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No. |
Description |
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PRE-REQUISITES |
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1 |
Electrical
Distribution System in service |
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2 |
Instrument and
Service Air System is in service |
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3 |
Auxiliary
Cooling System is in service |
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4 |
Boiler Feed
water system in service |
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5 |
Circulating
Water System in service |
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6 |
DFW System is in
service, and condenser is filled (NWL) |
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7 |
Turbine Control and
Lube oil system is in service |
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8 |
Turbine gear is
in operation (Turning gear should be in operation for three (3) hours or more
to stabilize rotor eccentricity (< 50 microns) |
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9 |
HHP Steam is
available |
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10 |
Drive test of
motorized valves and control valves are completed |
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11 |
Online chemical
analysers are in service ·
Condensate Water Conductivity (specific) ·
Condensate Water Conductivity (Cation) |
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12 |
Confirm the following
conditions are met before Generator Synchronization (depending on the
Generator to be synchronized) ·
No.1 STG o
Earth Switch 1 and 2 is open o
89G disconnecting switch is close o
Bay 3 Line disconnecting switch (892-3-P0AEA00GS206)
is closed o
Bay 3 – Bus 1 disconnecting switch (891-3-P0AEA00GS205)
is closed § Not needed if in
house load operation o
Bay 3 Circuit breaker (52-3-P0AEA00Gs103) is closed ·
No. 2 STG o
Bay 7 line disconnecting switch (892-7 – P0AEA00GS214)
is closed o Bay
7 – Bus 3 disconnecting switch (891-7 – P0AEA00GS205) is closed o Bay
7 – Circuit breaker (52-7 – P0AEA00GS107) is open ·
No. 3 STG o
Earth Switch 1 and 2 are open o
89G disconnecting switch is closed o
Bay 14 line disconnecting switch (892-14-P0AEA00GS228)
is closed o
Bay 14 – Bus 2 disconnecting switch (891-14-P0AEA00GS227)
is closed §
Not needed if in house load operation o
Bay 14 circuit breaker (52-14-P0AEA00GS114) is open ·
No. 4 STG o
Bay 17 line disconnecting switch (892-17-P0AEA00GS235)
is closed o
Bay 17 – Bus 4 disconnecting switch
(891-17-P0AEA00GS234) is closed o
Bay 17 circuit breaker (52-17-P0AEA00GS117) is open ·
No. 5 STG o
Bay 19 line disconnecting switch (892-19-P0AEA00GS238)
is closed o
Bay 19 – bus 2 disconnecting switch
(891-19-P0AEA00GS238) is closed o
Bay 19 circuit breaker (52-19-P0AEAGS119) is open |
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13 |
·
Confirm CB select is selected before commencing BP2
start-up |
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14 |
·
Inform RBR Substation shift supervisor before start-up
of BP2 |
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15 |
·
As a default configuration, Generator Tap
Transformer Tap Position is 5 ·
Select appropriate tap position as per line/grid
voltage |
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16 |
·
Verify Generator Relay is already set |
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No. 1 STG |
No. 2 STG |
No.3 STG |
No.4 STG |
No.5 STG |
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For STG: ·
86Ua ·
86TA ·
86GA ·
86UB ·
86TB ·
86GB For Unit
Transformer: ·
86HA ·
86HB |
·
86TA ·
86GA ·
86TB ·
86GB |
For STG: ·
86UA ·
86TA ·
86GA ·
86UB ·
86TB ·
86GB For Unit
Transformer: ·
86HA ·
86HB |
·
86TA ·
86GA ·
86TB ·
86GB |
·
86TA ·
86GA ·
86TB ·
86GB |
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PRE-OPERATIONAL
CHECKLIST |
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1 |
All
work permits / hold orders for the steam turbine and turbine by-pass systems
are cleared |
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2 |
All
equipment is in safe operational condition and is ready for operation |
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3 |
All
instrumentation is available |
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4 |
All
annunciations and alarms for the system are available in the DCS |
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5 |
Valve
line-ups are complete |
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6 |
Power
supply line-ups are complete |
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7 |
Check
