Site Operating Procedures

Title:

STG STARTUP

425MW Nandipur, CCPP.

Prepared by: Date:

Reviewed by: Date:
Approved by: Date:

Albario Engineering (Pvt.) Ltd

 1. PREFACE

As compared with regular turbine, the steam turbine for combined cycle has its specialties in
fundamental regulation and operation mode. The output power of steam turbine changes with the
operating conditions of gas turbine, thus regulation of output power of power plant simply becomes that
of fuel charge of the gas turbine. Due to this characteristic, when output of the steam turbine for
combined cycle is less than 50% of the rated power, HP governing valve and HP bypass involve in
regulation and it operates under constant pressure. When the power is more than 50% of the rated power,
control valve of the turbine is fully open and not involving in pressure regulation any more.
Therefore, the turbine itself does not take part in primary frequency modulation and secondary frequency
modulation of the grid, which of the whole plant are realized by the gas turbine separately, this is the
basic regulation characteristics of the steam turbine for combined cycle.

Startup operation and shutdown procedures of the unit specified in the Instruction shall only be used as
reference if users for preparing field operation specifications. The user can make corrections in practices
based on accumulated operation experience, but each control index in startup based on accumulated
operation experience, but each control index in startup operation shall be as specified in the Instructio ns.
As for initial startup of a new machine, properly reduce its speed-up rate and loading up rate, and
properly prolong stable operation duration at each load point.

Startup status of steam turbine is determined via metal temperature of the lower inner casing before
startup, detail of which are shown as follows:

 Cold start: = 200°C

 Warm start: 200°C ~390°C
 Hot start: = 390°C

Rev 0 2 of 10

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 2. PREREQUISITE

 All LOTO have been closed properly.

 Perform physical inspection around the ST and auxiliaries.
 Check lube oil levels are normal and all oil reservoir are fulfilled.
 Power Supply is available.
 Firefighting system is healthy.
 Aux cooling system is in service.
 All equipment must be normal and on remote operation.
 Verify STG instrument air compressor is in service and pressure is normal and standby source
is available.
 Standby power source (EDG) must be available.
 Turbine Eccentricity is within range.
 All STG protection systems are healthy and emergency trip is available.

2.1. The following drains must be opened prior to startup.

 Drain of the casing of HP main steam governing valve.

 Drain of HP main steam pipe.
 Drain of the casing of LP combined steam valve.
 Drain if self-sealing system and gland steam supply pipe.

2.1. TSI measurement data displayed is within allowable scope and the following key records shall
be made before impulse starting:

 Absolute expansion of casing

 Differential expansion.
 Axial displacement.
 Shaft eccentricity and turning current.
 Temperature of the upper and lower inner walls at the steam inlet of casing.
 Temperature of each bearing bush and return oil.
 Temperature of the inner and outer walls of the casing of HP main steam valve.

Pre-Startup Checks/Tests
Step Procedure
No:
1 Engage STG turning gear by pressing SV
ACTION push button from STG TG motor
local panel. Verify TG lever is engaged
completely and limit switch is operated. Press
TG MOTOR ACTION push button.
2 Prepare HRSG as per standard procedure,-----
and generate steam.
3 Start Industrial cooling water pumps or start
CW self-cooling raw water booster pump.
Observations
Verify STG is at 0 speed before TG
operation. Lube oil system and jack oil
system is in service and temp and pressure
are normal. STG TG power supply is
available. Once the TG is engaged observe
rpm reaches at 4rpm. Keep STG on TG at
least 2 hours prior to startup.
Observe the drum levels, steam quality and
required temperature and pressure of
HP/LP live steam.
Ensure the cooling water flow is normal.

