DUYEN HAI 3 THERMAL POWER PROJECT

COMMISSIONING PROCEDURE

For
0 2016-5-11
Construction
Li bin Hu zhangwei Pu xiaoqin Guo Baodong

B For Approval 2016-4-17 Li bin Hu zhangwei Pu xiaoqin

A For Approval 2015.12.16 Li bin Hu zhangwei Pu xiaoqin
REV DESCRIPTION DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

OWNER
VIETNAM ELECTRICITY
THERMAL POWER PROJECT MANAGEMENT BOARD 3

CONSULTANT
POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 3

CONTRACTOR
THE CONSORTIUM OF CHENGDA-DEC-SWEPDI-ZEPC

SUBCONTRACTOR
THE COMMISSIONING & TEST INSTITUTE OF SICHUAN ELECTRIC
SECTI POWER INDUSTRY

CONTRACT No.
PROJECT DUYEN HAI 3 THERMAL POWER PROJECT
DH3-05082011

FILE NAME Commissioning procedure of complete-set startup of steam turbine

FILE CONTROL No. DH3-31MA-T-SCT-0001

FILE No. SECTI-TS-QJ-CS-001-2014D REV: 0

 CHENGDA-DEC-SWEPDI-ZEPC

Contents
1. Objective of commissioning...................................................................................................... 3
2. Content of Commissioning........................................................................................................ 3
3. Compilation Basis ..................................................................................................................... 3
4. Tools and Instruments ............................................................................................................... 4
5. Conditions to be met prior to Commissioning .......................................................................... 4
6. Commissioning Procedure ........................................................................................................ 5
7. Safety measures ....................................................................................................................... 16
8. Appendix ................................................................................................................................. 19
 CHENGDA-DEC-SWEPDI-ZEPC

1. Objective of commissioning

1.1 The commissioning is intended to test the correctness and reliability of function of the
control system via startup commissioning of unit.
1.2 It is intended to inspect whether the operation parameters of main equipment and
auxiliary equipment meets the rated output and meets the design requirement.
1.3 It is intended to complete the test that must be carried out during dynamic operation
of the unit such as overspeed test, vacuum tightness test, load rejection test, etc.
1.4 It is intended to examine the quality of construction, design and equipment.
To check the stability of operation of steam turbine generator set via continuous full-load
operation; to check the correctness of control system function and reliability of protection
system, to check whether the main and auxiliary system is optimized, the operation of the
equipment is well-performed, the parameters meet the design and manufacture
requirement and meet continuous operation demand of the steam turbine generator set.

2. Content of Commissioning

2.1 The steam turbine start for the first time

2.1 No-load Commissioning of Steam Turbine
2.2 On-load Commissioning of Steam Turbine
2.3 Reliability Commissioning of Generator Set of Steam Turbine

3. Compilation Basis

3.1 Manufacturer’s manual and instruction

3.2 Design drawing
DH3-31(32)LA-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LBG-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LB-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LB-M-SWE-1009（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LCH-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LCJ-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LC-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)LCT-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)MAJ-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)MAV-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)MAV-M-SWE-1002（Letter No. DH3-CS-A3-M-15-0445）

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DH3-31(32)MAX-I-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）

DH3-31(32)MKF-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)MKG-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)MKW-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)PAB-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)PCB-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-31(32)PGA-M-SWE-1001（Letter No. DH3-CS-A3-M-15-0445）
DH3-39PA-M-SWE-1002（Letter No. DH3-CS-A3-M-15-0450）
DH3-39PA-M-SWE-1101（Letter No. DH3-CS-A3-M-15-0450）

4. Tools and Instruments

4.1 Portable digital vibration meter

4.2 Infrared thermometer
All tools and instrument/equipment shall be calibrated and the calibration certificate shall
be separately submitted to O/E for information.

