oe EE I Ie en at ese RRR eT Operating manual Solenoid Valve 1-2222-01-0 Solenoid Valve Function ‘Two position Three way solenoid valve is mounted on the pressure oil pipe. which is into the emergency system. It is able to cut off the pressure oil that is into the emergency safety device, also result in the reaction of the emergency safety device to make the trip oil discharge and make the trip valve shut down rapidly at last. The solenoid valve is controlled by the central control room or some protect device (according to the actual need the solenoid valve is interlocked with the protective physical value, which is converted into the electrical signal by the real protect device). Structure and Function Principle Because the solenoid valve is the purchasing part, the detailed introduction is referred to the relative manual provided by the solenoid valve manufacturer. Hangzhou Steam Turbine Company LimitedOperating Instructions Emergency Stop Valve 1-2300-02-01 Emergency Stop Valve The emergency stop valve is the fundamental shut-off organ between the live-steam line ‘and the turbine. Under an emergency condition, it cuts off the steam supply to the turbine immediately, resulting in the turbine shutdown quickly. It will be in the closed position when the turbine is at standstill and in the fully opened position during wrbine start-up and normal operation. ‘The emergency stop valve is mounted horizontally on the admission chest of the casing. The housing of the emergency stop valve is integrated with the admission chest of the turbine casing, so the emergency stop valve has no independent valve housing. One turbine may be equipped with one or two emergency stop valves based on the volume flow of the live steam admitted to it The emergency stop valve mainly consists of three sections, steam section, hydraulic section and connection part, as showed in Fig.1. a nae 2 ~~ yRyes 1. Valve cone 12, Piston rod 22, Seal ring, 2. Relief cone 13, Connection part 23. Valve seat 3. Steam strainer 14, Pressure gauge 4. Guide and labyrinth bush connection D__Live-steam inlet 5, Valve cover 15. Test piston E Tipoil 6. Bolt 16. Piston F Starting oil 7. Segment 17. Spring, Ho Testoil 8. Press ring 18. Spring eap K _Leakesteam drain 9, Valve spindle 19, Piston dise Ty Oildrain 10, Heat shield 20. Oil eylinder 7 Leak-il drain 11, Oil-retaining cone 21, Flexible joint Fig, 1 Emergency stop valve The steam section mainly consists of items 1 to 9 and item23. Hangzhou Steam Turbine Company Limited Page | of 4Operating Instructions Emergency Stop Valve 1-2300-02-01 Before the emergency stop valve opens, the live steam, after having passed the steam strainer (3), arrives 10 the compartment before the valve cone (1). The valve cone is pressed on the valve seat (23) under the steam force and the spring foree (7), blocking, Ihe Tive steam to the turbine. The relief cone (2) is provided in the valve cone, which helps in reducing the actuating forces when the emergency stop valve is being opened, because it tends to balance the pressure differential existing between the upstream and downstream sides of the valve cone. Most of the steam strainers used in the emergency stop valve are made of corrugated stainless steel band through winding, But the welded steam strainer made of stainless steel band with holes is also used in some of the turbines. In order to eliminate the steam leaking out, a corresponding sealing is adopted between the moving and stationary sections ofthe valve. The segment ring (7) eut in 4 pieces is flosh-mounted in the admission chest, the seal ring (22) is pressed by the valve cover (5) and contacted tightly tothe inner wall ofthe admission chest under the action ofthe bolt {6 via the press ring (8) and the scgment ring. This structure will have selfsealing function under the steam pressure. In this way, the steam leakage from the stationary partis eliminated. During the emergency stop valve being closed or openei, & part of Hivam leaking out between the valve spindle (9) and the sleeve (4) will be drained off through connection K. As long as the emergency stop valve is open, the valve cone contacts to the seal face of the sleeve tightly, blocking the steam leaking along the valve spindle, In order to facilitate the assembling or disassembling of the segment ring (7), an acce’s hole is machined in the housing and blocked with the screw plug. The steam section is Connected to the hydraulic section via the connection part (13). A heat shield (10) is ‘nounted on the connection part at the side near the steam section to reduce heat radiation to the oil cylinder. The valve spindle (9) is jointed to the piston rod (12) via @ flexible joint (21), on which the oi-retaining cone is fitted. In the event of the sealing clement of the piston rod damaged, the oil-retaining cone will take up the oil leaked form the oil cylinder and drain it out through connection T:, The hydraulic section mainly consists of eil cylinder (20), piston (16), spr piston dise (19) and sealing element. The oil eylinder is bolted on the connection part (13). On the end face of the oil eylinder three extension bolts are fitted for safety in rout and dismount, The bolt holes on the oil cylinder are fitted with thread bushes. Cantion: the extension bolts and the nuts must be used in mom dismounting the oil eylinder; otherwise the human injury can result. ‘The emergency stop valve is hydraulically actuated by the oil pressure, The valve opening operation is initiated by the starting control (refer to 1-1840- ). Firstly the Starting oil F enters into the space at the right of the piston (16). By overcoming the action of the spring (17), the piston is tightly pressed against the piston disc (19). Then ‘Hangzhou Steam Turbine Company Limited Page 2 oftOperating Instructions Emergency Stop Valve 1-2300-02-01 the trip oil E enters to the left of the piston dise, making the sealing faces of the piston dige and the piston remain to contact each other. After that, the staring oil bewins to drain under control, Thus the piston disc and the piston, as an integral part, move rightwards under the pressure difference at both sides until limited by the test piston (as) ‘So that the emergency stop valve is opened by means of the piston rod, the flexible joint and the valve spindle with the movement of the piston disc. Once any of the loops in the protection system acts, the trip-oil pressure will be lost The piston will separate from the piston disc under the action of the spring foree, the trip oil at the left of the piston disc drains through connection 1, the piston disc, together with the piston rod, the valve spindle and the valve cone, are pushed 10 the ‘lose position, closing the emergency valve. ‘As showed in Fig2, a test piston (15) is equipped in the hydraulic section. It, together ‘with the test valve and the pressure gauge, forms a test device of the emergency stop valve for checking its proper function during turbine operation. * ) Fig.2 Test device of emergency stop valve ‘The test valve is a manual reversal valve (or electric reversal valve) mounted in the piping or integrated in the trip block (refer to 1-2001- ). Through operating the test valve the pressure oil is admitted via an orifice to the right of the test piston. Sinee the area of the test piston is larger than that of the oil-cylinder piston, when oil pressure Pa reached a certain value the test piston pushes, under the action of the oil pressure, the piston together with the piston dise and valve spindle and cone to move in close direction by a distance h, which has on effect on the normal turbine operation. So the check may be carried out during normal turbine operation under an load up to and including rated load. When the test valve is switched to the position as shown in the picture, the test is disabled If the emergency stop valve functions properly, Pz is the actual fest pressure at which the test piston begins to move ‘Hangzhou Steam Turbine Company Limited Page 3 ofEmergency Stop Valve The permissible test pressure can be caleulated P)SA+B (Pi“1) Where: “A.B. The characteristic value related withthe size ofthe emergency stop valve see Technical data 0-0300-T.Nr-00 Py Trip-oil pressure when turbine operation If the pressure Py observed on the pressure gauge happens to be in excess of the permissible pressure P}, this will be indicative for deposits of salt on the valve spindle br deposits of oil carbon on the piston. In such a case the above testing operation has to be repeatedly a couple of times in order to recondition the emergency valve to proper function. If this fails to reduce P2 below P, the emergency stop valve must be disassembled and the fault cleared as could as possible. -The emergency stop valve can be equipped with the position switcher, as required, for sending out a corresponding signal when the valve is at full-opened or full-closed position, Based on the diameter of the live-steam inlet, the emergency stop valve i divided into five sizes with same structure; they are 100, 125, 150, 200 and 250. Page 4 of 4Operating Instructions ‘rement of casing expansion pues Mex Ree enol GasiaelxPanate Funetion the casing expands absolutely in axial direction due to the turbine heated. The Bere tne cea, indicates whether the SuppOE SUFHCE of the benring pedestal is glided freely snd the tilted displacement exists during casing expansion. Continuous a onitoring is required, especially £OF the load changing, start nd shutdown processes. In order (0 measure the casing ExpansiON & pointer (2) is fixed on the right or Heft side of ‘the front bearing pedestal ()- When the casing, le on the soleplate or baseplate expands te pointer moves relative (© the sea “Flangzhou Steam Turbine Company LimitedMeasurement of 1. Front bearing pedestal Page? of? 2Pointer 3.scale Figure 1 Hangzhou Steam Turbine Company Limited 4, Soleplate or baseplateOperating Instructions ‘Main Oi! Pomp _ Main Oil Pomp “The main oil pump provides the turbine-et with governing oi and lubricating oil. 1Lis @ single-stage, horizontal centrifugal pump and is directly driven by the turbine rotor. Gear sing ‘dap sealing impel eater key Siese Ul shat Nutop Pump housing ‘ Balan bole P Outlet S_ Inlet gq -The main oil pump consists basically of the pump housing, shaft impeller, , sea rings and ete. it is mounted at the end face of the gearbox via the adapter (°) and seal ring, 3)- Positioning pins are fitted between the adapter and the pump housing (9) as well as the adapter and the gear casing (1) for securing their positions with respect to each other. ‘The adapter not only facilities the mounv/dismount and alignment of the pump with the gearbox, but also serves as the pump cover. “The pump housing (9) is of single-cast design with an axial suction compartment and @ ce paferential ring-shaped discharge compartment. The suction and discharge compartments are sealed off from one another by the seal ring G3) fixed on the adapter cory the steve (6 fitted inthe pump housing, The sleeve, atthe same time, functions 25 a bafiler to ensure the inflow switl-free. ‘The impeller (4) is a cast of aluminum alloy. Tt is mounted, after machined and “angmion Steam Turbine Company Limited Page 1 ofOperating Instructions 1-4200-02-01 dynamically balance, on the shaft (7) and fixed by the nut cap (8) and the feather key (5). Balance holes (10) are drilled on the impeller for balancing the axial force acted on the impeller by the oil pressure. The residual thrust is taken on by the radial-thrust bearing in the gearbox. In order to enhance the suction performance of the pump and ensure its reliable operation, the main oil pump is always equipped with a suction injector (see 1-4205- ). According to the rated flow, three sizes of pumps are available (60 m°/h, 100 m’/h and 160 m‘/h). They all have a similar structure with a rated speed of 5000 r/min and a discharge pressure of approximately 0.75 MPa. Hangzhou Steam Turbine Company Limited Page 2 of 2--—--w~ Sw we 2 Hangzhou Steam Turbine Company Limited Operating Instructions Lube-oil Throttle 1-5501-01-01 Lube-oil Throttle ‘The throttle is used in fube-oil line for control the oil flow. Its structure is shown in the picture. There are two forms of casing (4) available; one for connecting to the piping with the welding connection (5) as showed in the picture, the other is connected to the piping with flanges. The casing is made of carbon stec! oF stainless steel as required ‘The oil flow to the bearing is adjusted through varying the stroke of the throttle screw (6), keeping the temperature rise of the bearing within the permitted range during turbine operation. To adjust, remove the cover screw (1), after loosing the cap nut (2), tum the throttle serew counterclockwise with a screwdriver or inner-hexagon spanner to make it move upwards. This will inerease the opening of the throttle and decrease the differential pressure before and after the throttle, resulting in oil flow increased. The opening of the throttle is restricted by its structure. It cannot be opened fully even if the throttle serew is at its maximum stroke, because the excessive oil will fll up the bearing 1g. Turning the throttle screw clockwise will reduce the oil flow. In order to avoid blocking the oil due to misoperation, the minimum flow about 0.5m’/h is permitted in its lowest posi hou Cover screw Cap nut Seal ring Casing, ‘Welding connection ‘Throttle screw Seal ring oi | ‘After adjusted, the cap nut must again be firmly tightened and the cover screw must be serewed in ag: sage VETOperating Instructions ‘One-way Throttle Valve 1-5600-03-01 One-way Throttle Valve “The one-way throttle valve is mounted in the secondary-oll line ip proximity of the oil relay. lis purpose isto prevent the transmission of possible pressure fluctuations arising tn the secondary-oil cireut, bringing, about the stable eperaion of the pilot valve without disturbance, Adjustable sleeve Spring seat One-way valve Retaining ring, Retaining ring, P| Lie iW Spring NaaLU Ms lve casing ee OGL GO eae KK “The secondary cil enters into the valve easing (8) from the ‘end B. The one-way valve (3) is pressed against the valve seat under the action oF he sprint force (7) and oil pressure, the secondary ol flows to the end A through bypass holes on ‘the one-way valve and the throttling passage between the valve casing and the adjustable sleeve (1). If the pressure st end Ais higher than that atthe end B by 0.05 MPs, the one-w Ay valve is opened. The sil lows in the opposite direction without throttling, s0 a5 0 ‘unload the turbine quickly. -Tum the adjustable sleeve to change the area of the throtiling Passase infinitely. Turning the dleeve clockwise (looking from B to A) will decrease the area of the passage, whi turning it in the opposite direction will increase the area. ‘There are a scale ring on the vrvical surface of the sleeve (1) in proximity of the end A and reference scale and ‘ndieating ring on the end A of the valve easing, which indicate the working position of the one-way throttling valve. When adjusting, if pressure gauges are fitted at both ends of the valve, turn the sleeve and observe the readings on the ganges. When the pressure afer the valve decreases modestly and the differential pressure between two ends reached 0 60N/mm?. If the epoxy mortar 1s used, the relevant satety measurement should be taken for the toxicity of epoxy during working, And atthe sie time, the foundation and the packing plate surfaces that contacted withthe mortar should be treated according to the relevant specification. In order to preven! the epoxy mortar aging and strength decreasing in the air, after grouting the mortar surlacs should be protected with a layer of cement mortar. 2, Embedding bearing plate for trimming screw ‘The mounting postion of the bearing plate should be corresponded with the pasion of the wimming serew on the pedestal (or soleplte). The seating area on the foundation for the bearing plate should be flattened by chiseling or scraping so that the whole bearing plate is contacted with the seating face evenly. The bearing plate is treated by user. Hs * iface should be flat and without burrs. The thickness of the bearing plate is about 30 mam (see Fig.3). The dimension of the cross section ean be calculated based on the load indicated in the Layout Drawing. The pressure intensity on the bearing face should be <24.5N/mm’. Pedestal (soleplate) ‘Trimming screw Bearing plate for trimming screw Foundation Fig3 3. Anchor-bolt holes ‘The anchor-bole holes should be cleaned of sundries. Check the contact condition between the bottom plate of the anchor Polt and the foundation surface around the hole. Under normal condition, the pre-tightened force of the anchor bole acts on the conerete foundation vis whole bearing face of the bottom plate, If the protruding edge-angles and stones are existed around the anchor-bolt hole, the load on the foundation becomes unevenly distributed. This will eause part of the foundation cracked and damaged in a short time, resulting in the tightened force of the hor bole lost and then endangering the normal operation of the turbine, Therefore, at approx. Smm thick layer of high viscosity and stagnation cement mortar S to be applied Hangahou Steam Turbine Company Limited Page 2 of 3Operating Instructions Preparation for Foundation 2-0300-01-01, ‘on the bottom plate or the corresponding surface on the foundation, if necessary (see Fig4). Tighten the nut t0 press the bottom plate and it will do just for the mortar beginning 0 be pressed out. This will not only benefit the turbine in long period poration but also prevent the mortar feakage during filling the hole with the mortar. ‘The anchor-blot hole only can be filled after 12 hours. The strength of the filled mortar after 72 hours should be >60N/mm’. Asphalt tape ‘Anchor bolt ‘ Anchor-bolt hole Foundation Filled cement Bottom plate of anchor bolt Nut ‘ os iy Fig. 4 4, Pre-treatment of anchor bolt Ty order to allow the anchor bole to be in elastic strain when tightened after back grouting, the mortar is not allowed to attach on the bolt or enter into the nut during routing, So the bolt should be wrapped upwards from the nut to the thread end with the asphalt tape (see Fig.4) in the direetion as the nut suming direction. When screwing in the aut the tape will be pushed upwards and form a ball-like ferrule ‘After the turbine installed, the anchor bolt should be secured by spot welding and the exposed thread should be coated with thick grease for corrosion prevention. Page 3 of3 49Operating Instructions Back Grouting for Foundation 2.0310-01-01 Back Grouting for Foundation After the turbine ( including the gear box) has been installed and it is sure that the position of the turbine set will not be moved, grout the bottom part of the pedestal {support plate or baseplate) with specified mortar to connected it to the foundation firmly. The material and formulation of the mortar is independent of turbine type and size, itis selected by user and construction company. But we recommend: When the thickness of the grouting layer <60mm, either the cement mortar mixed with cement, sand and water in a given proportion or the epoxy mortar prepared with ePoX, curing agent and quartz. sand can be used. When the thickness of the grouting layer is 60 to 100 mm, either the concrete with pebble in the specified granularity or the cement mortar ean be used. No matter which grouting material is used, the following requirements should be satisfied: 1. Compression strength 240N/mm’, afier 24 hours 260Nimm’, afler 72 hours >70N/mm’, final strength 2. Volumetric change “The contraction is not allowed. The grouting material should expands slightly within 24 hours after grouting so as to ensure that there is enough cohesion between the foundation and pedestal, but the further expansion is not allowed after 24 hours, 3. Expansion coefficient The coefficient of the linear expansion for the mortar after solidified should be in conform with that of the foundation. 