TURBINE

COMMISSIONING

May 24, 2012 PMI Revision 00 1

 Turbine and auxiliaries
• Acid cleaning-oil lines
• Lube oil flushing and hydraulic test
• Jacking oil lines flushing and hydraulic test
• Detergent flushing and hydraulic test of
regenerative system
• BFP commissioning

May 24, 2012 PMI Revision 00 2

 Turbine and auxiliaries
• Commissioning of HP/LP heaters
• Barring gear operation
• Vacuum tightness test
• Steam blowing procedure
• Check list for first rolling of turbine

May 24, 2012 PMI Revision 00 3

 ACID CLEANING
• Purpose?
• Steps
– Mechanical cleaning and flange preparation
– Acid cleaning
– Passivation and drying
– Final erection in position

May 24, 2012 PMI Revision 00 4

 ACID CLEANING
• Mechanical cleaning and flange preparation
– Chipping & grinding of protruding welds
– Wire brushes pulling through pipes
– Steel chains for smaller pipes
– Blow compressed air
– Ready for acid cleaning

May 24, 2012 PMI Revision 00 5

 ACID CLEANING
• Acid cleaning
– Looping of pipes of same diameter
– Flush the loop with 15% Orthophosphoric acid at
30-40deg. For 2-3 hours
– For strongly corroded pipes:3-4 hours flushing,
pressurize at 0.5-1Ksc for 6-7 hours then again
flush for 2-3 hours
– Stainless steel mesh at the return line

May 24, 2012 PMI Revision 00 6

 ACID CLEANING
• Passivation
– Circulate 2% solution for 1-1.5 hours
– Drain loop and dismantle for drying
– Blow dry hot air for 30-40 min at 3-4 Ksc. At 50-
60deg. For each pipe
– Inspection: dark steel grey color-completion
– Cover ends with new cloth / wooden blanks

May 24, 2012 PMI Revision 00 7

 ACID CLEANING
• Final erection in position
– Gasket inner bore> pipe diameter
– No cutting / welding after cleaning
– No jute for cleaning
– Use electric bulb during inspection

May 24, 2012 PMI Revision 00 8

 OIL FLUSHING & HYDRAULIC TEST
OF TURBINE OIL SYSTEM

May 24, 2012 PMI Revision 00 9

 TG LUB OIL & JACKING OIL SYSTEMS
• L.O SYSTEM
– LUBRICATION
– BARRING GEAR
– HEAT DISSIPATION

• J.O SYSTEM
– SHAFT LIFTING
– PREVENT DRY FRICTION
– OVERCOME BREAKING AWAY TORQUE DURING START UP ON HYDRAULIC TURNING
GEAR

• ELEMENTS
– AOP
– JOP
– MOP
– INJECTORS
– COOLERS
– OIL TEMPERATURE CNTROL VALVE
– DUPLEX FILTERS
– OIL THROTTLES
– HYDRAULIC TURNING GEAR
– MOT
– VAPOUR EXHAUSTER FANS
– CENTRIFUGE
– DIRTY OIL TANK
– WASTE FLUID TANK
May 24, 2012 PMI Revision 00 10
 TG LUB OIL & JACKING OIL SYSTEMS

L.O.FLUSHING OBJECTIVE
– TO FLUSH COMPLETE TG L.O&J.O SYSTEMS WITH TURBINE OIL TO REMOVE
MECHANICAL IMPURITIES
ARRANGEMENTS FOR LUB OIL SYSTEM
– LO SYSTEM COMPLETE
– TEMPORARY PIPING CLEANED & INSTALLED
– THERMAL SHOCK SCHEME READY
– COT & DOT AVAILABLE
– FIRE FIGHTING SYSTEM
MOT
– MOP SUCTION & DISCHARGE ARE LOOPED WITH ½” VENT VALVE(KEEP OPEN)
– BEARING PEDESTALS, MOT & STRAINER CLEANED MANUALLY & INSPECTED
– VAPOUR EXTRACTERS AVAILABLE & LINE VALVES KEPT OPEN
– AOP, JOP, CENTRIFUGE AVAILABLE
– MOT & ITS EVEL INDICATOR

LO SYSTEM
– OIL THROTTLES FOR INJECTORS REPLACED WITH ADAPTERS
– TURNING GEAR NOZZLE BOX REPLACED WITH FLUSHING DEVICE
– L.O SUPPLY & RETURN HEADERS LOOPED AT BRG-7 END WITH VALVE
– BRG- 1TO 4 PROVIDED WITH FLUSHING DEVICES
– BRG- 5 TO 7 SUPPLY & RETURN LINES LOOPED
– THRUST BEARING PADS REMOVED

May 24, 2012 PMI Revision 00 11

 TG LUB OIL & JACKING OIL SYSTEMS
– COOLERS ADJUSTED FOR MAXIMUM FLOW
– DUPLEX FILTER ELEMENTS TAKEN OUT
– ALL THROTTLES IN THE LO SUPPLY LINE TO BRGs ARE FULLY CLOSED
– MOP REMOVED , SUPPLY & DISCHARGE LINES LOOPED
– TEMPERATURE INDICATORS BEFORE & AFTER COOLER