condition of the first stage metal temperature as per start-up condition: ·
Complete cold = FSMT < 70 degree Celsius o
Speed up rate = 180 rpm/minute o
Rub check @ 500 rpm = 30 minutes o
Rub check @ 2300 rpm = 180 minutes o
Initial load hold time = 30 minutes (6 MW) o
Load up rate = 0.6 MW per minute ·
Cold = 71 degree Celsius < FSMT < 120 degree
Celsius o
Speed up rate = 180 rpm / minute o
Rub check @ 500 rpm = 30 minutes o
Rub check @ 2300 rpm = 120 minutes o
Initial load hold time = 30 minutes (6 MW) o
Load up rate = 1.2 MW per minute ·
Warm = 121 degree Celsius < FSMT < 380 degree
Celsius o
Speed up rate = 180 rpm per minute o
Initial load hold time = 20 minutes (12 MW) o
Load up rate = 2.4 MW per minute ·
HOT = FSMT > 380 degree Celsius o
Speed up rate = 180 rpm per minute o
Initial load hold time = 20 minutes (12 MW) o
Load up rate = 2.4 MW per minute
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Condenser
Vacuum Start-up Prior
to condenser vacuum start-up, check the following conditions: ·
Turbine is on turning gear and no gland rubs are
observed ·
Check condenser out MOV open at 20% ·
Rotor eccentricity is normal (< 50 microns) ·
Turbine supervisory instruments are in service ·
All equipment and valves are in AUTO ·
Any condensate pump is in operation with ready AUTO
standby mode ·
All functional groups are started o
Condensate water group o
Turbine vacuum group o
Turbine steam and drain group o
Turbine extraction group o
Turbine oil supply group o
Turning gear group ·
At this point of operation, verify first stage metal
temperature (> 80 degree Celsius) ·
Make sure that the LP Balance Manual isolation valve
(T1-T5MAM40AA101) should be fully open before condenser vacuum start-up |
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1 |
Start
condenser vacuum pump in functional group |
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2 |
One
condenser vacuum pump will automatically start since gland steam pressure are
already established |
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3 |
Vacuum
breaker MOV (T1-T5MAC21AA601) will automatically close when condenser vacuum
is <-18.75 mmHg. |
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4 |
Additional
condenser vacuum pump will automatically start when condenser vacuum is >
-39.98 mmHg ·
Check for the opening of the condenser vacuum pump
inlet valve (T1-T5MAJ01AA101/102) at local |
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5 |
When
the condenser vacuum pressure reached to -690 mmHg and will hold at this
vacuum pressure for about 30 seconds, one condenser vacuum pump will
automatically shutdown and one condenser vacuum pump will be in operation and
will keep the condenser vacuum pressure < - 690 mmHg |
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Extraction
Control Valve Exercise |
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1 |
Manually
reset the Steam turbine generator at the DEH Screen 1 ·
GV and ECV will open 100% and MSV about 4% open o
Immediately trip the turbine upon confirmation of
100% open of GV and ECV o
Avoid long duration of GV/ECV/MSV opening to prevent
rolling of the turbine |
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2 |
Immediately
trip the steam turbine and monitor the close position of MSV/GV/ECV ·
Steam turbine can either be trip by local hand level
trip or emergency push button ·
Upon tripping, all MSV/GV/ECV will fully close |
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3 |
If
any valve did not full close, prepare maintenance work request and repeat this
procedure together with maintenance |
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4 |
After
completion, the steam turbine generator can be started by ATS |
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Turbine
Start-up by Automatic Turbine Start-up |
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Check
first the following parameters before commencing ATS start-up: ·
HHP Steam Pressure => 103.5 Kg/cm2 ·
HHP Steam Temperature => 490 degree Celsius o
During initial plant start-up, HHP Steam Temperature
= 425 degree Celsius ·
Rotor eccentricity = < 50 microns ·
Lube Oil pressure = > 1.2 kg/cm2 ·
Lube oil temperature = 30-35 degree Celsius ·
Drain oil flow at all turbine and generator bearing
pedestals are normal ·
Condenser vacuum pressure = > 680 mmHg ·
All turbine auxiliary equipment operating parameters
are normal ·
Real time trends are set up to monitor activity
during start up ·
All functional groups are started o
If functional group has not been started, ATS will
not have permissive to Turbine Reset ·
Inform Petro Rabigh Utilities Supervisor and RBR