5. Conditions to be met prior to Commissioning

5.1 The installation work is over and the commissioning team agreed to accept the
system to start commissioning.
5.2 A Punch list covers all defects or unfinished works are confirmed by the
Owner/Engineer and the Commissioning Team that the defects or unfinished works
do not affect the Commissioning and normal operation of apparatus.
5.3 Work permit system is in working.
5.4 Safety isolation measures are implement.
5.5 All the equipment, instruments, valves have been officially tagged /labeled and
medium type and flow direction have been indicated on the pipelines.
5.6 Operation department is ready for the unit startup, operating manual and related
regulations and record forms are ready, and operation tools are ready.
5.7 Correct system drawing and curve for startup of unit have been hung on the
commissioning site.
5.8 The grid and switch yard is available.
5.9 Service power supply system works properly, UPS, DC supply are reliable and
diesel generator system is in standby state.
5.10 Firefighting system and equipment in the commissioning site has passed the
examination and ready for service. The local site must be equipped with enough
and suitable fire extinguisher , firefighting water pool/tank must be fulfilled.
Firefighting trucks and firemen are on duty. Safeguard personnel are located in

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necessary area.
5.11 Fresh water and demineralized water is well prepared.
5.12 Domestic water supply is normal and air conditioner, ventilation system and sanitary
fixtures can work properly.
5.13 Steam blowing for boiler and turbine system is completed, all temporary system is
removed.
5.14 B-T-G interlock test is completed.
5.15 Equipment and systems required for the unit startup are commissioned and ready
for service, including but not limited to the following :

1) Circulating water system

2) Open cooling water system
3) Closed cooling water system
4) Condensate system
5) Motor-driven feedwater pump and deaerator system
6) Steam extraction and regeneration system
7) Steam turbine lube oil system
8) Jacking oil system and turning gear
9) EH oil system
10) Condenser rubber ball cleaning system
11) Generator stator cooling water system
12) Generator hydrogen system
13) Auxiliary steam system
14) Gland seal system
15) Bypass system

6. Commissioning Procedure

6.1 Initial startup of steam turbine

6.1.1 Division of start-up status of the turbine
The division of start-up status of the turbine depends on the metal temperature of the
upper inner wall (at the regulation stage) of the HP inner casing before start-up, and
details are shown as follows:
Cold start: t≤240℃ Speed up rate: 100r/min/min
Warm start: t=240～360℃ Speed up rate: 200r/min/min
Hot start: t=360～480℃ Speed up rate: 300r/min/min
Extremely hot start: t≥480℃ Speed up rate: 300r/min/min

6.1.2 Initial startup mode of steam turbine

Cold-state IP casing (IP) impulse starting is applied for initial start-up of the turbine, and

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the control valve is in the mode of “single valve control”.

Preparation before start-up of the turbine:
（1） Check the system according to operating instructions before start-up, check
power transmission of related I&C and electrical equipment, check I&C and
electrical control, protection and monitoring system for normal operation.
（2） Check the status of all system valves and make sure that they are in the
specified status.
（3） Start up the circulating water system, open cooling water system, closed
cooling water system, compressed air system and other utility systems.
（4） Supply steam to the auxiliary steam header for warming, and maintain the
pressure of the auxiliary steam header at 0.8MPa after warming.
（5） Feed the condenser with water to normal level, start up the condensate pump,
fill water to the deaerator; maintain the normal water level in the deaerator,
use auxiliary steam to heat the feed water tank.
（6） Start up the AC lube oil pump TOP and AC startup oil pump MSP, check the
lube oil pressure, inlet oil pressure of main oil pump, oil temperature and oil
level of fuel tank; start up the smoke exhaust fan.
（7） Start up the generator sealing oil system.
（8） Start up the jacking oil pump, check its oil pressure, and then start up the
turning gear, check the turning gear current and mechanical eccentricity of
the rotor, which must not exceed the original value 0.02mm.
（9） Check for abnormal noise of the turbine generator.
（10） Carry out the generator gas replacement, and maintain the generator
hydrogen pressure at 0.25MPa.
（11） Start up the EH oil pump, check the fire-resistant oil pressure at 11.2MPa, oil
temperature and level of the oil tank.
（12） Start up the stator cooling water system, adjust the stator inlet water pressure
to 0.18-0.2MPa and the flow rate to 102t/h.
（13） Start up the motor-driven feedwater pump to fill the boiler with water as
required.
（14） Close the vacuum breaking valve, start up the vacuum pump and vacuumize
the condenser. Notify to ignite the boiler when the vacuum is at -27KPa.
（15） The main pipe of shaft seal feeds steam to it after warming, the shaft seal fan
is started to maintain the pressure in steam seal header at 0.123MPa and
temperature of it within 150~260°C; temperature of the LP shaft seal is not
more than 160°C, and desuperheating water must be fed if necessary.
（16） Start HP and LP bypass systems for operation as required by the boiler.
（17） Check the opening position of each drain valve, warming of the main steam
system and reheat steam system, make records of metal temperature rise
and difference in temperature of casing, steam pipe and valve as well as
expansion, differential expansion, axial shift changes of the unit.
6.1.3 HP casing pre-warming
When the condenser vacuum does not exceed 13.3Kpa, conduct the pre-warming of the