4. No cracking on impact and vibration Fefore back grouting fill the anchor-bolt holes with the cement morta, first. The back ‘grouting only can be done at least after 24 hours. ‘Mounting or dismounting heavy component on the pedestal only can be done after back grouting finished at least for 24 hours. -The anchor bolt only can be retightened affer back grouting finished at least for 72 hours. “Hangzhou Steam Turbine Company Limited Page 1 of 2Operating Instructions 2-0310-01-01 lation routing, the relevant safety measurement Back Grouting for Fo when the epoxy mortar is used for back gt should be taken for the toxicity of epoxy during working. ‘The preparation forthe foundation before grouting and the maintenance should be done according with the construction procedure, ‘Vlangzhou Steam Turbine Company Limited Page 2 0f2 |Operating Instructions Installation of Condensing Turbine 2-0400-16-01 Installation of condensing Turbine ‘The turbine has been assembled and has passed the test running under no-load i the workshop of the manufacturer. It is demounted and packed several boxes when delivering to the user. The installation procedure described below is to begin from the positioning ofthe pedestal inthe installation of the turbine body. But for the turbine that the pedestal is assembled and fixed together with the casing in delivery, it is recommended that when instalfing the turbine on site, do not demount the component that has been assembled as could as possible. You have only to check the related tssembling dimensions against the actually measuring records in the Product Certificate and make proper adjustments, if necessary. The check results during installation should be recorded. The installation for the turbine of model ENK may be carried out following the guideline below. The fixers for shipping (see the Shipping Drawing No.2-8470-xxax-xx) should be removed timely during turbine installation. ‘The installation steps: 1. Preparation for foundation ‘According to the description in 2-0300-O1-xx. 2.Positioning condenser Install the condenser according to the Layout Drawing No.0-2015-T.N1-00, the ‘Assembly Drawing of Condenser No.2-3580-xxxx-xx and the Exhaust nozzle Drawing No.2-6056-T.Nr-00. Lift the condenser and place it on the foundation pier. The bearing plate (slide plate) Should be fitted between the pedestal of the condenser and the foundation pier. Adjust the condenser to the proper position based on the longitudinal and lateral centerlines of the foundation pier. The condenser pedestal near the water inlet and ouvct piping is the fined end; the other pedestal with the oval anchor-bolt hole is a movable end. During operation the condenser can be slide on the bearing plate towards the movable end. ‘The exhaust nozzle is delivered with an allowance about SOmm in length. After the turbine positioned in field installation, make up the length of the exhaust nozzle according with the actual distance between the exhaust port on the casing and the steam weret of the condenser, Weld the exhaust nozzle to the steam inlet on the condenser following the requirement after the turbine body installed and adjusted. The given cold-draw clearance (see The Layout Drawing) must be pre-kept between the exhaust sezele and the flange of the exhaust port on the easing. The clearance should be even sevund the flange surface. On the flange seal surface and the gasket the sealing coating neat be mopped. When connecting the flanges, tighten the bolts evenly and Page 1 of 14 Hangzhou SteamOperating Instructions installation of Condensing Turbine 2-0400-16-01_ symmetrically so as to ensure the tightness ofthe connection. “The foreign materials must not fall into the condenser during instalation 3. Positioning front pedestal The structure and adjustment ofthe front pedestal are described in 1-0710-O1-xx Suspend the pedestal horizontally and clean its bottom face. Coat the threads of the trimming serews atthe bottom of the pedestal with the lubricating agent and then screw flown them until they protrude from the bottom surface about 20mm. Lower the pedestal, making all of the trimming serews contact t0 the packing plates on the foundation When positioning it, the position of the pedestal should be in. consistent with the centerline of the foundation, Penetrate in the anchor bolts and tighten the nuts with hand. Remove the upper half of the front bearing housing, the radial bearing and the thrust bearing, Clean the bearing housing. ‘Adjust the center height and the level of the pedestal with the ‘trimming screws on it. Cheek the axial and lateral levels of the front pedestal on the split of the front bearing housing with flat ruler and level gauge. The deviation should be <0.06mm/mn. 4. Positioning casing For the turbine that the inner casing (inner casing in halves, steam chamber or nozzle chest, the same below), the guide-blade carrer, the middle gland bush, the front and rear gland bushes are mounted with the bottom casing in delivery, the components mentioned above should be removed first when installation. “The rear pedestal (see 1-0750-xx-xx) of the condensing turbine is usually integrated ‘with the lower supporting bracket of the exhaust casing, Lift the bottom casing horizontally, coat the threads of the trimming screws on the rear pedestal with Tubricating agent and serew down them until they protrude from the bottom face about 20mm. Then lower the easing; now the front end of the casing is supported on the jacking screws by means of the bottom-casing supporting bracket, the rear end is supported on the packing plate via the trimming screws. Sere down the trimming screws, making all of them contact to the packing plate, and then penetrate the anchor bolts into the pedestal and tighten the nuts with hand. Before positioning the bottom casing, remove the pull rods atthe front end of the casing, ‘and penetrate them into the eye-ring on the front bearing housing Screw the pull rods into the lugs on the bottom casing and lock them with nuts after the bottom casing positioned. “Hangzhou Steam Turbine Company “Page 2 of 14Operating Instructions ‘of Condensing Turbine 20400-1601 ie ea uae Usually, the adjustment of the rel mm casing and the pedestal is carried out alternately with the auiustment of the casing center height and peel The airoeeion) La which) gaven ix thes proces Coban cacy is taken as the reference ofthe axial position when positioning the bottom casing ‘Agjusting height of casing center: ‘Adjust the jacking screw of the lower supporting bracket of the front casing to make ref the easing split in conformity with that of the bearing-housing split Daring adjusting, the dimension B (see the picture), which is the distance from the casing split to the topping of the pedestal, must be ‘compromised. After adjusted B to the wale given in the Product Certificate, lift and mount the toP casing, bringing the supporting bracket of the top casing 10 support on the spherical washer. Adjust the tihead seat under the spherical washer, making B unchanged when the thread seat is Tonded and locked by the locking serew. Then, adjust the jacking serew ofthe lower supporting bracket to bring the splits ofthe top and bottom casings to contact each other. ‘Tie contact condition ofthe spits ean be checked only in a part extent around them for the split bolts are not tightened (the positioning pin should be fitted). The adjusted amount of the jacking screw for the lower supporting bracke! may be monitored with the dial gauge fitted on the upper supporting bracket, After the position of the bottom casing adjusted, the jacking screw should be locked (When Jocking it the position of the bottom easing should not be changed). After tha, Tift and remove the top casing. This rot only can re-check the position of the easing with respect 10 the pedestal from the Clearance (usually the adjustment for the axial position of the easing based on this Clearance, Lis only taken as a reference) between the screw hole in the upper supporting bracket and the distant serew (see the Product Certificate) but also reduces the adjustment work on aligning the rotor with the easing Leveling-up casing: Tlangehou Steam Turbine Company LimitedOperating instruct nstallation of Condensing Turbine 2-0400-16-01 radial bearing into the bearing housing. Lit and put the rotor into the casing with the Lifting Tool 2-8540-x1x1-00). The journal must be cleaned first. “The lift of the rotor should be in command of the person specially assigned. When lifting it, the rotor should be remained level axially. The ends of the rotor should be buttresoed by the skilled installation personnel when positioning the rotor. Mt must be noticed that do not collide the moving components with the stationary ones. Lower the rotor until the journal is away from the bearing pad about 150 mm, pour the pad swith clear turbine oil and seat the rotor on the axial bearings. Then, mount the thrust pearing and tur the rotor to check whether iis seized by or collided with the stationary parts. ‘The alignment of ifbtor ? casing? is done through aligning the rotor with the recess of the gland bush. Make the axial line of the rotor be in consistent with the central line of the casing as could as possible. On the recess end face of the front and rear gland bushes of the casing there js an annular groove called as H easuring ring for casing? as showed in details Cz and C3 on. the Shipping Drawing. During assembling the turbine in the workshop of the manufacturer, the measurement is made at the measuring ring and recorded after the alignment of the rotor with the gland-bush recess. R and r4 in the Product Certificate are the alignment values of the front and rear gland-bush recesses, while > and 13 are the measurements at the front and rear measuring rings. During installation or after turbine has been operated for a period, to check whether the casing center changes OF ot, it is only needed to make a measurement at the measuring ring and compare the measured results with the original records, opening the casing is not necessary (Note2.1 and 2.2). The alignment tool supplied withthe turbine includes a thread steel tape (100), a fixed connection (101) and an angle plate for dircetion change (102). It is contained in the instrument box for delivery. To check the alignment, attach the alignment ol to to seioe aad thai diallgange: end is)seat t0\ the) fixed) eonncetion, 05) shoved Ot the Shipping Drawing, There are six measuring spots for each checkpoint The number and position of the measuring spot are indicated on the Shipping Drawing The values Rey rs, and Rs, ra in the Product Certificate are the measured values after the casing jointed, During aligning the rotor with the casing in field installation, the top half of the easing has been removed, so there are only 3 measuring spots at each checkpoint, Make the measurements at the measuring spots 3,4 and 5 in the recesses of the front and rear gland bushes of the casing. If the deviation of the rotor center with respect to the casing is <0.05mm and the rotor center is lower than the casing one, the installation ean be carried on. Ifnot, the adjustment is required. To adjust the casing or the bearing housing is determined by the field condition. After the center adjusted to Fangrhou Steam Turbine Company Limited Page 5 of ItOperating Instructions Installation of Condensing Turbine 2.0400-16-01 the requirement, put on the top half of the casing. Now, the casing is still supported by the jacking screws of the lower supporting brackets. Fit the positioning pins and tighten the split bolts of the casing at intervals of one bolt. After that, carry out the supporting transfer for the casing. If the upper supporting bracket is padded with the spherical washer, loose the jacking serew of the lower supporting bracket, transferring the support of the casing from the jacking screw to the thread seat of the spherical ‘washer, The monitor should be made at the recess of the gland bush with a dial gauge when transferring the casing support. If the ca: 1g center moves down after the transfer, bring the reading on the dial gauge to the original value through adjusting the thread ‘seat and then lock the thread seat. Subsequently, make the measurements at the recesses of the front and rear gland bushes of the casing. When the center of the rotor with respect to the casing is in accordance to the requirement, measure the measuring ring of the casing and record the results as the reference for latter center checking (see 10.4). ‘Then lift and remove the top half of the casing. It is required to jack the lower supporting bracket with the jacking screw before loosing the split bolt. Tur it until the reading on the dial gauge begins to change. 7. Check bearing housings and bearings This is usually done during aligning the rotor with the casing. ‘The values RI, R2, rl and 12 in the Product Certificate are the actual measurements during centering the front and rear bearings and bearing housings. When positioning the bearing housing in assembling the turbine, various adjustment requirements should be compromised, and additionally the various deflections exist in the fabrication of the bearing housing, Thereby, the values R1, R2, rl and 12 are just taken as the reference for judging whether the center line of the bearing housing is parallel to that of the rotor ‘when aligning the bearing housing with the casing. If R1, R2, rl and r2 are not in coordination with the requirements for leveling the turbine and centering the rotor during assembling, the alignment of the rotor with the casing and the bearing good contact should be ensured first. ‘When the front bearing housing contains a thrust-bearing carrier the value RS and R6, which are the measurements for centering the inner circle of the thrust-bearing carrier and the runout on the carrier end face, will be found in the Product Certificate. Por the check of the bearing, refer to 2-0700-01-xx. 8. Checking other assembling dimensions 8.1 Steam-path section Lift and remove the rotor, mount the lower half of the inner casing, the guide-blade carrier and the middle gland bush. Lift in the rotor again, mount the lower halves of the front and rear gland-bush housings ‘Turbine Company Li Page 6ofi4~ =m Operating Instruetions n of Cas 2-0400-16-01 estat lensing Turbin Check the assembling dimensions of the steam-path section taking the actual measurements in the Product Certificate as the reference, according to the Steam Path Drawing No.0-2100-TNr-I1 There is no adjusting element so that the axial position of the moving blade for each stage on the rotor is guaranteed by machining. Also, the positions of the inner casing, the guide-blade carrier and the gland-bush housing in the casing are fixed. This ean be seen from the real rotor and the Steam Path Drawing. Therefore, the requirement of each section should be compromised and the clearance of each section should be re-allotted reasonably when positioning the rotor. On the whole, the minimum axial clearance between the rotor and the stationary section is at the front gland bush (or at the dummy piston gland). The axial positioning of the rotor should ensure the required clearance of the gland bush as well as that clearances at the leading and trailing edges of the moving blades of each stage are larger than the specified minimum value (Firstly, the clearance at the trailing edge of the moving blade must be larger than the specified minimum value). When assembling in the workshop of the manufacturer the axial positioning dimension E; (E; is the distance from the reference face at the front end of the casing to the end face of the dummy-piston drum and is listed in the column HBositioning of main shaft? of the Product Certificate) is determined after synthesized ‘the measured data of the axial clearance between the moving and the stationary parts for each section. The axial position of the thrust bearing is decided based on the E). To make the position of the thrust bearing be fitted with Ei, adjust the position of the front bearing housing or the thrust-bearing carrier with the pull rod when necessary. The axial position of the rotor is ensured by the thrust bearing. ‘The X+ and X- in column {Mositioning of main shaft? of the Product Certificate denote the backward (primary thrust direction) and forward (secondary thrust direction) plays of the turbine rotor with respect to its positioning reference F, with the thrust bearing removed. Afier the thrust bearing mounted the axial clearance between the rotor and the stationary parts must be checked under the condition that the collar on the rotor contaets to the primary thrust pad. Usually, the clearances between the moving blade and the nozzle and guide blade and between the moving and stationary seal strips are ‘measured with the feeler gauge or vernier calipers. Usually, the axial clearance of the twisted blade is not measured. But the clearance between the tip of the blade and the conical surface in the guide-blade ring should be checked with feeler gauge. ‘The radial clearances between the guide-blade carrier and the rotor gland at right and left sides are measured with the feeler gauge. Adjust the lateral center of the guide-blade carrier with the eccentric guide stem at the bottom of the guide-blade carrier to make Hangzhou Steam Turbine Company Limited Page T of Id aee Ee Operating Instructions Installation of Condensing Turbine 2.0400-16-01 the clearances at the right and left sides equal. Then lock the eccentric guide stem (for the turbine using the guide-blade carrier without the eccentric guide stem, the adjustment is not required). The clearances in the vertical direction are measured in the following method. Mount the upper half of the guide-blade carrier, fit the positioning pins and tighten the split bolts. Put a dial gauge with the seat on the casing split at the right and left sides of the guide-blade carrier and the gauge outfit on the proper position of the carrier flange. Set these two dial gauges to the same readings (0). Then, at the time when turing the rotor move the carrier down parallelly with the lower thread seat of the adjusting clement until it contacts to the rotor and the rotor ean not be turned (only two on the cross are required to be adjusted for the carrier with four adjusting elements). The reading indicated on the dial gauge is just the um upper clearance between the carrier and the rotor gland. In the same way, the minimum lower clearance can be measured through moving the carrier up. Two data listed in the column fffertical Clearance? of the steam path in the Product Certificate denote the actual measurements of the upper and lower clearances, respectively. ‘The clearance between the adjusting element of the guide-blade carrier and the casing split can be measured with the large leveling rule and feeler gauge or the depth calipers. ‘The upper and lower clearances between the carrier and the rotor gland can be adjusted with the lower thread seat in the adjusting element of the carrier, while with the upper thread seat the clearance between the spherical washer in the adjusting element and casing split can be adjusted. After adjustments, the thread seats must be locked under the precondition that the adjustment is not changed ‘The top clearance between the moving-blade shroud of the control stage and the gland bush in the inner casing (inner casing in halves, steam chamber and nozzle chest, the same below) is measured with the feeler gauge and can be adjusted with the adjusting gasket (plate) of the inner casing. ‘The axial positioning clearance between the carrier and the casing is measured with the feller gauge. When installing the turbine of model N, it is not required to measure the seal ring of L-shaped cross section in the inner casing, except for replacing the seal ring and the thread bush. But it is needed to check the seal ring whether it can move freely in circumferential direction and the positioning pin of the thread bush is welded firmly. 8.2 Assembling dimension beyond steam-path section Check the radial and axial clearances of the front and rear gland bushes, the positioning dimension of the emergency trip gear, the adjusted data of the front and rear pedestals (Supporting brackets, bearing housings, guide of the casing and bearing-housing connectors) and the clearance of the oil-seal ring in the bearing housing taking the actual measurements recorded in the Product Certificate as the reference, according to Page 8 of 14 Hangzhou Steam Turbine Company LiOperating Instructions Installation of Condensing Turbine 2-0400-16-01 ‘the Turbine-body Drawing No2-825x200%70 the view AI-Z1 on the drawing No.0-2011-1300s-00 and the view A3-Z3 on the drawing No.0-2011-4xxx-00. Check the stroke of the control valve according (0 the Characteristic Line of Control Valve No.0-2505-T.Nr-00 and the Produet Certificate. “The checks mentioned above can be done in the intervals ‘of the installation steps before the back grouting ofthe foundation depended on the site condi 49. Initial alignment with driven machine For turbine directly coupled with the driven machine, the turbine rotor is usually taken ne the reference. The adjusting value for the rotor center of the driven machine is setemnined by the alignment value (0-0340-T.NF-00) of the turbine rotor under cold state and the alignment data ofthe driven machine. For the turbine that is connected with the driven machine via the gear box or that drives aeulticeylinder compressor, the common central line of ‘the rotors is usually fixed on in ach a way that make the driving shaft of the gear Box smi level or the position for ne of the compressor rotor fixed, move the other ‘machines? rotors through adjusting the position ofthe bearing housing, $0 as to achieve the couplings to be concentrie and the end faces parallel during turbine-set operation. For the turbine with the drive element for driving the speed governor and main oil pump. the alignment of the coupling between the driving shaft of the drive element and the turbine rotor should be checked 10. Joining top and bottom casings The join of the turbine casings will spend a lot of time and need a lager amount of hhuman labor. The casing jointed in good oF not will haye 8 direct effect on the project quality and the turbine safety operation. So the casing-joined work must be scheduled deliberately and done carefully. 10.1 Preparation before joining casings 10.1.1 Preparation for appliances and tools “The required parts in joining the casings must be ‘counted, checked and placed in order, in advance, ‘The required tools must be counted and registered. After the casing joined the Wools must be counted again, ensuring no tool lost. ean the split ofthe casing and prepare coating forthe split. 