Short Notes on Steam Turbine

(Type: DKYZZ3-2N41C)

Prepared by:Eng. Osama Mohamed Aggag

Eng. Ahmed Zaki Fayed

&
&

Eng. Abd El-Hamid Mohamed

Eng. Anwar Attia Anwar
August 2014




{

}

, .
,
(.)Manuals

.

(.)set point
( )Logic
.
"
"

.

/
/
/
/

Index

A)

Introduction ...................................................................................................

B)

Skids .................................................................................................................
1-

Lube oil system.

2-

Turning gear system.

3-

Jacking oil pump.

4-

Hydraulic system.

5-

Gland steam system.

6-

Vacuum condenser system.

7-

Vacuum breaking system.

8-

Water box Evacuation system.

9-

HP bypass.

10- IP bypass.
11- LP Hood water injection.
12- Turbines drain system.
13- Tube cleaning system.
14- Debris filter.
15- Generator.
16- Turbine Instrument.
17- Condenser.
18- Tests

C)

STG Settings ..................................................................................................

D)

STG Protections ............................................................................................

E)

Startup .............................................................................................................

F)

Shutdown ........................................................................................................

A) Introduction

A) Introduction
:
HP (high pressure) MAA -1

IP (intermediate pressure) MAB -2

LP (low pressure) MAC -3
combined 2 journal bearing -4
)journal +thrust( bearing
Technical data ( electrical generator)

 .
.steam turbine protection system
(turbine instruments) :
Turbine speed
Vibration
Shaft eccentricity
Thrust bearing position
Expansion measurement

):(steam process
: HP HP

:
( P=70 bar )t=558Co ) HP (MAA10
) P= 13.79 bar )t=384 Co

: IP HP
(IP super heater )
hot reheat super heaters
) IP (MAB 10 10
556 Co
: LP IP LP live
steam IP cross over tube
LP turbine double acting
: LP hot
well .condensate pump
HP & IP
Thurst bearing Axial Force
HP & IP .Steam Flow

 HP & IP :
-1 Force balance .
-2 .
-3 .Rotational Torque
)Double Acting( LP LP
( )m. Total . HP & IP
T= F * R.
F , ( R ) , R
.LP
Double acting Axial .LP

) (Rated voltage = 19 KV
19 KV 500 KV Losses
,
.

B) Skids

B) Skids
Lube oil system.

1-

:
-1 ( .)
-2 .
-3 purifier .
-4 .)Jacking(
There are four types of pumps in the lube oil circuit:
Drive
Turbine Shaft
AC Motor
DC Motor
AC Motor

Type
Gear
Centrifugal
Centrifugal
Axial Piston

Pump
Main Pump.
Auxiliary Pump.
Emergency Pump.
Jacking Pump.

1234-

Main Pump
Auxiliary Pump .
Emergency Pump AC Auxiliary
.
Jacking pump Main /or Aux
.300 bar
: %90 ( ,)2700 rpm
< 2700 rpm self-lifting bearing
.
: Jacking Pump %90 (.)2700 rpm
). (Range: 1.5 1.85 bar

( )Two pressure transmitters :
)0.9 bar( %06 -1 -:
) .STG Trip
) .Auxiliary Pump
) Emergency )Time delay (10 sec
)0.6 bar( %46 -2 ( -: )FG >> OFF
) .STG Trip
) .Auxiliary Pump
) Emergency .Immediately

Auxiliary Pump %90 .Emergency

) (2 oil vapor extractor
)0.98 bar(
Switch off 40%
off .20 sec
DC Turning gear
DC Pump . .
over current Emergency
.
cooler
( )43 C .)40-45 C(
70 C
.
2 Diff Pressure Switch
.
( )Spring loaded check valve bypass
.
Constant Pressure valve .
Check Valve Auxiliary Pump Main Pump
Auxiliary Pump Start Up Turning
.Gear
Orifice Check Valve
Main Pump .
6 Heaters Start Up Permissive
30 C .40 C
Lube Oil Purifier .Local

 Lube Oil Logic:

Lube Oil Function Group (FG):
1- FG Permissive (Auto On).
It must be level and temp of tank are OK.
Level 300 mm.
Temp 15 C.
Emergency lube oil pump OK.
2- FG Permissive (Auto Off).
Release to off in the following.
Fire protection.
Or, Steam Turbine Speed Stand Still & HP&IP Average rotor temp < 150C.
Hydraulic FG Permissive lube oil Fire :
.Fire off
Trip: - Steam Turbine Trip if:
- P 0.9 bar.
- Level 200 mm.
Auxiliary lube oil pump logic:
Logic:
1- Auto on:
P 0.9 bar (60%).
Or, Steam Turbine Speed < (2700 rpm) 90%.
2- Auto off:
Steam Turbine Speed > (2700 rpm) 90%.
3- Manual on:
FG Block.
4- Manual off:
FG Block.
Aux Pump Safe Acknowledge.
Steam Turbine Speed > (2700 rpm) 90%.

 Emergency Pump Logic:

Logic:
1- Auto on:
P 0.9 bar (60 %), after 10 sec.
Or, P 0.6 bar (40 %), after 0 sec.
OR, Auxiliary lube oil pump FB (OFF) & Steam Turbine Speed < 2700 rpm after
5 sec.
2- Auto off:
Steam Turbine Speed > 2700 rpm.
P 0.9 bar (60 %).

2-

Turning gear system.

Turning Gear:

) Casing ( Deformation
HP 0=
. twisting tourqe
.Frequency Converter ) MAK80AE001( AC Motor TG
Solenoid TG 4 rpm TG
.16 rpm )MAK80AE015(
TG Jacking Jacking
.
Operation of TG: is interlocked by the operation of the auxiliary lube oil pump.
. off Jacking TG Lube oil
. 0 TG
If hot turbine cant be turned due to AC supply failure or failure of jacking oil pump. The
turbine may be bending due to temp differences.
After (2 to 3) days of cooling down; turbine should be operated on TG for about (4 to 6)
hours prior to restarting.
) 4 to 6( TG
.
a) Case of shutdown of turbine:
1- Must:
- Lube oil (Auxiliary) pump in service.
- Jacking pump in service.
2- At speed 4 rpm solenoid is engaged and frequency converter raise speed to 16 rpm.
3- In case of failure for any reason, hand lever is used to turn shaft by (180 ) as
following:
- Every 5 minutes during the first 2 hours.
- Every 10 minutes during the next 10 hours.
- Every 30 minutes until the metal temperatures of the HP and IP turbines are below
150 C.
()
.