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HP casing. When the metal temperature of inner wall of the upper half casing in the first
stage of the turbine HP casing exceed 150°C, close the HP casing pre-warming valve,
stop the HP casing pre-warming, and maintain it according to the time requirement.
During the HP casing pre-warming, monitor the turbine speed and the running conditions
of turning gear. In case of the turning gear tripping and turbine speed rise, immediately
close the pre-warming valve, and decrease the HP casing’s pre-warming pressure. After
the turbine speed is decreased and the rotor stops, put the turning gear into service again.

6.1.4 CV pre-warming
Trip the turbine. On the “CV WARMING” screen of DEH, press “ON” to confirm the
pre-start valve of the HP main steam valve (right) is opened. When the metal temperature
difference between inner and outer casings of CV valve is higher than 80°C, close the
pre-start valve of the HP main steam valve (right). When the temperature difference is
lower than 70°C, open the pre-start valve again. Repeat these actions for pre-warming the
HP regulating valve. When the metal temperature of inner and outer casings of HP
regulating valve exceeds 180°C, press “OFF” under “CV WARMING” to end the
pre-warming of HP regulating valve, and confirm the left and right main steam valves are
fully opened.

6.1.5 Check the impulse starting parameters of steam turbine

Cold startup parameters of steam turbine are as follows:
(1) Main steam pressure P0=6MPa;
(2) Main steam temperature t0=335℃;
(3) Reheated steam pressure PR=1.1MPa;
(4) Reheated steam temperature tr=320℃;
(5) Vacuum Pv of condenser = above -0.08MPa;
(6) Lube oil pressure: 0.14~0.18MPa; oil temperature: 35~40℃;
(7) EH oil pressure: 11.2MPa; oil temperature: 35~50℃;
(8) Temperature difference between upper and lower cylinder: <40℃.

6.1.6 Impulse starting of the turbine

（1） Select the IP casing start-up on DEH screen.
（2） Start the impulse starting and complete the friction inspection.
（3） After the valve friction inspection, raise the speed to 1500rpm for
warming if there is no abnormality.
 When raising the speed to 1500r/min for warming at medium speed,
conduct the following inspections:
 Check indications of all monitoring instruments, and make sure
there is no warning signal.
 Check the bearing vibration, temperature of metal bearing bush
and also the bearing return oil temperature.
 Check the pressure of lube oil.
 Check the exhaust temperature of the LP casings and the

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actuation of desuperheating water valve.

 Make sure that the expansion indications at both sides of casings
are even, and that the differential expansion and axial
displacement are normal.
 Check the parameters of main steam and reheat steam.
 Confirm the temperature difference of upper and lower casings,
and various temperature differences at different places shall be
within the required range.
 Check all operating parameters of auxiliary system.
 Check gland sealing steam pressure and temperature.
 During the warming period, maintain the stability of main and reheat
steam pressure and temperature. To properly improve the warming
effect, increase the reheat steam appropriately (＞350℃) and pay
attention to the variation tendency of steam casing expansion, HP
expansion, LP expansion, axial displacement, temperature difference
between upper and lower casings as well as the thermal stress of rotor.
Pay attention to the lube oil temperature that rises slowly to about 38℃
and is set automatically to 40℃; check the metal temperature of
bearings and the return oil temperature. Check the operation of all
auxiliary machines. Fully record the operating parameters of the unit.
 Pay attention to monitoring the metal temperature at exhaust positions of
HP and IP casings; when the metal temperature of inner wall of HP
exhaust casing reaches 250℃, adjust the opening of manual valve
behind the VV valve to control the metal temperature of HP exhaust
casing at about 250℃. When both the inner wall temperature at the
adjustment stage of HP casing and the steam inlet chamber
temperature of IP casing are above 320℃ or the warming time exceeds
4 hours under the impulse starting parameters of steam turbine, stop
the intermediate-speed warming.
（4） Run up to 3000rpm for high-speed warming
 After completing the intermediate-speed warming, select the TARGET
SPEED at 3000r/min and the speed-up rate at 100r/min, continue
enlarging the opening of IP regulating valve and raising the speed of
steam turbine.
 When speed rising passes the critical speed area at an increasing speed,
pay close attention to the vibration of the unit, and the speed of the unit
is prohibited to stay within the critical area. Carry out the emergency
shutdown when any shaft vibration exceeds 250μm.
 Check the metal temperature of each bearing and the return oil
temperature.
 Stop the jacking oil pump when the speed reaches 2000r/min.
 Carry out the oil impeller adjustment when the speed is between
2500r/min and 3000r/min.

