Professional Documents
Culture Documents
GBll34789 Mechanical Vibration of Large Rotating Machines with Speed Range from 10 to
200 r/s--Measurement and evaluation of vibration Severity in Situ
GBl214589
Equipment
Quality Criterion of Water and Steam for Generating Unit and Steam Power
DL42891 Technical Rules for Power System Automatic Under-Frequency Load Shedding
DLT56195 Guide for Chemical Supervision of Water and Steam in Thermal Power Plants
operation and technical management shall be carried out taking the life management as the main
line.
4.1 Distribute and Use the Service Life of Steam Turbine Reasonably
4.1.1 The service life distribution of heavy steam turbines generally depends on the turbine
structure and characteristics of its application, the numbers of start-stop, change of operation
conditions, the numbers of load rejection with auxiliary power, etc. The allocation shall be made
according to different models and operation methods.
4.1.2 The creep life consumption accounts for 20 and 80% for the fatigue life expenditure
according to the life management curve provided by the manufacture within the design service life
of steam turbine. The unforeseen circumstances shall be allowed when distributing the service life
of the steam turbines, and the generally, the life consumption only accounts for only about 80%
and 20% for possible emergency accidents. The examples for life distribution of steam turbine are
shown in Appendix E (informative appendix).
4.1.3 For the steam turbines with base load, the life consumption for each cold start can be larger,
which shall be controlled in the range of 0.05%/times, the life consumption of peaking unit is
mainly consumed in the hot start-stop, so the life consumption of each start-stop can be smaller,
usually in 0.01%/time.
4.2 Supervision and Management over the Service Life of Steam Turbine Rotor
4.2.1 Each turbine should be drawn with starting curve for different operating modes based on the
life management curve of steam turbines provided by manufacturers. And the examples of starting
and stopping curves for steam turbine are shown in Appendix D (informative appendix).
4.2.2 The database of rotor life loss shall be established and improved gradually for each turbine,
which is controlled by the service life management curve provided by the manufacturer so as to
make the life loss of the steam turbine under control as well as guide the operators to start and stop,
adjust the operation parameters and handle the abnormal operating conditions.
4.3 Principle for Reducing the Life Loss of Steam Turbine Rotor
4.3.1 Prevention of Brittle Damage to Steam Turbine Rotor in Startup
a) Select the running steam parameters and shaft seal steam supply temperature reasonably
according to the temperature of cylinder mental when start-up and control the rate of temperature
rise of metal strictly.
b) Take the metal temperature at the steam exhaust port of intermediate pressure cylinder or the
turbine-exit temperature for reference, and determine if the metal temperature of rotor, especially
the metal temperature of the central center of the intermediate pressure rotor, has exceeded the
4.4.1 The reliability index not only reflects the level and quality of design, manufacture and
installation, but also is an important basis for technological transformation and technological
progress, and it also directly reflects the operation and management of power plants and the
equipment maintenance, which is an important part of operation and management for modern
steam turbine.
4.4.2 Most equipment of the steam turbine is serviceable and its service life distribution has
something in common. The service life loss resulting from the improper repair and maintenance
can be found by reliability statistics analysis, thereby improving the operation method and repair
and maintenance program and changing gradually from passive repair and maintenance to state
monitoring and predictive maintenance so as to improve the equivalent available factor (EAF) of
equipment, reduce the equivalent forced outage rate (EFOR), reduce the maintenance costs,
extend the service life of the steam turbine and get more and safer economic benefits.
5 Startup of Steam Turbine
The steam turbine shall speed up with load stably within reasonable life loss, prevent the
differential expansion exceeding limits, the temperature difference of cylinder exceeding limits,
static and dynamic friction, abnormal vibration of shafting and other unusual circumstances, avoid
the abnormal operation of auxiliary equipment and thermal control device that may endanger the
safety of the host and minimize startup time and reduce the startup overhead so as to obtain the
best safety economic benefits.
5.1 Classification of Startup Mode
5.1.1 Classify according to the admission mode of cylinder at startup
a) High-pressure cylinder starting-up (or high-pressure and intermediate-pressure unite
starting-up )
b) Intermediate-pressure cylinder starting-up
5.1.2 Classify according to the metal temperature at governing stage for high pressure cylinder
starting-up; classify according to the metal temperature at first pressure stage of intermediate
pressure for intermediate pressure cylinder starting-up. The specific division temperature should
be prescribed by the manufacturer and classified as follows:
a) Cold start
b) Warm start
c) Hot start
d) Extreme hot start.
5.1.3 Classify according to downtime
a) Cold start: The metal temperature drops below 40% of is rated load after the turbine shuts down
for more than 72h.
b) Warm start: The metal temperature drops down at 40%~80% of is rated load after the turbine
shuts down for 10h~72h.
c) Extreme hot start: The metal temperature remains or is close to its rated load when the turbine
shuts down within 1h.
5.1.4 Classify according to valve control mode
steam turbine, and ensure the temperature of exhaust steam does not exceed limits and the bypass
system can be put into use in a timely manner.
