Proper Steam Turbine Operation

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Determining Whether Steam

Turbines Are Properly Operated
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
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domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Rotating Equipment For additional information on this subject, contact

File Reference: MEX21306 Darryl Turner on 873-4120
Engineering Encyclopedia Rotating Equipment
Determining Whether Steam Turbines Are Properly Operated
Content Page
INTRODUCTION................................................................................................................ 1
OPERATIONAL SAFETY AND RELIABILITY ISSUES................................................... 2

Water Induction ........................................................................................................ 2
Turbine Damage from Water Induction .......................................................... 2
Sources of Water and Preventive Procedures ................................................. 4
Steam Traps and High-Pressure Drain System................................................ 8
Thermal Effects and Preventive Procedures ....................................................................... 9
BASIS OF INITIAL CONDITIONS REQUIRED FOR STARTUP.....................................13
Valve Line-Ups ................................................................................................................13
Lubrication System Status ................................................................................................14
Condenser, Hotwell, and Cooling Water Status on Condensing Turbines ..........................15
Control Air System Status ................................................................................................16
Turing Gear Operation .....................................................................................................16
Driven Machine Status .....................................................................................................16
BASIS OF SEQUENTIAL STEPS FOR TURBINE STARTUP..........................................18
Pressurizing Piping ...........................................................................................................18
Backpressure Turbine Exhaust Warmup ...........................................................................19
Extraction Turbine Extraction Line Warmup.....................................................................19
Auxiliary Steam Startup....................................................................................................19
Turbine Warmup to Operating Speed................................................................................20
Turbine Radial Shaft Vibration......................................................................20
Critical Speeds..............................................................................................21
Placing the Turbine on the Governor ................................................................................22
Placing a Backpressure Turbine Exhaust in Service...........................................................23
Placing an Extraction Line in Service................................................................................23
BASIS OF SEQUENTIAL STEPS FOR NORMAL TURBINE SHUTDOWN....................24
BASIS OF SEQUENTIAL STEPS FOR EMERGENCY TURBINE SHUTDOWN

(ESD) ..................................................................................................................................26

GLOSSARY........................................................................................................................27

Table of Figures Page
Figure 1. Effect of Thermal Expansion on Rotor and Case Configurations ...............10

Figure 2. Typical Steam Turbine Startup Map..........................................................22

INTRODUCTION
Proper operation of a steam turbine and steam turbine systems is essential to turbine safety and
reliability, the limitation of process downtime, and the minimizing of unplanned maintenance.
Steam turbine operating procedures ensure that turbine startup, operation and shutdown are
properly performed. Many aspects of safe and reliable steam turbine operation are considered
during the steam turbine and the steam turbine support systems design stages. Once a turbine
system is installed, operating considerations must also be taken into account. Depending on the
turbine manufacturer, the application of the turbine, and the system design, steam turbine
operating procedures will vary for both special-purpose and general-purpose steam turbines. This
module discusses the procedures for operation of steam turbines. An understanding of these
procedures will help the Mechanical Engineer to determine whether mechanical faults or
malfunctions leading to shutdowns of steam turbines are due to the failure of operators to follow
proper procedures.
Saudi Aramco DeskTop Standards 1

OPERATIONAL SAFETY AND RELIABILITY ISSUES
Regardless of the turbine design or application, the following are two common causes of turbine
damage:
• Water Induction
• Thermal Effects
Water Induction
Efficient, reliable operation of large steam turbines requires high pressures and temperatures. To
accommodate these conditions, heavy metal sections are used in the early stages, moderate
clearances are used between rotating and stationary parts, and long buckets are used in the later
stages.
Water induction consists of the accidental introduction of water into any part of a turbine. Such
induction of water can lead to water hammer and water impingement. The damage that these
conditions can cause to a turbine is discussed below.
Water hammer occurs when condensate or water in the steam line is accelerated by steam flow
and forms large water “slugs.” A water slug cannot change direction as fast as the steam. As a
result, water slugs slam into piping components, such as elbows and valves, with extreme force.
Water impingement is a result of small drops of water that are accelerated by steam flow
contacting steam piping components and turbine blading. The small drops of water have the
potential of reaching the same velocity as the steam.
This section will discuss the following aspects of water induction:
• Turbine Damage from Water Induction

• Sources of Water
• Operating Practices to Avoid Water Damage
Turbine Damage from Water Induction
The accidental introduction of water in any part of the turbine can cause serious damage to the
high pressure shells, the rotors, the buckets, and the thrust bearing. Turbine damage from water
induction typically occurs from water hammer and water impingement. Water hammer and water
impingement on turbine blading can potentially cause a catastrophic failure of turbine blading,
which can result in extensive turbine damage.

The force from a water slug during a water hammer condition can cause piping component
damage and, in extreme cases, steam piping failure. If a water slug travels to a steam turbine, the
resultant force of the water slug on the turbine blading may result in blade damage. Water slugs
are particularly damaging to turbine extraction lines and up-exhaust nozzle turbines.
Water impingement damage occurs when the small drops of accelerated water strike the turbine
components, which results in pitting and erosion of metal components. Pitting and erosion of
turbine blading affects the aerodynamics of the blade, which causes a decrease in turbine
performance. Excessive pitting and erosion of turbine blades may weaken the blade to the point
of failure during operation. Water impingement can also damage turbine trip throttle valve seats
and discs.
The extent of each type of turbine damage from water induction depends upon the quantity of
water induced, the point of entry, the initial temperature of exposed metal parts, the turbine
speed, and the rate of the normal steam flow that can minimize the cooling effect. Once water
induction is initiated, the point of entry and the initial temperature of exposed metal parts are
beyond the control of the operator. The other factors are often operation-dependent and can be
controlled to some extent by the operator.
Water induction can cause one or more of the following six general categories of turbine damage:
• Thrust bearing failure
• Damaged buckets
• Thermal cracking
• Rub damage
• Permanent warping and distortion
• Secondary effects
Thrust Bearing Failure - Water carryover from a boiler or steam generator will increase the
thrust load on a turbine rotor to the point at which the babbitt-lined thrust shoes or pads of the
thrust bearing may fail. The greater density of water, as compared to steam, prevents the proper
acceleration and direction by the turbine nozzles. The relative velocity of the water is backward
against the buckets instead of through the buckets, and a large pressure drop across the buckets
develops. The actual amount of thrust increase can be ten times the normal amount of thrust.
Damaged Buckets - As the point of water entry moves downstream from the turbine inlet, the
length of the buckets in the stage that is first encountered by the water increases, which increases
the likelihood of damaged or broken buckets due to water impact. Final stage bucket damage in
the form of numerous cracked tie wires or covers and, in extreme cases, broken buckets almost
always results when a turbine running at rated speed receives water.