JACKING OIL SYSTEM ARRANGEMENTS

– A LOOP GIVEN FROM AOP DISCHARGE HEADER TO JOP DISCHARGE LINE WITH AN
ISOLATING VALVE & JOP DISCONNECTED
– JACKING OIL SUPPLY HEADER LOOPED TO L.O RETURN HEADER AT BEARING#7 END
WITH AN ISOLATING VALVE
– J.O LINE TO BEARINGS DISCONNECTED & KEPT OPEN TO DRAIN INSIDE BEARING
PEDESTALS
– ALL NRVs IN THE PUMP DISCHARGE & SUPPLY LINE TO BRGs ARE REMOVED
– JACKING OIL PRV REMOVED & BLANKING GIVEN

METHOD
OIL FILLING
– OIL QUALITY TESTED
– 40 M3 OIL FILLED INTO MOT THROUGH CENTRIFUGE
LO SYSTEM FLUSHING
STAGE-1
– OIL COOLERS BYPASSED,SUPPLY & RETURN HEADERS LOOPED & ALL OTHER LINES
KEPT ISOLATED
– START EOP FOR LINE VENTING & LEAKAGES CKECKING
May 24, 2012 PMI Revision 00 12
– AOP STARTED FOR LINE FLUSHING & CENTRIFUGE WAS KEPT IN SERVICE
 TG LUB OIL & JACKING OIL SYSTEMS

 INSPECT MOT STRAINERS FOR EVERY HOUR DURING INITIAL FLUSHING & THERE AFTER
ONCE IN A DAY
 AFTER 2-3 DAYS COOLERS CAN BE NORMALISED
 HEAT THE OIL UP TO 70-750C WITH THERMAL SHOCK ARRANGEMENT
 START COOLING SO THAT OIL TEMP. BEFORE COOLER IS BRAUGHT DOWN BY ABOUT 35-
400C
 REPEAT THERMAL SHOCKS WITH INTERMITTENT RAPPING OF OIL LINES
 COLLECT THE OIL SAMPLE AT CENTRIFUGE INLET& CHECK FOR M.I & MOISTURE
 IF COMPLETION CRITERIA IS MET , CLOSE THE SUPPLY&DRAIN HEADER LOOP VALVE

STAGE-2
 SELECT 2-3 BEARING PEDESTALS AT A TIME
 THROTTLES ARE KEPT WIDE OPEN TO ENSURE MAX. FLOW IN THE RETURN LINES
 ENSURE THAT AOP SHOULD NOT GET OVERLOADED
 START FLUSHING & THERMAL SHOCKS
 DO FLUSHING FOR TURNING GEAR LINE TWICE IN A DAY
 COLLECT THE OIL SAMPLE AT CENTRIFUGE INLET& CHECK FOR M.I & MOISTURE
 IF COMPLETION CRITERIA IS MET , CLOSE THE THROTTLES & GO FOR NEXT SET OF
BEARING PEDESTALS
 MOP SUCTION & DISCHARGE LINES FLUSHING TO BE CARRIED OUT, BY LOOPING THE
SUCTION LINE NEAR INJECTOR IN MOT, TO DIRTY OIL CHAMBER

May 24, 2012 PMI Revision 00 13

 TG LUB OIL & JACKING OIL SYSTEMS
FINAL STAGE OF FLUSHING
• TAKE ALL THE CIRCUITS FOR FLUSHING & CONTINUE THERMAL SHOCKS
• IF MOT STRAINER REMAINS CLEAN FOR 24 HOURS, STOP FLUSHING & INTRODUCE
DUPLEX FILTERS
• REMOVE OIL THROTTLES & PUT LINE FILTERS IN THEIR PLACE
• CONTINUE FLUSHING USING THERMAL SHOCKS TILL COMPLETION CRITERIA IS MET
• CLEAN DUPLEX FILTERS & LINE FILTERS REGULARLY IF REQUIRED

NOTE: JACKING OIL SYSTEM FLUSHING IS SIMILAR TO THE LO

FLUSHING

COMPLETION CRITERIA
– MECHANICAL IMPURITIES <100PPM
– MOISTURE CONTENT <100PPM
– BASKET STRAINER REMAIN CLEAN AFTER 24 hours
– DUPLEX FILTER ELEMENT SHOULD REQURE CLEANING AFTER 12 hours

