78MPa

1# steam extraction 6.56MPa








2.4 Temperature Difference Between Metal and Steam: (main and reheat steam)

Before start-up, the steam temperature after the HP control stage or IP Stage 1 shall match the metal temperature. The temperature difference between the metal and steam temperatures of cylinder inner wall after the HP control stage or IP Stage 1 shall meet the following requirement:

Δ t=steam temperature-metal temperature

Δ t ideal value Δ t permissible value Δ t limit

10℃ 90℃ 150℃

-20℃ -50℃


6-2-8

(Main

Steam

Temperature-Reheat

Steam Temperature=) Temperature

Difference ℃

Permissible Operating Area

Prohibited Operating Area

Prohibited Operating Area

Load

Fig. 6-2-1 Permissible Temperature Difference Between Main

Steam and Reheat Steam



6-3 General Precautions

a. The set is not permitted to operate for long term when the main steam value opens at one side and closes at the other side;

b. Long term operation at less than 30% rated load shall be avoided;

c. Before the set is disconnected, the operating time of motor shall not exceed 1 min and the vacuum of steam condenser shall be normal;

d. Before engaging the turning gear, steam shall not be supplied to the gland seal;

e. When the exhaust temperature is high, watch the changes of expansion difference, vibration, bearing oil temperature and bearing metal temperature. When the exhaust temperature reaches the alarming value, besides engaging the spray system, other methods such as increasing the degree of vacuum or load shall be taken as well;

f. Except that emergency shutdown requires to break the vacuum immediately, normally, the vacuum shall be maintained if the set trips until it drops to 10% rated speed under the idling state;

g. The drainage systems of steam proper, main steam pipe, hot section of reheat steam pipe, cold section of reheat steam pipe and steam extraction pipe shall keep unblocked during start-up and shutdown;

h. The overspeed test can not be performed right after the oil spray test in order to avoid the inaccuracy of overspeed test due to accumulated oil;

i. When the set runs at 50%-60% rated load, the steam condenser is allowed to be cleaned and repaired at the half side. However, the changes of vibration, oil temperature and metal temperature of 3# and 4# bearings shall be watched out;


6-3-2

j. When the set is out of power grid and uses the plant power, any continuous operating time shall not exceed 15 min. During the life time of 30 years, the total times shall not exceed 10 times;k. When all the HP heaters are removed, the rated output (300MW) can be ensured, but no exceeding is allowed;

The removal of HP heater shall be performed from HP to LP. If the LP heater needs to be removed as well, the steam turbine generator set must reduce the load;

When the heaters are removed, the pressure after the control stage and the extraction pressure of each stage shall not exceed the limited value. See Article J in Section 6-2;

l. When engaging the heaters, they shall be engaged with the start-up from LP to HP in turns;

m. During the accelerating process, the set shall rapidly pass through the following critical speeds of various steps. During this phase, the vibration of bearing pad shall not exceed 0.10mm;

Shafting Critical Speed (calculated value) Step 1(Step 1 of Generator Rotor) 1370r/min Step 2(Step 1 of LP Rotor) 1688r/min Step 3 (Step 1 of HIP Rotor) 1750r/min Step 4 (Step 2 of Generator Rotor) 3517r/min

For the initial start-up of newly installed set, the shafting critical speeds shall be recorded. After confirmation, the actual measured values shall be used for the actual shafting critical speed.

n. The speeds of Step 1 vibration type of long blade at the last two stages of LP casing and harmonic resonance of k≤6 are lower than the working speed. In order to ensure the safety of blades, warming up and stop in the resonance speed range are not allowed. The shade line part in Fig. 6-3-1 represents the resonance speed range to be avoided;

p. ”Manual Mode” control can not be used as the control mode for long term operation;


6-3-3

q. During the entire operation period, monitoring and inspection shall be enhanced. Any found problem shall be handled timely to avoid accidents.

At this speed, listen to the soundsand check the monitoring instruments

Warming up Speed at Medium Speed

Warming up Speed at High Speed

Rated Speed

Fig.6-3-1



6-4 Regular Check and Test

Besides the tests performed during the start-up period, regular performance tests are necessary to ensure the reliability of set operation. The tests shall be performed strictly in accordance with relevant test regulations and specifications. Any defective part found shall be repaired or replaced immediately.

a. Valve Movement Test once per week

Before doing the valve movement test, the set load shall be reduced to 50%-70% rated load. Otherwise, the main steam parameters or reheat steam parameters and boiler level will change greatly during the test period, which affects stable operation.