Thermal Cracking - Thermal cracking results from either extremely high thermal stresses or
from repeated thermal stresses of lesser magnitude. In some cases, no noticeable permanent
damage is evident after water or cold steam has been admitted to the turbine. However, if water
admission is repeated several times, cracks may develop. Water or cold steam from any source
can contact metal parts that are normally at temperatures that are high enough to cause thermal
cracking. Cracks that develop in packing casings and in packing regions of rotor surfaces may
result from repeated quenching by water or cold steam from the gland seal system.
Rub Damage - Water that is introduced from the main steam and reheat lines can cause
differential expansion between the rotating and stationary parts of the turbine. Such expansion
results in axial and radial rubbing in reaction turbines where shroud seals are used. Water that
backs up from an extraction line and cold reheat lines will cause contraction of the lower turbine
casing half. This contraction results in a humping effect that can lift diaphragm packings against
the rotor and cause radial rubbing. Bowing of the rotor can occur when packing rubs cause
uneven heating on the rotor surface. The bowing of the rotor further increases the effect of the
uneven heating, which increases the intensity of rubbing. Packings, spill strips, and bucket covers
are the most frequently damaged parts, but permanently bowed rotors are not unusual.
Permanent Warping or Distortion - When hot components are subjected to severe quenching
from cooler steam or water, permanent warping or distortion of metal parts may result. Steam
leaks in valve and shell joints may occur as a result of the warpage. Diaphragms can become
dished from contact with water on one side. Bowed rotors can be caused by contact with water
on one side of a hot rotor when heavy rubbing that is caused by distortions stalls the turning gear.
Secondary Effects - Water induction can cause other secondary effects, such as axial rubbing
after a thrust bearing failure or after the damage to bearings, foundations, and oil lines that results
from the increase in vibration that accompanies heavy rubbing or bucket damage.
Sources of Water and Preventive Procedures
Water hammer and water impingement occur when condensate forms in steam piping during
steam header warmup and from water carryover from the steam system boiler or steam generator.
Water carryover in a steam system can be caused by excessive water level in the steam generating
system or from boiler water foaming due to improper boiler chemical concentrations.
Depending on the turbine design, water and condensate in the steam system may come from the
following sources:
• Extraction systems
• Boiler or steam generator and main steam leads
• Reheat spray attemperators
• Gland seal steam system

• Blowdown lines
• Side-exhaust condenser
• Turbine-driven feed pump exhaust
Extraction Systems - Extraction systems are the most frequent source of water induction. There
are many combinations of equipment failure, operating error, and system design weakness that
can lead to serious consequences because of the presence of water within a short distance from
the extraction opening in a turbine. Two potential sources of water induction from an extraction
system are leaking feedwater heater tubes and failure or inadequacy of heater and extraction line
drains. Leaking feedwater tubes can allow feedwater to enter the extraction steam line and back
up into the turbine. Inadequacy of heater and extraction line drains can cause extraction
condensate to back up into the turbine.
Feedwater heater level control problems and induction of water from leaking feedwater heater
tubes are indicated by the feedwater heater high-level alarms. When leaking feedwater heater
tubes or feedwater heater level control problems occur, water detection is only a matter of
responding to the high-level alarm and identifying the source. Dependable high-level alarm
switches are essential because turbine damage can be minimized or prevented if action is taken
immediately when a high level condition occurs. The installation of water detection
thermocouples in the turbine shell is considered the best means of identifying the source of water
to the turbine from the feedwater heater.
Feedwater heater level controls regulate the flow of condensate from the feedwater heater, which
maintains a constant heater level. The rate of condensate flow varies greatly over the full load
range of the plant, and it must change rapidly during turbine startup, changes in turbine load, and
turbine trips. The level controls must not permit level surges in the heater that will actuate the
level alarms. As soon as possible after a new unit begins operation, the level control system
should be tuned and modified, if necessary, to completely eliminate false alarms. If frequent,
false, high-level alarms are not corrected, operators may stop paying attention to the high
feedwater heater level alarms.
Boiler or Steam Generator and Main Steam Leads - The main steam leads are the second
most frequent source of water or cold steam involved in water induction. The usual cause of
water from the steam system is a loss of steam temperature control or boiler drum level control
due to misoperation or equipment malfunction.
Water carryover can be caused by a sudden, very large steam load increase. A large steam load
increase is typically a result of a major system disturbance, such as a simultaneous starting or
shutting down of multiple steam loads. The turbine unit should be tripped when unstable boiler
operating conditions that could result in water carryover or cold steam are encountered. The
practice of continuing to admit steam to a turbine when fires have gone out in a boiler is
particularly hazardous and is seldom justifiable.

Some once-through boilers produce water at full-rated boiler pressure against the turbine stop
valves during the boiler startup cycle. Quenching of the stop valves, as well as water admission
from misoperation or leaking valves, can be serious problems on these units. The feedwater
heaters in many of these cycles are pressurized during startup, which increases the possibility of
water entering the turbine from these sources. Careful consideration should be given to the
design and maintenance of the controls and equipment for feedwater heaters and stop valves.
On occasion, water has been introduced to a turbine through inadequate draining of the main
steam leads or the boiler superheater. Draining water from the turbine stop valve before seat
drains will drain the valve body and a portion of the main steam leads. The turbine stop valve
drains are not sized to drain the entire steam header from a boiler or steam generator to a turbine.
Additional steam lead drains must also be used to adequately remove condensate.
Steam traps are not adequate for draining the main steam leads, and they should only be used with
a parallel operating drain valve that can be opened for startup. Several cases of severe turbine
quenching are believed to have been caused by moisture from the superheater or main steam
leads. These incidents occurred during hot startups that commenced a very short time after
tripping. Another source of large amounts of condensate can occur when boiler fires are
extinguished after a turbine trip. Boiler startup procedures typically require that the boiler is
purged prior to igniting the fires. The boiler superheater cools during the boiler purge, which
causes condensation to take place in the superheater tubes. The turbine is then restarted before
satisfactory drainage of condensate from the superheater has occurred, and the water is carried
into the turbine by the steam flow.
Boilers that are equipped with pendant tubes can be a special problem in that they have many
piping loops that can fill with condensed water. Such pendant tubes must be carefully boiled out
to prevent slugs of water from being carried over into the turbine.
Instrumentation that is sensitive to temperature, pressure, or density in the steam lines might
detect passage of a slug of water, but the system response would be too slow to protect the
turbine by tripping. Operators must rely upon indications of drum level instability and rapidly
decreasing temperature and pressure that precede actual carryover for warnings of impending
water induction.
Reheat Spray Attemperators - Water induction can result from misoperation or leaking valves
when spray-water is injected into the cold reheat line to control steam temperature at the outlet of
the reheater.
Water is injected through nozzles that spray into venturi mixing tubes. With adequate water-to
steam-pressure differential, rapid atomization and evaporation occur, and only dry steam enters
the reheater.

