Fault Cause Remedy Other symptoms = Limit pressure control gear | Locate and attend fault in ‘opens: fault in pressure | pressure switch. switch, If only one of the hydraulic condensate pressure monitoring channels is faulty, the faulty channel may be blocked and bypass operation continued, Attention: No redundant pressure monitoring effective: use other criteria, 0.9. bypass ‘steam temperature, to asses’ injection water flow rate. Attend fault as soon as possible. + Reheat pressure > | Fault in interlock elements for ‘constant pressure setpoint, | loss of condenser vacuum. Condensate pressure nal + Diaphragm of limit | Replace diaphragm; pressure control gear damaged + Diaphragm of bypass | Replace diaphragm. condenser safety device damaged, Close cutoff valve upstream of ‘measuring element. Insert lever and lock. Replace diaphragm. In this case bypass operation may be continued for the duration of the repair. * Reheat pressure —_> | Fault in interiock elements for | Check temperature measuring constant pressure setpoint. | high bypass ‘steam | instrument circuit, actuators of Bypass steam temperature | temperature. solenoid valves’ and attend rormal fault. EEE BHEL, Hardwar 6.2-0490-00/3fazrep Steam Turbine es Maintenance In-Service Maintenance Introduction ‘The availabilty, reliability and economy of a turbine generator depend on the proper condition of all components. This goal can only be achieved through a comprehensive ‘maintenance program. This maintenance program specifies activities to be performed with the unit in service to establish the actual condition at regular intervals (inspection = tests and recording of operating data) and to maintain the desired condition (maintenance), Inspection Schedule ‘The inspection schedule [1] includes. all essential testing and operating data recording activities as well as procedures to identify the condition of components. ‘The inspection schedule is supplemented by tables specifying the testing intervals, instructions and test records for comparison of the desired and actual conditions. Maintenance Schedule The maintenance schedule [2] contains all maintenance activities to be performed during turbine operation or outages at specified intervals. ‘The maintenance work to be performed during prolonged outages, e.g. overhauls, has been elaborated separately [3] Also refer to the following section: ee BHEL, Hardwar [1183-0010 Inspection Schedule [2}6.3-002... : Maintenance Schedule [3]6.3.0200. Instructions for Overhaul 6.3-0001-01‘Steam Turbine n Schedule Dili ice i HLS Maintenance Frequency Parameter | > foury ‘Activity | Work tobe performed measured [4 = Pedy Remarks No. ortested |" Mee y= yearly 10 | Testing of Tests according to: 1.1 | Controllers Functioning | Ref.6.2-0021 | 6.3-0030 & setting 6.3-0035 1.2 | Automatic Turbine Tester | Functioning | pet.6.2.0022 | 63-0060 & 62.0023 | 63.0061 1.3 | Protective devices Functioning | Ret6.2-0024 | quring start up, & setting power operation, 1.4 | Safety devices Functioning | Ref.6.2-0025 | shut down & stand & setting sill 15 | Valves Functioning _ | Ref. 6.2-0026 free movement leak tightness 1.6 | Monitoring devices Functioning | Ref. 62-0027 setting and accuracy 20 | Recording ‘and | Comparison | Ref. 62-0028 | Also ref. 6.3-0037 documentation of | of specified and | for long term operational parameters | actual data | monitoring and conditions 2.1 | Steady state operation h 22 | Non-steady state operation every start-up 23° | Faults ‘every occurrence 2.4 | Analysis of steam 4 Ref. 6.3-0050 2.5 | Measurement of intemal 3m efficiency 3.0 | Inspection of LP turbine | During Ref Tech. Circular {ree standing blades intermediate | No. X-68 3.1 | Visual inspection Erosion, ‘and major looseness inspections, 32 | lade profile and root | Crack very £0,000 crack examination peretion 33. | Cleanliness of blade root | Cleanliness and groove 34 | Blade natural frequency | Natural freq test BHEL, Hardwar 6.3-0010-04/1,Frequency Parameter | = hourly Activity | Work to be performed measured |g = daily Remarks No. ortested [w= weekly m = monthly y = yearly 4.0 [Inspection of accessible During minor, | during shut down expansion joints in cross intermediate ‘around and extraction ines, and major 4.1 | Visual inspection Damages inspections 