substation regarding scheduled steam turbine generator start-up |
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Break
Point 1 ·
By selecting DEH operation Screen 1, selecting ATS
start up mode IN o
ATS will dictate turbine start up mode as per first
stage outlet metal steam temperature ·
Upon selection of ATS start up IN Mode, ATS will give
permit for start up BP 1 ·
Select ATS start up step for the monitoring of the
timing of steam turbine generator start up |
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1 |
Select
start ATS start up BP 1 ·
Announce to Bravo talk group before commencing GO BP
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Select
Go Push Button to begin turbine start up |
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Turbine
will be reset and during reset, GV will fully open and MSV will open to about
4% (MSV controlling the turbine speed) |
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During
initial rolling, monitor turning gear disengages when turbine speed is >4 RPM
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ATS
will speed up steam turbine to 500 RPM |
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2 |
Upon
reaching 500 RPM, ATS will automatically select RUBCHECK IN ·
Instruct local operator to RUBCHECK using vibration
stick |
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·
Turbine speed will drop a little bit because MSV
will close during RUBCHECK |
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3 |
Upon confirmation
from local operator that RUBCHECL is normal, proceed to RUBCHECK out |
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4 |
After RUBCHECK out,
ATS will again speed up to 500 RPM and shall be heat soaked for 30 minutes |
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5 |
After 30 minutes
heat soak, turbine speed shall automatically speed up to 2300 RPM |
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6 |
Note the eccentricity
recorder change-over from eccentricity monitor to rotor vibration monitor
when speed crosses to 600 rpm |
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7 |
Confirm that the
lube oil temperature set point changes automatically from 35 to 40 degree
Celsius when the turbine speed reaches 900 rpm |
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8 |
During speed up
to 2300 rpm, monitor turbine speed during turbine speed critical area ·
950 to 2150 rpm ·
Speed up can not be hold or speed down during
turbine speed critical area |
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9 |
As the turbine
reaches 2300 rpm. Turbine shall be heat soaked as per turbine start up mode: ·
Complete cold = 3 hours ·
Cold = 2 hours ·
Warm = NA ·
Hot = NA |
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10 |
Verify that the
HHP Steam Pipe drain MOV (T1-T5LBA01AA911) should be around 25% opening ·
This is done to maintain the steam at superheated
condition during low HHP Steam flow to STG |
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11 |
Monitor the
following parameters during Turbine Heat Soaking: ·
Turbine/Generator bearing vibration ·
Turbine/generator bearing metal temperature and
drain oil temperature ·
Casing and differential expansion ·
Rotor position ·
Turbine exhaust hood temperature < 70 degree
Celsius o
Verify with local operator that the turbine exhaust
hood spray water valve (T1-T5LCE01AA701) is actual opening at the field ·
Gradually increase the opening of the CW condenser
outlet MOV A/B and monitor closely the condenser vacuum pressure and open to
100% as required |
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12 |
At the end of
the heat soak, prepare for the turbine speed up from 2300 to 3600 rpm |
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13 |
During speed up
from 2300 to 3600 rpm. Monitor turbine when it crosses turbine critical speed
area ·
2310 to 2800 rpm and 3100 to 3350 rpm |
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14 |
Upon reaching
3600 rpm, turbine rated speed, BP-1 mode is complete, thus giving permissive
for BP-2 and ready for generator synchronisation |
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15 |
Before proceeding
with BP-2, perform turbine protective device testing ·
Condenser vacuum low and low-low alarm test ·
Low bearing oil trip test ·
Mechanical overspeed test ·
Turbine lube oil back up test |
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Break Point 2 –
Generator Synchronisation |
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1 |
Select start BP-2
mode |
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2 |
Announce in
Bravo Talk group that the generator is ready to be synchronised |
