19 Mar 2007

Typical Start Up of a
210 MW Steam Turbine
Generator Set in India
In-house Discussion TSN Tendering
M.P.Dutta
Technical Tendering Engineer
 Contents

 Typical layout of thermal cycle in conventional power

plant
 Function of different equipments.
 Preparation of unit for READY to START (Pre-startup
activities)
 Ref. Plant and Criteria for different Start Up
 Check list
 Start up of boiler.
 Vacuum pulling
 Rolling and synchronisation.
 Different protections

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 Typical Layout of Thermal Cycle

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 Main equipments in power plant

 Prime Mover (Turbine).

 Steam Generator (Boiler)
 Condenser
 Turbo Generator
 Feed Heating System.
 Power Transformer.
 Power Evacuation System (Switch Yard)
 BOP (Balance of Plants)
NEXT

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 Prime Mover

 Prime mover converts the shaft power to

electrical power.
 For conventional thermal power plant, prime
mover is Steam Turbine.

NEXT

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 Steam Generator

 This element of power plant will generate steam

which is the driving fluid for steam turbine.
 Conventionally it is called as Boiler .
 Modern name of this element is Steam generator
which produces Super Heated Steam.
 It is equipped with all kinds of mountings for
safety & monitoring of the equipment and
accessories which increase the overall efficiency.

NEXT

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 Condenser

 It will convert the steam coming out of LP turbine

to water which will be pumped back to boiler .
 Condenser is always at Vacuum , which helps in
more Expansion of steam thereby producing
more power output.

NEXT

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 Turbo Generator

 This element of power plant is responsible for

converting the turbine shaft power to electrical
power .
 Prime mover imparts rotation to generator rotor
which in turn produces electrical force (volts) by
cutting strong magnetic flux produced by electro
magnets in stator windings.
 Typical terminal voltages are 11KV, 15KV, 19KV,
21KV etc.
NEXT

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 Feed Heating System

 The feed water going to the boiler is heated in a

series of heaters using hot steam extracted from
some intermediate points in the turbine train.
 Feed heating system is responsible for
increasing the sensible heat to an optimum
value, thereby improving the thermal cycle
efficiency.

NEXT

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 Power Transformer

 It converts the low voltage at the generator

terminal to a high voltage for synchronisation
with Grid.
 This is a STEP UP Transformer.
 Primary winding is connected to generator side.
 Secondary winding is connected to the grid.
 Typical scheme.

NEXT

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Typical Schematic of Switchyard
BUS I

BUS II

ISO
ISO

BC

CB

ISO ISO

Y
TRAFO

LEGENDS
ISO:ISOLATOR
CB: CIRCUIT BREAKER
GEN.
NEXT
TRAFO:TRANSFORMER
GENERATOR
BC:BUS COUPLER
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 Power Evacuation System

 This is typically a switchyard where all the generators are

connected via power transformer to the grid.
 It consists of transmission lines through which power will
be transmitted to different locations.
 Switch yard comprises of many bays.
 Bay is a typical layout for power producing and power
transmitting units.
 Bay consists of a circuit breaker, isolators, current and
potential transformers.
 All the components of bay together constitute a switch
gear.
NEXT

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 Balance of Plants (BOP)

 BOP consist of all other components of power

plant which directly or indirectly support power
generation activity.
 These are basically pumps, blowers, fans,
heaters, air compressors, ESP etc.
 Some important BOP in conventional power plant
are BFP, CEP, PA Fan, FD Fan, ID Fan, service
air compressor, diesel engine, ESP, etc.

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 Technical specifications for reference
plant (BTPS 210MW, Unit IV)

Ratings at NCR (Normal continuous rating)

 LS pressure 130 kg/cm².
 LS temperature 535°C
 LS flow 670 MT/Hr.
 RH steam pressure 27 kg/cm².
 RH steam temperature 535°C
 RH steam flow 575 MT/Hr.
 Final feed temperature 246°C
 Condenser back pressure 0.09 kg/cm².

