Turbine Generator System

PRODUCTION (UTILITIES)
HEAVY WATER PLANT (MANUGURU)

ASWAPURAM
BHADRADRI KOTHAGUDEM
TELANGANA – 507116
OPERATION MANUAL
TURBO GENERATOR OPERATION
(DOC. NO. PU/III/29)
COPY NO.
Rev. No. 5.00 Date: 30.12.2019
DESCRIPTION NAME
B.T. SESHA SAYEE
DESIGNATION SIGNATURE
PREPARED BY G.S. RAO
M. SUBBARAMAIAH
CH KOTESWARA RAO SO/F
REVISED BY
G SRINIVAS Dy PM (U)
REVIEWED BY V.V. UPADHYAYA PM (U)
APPROVED BY ARUN BOSE DGM (U)
Doc. No: PU/III/29
HWP (M) INDEX Chapter A
SN Document Description Document No. Page No.

1.
Index PU/III/29, Chapter A 2
2.
Abbreviations PU/III/29, Chapter B 3
3.
Distribution list PU/III/29, Chapter C 4
4.
Amendment sheet PU/III/29, Chapter D 5
5.
Preface PU/III/29, Chapter E 6
6.
Introduction PU/III/29, Chapter 1 7
7.
System Description PU/III/29, Chapter 2 8
8.
Instrumentation, Controls and Logics PU/III/29, Chapter 3 11
9.
Protections PU/III/29, Chapter 4 13
10.
Start-up PU/III/29, Chapter 5 17
11.
Operation PU/III/29, Chapter 6 29
12.
Shutdown PU/III/29, Chapter 7 36
13.
Annunciations and Actions PU/III/29, Chapter 8 40
14.
Air Supply PU/III/29, Chapter 9 61
15.
Control Supply PU/III/29, Chapter 10 62
16.
Trouble Shooting PU/III/29, Chapter 11 63
17.
Performance Monitoring PU/III/29, Chapter 12 69
18.
Annexure PU/III/29, Chapter 13 73
19.
Technical details PU/III/29, Chapter 13.1 74
20.
Order to Operate PU/III/29, Chapter 13.2 77
21.
Safety Precautions PU/III/29, Chapter 13.3 92
22.
Check List PU/III/29, Chapter 13.4 93
Revised by: Reviewed by: Approved by:

Revision No: 5.0 Date: 30.12.2019 Page 2 of 123
Doc. No: PU/III/29
HWP (M) INDEX Chapter A
23.
Log Sheets PU/III/29, Chapter 13.5 100
24.
Governing Relations PU/III/29, Chapter 13.6 103
25.
Protection Relay Settings PU/III/29, Chapter 13.7 104
26.
Power Supplies PU/III/29, Chapter 13.8 106
27.
Turbine material of construction PU/III/29, Chapter 13.9 109
28.
Turbine and generator curves PU/III/29, Chapter 14.0 110

Doc. No: PU/III/29
HWP (M) ABBREVIATIONS Chapter B
SN Acronym Description
o
1.
AC/DC JOP Alternating/Direct current Jacking Oil Pump
2.
ACWP/CCWP Auxiliary/Condenser cooling water pump
3.
AOP Auxiliary Oil Pump
4.
CHP Coal handling plant
5.
COT/DOT Clean/Dirty oil tank
6.
DAVR Digital Automatic Voltage Regulator
7.
EHTC Electro Hydraulic Turbine Control
8.
EOP Emergency Oil Pump
9.
ERV Electromatic Relief valve (for Boiler)
10.
ESV Emergency Stop Valve
11.
GCP/GCD Generator control Panel/Desk
12.
GOP Governing oil pump
13.
GRP Generator relay panel
14.
GSCVEF Gland Steam Condensate Vapor Extraction Fan
15.
GT Generator Transformer
16.
HP/LP High/Low Pressure
17.
IBV Integral bypass valve
18.
LDB Lighting Distribution Board
19.
MCR Main Control Room

Doc. No: PU/III/29
HWP (M) ABBREVIATIONS Chapter B
20.
MD Maximum Demand
21.
MOP Main Oil Pump
22.
MOT Main Oil Tank
23.
MOV /LCV Motor Operated/Level Control Valve
24.
MSJAE/SAE Main steam jet/Starting air ejector
25.
OS Operating Station
26.
OTO Order To Operate
27.
OVEF Oil Vapor Extraction Fan
28.
PT/VT Potential/Voltage Transformer
29.
QC NRV Quick closing non-return valve
30.
SSG Station Switch Gear
31.
TCP/BCP Turbine/Boiler Control Panel
32.
UAT Unit Auxiliary Transformer
33.
USSG/UASG/UESG Unit Service/Auxiliary/Emergency Switch Gear
34.
VAR Volt Ampere Reactive

Doc. No: PU/III/29
HWP (M) DISTRIBUTION LIST Chapter C
0 MASTER COPY
1 Dy. GENERAL MANAGER (U) (Soft copy)
2 PRODUCTION MANAGER (U) (Hard copy)
3 TECHNICAL SERVICES MANAGER (Soft copy)
4 Deputy PRODUCTION MANAGER (U) (Soft copy)
5 Deputy SHIFT SUPERINTENDENT (Hard copy)
6 LIBRARY (Soft copy)
7 HRD SECTION (Soft copy)
8 RTC FIELD STAFF OF THE UNIT (Hard copy available in Dy SS cabin)
9 GENERAL SHIFT ENGINEERS (Soft copy)

Doc. No: PU/III/29
HWP (M) AMENDMENT SHEET Chapter D
Current revision New revision

SN Doc. No. Page No. Remarks
No. Date No. Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Doc. No: PU/III/29
HWP (M) INTRODUCTION Chapter 1
PREFACE
This Operation Manual has been prepared with an intention to provide sufficient
information to the Operation Personnel to guide them in operating the system as intended.
Though every effort has been made to include all details required for operation, it may be
noted that it is difficult to foresee each and every contingency that may arise during
operation of the system and no amount of written instruction can replace an EXPERIENCED
OPERATOR especially when coping-up with unforeseen operating condition.
Standard Order To Operate (OTO) given shall be used as a GUIDANCE for preparing
final OTOs which depends on conditions of the process existing at that time and also one
may have to ascertain the conditions from field.
Sd/-
(M. SUBBARAMAIAH)

Doc. No: PU/III/29
HWP (M) INTRODUCTION Chapter 1
I. INTRODUCTION
1.1 Steam Turbine-Generator of Captive Power Plant is single cylinder, condensing and
impulse-reaction turbine of type EK1800-2 supplied by M/s BHEL. TG is designed for a
normal output of 27 MWe and is capable of generating 30 MWe (Max). TG is
provided with HP extraction (controlled) and LP extraction (uncontrolled but
controlled externally) at 32 ata and 8 ata respectively. Extraction steam is used for
process requirements in Main Plant.
1.2 TG is also provided with Electro Hydraulic Turbine Controller (EHTC), Hydraulic
Governor (SR-IV), Turbine Stress Evaluator (TSE), Vacuum unloading gear and Load
shedding relay. Hydraulic governor acts as a back up to the EHTC.
1.3 Inlet steam conditions to TG are 101 kg/cm 2 (a) and 480oC. Maximum designed steam
flow through turbine is 241.5 T/hr. Under these conditions following are the output
values:
 Generation : 30 MWe
 HP Steam : 133 T/hr
 LP Steam : 39 T/hr
 Flow to condenser : 69 T/hr
 Condenser vacuum : 0.107 kg/cm2 (a)
1.4 The generator is of air-cooled type and is equipped with static excitation system with
digital automatic voltage regulator (DAVR). Generation voltage is 11 kV.

Doc. No: PU/III/29
HWP (M) SYSTEM DESCRIPTION Chapter 2
II. SYSTEM DESCRIPTION

2.1 Single cylinder, condensing turbine is provided with 42 + 1 stages out of which first
stage is single row having impulse blades on it. The first stage is followed by HP and
LP blades which are separated internally with steam glands. Steam flow to HP part
and LP parts of the turbine is regulated by steam control valves for the purpose of
controlling the HP steam pressure. HP part is nozzle controlled and LP part is throttle
controlled. HP extraction steam at 32 ata after 14 th stage and LP extraction steam at 8
ata after 27th stage of turbine is taken for process use at Main Plant. Axial thrust
coming on the turbine is taken care of by balancing piston and the residual thrust by
thrust bearing provided at the front side. The details of Turbine are as shown with
figure summary sheet (Thermal).
2.2 To facilitate operation, Turbine-Generator is provided with the following auxiliary

systems.
 Turbine Lube Oil System.

 Turbine Lube Oil Purification System.
 Turbine Governing Oil System.
 Main Condensate and Feed Water System.
 Condenser Air Extraction System.
 Turbine Gland Sealing System.
 Generator Air Cooling System.
 Generator Excitation System.
 CO2 Fire Extinguishing System.
 Main Steam, LP & HP Steam System. (For details on the above systems,
refer respective Operation Manuals)
2.3 On line testing facility is provided for the following:
 Auxiliary Oil Pumps (AC) & Emergency oil pump (DC)

 Over speed bolt (OIL INJECTION TEST)
 Emergency stop valve
For details regarding testing procedures of the above, refer Operation Manual
on `Procedures for functional tests’.
2.4 TG can be operated with steam drawn from any Steam Generator.
2.5 CO2 Fire Extinguishing System for Generators
Automatic CO2 Extinguishing System with provisions of Electrical and Manual
Operation is provided for fighting generator fires in Captive Power Plant, Heavy
Water Plant (M).

Doc. No: PU/III/29
HWP (M) SYSTEM DESCRIPTION Chapter 2
Two batteries of CO2 cylinders each of capacity 4 x 45 kg, are provided. The
batteries are designated as `Main’ and `Standby’. Each CO 2 cylinder is seamless,
solid drawn holding the liquid CO2 under 750-800 psi at about 34 oC. A selector
switch is provided on the CO 2 Main Control Panel to select either `Main’ or
`Standby’ CO2 battery to discharge in the event calling for CO2 release.
Generator CO2 system trouble’ annunciation appears when generator cooling air
outlet temperature reaches 80oC.
TG is to be tripped and CO 2 to be released manually (Local/Remote) after

physical check of fire.
Carryout Order to Operate No.7 to ensure that the CO 2 extinguishing system for
the concerned Generator is in poised state.

INSTRUMENTATION, Doc. No: PU/III/29
HWP (M) Chapter 3
CONTROLS and LOGICS
III. INSTRUMENTATION, CONTROLS & LOGICS

3.1 On Main Steam Inlet Line to TG
1. Pressure indicator : PI 5.1

2. Temperature indicator : TI 5.1
3. Flow Transmitter : 530 FX 0021
4. Pressure transmitter : PT 5.2
5. Temperature switch : TAL 5.1 (for steam temp. low alarm)
6. Temperature switch : TSL 5.1 (for steam temp. low alarm & trip)
7. Temperature switch : TAH 5.1 (for steam temp. high alarm)
8. Pressure switch : PAL 5.1 (for steam pressure low alarm)
3.2 On the Turbine
1. Pressure indicator : PI 5.11 (for wheel chamber pressure)

2. Temperature indicator : TI 5.100 } (for TSE)
3. Temperature indicator : TI 5.101 }
4. Temperature indicator : TI 5.11 (for turbine Exhaust hood)
5. Pressure indicator : PI 5.12 (for exhaust steam pr.)
6. Temperature switch : TAH 5.11 (for exhaust hood temperature high alarm)
3.3 On the Thrust bearing
1. Temperature indicator : TI 3.64 }(for lube oil return

2. Temperature indicator : TI 3.65 } temperature)
3. Temperature indicator : TE 3.77 A to TE 3.77 H (for bearing metal Temp.)
4. Pressure indicator : PI 3.64 (for lube oil inlet Pr.)
3.4 On Turbine front journal bearing
1. Pressure indicator : PI 3.65 (for lube oil inlet pressure)

2. Pressure indicator : PI 3.76 (for jacking oil inlet Pr.)
3. Temperature indicator : TI 3.63 (for lube oil O/L temp.)
4. Temperature element : TE 3.77J (for bearing metal temperature)
5. Vibration monitoring device
3.5 Turbine rear journal bearing
2. Pressure indicator : PI 3.77 (for jacking oil inlet Pr.)
3. Temperature element : TE 3.77K(for bearing metal temperature)
4. Temperature switch : TAH 3.77 (for bearing metal temperature high
alarm)
5. Temperature switch : TSH 3.77(for bearing metal temperature high
trip)

INSTRUMENTATION, Doc. No: PU/III/29
HWP (M) Chapter 3
CONTROLS and LOGICS
6. Temperature indicator : TI 3.67(for lube oil return temp.)
3.6 On Generator Front Journal Bearing

2. Temperature indicator : TI 3.72 (for lube oil return temp.)
3. Temperature Element : TE 3.77L (for bearing metal temp.)
4. Pressure indicator : PI 3.120 (for jacking oil inlet pressure)
3.7 On Generator Rear Journal Bearing

1. Pressure indicator : PI 3.69 (for lube oil inle pressure)
2. Temperature indicator : PI 3.73 (for lube oil return temp.)
3. Temperature element : TE 3.77M (for bearing metal temp.)
4. Pressure indicator : PI 3.121 (for jacking oil inlet Pressure)
3.8 CONTROLS: The following Controls are provided on EHTC:

3.2.1 Speed Control
3.2.2 Load Control
3.2.3 Frequency Control
3.2.4 HP Extraction Pressure Control
3.2.5 Vacuum Unloading Control
3.2.6 Load Shedding Relay
NOTE: Refer Operation Manual on Governing System for details regarding above
controls. 3.2.3 is only for TG#3, 3.2.5 and 3.2.6 are not commissioned for any TG
On hydraulic, only speed and extraction pressure controls are
there.