- Manual operation with hand lever:

. TG off Maintenance Switch
. ) Cap(
solenoid led Push Button
.emergency manual override
.led pinion
.
.on maintenance switch

-1
-2
-3
-4
-5
-0

b) Case of startup of turbine:

- In case of start up after trip therefore time of operation to shaft must be as following:-: TG
.20 min ) 500-600(
a- Less than 1 day, 2 hours.
b- Less than 7 days, 6 hours.
c- Less than 30 days, 12 hours.
d- More than 30 days, 24 hours.
For operation , must (permissive):
1- Voltage supply from (C03/cell 2/Q37), frequency converter TG.
2- Motor cover is closed.
3- Lube oil Jacking pump is ON.
4- Maintenance Switch is ON.
5- Pressure in header of lube oil P 40%.
Automatic operation as following:
- Start function group of TG or by sequencer if auto.
Pinion solenoid
.
. 16 rpm
.
25 rpm WDE (Wheel Driving End)
. TG

Logic:
1- Auto off (FG):
a- Fire protection Steam turbine.
b- FG turning gear (Sequencer).
c- HP, IP average rotor temp < min2 (150 C).
2- Auto on (FG):
a- FG Command on + TG safety + speed < 25 rpm.
b- FG turning gear (Sequencer).

Jacking oil pump.

Jacking Oil Pump:
It gives high pressurized oil during start up and shutdown and prevents metal to metal
contact between shaft and bearing during turning gear operation.
It is axial piston pump (AC Motor) is arranged on lube oil Tank.
Flow control valve is adjusted to give accurate guaranty of oil.
It gives approximate 300 bar.
It takes oil from filtered lube oil after cooler and filter.
No Jacking oil pressure for first bearing (NO 1).
If DC pump runs, jacking pump and turning gear are off.

Logic:
1- Auto on:
Steam Turbine Speed < 2700 rpm.
Release on:
Lube oil pressure > 20% (min 4).
2- Auto off:
Steam Turbine Speed > 2700 rpm.
Release off:
Steam Turbine Speed Stand still.
Or, Steam Turbine Speed > 2700 rpm.

4-

Hydraulic system.

Purpose
Each Steam Turbine Generator must be protected by a quick interruption of the steam
flow. The Stop Valves serve this task.
Also, the Steam Turbine Generator must be controlled, both its speed and, if the
generator is connected to the grid, the power output. Speed and power output are regulated
by the steam flow through the turbine, which is controlled by the Control Valves.
The stop valves and the control valves are actuated by hydraulically driven servomotors
(actuators). The task of the Hydraulic Control System (MAX) is to supply these actuators
with pressurized hydraulic fluid, or in case of emergency, to interrupt the supply.
The pressure of the hydraulic control fluid circuit directly acts on the stop valve actuators,
while the control valves are actuated via Electro Hydraulic Converters (EHC).
Main Components
The Main Components of the MAX-System are (in sequence of flow direction):
Control Fluid Tank
Two Control Fluid Pumps (one in operation, one in reserve) with
Suction Strainers
Accumulator
Pressure Regulation Valve
Two Filters (one in operation, one in reserve)
Safety Valve
Trip Unit S90
The consumers of the MAX-System are the actuators of the steam control valves and
the steam stop valves.
Function of the Hydraulic Control System
An overview of the MAX-system is shown in the figure.
The hydraulic fluid is stored in the Control Fluid Tank, which serves as a reservoir.
Inside of the tank are two Control Fluid Pumps (MAX-Pumps) with their Suction Strainers.
One of these pumps is in operation; the other is in automatic reserve. The suction strainers
protect the MAX-pumps against damages or abrasion by fluid dirtiness.
The manually adjusted Pressure Regulation Valve controls the pressure after the MAX-pump.
If for any reason the active MAX-pump trips, the reserve MAX-pump requires a short time for
start up, during which there would be an uncontrolled pressure drop in the MAX-system. A
pressure drop below an admissible value would cause the steam stop valves to close, therefore,
tripping the steam turbine generator! To prevent this from happening, an Accumulator with an
internal gas bubble is used to uphold the system pressure during MAX-pump switchover.
The control fluid then passes through a mechanical Filter. There are two filters, one is in
operation, and the other is in reserve. These filters ensure the cleanness of the hydraulic fluid to
protect the consumers. A Safety Valve located behind the filter acts as a pressure relief valve
and prevents damages to the consumers in case of too high pressure in the system.
The Trip Unit S90 works like a three-way-valve. One flow direction feeds the consumers.
This is the normal fluid flow during operation. The other line feeds back into the control

fluid tank. If this line to the control fluid tank opens the pressure in the whole MAXsystem breaks down, and the steam turbine trips.
This line to the tank will open only in case of emergency (trip). The trip unit
S90 works like a hydraulic 2 out of 3 relay, connected with the three safety channels.
After the trip unit S90 the hydraulic control fluid is fed to the consumers (valve actuators).

Hydraulic
MCC Axial Piston pump (AC)
.Stand By
. 36 bar 90% Main header
. Pressure relief valve 40 bar
. 2
. Trip Trip Unit
.Trip Unit , fluctuation accumulator

Logic:
. FG Hydraulic ON Pump selection :
Function Group permissive:
1- Lube oil temp > 15 C.
2- Lube oil level > 300 mm.
Trip:
- Pressure of header 27 bar.
Auto off:
- Fire protection.
There is a testing valve for manual test for standby pump start up.
If P < 36 bar
Stand by pump is operated after delay 8 second (MAX 11 AA 501).
In case of an electrical failure of operated pump, the stand by pump will be switched on
without time delay.
The pumps stop if FG is switched off or the fire protection is activated.

Gland steam system.

5-

The main tasks of gland steam system as following :- Prevent air from interring to condenser.
.
- Prevent steam from blowing into enclosure.
.
- Prevent gland steam temperature from exceeding the limits.
.

3 / Chambers/ Casing
( Casing ) -:
Optimization Orifice
IP exhaust . LP
Inlet gland steam .
Outlet gland steam .
2 Chambers / (
casing ) -:
Inlet gland steam .
Outlet gland steam .

-:
: HP & IP < 200 MW % 80
: Cold Reheat / HP Exhaust Check Valve
HP Bypass > . %80

 :
Drain valve Normally Open + Motorized
Shutoff valve ( 15 Co < t + ,
)

Motorized Shutoff Valve 5 +

(( 230 Co > t + ) 250 Co, 9 bad HP
& Average rotor temperature )

Admission Control Valve +

.30 mbar

Water Injection Stop Valve

( ) Condensate .

 Water Injection Control Valve ,

.180 Co

Excess gland steam Valve Normally Open +

< + 30 mbar Admission . < % 80
( . ) Self-Sealing
: Excess + Admission +
Auto .
Gland Exhaust Fan , 0.5 .
:
.

