TURBINE OPERATION AND CONTROL

The turbine can be divided into

Turbine and its governing system

Turbine auxiliaries

The turbine and its auxiliaries are controlled by 2 different control systems. The turbine system
which consists of the DEH system, steam governing system, turbo-supervisory system and the
turbine trip system are operated using a separate control system called DEH/ETS control
system. The turbine auxiliaries are operated through the plant distributed control system.

Turbine and its governing systemThe turbine is governed by a separate control system called the DEH/ETS control system. High
pressure steam admission into the turbine is controlled by two high pressure main stop valves
and four high pressure regulating valves. Intermediate pressure steam admission is controlled by
two intermediate pressure main stop valves and two intermediate pressure regulating valves,
which are combined. The DEH system acquires parameters like speed, power in MW, required
load to be achieved and uses them to control the admission of steam into the turbine. There is an
electro hydraulic servo valve which makes the high pressure regulating valves and intermediate
pressure regulating valves operate depending upon load requirement through oil servo motor.
The working pressure of oil used is 14.5 MPa.
The ETS is a control system used for emergency turbine trip. It continuously monitors
parameters of the turbine which are essential for unit safety and if any of the parameters go out
of limit, it trips the turbine in a safe manner without affecting its parts.
DEH system description

There is a main oil tank which is used to store the fire resistant oil. There are two oil
pumps, out of which one is working and one is standby. The working pressure is 14.5
MPa and if it goes below 11.2 MPa the standby pump. The tank is provided with level
switch to detect if level in tank goes low. To ensure that there is enough working oil

when the servo motor acts quickly there is an oil accumulator. The oil regeneration pump
is used to remove moisture and impurities from the returning oil. The oil temperature has
to be maintained at 38-40 degree Celsius, and a heater and cooler are provided for this
function, along with high and low temperature alarms. At low level in the EH oil tank
the pumps trip.

There are two actuators or servo motors in the system, one for the main stop valves and
one for the regulating valve. The actuator consists of oil cylinder, unloading valve and
test solenoid valve. When the turbine trips and the automatic shut down emergency trip
oil manifold loses pressure the unloading pressure quickly opens under the action of
pressure oil to quickly remove the pressure oil in the lower chamber of the high pressure
main stop valve oil servo motor piston rod and the main stop valve quickly closes under
the action of spring force. When the solenoid valve is energized the oil servomotor speed
is relatively slow so that the valve moving test can be conducted through the solenoid
valve. The oil servo motor is installed with position switch so that full open and full
close condition can be detected.
The high and intermediate pressure regulating valve oil servo motor is a continuous
actuator. The respective oil operated servo motors open or close the regulating valve
depending upon the control signal received from the DEH. There is an LVDT to give the
position feedback signal. The servo motor actuator consists of oil cylinder, servo valve,
hydraulic integrated block, LVDT, quick release valve and solenoid valve.

High pressure trip system consists of OPC and AST solenoid valves. They are activated
when the EH oil pressure rises above 18 MPa, hence tripping the turbine. There are two
OPC valves( Over speed protection) valves arranged in parallel, two check valves, one
control block, for over speed control. In normal operation the two overspeed protection
valves are closed without power and enclose the overspeed manifold oil leakage passage
so that oil pressure builds up in the lower chamber of the regulating valve actuator
piston rod, and when the turbine operation speed exceeds 103% rated speed the DEH
control system OPC controller sends out actuation signal and OPC solenoid valves act

and the oil is discharged through the oil return piping to EH oil tank, making the
unloading valve on the servo actuator act quickly making all the regulating valves close.
The AST solenoid valves act during emergency shutdown, when emergency shutdown
signal is given by the ETS to trip the turbine. There are four ATS solenoid valves. Two
pairs are arranged in parallel and the two pairs are then arranged in series. This gives a
redundancy to the system because the system will work reliably even if one valve in
each parallel pair is activated. In normal operation the four AST solenoid valves are
closed with power and enclose the AST oil leakage passage so that oil pressure is built
up in the lower chamber of the main stop valve actuator and the regulating valve
actuator piston rod. When emergency trip command is given the manifold oil is
discharged to the EH oil tank and the AST solenoid valves are activated. Thus the
unloading valve on the main stop valve actuator and regulating valve actuator quickly
open to make all steam valves quick close.
The AST and OPC oil are separated by the two check valves on the AST solenoid valve
assemblies. The check valves are so designed that when the OPC solenoid valve acts the
AST manifold oil pressure is not affected, but when AST solenoid valve acts, OPC oil
pressure is lost.
Main functions of DEH control systemThe following are the main functions of the DEH control system and the philosophy of
operation

Automatic turbine tripThe DEH system facilitates tripping of the system, so when the turbine trip signal is
received from ETS, it closes all steam admission valves(Main stop valves and regulating
valves), and the emergency governor and tripping solenoid valve act to establish low
pressure safety oil and allow the oil to go to the upper diaphragm chamber of the
diaphragm valve. The AST oil discharge is closed and the solenoid valve of the AST is
reset to establish AST oil pressure again. The pressure switches close when pressure is
resumed.