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 When the speed of the unit reaches 3000rpm, make sure the normal
operation of main oil pump, the inlet pressure of 0.098～0.147MPa and
the outlet oil pressure above 1.372MPa.
 Carry out self-start test of emergency oil pump, startup oil pump and
auxiliary oil pump. After the test, stop the startup oil pump and auxiliary
oil pump, monitor the inlet and outlet oil pressures of main oil pump; put
the emergency oil pump, startup oil pump and auxiliary oil pump into
standby state.
 Conduct the manual tripping at the site, make sure normal closure of HP
and IP main steam valves and regulating valves, speed reduction of the
unit and normal output; reset and raise the speed to 3000rpm.
（5） Precautions during impulse starting:
 During impulse starting and warming of steam turbine, try to keep stable
steam pressure, water level and other parameters.
 Not stay within the critical speed area during speed rising.
 In case of large shaft vibration under low speed, implement the tripping
for shutdown, rather than speed reduction and warming.
 Pay attention to checking whether steam turbine proper and pipes are
impacted by water or have abnormal vibration, and whether the drain
system of steam turbine is normal.
 Pay attention to monitoring the thermal expansion of steam casing,
differential expansion, axial displacement, temperature difference
between upper and lower casings as well as between inner and outer
casings, bearing vibration and temperature.
 Check the lube oil pressure and temperature, oil level in fuel tank,
generator hydrogen pressure and temperature, sealing oil pressure,
and hydrogen/oil pressure difference of sealing oil.
 Pay attention to the vacuum and water level of condenser, change in
water level of HP and LP heater and deaerator.
 Pay attention to the change in LP casing exhaust temperature and
actuation of LP casing spraying.
 Pay attention to the operation condition of bypass and auxiliary
machines.

6.2 Test of turbine at no-load

(1) Oil injection test of emergency trip device
(2) HP trip module (HPT/ETS HPT) solenoid online test
(3) Overspeed limiting module (OPC) solenoid online test
After completion of no-load test of turbine, the unit shall be operated at the
constant speed of 3000r/min and handed over to the electric discipline for test.
Note: During the electric test, the false synchronization signal shall not be sent to
DEH. Or else it will lead to overspeed of the unit.

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6.3 Synchronization with initial load

（1）After the electrical test is completed, coordinate the electrical synchronization
with 3% (18MW) initial load. Warm the machine with initial load, and keep the warming for
30 minutes. According to the demand, raise the hydrogen pressure to 0.35MPa. Based on
hydrogen temperature, cooling water temperature and lubricating oil temperature , adjust
the valves of each hydrogen cooler to keep proper hydrogen temperature.
（2）Before switching of the casing, keep the steam temperature and pressure
stable, to avoid the over-stress of HP casing, HP exhaust over-temperature, and large
load fluctuation due to switching of the casing.
（3）After finishing the warming at initial load, set the total opening of valve at 20%,
raise the load at 3MW/min load rise rate until the RCV valve is close to full opening, close
the LP bypass gradually, and close the BDV valve. When the total opening of valve is
close to 20%, increase the total valve opening setting, and set the load rise rate at
30MW/min. DEH switches to the HP casing automatically; open the CV valve gradually,
and close the VV valve; the HP regulating valve controls the unit load; turn down the HP
bypass gradually, and open the HP exhaust check valve. It means the casing switching is
completed.
（4）Precautions for turbine casing switching process:
 During switching of the casing, adjust the boiler combustion and bypass
operation well, and keep the main steam pressure parameter of turbine
stable as far as possible.
 Adjust the deviation between main steam temperature and HP casing metal
temperature, and make sure that the thermal stress at the HP casing body
and the first stage of HP casing after the HP casing admission is within an
allowable small range. .
 During switching of the casing, operate the HP and LP bypasses
automatically, and monitor the bypass action closely, so as to guarantee the
HP casing steam inlet flow during casing inversion. Monitor the HP casing
exhaust temperature and the opening conditions of HP exhaust check valve
during switching of the casing.
 Keep the boiler parameters stable, and pay attention to the water tank’s
level.
 During casing switching, open the HP regulating valve slowly. When the HP
exhaust pressure exceeds the reheat pressure, release the HP exhaust
check valve freely, put the HP casing into service automatically, and pay
attention to the change in exhaust temperature.
 After the HP casing is put into service, when the exhaust temperature of the
HP casing increases excessively, notify to improve the combustion of boiler,
and increase the unit load appropriately. In the process of switching, in case
that the HP exhaust temperature exceeds the limits and the HP exhaust
check valve cannot be opened, trip the machine.
(5) Raise the unit load to 20% for warming.
 After HP casing switching, set the target load at 120MW and the load rise