:
. ) 250
-1 , HP Bypass (9 bar
-2 FG ON Admission
.
-3 . Shut off
&Co

Logic:
1- Release on FG: Condensate pump feedback (ON)
2- Shut off valve (MAW 10 AA01):
Open.
Permissive in the opening is 2 min delay and as following conditions:
P 9 bar.
T 250 C.
Cold reheat steam is superheated by (T=20 C).
T between (HP rotor temp CRH steam) < 230 K.
Close.
FG of gland steam command off.
Or, temp of CRH steam < 250 C.
3- Gland steam drain (LBC 90,AA765):
Auto on.
Gland steam FG (ON) & Shut off valve (Closed).
Or, Gland steam FG (ON) & T CRH steam superheating < 15 C.
Or, Gland steam FG (OFF).
Auto off (delay 2 min).
Shut off valve closed.
& T steam superheating > 15 C.
& Gland steam FG (ON).

Vacuum condenser system.

6-

:
( )LRVP: Liquid Ring Vacuum Pump
,
.normal operation
:
Main Liquid Ring pump ,
) (Condensate .
Seal Water pump Separator
.
Separator .
Air Suction Valve , Inlet Pressure
switch 0.1 bar .

:
Service pump ON + Condensate Pump ON + Vacuum : -1
breaker Closed .
ON -2
. 0.1 bar
0.2 bar , -3
. )selected (
timer ) 20 day:20 hour( 500 H -4
timer ,automatic
.Trip separator auto
, ) LP ( :
.
Notes:1- Make up water from condensate water.
2- Cooling water from service water, the purpose of the cooler is to decrease
temperature of the seal pump.
3- There is line between separator and vacuum pump for protection from
cavitation when supply valve sudden close.
4- The system tripped if level separator is decreased under certain limit switch.
5- The vacuum pump (LRVP) is supporting and help condenser and should be
understand that condenser itself makes vacuum and pump support it. This
maximizes the condenser capability.
6- The impeller is eccentric.
Impeller .) outlet port( Liquid Ring
.single stage 7- Cavitation:
. Inlet pressure Liquid Ring Cavitation
Cavitation occurs when vapor bubbles collapse.
Cavitation causes damage to the impeller and makes holes.
8- The main purpose of vacuum system is to increase LP turbine power.
MW
.(T-S) diagram
.
Power = m st *(h1-h2).

Logic:
Condenser vacuum FG:
. FG (ON)
Permissive:1- Vacuum breaker closed.
2- Condensate supply (on).
3- Service water pump feedback (on).
If operated pump takes off, the other takes auto (on) direct.

Air suction valve:- Auto on:

If FG takes on, the following permissive must be for selected pump:
1- Inlet vacuum pressure switch closed (100 m bar).
2- Seal pump, feedback on, (flow meter reads a value).
3- Vacuum pump, feedback on, separator level ok (level > 16.5 cm) delay with
5 seconds.
- Auto off:
Selected vacuum pump unit auto off.

Vacuum breaking system.

7-

Description:
Trip Circuit breaker

.
Vacuum breaker Vacuum
.
Two different methods for breaking are used:1- Partial vacuum breaking.
2- Full vacuum breaking.
1- Partial vacuum breaking.
This happens when: (At speed > 50 %) & (Vibration > maximum).

) (ST Trip or Normal shutdown :
Vacuum , LP Overheating
.
back pressure LP .
2- Full vacuum breaking.
This happens when: (At speed < 50 %) & (Vibration > maximum).

) (ST Trip or Normal shutdown:
command 10 % . LP .
.Loss of lube oil : - .

8-

Water box Evacuation system.

:
. filling
water box
.
:
1234-

Vacuum pump.
Separator.
Cooler.
Vacuum control tank.

:
. seal pump -1
filling service Make up -2
.)float(
: terminal box -3
a- Pressure switch P < 100 mbar.
b- Separator level OK.
c- Flow water of sealing.
: vacuum control tank -4
.vacuum pump -a
water box 3 pressure switches -b
. 350 mbar level tank
level switch -c
.FG (ON)
Logic:
Function group:
- Auto on (SQ).
- Permissive:
1- Service water pump FB (ON).
2- Condenser Water box outlet isolation FB (ON).
3- Vacuum control tank level < Max (50 mm).
- Auto off (SQ).

Air suction valve A:

- Release:Water box Ext pump A FB (ON) with delay (10 sec).
- Auto on: Water box Ext inlet pressure switch < min (340 mbar).
& Select water box unit A (Auto on).

- Auto off: Select water box unit A (auto off).

OR, Vacuum control tank pressure switch < min (310 mbar).

Water Extraction pump:

- Auto on: Select water box unit A Auto on (delay 30 sec).
& Vacuum control tank pressure switch > min (350 mbar).
- Release on: Water box evacuation FG Release ready.
& level of separator water box > min.
& water box Ext A FB (OFF) for 3 min.
- Auto off: Select water box unit A Auto off.
& Air suction valve water box Ext FB close.
- Release off: air suction valve water box Ext FB closed.

9- HP bypass.
:bypass
-1
() pitting saturation .
-2 .PH
-3 bypass
.
bypass
.IP & HP bypass
HP bypass HRSG pipe
rack 452 Cold reheat HP
( )014&015 .
HP bypass IP feed water pump
HP bypass , t= 300 Co
).(t = 380 Co Alarm & t= 385 Co Trip
HP bypass skid:
1- Steam line >>>> - Stop valve (Manual).
- Control valve (Hydraulic).
2- Water Injection >>>>> - Stop valve (Hydraulic).
- Control valve (Hydraulic).
Hydraulic .HP bypass

HP by pass HP by pass
hummer .
HP bypass Protection:
HP/IP feed water Header pressure.
P/T HP steam > min.
HP bypass HSU.
HP bypass PCV smart track.
HP bypass Water injection smart track.
All bypass Trip Impulse (Sequencer).
Control OK Impulse.
T HP steam after bypass < max (385 Co).

 HP bypass bypass
.Diverter

Boiler
In Operation

HP bypass .)P= 5 bar & T superheat = 10 Co(

mode HP bypass:
Startup Mode
startup mode bypass .
Backup Mode
HP bypass Backup mode HP bypass .
-:

.HP steam after bypass
-:
set point .Manual
Temperature Set point

Pressure Set point

300.00

120.00
bar

300.00

120.00
LA

LA

Co

10- IP bypass.

1-

016 Hot reheat IP bypass

.
: : IP bypass
Steam line >>>> - Stop valve (Manual).
- Control valve (Hydraulic).

2-

Water Injection >>>>> - Stop valve (Motorized).

- Control valve (Hydraulic).

. IP bypass ) 5 (
. IP bypass
. Curtain spray IP bypass
: IP bypass

1- P LPT Exhaust 2o3 (P=0.5 bar).

2- P Cond sys WINJ (Alarm = 8 bar & Trip = 7.5 bar).
3- T IP/LP bypass in Condenser (Alarm = 90 Co& Trip = 110 Co).
4- Water INJ CV Dist.
5- Cont OK Impulsion.
6- Byp Trip P.B. CNTRL 2o3.
7- All cooling water pump.
8- Byp position CONTROLLER dist.
9- IP/LP Byp HSU Alarm.
10- All BypTrip.