Doc. No: PU/III/29
HWP (M) PROTECTONS Chapter 4
IV. PROTECTIONS
4.0 Turbine Protections
1. Lube oil header pressure very low : 0.7 kg/cm2 (g)

2. TG over speed : 3300 rpm
3. Condenser vacuum very low : 0.7 ata (228 mmHg)
4. TG shaft vibrations high-high : 110
5. TG bearing metal temp.high-high : 115oC
6. Control oil pressure very low : 4.5 kg/cm2 (g)*
7. Trip oil pressure very low : 2.0 kg/cm2 (g)
8. Axial displacement high-high :  0.8 mm
9. TG inlet steam temp. very low : 430oC
10. Controlled extraction pr.low-low : Only for annunciation
11. Controlled extraction pressure High-high : 40 kg/cm2 (g)
NOTE: Electrical and Mechanical trip settings are at the same level for Lube Oil
Header pressure low- low, condenser vacuum low- low, Axial displacement
high-high, controlled extraction pressure high-high whereas for over speed,
electrical trip setting is 3270 rpm and mechanical trip setting is 3300 rpm.
4.1 Generator Protections
All Generator, GT and UAT protections are divided into three

categories viz., Class-A, Class-B and Class-C.
4.1A Class-A trips (86G1 and 86G2)
Class-A group will comprise all those faults which are severe in nature
and needs complete shut down of both turbine and generators
simultaneously and instantly. These are,
I. Generator Protections
1. Generator differential protection : 87G

2. Generator Main stator earth fault : 64G1 (0-95%) TRIP
3. Generator standby stator earth fault : 64G2
4. Generator rotor earth fault : 64R (Stage-II)
5. Generator over voltage : 59G1 (Moderate)
6. Generator over voltage : 59G2 (Extreme)

Doc. No: PU/III/29
7. Generator reverse power and

turbine stop valve closed : (32 G1 with 1 second delay)
8. Generator reverse power and
Turbine stop valve open : 32G1 with 3 second delay
9. Low forward power relay : Provided GT is in
Service & 86G3 acted
10. Generator impedance (Min) : 21G (stage-I)
(for faults on 11KV bus
duct upto 33KV side of
GT)
11. Generator CO2 release
II. Generator –Transformer Protections
1. Generator transformer differential : 87T

2. Generator and GT overall
differential : 87GT
3. GT over fluxing : 99GT (Stage-II)
4. GT restricted earth fault : 64GT
5. GT Buchholz : 80GT (Stage-II)
6. GT OLTC Buchholz (Diverter
switch) : 80GT (Stage-II)
7. GT over current and backup earth
fault : 50GT+51GT+51 NGT
8. GT pressure relief : 63GT
9. GT breaker switch : 50 LBB
10. GT Mulsifire : 28GT
ii) Unit Auxiliary Transformer Protections
1. UAT differential : 87 UAT
2. UAT Buchholz : 80 UAT
3. UAT back up over-current : 50 UAT+51 UAT

Doc. No: PU/III/29
4. UAT Mulsifire : 28 UAT

5. UAT pressure relief : 63 UAT
3.3.2B Class-B Trips (86G3)
These are for the faults less severe in nature. In these cases, first
turbine is tripped and later generator. This group will comprise all those
faults for which it is safe to trip the turbine and subsequently allow the
generator to trip on low forward power/reverse power protection. This
ensures that the machine does not get over speeded during shut down.
1. Loss of excitation : 40 G
2. GT oil and winding temperature high : 90/950C
3. UAT oil and winding temperature high : 85/950C
4. Negative sequence protection (severe) : 46 G
5. Turbine tripping command from: Similar to Class B, but not
turbine I & P panels through 86G3
3.3.2C Class-C Trips (86G4)
These are for the external faults. Upon actuation of these
protections, GT breaker opens. This group will comprise faults beyond the
generator system which will trip HV side breaker of Generator Transformer.
TG continues to be in service supplying house load.
1. Generator under frequency : 81 G (47.5Hz + 10
Sec delay)
2. Generator out of step relay : 98 G
3. Negative sequence protection
(prolonged) : 40 G
4. Generator impedance : 21G (Step-II)
(faults in and beyond
33KV system)
5. 33KV bus differential } Lead to GT breaker
6. 33KV bus LBB protection } tripping (not through
86G4)

Doc. No: PU/III/29
NOTE: Fast change over of Unit Board to Station board will not take place when TG trips
after actuation of Class-C protection. Otherwise fast change over takes place on
class A protections. Class-B protection facilitates overlapping/parallel change over
where T4 closes on class-B lock out and subsequently sensing T 4 close, I1 gets
opened.
The details of settings of different generator protections are given in annexure

Chapter 12.7.

Doc. No: PU/III/29
HWP (M) START UP Chapter 5
V. TURBO GENERATOR START-UP
5.1 Pre-requisites for start-up
Ensure that the following pre-requisites are satisfied.

 Turbine trip circuit healthy’ indication is ÒN’ at Turbine Control Desk.
 Toggle switch TS-22 is ÒN’ in auxiliary control equipment room.
 Annunciation window lamp test is done for Turbine control panel and
Generator control panel and found all windows are healthy.
 The hand wheels of starting device and speeder gear are in `closed’
condition.
 Field breaker trip coil healthy’ indication bulb is glowing on Generator
Control Desk.
 The following annunciations are not existing on Generator Control Panel
(GCP)
a) Class-A Lockout trip
b) Class-B Lockout trip
c) Class-C Lockout trip
 The following annunciations are not existing
a) “6 A1 DC fuse failed” - on TCP
b) “6 A2 DC fuse failed” - on TCP
c) “PL-10 fuse failed” - on TCP
d) “6 A3 DC fuse failed” - on BCP
e) “6 A4 DC fuse failed” - on CCP
f) “Trip coil not healthy” - on TCP
 “Excitation system trouble” annunciation does not exist on TCP.
 Ensure that the following systems are in service.

a) 6.6KV Unit Board
b) 415V Unit Service Switch Gear
c) 415V Unit Emergency Switch Gear
d) 220V DC Unit Board-1/2/3 and Station Board
e) 24V DC Unit Board-1/2/3 and Station Board
f) UPS System
g) TG Lube Oil System
h) Lube Oil Purification System
i) Auxiliary Cooling Water System

Doc. No: PU/III/29
j) Common Auxiliary Cooling Water System

k) Compressed Air System
l) DM Water Transfer System.
m) TG Building AC System
n) Fire alarm and detection system
o) Main Condensate and Feed Water System
p) Fire fighting system for GT, UAT and MOT is in poised state.
q) CO2 fire fighting system for Generator is in poised state(OTO-7)
r) Chemical dosing system is in poised state.
For taking the above systems into service, refer respective Operation Manuals.
 Ensure availability of GT breaker in test position.
 Clearance for starting TG is existing.
 Start-up check list on TG is completed and TG is on barring gear.
4.2 Start-up checks

4.2.1 Ensure availability of standby lube oil pumps viz. AOP-1/AOP-2/EOP on
MANUAL and also on AUTO. Select standby lube oil pumps to Auto.
4.2.2 Ensure availability of AC JOP and DC JOP.
4.2.3 Ensure TG is on barring gear
4.2.4 Ensure availability of Turbine trip facility both from Main Control Room and
Local after actually resetting the turbine and tripping the same.
4.2.5 Check the operation of ESV in the field.
4.2.6 Ensure availability of all turbovisory instruments.
4.2.7 Ensure extraction isolation valves for both controlled and uncontrolled
extractions are in closed condition.
4.2.8 Ensure that 32ata extraction pressure controller is set for zero extraction.
4.2.9 Ensure that drain speeders for both HP and LP extractions are in isolated
condition in governing system.
4.2.10 Check the operation of ESV tester.
4.2.11 Check whether the over speed governor tester oil pressure is developing by
operating the over speed tester and keep it in released position.
4.2.12 Check for correct and smooth functioning of the hydraulic actuators of NRVs
by operating the drain speeder and keep them in closed position.
4.2.13 Vacuum unloading gear is not being in service. So, ensure oil line isolation
valve to this device is in closed condition.
4.2.14 Fill hot well with make up DM water and keep CEP in service. Check auto
change over of CEPs and keep one CEP in service and other on auto.

Doc. No: PU/III/29
4.2.15 Ensure accumulators in lined up condition. After MOP removal,

accumulators provided to take care of transient variation in control oil and
trip oil and hence may prevent TG trip during stopping/tripping of running
AOP(while auto AOP starts)
4.2.16 Start CCWP and line up condenser passes.
4.2.17 Line up generator air cooler.
4.3.0 Starting the Turbine-Generator (TG)
Turbine startup in general are classified into three categories viz. Cold startup,
warm startup and hot startup depending upon the length of shut down of TG/
turbine casing metal temperatures. Procedure for cold startup of the TG is
given below.
4.3.1 Cold Start-up (48 hrs. after shutdown)
4.3.1A Ensure minimum steam parameters for rolling of TG as per the

Table 4.1 Warm-up the following steam lines
1. Main steam inlet line to TG by opening startup vent valve and
Main steam drains of TG and IBV of Main steam inlet valve.
2. Steam pipe line to Starting Air Ejector.
3. Steam pipe line to Main Steam Jet Air Ejector.
4. Steam pipe line to Gland Steam System.
4.3.1B Open the following drain valves to condenser flash box.

1. 1-26-V313 : 32 ata extraction line drain valve
2. 1-26-V314 : 32 ata extraction line drain valve
3. 1-26-V315 : 8 ata extraction line drain valve.
4. 1-28-V100 } : { Balancing pipe line drain valves
5. 1-28-V101 } :
6. 1-28-V103 : Dump line drain valve
7. 1-26-V312 : Casing drain valve
4.3.1C Line-up spray water to TG exhaust hood.

Doc. No: PU/III/29
4.3.1D Pull vacuum in the condenser with Starting Air Ejector Admit gland
steam when vacuum in the condenser is 200 mmHg
After obtaining around 500 mmHg of vacuum, take Main Steam
Jet Air Ejector into service and cut off SAE (if vacuum starts falling,
check for air leakages, otherwise wait till TG attains rated rpm then cut off
SAE).
Keep gland steam pressure controller and steam Jet Air Ejector
pressure controllers on Auto as per the procedures given in respective
operation manuals.
4.3.1E After achieving 350oC before ESV, open main steam inlet valve
to TG.
4.3.1F For rolling of TG ensure the following:
1. TG is on barring gear.
2. Lube oil inlet temperature to bearing is in between 38oC to 40oC.
3. Main steam inlet temperature is more than 430oC.
4. The following turbovisory instrument readings are within limits.
a) casing expansion
b) shaft eccentricity
c) axial displacement
d) vibrations of shaft
e) vibrations of bearing housing
f) bearing metal temperatures.
5. Condenser vacuum is more than 600 mmHg.

6. Lube oil header pressure is more than 2.0 kg/cm2.
7. Ensure HP extraction & LP extraction pressure controller set point
is zero.
4.3.1G TG is now ready for rolling. Reset the turbine.
4.3.1H Open emergency stop valve through starting device Open the
starting device till HP and LP control valves begin to open and turbine
starts rolling. Record the HP & LP secondary oil pressures and
corresponding valve lift and ensure that they are matching with the chart
given in governing relations(chapter 12.6). Turbine stress evaluator is not
commissioned. So, it is not in line. Roll the turbine as per start up curves.
Rolling will start through starting device only if it is on hydraulic
control, i.e. either EHTC outlet valves are closed or EHTC signal (speed
reference) is more than actual speed required.

Doc. No: PU/III/29
For rolling on EHTC, i.e. with HP and LP EHC lined up in field,

starting device can be kept almost full and rolling will start after giving
speed reference.
Note: Point to be noted is secondary oil pressures are being developed by
hydraulic amplifier but are being continuously manipulated by
draining thro EHTC, hence the signal which (EHC or Hydraulic) is
lower will be in action. For details please refer Governing system
manual.
4.3.1I As soon as turbine starts rolling ensure turbine barring gear motor got
disengaged and stopped. Stop JOP at above 200 rpm. Monitor for any
abnormal noise in the field.
4.3.1J Bring TG speed gradually to 1000 rpm. Refer Table-2.2 for rate of rise of
speed and soaking period to be maintained during rolling.
4.3.1K Soak the turbine at 1000 rpm for 30 min. Ensure casing expansion,
differential expansion, shaft eccentricity, axial displacement, shaft
vibrations and lube oil return temperatures from bearings are within
limits. Record the values.
4.3.1L Raise TG speed further through starting device (on hydraulic)/speed
reference (On EHTC). Cross critical speed very quickly/instantly and bring
TG speed to 2200 rpm.
4.3.1M Soak the turbine at 2200 rpm for 30 min. Monitor turbovisory instrument
readings continuously for any abnormality.
4.3.1N After stabilizing the turbovisory instrument readings, raise TG speed as

per the startup time given in Table 2.2.
4.3.1O At a speed of around 2550 rpm governor will take control and hence is
not possible to raise TG speed further. Open the starting device fully.
Note down the governor take over speed and note down the starting
device position at that speed.
4.3.1P Now, raise TG speed to 3000 rpm with speeder gear (on hydraulic)/speed
reference (On EHTC).

Doc. No: PU/III/29
4.3.1Q At 3000 rpm conduct oil injection test for over speed governor. Note
down the pressure at which over speed bolt is acting. Carry out actual
over speed test if TG is being started after annual overhaul. (Refer
functional test procedure for details).
4.3.1R Ensure lube oil inlet temperature to bearings, exhaust hood

temperature and condenser vacuum are within limits.
4.3.1S Ensure Main Oil Pump (MOP) has taken over at rated speed by
observing the current of AOP. (Current drawn by AOP will decrease
once MOP takes over) Note down the MOP take over speed. Stop
AOP and keep it on Àuto’. (Not applicable pl see note below).
NOTE: As MOP is removed, AOP will be in service continuously, other
AOP must be on auto
4.3.1T Throttle the following drain valves

g) Drain valves opened at item no. 4.3.1B
h) Drain valves opened at item no. 4.3.1C
4.3.1U Close start-up vent valve of TG.
4.3.1V Take one set of readings of all parameters as per log sheets of TG and
check whether they are within limits.
4.3.2 Warm start-up
Start-up of Turbine after 14 hrs. of shutdown
4.3.3 Hot Start-up

Start-up the turbine after 6 hrs of shutdown. Warm startup
and hot startup procedures are substantially the same as cold startup
procedures with the variations of parameters given in Table – 4.2.
4.3B Starting TG with EHTC

Refer Operation Manual on TG governing system for rolling,
synchronizing, changeover from EHTC to hydraulic governor and vice-
versa. The general procedure for starting of the TG set with EHTC

Doc. No: PU/III/29
remains same as that of starting TG set with hydraulic governor. Pl

see 4.3.1 I also.
4.4.0 Synchronizing and Loading
4.4.1 When TG is at 3000 rpm check that the following parameters are
within limits.
1. Condenser vacuum
2. Lube oil temperature
3. Main steam inlet temperature
4. Lube oil header pressure
5. TG bearing vibrations.
6. Axial thrust
7. Turbine casing expansion (both in field and in MCR)
8. Turbine differential expansion
9. Thrust pad element temperatures
10. TG running noise
11. Generator air inlet temperature
12. Turbine bearing metal temperatures
13. Primary oil pressure
4.4.2 Close the field breaker of the Generator as per the procedure given in
Generator Excitation System manual. Adjust AUTO POT to reach 11KV
on Generator Terminals.
Note: DAVR has two AUTO and one MANUAL channel. All the three
channels tracking and healthiness to be checked and to be kept on
any AUTO channel.
4.4.3 Ensure Generator breaker is in service position and ready in all

aspects. Prior to making it ready it should be checked in test position
for electrical closing and opening.
4.4.4 Switch on synchroscope. Select the selector switch on GCD to

‘synchro check mode ‘
4.4.5 Match Generator voltage and frequency with that of 33 KV bus. After
obtaining synchro check permissive as indicated by synchro check
relay lamp and synchroscope, close the Generator breaker.

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4.4.6 Immediately after synchronizing, take a block load of 2 MWe to avoid

Generator trip on reverse power protection. Adjust VAR load.
4.4.7 Further raise of load on TG shall be governed by the values mentioned

in Table 4.3 depending upon the type of start-up. Maintain VAR load
as per the Generator characteristic curve given in fig. 4.1.
4.4.8 At each stage of raising of load on TG ensure all Turbovisory

instrument readings are within limits .At a load of 6 MWe, unit
auxiliary transformer can be taken into service.
4.4.9 In absence of HP extraction and LP extraction TG load can be raised to

a maximum of 16 MWe while maintaining rated condenser pressure
of 0.1 ata.
4.4.10 To raise the TG load beyond 16 MWe commission HP and LP

extractions.
14. Refer fig 4.2 for TG start up and loading
15. Commissioning of TG extractions.
16. Commissioning of HP extraction (32 ata)

In general HP extraction can be taken into service at a
secondary oil pressure (HP) of 2.2 kg/cm 2 which corresponds to a load
of 12 MWe. Carryout OTO-1 for taking HP extraction into service.
17. Commissioning of LP extraction (8 ata)

Ensure LP secondary oil pressure is more than 2.54 kg/cm 2.
Carryout OTO-2 for taking LP extraction into service.
18. Commissioning of vacuum unloading device

When TG load is more than 4.0 MWe, vacuum unloading
device can be taken into service. Carryout OTO-3 for taking vacuum
unloading device into service.
Vacuum unloading starts at a condenser pressure of 0.25 ata (570

mmHg vaccum.) and stops at a pressure of 0.4 ata (456 mmHg vaccum.)
which corresponds to 3 MWe on TG (At present the scheme is not
commissioned, so valve should be kept closed).