Servo system calibrationIt is necessary to maintain linearity and reliability of the servo control system. The
relation between the command and the actual valve opening should be 0% command
0% valve lift and 100% command 100% valve lift. Also the feedback received should
be accurate. This setting is done by doing the pull valve test, through the operator
station. When the DEH receives command to do pull valve test, it fully opens and closes
the oil servo motor and records the value of the LVDT in the extreme and positions, and
correct zero and span.

Pre start controlDepending on the turbine temperatures the controller decides whether the start-up is hot,
warm or cold. This is necessary because in order to reduce thermal stress on the turbine,
according to the type of start up, different start curves will be used. The temperature(T)
in the high pressure inner casing is measured. If T < 150 degrees, cold start up curve is
used. If 150<T< 300 degrees, warm startup curve is used. If 300<T<400 degrees, hot
startup curve is used. If T>=400 degrees, extremely hot startup curve is used.

Turbine speed-up controlThe speed-up control of the turbine is a closed loop control system with a PID controller.
The set point is the target speed. The actual speed of the turbine is measured and the PID
regulator performs calculations to control the opening of the oil servo motor so that the
steam admitted is controlled and thus speed is controlled. The operator can manually
control the speed from the HMI and set the speed up rate. The conditions under which
the DEH automatically sets the target speed are- when the turbine has just tripped the
target is the current speed, when the oil switch has just opened, the target is 3000 rpm,
and when the turbine trips the target is zero. The rate of speed up can be manually set

except in the critical speed zone when the rate of speed up is 500 rpm/min. at 500 rpm,
2500 rpm and 3000 rpm warming up needs to be done, i.e. the turbine needs to be
soaked at that speed. Hence speed up automatically stops at these speeds for a set time
till warming up is done.

Load controlThe DEH system also monitors and controls the load on the turbine. The operator can
manually set the target for the load to be attained. The load controller is a PI controller
and it compares the set power to the actual power produced. After the calculation it gives
an output to the regulating control valve. The operator can also set high and low load
limits in case he doesnt want the load to exceed a certain value.
Also the operator can set valve position limit so that he can limit the amount of valve
opening. If the load needs to be increased or reduced by a large amount in a small period
of time, the DEH system performs this function without affecting the system
performance.

Main steam pressure control and protectionIf the main steam pressure from the boiler becomes low due to some fault, the DEH
system puts this control into use and by reducing regulating valve opening to reduce
steam flow, co-operates with the boiler system to restore the main steam pressure to
normal.
In main steam pressure protection, the control system will follow up the opening of the
governing valve and if the main steam pressure goes below the set lower limit, it will
close the governing valve until the steam pressure returns to the allowable range.

Valve control-

Valve control is one of the main functions of the DEH system. It is also called
throttle/nozzle regulation and it brings all high pressure regulating valves into
synchronous control. In throttling operation mode all valves are in throttling state, as it is
required to heat the turbine uniformly. In nozzle regulation the regulating valves are
opened one by one in a preset sequence and at ont time only one regulating valve is open
while the others are fully open/fully closed.

Overspeed protectionThere are two modes- overspeed limit and overspeed protection. Overspeed limit is a
means to prevent the turbine tripping during high speed condition.
During load rejection, the turbine speed could rise sharply, and hence I is necessary to
set load rejection overspeed limitations. If overspeed is detected, then the overspeed
solenoid valve is actuated and all regulating steam valves are closed. Ideally the speed is
not allowed to go more than 103% of rated speed. After speed is lower than 103% the
regulating system is restored. If the turbine speed goes above 110% inspite of overspeed
limitations the turbine is tripped, and this is known as overspeed protection.

On-line testAnother function of the DEH system is to perform on-line tests. These tests are- min
stop valve and regulating valve leak tests, oil spray test, main stop valve and regulating
valve moving test, overspeed protection test, ETS on-line protection test.

