BY:

NAGESH H

PRE COMMISSIONING : The activities carried out before

passing steam to the turbine is called pre commissioning.
COMMISSIONING: The activities carried out to ensure
turbine performance is as per design is known as commissioning.

SUBBURAJ PAPER PVT LTD

TECHNICAL DATA

PRE COMMISSIONING
STEAM BLOWING
CONDENSER TEST
BEARING CLEARANCE, FLOAT, DUMP OF ROTOR,GEAR

AND PINION
THROTTLE VALVE SETTING
ALL SAFETY TRIP FUNCTIONING AND RESPONSE OF SEV

STEAM BLOWING
The purpose of blowing the steam lines prior to starting

up a new unit is to remove any foreign particle remaining

in steam inlet pipeline.
The principle behind steam blowing is thermal cycling i.e
heating of pipe lines by blowing steam & cooling. This
will tend to break mill scale / weld slag away from the
pipe wall due to difference in co-efficient of thermal
expansion.

EQUIPMENTS
Temporary piping
Temporary piping support
Silencer
Target plate

PROCEDURE FOR STEAM BLOWING.

Disconnect steam inlet pipe
from turbine emergency stop
valve
2. Arrange for target plate of
mirror finished aluminum of
thickness 10 to 12 mm to be
fitted at 1 meter away in the
temporary blowing line. which
is placed in the main steam line
by making a fixture
3. During the blowing down
process open all the drain lines
from boiler to inlet pipe flange
4. Steam blows should be carried
out by fully opening the
isolating valve.
1.

TARGET
PLATE

STEAM INLET

SUPPORTING PLATE

PROCEDURE FOR STEAM BLOWING

5.

6.
7.

8.

Bring the boiler press. up to 70 to 80% of

working press. & temp., blow down the
steam line until press. drops to 20 to 30%
of working press./temp. recommended
by boiler manufacturer and then allow
the line to get cooled(~40C ) and then
hammer the steam pipe line near joints .
Repeat this procedure for three times.
Now place the target plate in the fixture
& blow down the steam line and allow it
to cool.
This cycle is repeated till we get
acceptance value , In each cycle continue
hammering and Stamp the cycle no. on
the receiving face of the target plate.

ACCEPTANCE CRITERIA
Indentation is acceptable when there are no more than 2 dents of
0.2mm in a 50X50 mm section of target plate.

PRECAUTIONS
1.
2.

3.

Check that all pipes are supported properly during blow down.
Necessary safety precautions must be taken such as fencing of the area
and providing ear protection against the inevitable noise generated
during blow down process.
No one should move around the blowing area

CONDENSER MASS FLUSHING

Dummy
flange

Objective: To clean the cooling water inlet and

outlet pipe lines of condenser from cooling pond
to cooling tower.

To cooling
tower at 12 m
height

condenser

Dummy
flange

Drain

2 to 2.5
kg/sq .cm

Procedure:
Place the dummy flanges in cooling water inlet
and outlet line of the condenser.
Prepare a temporary pipe line for flushing
Pump the water from cooling pond till water
flows out on top of cooling tower and then
switch off the pump.
Drain the water .
Repeat this procedure until the water is clean.

Chemically treated
water from cooling
pond

CONDENSER TESTS
1.WATER LEAK TEST:

EXHAUST
STEAM

Pipe line is made from DM water pump to

condenser shell.
Fill the condenser with DM water up to the
bottom of exhaust casing until water leaks
from the exhaust thermo well of turbine.

COOLING WATER
OUTLET

Ensure that all the pipe lines are filled with

water which are connected in the vacuum
system.
Hold the water up to one hr and observe any
leakage from the flange and welded joints.
Ensure that
system
HOTWELL

COOLING WATER INLET

there is no leakage in the

Drain the water completely from the system

after the completion of test

CONDENSER TESTS
EXHAUST
STEAM

2. VACUUM DROP TEST

Isolate the turbine from condenser by
providing a ms plate of approximate 10 to
15 mm thickness between condenser
flange and bellow flange provided at
turbine exhaust flange along with turbine .

COOLING WATER
OUTLET

Fill the condenser hot well

level

to normal

Start hogger ejector and create vacuum to

the designed value of 0.1 ATA and close
the hogger ejector
Check the rate of vacuum drop
HOTWELL

COOLING WATER INLET

Drop in vacuum should not exceed 0.01

kg/sq.cm in 30 minutes.