Doc. No: PU/III/29
TABLE – 4.1
Minimum Steam Parameters required for rolling of TG
Type of start-up Steam Pressure Steam Temperature (oC)
Cold start-up 20 280
Warm start-up 20 Should have 100oC super heat for the

corresponding inlet pressure.
Hot start-up 40 Temperature should be same as that

existed prior to trip.
TABLE – 4.2
Rolling of TG
TG speed Cold start-up Warm start-up Hot start-up
(rpm) Time (Min) Time (Min) Time (Min)
0 to 1000 10 10 10
1000 (soaking) 30 15 -
1000 to 2200 Instantaneous Instantaneous Instantaneous
2200 (soaking) 30 10 10
2200 to 3000 Instantaneous Instantaneous Instantaneous
3000 (soaking) 20 10 05
TABLE – 4.3
Loading of TG
Load Cold start-up Warm start-up Hot start-up
* Block load 2 MWe 2 MWe 2 MWe
Rate of rise of load 1Mwe/Min. 1.5 MWe/Min. 3Mwe/Min.

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Block load is the load to be picked up immediately after synchronizing the TG with grid/
other TGs.
Fig: TG Start up and Loading Curve

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Fig: Generator Capability curve

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HWP (M) OPERATION Chapter 6
VI. OPERATION OF TG
5.1 Loading and unloading
5.1.1 During steady state operation of TG, when it is required to raise or

lower the load on TG, follow the load changing curve given in Fig. 5.1
preferably.
5.1.2 There is no fundamental objection against rapid unloading of turbine

in case of emergency.
5.1.3 Restart after a trip:
Match inlet steam conditions existing prior to the trip (in case of hot
start-up) follow cold start-up, warm start-up or hot start-up
procedure depending upon the length of shutdown period.
5.2 Limits for normal and transient operations
5.2.1 Low Frequency Operation
a) Turbine :  3% at constant voltage

b) Generator :  6% at constant voltage
 5% at combined variation of V& f.
5.2.2 Transient Operation on low frequency
a) Turbine : 1) From (+) 3% to (-) 4% for 20 min. permitted

total time/annum is 20 hrs.
2)From (+) 3% to (-) 5% for 10 min. permitted
total time per year is 1 hr.
b) Generator : Low frequency limit and its duration are not
specified.
5.2.3 Minimum load operation
TG shall not be operated below 6.0 MW.

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Fig: Load Changing curve

5.2.4 Limit on HP & LP extractions
1. With zero extractions, TG load shall not be raised more than 16.0
MWe for normal condenser vacuum conditions.
2. Maximum extractions operation is governed by Fig. 5.2
5.2.5 Operation of TG without Generator air cooler
a) Same is not permitted.

b) Air inlet temperature to Generator shall not be more than 500C.
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c) Reduce TG load to maintain air inlet temperature at 50 0C in case

of problem with any section of the air cooler.
5.2.6 Operation of TG with one half of the condenser
Reduce load on TG to half, if one half of the condenser is not available

for service. Operation of TG under this condition shall not exceed 45
Min.
5.2.7 Operation of Generator
Operation of Generator shall be governed by Generator capability

curve.
5.2.8 Specifications of lube oil in service
Lube oil shall have the following specifications:
a) Viscosity : 44.5 cst at 400C.

b) Moisture : <500 ppm
c) Acidity (Max.) : 0.15 mg KOH/gm
d) Sediments : Nil
To maintain above specifications, oil centrifuge shall be operated at

least once in a day for at least 4 hrs. Preferably, in the first shift.

Doc. No: PU/III/29
Fig: Steam Consumption curve
5.1.1 Specifications of condensate, feed water and steam to be maintained

(see Table – 5.1)
5.2 On load tests
5.2.1 Testing of auxiliary lube oil pumps.
5.2.2 Oil injection test for over speed governor.
5.2.3 Testing of emergency stop valve.

Doc. No: PU/III/29
Refer “procedures for functional tests” for carrying out above tests.
TABLE – 5.1
Specifications of Condensate, Feed water and Steam
Sl.No. Parameters Condensate Feed Water Steam

01. PH at 25oC 8.5 – 9.5 8.5 – 9.5 8.5 – 9.5
02. Sp.Conductivity at 25oC 1.48 1.48 0.2
s/cm (Max)
03. Hardness ppm BDL BDL BDL
04. TDS (Max) ppm - 1.0 -
05. D.O. (Max) ppm 0.02 0.005 -
06. Si O2 (Max.) ppm 0.02 0.02 0.02
07. Cu + Fe + Ni (Max) ppm 0.05 0.02 0.02
08. Residual N2 H4 ppm - 0.05 to 0.1 -
09. Phosphate ppm - - -
10. Sodium (Max) ppm - - 0.01
11. Ammonia (Max.) ppm - - 0.5
5.3 Important DO’s during TG operation
5.3.1 Ensure availability of over speed tripping device.

5.3.2 Ensure availability of standby AOP and EOP.
5.3.3 Ensure operation of vapor exhaust fan of MOT.
5.3.4 The rate of heating of steam lines shall not be more than 5oC/Min.
5.3.5 Ensure availability of sealing water to vacuum breaking valve.
5.3.6 Collect oil sample from bottom of MOT and send it for complete
analysis once in a week.
5.3.7 Ensure MOT level is normal.
5.3.8 Ensure that CO2 fire fighting system is in poised state.
5.3.9 Change over CEP & BFP once in a week.
5.3.10 Take log sheet readings as per the specified interval.
5.3.11 Examine brush gear for
* Abnormal sparking between brushes and slip ring.
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* Chattering of the brushes.

* Dust or oil accumulation.
5.3.12 Generator shaft earthing brush healthiness checking.
5.3.13 Front pedestal rings should be free.
5.3.14 Ensure that Dirty Oil Tank is empty to facilitate draining of oil from
MOT in case of fire.
5.3.15 In case of TG trip – open ERV of the service boiler to avoid tripping of
the same on drum level low-low.
5.3.16 After isolating cooling water to condenser, open condenser vents and
drains.
5.3.17 Automatic opening of vacuum break valve is commissioned. In case of
TG trip on lube oil pressure low-low (or) axial shift high-high, ensure
opening of vacuum break valve to reduce coasting down time
otherwise open it manually.
5.3.18 After shifting of AOP discharge NRV (to sustain during accidental
stopping of running AOP), discharge valves are provided in AOPs.
Ensure they are always open except under maintenance.
5.3.19 While carrying out routine weekly AOP changeover, ensure incoming
AOP has taken over (by monitoring pressure and current), before
stopping running AOP. EOP also can be kept in service for availability
checking as well as to ensure no dip in lub. oil pressure. EOP should
not run for more time as it bypasses lub oil filter and cooler.
5.4 Important DON’Ts for TG operation

5.4.1 TG shall not be allowed to operate on reverse power for more than a
minute.
5.4.2 The maximum load on TG with zero extractions shall not exceed 18
MWe.
5.4.3 Do not operate TG without emergency governor in service.
5.4.4 Do not allow hot rotor to come to stand still position. Ensure hand
barring if barring gear motor is not available for operation.
5.4.5 Does not supply gland steam to turbine unless TG is on barring gear.
5.4.6 Do not hold TG at/near critical speed while raising the speed of the
TG.

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5.4.7 When TG shutdown is planned, do not open Generator breaker after

unloading the machine. Instead trip the turbine first and allow
Generator breaker to open on low forward power/reverse power
protection.
5.4.8 If after turbine trip, MW does not come to zero, it may be because of
steam coming from inlet/ extractions due to passing of ESV/
governing valves/HP or LP extraction QCNRVs, close the isolation
valves in those lines and allow the generator to trip on low
forward/reverse power.
5.4.9 Do not change the trip set points of TG, unless authorized by
competent authority.
5.4.10 Do not bypass any protection on TG set unless authorized by

competent authority.
5.4.11 Subsequent to the tripping of steam generators, do not wait for the
turbine to trip on steam temperature low-low protection. Hand trip
the machine immediately.

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HWP (M) SHUT DOWN Chapter 7
VII. PLANNED DHUTDOWN

6.1.1 Unload TG up to a load of 6MWe as per the unloading curve given in
Fig. 5.1.
6.1.2 Cut out HP extraction as per OTO – 5.
6.1.3 Cut out LP extraction as per OTO-6.
6.1.4 Changeover 6.6 KV Unit Board Supply from UAT to 6.6 KV station bus.
6.1.5 Reduce TG loads to 1.5MWe and makeup hot well level by opening
hot well make up valve.
6.1.6 Hand trip the turbine and ensure TG has tripped on low forward
power/reverse power.
6.1.7 In case, TG does not trip on low forward power/reverse power, trip
the same from MCR, after applying the remedies suggested in the
trouble shooting section (Item-1).
6.1.8 Ensure emergency stop valve, HP control valves and LP control valves
have closed in the field.
6.1.9 Ensure Generator breaker and Generator Field Breaker have tripped.
Keep Generator breaker in test position.
6.1.10 Close turbine steam inlet valve and its IBV.
6.1.11 Ensure Auto start of AOP-I/II when `MOP discharge pressure low’
annunciation appears and note down the corresponding speed of TG.
Presently not applicable as MOP is removed.
6.1.12 Start AC JOP when TG speed comes down to 200 rpm.
6.1.13 After TG has come to rest, engage barring gear and start barring gear
motor.
6.1.14 Note down the time taken for bringing TG shaft to rest.
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6.1.15 Open drain valves on Main steam inlet line, 32 ata extraction line, 8
ata extraction line and Turbine casing drain valve.
6.1.16 Cut out Main Steam Jet Air Ejector.
6.1.17 When condenser vacuum falls to 200 mmHg isolate gland steam
system to TG.
6.1.18 Keep TG on barring gear for about 72 hrs. (If barring gear motor is not
available for operation, rotate TG rotor by hand each time by 180 o (i.e.
half turn) at an interval of 3 to 4 minutes during the first three hours
after shutting down. After-wards at longer intervals of about 10 min).
6.1.19 Adjust cooling water to oil cooler so as to maintain a bearing oil inlet
temperature of about 35oC.
6.1.20 Stop CEP after 4 hrs of turbine shutdown and switch off the modules
of CEPs. Keep the local push button in locked condition and open hot
well drain after closing make up. Continuous running of CEP not
needed for exhaust hood spray after shifting spray tapping from 0.3 m
elevation to 4.8 m elevation at the U/S of erstwhile hot well LCV.
Header is to be back charged.
6.1.21 Stop barring gear and auxiliary lube oil pump after 72 hrs of shutdown
or when casing temperature comes down to less than 100oC.
6.1.22 Isolate cooling water to oil cooler.
6.1.23 Isolate cooling water to Generator Air Cooler.
6.1.24 Isolate condenser-cooling water when LP exhaust hood temperature
comes below 40oC- 50 oC and open condenser vents and drains. If
condenser C W inlet and outlet valves are passing, drains may be kept
closed but intermittent periodic draining to be ensured.
6.2 Emergency Shutdown

6.2.1 In an emergency, TG can be shutdown at any power level. TG can be
tripped from MCR through emergency trip push button or through
local trip button provided on turbine front. The procedure that has to
be followed after turbine trip is similar to the procedure adopted for
planned shutdown of TG. Given at item 6.1.
6.2.2 In case of sudden tripping of one TG, when plant is running at full
load, ie.. 2 Boilers, 2 Turbines and 2 Exchange Units, following actions
are to be taken.
1) Open ERV’s of running boilers and start standby BFP of any unit.
2) Ask M.P to cut out 3 À’ sections.

Doc. No: PU/III/29
3) Reduce firing in boilers & close ERV’s .

4) Minimise plant import so that the plant MD will not cross permitted value
by:
a) opening ESP transformers H.T breakers.

b) stopping CHP loads.
c) stopping 3rd BFP if drum levels are normal.
d) stopping one Coal Mill in any of the boiler.
6.3 Shut-down state of TG
6.3.1 TG is on barring gear

Or
TG is at rest. Lube oil pumps are in stopped condition.
6.3.2 Space heaters (module number 2.8R on respective TG Building LDB)

for Generator are ÒN’.
6.3.3 CO2 system for generator is isolated.
6.3.4 Cooling water to oil coolers and Generator air cooler is in isolated
condition.
6.3.5 Main Steam inlet valve to TG is in closed condition.
6.3.6 Gland sealing System and condenser air extraction system are in
isolated condition.
6.3.7 Speeder gear and starting device hand wheels are in closed position.
6.3.8 Drain speeders of HP & LP extractions are in isolated condition.
6.3.9 HP & LP extractions line isolation valves are in closed condition.
6.3.10 CEP modules are in OFF condition. Local Push Buttons are in pressed
condition.

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6.3.11 Hot well LCV down stream & bypass valves are in closed condition.
Hot well drain valve is in open condition and fill valve is in closed
condition.
6.3.12 GT breaker is in test position.
6.3.13 Monitor MOT oil level.
6.3.14 Ensure availability of fire fighting equipment & fire hydrant system.
6.3.15 Check for any oil leakage.
6.3.16 Ensure minimum oil stock of 50% in COT to take care of emergency
requirement. Inform to Mech. Maintenance if the stock is less.

Doc. No: PU/III/29
HWP (M) ANNUNCIATIONS AND ACTIONS Chapter 8
VIII. ANNUNCIATIONS AND ACTIONS
A. ANNUNCIATIONS AND ACTIONS TURBINE
Window
No.(TCP)
Sl.No Description Set Point Operator Action
01. Turbine over- R9 3300 rpm a) Check whether Turbine has

speed trip actually tripped and note down
the actual speed at which trip
occurred. Allow generator to trip
on reverse power protection/low
forward power.
b) Close turbine main steam
isolation valve, HP extraction
MOV & LP extraction MOV.
c) Investigate the cause and take
corrective action.
02. TG bearing T10 65 a) Check TG shaft vibrations.

housing Reduce the load and allow the
vibrations machine to stabilize.
high. b) If vibrations are occurring during
start-up, increase the soaking
period and also increase the TG
speed with controlled
acceleration (200-400 rpm/min).
03. TG shaft S-10 80 a) Ensure lube oil temperature is

vibrations between 38 to 40oC.
high b) Reduce load.
c) Maintain steam inlet temperature
and pressure steady.
d) Check condenser vacuum and

Doc. No: PU/III/29
improve the same if it is low.

e) Check for any abnormal noise/
vibrations in the field.
f) Check lube oil pressure and return
oil flow in each of the bearings.
Window
No.(TCP)
g) If vibrations are high during startup

allow more soaking time and also
control the acceleration between 200
to 400 rpm/min. while increasing the
speed.
h) Ascertain high vibrations from
portable vibration monitor.
04. TG shaft R-10 110 a) Ensure that turbine trips on

vibrations protection. If turbine does not trip,
high- trip the same manually.
b) Note down the vibrations level at
high
which trip has occurred.
c) Initiate DR to I/M check the accuracy
of the probe.
d) Initiate DR to M/M for further
investigations.
05 Turbine T-11 -5 mm a) During hot startup, ensure that inlet

differential steam temperature is more than the
expansion casing Temp.
high b) Roll and load the turbine as per the
(negative) startup curves. Too slow rolling and
loading will cause negative differential
expansion.
c) Increase the inlet steam temperature

Doc. No: PU/III/29
and if possible load the turbine faster.

d) In extreme cases tripping of turbine is
not advisable as it would worsen the
situation. Increasing steam
temperature and rapid loading are
better alternatives. If turbine trips
speed up coasting down by opening
vacuum breaking valve.
Window
No.(TCP)
a) Control the steam temperature
especially during cold start-up. Too
06. Turbine T-11 + 5 mm
high steam temperature should be
differential
avoided. Superheat of 50oC is
expansion Hi
optimum.
(Positive)
b) Allow turbine to soak for longer
time.
c) Load the turbine very slowly or if
possible hold the load.
d) In case of excessive positive
turbine differential expansion,
tripping of turbine will help.
e) High gland steam temperature is
also responsible. So control gland
steam pressure and temperature
within the limits.