5.2.5 By-pass System:
a) The configuration, type, capacity and control level of the bypass system shall be in accordance
with the characteristics of the units or relevant design codes.
b) The startup method with bypass system should be proposed by the manufacturer, such as IP
cylinder startup or HP and IP control valve and bypass coordinated starts, etc.
c) The automatic, interlocking and protection shall function properly and is put into use before the
bypass system is put into use.
d) The HP and IP cylinder steam flow shall match with each other when using the bypass system,
which shall meet the minimum cooling flow of HP and IP and LP cylinder at different working
conditions.
e) If the bypass system shall exit automatically if it cannot be set under hot standby state when the
steam turbine operates so that the water hammers can be avoided in steam pipelines when putting
in use.
5.2.6 The steam turbine is not allowed to run or connected into grid in case one of the following
occurs:
a) All tachometers are out of order.
b) The speed governing system fails to maintain idling or the dynamic overspeed exceeds the
operating value of the overspeed governor after load rejection.
c) The HP and IP main throttle valve, governing valve, HP cylinder exhaust check valve and any
extraction check valve in reheating system cannot be closed tightly, or jammed or malfunctions
d) The overspeed governor fails in the overspeed tests.
e) Any tripping protection of the steam turbine fails. The trip protection required by the steam
turbine is shown in Appendix A1 (standard appendix).
f) Any main control parameters of steam turbine are out of surveillance or any main control device
malfunctions. The main monitoring parameters of steam turbines are as shown in Appendix A2
(standard appendix), and the main control devices required by the steam turbine are as shown in
Appendix A3 (standard appendix).
g)
Any one of the startup oil pumps, fire resistance oil pumps, lubrication pumps, emergency oil
pumps, jacking oil pumps fails or one of its automatic starting devices is out of order.
h) The temperature differences of the inner walls of the HP and IP outer cylinders is greater than
or equal to 56.
i) The deviation value of the rotor eccentricity at the original peak phase is greater than 0.02mm.
j) The turning gear fails; the jigger remains still or the jigger current exceeds limits.
k) There is clear metallic sound between the static and rotating parts or other abnormal sound.
l) The quality of the steam, water and oil is below standard.
5.3 Cold Starts
5.3.1 Running Parameter Selection:
The main and reheat steam pressure in front of the main throttle valve and temperature hall meet
the requirements of starting curve provided by the manufacturer when the steam turbine starts up
in cold state. The overheat degree of the main steam entering into the steam turbine shall be at
least 50, but not greater than 426. The temperature differences between two pipelines shall
not be more than 17. The temperature differences between the main and reheat steam of the HP
and IP combined cylinder turbine are generally 28, may be up to 28 42 in a short time but not
greater than 80.
5.3.2 Check the main and auxiliary equipment as well as the relevant system thoroughly, which
shall have the condition for startup before the steam turbine runs.
5.3.3 Running of Steam Turbine:
a) Cut off the steam admission quickly when the turbine runs to 600r/min, and the friction check
should be carried out in the 5min; listen carefully to the sound within the turbine and speed up
after confirming there is no friction in flow path, the bearing oil return works properly. The rising
rate is 100r/min.
b) The warm-up time and the rolling speed shall be carried out in accordance with the startup
curve provided by the manufacturer.
c) Check or medium-speed warmup shall be carried out when the speed is up to the first-order
critical speeds of HP and IP rotors.
d) The warm-up time and temperature shall meet the requirements prescribed by the manufacturer.
5.3.4 Measure and record all relevant data after the steam turbine runs at constant speed and
relevant tests can be carried out after being checked thoroughly and found to work properly, and
the reset can be raised to constant speed at the rising rate of 200r/rain per minute.
5.3.5 Grid-connection and on Load:
a) Warm up with 5% rated load after the grid-connection, and run stably for at least 30min under
such load. For every 2 variation in main steam temperature, the stable warming up time shall
be increased for 1min.
b) Control the load acceleration and the changing rate of the main and reheat steam parameters in
line with the requirements of the startup curve.
c) Load up to the predetermined load and ensure that the corresponding drain valve is closed.
d) Check and confirm that the vibration of the turbine, cylinder expansion, differential expansion,
axial displacement, temperature of bearing metal, temperature of return oil, fuel system pressure,
temperature and other primary monitored parameters are within normal range.
e) HP and LP heaters shall be started randomly, and when the extraction pressure of the deaerator
is higher than the internal pressure of the deaerator, and can overcome the static pressure caused
by height differences, it shall be switched to extract the steam for this section and the deaerator
shall be under sliding-pressure operation.
f) Adjust the condenser vacuum according to the load increases, switch or put the pumps,
circulating pumps, drain pumps and other auxiliary equipment into use.
5.4 Hot Start
5.4.2 Running Parameter Selection
Determine the parameters of running according to the starting curve provided by the manufacturer
based on the cylinder temperature when the steam turbine starts up in hot state.