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rate as 3MW/min. Raise the load to 20% MCR for four-hour warming.
 When the load is increased to 10%, check that the LP casing spraying is
closed automatically. Pay attention to the checking that the HP section drain
valve is closed.
 Depending on the circumstances, put DEH into the power control loop.
 In case of unit load ≥20%, do the following works:
 Check that the drain valves of main and reheat steam pipes for the turbine
are closed automatically.
 Check that the drain valves of turbine proper and steam extraction pipes are
closed automatically.
 Put the steam side of the HP heater into operation, and pay attention to the
feed water temperature and feed water flow change. After the HP heater
is put into operation normally, close the drain valve of steam extraction
pipe.
 Check that the casing spraying control valve after the LP casing is closed
automatically, and pay attention to the exhaust temperature.
 When the 4th stage steam extraction pressure is higher than the setting
pressure of deaerator (0.2MPa), switch the steam source of deaerator to
the 4th stage extraction steam supply automatically, interlock and close the
control valves from auxiliary steam header to the deaerator, and operate
the deaerator at the sliding pressure.
 After warming, it is required to decrease the load, and it is out of
synchronization before the turbine over-speed test.

6.4 Overspeed Test

6.4.1 Preparation before Test
（1） Ensure that turbine-generator is de-synchronized from the grid and
running at rated speed with no load.
（2） Check each parameter of the main body of steam turbine including
vibration, axial shift and differential expansion etc.
（3） Check the pressure and temperature of lube oil.
（4） Start the AC lube oil pump before over-speed test.
（5） Oil injection test for emergency governor shall be carried out two hours
or more before the over-speed test.
（6） Complete the tightness test of turbine admission valves(MSV, CV, RSV,
RCV).
Operate at DEH control panel to close the MSV/RSV or CV/RCV and keep
the other valves open, monitor the turbine speed “n” shall meet the
following requirements.

Leak test calculation method: n < =（P/P0）×1000r/min

P— Main steam pressure at the moment of testing (MPa) shall >= 1/2 P0
P0— Rated main steam pressure (16.67MPa)

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Note: During the test, main steam pressure shall ＞50% rated main steam pressure;

6.4.2 Mechanical Overspeed Test

（1） Temporarily adjust the electric over-speed protection settings as 3360r/min.
（2） Access the mechanical over-speed test program on DEH, set the target valve
at 3360r/min and the speed up rate at 150r/min, and enhance the speed
slowly.
（3） The emergency overspeed governor shall actuate within 3270~3360r/min;
after its actuation, trip and maintain the speed of turbine at 3000r/min when its
speed reduces below 3000r/min. Then, conduct mechanical over-speed test
for the second time, the difference of operating values of the two tests shall
not exceed 18r/min.
（4） If the emergency overspeed governor does not actuate, conduct the
mechanical over-speed test again after shutdown for adjustment.
（5） Recover the electric over-speed protection value to 3300r/min at the
completion of test.
6.4.3 Electric Overspeed Test
（1） Electric overspeed includes TSI over-speed and DEH over-speed that are
conducted separately.
（2） Access the electric over-speed test program on DEH, check and test the
actuation of isolating valve. Set the target value at 3300r/min and the
speed-up rate at 150r/min, and raise the speed slowly.
（3） The electric over-speed protection actuates and the turbine trips when the
speed is up to 3300r/min.
（4） Trip and maintain the speed at 3000r/min for operation when speed of the
turbine reduces below 3000r/min.
（5） Exit the test program on DEH after test.