10.1.2 Preparation for assembling Remove the alignment too}, mount the upper half ofthe bearing and beat ‘well as the oil-seal ring, FHangahou Steam Turbine Company Limited Page of‘Operating Instructions {Installation of Condensing Turbine 2-0400-16-01 Fit the specified pins between the inner casing (inner casing in halves, tet chamber snd nozrle chest) and the upper/lower halves ofthe guide-Dlade cartier, ighten the split bolts and spot-weld them against loose, Mount the gland bushes, Connect the nozzle for pressure measuring inside the casing, if there is any. Inspect carefully and make sure that there is no sundry in the casing 10.2 Joining casings 10.2.1 Lifling and mounting top casing ‘After the guide stem mounted, mop a layer of seal coating (approx. 03 thickness) on the casing split. 5mm in Lift the top easing horizontally at the specified lifting position. When lowering it, the check should be made at any time. Uniform lowering and jamming are not allowed, When the casings are about to joint, fit in the positioning pins of the casing, Loose the lift rigging. Turn the rotor, listen carefully and make sure that there is no sound caused by frietion in the easing. 10.2.2 Tightening split bolts of casing For tightening the split bolts, refer to 2-0410-02-xx. 10.3 Support transfer for casing “The gross structure of the turbine determines that the easing is supported with the upper supporting bracket. Before and during joining the casing in turbine installation, the casing is temporarily supported with the lower supporting bracket. It should be feaneferred to the upper supporting bracket after the split bolts tightened as required. afore transferring, the spherical washer should contact tothe upper supporting bracket tightly. After the thread seat locked with the locking serew according to the specified torque (see views Av-Z; and As-Zs), Check the contacting face ‘between the spherical cas, and the upper supporting bracket, the feeler gauge of 0.03 mm showld not be rrerted, After that, loose the jacking serew of the lower supporting bracket Py 3-5 mm, and then lock it. 10.4 Re-check alignment of rotor-casing ‘The alignment of the rotor with the casing may be varied in support transfer of the casing. This is mainly caused by: ‘The saddles of the front and rear pedestals are thread-connected to the thread seats. Wen the thread seat is loaded, the clearance of the thread causes the casing 19 mows down. ‘Company Li Page 10 of 14Operating Instructions Installation of Condensing Turbine 2-0400-16-01 Before and after the support transfer of the easing, the foree acted by the casing on the pedestal and the distance from the force acting point ‘0 the center of the pedestal are vIiterent, Therefore, after the support transferred, the axial level of the front bearing housing will be changed to be lower at front and higher at reat, while the rear bearing housing becomes higher at front and lower at rear. “The tightness of the easing-split bolt and the costing on the split have an effect on the deformation of the casing recess and measuring ring Therefore, the values Rs and ry should be rechecked after support transferred. If AGeioear elas avons counparcdgitniyaicy orjesnall neers) 135 <7 + 0.03mm, the readjustment must be done. 11. Connecting exhaust nozzle Conneet the exhaust nozzle according with the instructions in item 2 12. Aligning coupling ‘After the exhaust nozzle connected, recheck the alignment of the coupling that connects the turbine with the driven machine. Readjust the pedestal if necessary, bringing the alignment of the coupling to the state before the nozzle connected. Making-up raising blocks The raising blocks are supplied with the turbine. Each group includes seven flat raising- blocks with different thickness. During installation, select the combination of the raising-blocks according to the actually measured distance between the packing, plate and the bottom face of the pedestal and mark them, ‘The number of the piled Faising-blocks in a group should not excess 3 pieces. Usualy+ mill the thickest one to rect the requirement. After made-up, insert them into the space betwee the packing plate and the pedestal firmly according to the marks made on them. Then loose the trimming screws by 1/2-1 turns. [After the turbine support transferred from the trimming serews tothe fst raising blocks, tighten the anchor bolts to the intial tightening tordu . Then recheck the alignment of the turbine with the coupling of the driven machine. Re-adjust it through changing the thickness of the raising block, if necessary. Or based on the field condition, adjust the bearing housing to meet the alignment requirement of the coupling, but the alignment ofthe rotor with the casing must be satisfied first 14, Ending turbine assemble Dismount the alignment too}, clean the color left on the rotor and the bearing pad during penetrant inspection. Mount the upper half of the Pearing and the bearing housing as ‘well as the oil-seal ring. Mount the barring gear. For the manual barring gear, check its function through ‘rangzhou Steam Turbine Cor mapany Limited Page It of 14Operating Instructions 1g Turbine 2-0400-16-01 operating it repeatedly during assembling. If the hydraulic barring gear is used, check the axial clearance between the frame and the ratchet wheel. The clearance at the backside should be larger than or equal to that of the rear gland bush. If the oil-turbine barring gear is used, check the axial and radial clearances between the impeller and the rear bearing housing (see view As-Z,). If the electrical barring gear is used, check the engagement and drive of the gears through manual operating and the engagement and disengagement functions during turbine test running. Instaltation of Conde Remove the positioning pin of the casing split. Spot-weld the nut on the pull rod of the front bearing housing as required (see view Aj-Z;). Mount the connectors between the turbine and driven machine, 15. Back grouting Make sure that the pedestals of the turbine will not be moved again, carry out the back grouting for the foundation, The back grouting of the turbine and the driven machine should be done simultaneously and finished at one time. For the requirement on the back grouting, sce 2-0310-01-00. Mounting or dismounting heavy component on the turbine only can be done after the back grouting finished at least for 24 hours. After back grouting finished for 72 hours, tighten the anchor bolts to the final tightening torque listed in the attached table so as to make the anchor bolts still has the enough remaining stress afier long period operation, ensuring the pedestals to be connected with the foundation firmly. 16. Other installation 16.1 Installation for relevant equipments The installations for the centralized oil-supply unit or the bulk oil tank, oil cooler and oil filter, the SRIV governor, the trip block, the local instrument cabinet, the ejector, the expansion tank of drainage, the condensate pump and etc can be carried out simultaneously with the installation of the turbine. 16.2 Installation for seam, water and oil piping The piping supplied with the turbine has been pickled in the workshop of the manufacturer (except for the straight piping that is not concerned with the no-load test run). The field fabrication piping only can be connected after pressure test and cleaned. Either chemical cleaning or water flushing can be adopted. The piping should be purged with compressed air or steam according with the field construction procedure. The steam piping connected with the turbine body, such as the balance pipe, the gland nd steam pipes and the vent pipe may be connected before back grouting. ted Page 12 of 14 Hangzhou Steam Turbine Company Ler ee ee yer ee eee: Operating Instructions Installation of Condensing Turbine 2-0400-16-01 The installation of the oil piping, the drainage piping, the steam, air and water piping for the ejector may he carried out before and after the back grouting based on the piping location and construction progress. The drainage piping should be so installed that the drainage must not flow back to the turbine and the drainage valve must be located at the place convenient for operating. The drainage from the negative-pressure zone duri turbine start-up should be led to the expansion tank of the drainage, The connections on the tank for drainage must be arranged in the specified order, ie. the drainage piping at the high pressure should be connected to the tank at the end far from the condenser, while the one at the lowest pressure to the end near the condenser. In this way the high-pressure drainage will not interfere with the flow of the low-pressure drainage ‘The inlet and outlet piping of the condensate pump can be connected after the pump and the ejector positioned. ‘The distance between the steam piping and the oil piping should be as large as possible In the event that the steam piping is erossed to and under the oil piping, it should be shielded to avoid the oil drop being on fire under the high temperature. “The steam inlet and exhaust piping should be connected after the back grouting and the anchor bolts tightened to the required tightening torque. When connecting, th in three directions (X, Y and Z) at the supporting bracket of the casing should be carried cout, ensuring the easing not to be moved Before turbine start-up, the oil piping must be cleaned by means of oil cycling (see 3-0340-) and the steam inlet piping must be blown with steam (see 3-0350-). 17. Instruments Itis batter to mount and verify the primary and secondary instruments supplied with the turbine according to the Bill of Material 0-2020-T.Nr-00 and the attached document « the Plant Monitoring 0-0101-T.Nr-01, afier back grouting. Verify the in have been mounted on the turbine before ot during turbine installation. Alter i check whether the instruments is in completion. rumenty thal tallaton, 18, Heat-insulating lagging ‘The layout of the heat-insulating lagging should be carried out after the oil cycle (see 3-0340-) and the steam piping blown (see 3-0350-) according to the description 49 2-7600-, 19. Encloser In general, the encloser is installed after turbine test running alone according We he Layout Drawing No.0-2015-T.Nr-00 and the Encloser Drawing No.0-201¥-x.4%-00 Note: 1 If the trimming screw is required to be adjusted after the anchor boll have Wega “Hangzhou Steam Turbine Company Limited Vage 13 0f 1@Operating Instructions Jnstallation of Condensing Turbine DMO tH-04 tightened to the htening torque, the turning angle in one time for cach screw should not be in excess of 30° for preventing thread damage duc to overle:l During adjusting, make ail trimming screws earry an equal share of load as vould as possible. 2. The description of the alignment data in the Product Certificate. 2.1 When assembling the turbine in the workshop of the manufacturer, the reading at the measuring spot 5 (the spot at the left bottom near the split) is usually corrected to 2 ? and taken as the comparing reference. Therefore, the datum of the measuring spot 5 in the alignment data of the Product Certificate is always 0. 2.2 From R3 and 13 we may see that the measuring ring may not be a perfect circle. This is caused by the error in selecting the split during machining the casing, the coating on the split of the casing or the deformation of the casing recess. Despite all this, R3 and 13 as the relative comparing reference will not influence the accuracy in alignment, ‘Table: Tightened torque for anchor bolt Size of anchor bolt M30 | M36 | maz | mas | mas | ms2 | oso | moa Initaltightenedtorque Nm 1) | 20 | 30 | 40 | so | so | 60 | 7 | so Final tightened torque Nm 2)] $10 } 890 | 1420 | 1770 | 2150 | 2750 | 3430 | 110 i) The allowed deviation is. = 10% 2) When the turbine is mounted on the concrete foundation that has been used for about 3 years, the 70% of the value listed in the table is taken. Page 14 of 1d Hangzhou Stea i ||SS NN Operating Instructions Tighter 1g Casing-Split Bolts 2-0410-02-01 Tightening Casing-Split Bolts ‘The state of the turbine casing-split bolt in delivery is determined by the conditions of the turbine delivery and shipping. For the turbine delivered in completion, the | casing-split bolts have been tightened in the factory according to the requirement. For | the turbine that is delivered in several packages or is disassemble and reassemble on site as required by user, the casing-split bolts are only tightened approximately when the | turbine being delivered and retightened during installing on site. ee. 2 2 18 8 2 z 24 27 2 s A742 a 46 Fig.l Tightening order of bolts for horizontal casing split The tightening method varies with the material and size of the bolt. For the bolt made of NiCr20TIAI, 21CrIMolVtiB (thread diameter M52), 21CrMoV (thread diameter = M64) or 35CrMo, heat-tightening or hydraulic-tensioning method must be adopted inf ) tightening the casing-split bolts. The other bolts can be tightened with special extension wrench. The special tool for tightening the bolt in heat-tightening or hydraulic-tensioning method is provided with the turbine, The tightness of the bolt should be in accordance with the value given in the attached document 'No.0-3400-T.Nr-00 (Data sheet of bolt tightness). When tightening the bolt with wrench it is not allowed to beat the wrench using a hammer because the tightening torque cannot be controlled and the thread of the bolt will be damaged in hammer beating During turbine installation or overhaul, tighten the casing-split bolts in a reasonable order to avoid the split flange being deformed and resulting in split leakage. Fig.1 shows the tightening order of the bolts for the turbine of model NK. For the turbine of model ENK or EHNK with extension sector and transition sector, the locations and number of the casing-split bolts will be different to that showed in the pi ture, but the Hangzhou Steam Turbine Company Limited Page 1 of 2Operating Instructions ‘Tightening Casing-Split Bolts 2.0410-02-01 Lightening order is the same, ie. tighien the bolts, from the one before the flange of the first guide-blade carrier, forwards in turn, and then, from the middle, backwards in turn The blot numbers in the picture indicate the tightening order. The bolts of the vertical split between the front and rear casings have been tightened in the workshop of the manufacturer. If it is necessary to tighten them on site, one of the tightening orders shown in Fig.2 can be selected Fig. 2 Tightening order of bolts for vertical casing split ‘Hangzhou Steam Turbine Company Limited Page 2 ofOperating Instructions Cheeking Bearings 2-0700-01-01_ Cheek Bearings ‘This section mainly describes the key points that should be noticed in checking. the bearing during turbine installation. For the structure, assembling and adjusting of the bearing, bearing carrier and bearing adjusting ring, please refer to 1-0710-, 1-0720 and 1-0730-. Check the bearing taking the actual measurements recorded in the Product Certificate as the reference. It may be carried out alternatively with the alignment of the rotor. 1, Radial bearing 1.1 Crest clearance For two- and four-wedge radial bearings, measure the inner diameter of the bearing, and the outer diameter of the shaft journal. The difference between them represents the crest clearance of the bearing For the tilting-pad bearing (see 1-0730- ), measure the aperture Da of the bearing: housing, the thickness W; of the bearing ring, the thickness W2 of the pad and the diameter d of the shaft journal. Calculate the bearing clearance Sz from the formula below: S2=Da- 2 (Wi+W2) -d 1.2 Side clearance of bearing pad Usually, the side clearance of the two- and four-wedge bearing is measured with feeler gauges with different thickness, in succession from the thicker to the thinner. 1’ the feeler gauge can be inserted into about 20 mm, and the measurements at four measuring points (front and rear, right and left) are the same, the coincidence of the bearing centerline with the axial line of the rotor is indicated. When checking the four-wedue bearing, the bearing split is at a horizontal position, which differs with the operation position by 45° 1.3 Contact between bearing pad and shaft journal In general, the staining method with red oil or blue oil (0.003~0.006mm in thickness) i» used for checking the contact mark between the bearing pad and shaft journal. After cleaned the pad and journal (see the note), coat the journal uniformly with red wil (or blue oil) in a length longer than the pad width. Turn the rotor slowly and uniformly, then take out the pad and check the contact mark. For the two-wedge bearing, the contact mark at the middle of lower pad bottom should be continuous and even in a width about 10mm within the whole pad width, The narrower is the contact mark, the smaller is the temperature rise of the bearing during operatior For the four-wedge bearing, it is at the position as mentioned in 1.2 when checking Ow Hangzhou Steam Turbine Company Limited Page tofOperating Instructions Checking Bearings 2.0700-01-01 its lower padi there are (Wo contact marks distributed continuously and evenly along the axial line, with a width of 3-Smm for each. For the width of the mark, the narrower the better, because with the narrower mark the bearing temperature will be lower during ‘operation. For the tilting-pad bearing, the contact marks on two pads in the lower half of the bearing should be distributed continuously and evenly along the axial line, with a length longer than 90% of the pad width. For the turbine using titling-pad bearing, the values Ry and Ro (r1 and r2) of the bearing, housing at the same side should be equal so as to ensure that the centerline of the bearing housing parallels to the axial line of the rotor. 2. Thrust bearing 2.1 Axial clearance ‘Two dial gauges are used in measurement, one for monitoring the bearing body, and other for measuring the axial play of the rotor. After the thrust bearing (including the adjusting gasket) mounted, turn the rotor in the sense of operation, while push the rotor forwards and backwards. Keep the reading on the first gauge unchanged, thus the difference of two readings on the second gauge represents the axial clearance of the thrust bearing, 2.2 Checking the contact of the thrust pad Coat two faces of the rotor collar with red oil (or blue oil). Turn the rotor when the collar contacts to the primary and secondary thrust pads respectively. Then check the contact marks on the pads. The mark area on each pad should be larger than 80 % of the pad area. ‘The checks mentioned above can be carried simultancously. Note: ‘To remove the radial bearing in the turbine delivered in completion, grasp the sling with hand making the shaft journal separate from the pad; tum out the lower half of the bearing. Attention: When the front and rear bearing removed, the rotor is supported on the gland bush, it is not allowed to turn the rotor at this time. For the turbine that is delivered in several packages, the bearing is checked before the casing jointed with the same method as that used in the turbine delivered in completion, or lift the rotor directly and remove the lower half of the bearing. For the heavy rotor, the tool (2-8540-00xx-08) for raising rotor, which is provided with the turbine, can be used in raising the rotor during removing the lower half of the bearing, Hangzhou Steam Turbine Company Limited "Page 2 of 2Operating Instru Heat Insulation of Turbine Casing 2.76004 Heat Insulation of ‘Turbine Casing (Aluminum Silicate) The heat-insulating lagging supplied with the turbine is used for heat insulation of the turbine casing, emergency stop valve, control valve and extraction stop valve Preserving the turbine casing with heat-insulating lagging reduces not only the turbine thermal lose and but also the temperature difference at the same cross-section of the casing and consequently the heat deformation caused by the temperature difference. At the meantime, it lowers the ambient temperature around the turbine, enhancing the ‘working condition for operator. After the piping that are connected to the casing and the instruments installed, the oil system and steam piping scavenged, the installation of the heat-insulating lagging can be carried out. ‘The heat-insulting lagging is formed by irregular-shaped blanket tailored by fibergalss cloth with aluminum-silicate filled. The shape and the thickness of the blanket are determined by the turbine type and steam temperature. The heat-insulating lagging is divided into inner and external layers. Each blanket has its own identification number. The number of the first layer (inner layer) is I-xx, the second layer (outer layer) is II-xx. The instructions, developed diagram and diagrammatic map of identification numbering for the heat-insulating lagging can be found in the document container delivered with the turbine. For the newly installed turbine the mounting of the lagging must be made with great care, The blankets should adhere to the casing over their entire surface so that no air cushions will be formed. In addition, adjacent blanket should abut tightly at the