BEARING CLEARENCE
Place the bottom bearing shells and load the
rotor on bearings.
Place a lead wire of 0.7mm thick with a coat
of grease circumferentially around the top
half of the journal.
Place the top half of bearing shell with its
bearing cap and tighten it.
Remove the crushed lead wire and measure
the thickness of the crushed lead wire which
gives the existing bearing diametrical clearance
DESCRIPTION

OBSERVED(mm)

REQUIRED(mm)

Rotor fore

0.21

0.18-0.23

Rotor after

0.21

0.22-0.26

Pinion fore

0.37

0.37-0.42

Pinion after

0.37

0.37-0.42

Gear fore

0.27

0.25-0.30

Gear after

0.26

0.25-0.30

Dump check is done to ensure

minimum clearance b/w rotor &
nozzle chest and diaphragm nozzle.
Place the rotor on journal bearing.
Assemble the top bearing shells
into the bottom bearings and place
the bearing cap.
Insert the active thrust pad into its
position.

Dial
indicator
position

Description (Dump) Observed

Required

Rotor

0.72

0.7-0.8

Gear

0.65

0.40-0.75

 To check the float of the

rotor ,the same procedure

has to be followed but the
rotor movement is
restricted by using non
active thrust pad.
Description Observed

Require
d

Rotor

0.30035

0.35

THROTTLE VALVE LIFT

MAX.LIFT

First valve is adjusted by feeler

gauge and other two valves are
set by vernier caliper

PRESSURE SETTING
Control oil pressure

14kg/sq.cm

Bearing oil pressure

1.9 kg/sq.cm

Accumulator pre-charge pressure

12kg/sq.cm

(80% of control oil pressure)

Trip circuit oil pressure

1.5 kg/sq.cm

VERIFY ALL INTERLOCKS AND ALARMS

CHECK ALL SAFETY TRIPS

MANUAL TRIP

ITEM

SETTING
VALUE

SET
VALUE

TRIP PR.

0.5-0.8

0.8

RESET PR.

0.8-1.2

SOLENOID
TRIP

0.5

L P TRIP

LP TRIP

OVER SPEED TRIP

0.9
0.5

ENSURE THAT SEV AND TV CLOSES

IN ALL TRIPPING
SOLENOID
TRIP

VIBRATION PROBE SETTING

PROBES HAS TO BE SET

FOR 9 to 12VOLTS

1.TURBINE FORE
2.TURBINE AFTER
3.PINION FORE
4.PINION AFTER
5.GEAR FORE
6.GEAR AFTER

7.ALTERATOR FORE
8.ALTERNATOR AFTER
9.AXIAL

COMMISSIONING AND LOAD TRIAL

OBJECTIVES:

To check various pressure settings with in the lube oil and control oil

system
To check vibration level with in limits
Governor take over
To check the over speed trip and electrical trips are functioning correctly
To prove performance of machine and to satisfy customer

COMMISSIONING PROCEDURE FOR SOLO RUN

TEST AND LOAD RUN TEST
Start AOP
Open all drains of steam in turbine
SEV drain
Nozzle chest drain
Wheel case drain
Casing drain
Throttle valve drain

Check oil level in oil tank through oil level gauge and temperature of
the oil should be minimum 35deg c
Ensure that cooling water to oil cooler, condenser,GVC is flowing

Start the motor driven barring gear. An interlock ensures that the baring gear
can not be started before bearing oil pressure is established i.e 1.5kg/sq.cm
Run barring gear for a period of 12 hours, if turbine is started first time for
an SCG 3 turbine.
Check the vibration level are with in limits
Allow sealing steam for laby packing's

START EJECTOR SYSTEM

VAPOUR FROM
CONDENSER
BASIC PRINCIPLE

MOTIVE STEAM
HOGGER

Entrapped gases
COOLING WATER INLET
AND OUTLET

MOTIVE STEAM

START MOTOR DRIVEN CEP

Balancin
g leak
of
DISCHARG
E
BLO
DELIVERY

Suction from hot

well

SUCTION

P=6kg/cm sq

To ejector
tubes

 RESET ALL SAFETY TRIPS

Solenoid trip

PUSH TO TRIP

Manual trip
LP trip

PULL TO
RESET

SOLENOID TRIP
L P TRIP
CONTROL OIL LINES
DRAIN LINE

MANUAL TRIP

Crack open the steam supply isolating valve and warm up the
steam pipe line to turbine SEV
Reasons for warm up :
To avoid uneven expansion of pipe line, rotor and casing
To avoid water hammering effect
Start GVC blower
Initially lift the HP actuator lever
Gradually open the SEV, which should be sufficient for
warming nozzles and casing.
After few minutes, when the turbine warmed through and all
water has been expelled, then partially close the turbine drains

TURBINE START UP CURVE TO BE FOLLOWED

1st cs-2600 rpm

Sudden jump 2300-2900

 CHECK FOR OVER SPEED TRIP AND SET ELECTRICAL TRIP

SET OVER SPEED TRIP WITH IN THE RANGE OF 110-115% OF

RATED SPEED
7829rpm
Remove material on
this opposite face if os
trip is less

TO INCREASE TRIP SPEED

Valve

TURBINE START UP CURVE TO BE FOLLOWED

TURBINE START UP CURVE TO BE FOLLOWED

CHECK FOR VIBRATION LEVELS AND TEMPARATURE

VIBRATION READINGS IN SOLO RUN TEST

ITEM

POSITION

READINGS
MILS/PP

ROTOR
FORE BRG

0.8

0.7

ROTOR
AFTER BRG

0.73

0.42

PINION
FORE BRG

1.75

1.48

PINION
AFTER BRG

0.74

0.46

GEAR FORE
BRG

0.25

0.27

GEAR
AFTER

0.33

0.42

X (TOP)