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3 |
Inform RBR
substation shift supervisor that the generator is ready to be synchronised |
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4 |
Select go and
execute to begin synchronisation |
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5 |
Monitor generator
electrical monitor for 41E (field circuit breaker) |
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6 |
Monitor generator
main circuit breaker closing upon stabilising field voltage: ·
Put to AUTO the HHP steam pipe drain MOV
(t*LBa01AA91) ·
Verify that the HHP Steam pipe drain MOV automatically
closes upon GMCB closing |
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7 |
Verify initial load
condition: ·
Complete cold = 6 MW ·
Cold = 6 MW ·
Warm = 12 MW ·
Hot = 12 MW |
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8 |
Monitor power
factor and reactive power during and upon synchronisation: ·
If power factor increases, set generator voltage
lower ·
If power factor decreases, set generator voltage
higher ·
Generator voltage must not exceed 103% of rated
generator voltage |
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9 |
Upon initial
load, heat soak as per start up mode: ·
Complete cold = 30 minutes ·
Cold = 30 minutes ·
Warm = 20 minutes ·
Hot = 20 minutes |
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10 |
After heat
soaking, valve transfer will automatically commence ·
During valve transfer, GV will close rapidly to
about 3-5% and MSV opens gradually to 100% |
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11 |
After valve
transfer, BP-2 start up mode is complete |
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12 |
Select LOAD
CONTROL and set load as per Petro Rabigh demand ·
Select DEH control mode and select CONTROL link in
the selection and make sure that LOAD and LL operation are in RED |
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13 |
Verify LOAD RATE
Set as per start up mode ·
Complete cold = 0.6 MW per minute ·
Cold = 1.2 MW per minute ·
Warm = 2.4 MW per minute ·
Hot = 2.4 MW per minute |
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14 |
As the load
increases to 20% (24 MW), verify that the turbine drain valves automatically
closes ·
LP Balance pipe drain valves (T*MAM40AA902) ·
First stage outlet drain valves *T*MAL03AA902) ·
IP steam chest drain valve (T*MAL03AA904) ·
Main steam lead pipe drain valve (T*MAL02AA902) |
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15 |
Monitor turbine
exhaust hood temperature closely and verify if the turbine exhaust hood spray
on-off valve automatically cuts-in if turbine exhaust hood temperature exceeds
70 degrees Celsius ·
Verify that the turbine exhaust hood spray water
valve manual isolation valve is fully open |
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16 |
Further load up
steam turbine generator as per load demand ·
As the generator load increases, slowly increase the
opening of CW turbine condenser outlet MOV A/B up to 100% and monitor closely
the condenser vacuum pressure |
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17 |
Verify that the
LP turbine flow limitation is automatically set IN upon closing of GMCB ·
LP turbine flow limitation is set at 350 tons per
hour Verify that the
initial pressure regulator and vacuum unloader are automatically set IN upon
closing of GMCB (52G) ·
Vacuum unloader is set at a sliding scale ·
IPR set point = 94.4 kg/cm2 |
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LP extraction
steam servicing |
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18 |
At 30 MW, LP
steam isolation MOV (from turbine) will automatically open once the LP
extraction steam temperature (after PCV) is > 135 degree Celsius |
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19 |
Verify that the
LP extraction steam line blow valve (outlet NRV) automatically closes when LP
steam isolation MOV (from Turbine is fully open |
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20 |
Verify that the
LP extraction steam line blow valve (inlet NRV) automatically closes when LP
steam flow is > 8 tons per hour |
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MP Extraction
steam service |
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21 |
At 30 MW, MP
extraction steam after DSH will automatically open at an ON timer of 180
seconds |
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22 |
MP steam
isolation MOV (from turbine) will automatically open once the MP steam isolation
MOV is fully open |
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HP extraction
steam service |