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 Generator Specification

 Rated terminal voltage 15.75 KV

 Rated stator current 9050 A
 Rated power factor 0.85
 Maximum KVA rating 247000 KVA.
 Hydrogen cooled rotor windings and distillate
cooled stator winding.

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 Criteria for different start up

 Cold start up: HPT casing metal temp < 150°C

 Warm start up: HPT casing metal temp >150°C and < 350°C

 Hot start up: HPT casing metal temp >350°C

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 Line up for cold boiler start up

 Fill the deaerator using boiler fill pump.

 Fill boiler circuit slightly lower than NWL of drum
using fill pump.
 Fill hotwell level to normal level to provide
sufficient NPSH to CEP.
 Check water chemistry which is very vital and get
all the parameters within normal range.
 Put the air pre-heater in service.
 Line up the draft system by putting ID and FD
fans in service.

CONTD..
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 Line Up for Cold Boiler Start Up

 Line up FSSS ( Furnace Safety and Supervisory

System).
 Purge the boiler with 30% air flow and maintaing
about 5 to 10 mm WCL furnace draft.
 When all permissives for purging are fulfilled,
start purging operation which is normally a cycle
of 5 minutes.
 After completion of purging operation, start light
oil firing at lower elevation.
 Check for flames; out of 4 scanners at least 3
has to show flames.
CONTD..
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 Boiler Start Up

 After getting stable flame, control firing Rate so

that steaming will start approximately after 45
minutes.
 Keep CBD open during warm up period.
 Flue gas temperature at the furnace exit should
not fall below 538°C.
 When boiler starts steaming, close the vents one
by one.
 Throttle the drains to control draining. Never
close the drains before rolling of the steam
turbine. CONTD..

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 Boiler Start Up

 After reaching a pressure of about 2.5 kg/cm² in

the drum, open the boiler stop valves.
 Throttle the start up vents to control the pressure
rise. Never close these until the flow is
established at HP/LP bypass system.
 Bring the boiler steam parameter to 5 kg/cm² and
195°C (about 40K, degree of SH).
 Ensure that the APH outlet flue gas temperature
is above 90 to 100°C.
 Charge auxiliary steam header.
CONTD..
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 Boiler Loading

 Bring Heavy Oil (HO) system into service

replacing Light Oil (LO) system.
 Once the HO system is established, start cutting
the LO system.
 Bring the LS pressure and temperature to 6
kg/cm² and 225°C.
 Give clearance for gland sealing and vacuum
pulling operation.
 When vacuum is 540 mm Hg, put the HP/LP
bypass system in operation.
S/U Graph
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 Steam Turbine Rolling
( Permissives )

 Once the vacuum is established, turbine is ready for roll.

 Before rolling, ensure that all the pre-start requirements
are over.
 Watch the metal temperature rise of MS, CR and HR
lines.
 After achieving the temperature differential of steam lines
less than 20K, start heating MS lines up to MSV by
opening the drains in between. HPT lines to be heated up
to a temperature of 150°C.This is done by throttling the
Bypass valves of MS/RH Boiler Outlet valves.
 Same needs to be done for IP turbine lines. Pressure at
Reheater outlet shouldn’t be more than 1kg/cm². IPT
lines to be heated up to a temperature of 100°C
NEXT
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 Steam Turbine Rolling

 Once the steam lines are sufficiently heated,

close the MSV and IV bypass valves. Ensure that
the steam parameters before the MSV are
around 20-25 kg/cm² and 280-300°C. Then close
all the steam line drains.
 Note down all steam and metal temperatures of
the MS and RH lines.
 Note down all turbo supervisory instruments
readings.
While heating the MS and RH steam lines, temperature difference should
not exceed 15°. Upper and lower casing temperature difference
should be below 50°C NEXT
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 Steam Turbine Rolling

 Open the drain lines of all extraction valves.