When performing the test, follow the valve test buttons on the operation board. After a group of valves are tested in sequences, test another group of valves. The sequence of valve test follows the arrangement on the operation board.

Test process of IP valve group: close Control valve→close Main Steam Valve→open Main Steam Valve→open Control valve, return to normal. The HP valve test is not restricted in this way. During the valve movement test period, the pressure feedback of control stage shall be engaged.

b. Start-up test of AC and DC lubricant pump once every 15 days

c. Change over test of hydraulic oil pump once every week

d. Movement test of extraction check valve (except for the HP exhaust non return valve) once every month

e. Vacuum tightness test, see Item e of Article 11 in Section 3-1

once every month

f. Tightness test of HP and IP reheat stop valves as well as HP and IP control valves once every six month


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(1) The test shall be performed at the rated steam pressure, normal vacuum and zero load;

(2) When the HP and IP reheat stop valves as well as HP and IP regulating values are fully closed respectively, the steam turbine speed shall be reduced below 1000r/min;When the main steam pressure is low but not lower than 50% rated, the dropped value “n” of steam turbine steam can be corrected by the following formula:

n=(p/p. )x1000r/min

n the formula: p ---main steam pressure during test

p. ---rated main steam pressure

Note: The valve tightness test shall be performed after each disintegrated repairing of HP and IP reheat stop valves as well as HP and IP control valves, set heavy repair and load rejection test.

g. Oil spray test of emergency governor

h. Raising speed test of emergency governor

i. On-line test of HP emergency governor according to “ Specifications for

IC (HPT) electromagnetic valve; Governing and Security System”

j. On-line test of overspeed limit IC (OSP)

electromagnetic valve;

k. Check whether the TSI, steam temperature and pressure as well as other meters are normal and precise once every month

l. Protection device test of low lubricant pressure verify during light repair


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m. Other tests for the DEH system can be found in the DEH manual

n. Check whether the sprayer of spray device of LP casing is blocked check during heavy repair



7 Auxiliary Operation of Start-up and Shutdown

The auxiliary operation of start-up and shutdown mainly refers to the operations of pre-warming system of HP casing, interlayer heating system of HP casing, emergency discharge system and ventilator valve system. Because the operating sequence of ventilator valve has been explained in the section of start-up with the IP casing, there is no more explanation in this section.



7-1 Pre-warming of HP Casing

1 Inspection before Warming up

1.1 Confirm whether the HP control valve is closed and the steam parameters:

Steam pressure: 0.4～0.8MPa; steam temperature: 200～250℃， maintain over 50℃ degree of superheating.

1.2 Confirm whether the operation of turning gear after engagement is over two hours.

1.3 Confirm whether the gland seal at the shaft end of HIP casing is engaged.

1.4 Confirm whether the pressure of steam condenser does not exceed 19.6kPa.

1.5 Confirm whether the metal temperature at the control stage of HP inner casing is under 150℃ .

2 Operation Process of Warming up

The operator runs the warming up system on the operation board according to the set state displayed on the CRT.

2.1 Operation Preparation

a. Fully open the drain valve on the HP main steam pipe, forcibly close the exhaust non-return flap of HP casing and confirm that each extraction non-return flap of HP casing is closed;

b. Fully open the drain valve in front of the exhaust non-return flap of HP casing;

c. Fully open the drain valve of HP inner casing;

d. Fully open the ventilator valve (VV valve).


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2.2 Warming up Operation

Gradually open the RFV to let the warming steam flow into the HP casing. Part of steam enters into the drainage system through each drain hole. Another part of steam leaks into the IP casing through the gland seal between the HP and IP casings. Then it is discharged into the steam condenser through the connecting pipe and LP

casing. Maintain the pressure in the casing within 0.4～0.5MPa by adjusting the RFV and drain valve.