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23 |
At 60 MW and HP
extraction line warming is completed (HP Steam > 200 degree Celsius), HP
steam isolation MOV (from turbine) will automatically open |
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24 |
Verify that the
HP extraction steam line blow valve (outlet NRV) automatically open |
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25 |
Verify that the
HP extraction steam line blow valve (inlet NRV) automatically closes when HP
steam flow is > 27 tons per hour |
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26 |
Verify with
local operator the opening of the HP steam forced check solenoid valve |
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LP heater
service |
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27 |
Make sure that
the Deaerator feed water by pass MOV will not open automatically in case the LP
heater level is high – high (250 mm) ·
Put to manual and immediately close the deaerator
feed water by-pass MOV and control the level of the LP heater through drains
(normal and emergency drains) ·
It is very important that the Deaerator feed water
by-pass MOV will not open because once that this MOV opens, cold water from
the mixing tank will be introduce to the Deaerator which will affect
deaerator pressure |
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28 |
Upon reaching 60
MW Generator load, LP header deaerator feed water inlet MOV will
automatically open ·
Instruct local operator to ready stand-by at the LP
heater are to monitor the start-up process |
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29 |
LP heater deaerator
feed water outlet MOV will open about 10% |
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30 |
LP heater inlet
MOV (from turbine) will automatically open at an interval of 10% per minute |
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31 |
Verify that the
LP header extraction steam blow valve and LP header extraction steam blow
valve (outlet NRV) automatically closes when LP header inlet MOV opens 100% |
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32 |
Instruct local
operator to verify the opening of the LP header MV (from turbine) and compare
the local level reading to that of the DCS reading |
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33 |
Verify the opening
of the normal and emergency drains of the LP header once it is already at
service ·
LP heater emergency level control valve opens automatically
when LP heater level is > 150 mm ·
LP Header inlet MOV (from turbine) protection close
when the LP heater level reached > 250 mm |
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34 |
Monitor Deaerator
pressure and deaerator heating steam header pressure during this process ·
If the Deaerator heating steam header pressure
increase to > 5.5 kg/cm2, BFPT will trip |
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NOTE: HP
extraction steam and LP heater servicing are almost simultaneous at 60 MW
load |
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Extraction
Control Valve service |
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·
The permissive for the Extraction Control Valve are
when the generator load is > 36 MW and the MP steam isolation MOV (From
turbine) are fully open ·
It is recommended that all the extraction steam
isolation MOV (HP/MP/LP/LPH) are fully open before servicing the extraction control
valve |
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35 |
Select CONTROL
START the Extraction Control Valve ·
Extraction control valve should be in AUTO mode and generator
load > 36 MW and MP isolation MOV (from turbine) are fully open ·
Standard MP extraction steam set point is 20.6
kg/cm2 ·
Verify that the MP extraction steam line blow valve
(outlet NRV) automatically closes when MP steam isolation MOV is fully open ·
Verify that the MP extraction steam line blow valve
(inlet NRV) automatically closes when MP steam flow is > 22 tons per hour ·
MP steam DSH spray control valve set point = 315
degree Celsius |
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36 |
Monitor HP/MP/LP
extraction steam flow to the headers as the normal operation of the steam
turbine generator progresses ·
HP extraction steam flow should not exceed > 300
tons per hour ·
MP extraction steam flow should not exceed > 260
tons per hour ·
MP extraction steam pressure should not exceed beyond
27.3 kg/cm2 because extraction control will close at this pressure and the steam
turbine will trip (protection trip) ·
LP extraction steam flow should not exceed > 60
tons per hour |
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