 Open the CVs of HP turbine fully with the help of
control gear.
 Now slowly open the bypass valves of MSV to
admit steam to HP turbine.
 Speed of turbine will start increasing and barring
gear will be disengaged automatically.

During the speed raising operation eccentricity of shaft should be less than 0.07 mm.
Bearing vibration should not exceed 40 microns.
NEXT
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 Speed is now 500 RPM

 Stop the steam supply to the turbine and

carefully listen any kind of Rubbing Sound.
 If everything is ok, then go ahead else STOP the
turbine.
 Again Raise the speed to 500 RPM and stay
there for 10 minutes. This is known as SOAKING
period.
 Jacking oil pump should stop in AUTO.
During this period Differential Expansion values to be checked.
If too large, speed shouldn’t be raised
NEXT
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 Speed is 1200 RPM

 If differential expansions are within the limit then raise the

speed to 1200 RPM.
 Once again soak the turbine at that speed for 20 minutes.
 At this point control valves of HP turbine need to be fully
OPEN. (Behaviour of CV is such that it always tends to
CLOSE with the rise in speed)
 Raise the speed from 1200 to 3000 RPM within 5
minutes as all the critical speeds of turbine lie in this
range.
 Critical speeds in this case are 1585, 1881, 2017, 2489
RPM.
NEXT
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 At 3000 RPM

 At 3000 RPM turbine is at FSNL.

 Hold the turbine here for at least 20 minutes to
observe the behaviour of all turbo supervisory
parameters.
 Check for excitation system.
 Observe the temperature of lube oil entering the
bearings.
 Check the parameters for synchronisation.

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 Synchronisation

 Check if the system voltage and the generator terminal

voltage are matching.
 Generator frequency has to be slightly higher so that
power can be pushed to the grid.
 If these conditions are satisfied, machine will be getting
SYNC permissives and the CB will be closed in AUTO.
 Manual synchronisation:
 If voltage at the generator side is Low/High, adjust the
voltage level manually, keeping AVR in manual.
 Frequency of prime mover can be increased by firing
more oil.
NEXT

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ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
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 RH
MS TEMP
TEMP

MS Flow
MS
Pressure
RH
Pressure

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 Different Protections for Steam
Turbine

 Low bearing lube oil pressure.

 High vacuum.
 Low live steam temp.
 Axial shift
 Overspeed
 Differential expansion
 High eccentricity
 High level in HP heaters
 High vibration trip NEXT

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 Different Protections for Steam
Turbine

 High exhaust temperature trip.

 Hydraulic oil low pressure trip
 Electrical tripping.
 Emergency PB trip

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 Minimum time required to synchronise
ST from Barring Speed (Cold Start Up)

 Speed from 0-500RPM 5 minutes.

 Holding at 500 RPM 10 minutes.
 Speed from 500 to1200 RPM
@50RPM 14 minutes
 Holding at 1200 RPM 20 minutes
 Speed from 1200 to 3000 RPM 5 minutes.
 Holding at 3000 RPM 20 minutes.
75 minutes

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 Pre-checks before rolling

 SLC for aux. lube oil pumps and EOP are ‘ON’ and one
pump is in service. (Both pumps are in ‘Auto’ mode).
 SLC for jacking oil pumps are ‘ON’ and one pump is
running.
 Turbine is on turning gear and eccentricity is around 40 to
50 micron.
 SLC for control oil pumps are ‘ON’ and one pump is in
service (Both pumps are on Auto). Also AFS pump is
running. Control oil pressure is about 160 kg/cm².
 Seal oil pressure is adequate (> 2.8 kg/cm²) and
hydrogen purity is more than 96%.
 Ensure vacuum breaker valve is CLOSED and its SLC is
on AUTO.
NEXT

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 Pre-Start checks for Rolling

 Ensure that all the “before and after Turbine

Control Valve drains” are in OPEN and its SLC in
AUTO.
 Ensure that the MS Strainer Drains, CRH and
HRH line drains are OPEN.
 All relays in the generator relay panel are in reset
condition.

