Section -3 Operation - Amec Foster Wheeler Talcahuano · Section -3 Operation ... turbine is being...

A9trvPowef G E K 105H2

Section 3 - Operation

INTRODUCTION

The GE Company considers these starting and loading instructions both practical and adequate for ensuringcomplete turbine readiness before starting and continued successful operation after starting. However, becauseequipment and operating techniques differ considerably between sites, the station may find it helpful to modify orotherwise implement these instructions to suit its established routine.

The prestart and operating procedures are concerned mainly with the turbine-generator and related auxilia-ry equipment, and reference is made to station equipment only insofar as it affects turbine operation. All procedurescall attention to specific important factors before and during starting-factors which will determine to a great extentwhen the turbine can be started on steam, the length of time required to start the turbine, and the very success orfailure of the start. In addition, the procedures are based on considerations of certain prestart conditions of the tur-bine-generator and assume that the turbine has been in formal commercial operation.

Before attempting to prepare the turbine-generator for starting, thoroughly check turbine-generator assem-bly work to make sure that the interior of each section is clean and that no foreign material has been left in the ma-chine. See that all bearings and pivots are oiled or greased, as required, and that all bolts are tight. Prepare to testall bolts which are subject to high temperature a second or third time during the first week of operation to insurethat they retain their full tension.

C‘b.UTION

Before introducing steam to the turbine, re-torque all steam joint bolting, in-cluding access hole flanges, per Fastener Tightening Instruction P12A-AF17found under Tab 6 of this manual.

In general, practice demonstrates that the turbine, when being started, is subject to variable expansion move-ments under the changing conditions of temperature and load. This is especially true during the first several monthsof operation, before the structure seasons and accommodates itself to service conditions. For this reason, when aturbine is being put in service, a reasonable time should be spent in warming it, gradually bringing it up to speed,and applying load.

The operator should review these instructions in their entirety and become thoroughly familiar with the sug-gested sequence of operating procedures and the reasons for them. In conjunction with the instructions, he shouldalso study the following drawings for data pertinent to the installation:

1. Elementary Electrical Outline - B777AllE155403

2 . Bill Of Materials Drawing - B777A23A155403

3. Electrical Outline (Wiring) Drawing - B777A37A155403

4 . Turbine Control System Lineup and Checkout Procedure - B777A39A155403

5. P&IDiagram- B777A54D155403

6-8. Speedtronic Mark V GEH’s 5979,5980, and 6195, published by GEMIS - Salem. ,

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GEK 705632 Petro Power

PRESTART CHECKOUT OF LUBRICATION AND HYDRAULIC SYSTEM

For detailed information on the VF-95OHP, Combined Lubrication and Hydraulic System, refer to Section5 of this manual.

A. Lube Oil Pump Reference Designations.

Reference designations used for the lube oil pumps are as follows:

P500 and P501 Main and Auxiliary Lube Oil Pumps (MOP/AOP) and Motors(AC)

P502 Emergency Lube Oil Pump (EOP) and Motor (DC)

B. Hydraulic Fluid Pump Reference Designations.

P503 and P504 Main Hydraulic Fluid Pumps and Motors (AC)

P509 Hydraulic Fluid Conditioning System Pump and Motor (AC)

C . Routine Cold Start Checkout Procedure (Oil Conditioner Is In Service)

1.. Verify the oil reservoir level for both lubrication oil and EHC fluid is near or above the maximumoperating level.

2 . Verify the power supply to the AC motor driven pumps, P500, P501, P503, P504 and P509, andthe battery power supply to the emergency oil pump, P502. Place all pump selector switches in the& position.

3 Verify oil reservoir temperature is above the minimum lube oil and emergency pump start tempera-ture (minimum temperature 10°C). Use the reservoir heater and/or hydraulic pumps to increasetemperature as needed. Set the heater selector to automatic to permit temperature control by theoil system thermostat.

4 Verify the cooling water supply is available and any water temperature controls are operational.

5 Start reservoir mounted vapor extractor (B500) before starting oil pumps.

6 Start either P500 or P501 to circulate oil through the lube system. If the system has been idle fora period of time operate the lube filter and lube cooler high point vents to bleed trapped air. Placethe transfer valves in an intermediate position to pressurize both lube filters and coolers simulta-neously.