6.5 Hot start of steam turbine

6.5.1 For the turbine start-up curve under various start-up modes, see the appendix. The
impulse starting parameters, steam temperature and pressure rise rates, speed rise rate,
load rise rate, and warming time of each stage shall conform to the corresponding start-up
curves.
6.5.2 Hot start shall strictly observe the control startup parameters of hot start curve, and it
is required to pay attention to the following points:
（1） The parameters of main and reheat steam reach the impulse starting
parameters; the temperature of main and reheat steam is over 50°C higher than
the metal temperature of the upper half casing in the first stage of HP and IP
casings, and the overheat exceeds 50°C.
（2） The control change control range of main and reheat steam shall
correspond to the metal temperature as per the curve provided by the
manufacturer.
（3） Before start-up of the unit, check that the HP exhaust check valve is closed,

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the motorized valve for pre-warming the HP casing is closed, and the vent valve
of the HP casing is opened.
（4） In the hot start, conduct shaft sealing before vacuum pumping. Pay attention
that the shaft seal temperature shall match the turbine metal temperature.
（5） In the hot start, check that the shaking degree of main shaft conforms to the
requirement and the condenser shall keep a high vacuum degree.
（6） Check and confirm that the drain valves of body, main and reheat steam
pipes are opened, and the main and reheat steam pipes are drained adequately.
（7） Before start-up of the unit, make all preparations for impulse starting and
speed rise as soon as possible. After necessary inspection at the constant speed
is OK, conduct synchronization with load as soon as possible to the load level
corresponding to the metal temperature of inner wall of the upper half casing in
the first stage of the turbine HP casing.
（8） Set the target speed at 3000r/min directly before impulse starting of the unit.
（9） In the process of start-up and speed rise, the shaft seal pressure and the
shaft seal temperature after desuperheating shall be normal.
（10） In the process of speed rise and load rise, strengthen the monitoring of unit
vibration, keep an eye on the changes in differential expansion, casing
expansion, axial displacement, main and reheat steam temperature, as well as
the changes in the metal temperature and temperature rise of HP and IP
casings.
（11） In case of idling of the turbine upon resetting, it is required to confirm that the
turbine speed is not within the range of critical speeds.
（12） Before impulse starting of the unit, the lube oil temperature of generators is
above 35°C, and the impulse starting is prohibited when the oil temperature is
less than 30°C.
（13） During impulse starting and speed rise of the turbine, start the first
steam-driven feed water pump, and make sure that the steam-driven feed water
pump can be connected to the feed water system timely during load rise.
（14） Other operation and inspection items are the same as the cold start.

6.6 On-load trial run of the unit

6.6.1 After constant speed of the steam turbine is actuated in hot-state (cold-state) mode,
the electric synchronization is switched to be on-load.
6.6.2 Initial load to 30% rated load
（1） After finishing the warming at initial load, select an appropriate run-up rate;
set the target load at 180MW, and start to raise the load of the unit.
（2） Conduct the HP casing switching when the load is raised to 9% rated load.
（3） When the load is raised to 10% rated load, make sure that the LP casing
spraying is automatically closed; put the steam side of LP heater into service.
（4） When the load is raided to 15% rated load, put the steam side of HP heater
into service. Actuate the steam extraction and drain protection. Make sure that
the HP drain valves are closed; check the HP and LP bypasses and set their

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desuperheating water into automatic mode. Switch the steam source of

deaerator to stage-4 steam extraction when the pressure of stage-4 steam
extraction is above 0.15MPa.
（5） Conduct the impulse starting of the first steam-driven feed water pump.
（6） When the load is raised to 20% rated load, make sure that IP and LP drain
valves are closed; connect the first steam-driven feed water pump to the feed
water system.
（7） Conduct the warming for 30 minutes after the load is raised to 30% rated
load.
6.6.3 Run up to 50% rated load
（1） Conduct the impulse starting of the second steam-driven feed water pump
when the load is raised to 40% rated load.
（2） When the load is raised to 45% rated load, the unit gets into sliding pressure
operation; raise the main steam pressure and temperature as well as reheat
steam temperature according to the sliding pressure curve.
（3） Conduct the warming for 30 minutes after the load is raised to 50% rated
load.
（4） During the load raising of the unit, start up the second circulating water
pump according to the situation.
6.6.4 Run up to 100% rated load
（1） When the load is raised to 60% rated load, connect the second steam-driven
feed water pump to the feed water system, stop the motor-driven feedwater
pump and put it into hot standby state.
（2） When the load of the unit is above 80% rated load, the vacuum leak test can
be conducted.
（3） When the load is raised to 90% rated load, the unit gets into fixed pressure
operation from sliding pressure operation; the main steam pressure and
temperature as well as reheat steam temperature reach the rated values. With
slow increase in boiler burning capacity, gradually increase the load of steam
turbine until it reaches the full load.
6.6.5 Precautions during load raising of the unit:
（1） Pay attention to the changes in lube oil pressure, lube oil temperature and
oil level in fuel tank.
（2） Pay attention to monitoring the changes in casing expansion, HP differential
expansion, LP differential expansion, axial displacement, shaft vibration, bearing
temperature, bearing return oil temperature.
（3） Pay attention to monitoring the operation condition of generator sealing oil
system, hydrogen system and stator cooling water system.
（4） Strengthen the equipment inspection and timely report and handle any
abnormality.