May 24, 2012 PMI Revision 00 14

 TG LUB OIL & JACKING OIL SYSTEMS

• TECHNICAL DETAILS
OIL PUMPS

MOP AOP EOP AC JOP DC JOP

QUANTITY 1 2 1 1 1

MAKE BHEL MATHER- MATHER- ALLWEILER AG ALLWEILER AG

PLATT PLATT

TYPE 350M3/Hr 5/6 EHLH 4/5 KL-70 SDF/A80R4669- SDF/A80R4669-

W112 W112

CAPACITY 87.48dm3/s 6016LPM 1800LPM 1.84 DM3/S 1.84 DM3/S

DISCH.PR 84M 75.7M 27.6M 178 BAR 178 BAR

SPEED(RPM) 3000 2965 1425 2900 2900

DRIVE TURBINE AC MOTOR DC MOTOR AC MOTOR DC MOTOR

May 24, 2012 PMI Revision 00 15

 TG LUB OIL & JACKING OIL SYSTEMS

• LUB OIL SECIFICATIONS

– OIL OF VISCOSITY CLASS ISO VG 46 SHALL BE USED
– CAPABLE OF WITHSTANDING BEARING TEMPERATURE OF MAX 1300C
– TOP UP THE OIL SHOULD BE OF SAME BRAND & QUALITY
– CENTRIFUGING SHOULD BE FOR 40 HOURS, IF DIFFERENT OIL IS TOPPED
– OIL SHOULD COMPLY THE REQUIREMENTS GIVEN IN THE TABLE, WHEN TESTED
ACCORDING TO THE TEST METHOD GIVEN AGAINST THEM.

May 24, 2012 PMI Revision 00 16

 L.O.SPECIFICATIONS VALUE TEST METHOD

KINEMATIC VISCOSITY 41.4 TO 50.6 CST ( AT 400C) IS:1448 P-25

28 CST ( AT 500C)

VISCOSITY INDEX MIN. 98 IS:1448 P-56

NEUTRALISATION NO. MAX.0.2 mg of KOH PER gm of OIL IS:1012 P-58

SPECIFIC GRAVITY 0.85 IS:1448 P-32

FLASH POINT MIN 2000C IS:1448 P-59
POUR POINT -60C MAX. IS:1448 P-10
DEAERATION CAPACITY 4MIN MAX. AT 500C DIN:51381
ASH % BY WEIGHT MAX. 0.01 IS:1448 P-4
WATER % BY WEIGHT MAX. 0.01 ISO:3733
SOLIDS % BY WEIGHT MAX. 0.05 DIN:51592
FOAMING TENDENCY MAX 400CM3 ASTM:D892
FOAMING STABILITY MAX 450S ASTM:D892
COPPER STRIP CORROSION NOT WORSE THAN NO-1 IS:1448 P-15

TOTAL ACIDITY AFTER 1000 Hrs MAX.0.2 mg of KOH PER gm of OIL DIN:51587
OF24,
May OXIDATION
2012 PMI Revision 00 17
 LUB OIL HEATING ARRANGEMENT

L.O INLET ECW OUTLET

AUX STEAM

L.O OUTLET
TEMPORARY
ECW INLET
TANK

DRAIN

CIRCULATION
May 24, 2012 PUMPS PMI Revision 00 18
 LUB OIL COOLING ARRANGEMENT

L.O INLET ECW OUTLET

AUX STEAM

L.O OUTLET
TEMPORARY
ECW INLET
TANK

DRAIN

CIRCULATION
May 24, 2012 PUMPS PMI Revision 00 19
 LUB OIL RETURN HEADER

INJECTOR

LUB OIL SUPPLY HEADER

COOLERS

FILTERS

AOP-2 AOP-1 EOP

MOT
May 24, 2012 PMI Revision 00 20
 LUB OIL RETURN HEADER

JACKING OIL SUPPLY HEADER

AOP DISCHARGE HEADER

PRV

FILTERS

JOP-1 DC JOP

MOT
May 24, 2012 PMI Revision 00 21
 MOT

INJ AOP-1 AOP-2 EOP ACJOP

DC JOP

VEF
DOC

LUB OIL TOP VIEW

RETURN

LUB OIL
May 24,RETURN
2012
REAR VIEWPMI Revision 00 SIDE VIEW 22
 DUPLEX FILTERS
L.O RETURN LINE

1
SIGHT GLASS

2
OVERFLOW

MOT 3
4
INST.RACK L.O COOLERS

L.O
OUT

INST.RACK
CENTRIFUGE

VAPOUR LINE
DRAIN POT
J.O FILTERS
1. FILLING LINE FROM COT
2. COOLERS VENT
3. AOP DISCH. HDR DRAIN
May 4.
24, 2012
DUPLEX FILTER VENT PMI Revision 00 TO DIRTY OIL TANK 23
 Hydraulic test of oil lines