-:
Trip Circulate Trip
IP Bypass IP Bypass
. LP back pressure IP Bypass

11- LP Hood water injection.

During low load and no load operation, the turbine blades generate windage energy which
may cause temperature increase in the blades.
To prevent overheating due to ventilation at low load operation of the LP turbine, water is
injected to exhaust of LP turbine, (Temperature ventilation of LP turbine).
LP
.windage energy LP
LP -1
.
. Hood water injection -2
. Pneumatic Hood water injection -3
LP Hood spray LP ventilation Trip -4
.Trip

Logic:
1- Auto on: at
ST speed > 50 % & (Turbine load < 10% or Temperature ventilation of LP
turbine > 180 Co).
2- Auto off: at
ST speed < 50 % OR (Turbine load >10% & Temperature ventilation of LP turbine
< 180 Co).

12- Turbines drain system.

The main tasks:
Removal of Condensate to protect turbine from water hammer in the piping.
Warming up of pipes.
Maintain constant temperatures in order to prevent condensation in the components
during operation and thermal stresses during start up.
.
Classification:
1-

External drain.

-: 2- Internal drain.

1- External drain.
It is the Drainage of piping system.

High energy vent stack )Pipe rack(
. Cold reheat ) 054 & 062 & 055(
2- Internal drain.
. .
. vacuum Flash box
.)Startup drain & Continuous drain(
1Startup drain >>>>>> as in turbine casing.
2Continuous drain >>>>>>> as in gland steam system.
Logic:
FG:
Auto on (SQ).
Auto off (SQ), but have release turbine power < 15 %.
:
solenoid solenoid pneumatic
.

 HP turbine drain:
1- Drain valve downstream MSV (MAL40AA711).
2- Drain valve HP turbine casing (MAL10AA711).
:Solenoid
- Auto on >>>>>>> FG turbine drains (Command on).
and turbine power < 15 %.
- Auto off >>>>>>>> FG turbine drain (Command off).
or turbine power > 15 %.
HP turbine exhaust drain: (LBC10AA781).
- Auto on >>>>>>> FG (CMD ON).
and turbine power < 15 %.
and Drain HP Exhaust Drip LVL (LBC10CL281)
< High with delay time 10 sec.
and Drain HP Exhaust Drip LVL (LBC10CL381)
< High with delay time 25 sec.

- Auto off >>>>>>> FG (CMD ON).

or turbine power < 15 %.
or Drain HP Exhaust Drip LVL (LBC10CL281)
< High with delay time 10 sec.
or Drain HP Exhaust Drip LVL (LBC10CL381)
< High with delay time 25 sec.
IP turbine Casing drains and downstream ISV:
(MAL20AA711) & (MAL20AA721) & (MAL50AA731)
- Auto on: FG (CMD ON) and power < 15 %.
- Auto off: FG (CMD OFF) and power > 15 %.
LP line drain:
(MAL70AA711) & (MAL70AA721)
- Auto on: FG (CMD ON) and power < 15 % & valves open.
- Auto off: FG (CMD OFF) and power > 15 % & valves closed.

13- Tube cleaning system.

Objective:
:
Calcium.
Sodium.
Silica Deposit.
Sediments.
Advantages::

Increase in the heat transfer rate.

Optimum turbine back pressure.
Avoid corrosion in tubes.
Reduction of chemical costs for water treatment.
Reduction in fuel costs.

Consists of:Circulating pump.

Ball vessel.
Cleaning balls.
Ball separator.
V-piece.
Ball sorter.
Ball valve.
Differential pressure transmitter.

Permissive:Circulate water pump >>>>>> ON.

Operation: P , 24 8
.operation Back wash 30 min 30 mbar
.Ball recirculating pump
Bypass Ball collection vessel
.5 min
.water cycle Water box

 Ball Recirculate
P > 30 8 Open
. 8 mbar
-:
. Bypass vessel
3 way valve :Sorting
sorter pump discharge Bypass
sorting Ball collection vessel
, Ball vessel ,
. bad ball vessel
:
- Discharge counter.
- Good ball counter.
- Bad ball counter.
.30 min
. 80 %

Operation logic:
1- Auto start
Inlet open & bypass open & ball sorter valve close & vent
on & pump on
Water timing running 5 min
drain off
Outlet open & vent close & bypass close
system cycle on.
2- Auto stop
outlet close & inlet open & bypass open & vent close & pump
running.
ball collection running for 30 min in ball vessel
pump off &
inlet & bypass off
drain open for 3 min
bypass open & sorter
valve open
ball feed to the ball sorter for 1 min
drain open for 3
min & bypass close
gear motor start
ball counter start
no signal from ball counter for bad or good ball for 5 min
gear
motor stop.

 30 sec strainer P
Back wash strainer strainer ball collection
P > 30 mbar P check strainer 30 min
P 30 min back wash
.
5 min fast collection P> 50 mbar P
.failure P 30 min back wash
Water timer: 5 min, at start.

Bypass open & inlet open & vent open & outlet close & sorter valve close & pump
running.
Ball collection: 30 min, at stop.
: sorter ball vessel
Inlet valve open & outlet valve close & bypass valve open & sorter valve close &
pump running.
Water drain timer: 3 min, at stop.
: ball vessel ball vessel
Inlet valve close & bypass close & pump off & outlet valve close & drain on & sorter
valve close.
ball sorter ball vessel
.ball vessel
Ball feed time: 1 min.
. ball sorter ball vessel
Inlet valve close & outlet valve close & pump stop & bypass open & sorter valve open.
sorter bypass
bypass
ball sorter ball sorter ball vessel
. drain
ball sorter gear motor bypass
, helical
bad ball
. ball vessel (good ball)

14- Debris filter.

: Debris Filter Inlet Water box
.
Debris Filter-:
Motor and gearbox Rotation.
Strainer (Screen basket).
Debris Extraction.
Valve for extracted water.
P Measurements.
Control Panel.
-: Debris Filter
Control Panel Manual.Auto Auto P P = 100 mbar P Timer
4.
, Flushing arm Gearbox . Flushing arm .Strainer
- .Circulate

123456-

15- Generator.
Air cooled generator and Excitation system P32OV2:
Components:
1- Stator winding.
2- Terminals.
3- Bus ducts.
4- Grid voltage.
5- Field current to rotor via slip rings.
Technical data:
Type: 50WX23Z-109
50:
WX: .
23: Rotor diameter code.
Z:
109: core length code.

Rated apparent power: 324 MVA.

Rated terminal voltage: 5 %, 19,000 V.
Rated frequency: 2 %, 50 HZ.
Rated power factor: 0.85.
Cooling air inlet temp: 34 Co.
Air overpressure: 0.2 bar.
n=60*f/p.
Control of MW by steam valves.
Control of MVAR by Voltage.
= 99%.

Main components of generator:

1- Generator housing.
2- Stator.
3- Rotor.
4- Generator cooling system.
5- Slip ring unit.
6- Bearing.
7- Filter.
8- Sound absorption.