Doc. No: PU/III/29
07. Turbine Axial S-11  0.5mm a) Check turbine inlet steam

displacement parameters. Control sudden
Hi changes.
b) Control condenser vacuum.
c) Reduce load to reduce axial shift
to permissible limits.
d) Check lube oil pressure to thrust
bearing. Increase if it is low ( i.e.
<0.8 kg/cm2)
e) Excessive salt deposition on
turbine blades. Initiate DR to
carryout steam washing or
overhaul.
f) Avoid too fast pickup of speed.
08. Turbine axial R-11 0.8mm a) Ensure that turbine has tripped
displacement and vacuum breaking valve opens
hi-hi by itself. Otherwise open the
vacuum breaking valve manually
and cut off ejectors to speed-up
coasting down.
b) Investigate the reason and take
corrective action.
Window
No.(TCP)
09. Turbine T-12 115 a) Deflection of turbine rotor due to

eccentricity improper heating during start-up.
high Follow startup curves strictly.
b) Ensure that turbine casing drains
are in open condition during
startup.
c) Ensure that turbine is on barring
gear till casing temp. reaches
100oC.
d) Minor increase in eccentricity can

Doc. No: PU/III/29
be reduced by prolonged barring

gear operation and/or prolonged
soaking during rolling.
10. TG bearing S-12 100oC a) Check and maintain correct lube oil
metal Temp. flow, pressure and temperature to
high (and fuse bearings.
fail) (Note: b) Periodically analyze lube oil for
Blowing of moisture and other impurities.
UPS supply c) Check axial shift, if thrust-bearing
fuse to the temperatures are high.
turbovisory d) If bearing vibrations are high and if
panel’s temp. bearing temperature continues to
monitoring remain high, reduce load to see if
unit was situation improves, otherwise trip
leading to the unit after ruling out instrument
tripping of malfunctioning.
unit TG; e) If it is the case of power supply
which is now problem to bearing temperature
announced as monitor, take steps to restore the
above. This is supply with the help of I/M.
only an alarm)
11. TG bearing R-12 115oC a) Ensure that turbine has tripped

metal and note down the temperatures
temperature of all the bearings.
hi-hi b) Initiate D/R to M/M.
c) Check the reading in the
Turbovisory panel. If it is reading
297oC, then it is a spurious trip due
to open circuit in RTD. Initiate DR
to I/M.
Window
No.(TCP)
12. Turbine T-14 100oC a) Check lineup of exhaust hood

exhaust spray. Ensure that solenoid valve
steam has opened. If not, ensure spray
temperature through bypass valve.
hi. b) Condenser vacuum may be too
Doc. No: PU/III/29
low. Take steps to improve the

same.
c) Reduce inlet steam temperature
and pressure to turbine during
start-up.
d) Turbine may be running at low
loads for long periods. Load the
turbine quickly.
13 Controlled S-20 36 ata a) Auto set point may be high. Select

extraction the correct set point.
pressure high b) Check opening of HP quick closing
NRV. Check whether drain speeder
is released fully or not.
c) Check whether motor operated
isolation valve is open fully.
d) HP steam demand may be
fluctuating. Take up the issue with
SS of MP.
e) Load variations due to governor
hunting. Reduce hunting.
f) Check HP and LP secondary oil
pressures and valve opening and
co-relate with standard relations
14. Controlled R-20 40 ata a) Ensure that turbine has tripped

extraction and isolate HP extraction by
pressure hi-hi closing the MOV.
b) Investigate the cause. If it is a
sequel of Main Plant tripping,
turbine can be re-rolled if
situation warrants.
c) Note whether Extraction safety
valve has lifted at its set pressure
(35.5 ata).
Sl.No Description Window Set Point Operator Action

No.(TCP)

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15. Controlled S-21 27 ata a) Auto set point may be low. Select
extraction the correct set point.
pressure low b) Turbine may be running on low
loads. Load the turbine further.
c) HP steam demand may be high.
Improve the header pressure
through PRDS.
d) HP steam demand may be
fluctuating. Take up the issue with
S.S. of MP.
e) Governor may be hunting. Trip the
turbine and initiate DR to M/M.
16. Controlled R-21 24 ata Same as above

Extraction
pressure low-
low
17. Turbine inlet T-13 490oC a) Control super heater outlet

steam temp. temperature.
high
18. Turbine inlet S-13 460oC a) If this condition occurred due to

steam temp. tripping of steam generator, hand
low trip the turbine immediately and
close main steam isolation valve to
turbine to prevent condensate
entry into turbine.
b) If the cause of low steam
temperature is due to emergency
situation like tripping of mill etc.,
first try to decrease the pressure
and take steps to improve the
temperature.

Doc. No: PU/III/29
Sl.No Description Window Set Point Operator Action

No.(TCP)
c) If the cause of low steam temp. is

due to carry over in the Steam
Generator, hand trip the turbine
immediately and close main steam
inlet valve to turbine to prevent
condensate entry into turbine.
d) Control super-heater outlet
temperature.
19. Turbine inlet R-13 430oC a) Ensure that turbine has tripped, if
steam temp. not, trip the same manually.
low-low b) Close main steam isolation valve to
turbine.
c) Open all the drains on Main steam
line.
20. Trip coil not S-7 a) Inform I/M and get the problem
healthy rectified.
b) If problem is not rectified, reduce
the load on TG and trip the same.
Initiate DR.
21. Trip circuit TCD a) Inform I/M and get the problem
healthy on rectified.
GCD b) If problem is not rectified, reduce
disappeared the load on TG and trip the same.
Initiate DR.

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B. ANNUNCIATIONS AND ACTIONS (GENERATOR)

Sl. Description Window Effect on the system Operator Action
No. No.
1. Ensure that the GT
breaker has opened.
01. Generator U-1 Leads to Class-A tripping
2. Ensure that the
Differential of TG through 86G1
Turbine has tripped.
trip Lockout relay in RA2,
If not, trip the turbine
GRP wherein –
manually.
a) Generator 3. Ensure that the Field
Transformer Breaker Breaker has opened.
opens 4. Ensure that the UASG
b) Generator Field supply has changed
Breaker opens over to SSG supply
c) Turbine is tripped. without interruption
d) Fast auto change otherwise, normalize
over of UASG supply supply to UASG at-
occurs. once.
5. Note down the flag
and alarm window
operation
corresponding to this
tripping.
6. Inform E/M section at
once.
NOTE: Presently CO2
release system is available
on manual operation
only. It is to be released
from GCD by pressing CO2
release button or from
local manually in case of
any fire in the generator
and/or hot air temp. goes
beyond 100oC.
02. Generator S-3 Same as above Same as sl. No. 01

Transformer
differential
trip.

Doc. No: PU/III/29

No. No.
03. Generator U-9 Same as above Same as Sl no. 01. (This

95% stator alarm is generated when
E/F relay trip. 0-95% earth fault trip of
Main Stator E/F Relay
(64G1) or standby earth
fault relay 64G2 operates.
The trip commands are
parallel as well as alarm
contacts are paralleled).
04. Generator U-2 Same as above Same as Sl no 01. (This

Reverse ensure total isolation of
Power Relay working steam to the
Trip. turbine).
05. Generator U-10 Same as above Same as in Sl.No.1

Over-voltage
relay trip
(Stage-I)
06. UAT backup R-3 Same as above. Same as above.

over-current
relay trip.
07. UAT pressure T-6 Same as above Same as above.

relief relay
trip

Doc. No: PU/III/29
08. UAT Buchholz S-7 Same as above. Same as above.

Relay Trip
Generator
Backup
09. T-5 Same as above Same as above.
Impedance
Relay
Trip(Stage-I)

Doc. No: PU/III/29

No. No.
UAT Mulsifire Same as above. Ensure
trip the operation of deluge
10. T-9 Same as above
valve to Quench the fire.
Also ensure that the UAT
fire is put out with the
assistance of Fire Fighting
Staff.
Generator Leads to Class-A tripping Same as Sl no. 01
Transformer of the TG set through
11. U-6
overall 86G2 lockout relay in
differential RA2 of GRP wherein the
relay trip. effects mentioned above
occur.
12. UAT R-2 Same as in Sl.No.11 Same as in Sl.No.01

differential
Relay Trip
13. 100% U-8 Alarm only Inform E/M at once (This

Generator indicates stator earth
Stator E/F fault in 95-100% of stator
Relay winding which is very
operated close to the neutral).
14. Generator U-10 Same as above (Sl.No.1 Same as in Sl.No.1

over- voltage above except that, this
relay trip trips through 86G2
(Stage-II) lockout relay)

Doc. No: PU/III/29

No. No.
15. Generator U-7 Same as above Same as above

Rotor Earth
fault relay trip
(Stage-II)
16. Generator T-2 Same as above Same as above

Transformer
over fluxing
relay trip
17. Generator S-4 Same as above Same as above

Transformer
REF relay trip
18. Generator R-1 Same as in Sl.No.14 Same as in Sl.No.1

Transformer
Buchholz
relay trip
19. Generator S-5 Same as above Same as above

Transformer
O/C and
Backup E/F
relay trip
20. Generator R-1 Same as above. Same as above

Transformer
OLTC

Doc. No: PU/III/29
Buchholz trip.

Doc. No: PU/III/29
Sl. Description Wind Effect on the system Operator Action

ow
No.
No.
21. Low forward power U-3 Same as in Sl.No.11. Same as in Sl.No.11

relay trip. This protection
(Interlocked with advances the tripping
voltage balance of Generator breakers
scheme which as compared to
ensures PTs are Reverse power
healthy, Generator conditions. This is to
Breaker close ensure that Generator
condition and does not go for
Turbine trip relay motoring action.
86G3 operated
which ensures
Turbine has
tripped).
22. Generator Negative T-10 Leads to Class-B 86G3 1. Ensure that turbine has
Sequence Relay (RA4 in CRP) tripping of tripped. If not hand trip
Trip. (Stage-II). Turbine and the turbine.
(Stands for extreme subsequently 2. Ensure opening of Gen.
Negative sequence Generator Breaker Breaker on low forward
over current through Low Forward power relay. (this is backed
conditions) Power Relay trip action up by reverse power relay
when 86G3 operates trip).
the following occur- 3. Ensure that UASG supply
has changed over to SSG
a) Low forward power
supply. If not, normalize
interlock is made
UASG supply through the
through for the
station tie breaker.
purpose indicated
4. Ensure that GT breaker has
above.
opened.
b) Turbine trip relay is
5. Inform E/M at once.
energized.

Doc. No: PU/III/29

No. No.
c. UASG supply is 6. Identify and isolate

changed over to SSG the feeder causing
supply through over- unbalance in the 3
lapping. (i.e. UAT phase currents.
incomer-I1 and SSG tie
breaker T4 remain closed NOTE: Both Class-B and
for a moment and then I1 Class-A Lockout Relays
trips. If I1 fails to open, operate.
then T4 also trips after
set time delay).
23. Loss of T-4 Same as in Sl.No.22. Same as above

Excitation Sustained loss of
trip. excitation leads to
a) Damage of rotor due
to excessive
overheating and
b) Local voltage dips.
24. Generator S-9 Same as in Sl.No.22 Same as in Sl.No.22

Transformer
oil
temperature
hi-hi trip
(90oC)
25. Generator S-8 Same as in Sl.No.22 Same as in Sl.No.22

Transformer
winding
temp. hi-hi
trip(95oC)

Doc. No: PU/III/29
26. UAT winding S-2 Same as in Sl.No.22 Same as in Sl.No.22

temp hi-hi
trip (95oC)

Doc. No: PU/III/29

No. No.
UAT oil temp.
hi-hi trip Same as in Sl.No.22 Same as in Sl.No.22
27. S-3
(85oC)
28. Negative T-10 Leads to Class-C tripping 1. Ensure that TG load

sequence of the TG set through has come to
protection 86G4 lockout in RA4 of unit/house load, if
(stage-1 GRP, wherein- UAT was in service
prolonged) prior to the
a) 33 KV Generator
transformer breaker occurrence of Class-C
lockout protection.
is opened.
2. Attempt to Re-close
b) Unit TG does not
the 33 KV breaker so
trip. Its UAT is
as to start the station
feeding UASG, TG
auxiliaries such as FO
comes to house
pumps and DM water
(unit) load.
transfer pumps, in the
c) If in islanded mode
event of loss of Class-
the opening of all
IV 33KV supply, and
33KV GT breaker
sustain SG-TG
may lead to total
operation.
loss of Class-IV
3. If only one GT breaker
power supply.
trips on such an event,
re-synchronize the
unit TG to the grid.
4. Inform E/M section
29. Generator T-1 Same as in Sl.No.28 Same as in Sl.No.28

under
frequency
(Generator
Transformer
breaker in
closed
condition).

Doc. No: PU/III/29
30. Generator U-5 Same as in Sl.No.28 Same as in Sl.No.28

pole slip (out
of step)
protection
trip.

Doc. No: PU/III/29

No. No.
31. Generator T-5 Same as in Sl.No.28 Same as in Sl.No.28

backup
impedance
trip. (For
faults beyond
33KV system
step 2)
This alarm normally
comes during excitation
32. Generator VT- T-8 1. If `VT-2 supply fail’ is
and de-excitation of the
2 supply fail. continuously ÒN’ the
Generator in all the 3 Reverse Power Relay
nos. of units in CPP.
is bypassed.
When VT-2 supply fail is 2. Inform E/M at once.
existing, then 32G1
(reverse power relay) is
blocked. Normally this
alarm gets reset
subsequently in all the 3
units).
As per the
correspondence vide:
IOM initiated date:
30/09/2009 by
Sri.M.R.V.Rajesh SO/F
responded by
Sri.A.N.V.Ratnam SO/F
on 01/10/2009 “VT1” is
used for “32 G1 reverse
power protection”
whereas “VT2” is used
exclusively for metering
in TG-I & TG-III . In TG-II
“VT2” is used for “actual
value” of DVR channel II
along with metering.
33. Generator VT- T-7 Leads to blocking of low 1. Control excitation on

Doc. No: PU/III/29
1 supply fail. forward power relay, loss manual.

of excitation relay, out of 2. Inform E/M at once.
step relay, and backup
impedance relay.
Also, leads to
changeover of excitation
from AUTO channel to
MANUAL channel.
34. Generator U-4 Alarm only. 1. Reduce generator

overload.
current(over 2. Isolate any load
load) relay known to be causing.
operated.