May 24, 2012 PMI Revision 00 24

 DETERGENT FLUSHING OF
PRE BOILER SYSTEM

May 24, 2012 PMI Revision 00 25

 DETERGENT FLUSHING OF PRE-BOILER SYSTEM
PRE-BOILER SYSTEM CONSISTS OF
CONDENSATE SYSTEM
DRIP SYSTEM
FEED WATER SYSTEM
EXTRACTION STEAM LINES TO REGENERATIVE HEATERS
 CONDENSATE SYSTEM: COMPRISES OF 3 NO’S OF CEP’S, L.P.HEATERS,
G.S.C, DRAIN COOLER, DEAERATOR, CONNECTING PIPELINES INCLUING
EXCESS CONDENSATE LINE UPTO C.S.T.
 FEED WATER SYSTEM: COMPRISES OF 1 NO. MDBFP AND 2No’s.
TDBFP’S, THEIR BOOSTER PUMPS AND RECIRCULATION LINES , H.P
HEATERS, THEIR CONNECTING PIPE LINES UPTO ECONOMISER INLET.
RH & SH SRRAY LINES ARE ALSO INCLUDED FOR THE PURPOSE OF
FLUSHING.
 DRIP SYSTEM: COMPRISES THE SHELL SIDE OF ALL LP &HP HEATERS
& THE DRIP LINES.
 EXTRACTION
May 24, 2012 SYSTEM: INCLUDES ALL 00EXTRACTION LINES TO LP & HP
PMI Revision 26
HEATERS
 • OBJECTIVE: TO REMOVE DIRT, OIL, GREASE etc., FROM THE
CONDENSATE , FEED WATER, DRIP & EXTRACTION STEAM LINES OF HP &
LP HEATERS, USING A NON-IONIC DETERGENT ,PRIOR TO PUTTING THESE
SYSTEMS IN REGULAR SERVICE.
• THIS ENSURES FLOW OF CLEAN CONDENSATE & FEED WATER TO
BOILER
• THE FOUR STAGES OF DETERGENT FLUSHING ARE:
• STAGE-I: FEED LINES
• STAGE-II: CONDENSATE LINES & DRIP LINES OF HPH-5A & 5B
• STAGE-III: EXTRACTION STEAM LINES AND DRIP LINES OF HPHs
• STAGE-IV: EXTRACTION STEAM LINES AND DRIP LINES OF LPHs
• NOTE: EACH SYSTEM SHALL BE SUITABLY SUBDIVIDED INTO
VARIOUS SUB CIRCUITS TO COVER ALL THE LINES AND COMPONENTS

May 24, 2012 PMI Revision 00 27

 DETERGENT FLUSHING REQUIREMENTS
1) CHEMICALS &WATER
a) DM WATER : 5000T

b) NON-IONIC DETERGENT
 RINOPOL-JET 100% 1000 LITRES
 (OR SUMISOL-N 100% )
@0.05%CONCENTRATION

c) FOR PASSIVATION
 HYDRAZINE HYDRATE -800KG @ 80% CONCENTRATION
(IS:12086/1991)
 LIQUOR AMMONIA------ 400KG @ 25% CONCENTRATION
(IS:799/1985)

2) PUMPS AND VALVES:

a) TEMPORARY CIRCULATION PUMPS ( 4Nos) CAPACITY : 200T/hr
Head: 20 KG/CM2
MOTOR : 180 KW

b) TEMPORARY MIXING TANK CAPACITY 40 M3 .

c) VALVES & INSTRUMENTS

a) STEAM SUPPLY LINE V/V (1No.) 3''

b) DM WATER SUPPLY LINE V/V (1No.) 4''
c) MIXING TANK DRAIN TO NEUTRALISATION PIT V/V (1No.) 4''
d) PUMP DISCHARGE SAMLE LINE V/V (1No.) 1''
e) DETERGENT RETURN SAMPLE LINE V/V (1No.) 1''
f) PUMP DISCHARGE LINE DRAIN V/V (1No.) 1''
g) DETERGENT RETURN LINE DRAIN V/V (1No.) 10'‘
May 24, 2012 PMI Revision 00 28
 DETERGENT FLUSHING REQUIREMENTS

h) TEMPORARY P/P SUCTION LINE V/Vs (4Nos)

i) TEMPORARY P/P DISCHARGE LINE V/Vs (4Nos)
j) PUMPS RECIRCULATION V/V (1No.)
k) PUMPS COMMON DISCHARGE LINE V/V (1No.)
l) PRESSURE GAUGES (0-40Ksc) (2Nos)
m) TEMPERATURE GAUGES (0-1500C) (2Nos)
n) LEVEL INDICATOR FOR MIXING TANK (2Nos)

3) OTHER REQUIREMENTS

a) POWER SUPPLY TO TEMPORARY CIRCULATION PUMPS(415V)

b) ADEQUATE LIGHTING IN ALL WORKING AREAS
c) LABORATORY FACILITY FOR ANALYSIS OF FLUSHING WATER
d) SERVICE WATER
e) FIRE EXTINGUISHERS
f) ADEQUATE TEMPORARY PIPING & SUPPORTS