5.4.2 Running
a) Drain the main and reheat steam pipelines completely, and the drainage for the cylinder block is
opened for 5min and then turned off before the turbine is started and run at extreme hot state.
b) Speed up when the turbine is found to work properly after rub checks after running, but the
rising rate shall not be less than 200r/min per minute.
c) Connect to grid as soon as possible through necessary checks and found normal after constant
speed.
Stop the jacking oil pump when the speed is raised up to 1200rmin.
5.5.3 If the turbine vibrates abnormally when it runs at 80%~85% first-order critical speed of shaft,
dont speed up forcibly but identify the causes and eliminate the troubles and then pass through
the critical speed after the vibration is normal.
5.5.4 Pass through the critical speed quickly and smoothly and the speed should not stay in that
range.
5.5.5 Manage the temperature rise rate of the cylinder metal to be 2~2.5 /min, and the
temperature dropping rate to be 1~1.5 /min; stabilize the speed or load and extend the
warming-up time.
5.5.6 Pay attention to the coordination of adjacent professional to prevent the substantial
fluctuations in steam parameters and load when startup.
5.5.7 Monitor and record the changes in cylinder expansion values, which shall be even and
uniform, if the sliding key system is found to be jammed or stuck, prolong the warm-up time or
discuss the solutions to prevent cylinder vibration caused by uneven expansion.
5.5.8 The oil temperature of the oil cooler outlet shall be adjusted and controlled at 3845
after running and during running, and that of the fire-resistant oil cooler outlet shall be
controlled at 40~ 5 degrees centigrade.
5.5.9 The exhaust cylinder water-spray shall be put into operation when the steam turbine runs to
600r/min and stop the operation at 15% of rated load. The turbine can operate for a long term
when the temperature of the exhaust hood does not exceed 65 C under normal conditions, and
the load shall be limited to no more than 80~C. If the measures taken dont work before grid
connection, and when the temperature of low-pressure cylinder exhaust steam reaches 120~C, the
steam turbine should be shut down.
5.5. 10 The steam turbines that carry out peak-load-dispatching operation in two shifts shall select
the running parameters and temperature rising rate properly according to the metal temperature of
the cylinder when startup, and accelerate the on-load speed and reduce the cooling time of the
turbine rotor.
6 Operation of Steam Turbine
6.1 Give consideration to the safety and economy when operating the steam turbine, and adhere to
the principle of safety first.
6.2 Normal Operation of Steam Turbine
6.2.1 Monitor the main parameters of the steam turbine and its changes shall comply with the
provisions according to the provisions on normal operation and control parameter limits.
6.2.2 Make routine inspection and maintenance periodically according to prescribed content.
6.2.3 Analyze the parameters printed out or copied regularly each hour so as to make the unit
operate under economic state.
6.2.4 Switch and test the relevant equipment regularly.
6.2.5 Load Adjustment:
a) Adopt variable pressure or constant pressure--sliding pressure--constant pressure mode.
b) The load changing rate shall subject to the adaptability to variable working conditions at
governing stage when operating under constant pressure, which shall meet the requirements of life
management curve, generally at l2 of rated load per minute.
c) The load changing rate shall be determined by the adaptability of the boiler when operating
under constant pressure, generally at 2%-3% of rated load per minute.
d) The steam turbine with cut-out governing shall avoid operating at the load transitional point for
a long term so as to reduce the throttle loss of the governing valve.
e) The operation mode of auxiliary equipment shall meet the corresponding requirements of load
adjustment.
exceeding the limits or having such tendency, make adjustment and record the limits of exceeding,
overtime and accumulative time, and make corresponding process.
Main steam
pressure
1OOp
105p
l 20p
Main steam
temperature
Limits
125p
1OOt
t+8
t+(814)
t+(1428)
Non-permitted value
>t+28
Note: 1. p. refers to the rated main steam value (MPa);p1 refers to the rated cold reheat steam
pressure (MPa); t refers to the rated temperature of main steam or reheat steam.
2. The temperature limits only apply to the situation oft566.
6.2.7 The quality of the steam, water and oil shall meet the standards. The process for the
deterioration of the water vapor quality is shown in Appendix B (Standard Appendix). The
commonly-used standard for the cleanliness of the fuel system is shown in Appendix C (Standard
Appendix)
6.3 Special Operation of Steam Turbine
6.3.1 The provisions for load limits prescribed by the manufacturer shall be implemented strictly
when part or the whole of the HP heater stops; in particular, manage the main steam flow and
monitored section pressure as well as the extraction pressure of each section not to exceed the
maximum allowable design value, and pay attention to the influence on the steam temperature of
the boiler.
6.3.2 Manage the vacuum under allowable range when half side of the condenser stops, otherwise
run with reduced load. Attention shall be paid to monitor the expansion of the steam turbine, axial
thrust and the differential expansion of LP cylinder shall not exceed the limits.
7.1.4 Jigger:
a) The turning gear shall be put into use immediately after the rotro is at a standstill.
b) The eccentricity of the rotor is found to exceed the maximum allowable value or a clear
metallic sound is heard during the turning is running, the continuous turning shall be stopped, but
changed to intermittent turning for 180. The causes shall be identified and eliminated, and the
turning cannot be put into continuous operation until the eccentricity is restored to normal.