Doc. No: PU/III/29
Sl. Description Win Effect on the system Operator Action

dow
No.
No.
Inform E/M at once
35. Generator R-7 Leads to loss of certain 1. Identify the failure of
protection protections: DC feeder by
panel Dc fails. inspecting the relays
DCI failure leads to –
in the bottom most
a) Gen. Differential rack right of RA1
Protection. panel.
b) Gen. 95% stator E/F 2. Keep the DC selector
Protection. in RA1 to the healthy
c) Gen. Over-voltage feeder position.
Protection. 3. Reset and switch ÒN’
d) Gen. Overload alarm. the feeder suspected
e) Gen. Negative Sequence to be faulty once
Relay Protection. again and observe
f) Loss of excitation that the relay flag in
protection. RA1 and annunciation
g) Voltage Balance Scheme. in GCP get reset. If
h) Backup Impedance not, inform E/M
Protection. section at once.
i) Reverse Power 4. If the module resumes
Protection. power supply to the
j) UAT Over current panel, select the DC
Protection. selector switch to
k) UAT Buchholz ÌNDEPENDENT’
Protection. position.
l) UAT winding temp. 5. Trip TG, if supply can
Protection. not be restored (after
m) UAT pressure relief informing to PM(U).
protection.
n) UAT Mulsifire trip.
o) UAT oil temp protection.
p) UAT Buchholz Alarm.
q) UAT winding temp. High
alarm.
r) UAT oil temp. High
alarm.
s) UAT oil level gauges low
alarm.

Doc. No: PU/III/29

No. No.
t) GT differential
protection.
u) GT oil temp.
Protection.
v) GT winding temp.
Protection.
w) GT oil temp. high
alarm.
x) GT winding temp.
High alarm.
y) GT Mulsifire trip.
DC II failure leads to
failure of the other
protections.
1. Ensure that all the
radiator cooling air
36. Generator S-6 Occurs when one or
fans are in service
transformer more of the following
and all the radiators
trouble protections act:
are in service.
a) Buchholz Alarm 2. Ensure that the local
b) GT winding temp. readings correspond
high alarm (85oC) to alarm level.
c) GT oil temp. high 3. Reduce load to
alarm (80oC). normal and isolate
d) GT Oil level low known overload.
4. Inform E/M section.
5. Physically check the
transformer for any
visible oil leakages or
any other
abnormality
6. In the case of
Buchholz alarm
reduce load to the
minimum or
shutdown the
transformer without

Doc. No: PU/III/29
interruption to
essential services,(if
standby TG is on the
bus bars).

No. No.
37. Generator R-9 This alarm is generated 1. Record the details of

Excitation whenever abnormal relay operation/LEDs
system operating condition is from DAVR panel.
trouble announced in the DAVR (Refer excitation
panel. system manual for
details).
2. Inform E/M section at
once.
38. Generator R-10 This alarm is generated 1. Check-

CO2 system when, a) Whether power
trouble supply to the CO2
a) CO2 main control
panel is disturbed and
panel power supply is
restore it.
disturbed, and/or
b) Whether 80oC temp.
b) Generator hot air
alarm is existing on
temp. goes beyond
the CO2 panel. If yes,
80oC.
reduce load and
ensure that coolers
NOTE: Presently tripping are healthy.
c) Cross check hot air
of Generator and release temp. on CRT with
of CO2 are not provided local reading.
on auto. CO2 to be d) Start standby ACW
released manually in pump.
case of fire in the
generator after physical
check up.
39. Generator R-8 This alarm is generated 1. Note down the relay
lockout relay when any of the lockout with faulty coil. Check
Doc. No: PU/III/29
coil relay 86G1, 86G2, 86G3, whether its

unhealthy. 86G4 coil develops an supervising relay LED
open circuit fault. As a is ÒFF’.
result of the coil fault, 2. Inform E/M at once.
that particular group 3. If standby generator
protection will not be are on the bus bars,
available to the unit. de-synchronize the

No. No.
Each lockout relay is Unit, without

supervised by a relay interrupting supply.
with `GREEN'’LED.
4. If problem is not
resolved, initiate actions
NOTE: There are 2 nos. for safe shutdown in
such green LEDs in RA2 consultation with higher
and 3 nos. in RA4 panel ups.
of each GRP. The 3rd in
RA4 monitors the trip
coil of 33KV GT breaker.
Hence, it is essential that
all these LEDs be ÒN'
always.
40. Class- A R-4 This alarm singly can Same as in Sl.No.1 Also,
LOCKOUT appear when 33KV GT ensure that the 33KV
TRIP. breaker failure, relay or zone of interest is isolated
LBB trip is generated. from all sides (incoming
This leads to effects as and outgoing including
mentioned in Sl.No.1 bus coupler).
NOTE:
1. Some relays are provided with DC/DC converters. Some of the converters have
healthiness indicating àmber’ coloured LEDs which should normally be glowing. Ensure
that whenever DC/DC converters have this LED, these LEDs are glowing.
Doc. No: PU/III/29
2. Generator over-voltage and over-fluxing relay alarm stages are used for DAVR limitation
also. E.g. When the `Start’ LED on over-fluxing relay is glowing any attempt of increasing
generator terminal voltage is nullified.
3. The following flags are normally in òperated’ condition: they are known as `supply
monitoring’ flags and prevent trip commands during generator stand still or excitation
buildup/de-excitation conditions:
a) Low Forward Power Relay(RXPE40) Flag.
b) RXIG21, RXEG21 of 64G1 (Stator earth fault relay)
c) RXEG21 of 40G (Loss of Excitation Relay)
d) RXEG21 (3 nos) of VT-1 (voltage balance scheme)
e) RXEG21 (3 nos) of VT-2 (voltage balance scheme)
4. When the `stator 100% Earth Fault’ alarm comes ÒN’, it means that the fault is very
close to the neutral and does not affect the system directly. However, second Earth
Fault may prove disastrous.
5. CO2 is automatically released into the generator stator air space in the following events:
 87G (Generator Differential Relay) trip condition.

 Generator air temperature 100oC (along with 80 oC) condition.
CO2 `released’ feed back will occur on sensing of pressure in the CO 2 piping of the unit
generator. This feed back is available on Generator Control Desk.
Presently auto release of CO2 is not incorporated.
6. `CO2 system on test’ feed -back is available on GCD. This indicating lamp will glow when
unit CO2 system is put on test by the selector switch in CO2 control panel.
7. Class-A 86G1 lockout relay operates on CO2 release. Presently this is not incorporated.
8. CO2 can be released on emergency basis through emergency release push button on:
a) GCD and/or
b) CO2 main control panel.
c) TG operating floors push button box. On all these cases TG will trip on 86G1 lockout
relay operation. When the Electrical operation is not possible due to any reason, CO 2
can be released by operating the Pull cord system manually. (presently this facility is
not made available)

Doc. No: PU/III/29
HWP (M) AIR SUPPLY Chapter 9
IX. AIR SUPPLY

a. Air supply is required for 32 ata extraction pressure controller, HP extraction ( i.e.
follow up piston positioner), LP extraction CV and vacuum unloading controller.
b. Loss of Air Supply
i. Controlled extraction goes to minimum position.
ii. Electrical vacuum unloading will not be effective in case of fall in

condenser vacuum.
iii. LP control valve (EXV-14) goes `CLOSE’.
iv. 32 ata and 8 ata final de-superheating spray CVs go full ÒPEN’.
v. 32/16 ata PCV and gland steam PCV will close, hence their bypass to
be opened urgently to maintain vacuum.

Doc. No: PU/III/29
HWP (M) CONTROL SUPPLY Chapter 10
X. CONTROL SUPPLY
a. Control supply for turbovisory instruments is extended from 110V UPS. On
loss of control supply, turbovisory protections will not be effective, turbine
continues to be in service with the alarm on TCP (S.12) as turbo generator
bearing metal temperature high/Fuse fail.
b. On loss of 220V DC control supply to Trip Solenoid Valve, Turbine trips will
not be effective. Turbine trip coil healthy annunciation on TCD will disappear.

Doc. No: PU/III/29
HWP (M) TROUBLE SHOOTING Chapter 11
XI. TROUBLE SHOOTING/EMERGENCIES IN TG
Sl.No Trouble Possible Cause Suggested Remedy

1. Ensure that the both Auto and
01. Generator fails 1. Auto rundown of Manual Potentiometers are in
to trip on excitation system has not minimum position.
Reverse Power occurred. 2. Close Turbine Main steam
protection 2. ESV might not have inlet valve and its IBV.
following turbine closed fully. 3. Close HP extraction Motorised
trip. 3. HP extraction QCNRV isolation valve and its IBV.
passing. 4. Close LP extraction Motorised
4. LP extraction QCNRV isolation valve.
passing.
NOTE: Take the above-suggested
remedial measures and allow
generator to trip on reverse
power protection. Under these
circumstances never open the
generator breaker manually.
In new DCS, auto closing of HP
and LP extraction MOVs are
provided on turbine trip( subject
to module is ready), other wise to
be closed manually.
02. Turbine did not 1. Turbine Main Steam inlet 1. Open turbine main steam inlet
start rolling even valve is in closed valve after ensuring that HP
after HP and LP condition. and LP control valves are at
valves got 2. HP control valve stem min. position.
opened fully. might have broken. 2. Trip the turbine and initiate
D/R to M/M.
03.
MOT level 1. Solenoid valve at
1. Always isolate the centrifuge
dropping centrifuge inlet failed to
by closing the inlet manual
alarmingly. close when supply/ dis-
isolation valve. Initiate D/R to
charge pump is stopped
I/M.
and oil is getting drained
2. Check for oil traces in the fore-
through bowl overflow.
bay of CWPH. If oil is found
2. Turbine lube oil cooler
floating in the fore-bay change
tubes developed
over lube oil cooler, isolate
leakage/got punctured.
faulty lube oil cooler on
3. Severe lube oil leakage in
Doc. No: PU/III/29
the oil lines cooling water side and raise

DR to M/M.
3. Trip the turbine immediately
and isolate the system at the
earliest.

04. 1. Generator is operating 1. Reduce the load (Amps) on
Generator beyond the limitations the generator.
cooling air imposed by capability 2. Check line up of cooling
temperatures curve. water. Ensure that all the 7
remaining high. 2. Insufficient cooling water banks of the air cooler are in
flow in the generator air service.
cooler. 3. Start standby ACW pump.
1. Reduce generation and try to

05. Generator Auxiliary cooling water restart ACWP, otherwise trip
cooling air pump trips/not running. the turbine.
temperature
rises suddenly
06.
 Reduce turbine inlet steam
Wheel chamber Salt deposits on turbine
pressure.
pressure high blades.
 Maintain steam purity.
(65kgf/cm2,Max)
 Maintain drum level normal.
 Overhaul the turbine at the
earliest.
07. Abnormal noise/ Impending failure of GOP Trip the turbine immediately and
vibrations at and their assembly. initiate DR to M/M.
turbine front
pedestal.
08. 1. Efficient house keeping to keep

1. Lube oil dripping on the area clean from oil leaks,
Fire near MOT or exposed hot steam lines, accumulation of oil etc. If oil
near turbine or insulation etc. dripping is observed make
anywhere in the 2. Accumulation of oil arrangements to collect oil in
lube oil system. vapours in main oil tank. the containers away from
turbine steam pipes and
Doc. No: PU/III/29
insulation (If leakage is more

and posing fire hazard, trip the
turbine), otherwise till leakage
is attended to –
 Inform Fire Station.
 Use foam and CO2 fire
extinguishers to control fire.
 Place fire extinguishers close
to turbine and ensure that
they are full in every shift
beginning.
2. See that the oil vapour
extractor fans are always in
service.
If MOT is on fire and
cannot be controlled, trip the
turbine and drain the oil to
DOT after switching off all the
LOP’s. Open vacuum breaking
valve. This is a very serious
decision and should be taken
with extreme caution.
Valve in firewater spray for

the tank by opening firewater
isolation valve available near
ST-1 for MOT-1, near ST-2 for
MOT-2 and near emergency
air compressor for MOT-3 to
quench the fire.
1. Power supply to barring 1. Switch òn’ and reset the

09. Barring gear gear motor not module.
motor does not available. 2. Start jacking oil pump and see
start. 2. Jacking oil pump not that jacking oil pressure is
running or jacking oil okay.
pressure low. 3. Start auxiliary oil pump and
3. Lube oil header pressure see that lube oil header
low or AOP not running. pressure is okay.
4. Barring gear motor 3 4. Correct the switch position to
position switch in off or forward. Engage barring gear
reverse .Barring gear lever and ensure switch
Doc. No: PU/III/29
lever not engaged/limit contacts are through with the

switch contacts not help of M/M.
through.

1. Possible steam entry into 1. Take steps to restart barring
10. Barring gear trip turbine from drain lines, gear.
while in engaged gland seals, extraction 2. Typically the lube oil pressures
condition. lines etc. Barring gear are 1-2 kg/cm2. Jacking oil
disengages if there is pressures are 30-60 kg/cm2.
even a minor steam Ensure that these values are
leakage into turbine. existing at all the bearings.
2. Lube oil and jacking oil
pressure at the bearings
insufficient.
11. Sparking
observed from 1. Flash over due to 1. Shutdown the TG and initiate
Generator sight insulation failure. DR.
glasses. 2. Foreign object in the 2. Shutdown the TG and initiate
Generator. DR.
12.
1. Ensure excitation system
1. Carbon brushes got
Heavy sparks voltage and currents are
worn- out.
observed from within limits.
Generator 2. Raise DR to change the brushes.
Excitation If sparks are excessive, trip the
carbon brushes. turbine.
3. Strictly adhere to PM schedule
for brushes checking and
replacement
13.
1. Sudden fall in HP steam 1. Immediately cut out extraction
HP extraction demand due to partial/ and try to save turbine from
pressure rising whole tripping of Main tripping.
suddenly. Plant.

Doc. No: PU/III/29
2. Hunting of the control 2. Refer governing system

valves.3. HP quick closing manual.
NRV not fully open or 3. Isolate HP extraction and
malfunctioning. establish the cause.

1. Maintain rated load through
14. Sudden increase 1. Fall in frequency. speeder gear.
of load on TG. 2. Sudden rise in boiler 2. Reduce boiler pressure and
pressure. adjust the load through
speeder gear.
3. Mal-function of Load/ 3. Take to hydraulic and resolve
Import-export control on the matter with the help of
EHTC I/M.
15. Smoke from TG 1. Gland steam

gland seals. temperature high. 1. Reduce gland steam pressure/
2. Differential expansion temperature if found high.
high. 2. Investigate.
16.
1. Condenser tube leak. 1. Reduce load and isolate one
Hot-well 2. Contamination of Make- half of condenser at a time to
conductivity up water. confirm tubes leak.
high. 2. Check for proper chemistry.
Increase TSP dosing and
initiate blow down
3. Take earliest shut down if tube
leak is confirmed.
17.
1. Sudden increase in load 1. Follow loading and
Parting plane on TG. unloading curves given by
steam leaks. 2. Entry of wet steam. BHEL.
2. Main steam inlet parameters
within limits.