ETS system
The ETS system is a separate system called the emergency trip system which trips the
turbine. By tripping the turbine we refer to closing of all the steam admission valves of
the turbine for emergency shutdown. The ETS system receives the emergency signals
from either the DEH or the TSI system. The turbine is tripped if any of the following
conditions occur-

Turbine overspeed 110% (DEH)

Turbine overspeed 110% (TSI)

Axial displacement high ( TSI)

High pressure turbine differential expansion high (TSI)

Low pressure turbine differential expansion high ( TSI)

Bearing vibration high (TSI)

Shaft vibration high (TSI)

Temperature of #1-#5 radial bearings > 110 degree (Direct signal)

Return oil temperature of #1-#5 bearings > 75 degree ( Direct signal from RTD)

Temperature of positive thrust pad > 110 degree

Positive and negative thrust pad return oil temperature > 75 degree

Lube oil pressure low

Condenser vacuum low

EH oil pressure low

Condenser level high

DEH power failure

Loss of AST solenoid valve 1/3 and 2/4 power supplies

Boiler MFT relay activated

TSI system-

The TSI system, or the turbo supervisory instrument system, is a separate system which
is used to measure and monitor the critical turbine parameters. It is a set of specialized
instruments which terminate in a separate cabinet. There are a number of very critical
parameters which need to be continuously monitored because if any of these values goes
out of limits the turbine needs to be tripped, else it will get damaged. The accuracy of
the sensing and measuring instruments needs to be extremely high. The following are
the parameters that are monitored using the TSI system1. Turbine speed
2. Turbine radial vibration of bearings
3. Turbine differential expansion
4. Axial shift
5. Thrust position

Turbine auxiliaries
The steam turbine auxiliaries can be sub-divided into the following systems

ATRS system

Condensate system

Lube oil system

Auxiliary PRDS system

Gland steam system

Vacuum system

HP-LP bypass system

Regenerative feed heating system( LPH, Dearator, BFP, HPH)

Extraction steam system

These systems are operated using the main plant distributed control system. The operation and
control of each of these systems is discussed in detail below. Before rolling the turbine we need
to charge some of these auxiliary systems and some, like extraction system, LPH, HPH need to
be charged after turbine rolling. The auxiliaries are charged before turbine rolling using the
ATRS system, i.e automatic turbine run-up system which is a sequential logic to bring all the
necessary auxiliaries in line.
The ATRS system consists of the sequence in which the systems are charged. Each sub-system
comprises the main group logic. Each main group has a sequence start permit. In order for the
ATRS to start the following permissives need to be satisfied

Boiler MFT should be reset

Boiler firing should be on

Boiler drum pressure > 2 kg/cm2

The ATRS charges all the turbine systems in the following sequence1. Permit to start ATRS satisfied, start condensate sub group sequence
2. Condensate system ready, start lube oil system sequence
3. Lube oil system ready, start APRDS system
4. APRDS system ready, charge gland steam header
5. Gland steam header charged, start vacuum system
6. Vacuum system ready, charge turbine gland sealing system
7. Gland sealing system ready, start steam pipe warmup system
8. Steam pipe warmup system ready, start bypass system

9. All systems ready, turbine ready for rolling.

Each sub-group has its own start sequence, which the ATRs executes by itself in auto mode, and
in manual mode is done by the operator.
A detailed explanation of the operation of all the turbine auxiliary systems as executed in the
ATRS and also during unit operation is discussed below. The operation of the closed loop
controls is also discussed.

Condensate system-

The condensate system is charged. The system consists of the condenser, hot well, CEP. The
CEP discharge goes through the gland steam condenser, from where it is divided mainly into
three lines- minimum recirculation line which goes back to the condenser, condensate reject
line which goes to the condensate storage tank and condensate line which goes to the LPH.
There is a makeup line which gives hot well makeup water from the condensate storage tank.
All these lines have control valves to control the flow of condensate through them. Before
charging the condensate system the following permissives need to be followed at the same
time Hot well level > minimum
Condenser make-up isolation valve open
Condensate reject isolation valve open
Condensate recirculation isolation valve open
Condensate Flow to Deaerator Isolation Valve open
CEP - Ready to Start Condition available
CEP-B - Ready to Start Condition available
The steps to start the condensate system are as follows-

1. Open hot well make up CV inlet valve, condenser reject CV inlet valve, condensate
recirculation CV inlet valve. Force close CEP A and B outlet valves. Force CEP
minimum recirculation valve to 100% open. The following control loops should be
thrown to auto- deaerator LCV, Hot well makeup valve and condensate reject valve.
2. When the above valves are open and CEP minimum recirculation valve > 80% open,
open deaerator CV inlet valve and LPH 1,2 3,4 bypass valves since the LPHs are not in
service.
3. When all valves feedback open is received start CEP A or CEP B or both the CEPs. In
order to start the CEPs the following permissives need to be satisfied, along with the
following trip conditions-