6.6.5 Tests during on-load stage of the unit

（1）

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Vacuum leak test

When load of the unit is above 80% (498MW), conduct leak test for vacuum
system of the turbine, the method of which is shown as follows:
1) Temporarily release low vacuum protection; temporarily release the standby
status of standby vacuum pump.
2) Close the manual valve at the inlet of vacuum pump and stop the vacuum
pump after it is closed to place.
3) Record vacuum value of the condenser at 30s interval for 8min.
4) After data recording, immediately recover the operation of vacuum pump,
implement the low vacuum protection and the standby status of the
vacuum pump when the vacuum value recovers to that before the test.
5) Calculate the vacuum reduction rate:
The vacuum reduction rate shall be calculated according to vacuum data of
the last five minutes, and it is qualified if less than 200Pa/min.
（2） Hydrogen Leakage Test of Generator
Refer to Commissioning procedure of hydrogen system of generator
DH3-31MKG-T-SCT-0015
（3） Load change test
Refer to Commissioning procedure of varying load of turbine-generator
DH3-31MA-T-SCT-0018
（4） Load Rejection Test
Refer to Commissioning procedure of load rejection test
DH3-31MA-T-SCT-0019
（5） Island operation test
Conduct the operation based on the Island Operation Test Program.
（6） RB test
Conduct it based on RB Test Program.
（7） AGC test
Conduct it based on AGC Test Program.
（8） Primary frequency modulation test
Conduct it based on the Primary Frequency Modulation Test Program.

6.6.6 Load Up to Full Load of Unit

After the unit has rated load, fully inspect the operation status of the main and
auxiliary unit and record the operation parameters.

6.7 Reliability Running of Unit

Implement the 30-day reliability running (RR). During the reliability running, carry out
96-hour continuous full-load (622MW) operation, and implement the running under the
load required by the dispatcher at the rest of the time.

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7. Safety measures

7.1 Rules on Commissioning Safety

7.1.1 Personnel participating in commissioning shall beware of and abide by relevant
safety system of the site, be in reasonable clothing and wear suitable safety protection
articles, and use qualified tools and machines.
7.1.2 Before commissioning work, the commissioning personnel will make technical
and safety clarification to other personnel involved in commissioning to enable them to
beware of the objective, steps and possible risks in the work and precautions that can be
adopted.
7.1.3 Power failure and transmission for equipment must be made in written
communication for operators to signing for confirmation of power failure and transmission
work is completed before commissioning.
7.1.4 Hang warning boards for equipment of which operation is prohibited such as
valves, electric switches, buttons, and when necessary adopt mechanic measures for
locking.
7.1.5 If equipment damage or personnel injury accidents have or might to be occurred
in working, stop working immediately and put the equipment in minimum energy status
and analyze the reasons and put forward resolution measures.
7.1.6 Each party participating in commissioning shall follow the commissioning
personnel, and in case of emergency that endangers personal or equipment safety, any
person has the right to immediately stop the running equipment and report immediately to
the control room.
7.1.7 Any personnel working at site shall follow the Lock Out/Tag Out (LOTO) and Permit
To Work regulations. Un-authorized activity is strictly prohibited

7.2 Measures for Personal Risk Prevention

7.2.1 Prevent scald due to accidental leakage of high temperature radiation, water or
steam.
7.2.2 Keep away as far from the operation equipment with dust and harmful chemical
gases as possible, to prevent personal injury.
7.2.3 At places adjacent to rotating equipment, it shall be prevented the human body,
tools, or other articles from being involved in.
7.2.4 Qualified electric equipment should be used to prevent personal injuries and
equipment damage.
7.2.5 Protective helmet and safety belt shall be correctly worn to prevent from personal
injury accidents.
7.2.6 Safety protection facilities shall be well prepared for working at height and on
platforms.
7.2.7 Protective helmet and safety harness must be properly used for work on

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temporary platform or scaffold.