7 Start either P503 or P504.

8 . Observe the lube oil and hydraulic oil delivery pressures and adjust to normal operating values ifthey are out of tolerance. Hydraulic pump discharge should be steady without oscillation (airtrapped in pressure controls).

9 . Verify oil level is within the normal operating range.

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1 0 . Allow oil to circulate and increase in temperature (min. temperature to start turbine and EOP is38OC). With the AC motor driven pumps running and the EOP, P502 in the off position, push andhold the pump test pushbuttons (HMS323, HMS324 and HMS325) for five to ten seconds thenrelease. Repeat the process several times to bleed the switch sensing lines.

11 . Place the EOP, (P502), in the standby position via selector switch.

12 . Stop the operating lube oil pump and permit the EOP (P502) to start on low oil pressure via switchPSL503. Verify the EOP starts and that the system lube oil pressure rises directly and continuouslyto the expected emergency oil pressure level. The period of time to start the pump and restore pres-sure is less than two seconds. Verify EOP operating speed and supply voltage are within the ex-pected range. Stop the EOl?

NOTE

The EOP starter is tied electrically to the AOP/MOP starters, if the AC starterstrips, the EOP will not wait for a hydraulic signal, it will start immediately. Tocheck the hydraulic start, the electrical start should be temporarily disabled.

NOTE

Prior to operating the STG for the fiit time, an EOP test with a high speed recorderis to be conducted to assure the adequacy of the system EOP and battery system.GE site engineer to approve.

13 . Start one lube oil pump and place the other lube pump in Ihe standby position.

14 . Operate the pump test pushbutton HMS323 and verify the standby lube oil pump starts. Stop onelube pump and return it to standby.

1 5 . Operate the EOP pump test pushbutton HMS324 and verify the EOP starts. Stop the pump andreturn it to standby.

16 . Operate one hydraulic oil pump and place the other pump in standby.

17 . Operate hydraulic pump test pushbutton HMS325 and verify the standby hydraulic pump starts.

18 . Position all manual valves and transfer valves in normal operating position.

19 . The oil system pumps and pump controls are operational and ready for turbine startup.

D. Oil System Preparation For Turbine Startup

1 . Verify lube oil delivery temperature and reservoir temperature are above lOOoF (38’C).

2. Establish reservoir vacuum.

3 . Verify that hydraulic oil header is pressurized, PI502.

4 . Verify standby lube oil pump is in AUTO/STANDBY position.

5 . Verify the EOP is ready and in AUTO/START position.

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1 .

2 .

3 .

4 .

5 .

6 .

7 .

8 .

6. Verify bearing oil pressure at oil system console (PI508) indicates approximately 2&25 psig(1.4-1.8 Kg/Cm2g).

7 . Verify oil temperature to the bearings is between lOO”-130’F (3854OC).

8 . All bearing oil sight flows should indicate oil flow during test.

9 . Verify hydraulic oil pressure at PI502 is 1100 to 1175 psig (77.3-82.61 Kg/Cm2).

PRESTART MODE -TURBINE AUXILIARY EQUIPMENT

Determine the status of the equipment listed, then check the associated indication.

EQUIPMENT AND MODE

Generator vapor extractor (B502) is operating.

Lube oil system vapor extractor (BSOO)motor is on.

Electrical trip devices (PVNSOO and PVNSO 1)and turbine are tripped.

Inlet trip throttle valve closed.

Extraction non return valve(s) closed.

Source of steam to steam seal systemis closed.

Air supply to steam seal system at 2-2.4Kg/Cm2 and electrical signal to I/P Xmittr is on.

All drain valves in turbine casing, inlettrip throttle valve and piping are open.

1 .

2 .

3 .

4 .

5 .

6 .

7 .

8 .

INDICATION

Panel indicating lamp or OIM displayshowing motor is on.

Panel indicating lamp or OIM displayshowing motor is on.

To ensure that the unit is tripped, pushthe EMERGENCY TRIP PB’s.

Inlet TFV valve CLOSED display on.

Extraction non return valve(s) CLOSEDdisplay(s) on.

Visual inspection of shut off valve andhand test for closed position.