4.2 _| Surface crack examination | Crack 5.0 | Inspection of casing guides and supports 5.1 |Seating of casing on w support elements 52 | Cleantiness w 5.3 _ | Integrity of keys & packers | Damage During | During shut down 6.4 | Thermal clearances as per | Clearances intermediate drawing “and major inspections 60 | Visual inspection for | Leakage d steamtightness noise 61 | Casing joints 62 | Flanges 63 | shaft seals 64 | Valve stems 65 _| instrument connections 7.0 _| Inspection of drains 7.1 | Internal leak-tightness w 72 _| External leakctightness w 8.0 [Inspection of pumps, motors and other drives in ‘continuous operation 8.1 | Vibration behaviour a a2 |Head 4 83 | Bearing temperatures a a4 | Thust a 25 | Leaktightness a 9.0 | Visual inspection of piping 9.1 | Leaktightness é 9.2 | Vibration 4 9.3 | Hangers w 9.4 | Expansion w 2.5 _| vibration dampers 3m. BHEL, Hardwar 6.3-0010-04/2Frequency Parameter |h = hourly Activity | Work to be performed measured |q = daily Remarks No, ortested | = weekly m = monthly = _yearh 10.0 | inspection of hydraulic accumulator 10.1. | Check charge pressure aw 11.0 | inspection of Main oil tank 11.1 | Level check a 11.2. | Foaming characteristics w 11.3. | Water collection on bottom 2w of oll tank 11.4. | Level check in bucket fiter w to assess fiter chocking 11.5. | Water content of oil a 11.8 | Solid particie content of oil dq 11.7 _| Analysis of properties Ref.6.1-0130_| Ref. 6.3-0080 12.0 | Inspection of FRF tank 12.1 | Level check 4 122. | Level check in bucket fiter w to access filter chocking 12.3. | Foaming characteristics of w FRE 12.4 | Analysis of fuld propertios | Ref.6.1-0140_| Ref. 6.3-0082 13.0 | OWl/ FRF fier 13.1. | Check differential pressure a reading 13.2 _| check venting _ 4 14.0 | Inspection of TG-deck springs 14.1 | Reference spring heights | Ref. Technical _| After frst year 142. | Alignment check Circular No. X-85| of operation 143. | Catenary check SS BHEL, Hardwar 6.3-0010-04/3YO)oct Steam Turbine Maintenance Schedule vy Maintenance Turbine | Frequency Parameter | > houty Activity Work to be performed measured My Remarks No, ortested |W > eet m= monty _ y = yearly + [Cleaning of siding | Visual 1m surfaces Inspection + casing supports + spacer bolts and discs for Bearing pedestals and fubineeatings Z| leaning oftubine blading | measurement [as iaicated by |The efteria by fusing though wih | of citeria Indicating “stage saturaled steam 36 pressure when prescribed in 65-0070 faturated steam fushing ts necessary are the ineraleffeleney ni and the stage 3 | Presewation of turbine | eae continuous | During shutdowns Using ar eying equipment | humicty in tastng tanger than fs preserbedin 62-0900 | turbine = 50% ‘week “| Lubcation of components a8 presebed in of the turbine onl and 81-0680 {urine protection systems _ 3 |Tiottening of turbine 1m contol valve packings © | Tightening of vaive stom Gm or in the seals event of teakages 7, Lubrication of valve stems as _proscbod 61-0600 ——— BHEL, Hardwar 6.3-0021-02error Steam Turbine Maintenance Schedule i Maintenance Oil system, Seal Steam system, Dr: ll system Frequency Parameter [0 = fou Activity | Work tobe performed | measured : Remarks No ortested | > och m = monthly [ y= yearly 1, [Cleaning of fiters and | strainers | + Switch over duplex fiters | p across | as indicated by | and clean fouled fiter | fiter criteria, max 6m cartridges as prescribed in6.1-1130 + Tum plate-type fiters 4 through two three revolutions as prescribed in 6.1-1 120 * Clean plate-type fiters em-y during appropriate shutdowns and overhauls, * Replace fiter papers in| Apacross | as indicated by fine mesh fiter fitter criteria, max 6 m “Change oll tank | cillevelin | Asindicated by | during strainers, clean chocked | bucket criteria, appropriate strainers’ as prescribed | strainers max.6m-ty | shutdowns and in. 1-1 010 overhauls * Clean wire mesh of oi 6m stripper 2 [Cleaning of oll using | solid ortiquid | continuous, as centrifuge foreign matter | indicated by in ol cfteria 3. | Gleaning of centifuge as | deposisin | 1m as specified by the | centrifuge _| indicated by manufacturer criteria 4 [Cleaning of oil tank after | deposits in ot | 3-4 during overhauls draining ot tank 5. [Maintain oll tank level at | levelin olltank | 1 d (check), service level; top up with topping up as il of same make and indicated by properties criteria 6. | Draining of water from the | water collecting | as indicated by | establish cause cil tank onoiltank | criteria of water bottom accumulation BHEL, Hardwar 6.3-0022-01/1Frequency Parameter |" = hourly Activity | Work to be performed measured |g = daily Remarks No. ortested |W = weekly m = monthly y = yearly 7. [Oil or grease change in as specified by valve actuators actuator + Motive oil valve manufacturer * Oil temperature controt valve 8. | Lubrication of pump and as specified by fan motors motor * Auxiliary oil pumps manufacturer + Emergency oil pump * Jacking oil pumps "Oil vapour exhauster fans 9, | Lubrication of oll vapour as prescribed by ‘exhauster fan bearings fan manufacturer 70. | lubrication of valve stem at 4s prescribed in the — lubrication points 63-0081 provided 11. | Tightening of valve, steam 3m or in the: seals event of leakages 12, | Elimination of oil leakages | ollleakages | continuous by tightening of flanges and bolted joints 13. | Check vibration dampers y as prescribed in 6.3-0100 14. [Charging of hydraulic | charge 1m accumulators. pressure ee BHEL, Hardwar 6,3-0022-01/2Seal steam system Frequency Parameter | h = hourly ‘Activity | Work to be performed measured |g = daily Remarks No. ortested [wy = weekly m = monthly | y= year 4. | Change of control fuid for ty seal steam control valve actuators as prescribed in 61-0690, 2. |Fiter change for seat ty steam contol valve actuators as prescribed in its manual 7 3. | Lubrication of vapour ‘as specified by exhaust fan motors motor manufacturer 4, | Lubrication of vapour {as prescribed by exhaust fan bearings fan manufacturer 5. | Lubrication of valve stems 3am at the lubrication points as LL prescribed in 6.3-0081 6. | Tightening of valve stem 3m or in the seals. event of leakages. Drains Frequency Parameter |h = hourly Activity | _ Work to be performed measured [qd = daily Remarks No. ortested | w = weekly m = monthly = _yearly 1. | Oil or grease change in ‘as specified by drain valve actuators actuator manufacturer Lubrication of drain valve 3m) stems at the lubrication points provided as prescribed in 6.3-0084 3, | Tightening of drain valve ‘3m or in the | stom seals event of leakages 4. | Check on drain line sludge 1-2y traps BHEL, Hardwar 6.3-0022-01/3,Gigzren Steam Turbine Maintenance Schedule CLA Maintenance FRFsystem Frequency Parameter 5 an Activity | Work to be performed measured | ‘weekly Remarks. No. criested | Sweety y = yearly 7, [Cleaning of ters 3 p across fier and strainers * Switch over duplex filers; and clean fouled fiter ‘cartidges as, prescribed in 6.1-1130 = Turn plate-type fiters 4 through two three revolutions * Clean plate-type filters 6-1 uring appropriate ia : ‘shut-downs and overhauls, * Replace fiter papers in | Ap across filter | 8 indicated by fine mesh fier 28 criteria, max 6 m prescribed in 61-1140 * Replace fuller's earth | Neutralization | 6m or as filing in regenerating | number indicated by filter as prescribed in criterion 6.3-0082 "Change FRF tank |FRFlevelin | as indicated by | during appropriate strainers; clean chocked | strainers criteria shutdowns and stainers overhauls + Regenerate air fiters of | Discoloration of | am, or as exchange fier filing | fiter filing indicated by aiiterion 2. [Cleaning of FRF tank after | deposits in FRF | S-4y during overhauls draining FRE tank 3. [Keeping the FRF in FRF tank at operating level. * Top up using FRF of the | Level inFRF | 1 d check; Top same brand and with the | tank upas indicated same propertios by erterion 4, [Lubrication of motors of as specified by pumps and fans the motor * FRE pumps manufacturer * ERF circulating pump = ERF vapour extraction fan BHEL, Hardwar 6.3-0023-01/1Frequency of the FRF vapour extraction fan. Parameter [h = hourly Activity | Work tobe performed | measured |g = daily Remarks No, ortested |w = weekly m = monthly = _yearh 5. | Lubrication of the bearings as specified by fan manufacturer 6. | Lubrication of the valve stems at the lubricating am accumulators. L points provided 7. | Retightening of the valve 3m of if leakage stem packing detected | Elimination of leaks by | leakage regularly, as retightening flanges and indicated by