Joints without leaving any gaps. If the gaps appear due to mounting deviation, the spare blankets can be used to fill them. For opening the turbine casing during turbine overhaul, only the blankets at the casing-split bolts are required to be removed. After overhaul, ‘mount the blankets removed to the original positions. Replace old ones with spare blankets, when necessary. Attention: The unused blankets should be stored properly. Dragging the blanket on the ground, standing or placing the heavy subjects on the blanket are not allowed. Flammable substance must not be infiltrated into the blanket. The blankets infiltrated with turbine oil or adhered with grease must not be used. The installation personnel should dress the ight work-clothes and rubber glove when mounting the heat- Hangzhou Steam Turbine Company Limited Page 1 offOperating Instruetions Preface of Operation Section Ka 3.0100 01 04 Preface of Operation Section The Operation section (document No. 3-xxxx-xx-xx) in this Operating Instruction deals with turbine operation (No. 3-1xxx-xx-xx) and common malfunctions and remed (No. 3-2xx-XX-xx), This section describes the operating requirements and key points that are to be strictly observed during turbine start-up, operation and shutdown. Furthermore, the operating procedure should be worked out based on these essential requirements. The user must ‘rite up a special operating procedure that applies to individual turbine according to the turbine application and performance, the attached documents and the laws and regulations issued by local authority. Usually, the operating procedure includes the responsibility of operating personnel, the specification of the turbine, the operating Program and adjustment, test and maintenance prescripts for main and auxiliary equipments, the treatment of accident, the system diagram for equipment running and ete, To facilities the description, some of the operation and check items are numbered. But these numbers do not present the order of operating steps In order to ensure the turbine safety run in long term the operating personnel, in addition to understanding and observing strictly the operating procedure, should acquaint the working principle, structure and performance of the turbine, should be familiar with the demands of turbine operation requested by the plant process, the changing regularity of turbine operation and characteristic under various conditions, the funetions and usage of the adjusting and operating elements and the instruments, should remember the critical operating data and monitoring limits in heart, should summarized the operating experience continuously and treat the various abnormal conditions timely and correctly, and eliminate the hidden troubles and prevent the accident occurring The Operation section in this Instructions also describes the turbine monitoring which aim to ensure safe and efficient operation. The operation safety of the turbine, or the reliability has a direct effect on the economical running of the turbine and plant. Generally, the reliability means that the turbine can normally operate under a specified Output and the operating parameters are within the given range in the due operation Period, the parts and components will not damage in their normal service life. In order o prevent the equipments from damage caused by improper operating or accident, the turbine is equipped with the monitoring, safety and protective devices as well as the isplaying, recording instruments, audible and visible alarm and interlocking trip system which are cooperated with the formers for realizing their functions. The monitoring devices are used for indicating the operation parameters, such as pressure, ‘temperature, speed, vibration, displacement and etc, from which the operating personnel can know the characters of the operation parameters and discover the deviation with respect to the setpoint. The safety devices serves to emit the unfavorable conditions in Turbine Company Limited Page 1 of 2,Operating Instruetions Preface of Operation Section 3-0100-01-01 peration By acting before the operation parameter reaches To the acting value of the mrotective device, avoiding turbine trip, e.g. the safety valve for exhaust. The protective devices fumetion for manual or auto emergency trip once the operation parameter reached the given limit. During turbine operation, the operating personnel should observe the operation parameters regularly: judge the operating condition through analyzing the displayed and recorded data, The operating personnel should immediately Teport abnormal condition, if there is any detected, to the chief on duty and take the Corresponding measure to correct them. If one or several parameters alarmed and the Condition will deteriorate judged from the changing tendency and rate of the alarmed Parameter trip the turbine decidedly o prevent person injury and equipment damage. [re safety operation of the turbine cannot rely on the monitoring devices completely, the operating personnel should make the perambulation for the operating equipments "egularly, checking the leakage of steam, water and oil, as well as the operation state of the auxiliary devices carefully. In the event that the abnormal conditions or faults are detected, find out the reasons and correct them immediately, eliminating the accident in the nascence as could as possible. ‘The turbine is a machine formed by thousands of parts with various functions, structures and materials. The defects in manufacturing improper installation and serviee, incomet Cpstating or accidental reasons will disturb the turbine normal operation, So, in the ap humbered with 3-3xxx-xx-xx, we gave out some common faults and treatments, which are collected by our service engineers from the field service for many years. But Uhey are applicable in a general way because of the different turbine types, operation Conditions and operating customs. Therefore, we are grateful to our users for giving us their experience in turbine operation and service. 2of2 Hangzhou Steam Turbine Company LimitedOperating Instructions Steam Quality 3.0310-01-01 Steam Quality The turbine is a rotary thermal power machine with steam as its working medium, the quality of the steam entering into the turbine will not only has an effect on economical operation but also be related with safety operation and service lift of the turbine. The deposits that occur in the steam path of a turbine due to impure steam_can lead to a reduced section area of the steam path, decreased turbine output and an inefficiency, also to increased axial thrust. The deposits that occur on the blades will increase the stress of the blade, resulting in blade breakages. Furthermore, the deposits can lead to seizure of the spindles of the emergency stop valve and for control valve. Therefore, in order to operate the turbine safely and economically in a long term, the qualities of the steam and boiler feed water should be in line with the standard listed in the tables below. ‘The standard value is the limit value, while the expected value is much favorable for the safe operation of the turbine. 1. Steam quality standard ‘The quality of the saturated and overheated steam from the drum boiler with natural circulation and forced circulation and concurrent boiler should be in accordance with the valves specified in the table 1 ‘Table 1: Steam quality standard —=— ae Drum boiler (One-through boiler ey 35~S8 259 239 A i Standard | Standard | Expected | Standard | Expected Patkcring : Sodium, u gk sis Volatilizing : <020} <0.5 usiem | combined-water treatment Silicon dioxide» g/kg <20 <20 <20 In order to prevent the metal oxide deposited inside the turbine, the content of the iron and copper in the steam should be in accordance with the valve given in the table 2. Hangzhou Steam Turbine Company Page 1 of 3Operating Instructions Turbine Oil 3-0320-01-01 Turbine Oil Usually, turbine oil of the type L-TSA46 or L-T$A32 is selected for lubricating and control system of the turbine, except for the electrie-hydraulic control system with fire-resistant oil. ‘The type of the turbine oil that is used for your turbine is specified in the Technical Data (0-0300-T.Nr.-00). ‘The fresh oil quality should be in compliance with the specification given in the standard GB11120. The inspection items and period, the quality standard that should be reached for the oil the table 2. 1g turbine operation are liste Hangzhou Steam Turbine Company Limited Page 1 of3 eeDees Operating Instructions Steam Quality 3-0310-D1-01 “Table 2: Steam quality standard —— Boiler sype_ esse MPa_| 238 em Standard Expected Iron, akg =20 : Coppers sik <5 - 2. Boiler feed-water quality standard ‘Table 3: Boiler feed-water quality Overteat | Conductivity (afer Distal Tyction exchange, | Hates Tron Copper Sodium steam onygen Boiler ase) L pressure Siem ‘ype T otboiter vino Ssandad | Exped ssandard | Standard | Standard | Expeced | Standard | Expected Pa pam | sess | - ~ | «20 | sis | 02s Without 013~0.25 <5 Table 2: Limit of granule quantity Quantity Pipe DN Cinch) Wall of pipe (mm) (piece) 2 53.91 20 3 <549 4s 4 6.02 80 6 <2 180 4. Work after oil flushing 4.1 Restoring oil system Remove the temporary piping, orifices and blank plugs for flushing, restore the piping to normal connection. Clean the insides of the oil eylinder of the emergency stop valve and pilot ‘wash the removed parts and components, including the bearings, restore Hangzhou Steam Turbine Company Limited, eee Operation Instructions Ramin cy wip gear to the original Turbine rotor, emergency stop valve, oil eylinder and emergen states. For the turbine bringing its own main oi pump, connect the inlet and outlet piping of the oil pump and mount the regulating valve of the oll injenor For the turbine with the electric-hydraulic converter mounted on the trip pe a tention should be taken that the blank plate between the convertor and the trip block is just used in ol flushing, is must be removed after flushing: 4.2 Replacement of oil ‘The flushing oil has to be thoroughly drained at the end of the flushing operation so that absolutely no residues will be left. Clean the insides of the oil tank, bearing housing, searbox and oil iter, wash the filter element, and then fil theo tank with qualified turbine oil to the quantity required for the turbine normal operation, The measures Should be taken during filling operation for preventing the oi fom contaminating. 4.3 Checking oil quality oe The quality of the oil that is going to be filling or replacing should be checked first. Two sealed and against light as sample ols ae required, one for test and other for keeping in d 4 the control sample in oil quality checking later on. The quality requirement ariel turbine oil is given in 3-0320-xx-xx (GB11120) and only the qualified oil can be file imto the tank. er et spore FFangahou Stcam Turbine Company LimitedOperating Instruetions Purging Steam Piping 3-0350-01-01 Purging Steam Piping The purge of the steam piping is an important measure for ensuring the turbine safety, it should be carried out after the tightness test has been passed. During manufacturing, welding and installing the steam piping, not only the dirt will enter into the piping but also the oxide and welding spatter will be attached on the inner Wall of the piping. Therefore, the solid impurities with the size less than the hole of the strainer will enter into the steam path at high speed through the strainer, colliding with and damaging the blade and gland bush. In order to eliminate this hidden risk, the steam inlet piping should be purged with steam prior to first commissioning after turbine installed To purge the steam inlet piping with steam, the emergency stop valve must be removed in advance, mount the {Surging tool? 2-8535-xxxx-xx) supplied with the turbine for blocking the passage through which the steam enters into the steam path A temporary exhaust pipe is required for purging, the inner diameter of the exhaust pipe should be equal to or larger than that of the purged piping with a length as short as Possible for reducing the exhaust resistance. The outlet of the exhaust pipe should be tilted up (by approx. 30° ) to the air, The exhaust pipe should be fixed by the firm support to bearing the reaction force of the exhaust. In order to reduce the noise level produced by exhaust, a muffler may be mounted in the temporary exhaust pipe. But the muffler mounted will inerease the exhaust resistance. To get the efficient purging, the scouring force against the piping wall during purging should be larger than that during normal operation. Therefore, the purging-steam parameters is determined and controlled by a momentum coefficient K, which is the ratio of the steam momentum mye; under purging condition to the steam momentum ‘movo under rated condition, i Kame K should be 21.2~1.5 Where: ‘m,fif-urging-seam flow ‘mo team flow under rated condition via. pecial volume of purging-steam Voi pecial volume of steam under rated condition Before purging, the piping should be warmed up and all of the joint bolts for flanges should be tightened under hot state. The purging is carried out in several times, which is based on the clean condition of the piping. Each time of purging will last for 10 minutes. ‘The interval time between two purges is determined by the time required for the piping temperature to drop below 100°C. When the temperature of the piping wall dropped Hangzhou Steat Page | of2Operating Instructions Purging Steam Piping i ‘below 100°C, the impurities deposited on the wall will all ‘down and be blown off in the next purging. In order to examine and evaluate the purging result, @ checkerboard may be fitted in the exhaust pipe (Fig.1) or at the outlet of the exhaust pipe (Fig.2). It consists of a support tnd target plate made of new aluminum plate with thickness of Imm and width of ‘Jomm, the length of the checkerboard is decided by the diameter of the exhaust pipe the target plate should be replaced and examined after exch PUTEINE On the premise that the scouring force of the steam does not decrease, when the impaling bblemishes on the target plate in two adjacent purges has been < 0.8mm and number of the blemishes ts Jess than 8, the purging is considered to be qualified. Following the purging, remove the temporary exhaust PIPE when the piping temperature dropped to room temperature, Carefully clean the emergency £0? valve housing and Feneve the purging tool. Make sure that there is mo impurity tn the steam inlet compartment and mount the emergeney stop valve FHanguvoa Steam Turbine Company Limited ReOperating Instructions 3-1100-01-01 Turbine start-up is a process in which the turbine is brought 10 a certain load from. standstill. This section simply describes the change rules of the factors that are related to turbine safety and life during start-up. The proper operation is based on mastering and observing the objective laws of the start-up, Please see the instructions in 3-13xx- for the detailed starting procedure. ‘The working condition and stress of the main components in the turbine (casing, rotor and ete) are going to be changed severely and complexly in the course of starting, due to heated. When starting, the steam, under high temperature, entering into the turbine will pass the heat to the components that are exposed to it through condensation heat transfer and thermal convection. Thus, the heated components will be bound to expand. Once the expansion is restricted, the thermal deformation and stress will appear. Although the thermal expansion, deformation and stress as well as the differential expansion between the casing and the rotor arc inevitable during turbine starting, they can be controlled within the permissible range through proper operating, ensuring the turbine for successful start-up and safety operation. The steam enters into the turbine through the emergence stop valve. The uneven temperature distribution in the valve housing after it heated by steam will produce a tremendous thermal stress in it, In order to improve the stress of the valve housing, it required to be preheated for a certain time during turbine start-up. Usually, the preheat of the valve housing is carried out during turbine warming-up at low speed. After the steam entered into the turbine casing, it will heat the inner wall of the casing, then transfer the heat to the outer wall and the split flange. Due to the thermal resistance in the course of heat transfer, a large differential temperature will appear between the inner and outer walls of the casing as well as the inner and outer sides of the flange. The expansion of the inner wall is larger than that of the outr? wall, thus the casing and the flange will be deformed horizontally and vertically during heating. This may cause the moving and stationary parts to collide each other. If the stress exceeds the permitted valve due (0 the excessive temperature difference, the plastic deformation of the casing ‘and the flange will occur and so far to cause the casing cracked in the control stage zone. ‘Once the casing is deformed plastically, it is evitable that the sealing function of the casing split becomes inefficient, resulting in leakage During starting, the heat is transferred from the casing wall to the flange and then to the split bolts. Since the temperature of the flange is higher than that of the bolt, the expansion amount of the flange in thickness is larger than the elongation amount of the bolt, The bolt will be deformed plastically if the its stress exceeds the permitted value duc to the excessive temperature difference between the flange and the bolt, resulting in it leakage. Hangzhou Steat Turbine Company Limited Page t of 4eee eee Operating Instruetions ‘Turbine Start-up, S110 at 6 Except for the full-admission turbine with high parameters and the turbine of Wik model, most of the turbines adopt the top-half-admission, and additionally the heat radiation of the bottom casing is faster than that of the top casing. [herctore, the temperature of the top casing will be evidently higher than that of the bottim «awing “The excessive temperature difference between the top and bottom casing will hye Ue casing. This may cause the moving and stationary parts to collide each other tn addiem, if the rotor is heated at standstill, the uneven temperature distribution between the upper and lower parts of the rotor will cause the thermal flexure of the rotor Usually, the thermal flexure of the rotor is a kind of elastic deformation, but it will become plastie permanent deformation under improper treatment. To rotate the rotor when has @ larger flexivity is not allowed, because this will cause not only the vibration ayy ated but also the moving and stationary parts to collide each other, resulting in he Nexwvity increased and plastic permanent deformation. Therefore, the rotor can not he heated @ standstill. During turbine start-up or stop, the expansion amounts of the casing and the rolot ae not same because of the different heated conditions, materials and masses (se difference between them is called as differential expansion. In the course of starting the casing heated by the high temperature steam will expand along the axial line (aking the dead-point (Exhaust end) as the reference. And at the same time, the front hearing, housing or thrust bearing carrier that is used as the axial positioning for the rotor mawee forwards too, Since the rotor is surrounded by the steam and additionally the rotor maa ig much less than the casing one, the temperature of the rotor rises faster than the casing, The elongation amount of the rotor along axial line is larger than the expansion amensit of the casing and they expand in opposite directions. At this moment. the dilterential expansion is called as a positive differential expansion. In the course of turhine stop, te differential expansion between the casing and the rotor is negative diftevential expansion. When the differential expansion reaches to the specified limits. 