The causes shall be identified and eliminated as soon as possible when the electric barring device
cannot work properly as the result of the turning motor failure, and it shall be made manually for
intermittent turning for 180, and the turning shall be put into continuous operation when the
eccentricity is restored to normal and the rotor can rotate freely. It is forbidden to turn or run
forcibly by mechanical methods.
c) The metal temperature of the steam turbine at the governing stage or IP first pressure stage is
more than 150, and it is required to stop the continuous turning for a short time, so normal oil
supply for bearing must be guaranteed so as to prevent the damage to the Babbitt of the bearing
caused by overheat and perform intermittent turning manually during this period of time.
d) Record the stop time of the turning as well as the eccentricity of the rotor and the phase at that
time accurately when the turning is stopped for a short period of time, and determine to perform
intermittent turning manually for 180~ straight shaft or put the turning into continuous operation
according to the changes of the eccentricity.
d) When the metal temperature of the HP cylinder metal is less than 150, stop the turning, but
pay attention to the eccentricity of the rotor; if there are significant changes, identify the causes
and perform intermittent turning.
7.2 Process for Exceptional Cases during the Shutdown of the Steam Turbine
The effective technical and safety measures shall be development if the shutdown cannot be
performed properly due to the defects of the equipment during the shutdown so that the steam
turbine can be shut down safely.
7.2.1 If the regulating system assembly is found to be jammed during the load shedding. It is not
proper to disconnect the generator, and if necessary, shut down the steam turbine or close the stop
valve of the main steam and then disconnect the generator after confirming the load at "0MW".
7.2.2 If the extraction check valve is struck or cannot be closed tightly, turn off the stop valve to
prevent the overspeed caused by backflow of the steam into the steam turbine.
7.2.3 Adjust manually timely if the automatic control system fails to prevent the steam turbine out
of control.
7.2.4 If the main and reheat steam parameters are out of control or water entrained by steam
occurs during the shutdown at sliding parameter, stop the turbine immediately.
7.3 Forced Cooling after Shutdown of Steam Turbine
7.3.1 Special attention shall be given to the prevention of the bending of main shaft as well as not
to increase the life loss for the forced cooling after shutdown of steam turbine.
7.3.2 Select cooling mode and methods after careful tests and calculation, which shall be reviewed
and approved by competent authorities of technology.
7.3.3 The introduction and extraction of the cooling medium shall be designed reasonably to
prevent the local thermal stress and stress concentration as well as prevent the ponding during the
operation or parts falling down to the pipeline equipment.
7.3.4 It shall be guaranteed that the turning can function properly during the whole process of
cooling, and it is prohibited to introduce the cooling medium when the rotor is under static status.
7.3.5 Strengthen the control over the current of the turning, the eccentricity of the rotor, axial
displacement, expansion of the steam turbine, differential expansion, metal temperature and other
important parameters, and stop cooling if any abnormal situation or limits exceeding is found.
7.3.6 The forced cooling system and its operation shall be as simple as possible, and the
monitoring instrument of the sensitive position for the cylinder thermal stress shall be calibrated
correctly and its control index shall also be determined.
7.3.7 Control the cooling rate strictly and the temperature dropping rate for the cylinder shall not
exceed 812.
7.3.8 At least turning continuously for 8h in order to guarantee even cooling of rotor and cylinder
after the completion of the forced cooling.
7.4 Maintenance after Shutdown of Steam Turbine
7.4.1 Effective rust and erosion prevention measures shall be taken to avoid damages to the themal
dynamic equipment during the shutdown (standby) period in order to ensure the safe and
economic operation of the turbine equipment.
7.4.2 The selection of the rust and erosion prevention against the shutdown (standby) equipment
shall be determined by the status of the shutdown equipment, the length of the outage period, the
supply of the rust and erosion resistance materials and medicament and its quality, rigor of the
equipment system, ambient temperature, process requirements of the rust and erosion method and
when they are out of service for a long time, and blow dry with compressed air after cleaning.
b) Rotate the auxiliary equipment to get ready for the long-term outage maintenance, inspect the
equipment under disassembled condition and refit in accordance with the relevant provisions after
rust-proof treatment.
c)Perform oil circulation periodically to regulate the oil system that may shut down for a long
time.
7.4.7 Take special measures to prevent the corrosion of equipment that is placed in coastal area
with heavy salt fog and under corrosive atmosphere.
7.4.8 The effective anti-freezing measures shall be taken in cold seasons.
8 The Thermal Control and Test of Steam Turbine
8.1 Thermal Equipment of Steam Turbine
8.1.1 The automation level of 300MW grade steam turbine in China has been significantly
improved due to the wide use of computer. The computer has become the main thermal control
equipment after the conventional analog instrument and manual manipulator have been reduced,
and the repair and maintenance should be strengthened to reduce and prevent misadjusting,
protection mal-operation and strive to improve the quality; meanwhile, the personnel training shall
be strengthened so as to improve the technical proficiency of the equipment maintenance and
operating personnel. At present, the distributed control system (DCS) used by 300MW grade
steam turbine generally consists of the following subsystems:
Data acquisition system(DAS)
Sequence control system (SCS)
Steam Turbine: Digital electro-hydraulic (DEH)
Boiler feed pump turbine electro-hydraulic of water-feeding pump(MEH)
Modulating control system (MCS)
Among them, DEH and MEH may not adopt DCS to achieve. In addition to the above system and
equipment, there shall also be systems and equipment with security monitoring and protection
function, such as ETS and TSI.