7.2.8 Operation with naked fire shall be prohibited in the vicinity of various oil
equipment and systems.
7.2.9 Basic fire safety training shall be performed for application of basic
fire-extinguishing equipment.
7.3 Safety Precautions for Startup of Whole Unit
7.3.1 At the time of air replacement of the generator, operation of the valve shall be
carried out with copper tools, to prevent sparks. Isolation area and warning board shall be
provided in the plant building of the steam turbine.
7.3.2 At the time of running up of the steam turbine, turning gear shall be monitored
whether it can be released normally. Otherwise, the unit shall be shut down immediately
for handling.
7.3.3 Before running up of steam turbine and after shutdown, mechanical eccentricity
meter shall be checked to confirm that bending does not occur to the rotor.
7.3.4 At the time of running up of the steam turbine, vibration shall be monitored. In
case of abnormal change of vibration, speedup shall be ceased for inspection and
analysis.
7.3.5 At the time of running up and operation of the steam turbine, lube oil temperature
shall be adjusted.
7.3.6 When the steam side of the heater is put into operation, the valve shall be
opened gradually and warming shall be carried out on pipes to avoid protection action due
to abnormal variation of water level of heater.
7.3.7 For overspeed test and load rejection test, personnel shall be designated at the
bearing box in front of the steam turbine, to facilitate manual trip operation in case of
emergency.
7.3.8 Operator and installation unit shall pay attention to monitoring of the system and
equipment. In case of any abnormality, they shall report to the control room in a timely
manner. In case of emergency, measures may be taken to cease the operation of the
faulted equipment and system.
7.3.9 When an accident occurs during commissioning, the commissioning personnel
and the operation personnel on duty shall quickly judge and find out the cause of the
accident, and correctly and decisively deal with it, so as to ensure the safety of person and
equipment and the operation safety of non-faulty equipment.

7.4 HAZID/HAZOP
Potential
Num Activity Potential Hazard Result Prevention Measure
Hazard Factor
Wear proper work clothes and keep the safe
High distance with high temperature object. If

1 Site work temperature Personnel scald need to contact with high temperature object,
object surface wear heat insulated gloves or protective
equipment.

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Wear proper work clothes, keep the safe

High
distance with the discharge , if necessary to
temperature
2 Site work Personnel scald work in the vicinity of the equipment, avoid
water, steam
standing on the side of the flange or the front
accident leakage
of the discharge.
Check the protective device of rotating parts
is in position, and keep safe distance with the
Contact rotating
3 Site work Mechanical injury rotating equipment, if need to work in the
device
vicinity of the rotating equipment, to avoid
clothes or hair to be involved
Check the pressure indicating instrument in
good condition and in service, pressure relief

Pressure device is reliable, maintain the

4 Site work protection Mechanical injury communication when working, when the

device failure pressure exceeds the limit, immediately stop

working and take measures to pressure
release.
Understand the voltage level of the work
area and equipment before work, check the
isolation measures correctly and reliably,
Insufficient
Electric shock wear suitable working clothes and shoes,
5 Site work distance with
casualties keep the safe distance with the energized
energized object
object. Reliable measure for de-energizing is
required for the work on the energized object
and the detection and confirmation is needed.
Safety helmet must be worn during
commissioning at site; Within special area,
Falling objects Injury due to falling
6 Site work provide alert symbols, warning board and
objects
from high fencing; operation personnel must wear
safety protection appliances as required.
Prepare strict fire control measures;
sufficient fire apparatus must be provided at
7 Site work Fire Fire hazard
site; smoking while moving around is
prohibited; Work out measures properly.
Remove oil or rubbishes from the ground.
Slip, fall leading to fall
8 Site work Ground oil dirt Equipment and instrument for operation shall
or hit injury
be placed neatly and orderly.

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Hydrogen leak device monitors in good

condition and input, pressure relief device,
Hydrogen reliable and keep communication flowing at
9 Site work Fire hazard
leakage work, it is strictly prohibited to fireworks,
leak detection immediately evacuate,
discharge of hydrogen in the air.

8. Appendix

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8.1 Cold startup (long term shutdown )-IP turbine startup

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8.2 Cold startup (72h shutdown )-IP turbine startup

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8.3 Warm startup (48h shutdown )-IP turbine startup

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8.4 Hot startup (8h shutdown )-IP turbine startup

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8.5 Hot startup (1h shutdown )-IP turbine startup

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