May 24, 2012 PMI Revision 00 29

 METHOD
LINE UP THE STAGE TO BE FLUSHED
FILL THE SYSTEM WITH DM WATER BY CIRCULATION PUMPS
CARRY OUT COLD WATER MASS FLUSHING IN ALL THE SUB
LOOPS FOR 1 HOUR, AS EXPLAINED IN THE FOLLOWING SLIDES
ADMIT STEAM INTO MIXING TANK & RAISE THE DM WATER
TEMP. UP TO 600C AND CARRY OUT HOT WATER MASS FLUSHING IN
ALL THE SUB LOOPS FOR 1 HOUR
STOP THE PUMPS AND DRAIN THE SYSTEM
REFILL TOTAL SYSTEM WITH DM WATER BY RUNNING
CIRCULATION PUMPS & ESTABLISH CIRCULATION
ADMIT STEAM INTO MIXING TANK, RAISE THE WATER TEMP. TO
600C ADD RINOPOL-JET 100% OR SUMISOL-N 100% TO ACHIEVE
SOLUTION CONCENTRATION OF 0.05%
CIRCULATE THE SOLUTION IN EACH OF THE LOOPS FOR A MIN.
DURATION OF 4 HOURS. DURING CIRCULATION GIVE MAKE UP
KEEPING THE SOLUTION TEMP.AT 600C
ON COMPLETION OF DETERGENT FLUSHING CARRY OUT
May 24, 2012
CONTINUOUS PMI Revision 00
MAKE UP AND DRAINING IN ALL LOOPS FOR 15 MIN. 30
 METHOD
DRAIN THE SYSTEM COMPLETELY & FILL IT AGAIN WITH DM WATER
CIRCULATE DM WATER IN EACH LOOP FOR ½ HOUR ONCE AGAIN
DRAIN THE SYSTEM COMPLETELY
RINSE THE SYSTEM WITH DM WATER BY CONTINUOUS FILLING &
DRAINING TO MEET COMPLETION CRITERIA
STOP THE PUMPS & DRAIN THE WHOLE SYSTEM
FILL THE SYSTEM WITH DM WATER & RAISE THE TEMP. TO 600C
ADD HYDRAZINE & AMMONIA TO GET 200PPM HYDRAZINE& PH OF
WATER TO 9.5 TO 10.0. RAISE THE TEMP. TO 800C & MAINTAIN
CIRCULATION FOR 8 HOURS
THEN DRAIN OUT THE SYSTEM & ALL AIR VENTS & FEED STORAGE
TANK MAN HOLES ARE OPENED TO AERATE THE SYSTEM
MAKE INTERNAL INSPECTION OF D/A FOR FOREIGN MATERIAL, IF ANY,
AND CLEAN THORUOGHLY
COMPLETION CRITERIA:DM WATER RINSING AFTER CHEMICAL
FLUSHING SHALL BE CONSIDERED COMPLETE ONCE
CONDUCTIVITY
May 24, 2012 OF DRAINED WATER
PMI Revision 00 IS LESS THAN 10MICRO
31
 POINT NEAR ECO I/L

PI TI
FEED CONTROL STN

R / C LINE
FEED STORAGE
SAMPLE
STEAM SUPPLY
TANK DRAIN

SH AND RH SPRAY
DM WATER SUPPLY

TEMP
TANK
BP SUCTION

DRAIN

P/Ps

HPH BYPASS
R/C
HPH-6A HPH-6B

BP BFP HPH-5A HPH-5B

SAMPLE

BFP SUCTION
BFP DISCHARGE PI TI

TEMPORARY PIPING
May 24, 2012
BLANK / FLANGE STAGE-1A
PMI Revision 00
OPEN DRAIN
32
 POINT NEAR ECO I/L

PI TI
FEED CONTROL STN

FEED STORAGE
SAMPLE
STEAM SUPPLY
TANK DRAIN

SH AND RH SPRAY
DM WATER SUPPLY

R / C LINE
TEMP
TANK
BP SUCTION

DRAIN

P/Ps

HPH BYPASS
R/C
HPH-6A HPH-6B

BP BFP HPH-5A HPH-5B

SAMPLE

BFP SUCTION
BFP DISCHARGE PI TI

TEMPORARY PIPING
May 24, 2012
BLANK / FLANGE STAGE-1B
PMI Revision 00
OPEN DRAIN
33
 SPREAY CONTROL STN

POINT NEAR ECO I/L

PI TI
FEED CONTROL STN

FEED STORAGE
SAMPLE
STEAM SUPPLY
TANK DRAIN

SH AND RH SPRAY
DM WATER SUPPLY

R / C LINE
TEMP
TANK
BP SUCTION

DRAIN

P/Ps

HPH BYPASS
R/C
HPH-6A HPH-6B

BP BFP HPH-5A HPH-5B

SAMPLE

BFP SUCTION
BFP DISCHARGE PI TI

TEMPORARY PIPING
May 24, 2012
BLANK / FLANGE
STAGE-1C
PMI Revision 00
OPEN DRAIN
34
 POINT NEAR D/A

LPH-3 BYPASS

PI TI
DEAERATOR

HPH-5A DRIP TO D/A

SAMPLE
STEAM SUPPLY
LPH-2 BYPASS

LPH-3 HPH-5A DRAIN

DM WATER SUPPLY
LPH-2
TEMP

HPH-5A ALT. DRIP TANK

LPH-1 B.P

DRAIN

LPH-1 P/Ps
CONDENSER. R/C
CONTROL STATION
D/A LEVEL

DRAIN CLR. CONDENSATE

EXCESS RETURN

SUC. SAMPLE
STRAINER
CEP’S
PI TI

CPU GSC.