11 untwates that the clearance between the moving and stationary parts is less than the required minimum valve. For the turbine connected to the driven machine with the excessive differential expansion may cause the axial clearance between the moving and stationary parts in the driven machine to be changed beyond the limity he collision of the moving part with the stationary one is bound to damage the equipment ‘The description above shows, during the turbine starting the temperatures vf the casing inner wall and the outer part of the rotor is rising continuously with the rise of the steqm parameter and the increase of the flow. Since the temperature rise in the outer wall af the casing and the centric part of the rotor lags behind that in the outer wall of the casing and the outer part of the rotor, the compressive stress will be produced the inner wall of the casing and the outer part of the rotor. The process of the turline stup ‘a cooling down process of the casing and rotor, With the decrease of the stea parameter and flow, the temperature at the rotor surface and casing outer wall will be Tower than that at the centric part of the rotor and casing inner wall. ‘Thus, a temaile stress is produced in the casing inner wall and outer part of the rotor {hi sil Hangzhou Steat Turbine Company Limited Page DotRN Hangzhou Steat Turi Operating Instructions Turbine Start-up 3-1100-01-01 ‘completes an alternating thermal stress eycle, which is also called as low-cycle fatigue, from the turbine starting to stopping. The low-eycle fatigue will shorten the turbine lift and make the turbine aged, risking the accident. Therefore, the starting and stopping times should be reduced as could as possible and the frequent load change should be avoided during turbine operation. The starting characteristic of the turbine is varied with the turbine size, steam parameter and application. The starting curve 0-0320-T:Nr-00 in the attached document is applicable to your turbine. The starting time given in the curve is calculated through controlling the temperature change rate in consideration of the thermal stresses in the emergency stop valve housing, casing and rotor as well as the expansion difference between the easing and the rotor. It is the shortest time required to bring the turbine to the rated operating condition from standstill under rated steam parameter. The actual lasted time during turbine starting must not be less than the given starting time. The turbine can be started with the constant-parameter or variable-parameter. In the former, the fresh steam pressure and temperature are constant and at rated value in whole starting process, while in the latter the steam parameters are changing gradually. With the variable-parameter starting, the turbine is rotated with the lower pressure steam. with a superheat degree above 50°C. After that, rise the pressure and temperature of the fresh steam gradually until to rated values. For the cold starting of the turbine of model H (the temperature of the casing and rotor is less than 150°C) , use the variable-parameter starting as could as possible if the operating conditions of the boiler and plant are permitted. This is because during cold starting the high temperature steam. will be cooled and condensed when it contacts with the components at lower temperature, the steam passes the heat to the turbine through condensation heat transfer ‘and the surface temperature of the component rise quickly, once the steam temperature reached to the saturation temperature corresponding to the throttled steam pressure the heat transfer becomes thermal convection. The coefficient of the condensation heat ‘transfer of the steam is much larger than that of the thermal convection and increases With the pressure rising, therefore to start the turbine with lower pressure steam with a certain superheat degree will slowdown the temperature change rate of the component when in is heated, eliminating excessive temperature difference and thermal stress. Another advantage of the variable-parameter starting is shortening the starting time. When starting the turbine under hot state, the temperature of the fresh steam must be higher than that of the easing In order to ensure the successful starting (or stopping) and safety of the turbine, it can be equipped with following monitoring instruments according to the requirement: Casing thermal expansion indicator: It is mounted on the front pedestal of the turbine. The operating personnel can locally monitor the absolute expansion of the casing from the indicator pointer. In the normal condition, the free expansion of the casing under guiding is guaranteed by the sliding-key system of the turbine, the pointer will move Page 3 of 4‘Turbine Stare-up + 1100 oF @t continuously. If one of the sliding Keys is seized due to improper in installation during starting, the movement of the pointer will be seized or jumped. the wirhine vibration wall be increased at the same time. In this case, decrease the turbine speed to ccstain val ‘and run it for a period of time. If the condition has not been impraved yet, the turbine must be stopped and handled Casing absolute dilatometer: It consists of sensor, preamplifier and indicator and may be used in the control room for monitoring the casing expansion. Differential expansion detector: It consists of sensor, preamplifier. indicat and relay module and used for monitoring the differential expansion between the casing. ane the rotor. Besides indicating the normal differential expansion, it has two atari points, (he warning alarm and risk alarm. Once the differential expansion reached to the preset limits, it will send out alarm or trip signal respectively. Eccentricity detector: The eccentricity detector of BENTLY company i @ microprocessor-based detector. It serves to indicate the deflection at the nl determining whether the turbine can be started normally or not. Casing temperature detector: The differential temperature is calculated by a computer according to the temperatures of the top and bottom casings measured with thermocouples. When the differential temperature reached to the permitted mut wll alarm. The speed (load) change of the turbine will be forbidden by the command from the controller. The monitoring instruments mentioned above are optional, except lor the caving expansion indicator. During turbine start-up, the speed, shaft vibration and displacement, bearing temperature and ete must be monitored. Please refer to section fj peration momtocing? 3-2010- for details. ‘Hangzhou Steat Turbine Company Limit Page dat 4enna ee Operating Instructions Preparation prior to Tuebine Starting Bn 3:1220-01.01 Preparation prior to Turbine starting Prior to the turbine starting, some necessary operations and checks should be carried out 80 as to ensure the turbine successful start-up. This section will describe the Preparations prior to turbine cold starting. The preparation concerning in turbine hot starting will be decided based on the shutdown duration The preparations of the operating circumstance, boiler, driven machine and auxiliary devices should be carried out in accordance with the related procedures. i 1.1 The isolated valve and bypass valve before the emergency stop valve are closed, 1.2 The emergency stop valve and control valve are closed. 1.3 The drain valves to the air in the main steam and extraction piping are opened. The drain valves in the piping connecting the casing, balance pipe and extraction pipe to the drain flash tank are closed. 1.4 The inlet valve and drain valve in the steam supplying piping for the gland bush are closed. 1.5 The extraction stop valve and isolated valve are closed. 1.6 The Steam inlet valve, the air valve and the drain valve for the air ejector are closed. 1.7 The steam inlet valve and the drain valve for the gland steam cooler are closed. Steam system 2. Oil system 2.1 Oil quality is checked off. 2.2 Oil level of the oil tank is at normal position. 2.3 The isolated valves of the inlet and outlet for the oil pump and the inlet and outlet valves of the oil cooler and filter are opened. The changeover valves of the oil cooler and filter are placed at the working position. The cooling water inlet valve is closed and outlet valve is opened, 2.4 If the oil temperature in the tank is lower than 20°C, it is required to be heated by a heater or through putting the oil pump into operation in advance. The inlet oil temperature of the bearing during turbine starting must be 35°C 2.5 Starting oil pump: Where the main oil pump is driven by the turbine, start the auxiliary oil pump. Where the oil is supplied by an external pump, start the electric main oil pump. After the oil pump operated, the vibration and noise of the pump should be within normal range, the output oil pressure stable, the control-oil pressure =0.8Mpa, the oil pressure in the lubricating-oil header approx. 0.25Mpa, 2.6 Observe whether the return oil of each bearing is normal or mot through the viewer. Check all of the oil piping joints for no leakage. 2.7 Where the hydraulic accumulator is provided, check the nitrogen filling pressure. ‘The required pressure is given in attached document 0-0300-T-Nr-00. 2.8 Start vapor exhaust fan to form a weakly negative pressure inside the oil tank, return-oil tank, return-oil piping and bearing housing. Usually, it is within 5 to 10 mm H20 during normal operation. Before turbine starting, the vacuum in the oil tank may be a little higher than this valve. But the excessive vacuum will cause a Hangzhou Steam Turbine Company Limited Page 1 of1 Operating Instructions Preparation prior to Turbine Starting 31220-01-08 Targe amount unclean air and steam (0 be drawn into the oil system 3, Steam condensing system 3,1 Where the exhaust is led to the common ‘condenser, the vacuum butterfly-gate is closed tightly. 32 Fill up the steam side of the condenser with watel which should be the condensate ve nceordance to the requirement or treated chemicals fo the level of 3/4 indicated by the level gauge of hot well 43 Fully open the outlet valve of the eyeling water and slightly open the inlet valve: 3.4 Open the water inlet valve of the condenssle PUMP and the cut-off valve in the ait piping from the condensate pump tothe steam, side of the condenser. Close the water pict valve to the boiler feed water system. Afr the condensate pump operated. gradually open the outlet valve of the condensate pump. Open the recycle valve, the ‘vater-supplying valve to the water-sealing element of the vacuum system. The level vrato control system of the hot well is disabled temporarily. 3.5 Putting the air ejector into operation Gradually open the steam inlet valve of the staring 2 ejector until the pressure alter athe valve reached to 0.2 MPa. Warm up the BiPINE for 5 minutes, and then rise the pressure to the normal working pressure Slowly open the air valve between the 2 cjector and the condenser, building up vacuum in the system. When the vacuum reached aoe ot MPa and the condensate pump has worked normally, start the main air ejector ‘Warm up the piping of the main air ejector; open the drain valve of the cooler when the vfeam admitted. Put the second stage of main air e}ecioe first and then the first stare ‘After the main air ejector has operated normally: SP the starting air ejector. Durinr stopping, close the air valve first and then ‘the steam inlet valve. When turbine starting, the vacuum should Be at 2.06 MPa, the be tess than? .053 MPa. mur value ©: 4. Supplying gland steam and barring Ty order to build up the vacuum in the condensing system quickly, itis required supply the gland steam for the gland bush during barring, The attention must be pant that supplying the steam for the gland bush ‘under rotor standstill should be averted “Adjust the supplying steam flow based on the vaci change in time. Meanwhile, nee the gland bush has be supplied with the steam, rotated the rotor as soon as pussies as to avoid the excessive temperature difference between the upper and lower parts of the gland bush. ‘The attention must be paid during turbine hot starting, under barring the pland bush Should be supplied with gland steam first and then start the air ejector to buikl up the vacuum, The cold water or cold steam (the fempera!we ower than casing temperature “hould be avoided entering into the gland bush during supplying the gland stea" Before turbine staring, the barring gear must Pe Put into operation in advance WH longavou Steam Turbine Company Limited Wage 1064sti. dina. eshte. bln ae eens) ee Operating Instructions. Preparation prior to Turbine Starting, 3-1220-01-01 important especially for turbine hot starting. Where the shaft jacking system is provided, ‘enable the barring gear after the jacking system has worked normally. For the turbine with manual or hydraulic discontinuous-type barring gear, the barring gear must be disabled before the rotor rotates. But the interval from stopping barring to rotating the rotor should not be longer than 5 minutes. 5. Protection system Before checking and adjusting protection and control system, the steam source to the turbine must be cut off. 5.1 The emergency trip gear is engaged. The manual trip valve, trip solenoid valve and extraction solenoid valve are at normal operation states. 5.2 Opening emergency stop valve and trip test: Where the trip block is provided, refer to the description in 1-2001-xx-xx. For the turbine without the trip block, see 1-1840-xx-xx. For the extraction turbine, open the extraction stop valve following the emergency stop valve fully opened, and then under valve fully opened, carried out trip tests manually and remotely, respectively. After received the trip command, the emergency stop valve and the extraction stop valve should close immediately. The closing time of the stop valve should be less than I second. 5.3 Where the test slide valve for the overspeed governor is provided, the slide vaive should be at the normal operation position. 5.4 The pressure protection functions for exhaust and extraction are leased temporarily. 6. Control system The control system should be adjusted and tested prior to the first starting for the newly installed turbine or after turbine or control system overhauled. Otherwise it is not required to readjust before turbine starting, except for the routine inspection. If the adjustment is necessary, please refer to section 3-1400-01-xx ffurbine commissioning? For the turbine with hydraulic or mechanic-hydraulic governor, continue to operate the starting control after the emergency stop valve opened for building up the secondary-oil pressure. The secondary-oil pressure 0.15 MPa and 0.45 Mpa correspond to the zero and full openings of the control valve, respectively. When the emergency stop valve tripped, the control valve should be closed simultaneously. Before the turbine starting, set the speed governor at its low limit, Where the extraction is provided, set the extraction controller at zero extraction position. For the turbine with the controlled backpressure or fresh-steam pressure, set the backpressure or fresh-steam pressure controller at its low limit before they take over the control. For the turbine with digital controller, select the manual control mode in open loop on. the controller. Change the output of the controller after the emergency stop valve opened. The minimum output of the controlled corresponds to the secondary-oil Hangzhou Steam Turbine Company Limited Page 3 afda Operating Instructions Preparation prior to Turbine Startin ‘pressure 0.15 MPa from the clecric-hydraulic converter and Zer0 opentie of the contrat valve, while the maximum output of the controller corresponds to the secondary il pressure 4.5MPa and full opening, of the control valve. When the emersency 0)» alve tripped, the control valve should be closed simultaneously. The controlling funetions Lov extraction pressure and backpressure or fresh-steam pressure in the controller are sll at the fifisabled? states. 3.470 61-0 7, Instruments [All of the readings on the primary and secondary are in accordance with current sales the measured parameters. 8. Warming up piping Warm up the main steam piping before the isolated valve. Limited Page 4 of 4 ‘Flangzhou Steam Turbine CompanTT ‘Operating Instructions Starting Turbo-generator ___3.1320-01-01 Starting Turbo-generator Make sure that the preparations have been ready, commence fo start the turbine. 1, Warming up piping To warm up the main steam piping between the emergency stop valve and the isolated valve, gradually open the bypass valve of the isolated valve and then the isolated valve. The warm-up of the piping should be carried out according to the pressure and temperature rising rates specified in the operation procedure. After the pressure before the emergency stop valve reached to the rated value, fully open the isolated valve. 2. Starting Curve The Starting Curve 0-0320-T:NF-00 in the attached document is applicable to your turbine. As showed in the picture below, it consists of two sels of curves. The longitudinal coordinate for the upper set of curves is power ratio P ( P = P/P,, P- turbine actual power, P,~ turbine rated power) or power P (KW), the horizontal coordinate is the time 1, Cmin) required for starting. For the lower set of the curves, the longitudinal coordinate is speed ratio 7 (7 ny» m2 actual speed » ny - rated speed) or speed n (r/min), the horizontal coordinate is the time 1, required for starting, which is the shortest time the turbine speed rose to rated speed from standstill and includes the pre-warming time of the emergency stop valve housing. 1, is the shortest time the turbine load rose to rated value from standstill, which includes ty . Hangzhou Steam Turbine Company Limited Page 1 of fpOperating Instructions 320. Starting Turbo A t Lo Forbidding to stay 3. Opening emergency stop valve Open the emergency stop valve with the Starting control (1-1840-) or the starting valve ‘mounted in the trip block (1-2001.-). 4. Rotating rotor and low-speed warming up Open the drain valves ofthe casing and in the extraction piping. “Page 2 of 3Operating Instructions Starting Turbo-generator 31320-01-01 ‘opened. Where the electric-hydraulie control system is provided, increase the governor output in a preset operating mode (speed control or valve-position control). the control valve will be opened with the raising of the secondary-oil pressure from the celectrie-hydrautic converter. When rotating the rotor under the same working condition as the test running, if the secondary-oil pressure P3> P2? 0.015 Mpa, the rotor is not yet be rotated, stop immediately and find out the reasons. P:? is the secondary-oil pressure at which the rotor begins to rotate during test running, ‘After the rotor rotated, run the turbine set stably at the low-speed warming speed, which js usually 10 to 15% of the tated speed. During warming the turbine at low speed. carefully check the operating condition of the turbine set. After the rotor has been rotated, check and make sure that the electric barring gear has ‘been locked at the disabled position, if it is used. For the turbine with the hydraulic batting gear, close the oil inlet valve to the oil turbine and then stop the shaft jacking system. When rotating the rotor and warming up the turbine at low speed, the attention should be paid in complete drain, When the colorless steam is emitted from the drain port, close the drain valve in time When the level of the condenser hot-weli has been raised and the water quality qualified, gradually open the condensate outlet valve to the feed water system. The automatic control system of the hot-well level may be enabled at this moment. 5. Raising speed Raise the turbine speed from the low warming-up speed to the rated speed in steps. ‘After the turbine speed reached to 80% ny, the inlet oil temperature of the bearing should not be lower than 42°C. When it is higher than 42°C, adjust the opening of the ‘water inlet valve of the oil cooler to keep the oil temperature within the range of 453°C. ‘Where the main oil pump is driven by the turbine shaft, switeh the auxiliary oil pump to the main oil pump when the turbine speed reached to 80~85% ny. For the turbine speed and discharge pressure of the oil pump when changeover, refer to the data recorded during test running. ‘When the governor takes over the control, increase the speed setpoint of the governor raising the turbine speed to the rated speed. Hangzhou Steam Turbine Company Limited Page Sf 5 LEOperating Instruetions Starting Turbo-generator 3:1320-01-01 Usually, when the abnormal condition, such as excessive vibration, occurs during raising speed, lower the speed first and then continue to raise the speed after stabilized for a while. For the turbine with gland steam condenser or pressure control of the gland steam, it is required to adjust in time according to the gland steam condition during raising speed and loading. Afier the turbine speed reached to the rated speed, the vacuum of the condenser should reach to the rated value. The vacuum monitoring may be enabled at this moment. Carry out an overall inspection for turbine operation and prepare for paralleling in network When the turbine is running under no-load, the steam flaw passed through the turbine is very small, it is not enough to carry off the heat in the exhaust section, resulting in the exhaust temperature rose, The excessive high temperature of the exhaust not only will change the turbine center, resulting in vibration, but also may cause the expand joint of the cooling pipe in the condenser loosed. Therefore, the turbine cannot run under no-load at rated speed for a long time and the exhaust temperature must not exeeed 120 G 6. Loading Once the turbo-generator has been paralleled in the network, load up the generator with approximate 5% P, immediately, so as to avoid impact of the reversal load, During loading the turbine set, the loading rate should be controlled. This is because the steam flow passed through the turbine under no-load operation is smaller, so that the turbine is not warmed-up completely. With the increase of the steam flow during foading, the pressure and temperature in steam path is increased, the turbine is heated continuously. In order to keep the expansion and thermal stress of the heated components within the permitted range, the loading rate must be controlled. According to the changing rule of the permitted temperature rising rate, the loading rate in the low-load zone may be a little fast, but in the high-load zone the loading rate must be slowdown. For a cold-starting turbine, it will take approximate 0.35 1, from 5% Py to 50% Py, approximate 0.654, from 50% P, to 100% P,. For the hot-starting turbine, the ratio of the times lasted for different load zone is differed with the shutdown time. In general, with the shorten of the shutdown time, the ratio of the time lasted in low-load zone will be decreased, while that lasted in high-load will be increased When turbine load rises to about 10%~20% Py, the drainage valves of turbine can be closed. Hangzhou Steam Turbine Com Page 4 of 5Hangzhou Steam Turbine Company Limited Operating Instructions ng Tur ut sano urn For the turbine with controlled extraction, the extraction control can be enabled alter the turbine power reached to the minimum power under extraction operating, condi which is given in the Power vs. Flow curve (0-0306-T:Nr-00). When the pressure at the extraction port is higher than the pressure in the extraction line, open the extractions soy valve to supply steam to the extraction line. After that, close the drain valve in the extraction piping and enable the extraction pressure monitoring. The cha extraction flow (increasing or decreasing) should not be too fast, usually, it is about of the rated extraction flow per minute. rate of the For the turbine with non-controlled extraction, when the pressure at the extraction port is higher than that in the extraction line downstream the check valve in loading the turbine, open the non-extraetion stop valve or isolated valve to supply the steam to the extraction line, and then close the drain valve in the non-extraction line. For monitoring the shaft vibration and displacement, bearing temperature, casing expansion and parameters of the inlet steam and exhaust during starting, sce 3-2010-xx-xx Operation Monitoring,Operating Instructions Turbine Commissioning stam oro Turbine Commissioning ‘The commissioning must be carried out first after the turbine-set installed wid betuee put into production. ‘The main purposes of the turbine commissioning are: 1, Allround assessment of the quality for whole engineering, 1.1 The quality of the civil-work design and construction and the quality equipment installation. 