Doc No.: DST00181A Rev.

: A Page : 1/4

WATER INDUCTION: OPERATION AND TEST

This document covers Operational and Testing Recommendations for preventing or

minimizing damage caused by water induction.

I. DETECTING THE PRESENCE OF WATER

Usually the first signs of water induction into the turbine are rough starts, hammering
of steam lines, high rotor eccentricity, large differential expansions, and large
vibration increases. To better identify if there is a water induction problem causing
these symptoms and to help identify the source of water, turbines should be equipped
with water detection thermocouples.

A. Water Detection Thermocouples

Serious damage can occur if water enters the turbine through admission,
extraction or steam seal lines. This damage can result in overstressed and distorted
casings, badly rubbed internal components, and permanently bowed rotors, as well
as the resultant extended forced outages needed for disassembly and repair of this
damage. The turbine is equipped with thermocouples in the casing to detect the
presence of water. Water or cold steam in the steam seal header can be detected by
very low temperatures or abrupt changes in temperature indicated on the recorder.
The cause can be easily established by relating temperature changes to operation
of the admission valve or transfer of the sealing steam source.

Thermocouples for the detection of water in high pressure and reheat turbine
shells are provided with all new turbines except those using low-temperature
nuclear steam. Located in pairs, uppers and lowers at several points, axially, in the
outer shells, recorder temperatures from these thermocouples make it possible to
determine at which opening in the turbine the water entered.

Under normal conditions, the top and bottom thermocouples in a pair will indicate
approximately the same temperature. An abrupt decrease in temperature of the
bottom thermocouple, or a substantial differential between the upper and lower
temperatures of a pair, is an indication of the presence of water and resulting shell
distortion. If an alarm is used to annunciate the presence of water, it should do so
when the upper thermocouple of any pair indicates a temperature greater than the
lower thermocouple by 28°C (50°F) or more. The temperature alarm between
upper and lower thermocouples should be set at 28°C (50°F). However, in some
cases, the upper–to–lower temperature may exceed 28°C (50°F) even in the
absence of water. Therefore, an upper–to–lower differential alarm set point of
28°C (50°F) should be used as a starting point and should be adjusted upwards to
56°C (100°F), as normal operating data is reviewed to justify the increased set

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter
should be referred to Doosan Heavy Industries and Construction Co., Ltd.
 Doc No.: DST00181A Rev.: A Page : 2/4

point. If, with the differential alarm set at 56°C (100°F), alarms still exist, factory
consultation should be sought because it may be necessary to change the alarm
scheme to a rate–of–change of temperature type alarm.

B. Thrust Bearing Wear Detector

A thrust bearing wear detector alarm or trip can be caused by a slug of water
carrying over into the steam piping and entering the turbine through the main or
reheat bowls. Because of its higher density the water entering the turbine causes a
large axial thrust. If a thrust alarm or trip occurs then the turbine bowl
temperatures should be checked for sudden drops, and the steam flow measurement
(if measured with an orifice flow device) should be checked for sudden flow spikes.

II. OPERATION TO MINIMIZE DAMAGE

Once water has entered the turbine, the degree of damage done can be greatly
influenced by what action the operator takes. The station operating records often
show clearly that the most serious damage was done a considerable time after the
first indication of water induction, and in some cases was the direct result of the
action, or inaction, after the indication.

There are three factors which may be influenced by the operator that have a direct
bearing on the extent of damage.

A. Operator Action

1. Quantity of Water
The quantity of water entering the turbine directly affects the extent of damage
caused by quenching and distortion. Steps should be taken immediately upon
the first indication of water induction to shut off the source and drain the water
out of the turbine and steam lines.

2. Steam Flow
When a turbine is running under load the steam flow will be of some benefit in
uniformly distributing the water and minimizing distortion. Also, the casing
will re-straighten more quickly when the water is removed if steam flow is
maintained. For these reasons, a turbine carrying load when water enters
should be kept running unless high vibration, high differential expansion, or
some other serious condition requires shutting down. The source of water
must be immediately shut off.

3. Speed
The extent of rub damage caused by thermal distortion depends upon the
speed of operation. Slow rotation of the rotor on turning gear is best because
the heat generated at the rotor surface by rubbing will not be enough to cause
permanent bowing. If the turbine is accelerating below rated speed when water
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter
should be referred to Doosan Heavy Industries and Construction Co., Ltd.
 Doc No.: DST00181A Rev.: A Page : 3/4

enters, it should be tripped and placed on turning gear. Rubbing at speeds in

the range of rotor critical speeds and below can be very destructive because
the rotor tends to bow in a direction that increases the intensity of the rub.
Serious damage has been done by sustained operation at several hundred rpm
in the mistaken belief that a bowed rotor will straighten more quickly at this
speed than on turning gear.

The turbine should be left on turning gear until the source of water is
identified and shut off, the shaft eccentricity is normal, and there is no
significant temperature difference between upper and lower turbine shells.
Unless there has been permanent bowing of the rotor, the eccentricity will
return to normal in two to six hours; however, a humped shell may require a
much longer time to straighten. Without water detection thermocouples to
detect shell humping, a period of 24 hours on turning gear is recommended
before starting-up after water has entered a turbine casing initially above
260°C (500°F).

Shell humping may cause rubbing so hard that the turning gear motor cannot
turn the rotor. When this happens, the best procedure is to make sure all water
is drained from the shell and then make periodic (approximately once per
hour) attempts to place the unit back on turning gear. Rolling off turning gear
should not be attempted until the eccentricity is normal and the water
detection thermocouples (if provided) show a temperature difference of less
than 28°C (50°F) between the upper and lower shells. Do not attempt to free a
locked rotor by use of a crane or by the admission of steam into the turbine.

Rubbing at speeds well above the range of rotor critical speeds, a rotor will
tend to bow in a direction to reduce the intensity of the rub. This is another
reason why it is better to keep running if conditions permit, when water enters
during operation at rated speed, instead of tripping and coasting down through
the critical speed range.

B. Summary of Operation to Minimize Damage

1. Take action at the first indication of water induction.

2. If operating at rated speed, keep running unless high vibration, differential

expansion, or other serious conditions require shutting down.

3. If operating below rated speed, shut down immediately.

4. In any case, shut off the source of water and drain immediately.

5. Once on turning gear, never attempt to restart until:

a. Shaft eccentricity is normal.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter
should be referred to Doosan Heavy Industries and Construction Co., Ltd.
 Doc No.: DST00181A Rev.: A Page : 4/4

b. The temperature difference between upper and lower shells is less than
28°C (50°F) or 24 hours has elapsed since the water was drained.

c. The source of water has been identified and shut off with assurance that the
occurrence will not repeat.

6. If the turning gear motor cannot turn the rotor, make periodic (once per hour)
attempts to place it back on turning gear. Do not attempt to free a locked
rotor by the use of a crane or by admission of steam to the turbine.

III. OPERATING RECOMMENDATIONS

A. Extraction System

1. Heed all level alarms by taking prompt action to prevent water entering the
turbine.

2. For your units prepare specific operating instructions to be followed in the

event of high level alarms.

3. Do not operate the heater if some of the protective devices are known to be
faulty.

4. If a single heater or a string of heaters is to be removed in order to remove a

single heater, the operator must have specific instructions as to what load
reduction may be required because of turbine restrictions with heaters out of
service. This load reduction should be accomplished immediately.

Also when a heater is taken out of service, that heater's turbine side
extraction line drain valve should be opened to insure adequate drainage.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter
should be referred to Doosan Heavy Industries and Construction Co., Ltd.