Doc. No: PU/III/29
Condenser 1. Tripping of CCWP 1.Restart CCWP urgently and

vaccum falling/ 2. Tripping of CT fans reduce TG load to prevent trip
18 maintaining low 3. Mal-function of 2. Restart CT fans
32/16 ata PCV or 3.Control ejector steam and gland
gland steam PCV steam pressure through bypass
4. Overloading of
condenser 4 Reduce load on TG by shifting
5. Excessive air ingress load to other TG. Start additional
6. Accidental opening CT fans if CT outlet temperature
of vaccum breaking is more than 30 oC
valve. 5. Check rupture disc/expansion
bellow/ impulse lines etc for air
ingresses and plug them. If
required take starting ejector in
line
6. Close the vaccum breaking valve
immediately to prevent TG trip
also take starting ejector and try
to save turbine trip on vaccum
low-low

Doc. No: PU/III/29
HWP (M) PERFORMANCE MONITORING Chapter 12
XII. PERFORMANCE MONITORING OF TG

While TG is in operation, monitor the following parameters periodically and take
corrective action to maintain the parameters within limits and see that they do not reach
alarm and trip values. (After crossing maximum values, alarm limits will appear. Normal
value refer to 80% load on TG).
Sl.
No. Limits for Operation
Parameter Normal
Value Permitted Value
Max. Min.
01. Live steam temperature (oC) 480 488 460

(before ESV) TI 5.1
02. Live steam pressure (kg/cm2(a) 101 105 50

(before ESV) PI 5.1
03. Wheel chamber pressure PI 5.11 (ata) 60 65 -
04. HP extraction steam temperature (oC) TI 350 354 343

5.41
05. HP extraction steam pressure (ata) PI 32 33.5 28.5

5.41
06. LP extraction steam temperature (oC) TI 238 279 228

5.51
07. LP extraction steam pressure (ata) PI 8 11.68 8

5.31
08. Gland steam header pressure (kg/cm2) PI 0.05 0.1 0.01

5.31

Doc. No: PU/III/29
Limits for Operation

Sl.
No. Parameter Normal Permitted Value
Value
Max. Min.
09. Exhaust steam temperature (oC) 45 48.2 44

TI 5.11
10. Exhaust steam pressure PI 5.12(ata) 0.1 0.15 0.096
11. Control oil pressure PI 3.86 (kg/cm2) 8.5 9.5 7.8
12. Lube oil header pressure PI 3.63 2.3 3.0 2.0

(kg/cm2)
13. Lube oil inlet temperature TI 3.77 (oC) 40 42 38
14. Lube oil return temp. TRJB TI 3.67 52 65 45

GFJB TI 3.72 55 65 45
GRJB TI 3.73 60 65 45
TFJB TI 3.63 60 65 45
15. Condenser CW ∆T, (oC) 8 10 -
16. Steam pressure to ejectors (ata) 16 17 16
17. Steam temperature to ejectors 350 380 300
18. Condenser vacuum (mercury gauge) 685 - 600

(mmHg)

Doc. No: PU/III/29

Sl.
Value
Max. Min.
19. D.O. at De-aerator outlet (ppm) BDL 5 ppb -
20. Axial displacement (mm) ±0.35 ±0.8 -
21. Eccentricity (µ) 25 37 -
22. Differential Expansion (mm) 0.3 ±5 -

(short)
23. Casing Expansion (inch) 0.4 - -
24. Thrust bearing metal temperature (oC)
a) –do- A 85 100 -
b) –do- B 85 100 -
c) -do- C 85 100 -
d) –do- D 85 100 -
e) –do- E 85 100 -
f) –do- F 85 100 -
g) –do- G 85 100 -
h) –do- H 85 100 -
25. Bearing metal temperature (oC)

a. Turbine FJB 85 100 -
b. Turbine RJB 85 100 -
c. Generator FJB 70 100 -
d. Generator RJB 70 100 -
26. Vibrations (µ)

a. Turbine FJB H <50 63 -
b. Turbine FJB V <50 63 -
Doc. No: PU/III/29
c. Turbine RJB V <50 63 -

d. Turbine RJB H <50 63 -
e. Generator FJB V <50 63 -

Doc. No: PU/III/29

Sl.
Value
Max. Min.
f. Generator FJB H <50 63 -

g. Generator RJB V <50 63 -
h. Generator RJB H <50 63 -
i. Housing Vibrations TFJB <5 10 -
j. Housing Vibrations TRJB <5 10 -
k. Housing Vibrations GFJB <5 10 -
l. Housing Vibrations GRJB <5 10 -
27. Generator air inlet temperature (L) (oC) 45 50 -
28. Generator air inlet temperature (R) (oC) 45 50 -
29. Generator voltage R/Y/B (KV) 11.0 11.5 10.5
30. Generator current R/Y/B (Amps) <1850 1850 -
31. Generator rotor winding temperature (oC) <120 120 -
32. Generator stator winding temperature <120 120 -

(oC)
33. Generator Field Current (A) <560 560 -
34. Generator Field Voltage (V) <205 205 -
35. GT winding temperature HV/LV (oC) 70/70 80 -
36. GT Oil temperature (oC) 60 70 -

Doc. No: PU/III/29
HWP (M) ANNEXURES Chapter 13
ANNEXURES

Doc. No: PU/III/29
HWP (M) TECHNICAL DETAILS Chapter 13.1
Technical Details
12.1.1 TURBINE
1. Machine Nos. : T-0283, T-0284, T-0285
2. Type : EK-1800-2
3. Normal output : 27 MWe
4. Maximum output : 30 MWe
5. Normal speed : 3000 rpm
6. Inlet steam pressure : 100 kg/cm2 (g)
Permissible deviation : 105 kg/cm2(g)
7. Pressure in HP wheel chamber : 69.7 kg/cm2 (g) (Max.)
8. Extraction Pressure : 32.5 kg/cm2 (g)
Pressure variation : 33.5 to 31.5 kg/cm2 (g)
9. Steam temperature : 480oC
Permissible deviation : 488.3oC (Average)
Permissible deviation : 508oC (for 15 min).
10. Cooling water temperature : 33oC
11. Condenser vacuum : 0.1 kg /cm2 (a)
12.1.2 GENERATOR
1. Type : TGP 229251/2TS
2. Apparent output : 35.29 MVA
3. Active output : 30 MW
4. Rated p.f. : 0.85 (lag)

Doc. No: PU/III/29
5. Rated Voltage : 11000 ± 5% V
6. Rated current : 1852 A
7. Rated speed : 3000 rpm
8. Rated frequency : 50 Hz ±1%
9. Critical speed of Generator : 1794 rpm
10. No. of Generator terminals : Six
11. Generator phase connection : Star
12. Rotor voltage : 232V
13. Rotor current : 550A
14. Insulation : Class B (Rotor & Stator)
15. Type of cooling : Closed circuit air-cooling.

16.Volume of cooling air : 90,000 m 3/hr
17. Negative sequence current capability : 8% continuous, 13% for 30 Min.
18. Generator efficiency at 0.8 P.f. : 97.49%
19. Short circuit ratio : 0.61
20. Generator Field resistance :0.2582 ohms/ 20 oC
21. Moment of inertia of rotor : 6.3 tonnes-m 2
22.Critical speed of Generator :1794 rpm
23. Maximum short circuit torque : 153400 kg-m
24. Generator brushes
Number :8/ring
Size : 32*32 mm
25. Generator reactances :
Unsaturated synchronous reactance Xd : 183.91%
Transient reactance X’d : 19.01%
Sub transient reactance X”d :12.70%

Doc. No: PU/III/29
Negative sequence reactance X2 : 12.70%

Zero sequence reactance Xo : 4.84%
26 Generator time constants :
Open circuit transient time constant T’do. : 6.644 sec
Short circuit transient time constant T’d : 0.687 sec
Short circuit sub transient time constant T”d : 0.035 sec
Armature short time constant : 0.185 sec
27. Short circuit currents :
Maximum short circuit current : 14* In peak
(Including dc component)
Sustained 3-phase short circuit current: 3.24 kA
Sustained 2-phase short circuit current: 5.26 kA
28. Excitation requirement:
Amp volts power
At no load 233 60 14
At full load 568 205 116
29. Efficiencies at different loads and power factor
Output (as % rated) 100% 75% 50%
% efficiency (at unity pf) 98.10% 97.81% 97.10%
% efficiency (at 0.8 pf lag) 97.49% 97.15% 96.29%
30.Permissible temperature rise in generator parts :
Part of m/c permissible rise Measured by (above air temp.( 0C))
Stator winding 75 RTD between coil and slot
Rotor winding 85 increase in resistance
Slip rings 75 thermometer
Stamping etc. 85 RTD (in contact with winding
Note: Cooling air inlet temperature is assumed to be 450C

Doc. No: PU/III/29
HWP (M) ORDER TO OPERATE Chapter 13.2
12.2 ORDER TO OPERATE-1
Aim : To take HP Extraction into service.
Sl.No Valve No. Description Status required

(a) (b) (c) (d)
TG is in service with at least 12 MW
generation.
01.
02. Condenser vacuum is okay.
Turbine inlet steam parameters are okay.

(101ata and 480oC). TG vibrations and axial
03.
shift readings are within the limits.
HP steam header is in charged condition and
04.
HP PRDS is on AUTO.
HP de-superheating station is available and is
05.
lineup in all respects.
Pressure test point root valve on HP extraction Close
06.
line.
07. HP extraction pressure indicator root valve. Open
08. Root valve on the impulse line going for HP Open
extraction hi-hi hydraulic trip.
09. Pressure switch root valve (PSA 474) Open
13. Pressure transmitter (P X 5.45) root valve Open
(going to HP extraction controller in MCR).
14. Pressure transmitter ( P x 5.42 ) root valve. Open
15. Pressure indicator root valve (PI 5.41) Open

Doc. No: PU/III/29
16. 1-26-V300 Drain valve downstream of NRV Open
17. 1-26-V301 Steam trap isolation valve downstream of HP Open

extraction MOV.
Module of HP extraction MOV (15.4F USSG-1)

18. ON
19 1-26-V-303 Drain (on upstream side of safety valve Open

tapping) going to condenser flash box.
20. 1-26-V-304 Drain going to condenser flash box on Open

upstream side of NRV.
21. 1-26-EXV1 HP extraction Motorised isolation valve IBV Open

21A. HP extraction MOV Open
22. HP QCNRV return oil isolation valve Open
23. HP extraction controller in MCR Manual
24. HP extraction controller output Minimum

Doc. No: PU/III/29
Sl.No Valve No. Description Status

required
(a) (b) (c)
(d)
25. HP drain speeder released (Gradually lineup

instrument air to HP extraction pneumatic
positioner.
26. Observe piston rod of the HP QCNRV coming

out.
27. Also observe the indication of HP QCNRV

moving towards open position
28. Ensure availability of air supply at 6 kg/cm2 to

pressure controller. Select the set point of 33.5
ata by moving the pointer to 82% in the
controller on TCP/OS. (Measuring range of
controller is 0-40 kg/cm2)
Gradually cut in HP extraction manually by

increasing the controller output. Observe the
29.
pointer reading actual pressure. Adjust the
controller output such that actual pressure
coincides with the set point. At this stage a red
indication appears on the side marked auto.

Doc. No: PU/III/29
30. Now put the auto manual selection to auto and

observe the performance of the controller.
31. NOTE: While increasing the pressure manually,

observe the following:
1. Reset of HP extraction lo-lo window on TCP.
2. Reset of HP extraction lo window on TCP.
3. Increase in turbine inlet steam flow.
4. Increase in MW output.
5. NRV-I open LED on the turbine desk.
6. Improvement in condenser vacuum.
7. Decrease in LP secondary oil pressure.
8. Increase in HP secondary oil pressure.
9. Closing of HP PRDS-PCVs

Doc. No: PU/III/29

required
(a) (b) (c)
(d)
32. Observe the following in the field:

1. Full opening of the NRV
2. HP extraction Pr. on local gauge board.
3. Steam leaks.
33. 1-26-V300 Drain valve downstream of NRV Close
34. 1-26-V303 Drain going to condenser flash box on Upstream Close

side of safety valves tapping.
35. 1-26-V304 Drain going to condenser flash box on upstream Close

side of NRV.
36. 1-26-EXV1- IBV of HP extraction MOV. Close

IBV

Doc. No: PU/III/29
ORDER TO OPERATE-2
Aim : To take LP extraction into service

required
(a) (b) (c)
(d)
01. TG is in service with inlet steam parameters

close to 101 ata and 480oC.
02. TG vibrations and axial shift readings are within

the limits.
03. Condenser vacuum is okay. LP secondary oil

pressure is above 2.54 kg/cm2
04. LP PRDS is on auto and header pressure is 8 ata.
05 LP de-superheating station is available and lined

up in all respects.
06. Pressure test point root valve. Close

Doc. No: PU/III/29
07. Pressure indicator root valve (PI 0441) Open

required (d)
(a) (b) (c)
08. Pressure indicator root valve (PI 5.51) Open
09. Pressure transmitter root valve (PX 0401) Open
10. 1-26-V311 Drain line going to condenser flash box. Open
11. 1-26-V305 Steam trap isolation valve Open
12. 1-26-V308 Steam trap isolation valve on the drain line Open
downstream of LP extraction control valve.
13. 1-26-V309 Steam trap isolation valve downstream of MOV. Open
14. Pressure transmitter root valve (PX 5.55) Open
15. Instrument air lineup to LP extraction I/P Ensure

converter and control valve.
16. LP QCNRV return oil isolation valve Open

Doc. No: PU/III/29

required (d)
(a) (b) (c)
17. Module of LP extraction MOV 15.6F USSG ON
18. LP extraction MOV Open
19. LP extraction Auto/Manual selection Manual
20. LP extraction control valve Close
21. LP drain speeder Release

gradually
22. Observe the piston rod of LP QCNRV coming

out.
23. Also observe the (close/open) indication of LP

QCNRV moving towards open position.

Doc. No: PU/III/29

required (d)
(a) (b) (c)
Slowly open the LP extraction control valve till
the LP extraction pressure reaches 9.5 ata.
24.
25. Select the set point of 9.5 ata on the Turbine

control desk.
26. LP extraction Auto/Manual selection Auto

While cutting in LP extraction observe the
following:
27.
a. Decrease in condensate flow to de-aerator.
b. NRV-II opens LED on the turbine control
desk.
c. Increase in LP secondary oil pressure
Closing of LP PRDS PCVs
Observe the following in the field:
28. a. Full opening of the LP NRV.
b. LP extraction pressure in local gauge board.
c. Operation of LP extraction control valve.
d. Cross check the control valve opening with
control room indication.
e. Steam leaks.
f. LP secondary oil pressure.
Drain line going to condenser flash box.

29. 1-26-V311 NOTE: If LP secondary oil pressure goes below Check, Open
2.54 kg/cm2 load limiting device cuts off the trip
oil to LP QCNRV and makes the LP extraction
ineffective.