Rev 0 3 of 10

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 4 Start ST CW system and start CT fans as per
requirement of temperatures.
5 Put Aux: Boiler in service and open Aux:
steam gland valve. Throttle control valve
manually to maintain desired temperature and
pressure.
6 Close vacuum breaker MOV. Start vacuum
pump and maintain.
7 Put HP/LP bypass steam in service.
8 Check permissive of main HP Steam header
temp and pressure MOV. Open drains of
header and MSVs.
9 Open main HP steam HRSG MOV when
parameters are normalized.
(Cold; temp=320°C; pressure=3.8 MPa,
Warm; temp=400°C; pressure=3.8 MPa
Hot; temp=480°C; pressure=3.8 MPa,)
10 Open HP/LP Steam Header Charging valve
i.e. HP Steam In MOV 2.
1 Open HP Steam In MOV 1
12 Perform AC/DC lube oil pump interlocking
test by stopping T/G from HMI. Stop AC lube
oil pump from HMI.
13 Perform EH oil pump interlocking test. Start
EH oil pump and its oil recirculation pump.
14 Go to DEH menu from HMI, select Control
Mode on AUTO and select LATCH.
15 Perform turbine emergency trip test from
CCR desk. Push turbine emergency trip push
buttons from CCR desk.
16 Perform turbine emergency trip test from
local trip. Pull turbine emergency trip lever.
17 Switch OFF STG space heaters MCB, located
inside generator enclosure.
18 Put HP bypass steam valve on AUTO and
press CONNECT to header.
19 Again verify the steam temp & pressure
permissive from screen and select LATCH.
Rev 0 4 of 10
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Check header discharge pressure, put
standby pump on auto.
Verify there is no condensation in gland
steam piping, drain if necessary. Maintain
header temperature upto 150°C ~ 250°C
and pressure up to 0.123 MPa.
Maintain vacuum of < -85 kPa. Check
vacuum pump physically and observe any
abnormal sound coming of it. Run
secondary pump if necessary.
Observe the CW inlet and outlet
temperature and HP/ LP bypass de-super
heating spray and bypass line temperature.
HP bypass temp & pressure must be lower
than 210 ºC and 0.8MPa and LP temp
180ºC and 0.5MPa.
Verify temperatures difference of HP live
steam must be ≤ 50º C of HP front lower
HP cylinders outer surface temperatures.
Check valve position from local and
observe the header pressure and
temperature.
Check valve position from local and wait
for a while to ensure priming of governor
piping.
Observe physical condition of valve and
conform its operation from local.
DC lube oil pump will come into service
check the discharge pressure. After test
performed successfully engage the TG
motor.
Observe the discharge pressure from local
as well as from HMI.
This action will enable control mode to
detect STG startup mode on either cold,
warm or hot.
Conform EH oil is released and TRIP
signal is on DEH screen.
Conform EH oil is released and TRIP
signal is appeared on DEH screen.
Verify from HMI.
Observe for AUTO operation of bypass
control steam valve with HP main steam
 STG is ready for rolling.

Rolling Procedure.
Step Procedure Observations
No:
20 Observe the 100% opening of MSVs from
HMI as well as from local. If the required
temperate before MSV is low than just
Go to “Auto Control” from DEH menu and open the MSV and associated drains to
select RUN. This action will open the MSVs. achieve required temperatures by selecting
RUN command from DEH menu.
Reconfirm the target is 0 from CONTROL
SP before selecting RUN command.
21 Go to “Control SP” from DEH menu. Input Observe the RPM of machine and
TARGET =3000, SPD Rate = As per Startup especially vibration on bearings from local
mode (Cold=150, Warm=250, Hot=300) and as well as from Axis VB screen in HMI..
LD Rate =According to startup Keep concentration on HP drum level.
(Cold=1MW/min; Warm=2MW/min; Ensure the thermal expansion of HP/LP
Hot=3MW/min). Select GO to proceed. cylinder value is within range.
Hold STG at 15MW for 20 minutes in cold
startup for warming.
22 Stop turning gear motor at > 4 rpm from Check motor status from local. Observe
DCS. auto stop operation of jacking oil pump at
≥ 1200 rpm, if not stop on auto stop pump
manually.
23 Ensure the rpm reaches at 3000, observe main DC lube oil pump will come in service,
lube oil pump header pressure maintained at stop DC lube oil pump.
1.86MPa and stop AC lube oil pump.
Note: After sync as per procedure close drains of STG at 25% load.
: If the startup of STG is cold, warmup ST by hold ST at 500 rpm for 15 minutes.
: During speeding-up or loading up, immediately trip and stop the machine in case of any
abnormal vibration, or reduce the speed or load down till it becomes normal; operate stably at the
speed or under the load, find out the cause(s) and continue speeding up or loading up after
troubleshooting, otherwise, trip and stop the machine.