8.1.2 The control system of computer shall cover the following functions:
a) Speed control
b) Load control and limitation;
c) Unit coordination and control;
rmin
Perform the tests twice at 110 111 of rated speed for the mechanical overspeed
operation, but the differences between the speed of such two operations shall not be greater than
06 if the speed reaches 3330rmin, but the emergency governor still does not operate, stop
the turbine immediately;
The test duration shall be kept within 15min.
e)Load Shedding Tests:
The unit and power grid shall have required conditions before tests, and perfect measures shall be
developed. The tests shall be performed with the approval of the relevant superior competent
authorities of technology.
8.2.3 Please see Table 2 for tests and switch of steam turbine under operation.
Table 2
Item Name
Without jam
Whole stroke or part of stroke
Frequency
Once every day
Oil
charging
tests
emergency governor
Operate properly
Switching operation
of
9.3.4 The circulating water shall be clean, and the water temperature and volume shall be adjusted
according to the changes in seasons and load to meet the requirements of the circulating rate,
terminal temperature difference and temperature rising. The concentration ratio of the circulating
water shall be controlled strictly by blowdown and chemical feeding and other ways. The
microbial attachment and blockage shall be prevented for open circulating water system.
9.3.5 Flush the condenser with rubber ball periodically, handle the defects of the equipment and
calculate the rate of ball recovery for each flush and record the changes of the terminal
temperature difference and vacuum.
9.4 HP Heater
94.1 It is not allowed to put into operation if the protective operation of the HP heater is
abnormal.
9.4.2 The causes shall be identified to prevent the steam turbine from water when the HP heater
operates and ensure continuous water supply to boiler.
9.4.3 Avoid HP heater to operate at low water level.
9.4.4 Handle the abnormality when the HP heater in operation adjusts the abnormality
automatically, and stop the HP heater when the water level is out of control.
9.4.5 Make analysis on the changes in terminal temperature differences of HP heater and the
opening of the regulated drain valve periodically.
9.4.6 The newly installed or overhauled safety valve of HP heater can be put into operation after
being proven qualified by calibration.
9.4.7 The HP heater shall be started randomly under normal conditions. Generally, water can be
supplied first into the HP heater when the unit is under operation, but steam can be supplied first,
but special attention shall be given to reduce the thermal impact on the tube sheet, pipe orifice and
barrel and other parts and the steam shall be supplied from low pressure to high pressure just like
that of the extraction pressure.
9.5 Deaerator
9.5.1 The safety valve operation test shall be performed after the deaerator is overhauled or the
safety valve is overhauled, and it cannot be put into operation if the test fails.
9.5.2 Control the water level strictly to operate in normal range.
9.5.3 Prevent the deaerator from overheat and over-pressure when the load increases abruptly or
the HP heater trips.
9.5.4 Prevent the vaporization of deaerator caused by decompression if the load decreases abruptly
or the steam extraction stops suddenly.
10 Accident Prevention and Handling for Steam Turbine
10.1 Basic Principle for Accident Prevention
10.1.1 The accident shall be handled based on the principle of "Protecting personal safety,
Protecting power grid and Protecting equipment" when the accident occurs.
10.1.2 Key points for Handling when the Accident Occurs:
a) Determine whether the accident has happened according to the instrument display and
equipment abnormality.
b) Handle the accident quickly, and remove the threat to human safety, power grid and equipment
to prevent the failure propagation.
c) Disconnect or stop the faulty equipment immediately if necessary, and ensure the equipment
without defects can operate normally.
d) Identify the causes quickly and eliminate the accidents.
10.1.3 Record the observed phenomenon, the process of the accident development and time as
well as the eliminating measures that are taken in details.
10.1.4 Keep the relevant date related to accident occurrence and handling process.
10.2 Accidental Shutdown of Steam Turbine
Break vacuum for shutdown if any of the following occurs:
10.2.1 The speed of the steam turbine rises to 3330rmin, while the overspeed protection does
not operate.
10.2.2 The steam turbine vibrates strongly in a sudden or exceeds the trip value.
10.2.3 There are obvious metallic sounds or noise within the steam turbine.
10.2.4 The axial displacement reaches the limit value or the metal temperature of thrust bearing
pad exceeds the limit.
10.2.5 The lubricant oil supply interrupts or the oil pressure drops to the limit value, but the
1) Shut down the unit immediately and confirm that the speed shall drop down.
2) Check and open the vent valve of HP steam lead pipe.
3) If the speed keeps on rising, take measures to isolate and release the pressure decisively.