. axial fan ) Rotor + Stator(

.Closed Cooling Stator + Rotor
ALARM
TRIP
o
Cooling air temp
53 C
63 Co
Warm air temp
88 Co
98 Co
Stator wind temp
118 Co
128 Co
.disturbance alarm fails
. Start up Leakage detector (MKA 13CL031/032)
L1 : Leak gen cooler temp > high.
L2 : Leak gen cooler temp > high.
Top air fan:
- Speed: (0 to 4600 rpm) using frequency converter.
- Permissive:
1- Frequency converter (Ready).
2- F.G. top air fan (Command on).
- Auto on: Slot temp T9= 103 Co.
- Auto off:
1234-

Slot temp T9= 93 Co

Dist of: Frequency converter or Tslot generator.
FG Command off.
Top air fan Emergency stop.

- The fan should reach pressure to 1.2 bar.

- The fan speed depends on measured pressure.
Leakage air filter has a silencer too.
Brush gear cooling air filter.
Alarm brushes brushes
. P
Carbon brushes:
. Excitation DC
Excitation transformer 1730 KVA:
. )19 KV to 690 V( AC

 There are (4) heaters:

. 50% , 50%
.
Capacitive shaft grounding:
RC Capacitive grounding Static Excitation
.Romon Model
Romon: Rotor Condition Monitoring.
.

.Seal Journal Bearing
Generator Protection Trip:
1- Stator Grounding fault (100 %).
2- Voltage rise (over voltage protection).
3- Generator differential protection.
4- Stator ground fault (80 %).
5- Over Excitation.
6- Under frequency protection.
7- Rotor ground fault protection.
8- Impedance protection (long time).
9- Impedance protection (short time).
10Reverse power protection T2.
11Reverse power protection T1.
12Under excitation protection (Static).
13Under excitation protection (Dynamic).
14Unbalance protection.
15Generator protection.
AVR:
Synchronous generators require fast response excitation system to:
1- Voltage of generator constant.
2- Give stable reactive power.
3- To give need of reactive power.

 There are two types of excitation systems:

1- Indirect brushless excitation (Not our type).
2- Direct or shunt supplied static excitation.
.Thyristor Converter
The component of AVR is:
1- Thyristor.
2- Regulation & pulse electronics.
3- Field suppression.
4- Converter (or excitation) transformer.
Thyristor
.DC AC
Field flashing:
MCC 4
Excitation 8 4
.field breaker converter
AVR:
1- Control in voltage output.
2- Supply DC voltage to generators rotor.
Difference between Automatic controller & base controller:
1- Base controller.
It is designed for manual operation.
base controller set point
. valve position and speed control
2- Automatic controller.
. Base control
There are two types of synchronous generator:
1- Salient pole:
rotor
.Hydraulic station
2- Non-Salient pole:
cylindrical Rotor
.

16- Turbine Instrument.

Turbine supervising instrumentation (TSI) includes those measurements which monitor
the speed, relative shaft vibrations, axial shaft position and expansion of the turbine.
.
1- Speed sensor:
The turbine speed is measured by three eddy current probes MAD 20CS001/2/3
.
. 2 bearing 3 probes
.)60(
.pulse Inductive proximity probe
.60 pulse = 1 rpm
2- Relative shaft vibration:
Is used to detect and monitor changes in the vibration behavior of the turbine
to prevent overloading of bearing and the bending of rotor.
The installation on the bearing within 90o angle between the two probs in (x
& y) direction and every probe has 45 degree angle with the horizontal.
. displacement transducer
.)alarm 180 & trip260( vibration Trip
3- Axial Thrust bearing position:
Bearing number (2) probes (2)
.)MAD 20CY011/012(
.)alarm 0.6 mm & trip 0.8 mm ( :
4- Absolute casing expansion:
Absolute expansions will indicate any impediment to free expansion of the
turbine casings. No alarm or trip values are set.
HP turbine position probe HP
. casing
.)MAA 10CY004( probe
.thrust bearing probe
.)MAA 20CY004( probe
- Note: No alarm or Trip.

5- Differential expansion:
Differential expansion can be explained as the difference in mutual positions of the
rotor and casing during operation, compared to their mutual positions in a cold
condition. The deviation in mutual position between rotor and casing during operation
is caused by the individual thermal expansion rates of the components and a certain
lateral contraction of the turbine rotors.
) HP & IP & LP(
.shaft seals blades
axial shaft casing 2 probe
:
1- HP Turbine alarm: (6.5 & -3 mm).
2- IP Turbine alarm: (6 & -2.8 mm).
3- LP Turbine alarm: (38.4 & -2).
6- Key phasor:
Key phasor measures the angle of the shaft rotation by using groove in the shaft as
zero marking.
.oscillation vibration
7- Bearing temperature:

: Combined bearing (2) Trip
o
Bearings (1 & 3 & 4 & 5) temp = 120 C .
Bearings (2) temp = 125 Co.

Turbine instruments distribution:

17- Condenser.

In general condenser is used to condensate the steam to water.

There are many types of condenser depending on flow direction or fluid used.
In Alstom power station (Nubaria III), the condenser is single pass gross flow.
The operated pressure is P= 0.07 bar.

Function of condenser as following:

1- Condensate steam to force the cycle of the steam power plant.
2- To generate the highest possible vacuum that maximize the enthalpy difference
over the turbine that lead to increase power.
Circulating water from circulate pump is used to cool the steam. This water is passing
through the tube which enter into water box and exit in the outer water box.
The steam out from LP exhaust and Passover tube then it condensate to water in the hot
well.
The condensate pump takes water from hot well to HRSG (3A & 3B).
The condensate water from drain (Internal drain). Is forced to condenser via (flash box).
To increase heat transfer between water and steam smaller diameter tube is used in
condenser (d=20 mm) to increase surface area then increase heat transfer.
The number of condenser tube = 16,200 tubes.
Tube cleaning system is used to decrease fouling then increase the heat transfer.
IP bypass is passing steam at startup and shutdown to condenser. Curtain spray is used to
spray water on the steam to help condenser.
Condenser vacuum pump help condenser to support required vacuum in the condenser
to increase power.
Logic
- STG trip back pressure (Vacuum pressure) > 0.25 bar.
- IP/LP bypass temperature in the condenser give IP/LP bypass trip at T>110 Co.
- Level of hot well < 385 trip of condensate pump.

 Steam Turbine cooling waters

Cooling water
Skid
1- Circulate water.
a) Condenser tubes for condensation.
2- Service water.
a) Condenser vacuum pump cooler.
b) Water box vacuum pump cooler.
c) Water box vacuum pump tank.
3- IP Feed water.
a) HP bypasses spray.
4- Closed cooling.
a) Generator coolers.
b) Lube oil coolers.
5- Condensate.
a) Hood spray.
b) Curtin spray.
c) Flash box.
d) Gland steam.
e) Compensation on condenser vacuum pump separator.