START PERMISSIVES
CEP switchgear available
CEP in remote
CEP trip circuit healthy
CEP switchgear no disturbance
CEP trip relay(86) not operated
CEP trip condition not present
CEP manual inlet valve open
CEP motor winding temperature not high (any 2 out of 6)
CEP motor bearing temperature not high
CEP vibration not high( x and y axes)
Hotwell level not low
CEP in auto or discharge valve closed
CEP in auto or minimum recirculation path available
CEP motor thrust bearing temperature not high

TRIP CONDITIONS
Hotwell level low low
CEP on and discharge valve not open
CEP tripped(86)
CEP motor winding temperature high high
CEP motor bearing temperature high high
CEP vibration high high ( x and y axes)
CEP suction strnr dp high
CEP stop PB operated-console
CEP thrust bearing temperature high high

4. When CEP A/ CEP B/ both CEP are running, open either one or both the outlet valves
and throw the CEP minimum recirculation loop to auto.
5. When either/ both outlet valves are open, CEP discharge header pressure not low ( > 10
kg/cm2), and CEP minimum recirculation flow established , the condensate system is
ready.

There are three closed loop controls in the CEP system- hot well level control, deaerator level
control and CEP recirculation control loop. Description of CLCS.

Lube oil system-

The lube oil system provides oil for proper lubrication of the turbine bearings. It consists of
main oil tank, AC lube oil pump, DC lube oil pump, AC and DC jacking oil pumps, high
pressure, oil coolers and oil filters.
Before starting the lube oil system the following conditions need to be checked. In ATRS
these conditions are checked automatically otherwise need to be checked by the operator.
Any one ACW pump should be running
Lube oil tank level should not be low (< 100 mmWC)
AC LOP, DC LOP, AC JOP, DC JOP, HP pump ready to start
Lube oil temperature > 25 degree Celsius
The procedure to start the lube oil system is as follows1. When all permissives are satisfied, the oil vent fans A and B or both are started. HP oil
pump is started.. when HP pump is ON, HP pump protection start command is bypassed.
2. After oil vent fans are on, HP oil pump is running and HP pump outlet pressure OK (1.96
MPa), start AC Lube oil pump.
3. When lube oil pump is running and LOP outlet header pressure OK (0.08 MPa), check if
barring gear motor is running. If motor is not running then stop AC LOP, else LOP
continues to run.
4. If AC LOP not running, and lube oil header pressure low (< 0.058 MPa), start DC LOP. If
lube oil header pressure becomes OK and DC LOP is running, then it is stopped.
5. If AC LOP is running, lube oil header pressure OK(0.08 MPa) and JOP inlet header
pressure OK ( 0.048 MPa), then AC JOP is started

6. If barring gear motor not running then stop AC JOP

7. If AC JOP not running, JOP header pressure low (< 4.2 MPa), and barring gear motor
running, then start DC JOP.
8. If DC JOP running and JOP header pressure ok then stop DC JOP
9. If DC JOP not running, JOP header pressure low and barring gear motor running then
start AC JOP
10. If AC LOP running, lube oil header pressure ok (0.08 MPa), turbine speed< 1.5 rpm, AC
JOP running and JOP header pressure OK then throw barring gear to auto
11. If turbine speed > 4.5 rpm, barring gear motor running, barring gear engaged then
message flashes on HMI turbine lube oil system ready to start:.

Main oil tank- The oil is stored in the main oil tank( MOT). The main oil tank has a level
transmitter to indicate the level of the tank and also a level switch which detects high level in
the tank. If level switch is acted it means that the filter placed inside the MOT has been
choked hence oil is not going to bottom of the tank, hence indicating high level. If switch
acts, the tank needs to be cleaned. The temperature of the lube oil inside the tank needs to be
controlled using the heater, at 43 degree Celsius. There is a control panel near the heater
which contains a temperature controller. If temperature goes above set point the heater is
turned off and if temperature goes below set point heater is turned on. The HP pump and AC
and DC lube oil pumps are on top of the MOT and draw oil directly from the MOT.
Oil vent fans- the oil vent fans are used to remove moisture and oil mist from the lube oil
tank. Only one oil vent fan is running at a time and it needs to be selected in auto mode from
HMI. If the fan goes into overload it trips
High pressure pump- The high pressure pump is started manually through HMI or
automatically through ATRS system. It supplies oil to turbine till 2900 rpm speed is reached
after which MOP starts. The following are the conditions under which protection start
command is given to HPP-