Visual inspection of SUPPLY pressuregauge on controller, or inspection ofI/P Xmittr, and valve positioners.

Visual inspection of drain valves andalso hand test for open position. OIMdisplay shows status of drain valves.

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PRESTART MODE FOR GENERATOR AND RELATED AUXILIARY EQUIPMENT

AIR COOLED GENERATORS

Determine the mode of the equipment listed, then check the associated indication. Refer to the Table of Con-tents in generator section of manual for data pertinent to the generator, hydrogen system, and exciter.

1 .

2 .

3 .

4 .

5 .

EQUIPMENT AND MODE

Water supply to generator coolers is on.

Armature circuit breaker is open.

Main and spare field circuit breakersare open.

1 .

2 .

3 .

Automatic voltage regulator is out ofservice.

Exciter output is minimum.

4 .

5 .

PUTTING THE TURNING GEAR INTO OPERATION

CAUTION

INDICATION

Visual inspection of shutoff valve andhand test for OPEN position.

Panel indicating lamp is showingbreaker is open, or readout at GPP.

Panel indicating lamps showingbreakers are open, or readout @ GPP.

Regulator transfer switch is inMANUAL, OFF, or OUT position (GPP).

Panel indicating lamp showing extremeLOWER, or readout @ EX2000.

Never attempt to engage the turning gear unless the turbine rotor is at rest asindicated by the zero speed indicating display or light, or by visual indicationof the rotor.

The turbine should be placed on turning gear during a normal overnight shutdown or during any shutdownof short duration. If it is necessary to put the turning gear in operation, perform the following procedure:

1 . The turning gear motor run switch (HS317) is assumed to be in the STOP position

2 . The turbine is assumed to be at rest with the ZERO SPEED lamp on, (if supplied).

3 . The TURNING GEAR DISENGAGED light (ZL20 1) should be ON and the TURNING GEAR EN-GAGED light (ZL200) should be OFF.

4 . Make sure that lube oil pressure is normal and lift oil circuit is pressurized.

5 . At the turning gear control center local to the turbine (refer to Fig. G28- 1) turn the switch for the turninggear motor (I-IS3 17) to the RUN or AUTO position. The turning gear will start and engage automatical-ly. In a manual mode, the operator must engage turning gear manually by operating the TURNINGGEAR switches HS317, HS200 and HS318. Normal operation of the turning gear will be indicated bythe following sequential display of lights or displays - after which the turbine rotor will be turning:

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a . TURNING GEAR DISENGAGED light or display is out.

b . TURNING GEAR ENGAGED lamp or display is on.

c . ZERO SPEED lamp or display is OUT, (if supplied).

6 . After rolloff, the turning gear will disengage automatically as rotor speed exceeds turning gear speed.When the TURNING GEAR DISENGAGED lamp or display comes ON, the operator must shut off theturning gear motor, unless automatic shut off has been provided.

7 . If manual turning gear operation is desired, the motor switch (I-IS3 17) must be turned to START positionuntil the turning gear has been engaged. The MANUAL selector switch (I-IS3 18) should be pushed toplace the turning gear in the manual engage mode. Engagement is accomplished by pushing the EN-GAGE PB (HS200) or operating the engage lever.

HEAT THE INLET STEAM LINES

1 . Make sure that all the dram valves in the steam lines are open.

2 . Establish a flow of steam in the lines so that they will be gradually heated and drained.

3 . Continue the heating long enough to ensure that no water will enter the turbine when steam is admitted,and steam temperature is close to rated conditions.

PUTTING THE GLAND SEAL SYSTEM INTO OPERATION

The gland seal system is put into operation with the main condenser and air extraction system. With the sys-tem in operation the following should be noted.

1 . Record vacuum (est. 150 mm Hz0 VAC.) at pressure gauge PI405 provided in the turbine piping. A neg-ative pressure must exist at the turbine glands to prevent escape of steam and possible contamination ofthe oil with water.

Refer to Condenser operating instructions included in this manual.

PRESTARTMODE-STEAMSUPPLY,CONDENSER,ANDGLANDEXHAUSTER WATERSYSTEMS

Check the following systems to make sure each is fully operative and in the prestart (ready) condition accord-ing to accepted station procedures:

A. Steam Supply

1 . Steam pressure should be about 40% of minimum design pressure.