unions. criterion 9. | Checking of damping fluid 12Y in vibration dampers as prescribed in 6,3-0100 10. [Charging of hydraulic | Filling 1m pressure BHEL, Hardwar _— 6.3-0023-01/2" Gaggen Steam Turbine Cid Maintenance Testing during Start-up Introduction ‘Tests demonstrate the readiness for operation and the proper functioning of important components. They must, be performed before and during start-up of the turbine generator unit, irrespective of the time of the preceding shutdown. If all prerequisites for performance of the complete test program are not fuliled, reduced testing to ensure the readiness of the auxiliary, emergency and jacking oil pumps for operation must be performed. The scope of the test program for start-up of the turbine is to make sure that all tests required to be performed before startup after a shutdown period of approx. 4 weeks [1,2] have completed. Test procedures Tests, prerequisites, test activities and criteria in table form is intended to simplify testing. The symbols at the head of the columns in the tables are an aid to understanding the concise test instructions. ‘The tables are also suited to use as checklists. Whenever ‘no specific test instructions are prescribed for any test, the sequences shown in the table must be followed. ‘A number of tests require that certain components be in a definite position (e.g. main trip valves in operating position, stop valve closed etc.) ‘The operation sequence establishing certain operating Conditions is given in the form of general instructions to avoid constant repetition in the table of test sequences. Test Performance Take care to avoid any risks to people or machines while performing tests. Any simulated conditions necessary for the tests must be cancelled after completion of tests. ‘Steam inlet valve may only be operated for test purposes, If the piping systems upstream of the valves are not under pressure and the systems concerned have been ‘expressly cleared for testing, Test performance must be recorded If incorrect operation of the equipment being tested ‘occurs, take action establishing full operational reliability of the turbine generator unit immediately. Pay attention to fault tracing instructions, Also refer to the following sections: [1] 63-0061: Testing During Standstill [2] 6.2-002..: Testing of turbine Component BHEL, Hardwé 6.3-0030-02/1Equipment tested ‘© Preconditions Date © Type ofttest (Q Test Step Result ie + Result Tested by Main trip valves in ‘operating Position © Stop valves closed ‘©. Starting and load limit device not in 0% position © Test valves of stop valves in left-hand end position (=stop valves open) (1) Move test valve pilot into right-hand end position Using hand wheel (= stop valves closed) (2) Bring starting and load limit device into 0% position Main trip valve in operating position (3) Bring starting and load limit device into 40% position ‘+ Main trip valve in operating postion and ready to tip = Stop valves closed Main trip valves in ‘© Starting and load limit devices not in 0% position operating Position Test valve of stop valve in left-hand end position (1) Bring starting and load timit device into 0% position ‘+ Main trip valve in operation position @) Bring starting and load limit device into 40% © Stop valves open position ‘© Main trip valve in operating position and ready to trip ‘+ Stop valves open ‘Auxiliary oll pumps. (© Pressure-dependent © Shaft at standstill ‘on command from ‘subloop control before starting turning gear] Auxiliaries and emergency oil pumps off operation © Oil system depressurized ‘© Subloop controls on Manual (1) Switch auxiliary oll pump 1 subloop control to Auto + Auxiliary oil pump 1 on + System oil pressure present (2) Switch auxiliary oil pump 2 subloop control to Auto BHEL, Hardwar 6.3-0030-02/2Equipmenttested | 0 _Preoondions Date © Type ofttest oO. Test Step Roa yy @® Switch aunllay ol pump 1 subloop Toonvl to Manuel (4) Switch auxiliary oll pump 1 off + ary of pump 2 on + System oi pressure present D.G. Emergency oll pump o Prseuedepenant_|() Sitch 8.6 emery of pump sop conte Sublaop contol before | (2) atch auxilary cll pump 2 subloop contol to ‘operation: bec (8) Switch aur ot pump 2 off + DC emergency i pump on + Lutvicating ot pressure present (4) Switch 0 