18- Tests
1- Safety device test
: 3
ST protection hardware Over speed P LP over pressure.
,
ch1 ch2 ch3.
trip , 3033
. 3333
2- Lube oil Pumps
Auxiliary Emergency Operation manual 3
. normal operation
.
3- HPT IPT full stroke test
P safety > 36 bar Program device off :
.%03 control stop
Select CV

CV closed

Test of CV pos reached

Select SV

SV closed

Test of CV pos reached

4- HPT IPT partial stroke test

: Program device off P safety > 36 bar
Select CV

CV opened < 50 %

Select SV

SV opened < 60 %

Test of CV pos reached

Test of SV pos reached

5- LP full stroke test

P safety > 36 bar Program device off :
% 00 < control stop

Select CV

CV closed (< 5%)

Select SV

SV closed

Test of CV pos reached

Test of CV pos reached

6- Power assisted check valve

P safety > 36 bar Program device off :
Open solenoid
7- Tightness
P safety > 36 bar Program device off :
FG turning gear On Speed 203 < 25 rp
Tightness FG ON

Speed 203 < 150 rp

Test Ok

C) STG Settings

C) STG Settings
1) HP turbine (MAA)Protection:- 29 Stages

Ventilation (Not in NUBARIA III).

HP exhaust T=425 Co for 5 min & )T=500 Co immediately).
HP exhaust p=28.5 bar.
Power assisted check valve in HP exhaust line to protect turbine from back flow (free
swing type) electro pneumatic via a solenoid valve.
2) LP turbine (MAC) Protection:- 12 Stages

Ventilation (200 Co trip).

(Hood spray) if Speed > 50% & {Twinding = 180 Co OR load < 10 %}
LP exhaust p=0.2 bar (Alarm) & 0.25 bar (Trip), depending on load.
LP main control valve open at:
1- LP superheat steam T=20 Co.
2- IP steam flow 30%.
3- LP steam pressure 2.5 bar.
Vacuum breaker opens at speed < 1500 rpm.
Rupture disk.
3) Gland steam (MAW) :

Shut off valve permissive.

p= 9 bar & T=250 Co.
HP average rotor temperature - (CRH temperature) = 230 K.
T=180 Co & p= 30 m bar.
Self-sealing at load 80 %.

4) HP bypass: Permissive: p= 5 bar & T (T superheat)= 10 Co, where, T=(Tincoming Tsuperheat)

If temperature after HP bypass valve reaches to 300 Co and HP bypass is opening water
injection valve will be open, cooling water from IP feed water pump.
If T Hp steam after bypass = 385 Co HP bypass Trip.

5) IP/LP bypass protection:6)

1- PLPT exhaust 2o3.
If we have a problem in vacuum (0.25 Alarm & 0.35 Trip), depending on load.
IP bypass will be tripped to prevent increasing of the pressure inside condenser to protect
turbine from back pressure flow (Reverse rotation) & .
2- PCONDSYS Winj (No Condensate water P ).
3- T IP/LP bypass in CONDR.
If IP bypass steam T inside condenser reached to 90 Co Alarm, 110 Co Trip.
4- Water INJ CV Dist.
There is a problem in water injection control valve.
5- Control OK Impulsion.
There is a problem in IP bypass software.
6- Byp TRIP P.B Ctrlr 2o3.
IP bypass has been Tripped from push button.
7- All cooling WTRS pump.
There is No circulate pumps running.
8- Byp Pos Cntrlr Dist.
There is a disturbance on IP bypass valve reading value.
9- IP-LP Byp HSU Alarm.
There is an Alarm on hydraulic supply unit of IP bypass:
- Pressure low low.
- Level low low.
- Emergency Stop.
10- All bypass Trip.
6) Generator (MKA):

123

Frequency: 5 % (52.5 Hz or 47.5 Hz).

Voltage: 5 % (19.95 KVor 18.05 KV).
Heating:
If cold air Temp > max 63 Co Trip.
If warm air Temp > max 98 Co Trip.
If slot 1 to 12 Temp > max 128 Co Trip.
If slot (1-12) T=103 Co Generator cooling fan will start up to decrease temperature, and it
shutdown at T=93 Co and will increase the air pressure inside the generator room to
reaches to 1.2 bar.
IF Generator cooling fan bearing Temperature = 100 Co ( fan will take Trip).
Leakage detector, if high level prevents startup of generator.

 coolers well
.S/D
2)

7) Condenser : Vacuum 0.07 bar absolute.

In the operation condition:(Alarm = 0.2 bar & Trip = 0.25 bar).
and at start up:
(Alarm = 0.25 bar & Trip = 0.35 bar), these values are variable.
Hot well level at start up 1500 mm.
Normal 1200 mm & 900 mm Alarm & 385 mm Trip.

3) 8) Important settings:4) :- Shaft vibration

180 m Alarm, 260 m Trip.
At shut down reaches to 360 m.
.Trip 360 m
Axial shaft position
0.6 mm Alarm & 0.8 mm Trip.
Thermal stress:
(HP, IP) turbine +102 % (HP, IP) rotor heating for 5 min, TRIP.
(HP, IP) turbine -102 % (HP, IP) rotor cooling for 5 min, TRIP.
(HP, IP) turbine + 105 % (HP, IP) rotor heating for 1 min, TRIP.
(HP, IP) turbine - 105 % (HP, IP) rotor cooling immediately, TRIP.
Metal Temperature bearings (1-5) >maximum.
Radial bearing 120 Co Trip.
Thrust bearing 125 Co Trip.
Instrument air compressor (Axial flow compressor).
P=6.5 bar Alarm & P=4.2 bar Trip.
Turbine drains
are opening from the beginning of startup and:
1- HP & IP Drains close at 15 % of load.
2- LP Drains close after opening of LP Turbine main control valve .
Startup status:
1- Cold (T < 170 Co).
2- Warm 1 (170 Co < T <310 Co) & Warm 2 (310 Co < T <450 Co).
3- Hot (T > 450 Co).
Stand still if Average rotor Temp < 150 Co.

9) Emergency push button Trip & Fire protection push button Trip:6) :12345-

At fire protection:
Turbine Trip.
Hydraulic pump off.
Release off F.G lube oil.
F.G Turning gear off.
Open command to vacuum breaker.

8) 10) Run back mode:-

9)

Conditions:
1- 2 CTG load > 260 MW & 2 diverter dumpers are opened.
2- And Tsh of (HP SH) or (HRH) > 572 Co.
HP/IP feed water pump.
LP feed water pump.
Circulate pump.
In normal operation two pumps are running.
If one of 2 pumps tripped reduces CTG to 50 % of load (120 MW).