2. Attemperator systems.

B . Condenser

1. Air-removal system.

2. Condensate system.

3. Circulating water system.

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4. Drain system.

C. Gland Seal System

1. Condensate system on, steam ejector operating.

In addition, make sure that condensate is available to the fog spray nozzles in the turbine exhaust hood, andprepare any other station equipment at this time, as required.

ESTABLISHING CONDENSER VACUUM AND STEAM SEALS

For a COLD, WARM, or HOT start (as previously determined), put the steam-seal system into operationbefore establishing condenser vacuum. Proceed as follows:

A. Open all turbine casing drain valves.

B. Drain and warm the line supplying steam to the steam-seal system and condenser ejector systems.

C . The condenser air-removal and gland exhaust equipment is operating and establish the maximum vacu-um obtainable in main condenser.

D. Open the manual valve to admit seal steam to the steam-seal regulator. The regulator should just main-tain a positive pressure of 3.0 to 5.0 psig (0.21-0.35 Kg/CM2) in the steam-seal system.

NOTE

The lube oil system should be in service with the turbine rotor turning, before ap-plying steam seal.

STEAM TURBINE FUNCTIONS AND OPERATING MODES

SAXC UNIT WITH INLET PRESSURE CONTROL AND EXTRACTION PRESSURE CONTROLCAPABILITY

Waste heat steam generators are often used to supply process steam in industrial power plant applications.Often these steam generators are not designed to be operated on their own pressure control systems, and turbine-gen-erator units are sometimes used to control both the inlet and process pressures while producing electrical power atthe same time. A single automatic extraction condensing (SAXC) unit will sometimes be used when one processpressure is involved (see Fig. 3- 1). It should be realized, however, that only the one process pressure can be con-trolled at any time that the SAXC unit is also used to control inlet pressure.

In such an application, the unit must be operated either in parallel with another unit or connected to a largesystem capable of controlling frequency. The electrical power generated by the unit will depend on the demand forprocess steam and the amount of inlet steam available. Operation should be planned in such a way as to ensure thatthere will be sufficient range to meet changes in process flow demand while controlling pressures.

In the inlet pressure control mode (if applied), the inlet (V 1) and extraction (V2) control valves respond toinlet pressure control signals to change the steam flow to each turbine section equally to control inlet pressure with-out affecting extraction flow (or pressure). Only the extraction control valves respond to extraction pressure signalsto control extraction pressure without affecting inlet flow (or pressure).

G E K 105§32 Petro Power

TRIP THROTTLEVALVE INLET ExTRAcTloN

\CONTROLVALVES VALVES

GENERATOR

FLOW TO

CONTROLLEDExTRAcnONSTEAM FLCWVTO PROCESS

UNCONTROLLEDEXTRACTIONS

NOTE: EXTRACTION CONTROL VALVES (V2) CONTROLSTEAM FLOW TO FOLLOWING SECTIONS

Figure 3-1. Single Automatic Extraction ‘hrbine

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This unit is designed for the simultaneous control of speed/load and extraction pressure, with inlet pressurecontrol out of service.

Development Of The Vl (Inlet Valves) And V2 (Extraction Valves) Control Signals

Figures 3-2 and 3-3 show the development of the Signals which control Vl and V2.

The Speed/Load and Pressure Control/Limiting signals are applied directly to the single automatic extractioncondensing (SAXC) control algorithm block, and then to the V 1 and V2 position control sub-systems. Changes inthose signals produce changes in the V 1 and V2 position signals to produce required flow changes. As a result, theExtraction Flow and Pressure is not disturbed by changes in the Speed/Load Control signal, when in Speed/Loadand Extraction modes.

Each Pressure Transducer produces a Feedback signal proportional to Extraction Pressure. This signal is sub-tracted from the Extraction Pressure Setpoint Reference signal in the Extraction Pressure Control Summer to pro-duce an Extraction Pressure Error signal which is amplified to produce the Extraction Pressure Control signal.