5.3

Y (BOTTOM)

4.2

BRG
AXIAL

LOAD CURVE DURING STABLE OPERATION

VIBRATION READINGS WITH LOAD RUN TEST

ITEM

POSITION

READINGS
MILS/PP

ROTOR FORE BRG

0.8

0.64

ROTOR AFTER
BRG

0.51

0.4

PINION FORE BRG

1.8

1.5

PINION AFTER
BRG

0.68

0.43

GEAR FORE BRG

0.28

0.38

0.37

0.58

5.3

DRIVEN MACHINE
FORE BRG

0.9

1.63

DRIVEN MACHINE
AFTER BRG

0.69

0.55

GEAR AFTER BRG

AXIAL

LOAD TRIAL(PARAMETERS)
SPEED

RPM

LOAD
STEAM INLET

MW
PRESSURE
TEMP.

STEAM FLOW

kg/Sq.cm
C
TPH

WHEEL CASE PR.

EXTRACTION

EXHAUST
PRESSURE
HOT WELL TEMP
COOLING WATER

EJECTOR

OIL PRESSURE

BRG TEMP. C

kg/Sq.cm
PR.
TEMP
FLOW
PRE.
TEMP

kg/Sq.cm
C
TPH
kg/Sq.cm
C
C

1.5
33.8
436
14.3
4
0.75
203
3.3
-0.83
84
45

INLET PR
kg/Sq.cm
INLET TEMP
C
OUT LET PR. kg/Sq.cm
OUT LET TEMP
C
STEAM INLET PR. kg/Sq.cm
INLET TEMP
C
VACCUM PR. kg/Sq.cm
LUBE OIL
kg/Sq.cm
CONTROL OIL kg/Sq.cm
D.P ACROSS FILTER kg/Sq.cm

1.6
19
1.3
28
10
330
-0.85
2.1
14
0.1

ROTOR

65.8
82.1
69.1
56.6
51.2
46.2
65
67
45
32

FORE
AFTER
FORE
AFTER
FORE
AFTER
DE
NDE

PINION
GEAR
ALTERNATER
COOLER OIL TEMP.

6822

INLET
OUT LET

C
C

COMPARISION OF SPECIFIC STEAM

CONSUMPTION
OF MACHINE AT SITE WITH RESPECT TO
PERFORMANCE CURVE

ACTUAL STEAM CONSUMPTION

PARAMETERS

Inlet steam
pressure.

Kg/sq.C
m

Inlet steam
temperature

Exhaust steam
pressure

Kg/sq.C
m

Turbine speed

Rpm

Electrical load

Mw

Total power consumption

Kwh

Total steam consumption

Kg

PROJECTED
VALUES

AVERAGE
VALUE

Correction factors

SL
NO

UNITS

Inlet steam
pressure
Inlet steam
temperature
Exhaust steam
pressure
Turbine speed
Age factor

STEAM CONSUMPTION*CORRECTION FACTORS(A,B,C,D)*AGE FACTOR

SSC =
SSC =

POWER GENERATION

Kg/kwh

Example: FR 1

ACTUAL STEAM CONSUMPTION

Sl
no

parameters

Projected
values

Average
value

units

Inlet steam pressure.

66

57

Kg/sq.Cm

Inlet steam temperature

490

502

Degc

Exhaust steam pressure

1.54

0.8

Kg/sq.Cm

Turbine speed

7055

6693

Electrical load

15

12.5

Total power consumption

25000

Kwh

Total steam consumption

165000

Kg

SSC =

Correction factors
Inlet steam
pressure

0.9

Inlet steam
temperature

1.0

Rpm

Exhaust steam
pressure

1.0

Mw

Turbine speed

0.965

Age factor

1.0

STEAM CONSUMPTION*CORRECTION FACTORS(A,B,C,D)*AGE FACTOR

POWER GENERATION

ACTUAL SSC = 5.73 kg/kWH at average load of 12.5 mw

PROJECTED SSC = 6.17 kg/kWH at average load of 12.5 mw

PROBLEM FACED IN SITE

SITE:SUBBURAJ PAPERS
Dump was found 0.37 instead of 0.75
Cause: High points in the nozzle chest seam welding.
Corrective action: The seam welding in the nozzle chest was blue matched with the shrouding of
moving blade and some high point was found in welding. welding high points were corrected by
filing and finally dump was achieved.
CEP was consuming more than rated current
Cause: Misalignment of pump and motor