13) 11) Lube oil (MAV):14) : Main oil pump:

Gear type-self priming (4bar), maximum (6 bar).
Working from the beginning of startup but its pressure will be sufficient to provide
lubrication at 90 % of speed (2700 rpm).
Auxiliary pump:
Centrifugal pump with AC motor (4bar).
1- At startup (AUX +Jacking) working up to speed reaches 2700 rpm then stop and main
pump pressure will be enough to provide the lubrication to STG.
2- At shut down main pump works till speed reaches 2700 rpm then (AUX + Jacking)
working.
- If lube oil pressure decreased to 60 %, (AUX + Emergency) run. Emergency runs after
delay time = 10 sec, and turbine will shut down at the same time.
- If lube oil pressure decreased to 40 %, (AUX + Emergency) run. Emergency runs
immediately without any delay time, and turbine will shut down at the same time.
Jacking Oil pump:
Axial piston with AC motor (300 bar).

 Emergency pump:
Centrifugal with DC motor (2 bar).
Lube oil tank heaters:
6 Heaters, ON, Toil 30 Co.
OFF, Toil 40 Co.
Lube oil temperature controller valve: If Toil 45 Co passing lube oil to the cooler.
F.G lube oil permissive:
1- Emergency LOP is OK.
2- Lube oil tank level > 300 mm, (200 mm Alarm).
3- Lube oil temperature > 15 Co.
19) 12) Hydraulic System(MAX) 40 bar :20)
Consists of two Axial piston pump with AC type motors, one running and the other is
standby.
- If hydraulic oil pressure decreased to 90 % 36 bar, standby pump will run together with
the original running pump to increase pressure.
- If hydraulic oil pressure 27 bar, Trip.

26) 13) Turning gear:27) Engaging at 4 rpm.

Dis-engaging at 25 rpm.
Normal speed 16 rpm.
Turning gear operation time before start up:
Less than 1 day
From 1 day up to 7 days
From 7 days up to 30 days
More than 30 days

2 hours.
6 hours.
12 hours.
24 hours.

If the turning gear doesnt start due to a failure, use the hand pump turning gear to turn the
shaft manually.
Turn the shaft by 180 o as follow:
1- During the first 2 hours, every 5 minutes.
2- During next 10 hours, every 10 minutes.
3- Every 30 minutes until the metal temp of the HP and IP turbines are below 150 Co.

D) STG Protections

D) STG Protections
1) Generator Impulse Non line.
C.B in switchyard has been opened.
Steam turbine Generator has NO C.B, like CTG which has generator C.B.
2) Generator protection Trip.
Relay in G.P.P (Relay Room).
3) Generator cooling protection.
Protection
Cold Air temp
Warming Air temp
Stator winding temp

Alarm
T 53 Co
T 88 Co
T 118 Co

Trip
T 63 Co
T 98 Co
T 128 Co

4) T metal Radial Bearing.

Trip @ 120 Co.
5) T metal Thrust Bearing.
Alarm

Trip

T 115 Co

T 125 Co

Alarm

Trip

0.6

0.8

Alarm

Trip

6) Thrust Position.

7) Vibration.
180 m
260 m
The high vibration value will cause overloading of bearing or impermissible bending of
rotor will occur.

8) Temperature HP turbine exhaust.

425 Co: Trip after delay time 5 min.
500 Co: Immediately Trip.

Full speed & Synch ,
(500 rpm&1150 rpm) ventilation
.exhaust flow 3000 rpm
9) ST speed 2 of 3 stand still.
If 2 channels of 3 read zero speed
10) ST frequency max 2.
ST frequency > max 2
105 % = 52.50 HZ (Trip).
ST frequency < min 5
90.5 % = 45.75 HZ (Trip).
11) ST frequency max 3.
ST frequency > max 3
106 % = 53.00 HZ (Trip).
12) Level lube oil tank Trip.
Alarm @ 300 mm.
Trip @ 200 mm.
13) Pressure safety system.
Hydraulic oil pressure
Trip @ 27 bar.
14) P lube oil 2o3.
Trip @ 0.9 bar.
- @ 60 % of pressure ( of 1.85 bar), AUX pump start and after delay time (10 sec)
Emergency pump starts.
- @ 40 % of pressure (of 1.85 bar), AUX and emergency start together, without delay time.
15) Temperature ventilation protection LP.
Trip @ 200 Co.
Hood spray open if speed > 50 % & (Twinding =180 Co or Load < 10 %).
16) Pressure HPT Exhaust 2o3.
Trip @ 28.5 bar.
:)Reaction Turbine(


cold reheat )back pressure(
.015&014 check valve
17) P LPT exhaust.

Trip @ 0.25 bar & Alarm @ 0.2 bar.

LP Back flow LP
.Circulate
Vacuum breaker IP Bypass
.Rupture disk
18) Test Turbine Protection.
Turbine has been tripped due to a test, if any test wasnt done successfully.
Ex: Over speed test.
19) Hard control protection.
Hard ware problem trip.
20) Cntrls OK Impulse.
21) Turbine controller Trip.
Basic controller problem.
22) Stress Calc HP 2o3 & 23) Stress calc IP 2o3.
+ 102 % HP rotor heating, for 5 min.
- 102 % Hp rotor cooling, for 5 min.
+ 105 % IP rotor heating, for 1 min.
- 105 % IP rotor cooling, immediately.
23) Tightness test.
Test was done but not passed.
24) Steam turbine sequencer trip.
25) ST trip P.B Cntrls 2o3.
P.B: is the push button of emergency.
26) DCS trip.
No feedback signals from DCS.
1. No feed water pumps work HP/IP & LP.
2. No circulate water pumps.
3. No condensate water pumps.
4. No instrument air compressor.
5. HRSG Protection.
27) ST fire protection P.B 2o3.
28) MPM123 card trip.
It is the card for HP & LP exhaust measurement.
If MPM123 card has a problem, Trip.
29) Over Speed:-

Trip @ 3300 rpm.

.

E) Steam Turbine
Start up Sequence

E) Steam Turbine Start up Sequence

34) 1) Local Checking:35)

Check all STG local area and make sure that everything is all right.
Check the MCC and make sure that all circuit breakers are OK.
Reset all Generators alarms and push up all Generator lock out relays from GPP.
GPP Alarms

APP Alarms
Healthy.

(read) then

(clear)

Healthy.

at the same time, then

at the same time

Reset all transformer cabinet Alarms.

Reset vibration cabinet Alarms.
Reset Romon system Alarms.
Reset the transformer cabinet Alarms in Switch-yard and push up lock out relays and
close isolation Switches and select Power House (PH) position.
Making line up for by passes and makes sure that hydraulic supply unit for each by
pass in service.
Lube oil skid & Turning gear must be in service.
Hydraulic system (FG ON).
Turbine Drains (FG ON).

42) 2) There are 4 main steps related by each other by sequence:43)

1st step: HP bypass opening.

2nd step: Gland steam system feeding.
3rd step: Condenser Vacuum pump start up.
4th step: IP bypass opening.