 Turbine speed falls below 2800 rpm, detected by speed sensors

MOP outlet pressure low (< 1.7 MPa)
Protection start command not bypassed.
Protection start command is bypassed when HP pump is started and feedback ON is received
for 15 seconds. An alarm is generated when the discharge pressure of HP pump < 1.96 MPa.
AC lube oil pump (LOP)The AC LOP along with the HP pump supply lube oil to the turbine bearings. The lube oil
pump is started after HP pump, and is given protection start command under the following
conditions Turbine speed > 2900 rpm, but lube oil header pressure low (< 0.069 MPa)
Turbine tripped
Protection start command not bypassed.
Protection start command is bypassed when AC LOP started and feedback ON is received for
180 seconds.
DC Lube oil pumpThe DC lube oil pump is used as standby pump if AC LOP stops working. It is also required
when the lube oil header pressure is low (<0.058 MPa), i.e. the AC Lop is not able to provide
sufficient pressure. If protection start command is not bypassed then the DC LOP starts.
Protection start command is bypassed when DC LOP started and feedback ON is received for
120 seconds.
AC Jacking oil pump (JOP)The AC JOP is used for providing oil to support the turbine shaft when the turbine is on
barring gear. After the turbine speed reached 1300 rpm the shaft becomes self supporting so
then the JOP is no longer needed. It is thrown to auto mode when turbine speed goes above

1300 rpm or when speed goes below 1200 rpm. The Ac JOP is started in auto when turbine
speed goes below 1200 rpm. In order to start the AC JOP the JOP suction pressure needs to
be >0.048 MPa. The AC JOP is stopped when the speed of the turbine goes above 1300 rpm
and is stopped in protection when the barring gear stops.
DC JOPThe DC JOP is used as a standby to the AC JOP. It is automatically started when the AC JOP
trips or AC JOP fails to start and turbine speed < 1200 rpm. Also if the JOP outlet header
pressure goes below 4.2 MPa for 3 seconds, the DC JOP is automatically started.
Auxiliary pressure reduction and de superheating system (APRDS)In the APRDS system, a tapping is taken from the main steam line of boiler and goes to a
common header called the auxiliary steam header. Before the turbine is rolled the APRDS
system is used for deaerator pegging and for gland sealing of the turbine. The steam for
pegging and gland sealing is taken from the auxiliary steam header. It is necessary to
maintain the temperature of the auxiliary steam header at 200-220 deg Celsius and pressure
at 8-10.5 kg/cm2. Before the CRH line is charged the steam is taken from the main steam line
using PCV 105 and after the CRH line is charged the responsibility of the auxiliary steam
header pressure control is switched to PCV 125. The temperature control is done through
TCV 105 and the spray water is taken from BFP inter stage tapping.
The pressure and temperature of the steam are controlled using closed loops. For header
temperature control the valve TCV 105 is used. It is air fail close type. The temperature is
sensed by temperature elements TE 105A and TE 105B. If the temperature of the header line
increases the control valve opening also increases to let more attemperating water into the
spray, thereby reducing the temperature. If the temperature of the header decreases then the
opposite action takes place, i.e. the control valve closes. Thus the controller action is direct
action.
For header pressure control the valve PCV 105 is used in the beginning, and after CRH
pressure increases above 17 kg/cm2 the responsibility of pressure control is handed to PCV
125. If the line pressure increases above setpoint, the control valve will close, thus reducing

the steam going to the line and controlling the pressure. Thus the controller action is reverse
action.
The following permissives need to be satisfied before starting the auxiliary PRDS system Main steam pressure > 0.12 MPa
Main steam temperature > 50 degree SH
Pressure at turbine inlet > 15 kg/cm2
Temperature at turbine inlet > 100 degree Celsius
BFP inter stage pressure ok
MSSV open
Auxiliary steam header drain valve more than 25% open
MS drain valves L and R open
Auxiliary PRDS PCV inlet and bypass valves open
The procedure for charging the APRDS system as given in the ATRS is as follows1. Put APRDS PCV and TCV in auto
2. Force close APRDS PCV bypass valve
3. Check if auxiliary header pressure and temperature OK ( 8-10 kg and 200 deg C)
4. If not then wait till ok. An alarm Auxiliary PRDS system ready is given to HMI.