During the warming up period, the operator shall not let the temperature rising rate exceed 50℃ /h. The temperature difference and expansion difference of each cylinder wall shall be maintained within the permissible range (by adjusting the RFV and drain valve of each section in the HP casing).

When the metal temperature of upper half inner wall at the control stage of HP inner casing reaches 150℃ over, the throttle valve in front of the RFV opens 10%. Refer to Fig.7-1-1 for the warming up maintaining time.

2.3 Finishing Warming up Operation

a. When warming up is finished, the RFV shall be closed (RFV);

b. Fully close all the drain valves of HP casing;

3 Pre-warming of HP Control valve

When the inner or outer wall temperature of HP main steam control valve is lower than 150℃ , during the pre-warming of HP casing, the HP main steam control valve casing shall be pre-warmed. During the pre-warming of HP main steam control valve casing, the HP main stop valve is at the closed state. The main steam for pre-warming enters into the control valve casing through No.2 Main Steam Valve. The pre-warming operational method is as follows:


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a. Confirm that the HP main stop valve and control valve are fully closed;

b. Open the drain valve on the HP main stop valve casing;

c. Open the electric main steam valve, turn No.2 Main Steam Valve of HP casing to the pre-warming position. At this time, actions shall be taken to prevent the rotor from turbine rolling and turning gear from being released due to the untightness of governing port.

d. Monitor the temperature difference between the inner and outer walls of control valve, when it exceeds 80℃ , close No.2 HP Main Stop Valve when it is less than 70℃ , return No.2 HP Main Stop Valve to the pre-warming position. Repeat the process until the metal temperatures of inner and outer walls of valve casing rise to

150℃ over and reach the requirement of valve pre-warming.

e. When the pre-warming is finished, close the HP main stop valve;

f. Close the drain valve of HP main stop valve casing.


7-1-4

Hea

t Con

serv

atio

n Ti

me

Metal Temperature of Upper Half of Inner Wall at Control Stage of HP Inner Casing before Pre-warming

Fig.7-1-1 Curve of Heat Conservation Time



7-2 Heating System of HP Casing Interlayer

1 System Composition and Function

The system composition is shown in Fig.7-2-1. The function is to introduce the main steam into the interlayer between the HP inner and outer casings to heat them so as to reduce the positive expansion difference of HIP casing and the temperature difference of inner and outer walls of HP inner casing as well as make the temperature of HP outer casing even along the axial direction. The control means is to change the flow to control the heating speed by adjusting the interlayer steam admission pressure. The steam admission box pressure of cylinder interlayer:

Normal Value: 0.98--4.9Mpa

Maximum Value: 6.5Mpa

2 Test Before System Engaged

a. The safety valve is reset according to 6.5MPa;

b. The electric valve and manual valve are agile;

c. The thermocouple and pressure gauge are installed and work properly.

3 Preparation before System Engaged

a. Confirm the drain valve of heating steam admission box of cylinder interlayer is opened;

b. Confirm the metal temperature of upper half inner wall of HP outer casing is less than 300℃ ;


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c. The operator manually opens the manual stop valve in the back of heating steam admission box of cylinder interlayer (the manual stop valve in front of the steam admission box is closed).

4 System Operation

a. Open the electric stop valve in front of heating steam admission of cylinder interlayer;

b. Before the new machine is put into operation, the operator manually adjusts the manual stop valve in front of the heating steam admission box of cylinder interlayer to let its pressure lower than that of main steam when engaging the system so as to reach the normal working pressure;

c. During the process of acceleration or picking up the load, the operator adjusts the manual stop valve in the back of heating steam admission box of cylinder interlayer to control the interlayer steam volume according to the HIP expansion difference, upper and lower temperature difference of outer walls of HP inner casing as well as the upper and lower temperature difference of inner walls of HP outer casing;

d. Closely monitor the temperature rising rate of cylinder not to exceed 50℃ /h, the upper and lower temperature difference of outer walls of HP inner casing and the upper and lower temperature difference of inner walls of HP outer casing not exceed

50℃ .

e. When the outer wall metal temperature of HP outer casing lower half at the steam inlet exceeds 350℃ and the HIP expansion difference is within the permissible range, the heating system of cylinder interlayer can be stopped.