Even a very small steam flow will carry the atomized spray into the reheater. However, without
steam flow, the spray will condense. Depending on the pitch of the steam line, the condensed
spray can run back through the cold reheat lines into the turbine, or it can accumulate in the
reheater, with the possibility of being blown into the turbine during startup. The flow of spray
water must be stopped when steam flow through the reheater is interrupted. The usual practice is
to use, in the spray line, two valves that are positioned manually or automatically by reheat
temperature: a stop or blocking valve and a motor- or a pneumatically operated control valve.
The stop and/or the blocking valves are closed by actuation of closed-position switches on the
turbine stop and control valves, either directly or through sequential tripping of the boiler and
turbine.
Gland Seal Steam System - Typically, admission of water or cold steam from the gland seal
system will not cause turbine damage; however, turbine damage will occur from severe thermal
shocking due to the gland seal system. Gland seal system thermal shock can cause a thermal bow
in the rotor, which will result in a high rotor unbalance with a corresponding high vibration during
startup. Thermal damage from water or cold steam from the gland seal steam system typically
occurs with gland seal steam systems that use an auxiliary steam source. The practice of placing
the turbine on the turning gear before commissioning the gland seal system will prevent gland seal
system thermal damage.
Blowdown Lines - Some turbines are equipped with various blowdown lines that exhaust steam
to the condenser after a turbine trip. Examples of these blowdown lines are the lines from
ventilator valves, shaft packing blowdown valves, and combined valve equalizer valves. If
vacuum is broken in the condenser under certain conditions, there can be a backflow through
these lines into the turbine.
Side-Exhaust Condensers - Turbine drains and other lines that discharge water to the side-
exhaust condenser may discharge water very close to turbine last stage wheels. When low turbine
exhaust flow conditions exist, steam circulates in the exhaust annulus area. Precautions must be
taken to prevent discharge of water into an area in which the water could be carried back into the
turbine final stage buckets by the steam circulating in the annulus area.
Turbine-Driven Feed Pump Exhaust - Some feed pump turbines exhaust to the condenser
when there is low load on the main unit. At higher loads, the feed pump turbine operates as a
non-condensing turbine with the exhaust going to the low pressure inlet of the main turbine unit.
Component thermal quenching and thrust bearing failures on the main turbine unit may occur
when feed pump turbine exhaust transfer occurs, which indicates the presence of water in the feed
pump turbine exhaust piping. This example illustrates the potential for water induction that exists
in any station design in which valves are opened to admit steam to an operating turbine.

Steam Traps and High-Pressure Drain System
With the exception of design considerations, both water hammer and water impingement can be
minimized or eliminated through proper operation of steam traps and through the use of a high
pressure drain system. Regardless of the type of turbine and the turbine system configuration, the
majority of the condensate in the steam piping must be removed prior to admitting steam to the
turbine. In order to collect any condensed steam that normally occurs in the process piping,
steam traps are typically installed in low points in the steam piping system and turbine
components, such as expansion loops and block valve bodies. Most steam traps are designed to
remove small amounts of condensed steam from the steam piping and turbine connections.
Large quantities of condensate cannot be readily removed by the normal operation of steam traps;
therefore, large amounts of condensate must be removed from the steam process piping and
turbine components before a steam turbine is started. Condensate removal is typically performed
by isolating the downstream side of a steam trap and by opening a trap bypass to drain large
amounts of condensate out of the system. Removal of condensate by bypassing the steam traps is
typically called “steam trap blowdown.” Steam trap blowdowns should be performed until
condensate-free steam issues from the bypass line. Large amounts of condensate are typically
removed as the turbine steam header is warmed and is brought to operating pressure. If a cold
start is being performed, a large amount of condensate will exist in the steam lines from the last
header operation, and additional condensate will form as the steam warms the system components
to operating temperature. Steam traps should be blown down in sequence from the pressure
source down the steam header line to the turbine. After a steam trap is blown down, the bypass
valve is shut and the downstream trap isolation valve is opened to place the trap in service.
In some installations, the turbine trip throttle valve body and first stage turbine drains are not
equipped with a steam trap bypass valve. Steam traps that do not use a bypass valve are designed
to handle large amounts of condensate, but the removal of the condensate may take longer.
Because of the time it takes for the steam traps to remove large amounts of condensate, a slow
and controlled steam pressurization of the trip throttle valve and the turbine first stage must be
performed to prevent slugs of condensate from damaging the turbine.
To prevent water hammer or impingement, steam traps, drip legs, and other condensate removal
systems or components are designed to constantly remove any condensate from steam and turbine
piping. Although the proper precautions of removing condensate from the steam header and the
turbine are critical to the safe and reliable operation of a steam turbine, the most critical time that
a steam turbine can be damaged from condensate in the steam lines is during turbine operation.
Constant surveillance of the steam process condensate removal systems is necessary to ensure that
the condensate is continuously removed from the steam system. Surveillance of condensate
drainage systems can include thermal imaging, audible inspection, and visual drainage checks,
which verify that the condensate removal systems are properly working. In addition to removing
condensate, condensate drainage systems should minimize the amount of steam loss from the
system in order to prevent a decrease in the plant efficiency. Periodic monitoring of the
condensate removal systems can identify problems that are associated with system condensate
removal and steam loss from the steam system.

During a turbine shutdown, steam trap bypass valves should be cracked open after the applicable
section of the steam header is isolated. The steam trap bypass valves should be opened to help in
the removal of steam from the isolated header and to prevent the formation of excessive
condensate in the steam supply lines. The removal of steam and condensate as a section of steam
header cools will minimize the chance of water slug formation on the subsequent steam header
startup, and it will also minimize the rust and corrosion that can form where condensate is allowed
to accumulate in the steam system. Rust and corrosion can weaken the pressure walls of piping,
joints, and turbine components. Rust and corrosion particles can also become loose and block
small steam passages in steam traps and turbine control valve stems. Rust and corrosion particles
can travel through a steam system and damage turbine blading, cause conductivity problems in the
feed and condensate systems, and accumulate in the steam-generating system.
Thermal Effects and Preventive Procedures
This section will discuss the thermal effects that can contribute to turbine damage and the
procedures that can minimize such damage during turbine operation. The most damaging thermal
effects are thermal expansion and thermal bow.
When turbines are started from a cold condition, they are subjected to expansive movements that
are caused by the temperature of the incoming steam. Because of the different materials and mass
of the turbine casing and rotor components, a rapid temperature increase can cause damaging
stresses and undesirable thermal effects on the turbine casing and rotor assembly. The following
equation and Figure 1 help to illustrate the point of thermal expansion. Both the rotor and casing
change dimensions by the following relationship:
D L = L in × (6.5 × 10−6 ) × D T
Where:
∆L = The change in material length in inches.

Lin = The initial length of the material in inches.
6.5 × 10-6 = The coefficient of thermal expansion for steel in inches/inch-°F.
∆T = The change in the material temperature in °F.
Because the rotor and the turbine casing are generally made of similar material and because they
are approximately of the same length, both the rotor and the turbine casing will expand
approximately the same amount for a given change in temperature; however, because the mass of
the casing is greater than the mass of the rotor, the rate of change in the length of the rotor will be
greater than the rate of change in the length of the casing.