24 Put LP bypass steam valve on AUTO and
press CONNECT to header.
25 When load is about 30MW. Select ADM
Control window and select auto and select
“Adm Control” and select LP SLP.
Observe for AUTO operation of bypass
control steam valve with LP main steam
Before admission control maintain temp at
LP header difference of 30ºC.Observe the
LSV is 100% opened and LCV is opening
gradually and load is increased. Check LP
exhaust temperatures from DEH menu.

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PREREQUISITE

 All LOTO have been closed properly.

 Perform physical inspection of ST and auxiliaries.
 Grid must be available & energized on DCS.
 Power Transformers oil levels must be normal.
 Control (DC) power supply must be available.
 Isolators must be closed and earth switches must be open.
 No any alarm on any breaker or panel in ECR.
 Firefighting system is healthy.

Synchronization Procedure
Step Procedure
No:
1 Reset Excitation panel and generator
Protection lockout relays. Close STG
excitation FCB from HMI in main electrical
system.
2 Insert the jumper LK_CLS_SYN (E4Q2) of
desired breaker from the automatic
synchronization panel located in CCR.
3
4 Turn ON excitation system from HMI.
5 Go to ST SYNC select SYN POWER ON
6 Select SYNCH REQUEST and select Auto
Sync from control mode in DEH menu.
7 Select 142CB (E4Q2) SYN START
8 Select SYN POWER OFF and observe
loading.
9 Select TCP Control and SLP Control and
close E4Q3 CB from ECR/DCS.
STG is now at max load
Observations
Ensure no alarm on HMI and panels.
Verify permissive appeared on sync
breaker E4Q2.
STG excitation will be energized, observe
the generator terminal voltages. Adjust the
ST Main transformer output voltage
matched with switch yard bus bar via
generator excitation current by applying
Remote LOWER and Remote RAISE
command.
This action will energize supply on STG
sync panel. Verify power is available.
The action enables the synch scope to
rotate, observe the direction of needle.
Verify the E4Q2 breaker is closed and STG
is synchronized. Observe STG vibration.
Observe sync panel power is OFF.
Observe load and vibration

Rev 0 6 of 10

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 3. SHUTDOWN OF STG.

Shutdown of the unit can be divided into shutdown at sliding parameters, shutdown at rated
parameters and emergency shutdown.

3.1 Sliding Pressure Shutdown

Shutdown at sliding parameters: it is mainly for reducing metal temperature of the casing to a lower
level after shutdown, and usually used for scheduled shutdown such as light repair and overhaul.

Preparations:

 Test the AC/DC lubrication oil pump and turning motor, which shall work normally.
 Confirm that the main steam valve and governing valve operate smoothly without binding.
 Warm up the pipe for auxiliary steam source of shaft gland.
 Bypass de-superheating system must be available and work on auto.

Cooling, depressurizing and loading down of the turbine shall be based on sliding parameters of boiler.