1.2 The synthesis performance of the boiler, steam turbine, driven mrachine auxiliary devices. 2. Allround assessment of the capacity of the leader, organization, tcl awd management, as well as the staff diathesis 3. Understanding and mastering the operation rule and eliminating the detect to tay good foundation for normal production. 4. Offering the grounds for perfecting and revising the operating procedure ail 1 hie renovation. In general, the commissioning is carried out in two steps, turbine sole test runniny turbine-set loaded test running. The Commissioning should be also carried ont atier the turbine overhaul, Turbine sole test running 1. Preparation before test running The preparation related to the turbine before test running should be made according. the description in the section #Jreparation before turbine starting? of the Operating Instructions? For the backpressure turbine or the condensing turbine, see 31.1001 xx or 3-1220-O1-xx, respectively. 1.1 Flushing oil system, see 3-0340-01-xx. 1.2 The steam piping blowing includes the main steam piping, the steam inlet piping the ejector and the gland steam piping (condensing turbine). The blowing of the main steam piping, see 3-0350-01-xx. 1.3 Inspecting tightness of vacuum system For a condensing turbine, the vacuum tightness at the steam side of the condenser, in the ‘exhaust section of the rear casing and of the device and piping that are under vacuum state during turbine no-load operation should be inspected With the water-filling test method, the chemical treated water or industrial water cin be used as the filling water. Usually, the water filling level is 100 mm below the gland » recess. Connect a transparent plastic tube as a water gauge before filling the water tor observing, the water level. After inspection, drain out the filled water (the chenvical Hangzhou Steam Turbine Company Limited Page tof SB.Operating Instructions ‘Turbine Commissioning treated water can be delivered to the deaerator. When inspecting with the pressuring method, fill the compressed air with a pressure <0.1Mpa into the casing, the end of the outer gland seal of which is wrapped with rubber or plastic strap. Check the leakage at the flange joint, welding seam, connection, choke-plug, cooling piping of the condenser and expanded joint with soap lye. No matter which method is used, the operating pressure of the exhaust relief valve should be set higher during inspection and restored to the normal value after inspection. Where the rupture disc is provided for the condenser, the disk should be removed and the connection blocked with the blind flange. 1.4 Prepare enough turbine oil with the same type and characteristic as the operating, for adding or replacing when the oil quality disqualified in test running. 1.5 Disconnect the coupling between the generator and the turbine (or geabox). 1.6 Steam and water systems 1.6.1 Set the operating pressure of the exhaust relief valve for the backpressure turbine. 1.6.2 Carry out the changeover test of the condensate pumps and adjust the controller of the hot-well level for the condensing turbine. 1.6.3 Performance test of the air ejector Before starting a condensing turbine, the air ejector has to be operated normally. Put the starting ejector into operation first after the condensate pump has supplied the ejector with cooling water. Open the drain valve of the cooler for main ejector, and then open the steam inlet valves of the second and first stage ejectors in turn. The reading in the vacuum gauge of the main ejector should be reached to the theoretical value (corresponding to the saturation-steam pressure under condensate temperature) when the air valve of the ejector closed. When the air valve has been opened, the turbine turned and the gland seal supplied with the gland steam, the vacuum in the condenser should be reached -0.06Mpa. It cannot be lower than ? .053 Mpa. If this requirement cannot be met, the relative examination and handling should be carried out according to the description in #8 bnormal operation of the air ejector? 3-0320-02-xx. 1.7 Oil system 1.7.1 Interlocking start and stop test of the emergency oil pump. 1.7.2. For the turbine with external oil pump, carry out the interlocking changeover test between the main and auxiliary oil pumps. 1.7.3. Verify the oil-level alarm of the oil tank. Hangzhou Steam Turbine Company Limited Page 2 of 9 GAS:Operating Instructions ‘Turbine Commissioning 3-1400-01-01 1.8 Protective system Before adjusting the emergency stop valve and control system, it must be ensured that the steam source to the turbine has been blocke Measuring the closing oil pressure of the emergency stop valve: Afier the emergency stop valve opened, lower the trip-oil pressure and record the oil pressure at which the valve closed. Where the trip block is provided, lower the ‘rip-oil pressure through losing the valve in the trip-oil line or the discharge valve of the oil pump. When the oil pressure drops to approximate 0.45 Mpa, slow down the lowering rate. For the turbine without the trip block, lower the trip-oil pressure by tuming the starting control clockwise. 1.9 Control system ‘The adjustment of the control system should be carried out when the system oil temperature is higher than 35 ‘C under the slide valve of the pilot valve rotated. The adjusting result should be recorded. 1.9.1, For the turbine using SRIV governor (sec 1-1110-01-xx), input a simulated primary oil temporarily from outside to the governor for measuring the relationship between the primary oil pressure P; and the secondary oil pressure P2, the speed control range as well, against the Governor Characteristic Line (0-2500-T.Nr-00) in the attached document. The speed droop 5 is calculated with the formula 5 = fAPTP, +1~1(where, Ry - primary-oil pressure under rated operating condition, AP, = speed difference between the primary-oil pressure at no-load speed and Ry under the speed setpoint unchanged. Measure the relationship among the secondary-oil pressure P, and the oil-relay stroke fi, and the control-valve stroke /, against the Control Valve Characteristic Line (0-2505-T.Nr-xx) in the attached document. If there is, no stimulated primary-oil source available in site, the secondary-oil pressure can be changed through operating the comparator lever of the governor with the starting control (1-1840-01-%8). Whether the stimulated primary oil is used or not, the #vershoot point? of the governor and the ffut-off point? (see 1-1830-xx-xx) of the amplifier should be checked during adjusting, Readjust them when necessary. If the relationship of P,with f, and h, is required to reset during adjusting, the setting method is given in sections Hontrol Valve? 1-0800-xx-xx and 4il il relay? 1-1910-xx-xx. For the turbine with controlled fresh steam pressure or backpressure, check the related Hangzhou Steam Turbine Company Limited "Page 3 of 9Operating Instructions 1400-0101 functions of the control system through changing the output of the pressure controller Where the controlled extraction is provided, set the extraction controller at lero? or #8 ax? extractions respectively for checking the relationship between the secondary-oil pressure and the stroke of the control valve under different extraction conditions. Check the hydraulic reference value relay (1-1114-01-xx) if it is functioned. 1.9.2 For the turbine using WOODWARD 505, 50SE or other digital governor, check the governor configuration item by item against the Programming Worksheet. If there is 1no error in the governor configuration, switch the governor to the run mode, change the governor output manually for check the relationship between the governor output signal and the secondary-oil pressure delivered by the electrie-hydraulic converter. Measure the relationship among the secondary-oil pressure P, and the oil-relay stroke fh, and the control-valve stroke 4, against the Control Valve Characteristic Line (0-2505-T.Nr-xx) When the turbine uses S0SE governor, check the entered data for operating condition whether they are met with the requirement in service mode. 1.10 Instruments Verify the alarm value and trip value of the instruments used for monitoring the speed, bearing temperature, shaft vibration, axial displacement, lubricating-oil pressure, extraction and exhaust pressures. 2. Turbine sole test running Start the turbine following the instruction in 3-13xx-01-xx. The starting time should be prolonged properly for the first start-up, compared with the starting curve. During test running, fill in the log and make the operation record as required For the high parameter turbine (e.g. H model), the lower pressure steam can be used in sole fest running. 2.1 Rotating rotor for low-speed warming up Record the inlet steam parameters, the secondary-oil pressure and the stroke of the control valve during rotating the rotor. Usually, the speed for low-speed warming is 10 to 15% of the rated speed. 2.2 Raising speed Raise turbine speed according to the starting curve. After the speed reached to the speed low limit of the governor, change the speed setpoint until to rated speed Page 4 0f9 ‘Hangzhou Steam Turbine Companyx Operating Instructions Turbine Commissioning 3:1400-01-01 2.3 Adjusting and testing 2.3.1 Verifying fnction of trip device During low-speed warming or raising speed, make the emergency trip gear, manual stop valve and trip solenoid valve act respectively, the emergeney stop valve and the control valve should be closed immediately. The close time of the emergency stop valve must be less than 1.0 second, 2.3.2 Switching from auxiliary oil pump to main oil pump Where the main oil pump is driven by the turbine shaft, switch from the auxiliary oil Pump to the main oil pump when the turbine speed reached 80 to 85% my and measure the turbine speed and discharge pressure of the oil pump while changeover. Since the oil system used in workshop test running differs with that in site, the changeover speed and oil pressure recorded in the Product Certificate is for information only. The data ‘measured in this test running will be taken as the reference for starting later on. 2.3.3 Setting speed governor fier the turbine speed reached the minimum governor speed, change the speed setpoint to examine the minimum and maximum governor speeds whether they are in conformance to the requirement. For the turbine using SRIV governor (see 1-1110-01-xx for details), if the synchronizing range is not in conformity with the Fequirement, correct the length of the threaded rod for the manual reference-value setter, or adjust the position of the limit nut for the electric positioning gear (1-1850-01-xx). Where the electro-hydraulie control system is used, the actual values of the minimum and maximum governor speeds are usually in conformity with the data entered in programming. If the adjustment is required, correct the assignments for the minimum and maximum governor speeds only under turbine shutdown. 2.3.4 Functional test of emergency stop valve During normal turbine operation, carry out the fimetional test for the emergency stop valve with the test valve (see 1-2300- for details). The oil pressure P. at which the test piston begins to move must less than the permitted test pressure P,. Record the valve of Pp as the comparison reference for this test later on. 2.3.5 Funetional test of emergency governor Where the emergency-governor testing valve is provided, the functional test of the emergency governor can be carried out under normal speed, taking the test data in the Product Certificate as the reference valuc. 2.3.6 Overspeed trip test When the turbine speed reached the maximum governor ‘speed and under the condition that all of the monitoring parameters are in normal, commence the overspeed trip test. The overspeed trip speed is 1.090 1.11 ny. Here ny is the turbine rated speed, Hangzhou Steam Turbine Company “Page 5 of 9Operating Instruetions issioning For the turbine using hydraulic control system, raise the turbine speed continuously swith the conical handle at the front end of the speed governor (see 1-1110- for details). During operating, observe the speed change and listen the sound inside the turbine carefully. Especially when the turbine speed has been close to the acting speed of the emergency governor, press the handle slowly and stably. Once the sound that the eccentric bolt strikes the trip lever of the emergency trip gear is heard and the emergency trip gear is tripped, release the handle immediately. The acting speed of the emergency governor must be witnessed and recorded by assigned person. ‘The reset speed of the eccentric bolt of the emergency governor is higher than the turbine rated speed ny. Therefore, when the speed has lowered to ny after the emergency governor acted, the emergency stop valve and the control valve closed, reset the emergency trip gear; restart the turbine to carry over the next test. The times of the test should be in accordance with the operating procedure. If the emergency governor does not act yet when the turbine speed has been raised to L.1my, stop the turbine immediately for examining and handling. After that, test it again. For the turbine using electro-hydraulic control system, carry out the electric and mechanical overspeed trip tests respectively with the overspeed test function of the governor. Usually, the electrie trip speed is 1.08 ny Ifthe turbine adopts the electric overspeed prevention system (two-out-of-three) and has no emergency governor, it is only required to verify the electric trip speed. 2.4 Operation supervision During commissioning (including the turbine-set test running described below), monitor the turbine inlet team and exhaust parameters, shaft vibration and displacement, bearing temperature, casing expansion according to the requirements given in section fi peration Supervision? 3-2010-Xx-xx. For the first starting, the special attention should be paid in monitoring the vibration and inspecting the leakage of the steam and oil 2.5 Stable operation After all of the tests finished, run the turbine stably at rated speed, the duration should be determined based on the test-running outline and the actual operation condition, 2.6 Stopping . Hangzhou Steam Turbine Company Limited Page 6 of 9‘Operating Instructions ‘Turbine Commissioning 3.1400-01-01 ‘After the stable operation, stop the turbine. 2.6.1 Measuring race time Where the main oil pump is driven by the turbine shaft, gradually lower the turbine speed from rated speed. Afier the auxiliary oil pump has been put into operation, trip the turbine and measure the race time and plot the race curve. For the condensing turbine, the vacuum must be maintained during coasting operation. 2.6.2 Barring Put the barring gear into operation after the turbine stopped. ‘Turbine-set commissioning Start the turbine according to the requirement given in 3-13xx-Ol-xx. During test running, fill in the log and make the operation record as required. ‘The continuous operation duration of the turbine-set under full load is specified by the test-running outline. 1. Preparation Make sure that the generator and electric system are ready for operation. ‘The instruments required for testing the performance of the turbine-set has been connected and are ready for using. Connect the coupling between the turbine and generator. 2. Measuring and tesing 2.1 During rotating, record the inlet steam pressure and temperature, the exhaust pressure (or vacuum), secondary-oil pressure and the control-calve stroke, at which the rotor begins to rotate or accelerate, as the comparison reference for the starting later on, 2.2 Whether the overspeed trip test for the turbine-set under no-load should be made is determined by the operating procedure. 2.3 After the speed reached the rated speed, measure the steam flow of the turbine under no-load and measure the turbine thermal performance and turbine=set performance during loading, 2.4 Determine the relationship between the chamber pressure and steam flow for evaluating the deposit extent of the steam path and load monitoring in operation later on. 2.5 Determine the relationship between the casing expansion and speed (or load). Hangzhou Steam Turbine Company Limited Page 7 0f9 94.Operating Instructions Turbine Commissioning _ . 3:1400-01-01 26 Record the relationship between the axial displacement and the thrust bearing temperature. 2.7 Carry out the tightness test of the vacuum system for the condensing turbine. This should be made periodically after the turbine-set put into operation. To make the test, stabilize the load at approximate 80% of the rated load and close the air valve connected with the air ejector. After 30 minutes, record the vacuum value once a minute for 5 minutes. The average vacuum drop value per minute in 5 minutes should not larger than 667 Pa. If not, the leakage of the vacuum system is in existence, It should be found out and eliminated. 2.8 For the condensing turbine, the condenser thermal performance curves, including the following items, are required to measure. Usually, These tests can be made during turbine-set operation, 2.8.1 The relation curve of difference between ends and cooling-water temperature vs, the condenser load; 2.8.2 The relation curve of the cooling-water flow and steam flow entered into the condenser vs. the temperature rising of the cooling water; 2.83 The relation curve of the absolute pressure in condenser and cooling-water vs, the steam load of the condenser, 2.9 Load rejection test The load rejection only can be carried out under the approval by the local electri authority. power After the full-foad test running of the turbine-set has been normal, arrange to make the load rejection test. Before testing, inspect the interlocking protection devices that are related with the load rejection and release the unnecessary interlocks. At the beginning of the test, the inlet steam and exhaust parameters should be at the rated values and the frequency of the network in normal value. ‘The times and the operating conditions of the load rejection test is decided based on the actual condition, Usually, reject 1/2 of the rated load first, then the rated load, once for cach test, When testing, the relative parameters should be plotted, the data before load rejection. and the peak values in load rejection and the table values after load rejection should be recorded by an assigned person. For the extraction turbine, the load rejection test under the maximum extraction should Hangzhou Steam Turbine Company Limited Page 8 ofOperating Instruetions e 3-1400-01-01 Turbine Commissi be carried out after the load rejection under zero extraction has been pass The control system should be able to stabilize the turbine speed rapidly when load rejection, The highest speed must be lower than the acting speed of the emergency ‘governor. If the turbine speed rises beyond acting speed of the emergency governor but the turbine still not be tripped on load rejection, the turbine must be tripped manually. 