4)Identify the causes of overspeed and eliminate the fault, and the steam turbine can be restarted
only after it has been confirmed by thorough checks that steam turbine functions properly. And it
can be connected to grid with load after the overspeed governor and the overspeed protection
device are calibrated and can operate normally.
5) Focus on inspection and monitoring of the vibration, internal sounds, bearing temperature, axial
displacement, thrust pad temperature and others when restarting turbine, and stop startup if any
abnormality is found.
e) Preventive Measures
1) Check the installation quality of the HP and IP main throttle valve and governing valve
carefully before startup and check if the open-close movement of each valve is flexibly.
2)Any of the overspeed protections fails, which cannot be eliminated during the operation, shut
down and eliminate.
3) Perform the oil charging tests for overspeed governor, online tests for the shutdown protection
and the movement tests for the main throttle valve and governing valve and the extraction check
valve of each section regularly.
4) If the main throttle valve or governing valve jams during the shutdown, try to reduce the load to
"0"MW, shut down the steam turbine and then disconnect the engine.
5) Strengthen the supervision on the quality of the steam, water and oil, which shall meet the
standards.
6) The speed monitoring and control system shall work properly.
10.3.2 Strong Vibration of Steam Turbine
a) Main Hazards:
It will lead to bearing damage, rotating and static friction and even break the unit down.
b)Main Causes:
)The rotating and static friction or main shaft bending.
Absolute
Displacement
Evaluation
80
100
120165
150200
180260
250320
limits
3) Clean the oil systems thoroughly after the bearing is damaged and ensure to start up again after
the oil quality is satisfactory.
e) Key Points for Prevention:
1) Strengthen the supervision and adjustment of the oil temperature and the oil pressure, and keep
close watch over the temperature of the bearing Babbitt and returned oil and identify the causes
and eliminate them if any abnormality is found.
2) The automatic and standby equipment of oil system is reliable, and shall be tested periodically
and strictly. The shutdown and switch of the oil pump or the oil cooler shall be smooth and careful
to prevent bearing burnout due to oil breakoff.
3) The oil cleaning device shall operate properly and the oil quality meets the standards.
4) Prevent the water from entering into the steam turbine and partial circulation from damage and
avoid main shaft bending and bearing vibration
5)The rotor of the turbine generator must be grounded firmly.
6) Adjust the interlocking setting for AC and DC oil pumps carefully before startup and check if
the wiring is correct.
10.3.4 Blade Damage
a) Main Hazards:
It will lead to the rotating and static friction of the steam turbine, deterioration of operating
conditions and vibration caused by uneven quality of the rotor.
b) Main Signs:
)The vibration increases.
2) The vibration of critical speed increases abnormally.
3)Metallic sounds or noise can be heard during turning.
4) The hardness of condensation water increases.
5)The pressure of monitored section rises up.
c) Causes:
1) The steam turbine vibrates or the rotating and static parts rub.
2) Water enters during the operation; especially the water or cold steam enters into the cylinder
resulting from improper maintenance after shutdown at startup or shutdown
3) Thermal bending resulting from large temperature differences between upper and lower
cylinder.
d) Key Point for Handling:
Shut down immediately after confirming that the main shaft bends and the turbine shall not be
restarted until the causes are found and eliminated.
e) Key Points for Prevention:
)Measure the eccentricity of the rotor and the turning current shall be normal before the steam
turbine runs each time and after the shutdown. If the thermal bending of the rotor occurs before
running, the turning time shall be prolonged appropriately, and if the thermal bending occurs
during the speed-up, the warming-up time shall be extended, but the turbine shall be shut down if
the thermal bending gets worse or warming-up is invalid.
2) The effective isolation measures shall be taken to prevent water and cold steam from entering
into cylinder when the steam turbine is under turning state.
3) It is forbidden to run the steam turbine when the temperature differences between the upper and
lower cylinders of the steam turbine or the eccentricity of the rotor exceeds the limits.
4) Drain completely and monitor the vibration, differential expansion, expansion, axial
displacement, sliding key system of the cylinder and so on during the startup of the steam turbine,
and avoid main shaft bending caused by rotating and static friction.
5)Check and confirm that the vibration of bearings are normal when the speedup of the steam
turbine is at 8085 of first-order critical speed for HP and IP rotor; if the abnormal
vibration is found, switch off and shut down till under turning state.
10.3.6 Water Intrusion into Turbine
a) Main Hazards:
It will lead to deformation of cylinder, collision and main shaft bending, etc. resulting from the
disappearing of the rotating and static clearance
b) Main Signs:
) The temperature differences between the upper and lower cylinders increase obviously.
2) The temperature of the main and reheat steam drops suddenly and the superheat decreases.
3) The vibration of the steam turbine increases.
4) The steam extraction lines vibrate.
5)The turning current increases under turning state.
c) Main Causes:
1)The main and reheat steam temperature of boiler is out of control or the water is entrained by
steam caused by instantaneous increase in main steam flow.
2)The reheater is full of water and flows backward to steam turbine.