SP Shutdown Procedure
Step No: Procedure
1 Ensure ST load is reducing. Watch the
Start decreasing the load of GT.
2 Ensure ST is at 39MW and the following
Stop reducing the load of GT when ST load
reaches to 39MW.
3 Put HP/LP bypass system in service. (When
the temperature of HP live steam is ≤ 30 ºC
than the temperature of HP turbine inner wall
of casing)
Observations
HP/LP live steam temperatures pressure
and drum levels.
parameters must be fulfilled:
 Temperature drop rate of HP steam:
less than 1.0 - 1.5 ºC /min
 Pressure drop rate of HP steam: less
than 0.03-0.05 MPa/min.
 Superheat degree of HP steam: more
than 50 ºC.
 Metal temperature drop rate of HP
casing shall not exceed 1ºC /min
 Loading down rate: 0.2-0.3MW/min
Ensure the following parameters are
fulfilled:
 The differential expansion is less than -
0.5mm. If expansion is less than -0.5
shutdown ST immediately.
 Make sure the HP/LP bypass line
temperatures not exceed.
 HP bypass temp & pressure must be
lower than 210 ºC and 0.8MPa and LP
temp 180ºC and 0.5MPa.

Rev 0 7 of 10

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 4 Open all drains valves of ST.
5 Initiate trip and shutdown the unit when the
load drops to 5% rated load.
6 Stop vacuum pump and open vacuum
breaker MOV at 300 rpm.
7 Stop gland sealing steam valve and its drains
at zero vacuum and stop glad sealing fan.
8 Engage STG turning gear at zero rpm by
pressing SV ACTION push button from STG
TG motor local panel. Verify TG lever is
engaged completely and limit switch is
operated. Press TG MOTOR ACTION push
button.
9 Stop TG when HP turbine upper inner valves
temperatures reaches below 150 ºC
10 Stop AC lube oil pump after 8 hours of shaft
zero speed detection. Put DC lube oil pump
on local operation.
11 Stop ST auxiliary. (Lube oil exhauster, EH
oil)
STG is now Stand Still.
Ensure load on STG must be 25%. Verify
gland sealing header temperature &
pressures, throttle valve if necessary.
Ensure diverter damper is 100% closed,
close manually if required.
AC lube oil pump start on auto, observe the
discharge pressure of lube oil pump.
Ensure when ST is at 1200 rpm jack oil
pump start on auto.
Observe vacuum is decreasing.
Check for any abnormality on local.
Verify STG is at 0 speed before TG
operation. Lube oil system and jack oil
system is in service and temp and pressure
are normal. STG TG power supply is
available. Once the TG is engaged observe
rpm reaches at 4rpm. Keep STG on TG at
least 2 hours prior to startup.
Verify shaft is at zero speed and jack oil
pump is stopped.
Inspect ST physically and auxiliaries.
Confirm no mist is in lube oil tank.

3.2 Normal Shutdown

Shutdown at rated parameters: it mainly aims at startup in good time after short-time defect
elimination to maintain metal temperature of the casing at a higher level and reduce the startup time of
the unit.
Shutdown at rated parameters is generally applied for peak regulation unit only shutdown for several
hours or other short time shutdown. It can leave a high metal temperature after shutdown, which is
good for restart and putting into operation quickly

Preparations:

 Test the AC/DC lubrication oil pump and turning motor, which shall work normally.
 Confirm that the main steam valve and governing valve operate smoothly without binding.
 Warm up the pipe for auxiliary steam source of shaft gland.
 Bypass de-superheating system must be available and work on auto.

Normal Shutdown Procedure

Step No: Procedure Observations
1 Ensure ST load is reducing. Watch the
Start decreasing the load of GT with rate of HP/LP live steam temperatures pressure
1MW/min. and drum levels.