Doc. No: PU/III/29
ORDER TO OPERATE – 3
Aim: To take vacuum unloading device into service.
( Not to be taken in to service, as it is not commissioned)

required (d)
(a) (b) (c)
01. Pressure transmitter root valve (P x 5.14) Open
02. Ensure air pressure to unloading device (2.5

kg/cm2 after regulator).
03. Select vacuum unloading controller (PIC 5.14) to

Manual mode.
04. Select vacuum unloading gear (HIC 5.14) to

Manual.
Keep the signal of PIC 5.14 at 1.0 kg/cm2

05.
06. Observe the output signal of HIC 5.14 it should

be 100% (left side indication of HIC).
Keep bias signal of HIC 5.14 at 100% (right side

indication on HIC).
07.

required (d)
(a) (b) (c)

Doc. No: PU/III/29
08. Auto/Manual selector of HIC. Auto
09. Match the set point of PIC 5.14 with the actual
process reading.
10. Auto/Manual selection of PIC 5.14 Auto
11. Now keep the auto set point at 12.5% for

unloading purpose. (Corresponds to 570 mmHg)
12. HP secondary oil isolation valve to vacuum Open

unloading device.
13. Now vacuum unloading device is in service and

starts draining the HP secondary oil pressure
proportionately when vacuum falls below 570
mmHg, thereby reducing the MW generation
upto a min. of 3 MW at 456 mmHg.
Note-Vacuum unloading device is not commissioned, so it should not be taken in to

service, i.e. its HP secondary oil isolation valve should always be kept closed.

Doc. No: PU/III/29
ORDER TO OPERATE-4
Aim: To isolate vacuum unloading device

required (d)
(a) (b) (c)
01. HP secondary oil isolation valve to vacuum Close

unloading device.
ORDER TO OPERATE-5
Aim: To take HP extraction out of service

required (d)
(a) (b) (c)
HP PRDS-PCV- A & B are in service with auto
set point of 32 ata.
01.
Ensure that HP extraction is in service for the
other running TG(s).
02.
Slowly decrease the MW load on the turbine
and simultaneously increase the generation on
03.
the other running TG(s) if possible.
Keep a close watch on 32 ata header pressure.
04.
If other TGs are not in service, observe whether
PRDS have taken over or not.
05.
06. Reduce the MW upto 12 MW.

Doc. No: PU/III/29

required (d)
(a) (b) (c)
07(a) If HP steam header pressure is okay, that is if

the other running TGs/PRDS is able to cope
with HP steam demand, take the controller to
manual mode, gradually reduce the output
signal of the controller to zero.
If extraction pressure cannot be maintained,

load reduction at MP may be required before
07(b)
cutting out HP extraction.
Keep a close watch on the condenser vacuum
and MW. While cutting out HP extraction, TG
08.
generation decreases, if it is on hydraulic so
simultaneously increase the generation on the
turbine using speeder gear as per the process
requirements to the max. of 18 MW.
Ensure that condenser vacuum and cooling
water Δ T are within the limits.
09.
10. HP drain speeder. Close
Ensure that NRV on HP extraction line closes
fully. (Piston rod of HP QCNRV fully inserted).
11.
12. 1-26-EXV-1 Motor operated isolation valve on HP Close
extraction line.
13. 1-26-V300 Direct drain downstream of QCNRV. Crack open
ORDER TO OPERATE-6

Doc. No: PU/III/29
Aim: To take LP extraction out of service

required (d)
(a) (b) (c)
LP PRDS PCV-A & B are in service with Auto set
point of 8 ata.
01.
Ensure that LP extraction is in service in other
running TG(s)
02.
Take the LP extraction control in manual mode.
03.
Slowly close the LP control valve keeping a
watch on LP header pressure. Ensure that LP
04.
extraction of other TGs along with LP PRDS has
taken over.
Also observe the vacuum in the condenser if it
is going low reduce the load on the turbine.
05.
06. LP drain speeder. Close
07. Ensure that LP QCNRV closes fully.
08. MOV on LP extraction line (1-26-EXV 15). Close
09. Ensure that steam trap isolation valves

upstream and downstream of LP extraction Open
control valve (1-26-EXV 14).
ORDER TO OPERATE-7

Doc. No: PU/III/29
Aim: To keep CO2 extinguishing system for the Generator in poised state

required (d)
(a) (b) (c)
01. Module 1.4R, 220V DC unit-1 switch-gear ÒN’
Ensure the following in the CO2 control room

located at 0.3m elevation.
02.
a) CO2 battery selector is on `Main’ or

`Standby’ depending upon which bank is
having charged CO2 cylinders and the lock ÒN’
pins released.
ÒN’
b) Power supply ÒN/OFF’ switch.
c) `Power supply ON’ indicating lamp ÒN’
d) Àll contractors okay’ indicating lamp.
e) Test selector position. ÒN’
f) All other indicating lamps. ÒFF’
03. Alarm `CO2 released’ on Generator control OFF/RESET

desk.
04. Indicating lamps `CO2 SYSTEM ON TEST’ and ÒFF’

`CO2 released’ on Generator Control Desk.

Doc. No: PU/III/29
HWP (M) SAFETY PRECAUTIONS Chapter 13.3
13.3 Safety Precautions

12.2.1 Ensure availability of fire fighting equipments near Turbine Generator on 11.3 m
elevation.
12.2.2 Ensure that the oil leaks from ESV, LP & HP servo motors, if any, are not falling on
hot surfaces of hot TG and its auxiliaries.
12.2.3 Governing system oil leaks, if any, should be collected in the tray provided there.
Remove the collected oil periodically.
12.2.4 If steam leaks from parting plane, are persisting continuously, barricade the area.
12.2.5 Ensure no smoking near the TG.
12.2.6 No cutting and welding permitted in the vicinity of TG.
12.2.7 Ensure CO2 system for generator is in poised state.
12.2.8 Ensure availability of fire water system for turbine main oil tank.
12.2.9 If HP and LP extractions are not in service/ valved in, ensure that their drain speeders
are in closed position and extraction isolation valves (MOVs) are in closed condition.
12.2.10 Check for any water hammering in 32 ata header and 8 ata header.
12.2.11 Check for any water hammering in HP & LP Return Condensate System.
12.2.12 Ensure that the slip-rings cover is in position and its viewing shutter closed.
12.2.13 Ensure that stop push button of barring gear motor is in locked condition before
engaging the turning gear.
Give utmost importance to housekeeping. Keep the floor free from oil and other
obstructions.

Doc. No: PU/III/29
HWP-M CHECK LIST Chapter 13.4
13.4 STARTUP CHECK LIST OF TURBO GENERATOR –1/2/3

FORM NO.1 (MCR)
12.4.1TURBINE
12.4.1.1 MEGGERING AND OPERATION OF FOLLOWING EQUIPMENTS
Sl.No. Name of the equipment Megger Status of Remarks with

value operation signature &
date
01. AOP-1
02. AOP-2
03. EOP
04. JOP(AC)
05. JOP(DC)
06. TURNING GEAR MOTOR
07. CEP-1
08. CEP-2
09. GSCEF-1
10. GSCEF-2
11. CENTRIFUSE & IT’S FEED PUMP
12. OVEF-1
13. OVEF-2
12.4.1.2 CHECKING OPERATION OF VALVES
Sl.No. Description of valve/Equipment Megger Status of Remarks with

value operation signature &
date
01. CEP MRV
02. CEP-1 DISCHARGE VALVE
03. CEP-2 DISCHARGE VALVE
04. HOT WELL LCV
05. HOT WELL MAKE UP VALVE
06. LP EXTRACTION MOV
07. HP EXTRACTION MOV
08. STARTING DEVICE
09. SPEEDER GEAR
10. M.S. INLET VALVE
11. EJECTOR PCV N.A
12. GLAND STEAM PCV N.A
13. 8 ATA EXTRACTION CONTROL N.A

Doc. No: PU/III/29
VALVE.
FORM NO.1 (MCR)
12.4.1.3 CHECKING LOGICS OF AOP’S & TURNING GEAR
Sl.No Description Status Remarks

with
Signature &
date
AOP-1
01. AUTO STARTING OF AOP-2
EOP
LOW LUB OIL

PRESSURE
02. TRIPPING OF TURNING LOW JACKING OIL

GEAR ON PRESSURE
TURNING GEAR DIS

ENGAGED (TO BE
ENSURED AT THE
TIME OF TG ROLLING)
CEP-1
03. AUTO STARTING OF
CEP-2
12.4.1.4 CHEMISTRY OF MOT OIL & HOT WELL WATER
Sl.No. Description Status Remarks with

Signature & date
MOISTURE CONTENT IN
01. MOT OIL

Doc. No: PU/III/29
CONDUCTIVITY OF HOT
02. WELL WATER AFTER
THOROUGH FLUSHING(AT
THE OUTLET OF HOT
WELL/ CEP DISCHARGE)
12.4.1.5 TG LUB OIL & GOVERNING SYSTEM
Sl.No Description of equipment Status Remarks with

Signature & date
01. TS-22 (SHOULD BE ÒN’)
02. TRIP CIRCUIT HEALTHY BULB ON TURBINE

I&P PANEL (SHOULD BE GLOWING)
03. VACUUM LOW HYDRAULIC PROTECTION

DEVICE (LEVER SHOULD BE IN VERTIFICAL
POSITION)
04. GOVERNING OIL FILTERS CLEANING
05. CONTROL OIL PRESSURE
06. TRIP OIL PRESSURE
07. T.G.L.O HEADER PRESSURE(2.3 Kg/CM2)
08. EHTC INLET VALVES
09. EHTC OUT LET VALVES
10. HP DRAIN SPEEDER
11. LP DRAIN SPEEDER
12. TG TRIPPING FROM MCR

TG TRIPPING FROM LOCAL TRIP LEVER
Doc. No: PU/III/29
13.
OVER SPEED TESTER OPERATING LEVER
14. (SHOULD BE IN LIFTED CONDITION)

Doc. No: PU/III/29
FORM NO.1 (MCR)
12.4.2 GENERATOR
Sl.No Status Remarks with

Description signature & date
01. AVR (NO ALARM SHOULD BE PERSISTING)
02.* RELAYS IN GRP’S SHOULD BE IN RESET

CONDITION.
03. ANNUNCIATION SYSTEM OF GCP
04. GT BREAKER TRIP COIL MONITOR(LED IN GEN.

PROT. PANEL – RA-4 SHOULD BE GLOWING)
05. FIELD BREAKER(TRIP COIL HEALTHY BULB ON

GCD SHOULD BE GLOWING).
06.** 110V UPS SUPPLY TO GRP IS “ON”.
07. EXCITATION SYSTEM TROUBLE WINDOW ON

GCP IS NOT GLOWING
NOTE: * 15 LED’S must be glowing in Generator 2 & 3 relay panels.

13 Nos .of LED’s must be glowing in Generator 1 relay panels.
** Feeder No 5, on respective AC distribution board (1, 2, and 3) of UPS, is to be

‘ON’ condition.

Doc. No: PU/III/29
HWP (M) CHECK LIST Chapter 13.4
Form No – 2(Local)
12.4.3.0 STARTUP CHECKLIST OF TG ( FIELD )
12.4.3.1 STATUS OF VARIOUS EQUIPMENTS
Remarks
Sl.No Description with
Signature
Status & date
01. LINE UP OF CEP ON RECIRCULATION
C. W TO CONDENSER
JOP’S
C.W TO GEN. AIR COOLER
02 TURBINE STARTUP VENT
03. MAIN STEAM LINE
DRAINS
04. TURBINE CASING
DRAINS
05. MOT LEVEL
06.  P ACROSS LUBE OIL (SHOULD BE  1.5
FILTER KG/CM2
07. TURNING
GEAR(TIED/NOT TIED)
08. AVAILABILITY OF CO2 LINE UP
SYSTEM AUTO /MANUAL
09. GT FANS MANUAL OPERATION
A/ M SELECTOR
ALARM/ TRIP SETTING OF
OTI
ALARM/TRIP SETTING OF
WTI
10. UAT FANS MANUAL OPERATION
A/ M SELECTOR
ALARM/ TRIP SETTING OF
OTI
ALARM/TRIP SETTING OF
WTI
11. FIELD FLASHING SUPPLY 1.2R ,UESG TO BE “ON”
MODULES 4.8F 220V UB TO BE “ON”
12. JOP (DC) MODULE 2.5F 220V DC UB TO BE
“ON”.

Doc. No: PU/III/29
13. EOP MODULE 2.3F 220V UB TO BE “ON”.

14. LOCAL STOP P.B OF TO BE PRESSED.
EOP.

Doc. No: PU/III/29
Remarks
Sl.No Description with
Signature
Status & date
15. G.T. BREAKER SPRING CHARGING OK.
DC SUPPLY “ON”.
16 PIN PLUG INSERTED.
SERVICE/TEST POSITION
TRIP HEALTHY BULB ÒN’
16. UAT BREAKER SPRING CHARGING OK
DC SUPPLY “ON”.
16 PIN PLUG INSERTED.
SERVICE/TEST POSITION
TRIP HEALTHY BULB ÒN’
17. G.T & UAT OIL LEVELS SHOULD BE NORMAL
12.4.3.2 HOUSE KEEPING
Sl.No Description of location Status Remarks with

Signature and date
01. HOT WELL DRAIN AREA(0.3M T ELEV.)
02. HOT WELL LEVEL GAUGE AREA
03. JOP’S AREA(4.8MT ELEV.)
04. TG BEARING PEDESTALS AREA(11.3MT

ELEV.)
05. GOVERNING SYSTEM TRAY(11.3MT ELEV.)
06. TRANSFORMER YARD

Doc. No: PU/III/29
12.4.3.3 GENERAL CHECKS
Sl.No Description Status Remarks with

Signature & date
01. AVAILABILITY OF FIRE FIGHTING EQUIPMENT

IN TG AREA
02. LIGHTING IN TG AREA ( 0.3 MT. ELEVATION)
( 4.8 MT. ELEVATION )
( 11.3 MT. ELEVATION )
03. DELUGE VALVES STATUS OF GT
04. DELUGE VALVES STATUS OF UAT

Doc. No: PU/III/29
HWP (M) LOG SHEETS Chapter 13.5
dssdsdfdfd

Doc. No: PU/III/29
HWP (M) GOVERNING RELATIONS Chapter 13.6
MINIMUM & MAXIMUM EXTRACTION CONDITIONS
11.1 Minimum Extraction Conditions
HP SOP LP SOP Valve lift (mm) and Divisions (%)

(kgf/cm2) (kgf/cm2) HP LP
1.54 - - -
1.635 1.5 3.3 (7.5%) -
2.00 2.44 12.2 (27.7%) 18.8 (52.2%)
2.33 3.3 20 (45.5%) 36 (100%)
2.50 >3.3 24.4 (55.5%) 36 (100%)
2.71 >3.3 29.4 (66.8%) 36 (100%)
11.2 Minimum Extraction Conditions - Before modification with 20 mm travel of

extractioner positioner
HP SOP. LP SOP Valve lift (mm) and Division (%)

(kgf/cm2) (kgf/cm2) HP LP
1.54 <1.5 0 0
1.635 <1.5 3.3 (7.5%) 0
2.00 <1.5 12.2 (27.7%) 0
2.47 1.5 23.7 (53.9%) 0
2.71 2.12 29.5 (67%) 12.4 (34.4%)
3.00 2.87 36.6 (83.2%) 21.4 (59.4%)
3.14 3.24 40 (90.9%) 34.8 (96.7%)
3.175 3.3 40.9 (93%) 36 (100%)
3.3 >3.3 44 (100%) 36 (100%)
11.3 AFTER MODICATION MAXIMUM EXTRACTION MODE WITH 24 MM