Another aspect of thermal expansion is the direction of expansion of the rotor and of the casing.
Figure 1 shows some basic configurations of steam turbine rotors and casings. Typical turbine
casings are anchored at one point, and a sliding anchor or wobble plate is used at the opposite
mounting location to allow for thermal expansion. Similarly, most steam turbine rotors are
equipped with one thrust bearing that is installed on one end of the turbine rotor (the end that
receives the active thrust direction). During turbine warming, the casing will expand in the
direction of the sliding (flexible) anchor, and the rotor will expand in the direction away from the
thrust bearing. The rates at which thermal expansion of the rotor and the casing occur becomes
especially critical when the thrust bearing is installed on the turbine end opposite of the casing
anchor. This arrangement causes the turbine rotating and stationary components to expand
toward each other.
Figure 1. Effect of Thermal Expansion on Rotor and Case Configurations
Rotor bow can be caused by the following conditions:
• When the top half and the bottom half of the rotor are at different temperatures.
The upper half of the rotor assembly will expand faster than the lower half of the
rotor assembly.
• When the rotor is expanding against a thrust bearing and a driven machine that is
immovable in the axial direction.
• When uneven temperatures occur in the steam seal area and the rotor is stationary.

To prevent turbine damage from thermal effects (thermal expansion and rotor bow), turbines
should be carefully warmed up to obtain uniform heating of the turbine parts. During the warm-
up period, the turbine should be carefully monitored for rubbing, for oil flow and temperature, and
for proper gland-sealing steam pressure. Steam turbines operate with relatively small radial
clearances of gland and diaphragm packings. The radial clearances can only be maintained at the
approximate design values by keeping the rotor straight. To prevent the rotor from bowing, a
uniform temperature must be maintained around the circumference of the rotor. If a turbine is
warmed up or cooled down with the rotor stationary, uneven heating will result. Uneven heating
will cause temporary bowing of the turbine rotor and, to some extent, distortion of the turbine
casing. If a turbine is started during a period of rotor bow or casing distortion, rubbing and wear
at the packings will occur. Under some conditions, if the operation is allowed to continue, the
bowing of the rotor will be increased by the heat that is generated through the rubbing contact.
In extreme cases of rotor bows, the distortion of the rotor may cause contact between the rotor
blades and the stationary blades of the turbine, which results in critical blade damage.
A uniform temperature is maintained around the circumference of the rotor by keeping the rotors
turning slowly during warming or cooling of the turbine. One method of keeping the rotor
turning is through the use of a turning gear; another method is by periodically allowing small
amounts of steam into the turbine. In some cases, the turning gear must be in operation for at
least eight hours prior to a cold turbine startup. During a turbine shutdown, the turning gear must
be engaged immediately after the turbine stops spinning. The turning gear must remain in
operation until all turbine bearing lubricating oil outlet temperatures are at least 80° to 90°F or
lower and until the turbine casing temperature is below the manufacturer’s specification for a
turbine shutdown. The time needed to cool down a turbine will vary greatly (anywhere from 2 to
40 hours), and it depends on the turbine size, the casing and the rotor materials, and the vendor
specifications.
Uneven heating of the rotor may also occur from the gland sealing steam system (if the turbine is
equipped with externally supplied gland seal steam). The turbine must be rotating any time that
steam is supplied to the turbine, including gland seal steam. Stationary periods of more than a
few minutes while any steam is supplied to the turbine (usually three minutes are allowed by most
manufacturers) will cause uneven heating along the length of the rotor, and it will result in rotor
bowing. Turbines that are not equipped with turning gears must commence spinning operations
as soon as gland sealing steam is applied.
During a turbine warmup period on a condensing turbine, a reduced condenser vacuum is

typically maintained at 10 to 15 inches of mercury to provide for maximum heating of the turbine
rotor. After the initial turbine warmup at slow speeds, the condenser vacuum is increased to the
normal operating range.

In accordance with API Standard 611, single-stage general purpose turbines are designed so that
they do not require a warmup period and so that they may be immediately started up to full load;
however, as API 611 advises, the manufacturer should be consulted for any considerations that
would apply to such a startup.
For turbines that are equipped with rotor position indicators, thermal expansion of the turbine
rotor can be checked while the rotor is cold and again after the turbine is hot. Rotor position
indicators may be manual direct contact devices or electronic axial position transducers. The cold
rotor position should be taken before the lubricating oil system is started. The cold rotor position
reading should be compared to the vendor specification for cold rotor position prior to admitting
steam to the turbine. Hot rotor position should be compared to the normal readings and the
vendor specification for hot rotor position.

BASIS OF INITIAL CONDITIONS REQUIRED FOR STARTUP
Prestart checks and procedures are used to verify that a turbine and its associated auxiliary
systems are in the proper condition to admit steam to the turbine.
Prior to starting any steam turbine, the following conditions must be checked:
• Valve Line-Ups
• Lubrication System Status
• Condenser, Hotwell, and Cooling Water Status on Condensing Turbines
• Control Air System Status
• Turing Gear Operation
• Driven Machine Status
This section will explain why these conditions must be checked and why they must be suitable
before a steam turbine is to be started.
Valve Line-Ups
A valve line-up is a verification of system valve positions, which ensures that all turbine systems
are ready for the turbine startup. A prestart valve line-up should be performed because the
shutdown valve positions in a system may not be correct for turbine startup or operation. Valve
line-ups are also used to verify that valves are in the proper position and maintenance has been
performed on the turbine systems. Turbine system valve position depends on the type of steam
turbine and the status of the support and auxiliary systems. Generally, the status of the valves in
the following systems should be verified by formal procedure:
• Main Steam System
• Lubricating and Control Oil Systems
• Condensate System
• Auxiliary Steam System
• Control Air System
The high pressure drains of the main steam system should be initially bypassed to drain any
condensate from the lines, then isolated until the steam header is pressurized. All main steam
block valves, root valves, and the associated bypass valves should be checked shut to prevent
inadvertent steam header pressurization and turbine operation before the turbine is ready for
steam. The turbine trip throttle valve and the turbine steam admission valve should be verified
shut after the lubricating oil system or, if equipped with a separate system, the control oil system
is started. Standard turbine operating procedures require that the drains of the turbine trip
throttle valve are left open until steam is admitted to the turbine.