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 2 Stop reducing the load when the temp &
pressure of HP steam at header becomes 400
ºC and pressure is about 3.8 MPa.
3 Put HP/LP bypass system in service,
according to operation of the HRSG and
changes of HP/LP steam pressure.
4 Open all drains valves of ST at 25% load.
5 Initiate trip and shutdown the unit when the
load drops to 5% rated load.
6 Stop vacuum pump and open vacuum
breaker MOV at 300 rpm.
7 Stop gland sealing steam valve and its drains
at zero vacuum and stop glad sealing fan.
8 Engage STG turning gear at zero rpm by
pressing SV ACTION push button from STG
TG motor local panel. Verify TG lever is
engaged completely and limit switch is
operated. Press TG MOTOR ACTION push
button.
STG is now Stand Still.
Ensure de-loading is smooth and load is
reduced gradually.
Ensure the following parameters are
fulfilled:
 The differential expansion is less than -
0.5mm. If expansion is less than -0.5
shutdown ST immediately.
 HP bypass temp & pressure must be
lower than 210 ºC and 0.8MPa and LP
temp 180ºC and 0.5MPa.
Ensure load on STG must be 25%. Verify
gland sealing header temperature &
pressures, throttle valve if necessary.
Ensure diverter damper is 100% closed,
close manually if required.
AC lube oil pump start on auto, observe the
discharge pressure of lube oil pump.
Ensure when ST is at 1200 rpm jack oil
pump start on auto.
Observe vacuum is decreasing.
Check for any abnormality on local.
Verify STG is at 0 speed before TG
operation. Lube oil system and jack oil
system is in service and temp and pressure
are normal. STG TG power supply is
available. Once the TG is engaged observe
rpm reaches at 4rpm. Keep STG on TG at
least 2 hours prior to startup.

3.3 Emergency Shutdown

Emergency shutdown: it is mainly applied when an accident happens with the unit, the safety of
personnel and equipment is at risk, or irresistible natural disaster happens accidentally.

Precautions of emergency shutdown:

 HP main steam valve and governing valve shall be closed

 LP main steam valve and governing valve shall be closed
 AC or DC lubrication oil pump shall be put into operation immediately
 Fully open all drain valves of the turbine.
 Ensure personal safety and no damage or less damage to equipment when dealing with
accidents
 Stop the failed equipment immediately when an accident happens to the unit, and take
precaution to prevent its spreading; keep running other good equipment if necessary.
 Accident treatment shall be quick, accurate and decisive.

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  The site shall not be disturbed, especially data recorded before the accident and when it
happens by meters and instruments for analyzing the cause and identifying the
improvement precaution for reference.
 After the accident is eliminated, operator on duty shall completely and accurately record
the observed phenomenon, operating parameters of the time, treatment process and
occurrence time for related personnel to inquiry when analyzing the cause.

The conditions of emergency shutdown with break the vacuum

Under the following conditions, immediately break the vacuum for emergency shutdown after tripping
the unit:

1. The unit vibrates intensively with bush vibration amplitude above 0.10mm.
2. There are distint metal friction noise and impact noise inside the steam turbine or generator.
3. Hydraulic shock happens to the steam turbine or HP steam temperature reduces more than 50℃
in 10min
4. Return oil temperature of any bearing rises up to 70℃ or any bearing is lack of oil and smoky
5. Babbitt temperature of any radial journal bearing rises up to 115℃ or that of thrust bearing
rises up to 110℃
6. Shaft gland or oil deflector ring is rubbing severely and sparking
7. Pressure of lubrication oil drops to 0.039Mpa , and it is unable to start the auxiliary oil pump
8. Oil level of main tank is less than the shutdown value of low oil level, and oil filling is
inefficient
9. Oil system is on fire
10. Axial displacement exceeds the trip value, and protection device of axial displacement is not
activated.
11. Rotation speed of the turbine exceeds 3360r/min, and the emergency tripper is not activated
12. Pressure of the condenser rises above 19.7Kpa
13. Circulating water is stopped and cannot be recovered soon

The conditions of emergency shutdown with not break the vacuum

Under the following conditions, it is possible to not break the vacuum after tripping the unit.

1. The main steam pipe is broken and the unit cannot run again.
2. The condensate pump fails, water level of the condenser is too high and the standby pump
cannot be used
3. The unit is idling after load dump or running with auxiliary power for more than 15min
4. DEH system, regulation and security systems cannot operate normally
5. Differential expansion of the unit increases and still exceeds the limit value after adjustment
6. The unit is running in the state of electric motor for more than 1min.

Note: All the startup & shutdown operation of HRSG shall be carried out as per HRSG standard
startup & shutdown procedure.

Rev 0 10 of 10

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