3)The drainage for steam supply for shaft seal or the regenerative extraction steam pipeline is
blocked, and the waterlogging or drainage flows into cylinder.
4) DEH or primary temperature components fails
d) Key Points for Handling:
1) Shut down the turbine emergently when the main and reheat steam temperature drops suddenly,
which exceeds the prescribed value or drops to the limit value during the operation.
2) If the water is found to enter into the steam turbine during the turning, keep turning till the
temperature differences between upper and lower cylinder of steam turbine is restored to normal.
And strengthen the supervision of the internal sounds, eccentricity of rotor, turning current and so
on.
3) If the water enters into the steam turbine during the speeding up, shut down the turbine for
turning.
4) Identify the causes and eliminate them when the steam turbine gives out alarms for water
intrusion into steam turbine. Shut down the turbine if the vibration, differential expansion and
changes in temperature differences between upper and lower cylinder reach the outage value.
e) Key Points for Prevention:
1) The steam turbine shall be equipped with water-induction prevention and monitoring device,
which can be put into operation reliably.
2) The cylinder cannot be opened for drainage if the temperature differences between the upper
and the lower cylinder is not big during the shutdown to prevent the water and cold steam of the
anti-drainage system from entering into the cylinder, and start up the turbine at extreme hot state
before running and then shut off 5min later.
3)The valve of the drainage piping shall be cleaned and checked to ensure the smooth operation.
4)The adjustment of the water level of the heater and deaerator shall be stable and the water level
alarm and protection shall be reliable.
5)There should be sufficient quantity and reliable temperature measurement elements for cylinder
mental and parameter display, and conduct calibration periodically.
10.3.7 Abnormal Adjustment and Control System
a) Main Hazards:
It will result in the malfunction of partial or whole regulation and control function, and it is unable
to maintain the operation of the unit when it gets worse, and even cause the operation parameters
to exceed the limits and the protection operates and trips.
b) Main Causes:
1) The regulation and control device is abnormal or the controlled device works improperly.
2) The regulation and control power blacks out or the power quality is abnormal.
3)The regulation and control air pressure is low or air loses
c) Key Points for Handling:
1) When two sets of the computer system runs, one of which is switched on for operation while
the other one fails and then the faulty computer will exit from operation. When the computer fails
and is unable to regulate or control automatically, it can be adjusted and maintained for operation
manually. When both computers fail, the steam turbine intertrips; otherwise, the turbine can be
switched off and shut down.
2)Try to make the unit operate stably at original state due to blackout of the control power and pay
attention to supervise the main parameters; the equipment that must be operated can be operated
locally, and apply for shutdown if it cannot be restored within a short period of time to ensure the
safety of the unit.
3) When the compressed air for control loses air locally, try to change over to adjust or control
manually as much as possible according to the impact on the overal operation of the unit, and if it
is impossible to maintain operation, it may lose air source or completely; reduce the load and shut
down immediately when the unit safety is affected.
d) Prevention Measures:
1)The computer for regulation and control shall be equipped with reliable power supply, which
usually is powered by UPS; however, it shall be ensured that power voltage, frequency and
harmonic quality and others are qualified because there are too many types of control power; it
shall have the capacity of anti-interference from inside and outside to prevent voltage fluctuation
or dead halt or mal-operation caused by poor cabinet grounding.
2) Strengthen the management and maintenance of the main host room and cabinet and make
moisture-proof, anti-dust, anti-static, protection against electromagnetic interference and
aeration-cooling treatment according to provisions to prevent damages to computer module caused
by improper maintenance.
3) In addition to strengthen the normal maintenance of the air compressor for control, the supplied
air shall be dewatered and drained for drying to prevent the operation failure caused by corrosion
to air conduit and pneumatic control elements as well as avoid waterlogging and freezing within
the pipelines in cold seasons.
4)The operator on duty shall be familiar with the operation characteristics (air-to-open, air-to-close
and air-to-maintain) of the pneumatic control equipment after losing air so as to process
respectively.
10.4 Analysis and Handling for Common Accidents
10.4.1 Dropping of Turbine Vacuum
a) Main Hazards:
The dropping down of turbine vacuum not only decreases the economical efficiency of the units,
but also leads to surge of last stage blade of HP cylinder, abnormal rotor vibration and others, and
even accidents to steam turbine.
b) Main Causes:
1)The cooling water is insufficient or interrupted.
2)The heat exchange efficiency of the condenser decreases.
3) The vacuum system leaks or the equipment functions improperly.
4) The shaft seal system is out of order.
a) Main Hazards:
The axial thrust of the steam turbine changes abruptly which is caused by great fluctuation of load,
and it may lead to the melting of the thrust pad or the wear of the steam path.
b) Main Causes:
1)The control system of the steam turbine is out of order or the governing valve operates
improperly.
2) HP and LP bypass mis-operates or the regenerative extraction steam stops suddenly.
3)The abnormal changes of grid frequency or the boiler operates abnormally.
c) Key Points for Handling:
1)Analyze the causes for the sudden rise of the load or sudden drop in line with relevant gauge,
drop the load to the rated value when exceeding the limits and analyze and confirm that the
internal of the steam turbine is normal.