Gland steam systemThe gland steam system is used for sealing of turbine glands before turbine is rolled. Before
turbine rolling since there is no steam being supplied to the turbine, steam is necessary to be

given to the glands externally. This is done through the gland steam system. After the steam is
passed through the turbine and warm-up has been done then the turbine glands become self
sealing. The gland steam temperature is required to be maintained at 150 degree Celsius and
pressure at 1 kg/cm2. There are two stages of gland steam PRDS, one in the HP side of turbine
and the other in the LP side of turbine. Pressure control is done at HP side through PCV 404,
where steam comes through the aux. steam header. Temperature control is done at both HP and
LP sides through TCV 407 at HP side and TCV 413 at LP side.
HP gland steam pressure control is closed loop in nature. The pressure of the inlet is measured by
PT 409 and feedback is given to PCV 404. If the pressure increases above set point then the
valve closes, and vice versa. Thus controller action is reverse in nature. There is also a provision
for gland steam over pressure control. If pressure exceeds the high limit then gland leak off is
given to the condenser through valve PCV 411. If the pressure increases the valve opening also
increases. Hence controller action is direct in nature. Gland steam temperature control is done by
taking temperature measurement using temperature transmitters TT 408. If the temperature
increases more attemperation is required hence TCV 407 will open at HP side and TCV 413 will
open at LP side.
While charging the gland steam system first the gland steam header is charged , followed by
charging of the vacuum system, and after that the remaining part of the gland steam system is
charged. This is because the GSC fans do not work unless there is vacuum in the condenser.
The following permissives need to be satisfied before the gland steam header can be charged
through ATRS system HP Gland PRDS PCV I/L Valve Open XV 434
HP Gland PRDS TCV I/L Valve Open XV 421
LP Gland Desuperheating TCV I/L Valve Open
I/L Valve to Gland Leak of Valve Open XV 423
Aux Steam Header Pressure > 8 kg/cm2 PT 206A
CEP O/L Header Pressure > 10 kg/cm2
GSC Exhaust Fan -A Running

or
GSC Exhaust Fan - B Running
Any CW Pump is Running for the Unit
CW Isolation Valve at Condenser I/L and O/L are Open and Pr. Healthy

One condition before the gland steam system can be started is that any one of the GSC
fans need to be on. The GSC fans operate one at a time. If the vacuum in the condenser is
low ( < 0.8 kg) then the GSC fans stop.

The following are the steps of charging the gland steam header-

1. Open HP gland steam PRDS PCV inlet drain valve and HP gland steam header drain
valve, HP GS PRDS PCV inlet valve, HP GS PRDS TCV inlet valve, LP desuperheater
TCV inlet valve and gland leak off valve inlet valve.
2. Once all the valves are open throw the HP gland steam PCV and TCV to auto and LP
gland steam TCV to auto. Force gland steam header drain PCV (PCV 411) to 25% open.
3. Once all valves are thrown to auto and PCV 411 is 25% open, charge vacuum system
4. Once vacuum system is charged come back to charging of gland steam system.
5. Once gland steam header pressure > 0.1 MPa and gland steam header temperature > 150
degree Celsius, throw gland steam header drain valve to auto.
6. When drain valve is on auto start GSC fan A and B.
7. If GSC fan A or GSC fan B or both are on, monitor all feedbacks.
8. Depending on type of startup ( cold, warm, hot, very hot), monitor conditions. HP gland
steam pressure should be greater than 0.1 MPa, and LP gland steam temperature should
be greater than 180 degree Celsius. If cold startup condition then HP gland steam

temperature should be greater than 150 degree Celsius. If warm startup condition then HP
gland steam temperature should be > 150 degree Celsius. If hot startup condition then HP
gland steam temperature should be greater than 250 degree Celsius. If very hot startup
condition the HP gland steam temperature should be greater than 250 degree Celsius.
9. After all the above conditions have been satisfied then the HMI shows message that gland
steam system is ready.

Vacuum system-

Components of vacuum system are

1) Vacuum pump
2) Sealing water pump
3) Vacuum breaker
4) Condensate tank
5) Water cooler

The minimum pressure of vacuum to be maintained in condenser is -0.85 kg/cm 2. If

pressure goes below -0.9 kg/cm2 or above -0.8 kg/cm2 the system trips.

Condensate tank and water cooler- The liquid medium for the vacuum pumps is water
which is taken from the CEP discharge, and filled in the condensate tank. The condensate
tank has high and low level switches which indicate when level is high or low. The tank
is filled through an inlet solenoid valve connecting CEP discharge line to the tank. When

the level switch is high, the solenoid closes the valve so that the tank stops filling and
when the level switch is low the valve is open to fill the tank. If the level in condensate
tank is low for 8 seconds or more, both the vacuum pump and the sealing water pump
trip. The water cooler is used to cool the water that goes into the vacuum pump. It gets
cooling water from ACW pump.