3. Stopping Stop the turbine following the instrument in 3-17xx-O1-xx. 4. Measuring race time To stop the turbine set, unload the turbine until to zero load and decouple the generator from the network, then trip the turbine. The speed change with the time from close of the emergency stop valve to rotor standstill should be recorded, based which the race-time curve can be plotted. Where the main oil pump is drive by the turbine shaft, trip the turbine after the auxiliary oil pump has been put into operation. The vacuum should be maintained constant when measuring the race time for the conde Page 9 of Hangzhou Steam Turbine Company Limited oe,\.structions Operating Instructions ator 3+1720-01-01 own af Turborgen ‘ero extraction has been passe s Passe town of Turbo-generator e the turbine speed rapidhutdowa is usually divided into two conditions, the normal stopping and the vr than the acting speed of thency stopping. The stopping following the schedule arranged in advance or based ing speed of the emergency vpcration condition is normal stopping, called as scheduled shutdown or routine on, the turbine must be trippeowsn. The force stopping for avoiding the aceidence worse due to the equipment ‘or aecidence during operation is emergency shutdown. Because of the different 1s ancl purposes for these two kinds of shutdowns, the stopping operations differ 3-17xx-O1-xx, Jinutly, val stopping ntil to zero load and decouple» « turbine normally, unload it first. Because the unloading process is also the speed change with the timeriure deceasing and cooling process for the turbine, it is certain to produce “A should be recorded, basal «tclormation and stress on the turbine components. The condition occurred is main oil pump is drive by thepposite to that during turbine starting, In general, the drop rate of the temperature 1 nas been put into operation: hcated components in the turbine is restricted through controlling the unloading ¢g the race time for the conde» that the changes of the thermal stress and the negative expansion for the casing stor ean be limited within the permissible range. In principle, the operation in the ‘of the stopping is a converse operation of the starting up. E normal stopping, the inlet steam parameters are usually kept constant. The ¢ is unloaded through reducing the steam flow entering it, operating in contrary according to the starting curve. This method is mostly used for the turbine that € shutdown for a long time or overhauled after stopped, which the lower casing ature is required. For the turbine that will be restarted after shutdown for a short the faster rate of unloading can be used in stopping, so that the higher temperature casing ean be kept when shutdown, benefiting the restart traction turbine, cut off the extraction duly based on the unloading conditi at the steam in the extraction line from entering back into the turbine. disconnected the generator from the network, the turbo-set runs under no-load illed by the governor, the no-load running time should be as short as possible Irip the turbine and record the running-out time, which is compared with that wed during commissioning. Where the main oil pump is driven by the turbine, the speed gradually after the generator disconnected from the network and trip the cer the auxiliary oil pump has been put into operation. stopping, the attention should be taken in checking the hot-well level of the niser and adjusting the recycling flow of the condensate. tain vacuum must be kept during a normal stopping (except the emergency ng, which requires the rotor to stop as could as possible through destroying the In), so that the sceper and moisture in the turbine can be vaporized and drawn out. Thou Steam Turbine Company Limited Page 1of3ST aA Nt, Operating Instructions Shutdown of Turbo-generator 3-1720-01-01 Keeping dry inside the turbine and avoiding corrosion during shutdown. Therefore, the | harmonizing operation of the air ejector and the gland steam supply should be carried | out during stooping, otherwise a series of problem will occur. Should the gland steam supply be stopped too early, the cold air will enter into the casing through gland seal, resulting in a rapid cooling of the casing and the rotor partially and wear of the gland seal under serious condition. If the gland steam is still supplied after the vacuum has dropped to zero, a part of steam entered into the casing cannot be exhausted. This may cause corrosion during shutdown and partial deformation of the casing and the rotor. | Generally, stop the air ejector stage by stage with decrease of the speed to drop the vacuum. After the speed lowered below 500r/min and the vacuum dropped to -0.03~ -0.02Mpa, stop the air ejector and gland steam supply. | Stop the condensate pump after the steam inlet valve of the ejector closed. After the emergency stop valve has been closed, close the isolated valve in the live-steam line, Open the drain valve and close the drain valve of the turbine body. | Where the oil-turbine barring gear is provided, put it into operation when the speed will have dropped to about 300 r/min for continuous barring. For the electric barring gear, put it into operation after the rotor came to a full stop for continuous barring (where the zero-speed detector is provided, it can be put into operation automatically). For the hydraulic barring gear, commence a durative barring after the rotor has stopped. The duration of the continuous or durative barring after turbine stopped should not be less than 3 hours. After that, a periodic barring should be carried out. Turn the rotor by 180° in every 30 minutes in first 4 hours and then in every 60 minutes. After 24 hours turn the rotor by 180° in every 2 hours. Before 2 hours the turbine restart, carry out the continuous or durative barring again. Should the shutdown duration be in a long time, the barring may be stopped when the casing temperature <150°C (where the casing temperature measuring point is not divided, the casing temperature can be evaluated from axial expansion amount of the casing, or measured with the temperature gauge at the location of the wheel-chamber under the heat-insulating lagging). ( | After the turbine has been stopped, keep the lubricating oil system in operation for a period to cool the relative components, such as the rotor journal and etc. Stop the oil pump and the oil cooler when the outlet oil temperature of the oil cooler >35°C, the return-oil temperature from the front bearing <40°C and the temperature rise of the bearing <15°C after the oil pump has been stopped. The bearings must be supplied with lubricating oil during barring. Where the jacking system is provided, put it into operation before barring. After the turbine has been stopped, the speed set-point, backpressure controller, extraction controller and other auxiliaries should be returned to their initial position. ‘Hangzhou Steam Turbine Company Limited ——SSSSS*~*~*~*~S«é age OSOperating Instructions Shutdown of Turb Emergeney stopping Any of the following condition occurs in operation, trip the turbine immediately 1) When the turbine speed has been raised to the overspeed trip specd, but it is not tripped. 2) The vibration of the turbine-set increased suddenly to or over the specified limit. 3) The metal contact sound can be distinctly heard inside the machine. 4) Water hammering 5) Sparking at the gland seal. 6) The temperature of any bearing rose rapidly to the specified limit. 7) The axial displacement of the rotor increased suddenly over the specified limit 8) The oil system was on fire and furthermore the fire cannot be extinguished soon. 9) Breakage of the live-steam piping and pressure-oil piping, 10) Vacuum or extraction pressure was suddenly beyond the limit. 11) The generator fault. 12) The auxiliary equipment fault. generator For items with the interlocking protection, such as 2), 6), 7), 10) and ete, the emergency trip is trigged by the trip solenoid valve that received a trip signal from such protection system. Where the items are not provided with the interlocking protection or the protection system is failed, the operator should close the emergency stop valve and the control valve with emergency trip gear, manual trip valve or trip solenoid valve. At the same time, inform the center control room to disconnect the generator from the network. For quick stopping the vacuum may be destroyed after the emergency stop valve and the control valve closed When necessary, the excitation is required for lower the speed quickly. ‘The other operation after the emergency stopping is the same as that for the normal stopping. Page 3 of3 | >— jer per mr oe Operation Instructions Operating Supervision 2010-01-01 Operating Supervision This section describes the monitoring requirements of the main operation parameters for the turbine. For the instrument configuration and fumetion (including monitoring limit) of individual turbine, please refer to fijill of Material? 0-2020-T.Nr-00. Pressure and temperature of live steam To obtain the economic and efficient operation of a turbine, the pressure and the temperature of the admission for the turbine should be kept with the ranges (Excluding, the boiler feed pump turbine), which are given in the Technical Data 0-0300-T.Nr-O0. When the admission pressure of the turbine has exceeded the normal value and tends toward the upper limit, the turbine operator should inform the boiler operator to reduce the pressure at once, When necessary, turn down the isolated valve in the live steam line for reducing the pressure; decrease the turbine load through reducing the opening of the control valve. When the admission pressure of the turbine has exceeded the normal value and tends toward the lower limit, the turbine operator should reduce the turbine load and inform the boiler operator to raise the pressure. ‘When the admission temperature of the turbine has exceeded the normal value and tends toward the upper limit, the turbine operator should inform the boiler operator to reduce the temperature. When necessary, decrease the turbine load through reducing the opening of the control valve. ‘When the admission temperature of the turbine has exceeded the normal value and tends, toward the lower limit, the turbine operator should inform the boiler operator to raise the temperature. When necessary, open the drain valve in the live steam line; decrease the turbine load through reducing the opening of the control valve. The continuous operation under the upper limits of both pressure and temperature for the admission cannot exceed 15 to 20 minutes. The cumulated time in a year should not exceed 20 hours. ‘The pressure and the temperature are monitored with pressure switch and thermal coupling. When the admission pressure and/or temperature reached the reset limit, the alarm and shutdown signal will be sent out. Under the special conditions, such as start-up and commissioning, the admission pressure and temperature of the turbine can differ to the normal values mentioned above. ngzhou Steam Turbine Company Limited Page 1 of8Operation Instructions Operating Supervision 3-2010-01-01 Wheel chamber pressure ‘The wheel chamber pressure is the steam pressure in the department behind the control stage. It is used for monitoring the turbine operating condition and the working condition of the steam-path section. ‘The chamber pressure has a coincidence relation with the steam flow. Under normal condition, the chamber pressure changes with the change of the live-steam flow, please see the attached documents No. 0-2505-T.Nr-00 #haracteristic Line of Control Valve? ‘The maximum steam flow can be restricted through monitoring the chamber pressure, 80 as to avoid aver loading. Chamber pressure also reflects the deposition of the steam-path section, which is related with the steam quality. The deposit on the blade surface not only increases the blade stress, but also decreases the section area of the steam-path, resulting in turbine output and efficiency reduced and the axial thrust increased. If the steam-path is deposited, the chamber pressure will rise under the same steam parameters and flow. With this characteristics, the measured relation of the chamber pressure to the steam flow during operation can be compared with that measured (the live-steam pressure and temperature under different operating conditions should be kept constant) under the clean condition for the steam-path after the turbine has been put into normal operation against #haracteristic Line of Control Valve? 0-2502-TNr-00. The relative increment A P is calculated with the formula Fr=Pro 5.100% , here Pyy is the chamber pressure corresponding to the Pro AP measured flow under clean steam-path, P, is the chamber pressure in current operation with the same steam parameters and flow. AP should not exceed 10%, otherwise the immediate flushing is required (see 4-0600-). Exhaust pressure ‘The exhaust pressure deviation from the normal value for the backpressure turbine will have effect on the turbine output and the safety as well. The excessive high exhaust pressure is going not only against the casing strength, nut also to increase the axial thrust, while the excessive low exhaust pressure will. endanger the blade safety. Therefore, the exhaust pressure during turbine operation is not allowed to exceed the permitted range. The exhaust pressure of the turbine is monitored with the pressure switch. When the exhaust pressure reached the preset limit, the alarm or shutdown signal will be sent, ‘Vacuum in condenser During condensing turbine operation, the vacuum in the condenser will drop and the exhaust pressure rise due to excessively high temperature of the recycling water, lack of the cooling water flow, deposit of the cooling pipe in the condenser, leakage of the vacuum system or bad work of the air ejector. Page 2 of 8 ine CompanyCV ee ee ee Operation Instructions Operating Supervision 3-2010-01-01 The drop of the vacuum will lower the economical efficiency of the turbine-set ‘operation and affect the safety operation as well. Besides the increase of the axial thrust, the exhaust temperature will rise with the increase of the exhaust pressure. The risen temperature of the exhaust portion of the casing may cause the vibration increasing. For the turbine that the bearing housing is integrated with the casing, this will also raise the rear-bearing temperature. The rise of the working temperature of the condenser can affect the condenser performance and safety. Therefore, when the vacuum dropped during operation, the turbine load should be reduced. When the vacuum dropped to ? .06Mpa, the turbine load should be reduced to zero for driving the generator, For the turbine driving the compressor (including blower, pump and etc.), the speed should be lower to the low governor speed or further and the output of the compressor should be disconnected with the system. If the vacuum is kept 2-0.06Mpa and the vibration and bearing temperature are at normal values, the turbine can run under no-load or small load. However, the check should be made in the shortest time to eliminate the defect. If the vacuum continues to drop, the turbine should be stopped. During turbine operation, the exhaust temperature under load should not exceed 70°C, and 120°C under no-load pressure of the first expansion section or the admitting steam pressure for the second expansion section, so that it should be controlled within a permitted range. In some of turbines, the extraction temperature is also he monitored besides the extraction pressure. Bearing temperature The journal and thrust bearings used in turbine and gearbox are hydrodynamic bearings, their normal working is lied on the oil film that can build-up loading capacity. The viscosity of the lubricating oil, which is related with the bearing temperature, plays an important role in influencing the loading capacity in the case that other factors have been decided. Therefore, the bearing temperature must be strictly limited. When the bearing temperature exceeded the specified stop value, the strength of the bearing babbit may be reduced obviously. In order to insure the reliable operation of the bearing, the Extraction pressure For the turbine with controlled extraction, the extraction pressure is either the exhaust 1 bearing temperature should be kept within the normal range during turbine operation. The rise of the bearing temperature during turbine operation is caused by friction power of the bearing and the heat produced in heat exchange. When the heat the lubricating oil takes out is equal to the heat the produce, the temperature tends to be stable. The bearing temperature: = 1, + Ar. Here, is the lubricating inlet temperature, which should be maintained within the range of 45°C (-3°C) , At is the permitted temperature rise of the bearing, which is determined by the measuring method. When Hangzhou Steam Turbine Company Limited Page 3 0f8)ae ed Operation Instructions Operating Supervision 3.2010-01-01 using the thermal resistance or thermocouple thermometers to measure the bearing-pad temperature, the up limit of the normal range for the bearing temperature should be 4, 445°C, while measuring the return-oil temperature of the bearing, it should be 1,420C The temperature rise of the journal bearing is related with the speed and load. Measuring the babbit temperature with the thermal resistance or thermocouple at the minimum oil film at the lower half of the bearing can make a quick reflection of the temperature change for the bearing pad. Where two temperature sensors are equipped for one journal bearing as required by user, the temperature readings on each measuring point are bound to be different. In this case, the journal-bearing temperature monitored should subject to the reading on the measuring point at the minimum oil film related with the rotating direction. When using the thermal resistance or thermocouple thermometer to measuring the thrust-bearing temperature, two temperature sensors (up to four) are usually fitted in cach primary and secondary thrust pad, The temperature rise of the thrust bearing is determined by the speed and axial thrust. In general, the temperature of the primary thrust pad is higher than that of the secondary one. The load on the individual thrust pad at the same side may be uneven, so when the bearing temperature rose, make sure whether the temperature of one measuring-point rose or that of all measuring-points rose. The former indicates that one of the pads is overloaded, while the later reflects the thrust increased, For the monitoring of the temperatures of the journal and thrust bearings, not only the absolute value (1,+At) should be observed, but also the change of the bearing temperature rise should be noticed. Compared with the highest temperature under same working condition in the operation record before, if the temperature rise of the bearing increased suddenly, it cannot be treated lightly even the bearing temperature has not reached the alarm value yet. Should the bearing temperature rose instantaneously and lasted for a very short period, and then it retune to the temperature in normal operation, the partial damage of the bearing is often indicated. In this case, the continuous operation of the turbine may cause the severe damage of the bearing For the alarm and stop limits of the bearing temperature, see 0-2020-T-Nr-00. Oil pressure For the turbine with the oil system using turbine oil as its working medium and the main pump driven by the turbine shaft, the pressure of the pressure-oil is between 0.6~ 1.3Mpa, which is related with the turbine speed. It will be ~0,8Mpa at rated speed. For the turbine with an external_oi] pump, the pressure of the pressure-oil is >0.8Mpa. The ‘Hangzhou Steam Turbine Company Limited Page 4of8eee Operation Instructions Operating Supervision 3.2010-01-01, pressure in the lubricating header is about 0.25Mpa. For the setpoints of the alarm and stop values for drop of the trip-oil and the lubricating-oil and excessive differential oil pressure between the inlet and outlet of the oil filter, see 0-2020-T.Nr-00. Where the pressure gauge is fitted in the oil inlet piping of the bearing, when adjusting the oil flow to the bearing with the throttle valve based on the bearing temperature, the oil pressure is only taken as the reference. The oil pressure behind the throttle valve is not stipulated, In general, the throttle valve is not required to readjust after adjusted in turbine commissioning, For the supervision of the high-pressure fire-resistant oil system, please refer to the related instructions. Shaft vibration Usually, the shaft vibration of the turbine is continuously monitored with the two-channel vibroscope. ‘The turbine has passed the high-speed balance and no-load test run in the workshop before delivering. The value of the shaft vibration recorded in the Product Certificate is the p-p value. The non-vibration deviation of the rotor resulted from the electric and mechanical deviation in the workshop is limited within 6 m. It is bound to produce slight vibration during turbine operates at the given speed and within the given load range. The amplitude will increase in the process of the start of stop, especially when turbine speed passes through the forbidden- to-stay-zone. As long as it does not exceed the permitted range, such a vibration is still normal Under the good installation condition, there are many factors that will aggravate the vibration during turbine operation, such as the uneven expansion of the turbine due to the over-fast rate of loading or unloading, the change of the damping characteristic due to the worsen bearing working status, the change of the original balancing state, water hammer, compressor surging and ete. The abnormal sound is often companied with the aggravating vibration. Therefore, listening the operation sound may be taken as the auxiliary method for monitoring the shaft vibration. When judging whether the vibration is normal or not, the absolute value of the amplitude cannot be taken as the only reference. For example, the measured amplitude js increased from 25 } m to 3031 m under a certain working condition, while under other working condition it is increased from 5 um to 25 m. The former condition does not always indicate the existence of some disturbances, while the latter may foreshow the appearance of the fault, which must be put om alter. The cause resulting in the abnormal vibration should be found out even it does not reach the alarm value, the eorresponcling Hangzhou Steam Turbine Company Limited Page Sof 8 eoOperation Instructions 3-2010-01-01 . “for preventing the operation worsen further. one ewes _ equipped wih Key-phase sensor, as required, to measure the f ines aft vibration for analyzing te vibration characteristic with wtb of te ‘! ce FE Most of ues pn rap? cl _ of two P-P values measured in two orthogonal directions is index for the shaft vibration, The alarm and stop values on 10 18°F nati 1ue but for suggestion. User can reset them based on e the ©. ;, not unidl noe and the standard adopted. sat per mechanical vibration of a turbine-set according to the ing the 8 oe nd 3: 7919 isplacement protective devices, mechanical and electrical ent axial i e used, for the others, only one of them is used mgs OF fem 2 | displacement for the mechanical protective device is about of te 8 peering damaged in operation and the axial displacement of France between the tipping lever and the cam on the rotor, oa stallation, the emergency trip gear acts and trips the ca he rotor from colliding with the stationary parts in axial ial eve gone OE aoement protective device continuously monitor the axial isp!" ect to the thrust bearing through the approximant sensor jal OT, res at-will can send an erly warning forthe thrust bearing damage to e000" of the turbine, For the alarm and stop limits of the axial ba 1, see 0-2020-T:Nr-00. When adjusting the sensor in ro" alue of the total clearance between the thrust collars of the ee dary thrust pads is take as the zero position. 