emergeney of pump subloop control to Manual (©) Switen De emergency oi pump of + ilaystom depressurzed Avon and emergency of pumps off ay and Emergency oll pumps © Operational reatiness | 0 Shaft at stand sti betore staring tuning | i system depressurzed flesting not required f | 0 Auiiay and emergency ol pumps of $20 00m geome | 5 subloop conte on Manual fuccestuly tested) | (1) Svitch auxiar and emergency ol pumps in turn to Menualon + Systm i pressure present ‘uxilary and © Turing gear in operation Emergency oll pumps 0 One auxiliary oil pump operating © Operational readiness |” switch stand-by aula cl punp io Manu on gear operational * Pressure buildup in system @) Switch stand-by aur of pun to Manual of (3) Switch emergency oil pump to Manual on + Pressure buldup in systom (4) __ Switch emergency oll pump to Manual off BHEL, Hardwar 6.3-0030-02/3Equipment tested ‘© Preconditions: Date © Type of test 0 Test Step Result + Result Tested by ‘Auxiliary Oil pumps © Speed-dependent © Turbine generator unit speed = rated speed cutoutwnenrated |) erty et outs ol pump Jacking oil pumps © Speed-dependent on | Shaft at standstill command of AC jacking oil pump from sub loop control |__o_Subloop controls on Manual before starting turning gear operation © Jacking oil pumps off (1) Switch AC jacking oil pump sub loop control to Auto = AC jacking oil pump on + Jacking oil pressure present (2) Switch AC jacking oll pump sub loop control to Manual (Switch AC jacking oil pump off © AC jacking oll pump off ‘© Jacking oil system depressurized Jacking ol pump © Manual on of AC| 0 Shaftatstand sti Baki 28 PUM |) wich AC jacking o pump to Manton ear operation +A jacking i pump on «System of pressure present (® _Swich AC jacking oi pump to Manual off + AC jckng ol pump off Systm depresses Jacking oll pumps © Speed-dependent on| 0 Shaftat stand still command of DC Jacking oil pump from | ° 28cking oil pumps off sub loop control | Sub loop control on Manual before ‘turning 982K | (4) witch OC jacking oil pump sub loop control to operation Fie ‘= DC jacking oil pump on ‘+ Jacking oll pressure present ———— BHEL, Hardwar 6.3-0030-02/4Equipment tested © Preconditions Date © Type of teat ©)” Test Step Result ve + Result Tested by @ __Swiich DC jacking ot pump sub loop contol to Manual 8) Switch DG jacking oll pump off ‘= DC jacking oil pump off + Jacking oil system depressurized Jacking oll pumps © Operational readiness | Shaft at stand stil of Jacking il Sumps © Jacking oil pumps off © Sub loop controls on Manual (1) Switch jacking oil pumps in turn to Manual on + Jacking oil pressure present Control fluid pumps © Pressure-dependent © Control fluid system depressurized ‘on command from sub foop vonval © Control fuid pumps off © Sub loop control on Manual (1) Select one control fluid pump (e.g. pump 1) (2) Switch sub loop control to Auto Control uid pump 1 on + Control fluid system pressure present (2) Select control fuid pump 2 (4) Switch control fuid pump 1 off # Control fluid pump 2.0n ‘+ Control fuid system pressure present (8) Switch sub loop control to Manual (© Switch control uid pump 2 off + Control fluid system depressutized ‘= _Controt fuid pumps off Control fluid pumps © Operational readiness | © Control fluid system depressurized {Testing not required nto uid pum if sub loop controls | ° Control fuid pumps off have alteady. been | © Sub loop contol on Manual =e (1) Switch control fluid pumps in turn to Manual on ‘+ Control fluid system pressure present BHEL, Hardwar . 6.3-0030-02/5Date Equipment ested | 0 Precondilons Dae © Type of test (Test Step esul a + Result Tested by Remote trip initiation ‘© Push button operation | © Main trip valve in operating position © Stop valves closed (1) Press trip push button + Trip annunciated Stop valves © Leak test © Main steam pressure present upstream of stop valves © Stop valves closed using test valves (1) Open control valves ‘+ No speed increase (2) Bring back test valves to operating position Control valves © Leak test © Control valves closed using motorized actuator © Main steam pressure present upstream of turbine (1) Open stop valves + Noabnormal speed increase (2) Bring back motorized actuator to open position Overspeed trip © Oilinjection test © Turbine speed < 2970rpm or © Unit in low-load operation (1) Release testing device for operation @) Press and hold down test valve for inhibiting trip (left-hand valve) (@) Tum hand wheel of hydraulic test signal transmitter to right until test oll circuit is, pressurized (4) Observe oil pressures where overspeed trip, device operates + Auxiliary trip circuit depressurized — BHEL, Hardwar . 