Vacuum pump- The suction side of the vacuum pump has one MOV XV 536A for
vacuum pump A and XV 536B for vacuum pump B, and butterfly valves SV 501A for
vacuum pump A and SV 501B for vacuum pump B. The MOVs should be open before
the pumps start. The butterfly valves open just after the pump starts. Thus for the vacuum
pump to start the following conditions have to be satisfied- inlet butterfly valve should be
closed, inlet MOV should be open, condensate tank level should not be low. The
conditions under which the vacuum pumps trip are- inlet valve feedback closed (5 sec),
condensate tank level low (8 sec) and vacuum pump feedback on but sealing water pump
feedback off (5 seconds).

Sealing water pump- The sealing water pump is used to provide the liquid medium for the
vacuum pump. Thus for the sealing water pump to be on the vacuum pump should be on
and the condensate tank level should not be low. The conditions under which the sealing
water pump trips are that vacuum pump is off and condensate tank level is low.

Vacuum breaker- Brings turbine speed to zero as it breaks the vacuum suddenly. By
breaking vacuum you reduce the energy to drive the system, causing it to come to a stop.
The vacuum breaker is an MOV XV 535. The conditions under which the vacuum
breaker opens are

Lube oil pressure low (<0.3974 kg/cm2) for 2 seconds and turbine tripped

Turbine tripped

Axial shift high (> +12 or < - 16)

HP turbine inlet steam temperature falls 50 deg C in 10 min

HRH temperature falls 50 deg C in 10 minutes

The following are the permissive to be satisfied in order to start the vacuum system Condenser airline valve L and R ( XV 503 and 504) open
CEP outlet pressure normal
Any CEP on
Any vacuum pump group( consisting of vacuum pump, sealing water pump)
ready to start
The startup sequence of the vacuum system is as follows1. Close vacuum breaker valve, open vacuum pump A airline isolation valve, and vacuum
pump B airline isolation valve.
2. After vacuum breaker closed and valves opened, start vacuum pump A and B and sealing
water pumps A and B.
The following are the start permissives and trip conditions for vacuum pump and sealing
water pump are given belowVacuum pump A/B start permissive

Vacuum pump A/B trip condition

Vacuum pump overload

Vacuum pump local stop PB
Vacuum pump on feedback fail
Vacuum pump control supply failed
feedback open
Vacuum pump outlet condensate tank level lo (8 sec)
Vacuum pump inlet butterfly valve closed
Vacuum pump inlet valve not open ( 5 sec)
Condensate tank level not low
Vacuum pump on and sealing water pump not on (5 s)
Sealing water pump feeder ready
Vacuum pump inlet valve not open

Vacuum pump feeder in service

2 Vacuum pump fan in remote
Vacuum pump airline isolation valve
1

3
4
5
6
7

Sealing water pump A/B start permissive

1 Sealing water pump feeder in service
2 Sealing water pump in remote
3 Vacuum pump on

Sealing water pump A/B trip condition

Sealing water pump overload
Sealing water pump local stop pb
Sealing water pump on feedback fail
Sealing water pump control supply failed
Process trip 1
Vacuum pump off
Condensate tank level low

3. After vacuum pump A or B or both and their respective sealing water pumps are on, the
butterfly inlet valves of the pump which is running is open and condenser vacuum ok,
then the vacuum system is ready. The ATRS sequence then goes back to charging the
gland steam system as described above.

HP-LP bypass system and steam pipe warm up system-

The HP-LP bypass system is one of the very important systems in the turbine. It is required to
bypass the steam from the boiler when the turbine is not running. Also while changing the load,
or load reduction we need to open the bypass valves so that the reject steam bypasses the turbine.
this bypassed steam is sent to other paths where it is reused. HP bypass steam is sent to the CRH
line and LP bypass steam is sent to the condenser. Each bypass has a temperature controlling
spray. The HP bypass temperature control is done through the BFP interstage tapping and the LP
bypass temperature control is done through the CEP outlet.

The steam pipe warm up system is used to raise the temperature of the pipes through which high
pressure steam is going to be passed, so as to not raise the temperature suddenly. The permissives
to start the system are as follows Permissive from CW system
Any CEP running
CEP outlet pressure normal
Condenser vacuum pressure normal
Gland steam header pressure and temperature normal
The following are the steps in which the ATRS charges the steam pipe warm up and bypass
system1. Open HPBP and LPBP PCV warm up valves and HRH and CRH drain valves
2. Monitor all feedbacks of above valves being opened
3. Check if main steam and HRH pipe temperatures > 50 degrees, and then steam pipe
warm up system ready.
4. Open HP bypass and LP bypass spray valve inlet MOV
5. When valves are opened, operator has to manually reset HP and LP bypass system
6. When HP-LP bypass reset, then put HP bypass and LP bypass PCV and TCV in auto
7. When valves in auto, monitor HP bypass and LP bypass inlet spray water pressure. Open
HP bypass PCV 2% open. When HP BP PCV > 2%open, close HPBP PCV warmup valve
8. Check both bypass spray water inlet pressure, and open LPBP PCV 2%. When LPBP
PCV > 2% open, close LPBP PCV warmup valve
9. When HPBP warmup valve and LPBP warmup valve are closed, open all drain valves of
HP and IP turbine