Auxiliary steam systems include the turbine gland seal steam, the gland seal exhaust, and the
condenser steam jet air ejector systems. A common practice is to line up the valves in the gland
seal steam system and the steam jet air ejector systems to receive steam as soon as the steam is
admitted to the turbine system piping. This practice prevents air from being drawn into the
condenser through the turbine gland seals as the condenser vacuum is established. If the auxiliary
steam system is supplied with steam from an alternate source, the steam should be isolated from
the turbine systems until the turbine is ready for steam admission.
The valves for the exhaust header(s) on backpressure turbines should be verified in the proper
position or condition (such as “open-permissive” on automatic control systems) for turbine
startup. Exhaust header drains should be placed on line to drain condensate from the exhaust
header.
Lubrication System Status
The lubricating oil and control oil system should be operating and within acceptable parameters
before steam is admitted to the turbine steam header to the turbine. Regardless of the condition
of the turbine steam valves, the assumption should be made that all steam valves leak. The
turbine steam admission valve and the trip throttle valve may leak and allow small amounts of
steam into the turbine. Steam leakage into the turbine may cause the turbine rotor to rotate, if
only slightly. If the lubricating and control oil system is not operating, a possibility of bearing
damage exists. In addition, the turbine turning gear (if equipped) should be in operation prior to
admitting any steam into the turbine. The lubricating oil system must be in operation before the
turning gear is operated.
All oil system sumps should be checked to verify that an adequate oil supply is available to start
the oil system. To prevent turbine bearing damage, many turbine manufacturers recommend that
oil samples be taken from the oil sumps and analyzed for water, emulsion, and particulate before
the oil system is started.
The lubricating and control oil systems must be brought up to the initial operating temperature
prior to rotating the turbine rotor by steam or by the turning gear. Most turbine manufacturers
recommend a minimum lubricating oil temperature of 80° to 90°F on the supply to the turbine
bearings before the turbine is rotated by steam or by the turning gear. If the oil temperature is too
low, there is a danger of shaft vibration due to oil whip as a result of high oil viscosity. Typically,
the lubrication and control oil systems can be brought up to the minimum temperature by the
sump (reservoir) heaters and by operating the associated oil pumps. If the oil system(s) are
equipped with oil coolers, the cooling water flow through the oil cooler should be minimized but
not isolated. A minimum cooling water flow through the oil coolers will prevent a rapid increase
in oil temperature when the turbine is initially rotated with steam.

If the control and/or lubricating oil system is equipped with stand-by oil pumps, the auto-start
function of the stand-by pumps should be verified. All oil pumps should be started and stopped to
verify proper operation.
When the lubricating and/or the control oil system is operating at the minimum temperature, the
system oil pressures should be verified in the operating band. If necessary, pressure regulators
should be adjusted to meet the oil pressure requirements of the system. All oil filter differential
pressures should be checked to verify that the filters are not clogged. Some turbine control oil
systems are equipped with metal edge type filters on the control oil supply to the turbine trip
throttle valve. Some metal edge type filters have a cleaning feature that requires the operator to
rotate a handle several times to clear any particulate from the filter element.
Oil flow at the turbine bearings should be visually checked through the flow sightglasses to verify
that adequate flow exists.
The oil system should be checked for system leaks, and such leaks should be corrected before the
turbine system is started. Oil puddles should be cleaned to remove any oil residue, especially from
any exposed turbine casing. A potential smoke and fire hazard may exist if free-standing oil is
allowed to accumulate on exposed turbine casing components. The turbine casing insulation
should be inspected for oil saturation. Any insulation pads, blocks, or lagging that contains any
amount oil should be removed and replaced with oil free insulation.
To verify proper operation, a system check of the control oil system emergency shutdown system
(ESD) must be performed prior to turbine operation. The turbine trip system is reset, and the trip
valve is fully opened. The trip valve is manually tripped while timing the trip speed. The valve
should immediately close (less than one second). If the valve fails to immediately close, or if
hesitant operation is observed, the valve must be repaired before turbine operation can commence.
In some turbine installations, the turbine trip is performed again during the turbine warmup when
the turbine is initially rolled with steam.
Condenser, Hotwell, and Cooling Water Status on Condensing Turbines
On condensing turbines, the condensate system should be properly lined up to the associated feed
system. The hotwell should be filled with enough water to supply the feed system during turbine
warmup. Excess hotwell level should be drained to prevent the condensate system from
overloading the feedwater and makeup system when the condensate pumps are started. To
prevent feedwater and boiler water contamination, condensate water samples should be taken and
analyzed to verify that the water chemistry is within the required specifications before the
condensate pumps are started.

The condenser cooling water system should be started before steam is admitted to the steam
header root to the turbine. Cooling water supply temperature must be verified in the operating
band. After the cooling water system is started, the condenser hotwell level should be monitored
for an increase in level that would indicate a leak from the cooling water side to the condensate
side of the condenser. Condenser leaks typically occur when the condenser is cool due to the
contraction of condenser tubes and tube sheet.
Control Air System Status
Some turbine systems use control air to operate pressure and flow regulators, valve actuators, and
turbine trip systems. The control air system should be checked to ensure proper control air
system operation and response by checking for proper system pressures, regulation, and air
quality. Moisture and oil separators should be blown down to remove any accumulated moisture
and/or oil. In control air systems that are equipped with in-line oilers, which are required for
some control air system components, the oil level in the in-line oilers bowls should be verified
within the operating band.
Turing Gear Operation
Turning gear operation should commence as soon as the lubrication oil system parameters are
within specifications. Some turning gear units are interlocked with the lubrication system to
prevent inadvertent operation of the turning gear without lube oil supplied to the turbine. Turning
gear units can be automatically or manually engaged or disengaged. For manual turning gears, it
may be necessary to jog the turning gear motor in order to engage the gear drive. Automatic
turning gears will automatically disengage from the gear drive when turbine speed reaches a
preselected rpm. Turning gear operation should continue as specified by the turbine
manufacturer.
Driven Machine Status
The status of the driven machine must be checked to verify that the machine is ready for startup.
In the case of turbine-driven generators, specific electrical tests must be performed on the
generator windings. Larger turbine generator units may use a regulated supply of hydrogen to the
generator casing to provide cooling and moisture reduction, and to increase the generator
efficiency. Hydrogen systems must be checked for proper operation and pressure before a turbine
generator is started.
Depending on the driven load, some turbine units are equipped with clutch mechanisms to
disengage the turbine from the driven load. The clutch mechanism allows the turbine to be started
and tested without load. If equipped with a clutch, the clutch mechanism should be verified
disconnected from the driven load (disengaged).

Reduction gear units should be inspected for proper lubrication. If the reduction gear unit uses a
pressurized oil supply that is separate from the turbine lubrication oil system, the system should be
started and warmed up. For reduction gear units that have integral oil sumps, the oil level in the
sumps should be verified in the proper operating band to ensure an adequate supply of oil is
available to the system.
Turbine-driven gas compressors, both centrifugal and positive displacement, typically require that
the compressor be started without load. To prevent compressor startup under load, the
compressor controls must be verified in the proper position for startup. If so equipped,
lubricating oil systems should be started to warm up the oil system.
Turbine-driven pumps should be checked for proper system valve line-up for startup at low load.
Turbine-driven pumps are started at low load through the use of a minimum flow bypass or a
throttled discharge valve.