TRAVEL OF EXTRACTIONER POSITIONER
SOP (kgf/cm2) Valve lift (mm) and Division (%)
HP LP HP LP
1.54 <1.5 0 0
1.635 <1.5 3.3 (7.5%) 0
2.00 <1.5 17.2 (27.7%) 0
2.47 <1.5 23.7 (53.9%) 0
2.62 1.5 27.3 (62%) 0
2.71 1.73 29.5 (67%) 4.6 (12.8%)
3.00 2.48 36.6 (83.29%) 19.6 (54.4%)
3.14 2.85 40 (90.9%) 27.0 (75%)
3.175 2.93 40.9 (93%) 28.6 (79.4%)
3.3 3.0 44 (100%) 30 (83.3%)

Doc. No: PU/III/29
HWP (M) PROTECTION RELAY SETTINGS Chapter 13.7
Relay settings for Generator, GT and UAT
S Relay Description of Setting % of setting, Basis and remarks

N Code protection
1 87 G Generator 100 Volts Calculated for sub transient condition
Differential
2 87 T Generator (a)Restrained Isr = 0.25 In (a) Restrained setting to account for CT
Transformer (b)Unrestrained Iur = 13 In mismatch and OLTC
Differential (b) Unrestrained setting given based on
ratting and transformer connection to
safe guard against fault during idle
charging when restrained relay is
blocked.
3 87 GT G and GT overall -----Do------- -------Do-------
differential
4 87 UAT differential ----Do--- -------Do-------
UAT
5 32 G1 Reverse power 10 mA with Iset= (10 /740) x100=1.35 %
relay (a)1 sec delay with ESV In=(1852/2500)x1= 0.74 A=740 mA
close CT used is 2500/1
(b) 3 sec delay with ESV
open
6 32 G2 Low forward 30 mA, 3 Sec Delay Iset= (30 /740)x100= 4 %

power Relay In and CT ratio same as above
7 64G1 0 -95 % Main 5 volt, Residual Voltage measured is 1.8 volts

stator earth fault 0.1 sec
8 64 G2 Stand by stator 6.9 volt Generator 11 KV PTs connected in open
earth fault 0.3 sec Delta
9 51 G Generator 0.85 A (0.85/0.74)x100= 115 % overload
overload/over 10 Sec
current Alarm
10 59 G Generator over (a) Moderate 121 volts, 10 (a) moderate (121/110)x100= 110 %
voltage sec (b) Extreme (142/110)x100=120 %
(a) Moderate (b) Extreme 142 volts,
(b) Extreme Instantaneous
11 46 G Generator (a)Alarm 6 %, 6 sec Negative sequence capability I22=30
Negative sequence (b)Start 8 % where
I2= NS current (Per Unit), t=duration (sec)
For I2= 8% , t= 78 min
For I2= 13 %, t=30 min
12 81 G Generator under 47.5 Hertz Set at 95 % of rated frequency

Doc. No: PU/III/29
frequency 10 sec
Continued on next page…
13 40 G Loss of Excitation
(a) differential power relay setting

( 25/740)x 100 = approx 30 % reverse
reactive power
(a) Differential power (b) Over current setting ( 81.3/740)x100=
relay 0.25A 110 % of rated current
(b) Over current relay (c ) Under voltage setting ( 93.5/110)x100
0.813 A = 85 % of rated
( c) Under voltage relay
93.5 vols, 1 sec
14 21 G Generator Stage-1, (V/I)n = 110/0.74= 148.65 Ohms
minimum 11.025 ohms Stage-1 setting= (11.025/148.65)x100=
impedence Stage-2, 7.5 %
Stage-1 class-A 45.05 Ohms Stage-2 Setting=
Stage-2 Class-C (45.05/148.65)x100 = 30 %
15 64 R Rotor earth fault Stage-1, First earth fault gives alarm as rotor is
Alarm 1.25 mA, 11 sec ungrounded for operator attention and to
Stage-2, take out generator at the earliest. Second
Trip 2.5 mA, earth fault directly trip the generator.
Instantaneous
16 99 GT Gt over Fluxing V/f set= 2.35 Volt/ Herts, (V/f)n = 110/50 = 2.2 volts /hertz
11.30 sec Set at (2.35 /2.2)x100= 107 % with delay
as transformer with stand capacity for
over fluxing is 10 % continuous and 35 %
for 15 sec
17 98 G Pole slipping or Directional reverse power D.P Relay set for (15 /740) x100= 2 % as it
Loss of = 15 mA indicates just motoring.
synchronism Relay Impedance relay 34.375 Impedance relay set for 40 %
ohms
18 64 GT GT Restricted 40 volts Calculated for sub transient condition
earth fault relay
19 50,51, For GT (a) High set (50 ) Based on transformer withstand
51N(G (a) 50- Iset= 7 A characteristics
T) Instantanious over (b) IDMT O/C
current Iset= 1.365, TMS=0.1, In=1
(b) 51-IDMT over (c ) Back up E/F
current Iset= 1, TMS=0.2, In=0.2
(c ) 51N- Back up
earth fault
Doc. No: PU/III/29
20 50,51 For UAT , (a) and (a) High set (50 ) Based on transformer withstand
UAT (b) same as above Iset= 13 A characteristics
(b) IDMT O/C
Iset= 1.64, TMS=0.4, In=1
21 Oil and Winding For GT Maximum Allowable Temperature is 105

Temperature Hi-Hi Oil=90 oC , Winding=95oC o
C for class A insulation set with suitable
for GT & UAT For UAT margin measuring limitation.
Oil=85 oC , Winding=95 oC

Doc. No: PU/III/29
HWP (M) POWER SUPLLIES Chapter 13.8
1 Power supply extended from respective 220 V DC unit board:
Sl
Description Module No
No
1 EOP 2.3 F
2 DC JOP 2.5 F
3 BHEL instruments and protection panel 3.3 F
4 Generator protection panel feeder 1 4.3 F
5 Generator protection panel feeder 2 4.5 F
6 BHEL Excitation system (Field flashing and DVR supply) 4.8 F
7 GCP Feeder 1 1.6 R
8 GCP feeder 2 1.8 R
Note: 1.4 R, on 220 V DC unit board-1, feeding to CO2 flooding system (All units) kept off, as
CO2 flooding system is to be actuated from field only.
12.8.2 Power supply extended from respective ±24 V DC unit board:
Sl
No
1 TGIP I/O module and excitation supply (each unit) 1.5F, 2.5F
2 BHEL EHTC Panel supply (each unit) 1.3F, 2.3F
3 TCP annunciation supply (each unit) 3.5R
4 GCP annunciation supply (each unit) 2.3R
5 NT I/O module and excitation supply (U#1) 5.3F, 2.5R
6 NT I/O module and excitation supply (U#2 & U#3) 3.3F, 4.3F
7 MP I/O module and excitation supply (U#1) 4.5F, 4.8R
8 MP I/O module and excitation supply (U#2 & U#3) 6.8F, 6.3R
9 Import/Export controller supply 2.3F on U#1
10 CO2 flooding system (all units ) 1.5F station board
These module nos. are only for guidelines and quick access. Pl cross check with the
breaker list and respective maintenance agency before carrying out any isolations.

Doc. No: PU/III/29
12.8.3 Power supply extended from respective AC distribution board of UPS:
Sl
No
1 Nova Tune (NT) CPU Feeder 2
2 Master piece (MP) 1 & 2 CPU Feeder 3
3 Generator Control Desk Feeder 4
4 Generator relay panel, thyristors etc,.. Feeder 5
5 Turbovisory panel Feeder 8
6 TCP, BCP, Hydra step etc,.. Feeder 9
7 TGIP CPU Feeder 10
12.8.4 Power supply extended from respective UESG:
Sl
No
1 AOP 1A, 2A, & 3A 8.8 F
2 AOP 1B, 2B, & 3B 9.8 F
3 Turning Gear Motor 1.6 R
4 OVEF 1A, 2A, & 3A 1.8 R
5 OVEF 1B, 2B, & 3B 2.4 R
6 Speeder Gear 2.6 R
7 AC JOP (U-1 and U-2) 10.5 R
8 AC JOP (U-3) 10.3 R
9 Starting Device 13.5 R
10 GT and UAT marshalling box 3.8 F
11 Generator field flashing 1.2 R
12 GCD, GCP, and GRP 12.8 F

Doc. No: PU/III/29
12.8.5 Power supply extended from respective USSG:
Sl
No
1 UAT Fan control cubical feeder 1 1.2 F
2 UAT Fan control cubical feeder 2 13.2 F
3 GSCVEF-1A, 2A, and 3A 1.4 F
4 GSCVEF-1B, 2BA, and 3B 16.6 R
5 CEP 1A, 2A, and 3A discharge valve 1.6 F
6 CEP 1B, 2B, and 3B discharge valve 1.8 F
7 CEP 1A, and 3A 5.5 R
8 CEP 2A 12.8 F
9 CEP 1B, and 3B 12.5 R
10 CEP 2B 13.8 F
11 HP Extraction MOV 15.4 F
12 LP Extraction MOV 15.6 F
13 Vacuum breaking valve 16.4 F
14 Main steam I/L Valve (AS004, 5, and 6) 16.6 F
15 GT Fan control cubical feeder-1 1.2 R
16 GT Fan control cubical feeder-2 2.2 R

TURBINE & HEADER Doc. No: PU/III/29
HWP (M) Chapter 13.9
MATERIAL OF CONSTRUCTION
Desig Hydr
Sl. Thick Design
Equipment/line Material Size n o test C
N ness pressu Mn P S Cr Ni Mo Si V
Description Specification mm temp. press %
o mm re, Bar
°C ure
0.05
Main steam header ASTM A-335 Gr. 146. 0.3 to < < 1.9 to 0.87t
1
to TG#1, 2 & 3 P-22
250 28.58 117.2 485 to - 0.5
5 0.6 0.025 0.025 2.6 o1.13
0.15
TG#1, 2 & 3 HP 0.29
ASTM A-106 Gr. < <0.03
2 extraction system
B
350 12.70 39.5 380 49.8 <0.3 to 0.4 0.4 0.15 0.1 0.08
header 0.035 5
1.06
TG#1, 2 & 3 to LP ASTM A-106 Gr. < <0.03
3
extraction steam B
350 6.35 10.8 300 13.5 <0.3 do 0.4 0.4 0.15 0.1 0.08
0.035 5
450
HP extraction ASTM A-106 Gr. < <0.03
4
common header B
& 14.27 39.5 380 49.8 <0.3 do 0.4 0.4 0.15 0.1 0.08
0.035 5
500
LP extraction steam ASTM A-106 Gr. < <0.03
5
common header B
600 6.35 10.8 300 13.5 <0.3 do 0.4 0.4 0.15 0.1 0.08
0.035 5
LP de-superheating <
ASTM A-106 Gr. <0.03
6 station to battery
B
250 9.27 10.5 180 13.5 <0.3 do 0.4 0.4 0.15 0.1 0.08
limit 0.035 5
HP de-superheating <
ASTM A-106 Gr. <0.03
7 station to battery
B
600 17.48 39.5 245 49.8 <0.3 do 0.4 0.4 0.15 0.1 0.08
limit 0.035 5
GS 17CrMoV
8 TG Casing
511
0.2 0.76 0.013 0.013 1.4 - 1.01 0.4 0.25
9 TG Shaft 28CrMoVNi 59 0.28 0.68 0.006 0.003 1.25 0.68 0.94 0.07 0.28
10 TG Blades A-wheel Hy19393 0.23 0.76 - - 11.98 10.74 0.99 0.46 0.26
TG Blades (row 1- <
11
22)
X22CrMoV12.1 0.22 0.5 - 12.0 0.4 0.8 0.3 0.3
0.03
TG Blades (row23-
12
40) and LP2
X20Cr13 0.2 0.45 - - 13.5 -- 0 0.3 0
13 TG Blades row LP1 Hy 10764 0.22 0.53 - - 13.4 - 0 0.36 0
90% tubes are Al. Brass, (Cu – 76%, Zn – 22%, Al – 2%)
14 Condenser Tubes
10% tubes are Cupro Nickel (Cu–90%, Ni – 10%)

Doc. No: PU/III/29
HWP (M) IMPORTANT GRAPHS & CURVES Chapter 14
Fig:Correction curve for deviation in inlet pressure

Doc. No: PU/III/29
Fig: Correction curve for deviation in Extraction pressure

Doc. No: PU/III/29
FIG: DESIGN DATA

Doc. No: PU/III/29
FIG: HP regulation curve

Doc. No: PU/III/29
FIG : LP Regulation curve

Doc. No: PU/III/29

Doc. No: PU/III/29


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Turbine Generator System

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PRODUCTION (UTILITIES)

HEAVY WATER PLANT (MANUGURU)

Rev. No. 5.00 Date: 30.12.2019

SN Document Description Document No. Page No.

Revised by: Reviewed by: Approved by:

Revised by: Reviewed by: Approved by:

Revised by: Reviewed by: Approved by:

Revised by: Reviewed by: Approved by:

1 Dy. GENERAL MANAGER (U) (Soft copy)

2 PRODUCTION MANAGER (U) (Hard copy)

3 TECHNICAL SERVICES MANAGER (Soft copy)

4 Deputy PRODUCTION MANAGER (U) (Soft copy)

5 Deputy SHIFT SUPERINTENDENT (Hard copy)

6 LIBRARY (Soft copy)

7 HRD SECTION (Soft copy)

8 RTC FIELD STAFF OF THE UNIT (Hard copy available in Dy SS cabin)

9 GENERAL SHIFT ENGINEERS (Soft copy)

Revised by: Reviewed by: Approved by:

Current revision New revision

Revised by: Reviewed by: Approved by:

Revised by: Reviewed by: Approved by:

Revised by: Reviewed by: Approved by:

II. SYSTEM DESCRIPTION

2.2 To facilitate operation, Turbine-Generator is provided with the following auxiliary

 Turbine Lube Oil System.

2.3 On line testing facility is provided for the following:

 Auxiliary Oil Pumps (AC) & Emergency oil pump (DC)

Revised by: Reviewed by: Approved by:

TG is to be tripped and CO 2 to be released manually (Local/Remote) after

Revised by: Reviewed by: Approved by:

III. INSTRUMENTATION, CONTROLS & LOGICS

1. Pressure indicator : PI 5.1

1. Pressure indicator : PI 5.11 (for wheel chamber pressure)

3.3 On the Thrust bearing

1. Temperature indicator : TI 3.64 }(for lube oil return

3.4 On Turbine front journal bearing

1. Pressure indicator : PI 3.65 (for lube oil inlet pressure)

Revised by: Reviewed by: Approved by:

3.6 On Generator Front Journal Bearing

3.7 On Generator Rear Journal Bearing

3.8 CONTROLS: The following Controls are provided on EHTC:

Revised by: Reviewed by: Approved by:

1. Lube oil header pressure very low : 0.7 kg/cm2 (g)

4.1 Generator Protections

All Generator, GT and UAT protections are divided into three

4.1A Class-A trips (86G1 and 86G2)

1. Generator differential protection : 87G

Revised by: Reviewed by: Approved by:

7. Generator reverse power and

II. Generator –Transformer Protections

1. Generator transformer differential : 87T

Revised by: Reviewed by: Approved by:

4. UAT Mulsifire : 28 UAT

Revised by: Reviewed by: Approved by:

The details of settings of different generator protections are given in annexure

Revised by: Reviewed by: Approved by:

V. TURBO GENERATOR START-UP

5.1 Pre-requisites for start-up

Ensure that the following pre-requisites are satisfied.

 Ensure that the following systems are in service.

Revised by: Reviewed by: Approved by:

j) Common Auxiliary Cooling Water System

4.2 Start-up checks