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 Vacuum Pulling

 Ensure CW pumps are in service.

 Ensure condensate system is in service, main
ejectors (both) and LP heaters (all) are charged
from water side. In case of vacuum pumps,
ensure that their coolers are in charge condition,
air supply for opening the solenoid is in service
and seal water pumps running.
 All valves subjected to vacuum should be sealed
by condensate water.
 Ensure that the turbine is on turning gear.
NEXT
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 Vacuum Pulling ( by ejector)

 Ensure auxiliary steam from 16 ata header is charged.

 Close the vacuum breaker valve.
 Put the starting ejector in service.
 Put the gland steam ejector in service and see the rise in
vacuum. Adjust steam pressure at 3 kg/cm².
 Admit steam to seals.
 After establishing about 400 mm vacuum at condenser,
bring the main ejector in service.
 Adjust the steam pressure to 6 kg/cm² and once the
vacuum starts building steadily, isolate the starting
ejector.
 At about 600 mm vacuum, protection for vacuum will be
reset.
NEXT

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 Vacuum Pulling (By Pumps)

 Ensure that at least 1 CWP is running and 4 IDCTs are in

service with their respective cells.

 At least one ACW booster pump is running

 Ensure one CEP is running

 Feeders of vacuum pumps and seal water pumps are in

restored condition.

 Vacuum pump suction butterfly valves are open.

 Seal water heat exchanger inlet and outlet valves are open.
Home
VACUUM PUMP HOGGING HOLDING
NEXT
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• At least one instrument air compressor is running and air
receiver tank

• IA pressure is adequate

• Ensure that STG is on slow roll.

• Vacuum breaker is closed and MOV put on remote.

• Manually check that VACUUM breaker is fully closed.

• Gland steam sealing is in service.

NEXT
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 Vacuum Pulling

• Open the seal water makeup valve and bring the water
level to normal and make sure that it overflows a little.
• Start both the vacuum pumps and confirm from local
offsite engineer.
• Vacuum pumps will run in hogging mode and condenser
pressure will start dropping.
• When vacuum in condenser reaches about 76 mm Hg,
the vacuum pump which is in stand by mode will cut off.
• Open the exhaust hood spray bypass if exhaust hood
temperature goes beyond 80°C.
VACUUM PUMP

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 HOGGING

From Condenser DISC TO ATM SPTR

AIR INLET

CHECK V/V

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 HOLDING

From Condenser
DISC TO ATM SPTR

AIR INLET

CHECK V/V

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separator

2nd 1 St MOTOR

SEAL WATER PUMP

HEAT EXH
Make up from CEP
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ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
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ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
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 Check list for Start Up

 This is a document which is used to check all the

positions of valves, their actuation mechanism,
time of start up, time taken for different activities,
etc.
 This helps to avoid any manual mistakes and
also helpful for auditing of start up activities.
 Typical check list example.

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 Operation

 Operation is an Activity where you are not

allowed to make a mistake .
 Everything has to be done correctly at the first
attempt.
 A command issued online can not be retrieved
back.

ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. 49
ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. 50
 Permissives for Purging

 AC and DC power supply is established to FSSS

related equipment.
 Drum level is normal.
 No boiler trip persists.
 At least one ID fan and one FD fan in service.
 Minimum of 30% air flow is established.
 Ignitor trip valve is proven closed.
 Light oil trip valve is proven closed.
 Heavy oil trip valve is proven closed.

ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. 51
 Permissives for Purging

 All the ignitor valves in all elevation proven

closed.
 All the warmup and heavy oil nozzle valves at all
elevations proven closed.
 All RC feeders are off.
 All hot air shut off gates are fully closed.
 All cold air dampers are less than 5°open.
 All elevation flame scanners show no flame.

ALSTOM 2007. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is
given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. 52