BASIS OF SEQUENTIAL STEPS FOR TURBINE STARTUP
This section will explain the basis for adherence to the sequential steps that are followed when a
steam turbine is started up. A sequential startup will ensure that all startup steps are performed
and performed in the correct order. Failure to follow a sequential startup can result in turbine
damage from water induction or turbine trips. This section will discuss the basis for a sequential
turbine startup, including the following steps:
• Pressurizing piping
• Backpressure turbine exhaust warmup
• Extraction turbine extraction line warmup
• Auxiliary steam startup
• Turbine warmup to operating speed
• Placing the turbine on the governor
• Placing a backpressure turbine exhaust in service
• Placing an extraction line in service
Regardless of the turbine configuration or size, the operator should notify the control room that
the turbine startup is about to commence prior to placing any portion of the steam header or the
turbine on line. Notifying the control room operator that a steam load is being placed in service
will allow the control room operator to monitor and control the boiler or steam generator,
preventing any conditions that may cause water carryover, loss of level control, flame out, or
other steam generating process casualties.
Pressurizing Piping
Before this startup procedure is performed, the main steam header pressure and temperature must
be at the operating specifications for turbine startup.
Most turbine startups commence with pressurizing the main steam line or steam header root to the
turbine through use of a bypass valve around the main blocking or root valve. Piping
pressurization should be performed in a slow, controlled, and deliberate manner. As steam header
pressure increases, the associated high pressure drain steam traps should be blown down and
placed on service. An additional precaution for a steam turbine that is equipped with a manual
turning gear should be taken prior to admitting steam to the header root at the turbine trip throttle
valve: the turning gear should be disengaged from the turbine. Disengaging the manual turning
gear from the turbine will prevent damage to the turbine and the turning gear in the event that
steam is inadvertently admitted to the turbine through steam valve seat leakage. Once the turbine
root header is pressurized, the turbine rotor assembly should be checked for rotation. If the
turbine rotor assembly is not rotating, the turbine should be placed back on the turning gear.

As soon as normal operating pressure is reached in the steam header, the main blocking or root
valve can be opened; subsequently, the associated bypass valve must be repositioned shut.
Sections of the main steam header are sequentially pressurized, warmed, and placed in service up
to the turbine trip throttle valve.
Small backpressure steam turbines can be rolled with steam without any warmup period. The
turbine can be brought up to speed and placed on the governor control. The turbine overspeed
trip function should be tested as discussed later in this section.
Backpressure Turbine Exhaust Warmup
Backpressure turbines typically require the exhaust headers to be warmed up prior to turbine
operation. This step can be accomplished through use of steam backflow from the low pressure
steam header. Because steam will be admitted to the turbine during the warmup, the turbine must
be on the turning gear (if equipped). Most backpressure turbines require a controlled
pressurization of the exhaust header (typically 10 psig/min) to control the turbine casing and rotor
heat-up rate. A backpressure turbine exhaust header is warmed by throttling the exhaust header
isolation valve or the exhaust header isolation valve bypass to control the exhaust header
pressurization rate. When the exhaust pressure is at full pressure, the exhaust header isolation
valve is fully opened and the bypass valve (if equipped) is repositioned shut.
Extraction Turbine Extraction Line Warmup
The extraction steam lines on an extraction turbine are typically warmed by backflow from the
applicable extraction header. Because steam will be admitted to the turbine during warmup, the
turbine must be on the turning gear before warming the extraction lines. Extraction steam headers
are typically equipped with power-assisted check valves to prevent backflow through the turbine
in the event of a turbine trip. The check valve must be opened by disabling the check valve
operation through a switch position on the electro-pneumatic controller or by a manual actuator.
The extraction valve control is operated to open the extraction valve to admit steam into the
extraction header. Some extraction valve installations are equipped with a small bypass valve
around the extraction valve. The bypass valve is used for extraction header warmup.
Auxiliary Steam Startup
If the auxiliary steam system is supplied from the turbine root header, the turbine gland seal steam
system should be placed in service. For condensing turbines, the gland seal steam system is
placed in service first and followed by the steam jet air ejector system. The gland seal steam
system is placed in service before condenser vacuum is initiated to prevent the introduction of air
and noncondensible gases from being drawn into the condenser. As explained previously,
distortion of the rotor assembly due to uneven heating will occur if air is drawn through the
turbine gland seals. If the condenser is equipped with an exhaust fan, the exhaust fan should be
started after the gland seal system is started. The turning gear must be in operation or the turbine
put on a slow roll to prevent rotor bow.

Condensing turbines typically require at least 10 inches Hg vacuum in the condenser before steam
is admitted to the turbine. The minimum vacuum requirement prevents overpressurizing the
condenser when steam is first admitted to the turbine.
Turbine Warmup to Operating Speed
The actions that are required for a turbine warmup to operating speed will vary depending on
whether the turbine startup controls are manual or automatic. However, the basis of a turbine
warmup is the same, regardless of the type of turbine controls used. If the turbine is equipped
with a manual turning gear, the turning gear motor must be stopped and disengaged from the
turbine. For automatic turning gears, the turning gear will automatically disengage from the
turbine when a specified rpm is reached. The turning gear motor is turned off after the turning
gear has disengaged.
If equipped, the emergency shutdown system must be verified as fault free, with the applicable
controls bypassed for turbine startup.
Steam is initially admitted to the turbine by slowly opening the trip throttle valve and observing
the point of turbine “break away.” The turbine break away is the point of steam pressure at which
the turbine rotor assembly initially starts to roll under steam and/or the point at which the turbine
speed disengages from the automatic turning gear. The trip throttle valve should be throttled to
provide a constant slow roll. A constant slow roll may require that steam be periodically admitted
to the turbine instead of a constant steam flow. The turbine should be slow rolled as designated in
the applicable turbine technical documentation. Vibration should be monitored during the entire
startup sequence. Turbine exhaust temperature and condenser or exhaust pressure should be
closely monitored at all times during the startup.
After the period of slow roll is completed, the turbine should be ramped up to operating speed in
small increments. Turbine technical documentation may designate specific steam chest pressure
increments and the time at each increment. For example, a turbine manufacturer may specify a 50
psig incremental rise in steam chest pressure for ten minutes at each pressure increment. The time
at each increment may be shorter if the turbine is already warmed or hot.
During the warmup to operating speed, radial shaft vibration is measured at specific rpms and
specific procedures are followed to bring the rotor assembly safely through its critical speed.
Turbine Radial Shaft Vibration
As the turbine speed is increased, amplitudes of radial shaft vibration should be less than 2.5 mils
(60 mm) peak to peak. Turbine vibration in excess of the specification can generally be attributed
to any one or a combination of the following:
• Water in the turbine

