TRAINING MANUAL
STG-IV BOARD
TABLE OF CONTENTS
1. Introduction …………………………………………………….05
2. Operational & Control Philosophy……………………………07
2.1. Operation & Maintenance Manual………………………………….08
2.2. Control System Functional Description…………………………….257
3. Online Functional Testing (OFT)……………………………...322
3.1. OFT-I Governor Operation During Startup…………………………323
3.2. OFT-II Auxiliaries Functional Testing……………………………..332
3.3. OFT-III Steam Bypass System……………………………………..346
3.4. OFT-IV Extraction Steam & Condensate Export…………………..352
4. Process Flow Diagram and P&IDs along with description….360
4.1. Piping & Instrumentation Diagrams STG-IV………………………361
5. Functional logic diagram………………………………………383
5.1. FLDs………………………………………………………………..384
5.2. FLD with Description………………………………………………594
6. Cause & Effect Matrix…………………………………………605
7. Checklists……………………………………………………….619
7.1. STG-IV Startup Checklist…………………………………………620
7.2. STG-IV First Hour Checklist………………………………………623
8. Startup/Shutdown Procedure………………………………….626
9. Specific Data Sheet……………………………………………...648
9.1. Steam Turbine Data Sheet…………………………………………..649
9.2. Generator Data Sheet………………………………………………..660
9.3. Condensate Extraction Pumps Data Sheet…………………………..664
9.4. Level Control Valves Data Sheet…………………………………....667
9.5. Bleeding Line De-superheating Station Data Sheet…………………670
9.6. Bleeding line Check Valve Data Sheet……………………………….676
9.7. Bleeding line Control Valve Data Sheet……………………………...679
9.8. Lube Oil Standby and Safety Pump Data Sheet……………………...682
9.9. Turbine Jacking Oil Pump and Motor Data Sheet……………………726
9.10. HP Oil Pump Data Sheet……………………………………………..770
9.11. Performance Table…………………………………………………....840
9.12. Power Correction Curves……………………………………………..843
10. Emergency Handling Procedures………………………...852
10.1. Tripping of STG-IV (60MW)………………………………………..853
10.2. UCP-04 (60MW) Failure…………………………………………….860
10.3. STG-IV Governor Malfunctioning…………………………………..867
10.4. Total Power Failure…………………………………………...……..876
10.5. One Boiler Tripping………………………………///……………….890
10.6. Instrument Air Failure…………………………………………….…899
10.7. Cooling Water Failure……………………………………………….913
10.8. Close Loop Cooling Water Failure………………………………….922.
10.9. Tripping of AUX Boiler………………………………………….….931
INTENTIONALLY
LEFT BLANK
INTRODUCTION
STG-IV is a Condensing steam turbine supplied by GE having 60MW capacity which is
delivered to National Grid via Karachi Electric (KE). Turbine has two extraction ports,
high pressure extraction port and low pressure extraction port, which can be taken into
service depending upon the load of turbine.
STG-IV is designed on following Parameters:
Inlet Pressure 92kgf/cm2
Inlet Temperature 515oC
Exhaust Temperature ≤50oC
Generator Frequency 50 Hz
Generator Voltage 11KV
There are four steam turbines installed in FPCL:
TG3 10MW 60Hz backpressure type with process bypass
TG1 and TG2 24MW each 60Hz condensing type
TG4 60MW 50Hz condensing type
All 60 Hz turbines TG1, TG2 and TG3 operate in parallel and provide power in island
mode to existing fertilizer plant. They are controlled in droop mode with load sharing
philosophy. TG3 is backpressure controlled.
The TG4 (60MW) is separated, power/inlet pressure controlled and connected to national
grid only; it is operated as balance ST, that is it produces power with the surplus of steam
produced by Coal Fired Boilers (CFB) and exports it to the grid.
BYPASS SYSTEM:
TG4 has its own by-pass system, consisting of a steam conditioning station and a dump
tube to the condenser. The steam conditioning station is made up of a pressure reducing
valve and a de-superheater fed with water from the condensate pumps. The by-pass
system is designed to discharge 100% of turbine inlet rated steam.
EXTRACTION:
In order to optimize the steam turbine efficiency and to feed the LP steam header at
different plant operating conditions and steam turbine loads, two different bleeding lines
on steam turbine are provided. Each bleeding line has its own pressure regulating valve
(butterfly type) and an assisted check valve.
Bleeding n.1 (or High Pressure bleeding) is taken upstream the bleeding n.2 (or Low
Pressure bleeding) in the turbine steam path. Bleeding n.1 shall be operated when the
steam pressure inside the inter-stages of the machine is low, i.e. at low turbine loads.
Bleeding n.2 shall be operated when the steam turbine is at high loads, in order to
increase the machine efficiency.