6.3-0030-02/6Equipment tested © Preconditions Date Type of test (Test Step P Dpecties © Result Tested by (© Tum hand wheel of hydraulic test signal transmitter to left until test oll circuit is depressurized (©) Bring trip device of overspeed trip into operating position using right-hand valve ‘© Auxiliary trip pressure built up (7) Repeat test until overspeed trip operates at the ‘same test oil pressure in successive tests BHEL, Hardwar 6.3-0030-02/7VUTesting during Power Operation ‘Test that demonstrate the readiness for operation and the proper functioning of important components, must be performed during power operation of the turbine generator unit, The time intervals between tests are given ina separate instruction [1] Test Procedures ‘The table containing tests, prerequisites, test activities and criteria is intended to simplify testing. The tables can be used as checklists. When no specific instructions are prescribed for any test, the test sequences shown in the Test performance must be recorded. If incorrect operation, of the equipment tested occurs, take action establishing {ull operational reliablity of the turbine generator unit immediately Pay attention to fault tracing instructions. [2] Also refer to the following sections: | tcpperd afl en {1]6.2-002. : Testing of turbine components (2) 62.0400 : Fault tracing Test performance Equipment tested © Preconditions Date © Type oftest 0. Test Step Result + Result Tested by Turbine controllers: —_ © Functional test © Control valve opening < 100% (1) Change setpoint of effective controler * Change in contro! valve-opening corresponding 10 setpoint change Bypass control © Functional test Load approx. 50% (1) Open HP bypass station slowly by operating pushbutton on control pane! ‘+ Reheat pressure increases ‘+ Injection water pressure present ‘Bypass stop valves open ‘+ Bypass control valves begin to open 2) Close HP bypass station ‘+ Reheat pressure drops + Bypass control valves close + Bypass stop valves close ‘+ Injection water pressure reduced BHEL, Hardwar 6.3-0035-02/1Equipment tested © Preconditions Date © Typeoftest Q Test Step Result a + Result Tested by ‘Seal steam controller © Functional test ‘© Seal steam controller on (1) Seal steam controller off (2) Induce control deviation by operating contro! valves (Pushbutton on control panel) (8) Seal steam controller on (4) _ Verity correction of seal steam pressure Oil temperature controller © Functional test © Oil temperature controller on (1) Oil temperature controller off (2) Induce control deviation by operating temperature control valve (Pushbutton on control panel) (8) Oiltemperature controller on (4) Verity correction of ol temperature ‘Auxiliary and ‘emergency oil pumps © Operational readiness | Auxiliary and emergency oil pumps off, = (1) Auxiliary pumps subloop control off (2) Auxiliary oi pump 1 Manual on + Pressure buildup downstream of pump Auxiliary oi pump 1 Manual off (4) Aunilary of pump 2 Manual on + Pressure buildup downstream of pump (8) Auxiliary oi pumps 2 Manual off (©) Auxiliary oll pumps subloop control on (7) Emergency oil pump Manual on + Pressure buildup downstream of pump (8) _ Emergency oil pump Manual off ‘Control fluid pumps : © Operational readiness | © Service control fluid pump on test (1) Stand-by control fluid pump Manual on ‘+ Pressure buildup downstream of tested pump @)__One control fluid Manual off ————— BHEL, Hardwar 6.3-0035-02/2Equipment tested Preconditions Date © Type of test 0 Test Step Result Result Tested by Main trip valves © Ease of movement ‘Automatic turbine tester available test (1) Select and start test program for one protective device Main trip valves respond No fault annunciations on automatic turbine tester Remote trip solenoids © Functional test Automatic turbine tester available Select and start Remoto trip solenoids test program Main trip solenoid respond No fault annunciations on automatic turbine