10. When all drain valves are open, open the drain valves of turbine extractions to LPH and
HPH
11. When all extraction drain valves are opened, open turbine interlayer header drain valve
12. Adjust the interlayer drain valve manually
13. Warm up and bypass system ready, await permit for turbine rolling.
Turbine rolling permissiveAfter the ATRS finishes charging all the systems one by one, it waits for a signal that all the
systems have been charged and that turbine is ready for rolling. The following are the
permissives for turbine ready for rolling permit HP oil pump running
CEP outlet pressure > 10 kg/cm2
Any CEP on
Condenser pressure < 0.85 kg/cm2
HP gland steam pressure normal (> 1 kg/cm2)
HP gland steam temperature normal (> 150 degree Celsius)
Barring gear on
Turbine speed > 4.5 rpm
HP differential expansion within limit ( +6 mm to -3mm)
LP differential expansion within limit ( +7.5 mm to -3mm)
Bearing vibration within limit ( +127mm to -127 mm)
Axial shift within limit ( +0.8mm to -1.2mm)

 Turbine inlet pressure OK for rolling ( for cold start up- 40 kg/cm 2 ; for warm startup- 45
kg/cm2; for hot startup- 55 kg/cm2; for very hot startup- 60 kg/cm2)
Turbine inlet temperature OK for rolling rolling ( for cold start up- 320 degrees ; for
warm startup- 400 degrees; for hot startup- 460 degrees; for very hot startup- 525
degrees)
When all the above conditions are satisfied, a message is displayed on HMI Turbine ready
for rolling.
After the turbine is rolled, the regenerative feed heating system and extraction system is
taken into service.

Extraction steam systemSteam is extracted from various stages of the turbine to provide steam to the HP heaters,
LP heaters and for dearator pegging. The extraction steam is charged when HP heaters
and LP heaters are taken into service and when deareator pegging is taken into service
from extraction.
The steam is provided through MOVs and there are NRVs in each extraction line to avoid
back flow of the steam.
LPH extraction linesThe LPH extraction lines are charged when LP heaters are taken into service at 40-50
MW. The QCNRV is opened first followed by the LPH extraction steam valve. If the
selected LPH level goes high then the QCNRV and the extraction steam MOV close.
There is a drain valve of the extraction line which is an NRV. It opens when load goes
below 42 MW, and when the extraction steam MOV closes. When load goes above 45
MW, the drain closes automatically. When the turbine is tripped the drain valves open.
HPH extraction lines-

The HPH is charged when the load reaches about 80 MW. Before charging the system the
drain valves are open, and when the QCNRV in the extraction line opens the drain valve
closes. The main extraction steam valve opens only after the QCNRV opens. The drain
valve opens when load goes below 12 MW and closes when load goes above 15 MW. If
HPH level goes high or if turbine trips then the QCNRV closes and the steam MOV also
closes.
Dearator extraction linesThe deaerator extraction line consists of 2 NRVs, QC type, 1 extraction steam MOV, one
dome valve and one isolation valve. There are 3 drains to flash tanks. The drains open
when the load goes below 27 MW or if turbine trips or if extraction steam valve and
QCNRV closes. The drains close when load goes above 30 MW and QCNRV, isolation
valve, dome valve and extraction steam MOV open.
The extraction steam MOV opens when both QCNRVs open. It closes in protection if
deareator level goes high or if turbine trips. The quick closing NRVs open in protection
when turbine is reset and close in protection when turbine trips, or deaerator level goes
high. The isolation valve and dome valve open when deaerator temperature goes above
90 degree Celsius.

Regenerative feed heating system

The regenerative feed heating system consists of 4 low pressure heaters, 3 boiler feed
pumps, deaerator and 2 high pressure heaters. This system pre heats the condensed water
in the condenser and pumps it back to the boiler.
Low pressure heatersFrom the condenser the condensate is pumped to the low pressure heaters through the
condensate extraction pump. If the low pressure heaters are not in service, then the
bypass valves are opened and the feedwater bypasses the LPHs and goes directly to the
deaerator. There is one inlet MOV and one outlet MOV for condensate.

If the bypass valve is open and both inlet and outlet MOVs are closed then the LPH is
said to be out of service and if the bypass valve is closed and both inlet and outlet MOVs
are open the LPH is in service.