• Bearing failure
• Bent or broken blading
• Unbalance due to broken blades or missing blades
• Rubbing of blading labyrinth packing or oil seal rings
• Bowed rotor
• Excessive differential expansion between the rotor and the casing
• Loss of coupling flexibility between the turbine and the driven machine
• Misalignment between the turbine and the driven machine
If a rumbling sound is heard from the turbine when the vibration occurs, the vibration is probably
caused by water or foreign material in the turbine.
There should be no unusual noises from the turbine and no system alarms. If turbine vibration
greater than 2.5 mils (60 mm) peak-to-peak is detected, the turbine speed should immediately be
lowered until the vibration is at a safe level. There can be many causes of vibration during the
turbine startup, including rotor thermal bow or water induction. Lowering the turbine speed until
the vibration is at a safe level allows for the straightening of the rotor or removing water without
damaging vibration. The turbine should be maintained at the rotational speed at which the safe
vibration level was measured until the vibration level falls. The turbine speed should be increased
if the vibration level begins to fall. A lowering vibration level is an indication that a temporary
thermal bow has been eliminated. If the high vibration level does not lower, the turbine should be
inspected.
Critical Speeds
Critical speed is defined as a rotational speed that corresponds to the natural vibration frequency
of a rotor system. If the rotor system natural vibration frequency is continuously excited by a
rotational speed that equals this frequency, radial shaft vibration will be resonant: that is, its
amplitude will be amplified. Such amplification can place dangerous stresses on the rotor
assembly and can cause contact between rotating parts and stationary parts. Such contact can
cause catastrophic damage. The critical speed of both the turbine and the driven machine(s) must
be taken into consideration. As the turbine approaches within 10% of the critical speed (of either
the turbine or the driven machine), the incremental turbine warmup should be stopped and the
turbine speed should be rapidly and deliberately accelerated above the critical speed range. Rapid
acceleration through the critical speed range reduces the time that the turbine or the driven
machine is operating at the critical speed and reduces the time that the rotor system is vibrating
with resonance. Also, as the rotor speed increases above the critical speed, a “settling effect” will
reduce shaft vibration.

The critical speed range of the turbine may be different from the critical speed of the driven
component. Also, the critical speeds of the turbine and of the driven component may not be
consecutive or overlap. Additionally, there may be more than one critical speed for a rotor
assembly. Typically, the second critical speed is 2.5 to 4 times the first critical speed. During a
turbine startup, it may be necessary to pass through two critical speeds for the turbine, the driven
component, or both. Figure 2 shows a typical steam turbine startup map that demonstrates a
turbine driven compressor startup speed through the critical speed range.
Figure 2. Typical Steam Turbine Startup Map
Once past the critical speed range, the turbine incremental warmup should be continued.
Placing the Turbine on the Governor
When the turbine speed reaches the governor minimum speed setpoint, speed control of the
turbine is transferred to the governor control system. Further opening of the trip throttle valve
will not result in an increase in turbine speed. Depending on the turbine load, the throttle valves
will close or throttle close to maintain the governor speed setpoint.
In the case of a constant-speed turbine, the governor control setpoint is adjusted to the desired
speed. For variable-speed governor control systems, the control setpoint is determined by a
controller (typically from the driven machine process variables), and control must be transferred
from manual to automatic control.

Placing a Backpressure Turbine Exhaust in Service
A backpressure turbine exhaust system is typically placed in service when steam flow through the
turbine reaches a specific minimum flow rate. If the exhaust header pressure is within the
operating range setpoint of the exhaust header pressure controller, steam flow through the turbine
will not change when the pressure controller is placed in automatic. If the exhaust header
pressure is outside the operating range setpoint of the exhaust header pressure controller, the
steam flow rate through the turbine will change when the pressure controller is placed in service.
To prevent an excessive heat-up rate of the turbine, the turbine should be completely warmed up
before placing the exhaust header pressure controller in service when the exhaust header pressure
is outside the operating range setpoint.
Placing an Extraction Line in Service
Prior to placing an extraction line in service, the extraction line manual isolation valve (if
equipped) should be verified as being fully open. The extraction flow or pressure controller (if
equipped) setpoint should be adjusted to the minimum value. The manual control on the
extraction header check valve (forced open for the extraction header warm up) should be released
to allow the proper operation of the check valve. The extraction header controller can be shifted
to automatic control after the appropriate checks have been performed, and the pressure setpoint
can be adjusted to the desired setpoint. For manual extraction control, the extraction valve(s)
may be opened after the checks have been performed. Extraction header flow or pressure and
temperature should be monitored to ensure proper operation of the system.

BASIS OF SEQUENTIAL STEPS FOR NORMAL TURBINE SHUTDOWN
This section will explain the basis for the sequential steps that are followed during a steam turbine
shutdown. Before a normal turbine shutdown can begin, the following preshutdown checks must
be performed to verify that the driven load has been unloaded and is ready for shutdown:
• In the case of a turbine generator, the generator output breaker must be verified
open and the generator field excitation must be verified off.
• For turbine-driven gas compressors, the compressor should be verified as
unloaded, and the surge control system should be verified as being in manual.
• For turbine-driven pumps, the pumps should be verified on minimum flow bypass
(if provided).
If any of the above conditions are not verified, the operator should notify the Supervising
Operator or the Foreman and should then wait for instructions. In no case should an operator
proceed with a normal shutdown unless the conditions for preshutdown checks have been verified
as suitable.
Regardless of the turbine configuration or size, the outside operator should notify the control
room operator that the turbine shutdown is about to commence prior to taking any portion of the
steam header or the turbine off line. Notifying the control room operator that a steam load is
being removed from service will allow him to monitor and control the boiler or steam generator,
preventing any conditions that may cause a loss of level control, flame out, or other steam
generating process casualties.
The turbine speed is then reduced to the minimum speed allowed by governor control. For
extraction turbines, the loads serviced by the extraction steam header must be taken off service if
the only source of steam supply is the operating turbine. The extraction pressure controller must
be taken out of service by raising the setpoint of the bypass pressure reducing station and
lowering the setpoint of the extraction controller to the minimum pressure value, then switching
the extraction controller off.
There are several methods used to shut off steam to a turbine based on the vendor technical
documentation. One method manually trips the turbine to close the trip throttle valve. The
turbine is allowed to coast to a stop and is then immediately placed on the turning gear because
steam is still being supplied by the gland seal steam system. Another method requires a controlled
reduction in turbine speed with the manual trip throttle valve or the starting device if the turbine is
not equipped with a manual throttle valve. Some turbine manufacturers require that the turbine
be maintained at a slow roll speed for a specified period of time before placing the turbine on the
turning gear. The slow roll allows for a controlled rotor system cooldown.

After a condensing turbine is placed on the turning gear, condenser vacuum is broken by isolating
the steam supply to the steam jet air ejectors or by turning off the condenser exhauster fan. To
prevent uneven cooling of the rotor, condenser vacuum should be broken before the steam supply
to the gland seal steam system is isolated. After condenser vacuum has been broken, the steam
supply to the gland seal steam system or the steam header root valve can be isolated.
After steam is fully isolated from any turbine, all turbine drains must be opened. Opening the
turbine drains allows condensate from the condensing steam to leave the turbine chambers.
Opening the turbine drains also prevents a vacuum from condensing steam from forming in
isolated turbine chambers.
The turbine lubricating oil system should be cooled to the minimum operating value prior to the
shutdown of the lubrication and control oil systems.