tester o @) ‘Overspeed trips © Functional test and ‘Automatic turbine tester available testing of setting (1) Select and start Remote trip test program COverspeed trips respond @) 1 ATT annunciates faut repeat overspeed tip ‘Overspeed trips (1) Release hydraulic test signal transmitter ‘© Manual functional test | (2) Depress left-hand piston of hydraulic test signal and testing of setting transmitter to limit and hold down (8) Increase test pressure using hand wheel of hydraulic test signal transmitter Overspeed trio(s) respond(s) (4) Ascertain pressure at which tn) responds) (©) Reduce test pressure using hand wheel of hydraulic test signal transmitter (©) Depress right-hand piston of hydraulic test signal transmitter to limit Auxiliary trip pressure builds up Release right-hand piston of hydraulic test signal transmitter Release left-hand piston of hydraulic test signal transmitter ———— 6.3-0035-02/3, BHEL, HardwarEquipment tested © Preconditions: Date o- Type of test (Test Step Result + Result Tested by @) Repeat test as often necessary until tip operates ‘at the same test pressure as set during commissioning Hydraulic low-vacuum trip © Functional test and | Automatic turbine tester available testing of seting (1) Select and start Low-vacuum trp test program ‘+ low vacuum trip operates + No fault annunciations on automatic turbine tester Differential pressure switch in extraction lines © Functional test ‘© Extraction system in operation ‘© Extraction swing check valve open ‘© Hydraulic release present (1) Reduce differential pressure across differential pressure switch + Extraction swing check valve closes slightly ‘Stop and control valves © Exercising © Automatic turbine tester available (1) Apply test load @) Select and start test program for stop and contro! valve unit to be tested + Control valve closes + Stop valve closes ‘+ Stop valve opens + Control valve opens ‘+ _ No fault annunciation on automatic turbine tester Extraction swing check valves © Exercising ‘© Extraction system in operation (1) Change load or extraction flow ‘+ Extraction swing check units perform movernents ——————— BHEL, Hardwar 6.3-0035-02/4Equipment tested ‘© Preconditions Date ©. Type ofttest © | Test Step Reus Alarms [ © Functional test © Alarms generated (1) _ Record alarms generated ‘Speed indicator (1) Compare with grid frequency Important operating - values © Recording (1) Record important operating values in accordance with 63-0036 & 6.3-0037 Drains o_Leaktest (1) __ Test temperature condition of drain values — BHEL, Hardwar 6.3-0035-02/5arage) Steam Turbine Acquisition and Archiving Ti Maintenance of operating data Procedural Instruction Introduction Documents from the olectronic data acquisition It is in the interest of both the plant operator and the supplier that the causes of faults, severe damage and unfavourable inspection findings be determined, and actions taken to prevent a recurrence of such incidents, In order to determine the cause of such faults, it is essential that information be available, in the form of operating documentation, on the operating history of the {turbine generator unit both in the past and immediately before and during the fault or damage. This instruction contains recommendations on the acquisition and archiving of operating data, ‘Scope of measurement and instrumentation ‘The scope of measurements and also, therefore, the instrumentation of the turbine generator unit are dictated by the agreements between plant operators and suppliers, The data are of importance for operations management. The scope of data recommended in Table-1 should therefore be available to permit post-event analysis. Scope of operating documentation Operating documentation comprises the following documents: + Printouts from continuous-line printer + Operating data logs or curves based on the data archived in the electronic data acquisition system + Alarm and switching logs ; such logs document the histories of faults or damage and should be archived + Logs with handwritten entries are required in cases where certain data are not recorded or archived + Logs used to document the long-term behavior of the turbine generator unit Documents showing the availabilty statistics ‘system * processing of analog measured values All the data