May 24, 2012 PMI Revision 00 35

BLANK / FLANGE TEMPORARY PIPING STAGE-2A OPEN DRAIN
 POINT NEAR D/A

LPH-3 BYPASS

PI TI
DEAERATOR

HPH-5A DRIP TO D/A

SAMPLE
STEAM SUPPLY
LPH-2 BYPASS

LPH-3 HPH-5B DRAIN

DM WATER SUPPLY
LPH-2
TEMP

HPH-5B ALT. DRIP TANK

LPH-1 B.P

DRAIN

LPH-1 P/Ps
CONDENSER. R/C
CONTROL STATION
D/A LEVEL

DRAIN CLR. CONDENSATE

EXCESS RETURN

SUC. SAMPLE
STRAINER
CEP’S
PI TI

CPU GSC.

May 24, 2012 PMI Revision 00 36

BLANK / FLANGE TEMPORARY PIPING STAGE-2B OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR

5A DRIP TO D/A
STEAM SUPPLY
FEED STORAGE SAMPLE
EXT TO 6A DRAIN
TANK
EXT TO 5A

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T EXT TO 6B R/C
HP FT EXT TO 5B

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 37
STAGE-3A OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR

5A DRIP TO D/A
STEAM SUPPLY
FEED STORAGE SAMPLE
EXT TO 6A DRAIN
TANK
EXT TO 5A

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T EXT TO 6B R/C
HP FT EXT TO 5B

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 38
STAGE-3B OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR
5A DRIP TO D/A

STEAM SUPPLY
FEED STORAGE SAMPLE
DRAIN
TANK

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T R/C
HP FT

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 39
STAGE-3C OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR

5A DRIP TO D/A
STEAM SUPPLY
FEED STORAGE SAMPLE
EXT TO 6A DRAIN
TANK
EXT TO 5A

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T EXT TO 6B R/C
HP FT EXT TO 5B

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 40
STAGE-3D OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR

5A DRIP TO D/A
STEAM SUPPLY
FEED STORAGE SAMPLE
EXT TO 6A DRAIN
TANK
EXT TO 5A

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T EXT TO 6B R/C
HP FT EXT TO 5B

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 41
STAGE-3E OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

DEAERATOR

5A DRIP TO D/A
STEAM SUPPLY
FEED STORAGE SAMPLE
EXT TO 6A DRAIN
TANK
EXT TO 5A

HPH-6A HPH-5A

6A DRIP TO 5A
TEMP
TANK
DRAIN

P/Ps
HPH ALT. DRIPS TO F.T EXT TO 6B R/C
HP FT EXT TO 5B

HPH-6B HPH-5B
6B DRIP TO 5B

5B DRIP TO D/A
SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 42
STAGE-3F OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

EXT-2
STEAM SUPPLY
EXT-3

LP3 DRIP TO LP2

LPH-3 LPH-2

TEMP

LP2 DRIP TO LP1

TANK
LPH ALT. DRIPS TO LP F.T

LP FT
P/Ps

LPH-1

CONDENSER.

DRAIN CLR. SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 43
STAGE-4A OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

EXT-2
STEAM SUPPLY
EXT-3

LP3 DRIP TO LP2

LPH-3 LPH-2

TEMP

LP2 DRIP TO LP1

TANK
LPH ALT. DRIPS TO LP F.T

LP FT
P/Ps

LPH-1

CONDENSER.

DRAIN CLR. SAMPLE

DRIP FROM D/C TO LPFT

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 44
STAGE-4B OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

EXT-2
STEAM SUPPLY
EXT-3

LP3 DRIP TO LP2

LPH-3 LPH-2

TEMP

LP2 DRIP TO LP1

TANK
LPH ALT. DRIPS TO LP F.T

LP FT
P/Ps

LPH-1

CONDENSER.

DRAIN CLR. SAMPLE

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 45
STAGE-4C OPEN DRAIN
 TEMPORARY LINE TO MIXING TANK

EXT-2
STEAM SUPPLY
EXT-3

LP3 DRIP TO LP2

LPH-3 LPH-2

TEMP

LP2 DRIP TO LP1

TANK
LPH ALT. DRIPS TO LP F.T

LP FT
P/Ps

LPH-1

CONDENSER.

DRAIN CLR. SAMPLE

DRIP FROM D/C TO LPFT

PI TI

BLANK / FLANGE TEMPORARY PIPING

May 24, 2012 PMI Revision 00 46
STAGE-4D OPEN DRAIN
 COMMISSIONING
OF
LPH & HPH

May 24, 2012 PMI Revision 00 47

 HP / LP Heaters
commissioning
• Objective:
– To commission 2 sets of HP Heaters 5A/6A and
5B/6B
– Make them available for unit operation.

May 24, 2012 PMI Revision 00 48

 HP / LP Heaters
commissioning
• State of the plant:
– HP Heaters 5A, 5B, 6A and 6B are erected
as per recommended drawing.
– Detergent flushing completed
– Stand Pipe, Level transmitters, Level
switches and Level gauge glass are erected.
– Hangers and supports erected
– Startup and continuous vent line with orifice
are erected.
– Insulation completed
May 24, 2012 PMI Revision 00 49
 HP / LP Heaters
commissioning
• State of the plant:
– Commissioning of all related valve done
– Simulation checking of all interlocks and
protections are complete.
– Feed water charged to all Heaters and BFP
in service
– All local and remote instrumentation of
heaters complete.