BASIS OF SEQUENTIAL STEPS FOR EMERGENCY TURBINE SHUTDOWN (ESD)
The emergency shutdown procedure (ESD) should only be used in the event that a turbine trips
due to any ESD shutdown actuation or by manual signal. The actions taken in event of an ESD
trip will vary depending on the cause of the trip, the turbine type, and the control system used by
the turbine. An immediate action that must be taken on any turbine trip is to acknowledge the
turbine operating parameters, alarms, and the first-out indicators (if equipped) that may provide
the information necessary to identify the cause of the trip. The operator must check that the
turbine trip is complete by verifying that the trip throttle valve fully tripped. The trip throttle
valve can be verified as closed by visual inspection or by monitoring the turbine first stage steam
pressure. The trip throttle valve position should be checked to ensure that a full turbine shutdown
has occurred. If necessary, the turbine should be manually tripped if the automatic shutdown
function has not fully initiated. The lubricating oil pressure and temperature to the turbine
bearings must be checked to verify that the turbine bearings are receiving an adequate oil supply
for the turbine coastdown. If the turbine trip was initiated by a lubricating oil problem, the
standby oil system should be operating or started. The driven unit should be unloaded or
disengaged from the turbine.
The turbine and driven unit(s) should be inspected for indications of damage. If the ESD trip was
not related to the turbine train or if there was no immediate damage to the turbine, then the
turbine should be slow rolled with steam while monitoring the turbine vibration and noise. The
slow roll may give an indication of potential internal turbine damage. If the cause of the turbine
trip cannot be readily identified, the turbine should be placed on the turning gear (if used) and the
turbine should be shut down through use of the normal shutdown procedure. The turbine is shut
down until the cause of the trip can be identified and corrected. If the cause of the trip is
identified and corrected, the turbine can be restarted through use of the warm turbine startup
procedure designated in the vendor technical documentation.

GLOSSARY
automatic A steam turbine with the capacity to extract steam. The pressure or flow
extraction turbine rate of the extracted steam is controlled by a valve gear at the inlet to the
LP section of the turbine and the main valve (hp) gear. (Steam turbines
can be furnished with automatic extraction and admission capability.)
backpressure A steam turbine that exhausts at a pressure that is equal to or greater than
turbine atmospheric pressure. Also known as a non-condensing steam turbine.
extraction factor The ratio of the increase in throttle flow over the increase in flow that is
required for zero extraction, for a given turbine and set of steam
conditions.
feedwater heater A steam-to-water heat exchanger that heats the boiler feedwater with
steam that is extracted from a steam turbine.
first-out indicator An indicating instrument or display that identifies the first event to cause a
trip or shutdown.
frequency The number of cycles that a periodic variation completes in a given
period. Sometimes stated in cycles per minute (cpm) or cycles per second
(cps, Hertz, Hz). For vibration, frequency is also expressed as a multiple
(1×, 2×) of shaft rotative speed.
induction turbine A steam turbine with the capacity to admit steam at two or more
pressures. Valve gear at the low-pressure opening can automatically
control the pressure in the low-pressure opening. Commonly called an
automatic-admission turbine.
mechanical-drive A turbine that is used to drive devices other than electric generators, such
steam turbine as pumps or compressors. Generally designed to operate over a wide
speed range.
rotor A turbine rotor consists of the rotating elements of a steam turbine the
shaft, the blade disks, and the blades. The rotor transmits the rotating
mechanical energy from the turbine blades to the load.
seal A seal is a device or material that prevents excessive leakage of fluids
(gases or liquids) by creating and/or maintaining a fluid-pressure
differential across the gap that exists between two relatively movable
and/or separable components of a fluid system.
shaft A shaft is a machined forging that supports the blades and transmits the

useful work of the turbine to the driven load.

slow roll A slow rotation, typically 300 to 600 revolutions per minute.
steam chest The steam chest section of a turbine is the steam inlet to the turbine. The
steam chest houses the control valves, receives the supplied steam, and
directs the steam to the first-stage nozzle assembly.
turning gear Turning gears are a motor and gear arrangement that is used to slowly
rotate the turbine rotor (usually less than 60 rpm) to ensure that the rotor
is evenly heated or cooled.
vibration Motion in which an object undergoes periodically occurring displacement.
Vibration is measured in terms of its variables of displacement (mils),
velocity (in/sec), and acceleration (g’s). For rotating machinery, vibration
is assessed in terms of frequency, peak-to-peak amplitudes of
displacement, and either root mean square (RMS) values or zero-to-peak
values for velocity or acceleration.
water hammer A destructive force generated by a sudden increase in water pressure due
to the instantaneous conversion of momentum to pressure. Water
hammer occurs when a slug of moving water in a pipe strikes an
immovable object, such as a pipe bend or turbine steam chest. Water
hammer is indicated by a loud banging condition in the steam pipe or
turbine.

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Determining Whether Steam

Chapter : Rotating Equipment For additional information on this subject, contact

OPERATIONAL SAFETY AND RELIABILITY ISSUES................................................... 2

BASIS OF SEQUENTIAL STEPS FOR EMERGENCY TURBINE SHUTDOWN

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards

Table of Figures Page

Figure 1. Effect of Thermal Expansion on Rotor and Case Configurations ...............10

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards 1

OPERATIONAL SAFETY AND RELIABILITY ISSUES

This section will discuss the following aspects of water induction:

• Turbine Damage from Water Induction

Turbine Damage from Water Induction

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Saudi Aramco DeskTop Standards 3

Sources of Water and Preventive Procedures

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Saudi Aramco DeskTop Standards 5

Saudi Aramco DeskTop Standards 6

Saudi Aramco DeskTop Standards 7

Steam Traps and High-Pressure Drain System

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Thermal Effects and Preventive Procedures

∆L = The change in material length in inches.

Saudi Aramco DeskTop Standards 9

Figure 1. Effect of Thermal Expansion on Rotor and Case Configurations

Rotor bow can be caused by the following conditions:

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During a turbine warmup period on a condensing turbine, a reduced condenser vacuum is

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BASIS OF INITIAL CONDITIONS REQUIRED FOR STARTUP

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Lubrication System Status

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Condenser, Hotwell, and Cooling Water Status on Condensing Turbines

Saudi Aramco DeskTop Standards 15

Control Air System Status

Turing Gear Operation

Driven Machine Status

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BASIS OF SEQUENTIAL STEPS FOR TURBINE STARTUP

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Backpressure Turbine Exhaust Warmup

Extraction Turbine Extraction Line Warmup

Auxiliary Steam Startup

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Turbine Warmup to Operating Speed

Turbine Radial Shaft Vibration

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Figure 2. Typical Steam Turbine Startup Map

Placing the Turbine on the Governor

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Placing a Backpressure Turbine Exhaust in Service