specified in Table-1 should be archived in MAXSTORIAN of electronic data acquisition system. It should be possible to retrieve data in the form of logs or time curves at any time over the course of the intended archiving period. Long-term data archiving is to be done ‘on magnetic tape / disc. Only those values for an operating parameter should be ‘electronically archived which, after the scanning interval hhas elapsed, lie outside the scatter band given in Table-1 when compared to the last recorded value. += processing of binary signals Normally, binary signals resulting from annunciations and ‘switching operations are continuously printed out with high time resolution by the electronic data acquisition system, alarm and switching logs are thus generated which form an important source of information for operations management. For troubleshooting purposes, the alarm and switching logs printed immediately before, during and after the fault should be retained and archived. Documents for long-term monitoring of the turbine- generator unit Certain operating data should be recorded at long intervals in order to document the long-term behaviour of the turbine generator unit, as well as any data relevant in terms of life expectancy considerations. ‘The associated logs may be of use in analysing faults or damages if the cause can be traced back to or is indicative of a gradually developing adverse change Documents on availability statistics For the purpose of providing information on the operating behaviour and the status of the plant, it is recommended that availabilty statistics is compiled which show, among ‘other things, the causes and duration of periods of non- availabilty BHEL, Hardwar 6.3-0037-03/1If the statistics show a frequent recurrence of an event which leads to plant non-availability, in-depth Investigations should be performed. Processing of operating documents + Fault report The control room personnel should prepare reports on fault or damage, showing all relevant data on the evolution of the event leading to the fault or damage, as well as the countermeasures implemented. Copies of the printouts from the continuous-line recorder or dotted-line recorder, operating data tables and curves generated by the electronic data acquisition system, and the fault and ‘damage lags should be appended to the fault or damage reports, + Evaluation of the fault report and the operating documentation Faults and damage usually occur when several adverse influences are present simultaneously. Because of the multiplicity of conceivable faults and their possible influencing factors, it Is not possible in this procedural instruction to present a reliable and complete picture of all the correlations involved. Itis the duty of the operator's or suppliers own experts to define the correlation between the event and the adverse influencing factors and to evaluate them and decide on countermeasures to be implemented. Retention period for documentation ‘The documents described above must be archived in a magnetic tape for consultation for a long time after the ‘operating data have been logged in order, among other things, to analyse any correlations between component status and operating conditions. + Documents containing operating data which are relevant in terms of life expectancy considerations must be archived unti the turbine generator unit is taken out of service. + Its recommended that all other documents be archived until the next inspection and overhaul has been completed, Importance of documents for settling guarantee claims ‘Without the data contained in the documents described above, the supplier of the turbine generator unit is not always able to check the legal validity of guarantee claims in the event of damage or a complaint regarding ‘component defects and may therefore reserve the right to reject any claims for which the requisite documents are not available Table-t lists the required operating data for acquisition ‘and archiving in accordance with the operating instruction, in order to permit evaluation of turbine performance. The requirements will have to be adapted fon the basis of the actual measuring point list Also refer to the following: [1] BHEL-EDN document on MAX control system ——— BHEL, Hardwar 6.3-0037-03/2