In Speed Load and Extraction modes, the Extraction Pressure Control signal is applied directly to the V2position control and an inverted Extraction Pressure Control signal is applied to V 1. Changes in the Extraction Pres-sure Control signal produce changes in the V 1 and V2 position signals, which are opposite in sign. The differencebetween the change in Inlet Flow and Extraction Control Valve Flow is the change in Extraction Flow. The changein power generated by the Inlet Section is essentially balanced by an opposite change in power generated by the lowpressure (LP) Section. As a result, the power generated by the Turbine is not disturbed significantly by changes inthe Extraction Pressure Control signal, in this mode.

As long as Extraction Stage Flow is greater than the Minimum Stage Flow, the V2 position control signalequals the V2 Position command.

When the V2 Summer Output signal is less than that required to produce Minimum Stage Flow, the V2 Posi-tion control command signal is held at that value required to produce Minimum Stage Flow. As a result, additionalincreases in the Extraction Pressure Control signal will have no effect, and the MINIMUM STAGE FLOW indicatoron the Operator Interface Module goes ON and an Alarm is given to alert the Operator to this condition. To returnto Normal Extraction Pressure Control, either the Load should be increased or the Extraction demand decreased.

If the Speed Error exceeds a preset level, the Low-Limit equivalent to Minimum Stage Flow is removed topermit the V2 Position signal to track the V2 Summer Output signal and close V2.

Extraction Pressure Setpoint Ranges

The Extraction Pressure Setpoint Range depends on the Design Extraction Pressure, as shown in the Tablebelow:

Design Pressure Pressure Setpoint Range

> 100 psig (7 Kg/Cm2) +\, 15 percent> 20 psig (1.4 Kg/Cm2) and c 100 psig (7 Kg/Cm2) +/-lo percent +\5 psic 20 psig (1.4 Kg/Cm2) As required by design

Thus, the 0 percent reading on the Setpoint Indicator represents the Minimum Extraction Pressure in theavailable Range, and the 100 percent reading represents the Maximum. Figures 3-4 and 3-5 illustrate the relationshipbetween Extraction Pressure, Flow, and Pressure Setpoint for an Extraction Pressure above 100 psig (7 Kg/Cm2).

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L.Y*

sCD

EPROCESS &

f

DISPLAYEXTRACTKINPRESSURE +

Q8B

EXTR. PRESS. SIGEXTR. PRESS. ERROR

%1) HL 22

b EXTR. PRESSURE A

2 SUMMER

EtDISPLAY B

EXTR. FLOWQ LIMITING INDICATION l

\ -A<E? A 3

RAISE

LOWER

EXTRACTION

Ep;Ey;;;y SETPOINT EXTR. PRESS.Jz.mLJRF\I EYTR I FLOW LIMIT

_I.. I 1.

RA,SE --) FLOW LIMITSETPOINT

LOWER--) BLOCK

SETPOINTb SETPOIN

REGISTEII

1 EXTR. FLOW LIMITTR

DISPLAY EXTR.PRESSURE SETPOINT

DISPLAY EXTR.FLOW LIMIT SETPOINT 4

1

TR. PRESS. CONTROL SIGNAL _

PetYo Power G E K 105632

1. PWR-HPX

EdFEE

INLET FLOYV

IN-FLOW. VI-FLOW

HP .xtr-FLOW I Vl-FLOW - v2-FLoW

EXH-FLOW I V2-FLOW

PWR = HPp I w-FLOW + LPpr = V&FLOW

WtUe M(pr=Wlblhr

Figure 3-3. Single Automatic Extraction Control with Inlet Pressure Limiter,Inlet Pressure Control (Condensing Unit)

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Extraction Pressure Control Characteristics - Regulation

The basic characteristic of the Extraction Pressure Control signal is proportional with a lag. An EXTRAC-TION PRESSURE REGULATION control software constant is Factory set at 5%. A steady-state pressure droop(regulation) of 5 percent for a 125 percent guaranteed extraction flow change is obtained with this constant set at5%. Lesser amounts of droop can be obtained with this constant set below 5%. See Figures 3-4 and 3-5. The factory-set constant is adjustable by changing control constants in the software. The regulation is seldom changed once theoptimum value is obtained for a particular application.