2) The load changes suddenly, which is caused by abnormal changes of the boiler, the throttle flow
of the steam turbine shall be adjusted correspondingly to stabilize the steam parameters; if the load
changes are caused by abnormal grid frequency, try to meet the load requirements as much as
possible and also prevent the steam turbine from operating with overload.
3) Switch to the manual-operated mode immediately if the control system is out of order.
4)The governing valve falls off with load according to the allowable flow, and it is not allowed to
increase or decrease the load when the governing valve jams.
10.4.4 Load Shedding of Generator
a) Main Hazards:
1) It may lead to the sudden changes of the axial thrust for the steam turbine, and will result in
wear of the steam path.
2) Lead to the overspeed of the steam turbine.
b) Main Causes:
The power grid or generator, the main transformer fails, and the main oil switch of the generator
trips.
lubricating when the oil pump under operation fails, but the turbine shall be shut down
immediately.
10.4.6 Failure of Main Steam and Water Pipeline
a) Main Causes:
1) Become thin due to flush, fatigue and damage, poor welding and vibration.
2) Poor material selection and improper supports and hanger
3) Over-temperature, over-pressure and water hammers, etc caused by improper operation.
b) Key Point for Handling:
1) Isolate the faulty location quickly within the minimum range.
2) When the main and reheat steam and main feedwater pipeline breaks, shut down the turbine
emergently and prevent burns and take fire prevention measures when the high temperature steam
leaks.
3) Try to isolate and eliminate the problem when the LP steam and water pipeline break, if
necessary, shut down for process and pay attention to prevent the equipment from being inundated
by water.
4) Strengthen the supervision on the metal of the pressure-containing member, in particular, pay
attention to measure the wall thickness of the drain pipe socket, elbow and welded junction, etc.
and flaw detection.
10.4.7 Axial Displacement Increases
a) Main Hazards:
The thrust bearing is damaged, which may lead to the wear of the rotating and static parts of steam
turbine when it gets worse.
b) Main Causes:
1) Main steam parameters, vacuum and load fluctuate greatly, which leads to the increase in axial
thrust.
2) The increase in scale of the steam path, broken blade or steam leakage may lead to the increase
in axial thrust.
the power frequency shall be limited if it deviates from the allowable range prescribed by the
manufacturer, and when it reaches the limit value, the generator shall be disconnected.
10.4.10 Fire Extinguishing for Boiler
Key Points for Handling:
a) Shut down the steam turbine immediately if the boiler is on fire.
b)Dewater completely when restoring the steam turbine.
c) Determine the proper HP and LP bypass opening before adopting HP cylinder to start the
running, so as to ensure the non-return valve on HP exhaust line can open automatically and the
HP and IP cylinder steam flow match with each after the steam turbine runs.
d)The load shall be increased quickly and smoothly to prevent the water entrained with steam
caused by great fluctuation of main steam pressure. Adjust and put the auxiliary equipment into
operation in a timely manner.
10.4.11 Oil System Firing
a) Main Hazards:
It may lead to the shutdown of the steam turbine or damages to equipment, even threat the
personal safety.
b) Main Causes:
1) Oil system leaks to high temperature parts
2) The cable is on fire or caused by other fire.
c) Key Points for Handling:
1) Put the fire out and report to the leader and contact the fire department.
2)Use the fire-fighting equipment correctly to put the fire out and prevent burns or suffocating.
3) Take isolation measures quickly and immediately to prevent fire spread.
4) Shut down the turbine emergently and immediately if the fire cannot be put out quickly and it
threats the safety of the steam turbine seriously.
5) Control the oil drainage speed appropriately when it is required to open the emergency oil
drainage valve so as to ensure the non-interruption of lubricant before the rotor is at static.
6) It is prohibited to start the HP oil pump when the oil system is on fire, and the lubricant oil can
be reduces so as to reduce the oil leaks, if necessary; the oil system shall be shut down if it is
forced to do so.
d) Key Points for Prevention
1)The oil system shall adopt flange connection as less as possible in design and installation, and
the oil pipeline shall be reliable and stable to prevent vibration, wear and leaks. The heat
preservation shall remain intact for the high temperature pipeline equipment near the oil pipeline,
and the surface temperature shall not be greater than 50 with metal shielding.
2)Strengthen the routine inspection, eliminate and take measures if minor leaks are found to avoid
oil leaking to the high temperature pipeline equipment and causing fire.
3) The emergency oil drainage valve of the oil system shall be equipped with eye-catching signs,
and it shall be placed in a place that can facilitate the operation and that is not easy to be
surrounded by fire, and shall be treated with lead seal to avoid mis-operation.
4)It is not allowed to use open fire on the oil system that has not been cleaned completely.
5) It is not allowed to extinguish the fire of oil system with water. The on-site fire-fighting
equipment shall be complete and sufficient, and the operator shall be familiar with the methods for
using the fire-fighting equipment and extinguishing methods, and perform anti-accident exercise
for fire prevention and fire extinguishing periodically.