May 24, 2012 PMI Revision 00 50

 HP / LP Heaters
commissioning
• Method:
– Charge feed water and Bypass closed
– Charge level switches / transmitters / gauges
– Open drain line isolating valves
– Check extraction oil relay operation
– Open shell side start up vent
– Ensure interlock in ATRS for solenoid valve
A5 are available and checked.

May 24, 2012 PMI Revision 00 51

 HP / LP Heaters
commissioning
• Method:
– Ensure the following interlock protection for any
one of Heaters 5A, 6A level very high.
(a) Closure of Extraction steam valves for the
HPH 5A and 6A.
(b) Opening of extraction line drain valves
(c) Bypassing of HPH on feed water side
(d) Opening of emergency drain control valve
to flash tank

May 24, 2012 PMI Revision 00 52

 HP / LP Heaters
commissioning
• Method:
– Ensure turbine load more than 40%
– Keep feed water valves on auto.
– Charge extraction steam to HPH 5A
gradually with drain control valve to
flash tank (emergency drain) in open
position.

May 24, 2012 PMI Revision 00 53

 HP / LP Heaters
commissioning
Method:
– As the heater shell pressure increases more than
deaerator pressure, open drain control valve to
deaerator (normal drain).
– Build up heater level to normal operating level and
ensure control valve operation on auto.
– Observe temperature raise in feed water outlet of
heater.
– Close startup vent of HPH5A and keep continuous
operating vent in open condition

May 24, 2012 PMI Revision 00 54

 HP / LP Heaters
commissioning
• Monitor and record the following parameter at
various load/full load
– (a) Extraction pressure
– (b) Extraction temperature
– (c) Heater shell pressure
– (d) Drain temperature
– (e) Feed water inlet temperature
– (f) Feed water outlet temperature
– (g) Heater level
– (h) Swing check NRV flap positions
– (i) Heater drip control valves positions.
May 24, 2012 PMI Revision 00 55
 HP / LP Heaters
commissioning
• Charge HPH 6 A with extraction steam
gradually.
• Build up HPH 6A level to normal level with
normal level controller. Keep the emergency
controller on auto
• Monitor and record all parameters at various
load/full load for HPH 6A as done for HPH 5A
• Commissioning of HP Heaters 5B and 6B is
carried out in the same way as done for HP
Heaters 5A and 6A.
May 24, 2012 PMI Revision 00 56
 Turbine and auxiliaries
• Barring gear
– Preparation
– Trial run of motor
– Preparation for putting the barring gear in
operation

May 24, 2012 PMI Revision 00 57

 TG On barring gear

May 24, 2012 PMI Revision 00 58

 TG on barring gear
• Objective:
– To rotate the turbine rotor system
continuously on low speed during start up
and shutdown of the machine.
– This is to over come the break away torque
during startup and enable uniform cooling of
the rotor system during shutdown to prevent
distortion of rotor.

May 24, 2012 PMI Revision 00 59

 TG on barring gear
• Services required
– Auxiliary oil pumps.
– DC Emergency oil pump.
– Jack oil pumps AC & DC.
– Oil Vapour fans
– Power and control supply for the
above.
– Gate valve gearing with power supply.
May 24, 2012 PMI Revision 00 60
 TG on barring gear
• Services required
– Cooling water to oil coolers.
– Availability of oil temperature controller.
– Required operating personnel.
– Availability of fire fighting system.
– Proper lighting arrangement in all the
floors.
– All working areas shall be free of debris
and no oil accumulation.
May 24, 2012 PMI Revision 00 61
 TG on barring gear
• State of the plant:
– Any one of AOPs is in service and the other
is kept on standby.
– DC emergency oil pump is on auto mode.
– JOP is in service.
– DC Jop is kept on auto mode.
– Oil temperature controller is put on auto.
– Coolers are charged with cooling water.

May 24, 2012 PMI Revision 00 62

 TG on barring gear
• State of the plant:
– All Turbovisory instrumentations are kept in
service.
– Machine is ready for barring gear operation.
– Open and close limit switches of gate valve
gearing is set and the
– operation of valve is checked.
– Throttles in the lube oil line to individual bearing
are set for its
– required flow. Turbovisory instruments are
calibrated & ready for
– barring operation. PMI Revision 00
May 24, 2012 63
 TG on barring gear
• Method:
– Start AOP and set throttles of header and
individual bearings to maintain pressure
– SLC of oil system checked
– OTCV commissioned
– SLC of JOP checked and PRV adjusted
– Start JOP and check bearing lift(0.02mm-
0.1mm)
– Do hand barring and check freeness

May 24, 2012 PMI Revision 00 64

 TG on barring gear
• Method:
– Do the P&I Checks of barring gear
– Open barring gear valve and see that specified
speed is attained
– Check for rubbing sound from seals / bearings
– If ok…run it for 8hours and check performance
– Close the valve and note coasting down time

May 24, 2012 PMI Revision 00 65

 TG on barring gear
Note down the following readings every hour.
1. Lube oil header pressure after filter
2. Lube oil temperature after cooler
3. Thrust bearing position.
4. Bearing and shaft vibration
5. Speed
6. Bearing Babbitt temperature.
7. JOP header pressure and the same at
individual bearing.
8. Return oil temperature at all bearings.
9. Return oil flow levels.
May 24, 2012 PMI Revision 00 66
 TG on barring gear
• COMPLETION CRITERIA:
– If the above parameters for 8 hrs. Barring is
found normal, the trial run of barring gear
operation is successful.