1 rotor is caused by the change of the axial thrust, which is spent OF ng condition and statues. The axial thrust in backpressure 1 isp iC pine sO" spproximately proportional to the live steam flow, The ine One if jppear at maximum power. For the extraction turbine, it does gr will 2Ph orking condition but under a certain middle working Hye FAC gction Condition. During normal operation, the axial thrust extra nge when the load is changed within the given range, so fy, But under abnormal condition, such as overload, worn seam path, over-low live steam temperature and water increased additionally a 1104 wafe' Page 6 0f8 |Operation Instructions Operating Supervision 3-2010-01-01 ‘When the axial displacement is gradually increased during turbine operation, the special attention should be paid to the monitoring of the thrust-bearing temperature. Ifthe thrust bearing temperature exceeds the up limit with the increased axial displacement, reduce turbine load at once. Should the axial displacement continue to inerease towards the stop setpoint after the measures have been taken, trip the turbine immediately. Speed Usually, tachometers are mounted on the local instrumentation panel and in the center control room for monitoring the turbine speed in operation. Where the electric-hydraulic control system is adopted, the digital governor also has the monitoring function for speed. Additionally, some of turbines are equipped with the overspeed protective system using two-out-of three logic. They will continuously indicate the actual speed of the turbine in operation. When the speed exceeded the rated speed or the maxi continuous speed rose to the reset acting value, the alarm or stop signal is sent. For the turbine with continuous barring gear, the barring speed should not be lower than the specified minimum barring speed. If there is any forbidden-to-stay zone (including the forbidden-to-stay zones for turbine and driven machine) in the process of the turbine starting and stopping, make the turbine speed pass through this zone quickly and continuously in operating. With the governing system the turbine runs stably within the specified speed and load. For the turbo-generator, after load rejection of the generator, the speed will rise instantaneously and then stabilize at the up governor speed under normal condition. During turbine operation, If the turbine speed is out of the control and rise to the stop value reset but the protective device has not acted yet, manually trip the turbine at once with the manual stop valve, emergency trip gear or the stop solenoid valve that receive the stop command from the control room ‘Thermal expansion of casing During turbine starting and operating, the sliding-key system can guarantee the casing to expand freely but maintain the center unchanged. If it is not adjusted properly in installation or the foreign force and moment that exceed the permissible value are acted on the casing, the expansion of the casing in radial or axial direction is obstructed, causing abnormal vibration of the turbine. ‘The thermal expansion of the casing in the axial direction is usually monitored with the expansion indicator mounted on the front pedestal. The casing expands forwards when heated and constricts when stopping, taking the dead point as the reference. The expansion of the casing when heated should be continuous. The appearance of the step change in expansion indicates the expansion obstructed, It is required, at any moment, to check the clearances of the bolt washers on the front and rear supporting brackets of Hangzhou Steam Turbine Company Limited Page 7 of 8Operation Instructions Operating Supervision 3-2010-01-01 the casing, The washers should be always in free statues, Race time ‘The soundness of the turbine can be judged through measuring the race time during normal stopping and comparing it with the race time measured in commissioning under the same operation condition. If the race time measured currently is shorted obviously, the rotor may be contacted with the stationary parts or bearing defect existed. While the prolonging race time indicates that the steam leaked into the casing because of the untight close of the emergency valve and control valve. AS the requirement in the order, the turbine may be equipped with casing-temperature detector, absolute casing-expansion detector, differential expansion detector, rotor eccentricity detector and etc. for monitoring the temperature deference between the top and bottom casings, the thermal expansion of the casing in axial direction, the relative expansion of the casing and the rotor and the flexural deformation of the rotor Hangzhou Steam Turbine Company Limited Page 8 of 8Nye er Operating Instructions 3.3010-01-01 Abnormal Vibration The turbine is a rotary machine in high speed, so vibration in different amplitude and direction will occur in its operation. Any of the vibration that is within the limited range is permitted and has no harmful to the machine, But some times the abnormal vibration will occur during turbine operation for various reasons, especially during commissioning. According to the statistics of the vibration troubles, most of the abnormal vibrations are caused by improper installation or misconduct in operation and maintenance. Since the turbine rotor has been balanced and passed the no-load running test before delivery, it usually is not required to rebalance, except for the rotor that has been repaired, bended permanently or which parts have been replaced. If the abnormal vibration occurred during turbine-set starting and operating, carry out the test and analysis by means of the frequency spectrograph or other real-time analyzer for finding out the reason and resolving it based on the vibration characteristies 1. Poor quality of installation or overhaul 1.1 Due to the poor quality of the back grouting, the turbine pedestal (baseplate) did not joint to the foundation tightly, the anchor bolts ware loosen and the foundation sunk unevenly. If you stand near by the turbine when raising the turbine speed, you will fell the foundation is vibrating with the turbine. The amplitude change of the shaft vibration is not evident; the vibration signal contains the low-frequency component. While the amplitude of the bearing housing increases obviously and is unstable. In this case, the best solution is to reinstall the turbine. 1.2 Piping 1.2.1 Steam piping Due to forced connection of the mis-positioned flanges or unreasonable piping layout, the force and torque acting on the turbine exceed the permitted values. The abnormal vibration is marked by: the vibration is related with the turbine hot state, the amplitude will increase obviously at a certain load (temperature), the vibration frequency is in step with the turbine speed, the vibration signal contains the low-frequency component. Measure the vibration of the shaft and the bearing housing at the front and rear sections of the turbine, if the larger vibration appears at the front section, the steam inlet piping is likely to be with the problem. If the larger vibration is at the rear section, it is mostly caused by exhaust piping, Measure: Reconnect the piping according to the requirement or adjust the piping supports. 1.2.2 Inlet and outlet piping of the main oil pump ‘The disturbing force of the piping caused by forced connection of the mis-positioned flanges make the turbine vibrate abnormally. With the rising speed, the vibration at the front bearing housing will increase obviously. The vibration signal contains the low-frequency component. Hangzhou Steam Turbine Company Limited Page 1 of 5Fanner ee Operating Instructions Abnormal Vibration 3:3010-01-01 Measure: Reconnect the piping according to the requirement. 1.3 Improper assemble and adjustment of turbine slide-key system ‘The thermal expansion of the turbine is restricted during start-up and operation, so that the alignment of the rotor with the casing and bearing housing is destroyed, resulting in vibration, which is related with the turbine hot-state, The vibration frequency is in step with the turbine speed. Measure the vibration at the front and rear bearing housings for judging which guide key to be seized Measure: Stop for inspecting and readjust the guide element. 1.4 Poor alignment 1.4.1 Poor alignment of turbine rotor with casing If the rotor is not aligned with the casing properly during turbine installation, the abnormal vibration will occur during turbine test running. In the course of the turbine ’ starting, the moving parts will collide with the stationary parts with the increasing speed and inside temperature so that the amplitude of the shaft vibration will increase with a squeal of metal friction. The vibration signal contains high-frequency component, with disturbing waveform Measure: Stop the turbine and recheck the alignment, repair or replace the damaged sealing strips, 1.4.2 Poor alignment of turbine rotor with driven-machine rotor The turbine has passed the test running, but the abnormal vibration occurs during turbine-set test running. Ifthe double frequency harmonies is included in the vibration waveform, the abnormal vibration is caused by the poor alignment of the rotors. Measure the vibration of the bearing housing: the increase in the axial amplitude indicates that the parallelism of the end face is out of condition, while the increase in the radial amplitude indicates that the deflection of non-axiality is excessive. The both often exist simultaneously. ‘Measure: Stop the turbine and realign the rotor. If the realigning is not allowed at the ’ moment for some extemal reasons, the imbalance correction can be carried out at the secondary balance surface of the rotor. But this is only a makeshif, the final solution is to realign and rebalance the rotor after the turbine stopped. 1.4.3 Alignment under cold state is conformed with the requirement, but the center is deviated during operation {In addition to the same characteristics mentioned in 1.4.2, the vibration characterist is related with hot state of the turbine set. For the backpressure turbine, the vibration at its driving end will increase obviously when the load or the exhaust temperature Teached to «certain value. For the condensing turbine, the temperature of its exhaust noz/le during operation is high than the ambient temperature when installation, If the re-pulling amount is too small when installing, the expansion of the exhaust nozzle during operation will raise the center of the turbine rear bearing. Meanwhile, the Inside ol the exhaust casing is under vacuum during operation, the exhaust casing Hangzhou Steam turbine Company Limited Page 2 of 5TSE Ko oH ew RE a) Operating Instructions Abnormal Vibration under the action of the atmospheric pressure will lower the center of the rear bear Therefore, the vibration resulting from the center change of the bearing is related with the exhaust temperature and vacuum. Measure: For the backpressure turbine, re-measure the aligning data immediately atier the turbine stopped and correct the aligning value under cold state based on these measured data, For the condensing turbine, maintain the vacuum as could as possible through barring and supplying the gland steam after the turbine stopped, check the aligning value and correct the aligning value under cold state based on these measure data 1.44 For the turbine coupled with the driven machine via a gearbox, if the offset ol the gear shaft when aligning the rotor is not conformed with the actual condition, the vibration and noise of the turbine will increase obviously when the load reached to a Certain value. The vibration waveform contains high frequency harmonies. The high frequency is synchronous with the working frequency. Measure: Stop the turbine and check the aligning valve of the turbine rotor with the gear shaft. Correct the aligning value according to the direction of the gear engagin force. 1.5 Bearing ‘The carrying capacity of the multi-wedge bearing is related with the arrangement of the oil wedge. The split of the four-wedge bearing should be angled of 45 ° to the split of bearing housing, this makes the load just be supported on the center of the oil-wedge during operation. If the four-wedge bearing does not be tumed by 45 when installing on site, the carrying capacity of the bearing will decrease. Therefore. during turbine operation the vibration will be increased in a sudden once the load reached to a certain value. The vibration signal contains eddy signal at a frequency lower than the working frequency. Measure: Reassemble the bearing according with the requirement. 1.6 The axial positioning between the turbine and the driven machine is not conformed to the requirement, especially for turbine that is directly coupled with the generator. During operation, the expansion of the turbine rotor will push the generator rotor to move axially. If the axial clearance between the moving and stationary parts of the generator is less than the axial expansion of the turbine rotor, the moving part will collided with the stationary one, resulting in turbine to vibrate violently with a loud noise, finally damaging the equipment. Measure: The turbine must be positioned correctly when installation. The amount of the axial expansion for the turbine rotor is given in the attached document 0-0341-T.Nr-00. 2. Operation 2.1 Poor behavior of bearing Insufficient lubricating oil, disqualified oil quality (emulsification, a lot of bubbles, Hangzhou Steam Turbine Company Limited Page 3 of 5Operating Instructions nal Vibration 3-3010-01-01 impurities and water contained in the oil), abnormally low oil temperature, excessive bearing clearance will cause the oil film of the bearing unstable. The eddy motion of the oil film results in discontinuous vibration with irregular waveform and abnormal noise. The vibration frequency is not in step with the speed. Measure: Take the corresponding measures according to the reason found out Abno: 2.2 The water contained in the steam causes the temperature of the admitted steam to drop suddenly, forming a water hammer. The turbine set vibrates. intensively companied by toneless roar: Measure: Stop the turbine immediately, drain the inlet steam and exhaust piping thoroughly, reinforce the monitoring of the boiler operation 2.3 The deposit and corrosion of the steam path section due to the poor steam quality will destroy the rotor dynamic balance, resulting in turbine vibration. In this ease, the vibration is increased gradually with prolong of the operation duration. Usually, it does not occur suddenly, except for blade breakage. The vibration frequency is in step with the speed Measure: The deposit content on the blade can be evaluated from the temperature of the thrust bearing and the pressure change after the control stage. Clean the deposit in time when necessary or during overhaul. 2.4 The drop of the vacuum for the condensing turbine will raise the exhaust ‘temperature and consequently change the rotor alignment under hot state, resulting in turbine vibration, In this case, the vibration at the rear end of the turbine often increases obviously. The vibration frequency is in step with the speed. Measure: decrease the load and raise vacuum. Return the turbine to original operating condition after the vibration reached to the normal value. 2.5 For the turbine that has been put into operation, most of the abnormal vibrations occurring during starting or changing load are caused by improper operating, such as improper barring after lat stopping and insufficient warming-up during staring. Ifthe abnormal vibration occurs during raising speed and the noise of the metal friction at the front and rear gland bushes can be heard, it indicates that the rotor has been warped (where the eccentric monitor is provided, it can be used in measuring the warping amplitude for the rotor. At this moment, the turbine speed should be lowered and maintained at a stable value after the vibration returned to normal for warming-up for about 15 minutes (the speed can not stay in the prohibition range), and then raise the speed again. If the abnormal vibration still cannot be eliminated after 3 repeats, the turbine must be stopped, check and repair the rotor. Fast load changing also causes the vibration due to deformation of the uneven expanded components. If the vibration occurs in loading, unload or lower the turbine speed immediately. After stabilized, load the turbine (or raise speed) according to the change rate given by the staring curve. Jf the vibration occurs in unloading, operate Hangzhou Steam Turbine Company Limited Page 4 of 5¢ Instructions Abnormal Vibration $308 the turbine in steps opposite to that mentioned above. 2.6 For the turbine driving compressor, if the abnormal vibration only appears certain load, it is mostly caused by the compressor and the characteristics of the network. Measure: When changing load to near this load, slow down the «h properly. ning 2.7 For the turbine diving compressor, the imprudent operation when reduc ig MP compressor flow or the improper set of the surge-proof system will case the (urbigg set running in the surging zone, resulting in sharp fluctuation of outlet pressure of iG compressor and consequently intensive vibration of the turbine and the «ompresaag ‘outlet piping companied with a loud noise. j Measure: Trip the turbine set. Operate the turbine set according with the rotated ‘operating procedure to prevent the compressor running in the surging sone 3. Defect of equipment 3.1 Toothed coupling The eccentric load produced by the floating parts of the coupling under the centetfagal force due to the existed backlash will cause vibration. Under the normal condition, a. vibration of the turbine will increase with the raising speed after the turline sane but the amplitude is within the permitted range. Additionally, under the action of ei centering the eccentric load will decrease with the increase of the torque the coupling is transferring, stabilizing the operation. But the excessive backlash restlted fram machining error or wearing may cause the amplitude to exceed the up limit with the increase of the turbine speed. Measure: Check the coupling during overhaul, improve the lubrication and replace the coupling when necessary. 3.2 Generator The vibration occurs when raising the generator voltage, but it disappears after the excitation of the generator released. This indicates that the vibration is caused by the unbalance magnetic field, which is arose from short-circuit of the generator wunding ‘or the uneven air gap between the generator rotor and stator. Measure: Inquire the electric technician. Hangzhou Steam Turbine Company Limited Page 5 uf 5