50) a) HP bypass opening:51)

HP bypass permissive:
P (HP) steam before bypass = 5 bar.
T (superheat) = 10 Co.
Startup mode.
Pressure set point (manual).
Temperature set point 300 Co.
Pressure set point:
0.5 bar 1 bar Pressure set point
manual HP Drum
auto manual 30 bar
.70 bar
Note:
HP bypass 3B
-:
.HP bypass Diverter -1
.T HP drum vents Stack dumper Diverter -2
HP drum vent -3
.T
. HP bypass Diverter -4
Diverter
. Diverter

b) Gland steam system feeding:58) :-

The main source of the Gland steam is the cold reheat line.
Cold reheat line provided with steam from 2 sources:
1- At normal operation: from HP turbine exhaust
2- At start up: from HP bypass so, 014 & 015 valves must be opening.
Gland steam shut off valve permissive:
Gland steam supply pressure = 9 bar.
Gland steam supply temperature = 250 Co.
[HP Average rotor T CRH T] = 230 K o.
FG Gland steam on.
Temperature Gland steam 180 Co and Auto.
Pressure Gland steam 30 mbar and Auto.
Note:
Open Local Remote Shutt off
. MCC CB Reset
DRNV CRH Steam valve bypass
Drain Saturation
. bypass Normal Operation

c) Condenser Vacuum pump start up: FG COND EVAC (ON):

vacuum
. 30 min 0.25 bar absolute
Note:
:
FG Blocked.
Vacuum pump on.
Vacuum seal pump on.
Solenoid valve on.
vacuum Blocked FG
.
3 min Trip 5 sec only
.3 min

d) IP bypass opening:-

 IP bypass permissive:
Vacuum in condenser must be 0.5 bar absolute.
IP/LP bypass pressure set point
IP Reset 3 bar
.Trip Drum
Bypass protection Reset.
IP/LP PCV control (manual) 5% then 10% then 15%.
IP/LP Bypass P_Grad set point 2 bar/min.
IP/LP Bypass pressure set point 12 bar.
IP/LP PCV control (Auto).
vacuum IP Bypass
.100 rpm Turning gear
protection IP Bypass (Trip)
. IP bypass Reset HSU Reset Reset
3) Turbine Reset:Turbine reset permissive:
HP pressure = 70 bar.
Vacuum 0.12 bar absolute.
Difference between Tlive steam and Trequired live steam 50 Co.
Safety protection Reset:
(main stop valves controller)
. Stop
Automatic controller on
Program Device ON.
(Main control valves controller)
%3 = control

Start status:

(Cold) 500 rpm Hold 20 minutes.

1150 rpm Hold 10 minutes.
(Warm) 500 rpm Hold 10 minutes.
1150 rpm Hold 5 minutes.
(Hold) =Program device OFF
Target Load AC 100%
Load Grade AC 10%
Initial Pressure set point 70 bar.
Note : 70 % Thermal Stress , )Speed SPT CRIT( 1150 rpm 500 rpm
.Critical speed
4) Syncronization: Synch. release Permissive:- Turbine running at nominal speed (3000rpm).
-Field breaker closed and Generator at nominal voltage (19kv).
(C.B)1 OR (C.B)2 Selection.
FG Excitation (ON).
FG Synchronization (ON).
Initial pressure mode, signal will be automatically activated.
Synch OFF program device (ON) synch
Control ON
.
Back up mode (HP bypass).
3 bar pressure set point HP bypass mode
IP bypass
.

 synch HP super heat flow

rate Trip HP bypass manual
.
Synch Thermal Stress
, Thermal Stress
Thermal stress Trip .

2nd HRSG Start up

Second HRSG preparation:98) : Purge: 5 min for Gas Turbine.
18 min for HRSG.
Exhaust Temperature matching::Gas Turbine Diverter
. Diverter Exhaust
Exhaust temperature matching
IGV 371 Co
.Diverter
Steam Generation:: IP bypass HP bypass Diverter
.
.014 & 015 & 016 & 452
.
STG operation
: Program device ON

Back up mode.
by pass
STG mode will be converted automatically from initial pressure mode to sliding
pressure mode.
Initial pressure mode (control valves open < 100%), (In Case of 1 HRSG), bypasses
closed.
Sliding pressure mode (control valves opened 100%), (In Case of 2 HRSG),
bypasses closed.

 Note:
HP bypass IP by pass IP/LP by pass pressure set point
.IP by pass
Matching:: 150mw 150mw
150mw base load
. mass flow rate

F) Steam Turbine
Shutdown Sequence

F) STG Shutdown
A) Shutdown STG Only:
.
.IP bypass HP bypass
-

123-

45678-

HP bypass startup mode.

Pressure set point (manual)
Steam turbine control (Load grade AC 1%/min). %10
Unloading turbine:

.Thermal Stress Trip

:
Change HP bypass mode from backup mode to startup mode.
The pressure set point of HP bypass will come down to be equal the actual valve of
pressure up stream HP turbine control.
In case of two HRSG in service (A&B).
Startup Mode Diverter
program initial pressure set point second bypass
.70 bar device on
The operator can start turbine unloading (at 25 MW).
HP & IP control valves will close gradually to decrease STG load.
HP & IP bypass will open to control HP & HRH steam pressure.
STG load will come down till the turbine trip by reverse power protection signal at -7
MW.
Both HRSGS will be under bypass operation to be ready for resynchronizing STG
again.

B) Shutdown For the Module without cooling for STG:

1 & 2 & 3 & 4 & 5 & 6 as the last steps
7- If the dispatch agrees to decrease both CTG 3A & 3B to minimum load, the operator
will decrease both loads to about 30 MW. They will close both diverter dampers.
8- The operator has to monitor HP & IP & LP drum level and refill it to be empty in order
to avoid increase T between the top and bottom of drum metals.

C) Shutdown For the Module with cooling for STG:

1- Change HP bypass Mode from back up mode to startup mode.
70 bar 125 bar
P=10 bar pressure set point (Manual)
.cold reheat
2- The pressure set point of HP bypass will come down to be equal the actual value
of pressure upstream HP turbine control valves.
3- The operator can start turbine unloading.
. unloading
4- HP & IP control valves will close gradually to decrease STG load.

5- HP & IP bypass will open to control HP & HRH steam pressure.
6- The operator has to understand that we follow this sequence to keep HP & HRH
steam temperature stabilized 565 Co to avoid increasing of HP & IP turbine
stress.
7- The operator has to wait 15 min at this case to check STG parameters and to be
sure that HP &IP bypass working properly .
8. 80 MW
9- The operator decrease load to 30 MW.
10 holding HP & IP
.80%
11- After check for STG parameters in limits. Then change CTG mode from load
control to temperature control.
. temp control load control Mode
12- The operator should decrease the set point to 371 Co.
. 371 Match
13- Turbine shaft temp will decrease.
. HP&IP
1415-

turbine unloading again 340

.reverse power trip
The operator can close diverter dampers for both HRSGs.