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5 Finishing Operation

Close the electric stop valve in front of the steam admission box;

Close the manual stop valve in front of the steam admission box;

Close the electric stop valve in the back of the steam admission box;

Close the drain valve.

Thermocouple

Pressure Gauge Relief Valve

Electric Valve Manual Valve

New Steam

Steam Admission Box of Cylinder Interlayer

Connect to left half of interlayer chamber

Connect to right half of interlayer chamber

Interlayer Chamber of HP Inner and Outer Casings

Drainage to Steam Condenser

To HP Exhaust

Fig.7-2-1 Diagram of Heating Interlayer System of HP Casing



7-3 Water Spray of LP Casing of Steam Turbine

1 Composition, Function and Control

The spray system consists of atomization sprayer, electric valve, manual throttle valve, manual stop valve, sieve, pressure gauge and steel tube. Refer to “ Spray Device System Diagram” for the detailed composition.

During the initial start-up, in order to prevent the steam condenser system from not timely taking the exhaust steam of LP casing and heat of LP by-pass steam, which causes the temperature rise of exhaust temperature of LP casing, as well as the exhaust temperature rise of LP casing due to the blast of LP stage when the set has low load and high back pressure, which impacts the movable blades of last several stages of LP casing and LP through flow, the water spray system of LP casing is built. The control can be manual and auto:

1.1 Auto Control:

When the exhaust temperature at any point before or after the LP casing equals or is more than 80℃ , the water spray is engaged. When the temperature of each point before or after equals or is less than 65℃ , stop the water spray.

1.2 Manual Control

When the spray control is under the manual control state, the temperature does not control the spray. The operator can start or stop the spray system based on the concrete situation.

Note: For the auto or manual control, the start or stop of water spray shall be done at the front and rear sides at the same time.


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2 Test before Spray System Engaged

a） In the system , all the electric and manual valves shall be agile;

b） before connecting to water (water source is the condensed water from the desalting device), fully open the electric and manual valves, remove the sprayer, and then connect to water to rinse the system until there is no impurity left on the sieve. Install the sprayer and firmly fix it by spot welding;

c）Start the electric valve after the manual throttle valve and adjust its opening so as to control the spray pressure after the throttle valve within 0.49～0.784MPa;

d）Check the atomization of sprayer and spraying angle. They are adjustable through changing the spraying pressure. After the adjustment is done, record the opening of throttle valve and spraying pressure.

Note:

a） The electric valve on the spray pipe shall be opened before start-up and closed after shutdown.

b）The normal engagement and shutdown are controlled by the electric valve after the throttle valve. When it fails to act, the manual by-pass valve can be used for that purpose.



7-4 Emergency Discharge System

1 Composition, Function and Control

The system consists of emergency blowdown valve, electromagnetic control ventilator valve and steel tube. Refer to “Diagram of Auxiliary System of Steam Turbine Proper” for details. When the set rejects the load, in order to prevent the residual steam in the HP casing and HP steam guiding pipe from fleeing into the IP and LP casings from the HIP gland seal gap and impacts the set, the BDV is installed. When the gland seal teeth wear and the gap becomes bigger, the overspeed possibility will increase. When the set trips, the BDV opens rapidly and directly guide the residual steam at the HIP gland seal to the steam condenser to prevent the overspeed of set.

The BDV open and close are controlled by the oil servo motor stroke of IP control valve:

When the oil servo motor stroke of IP control valve is ≥30mm, the BDV is closed.

When the oil servo motor stroke of IP control valve is <30mm, the BDV is opened.

2 Test Before Start-up

a）Check and confirm that the compressed air enters into the upper part of piston of BDV when the electromagnetic control ventilator valve excitates. The piston overcomes the downward shift of spring force to close the valve. When the electromagnetic control ventilator valve dis-excitates, the upper part of piston of BDV connects with the exhausted air to release the air pressure. Under the action of spring force, the piston moves upward to open the valve.

b） The controlling compressed air pressure shall be within 0.4～0.7MPa to ensure the close of BDV.


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Note: it is better to take the higer value of compressed air.

c） Check and confirm the correctness of electric control interlock.


1

Revision Record

Symbol Places File No.

Signature Date Symbol Places File No.

Signature Date

_we_d300n-000106asm(turbine start-up and operation manual)

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