May 24, 2012 PMI Revision 00 67

 Condenser flood test
and
Vacuum tightness test

May 24, 2012 PMI Revision 00 68

 Flood test
• Services required
– D.M water
– Flexible hose pipe
– Lighting
– Dewatering pump
– Wooden slippers for temporary support

May 24, 2012 PMI Revision 00 69

 Flood test
• State of the plant
– Condenser erection completed
– Flexible polythene hose fitted for level monitoring
– Jack bolts beneath condenser locked
– Wooden planks kept
– D.M Water line charged

May 24, 2012 PMI Revision 00 70

 Flood test
• Method
– All heater vents opened to vent out the air
– Start DM Water filling
– Check leakages for every one meter raise in
level (in level indicator)
– Fill water up to the tip of LP Turbine blades
– Attend leakages
– Drain condenser, clean Hotwell and remove
wooden slippers and release jack bolts

May 24, 2012 PMI Revision 00 71

 Flood test
• Completion criteria
– Declared completed when all the identified
leakages attended satisfactorily

May 24, 2012 PMI Revision 00 72

 Vacuum tightness test
• Services required
– Cooling water available
– Power supply to CEP, Vacuum pumps and CW
Pumps available
– Auxiliary steam available

May 24, 2012 PMI Revision 00 73

 Vacuum tightness test
• State of the plant
– Vacuum pumps ready for operation
– GSB trial completed
– CEP commissioned, P&I checks done
– Condenser CW water charged
– Vacuum breaker commissioned
– TG is on barring gear

May 24, 2012 PMI Revision 00 74

 Vacuum tightness test
• Method
– Put turbine on barring gear
– CEP is on recirculation
– Seal steam and GSC lined up
– GSB and Both vacuum pumps started
– Charge seal steam after achieving 0.2Ksc
vacuum (Seal steam 0.01Ksc and >1600c temp)

May 24, 2012 PMI Revision 00 75

 Vacuum tightness test
– Check for air ingress and attend leakages
– Stop one vacuum pump at desired vacuum
– Check for holding with one pump
– If air ingress points are not detected then use
helium leak detection or steam pressurization
method (Raise steam space pressure up to
0.1Ksc.)

May 24, 2012 PMI Revision 00 76

 Vacuum tightness test
• Completion criteria
– Stop both vacuum pumps at desired pressure
and observe rate of fall of vacuum. (Should not
be >2to3 mmwcl per minute)
– Total hogging time for achieving desired vacuum
with both pumps and with individual pumps to be
noted

May 24, 2012 PMI Revision 00 77

 Checklist for rolling
– Electrical supply HT&LT charged
– DM Water available in FST and Hotwell
– Turbovisory parameters are working
– Mot instruments working
– Regenerative system controls checked
– Start CW and charge passes
– Start ACW and charge lines
– Start ECW and charge equipment

May 24, 2012 PMI Revision 00 78

 Checklist for rolling

• Start mot VEF

• Start AOP &JOP and note pressures
• Ensure return oil flow from bearings
• Ensure all DC pumps are available
• Start control fluid pump and charge lines
• Check bearing temperatures
• Maintain lube oil temperature
• Check barring gear interlocks

May 24, 2012 PMI Revision 00 79

 Checklist for rolling
• Put seal oil system in service and do P&I
checks
• Put turbine on barring and note readings
• Ensure all mal drains are open
• Check governing characteristics of valves
• Ensure MS, CRH, HRH drains in open
• Ensure extrn valves are closed

May 24, 2012 PMI Revision 00 80

 Checklist for rolling
• Start CEP and open GSC min recirculation
• Charge gland sealing
• Open heaters shell vents to condenser
• Close vacuum breaker
• Start vacuum pulling
• Charge seal steam
• Ensure MS/ CRH /HRH line warming

May 24, 2012 PMI Revision 00 81

 Checklist for rolling

• Check turbine and generator protections

• Check heaters protections and interlocks
• Ensure HP&LP bypass available
• Start MDBFP and charge feed water system
• Put HP-LP bypass in operation
• Ensure rolling parameters

May 24, 2012 PMI Revision 00 82

 Checklist for rolling
• Start rolling in SGC or raise starting device
position to open stop valves
• Check that all steps are satisfied
• Soak the turbine at 360rpm
• Cross critical speed at set acceleration
• Be ready for synchronization after achieving
3000rpm

May 24, 2012 PMI Revision 00 83

 THANK YOU

May 24, 2012 PMI Revision 00 84