Extraction Flow Limit Control

An Extraction Flow Setpoint of 0 percent represents Zero Extraction Flow, and 100 percent represents 125percent of the Guaranteed Extraction Flow. The Extraction Flow Setpoint provides an upper limit on the amountof Extraction Flow that the Turbine can deliver to the Extraction Process. (See Figure 3-6.) When the ExtractionFlow Demand equals or exceeds this limit, Extraction Pressure may decrease in an uncontrolled manner. The EX-TRACTION FLOW LIMITED indication is lit in the Control Status Window of the Operator Interface Module andan Alarm is given to alert the Operator to this condition. To return the Unit to the Extraction Pressure Control mode,the Operator must either increase the Extraction Flow Setpoint or take action to reduce the Extraction Process Flowdemand.

Inlet Pressure Control Mode(s)

This unit also has the capability of controlling inlet pressure, as noted earlier, at the expense of either Speed/Load Control (usually) or Extraction Pressure Control. In this mode, the inlet control valves are positioned by inletpressure signals, using a preselected pressure setpoint, in response to available inlet flow. The range of pressure set-points available is usually from 80% to 105% of design pressure, with normal regulation or droop adjustable fromapproximately 2% to 5% for full inlet flow changes.

Inlet Pressure Limiting

In addition, this unit also has an inlet pressure limiting sub-system, which may be placed in standby serviceto provide protection against water carryover in the event that inlet pressure falls below the normal operating range.

With the unit either connected to the utility tie or isolated, limiting will occur on the Speed/Load control sig-nal and electrical load will be sacrificed if inlet pressure should fall.

In the event that inlet pressure falls below the minimum pressure level of the Inlet Pressure Limiter, a lowinlet pressure alarm will first occur, and if pressure falls further a low inlet pressure trip signal is provided to tripthe unit off line.

Steam Let Down Station - ‘lkbine Bypass Valve And Related Components

The turbine bypass system is supplied for operation when the quality of the steam is not suitable for use inthe turbine, and/or for a load rejection, where the turbine and steam generator are maintained in a standby condition,available for operation, but the driven equipment is not available.

The components include a pressure transmitter in the main steam header, (part of the turbine supply). SeePT400 GE Drawing B777A54D 155403, a combination steam conditioning and pressure reducing valve PV-029,between the main steam header and the condenser, a steam de superheating water control valve TV-423, andassociated temperature transmitter.

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115

85

) 5% A P FOR 125% A FLOW

L

NOTE: RESET RATE FACTORY SET FOR 10 SEC, BUT ACTUALRESET RATE WILL DEPEND ON APPLICATION.

Figure 3-4. vpical Time Response for a MaximumGuaranteed Extraction Flow Change.

0 25 50 75 100 125

EXTRACTION FLOW ( % GUARANTEED)

Figure 3-5. Typical Steady-State Regulation Curves(Control Constant @ 5%)

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0 2 0 4 0 6 0 8 0 1 0 0

EXTRACTION FLOW LIMIT SETPOINT (%)

Figure 3-6. Relationship between Extraction Flow Setpoint and Extraction Flow Limit.

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F’T4OOONGEDRAVVlNG -----_-_----B777A54D155403

“E Mr\” “VW I “VLLL”

I I MAIN STEAM e

1I TO TURBINEI

TV-019

GE MKV CONTROkER

The steam is taken from the steam generator through the high pressure steam header, to PV-029. The mainsteam header pressure is detected by PT-029 (PT400), in the main steam header. IT029 (PT400) outputs a 4 to 20mA signal to the process controller (MK V), proportional to the pressure range. If the pressure in the HP header isgreater than the setpoint, the process controller (MK V) outputs a 4 to 20 mA signal to PV-029 to open and pass steamthrough the bypass line. The pressure is reduced to the level acceptable for admission to the Main Steam TurbineSurface Condenser. The steam temperature on the LP side of the bypass system is detected by TI-019 downstreamof the steam conditioning valve. IT-019 outputs a signal to the process controller (MK V), which in turn outputsa 4 to 20 mA signal to TV-019 the cooling water temperature control valve. TV-01 9 will be modulated by the control-ler (MK V) to maintain the set temperature.

A solenoid valve, SV-029, is provided on the Steam Conditioning Valve PV-029, should it be desirable tooverride PV-029 closed on low pressure limit (MK V contact output).

Instrument Data

Pressure Transmitter PT-029 (Tag No. PI-400 Dwg. No. B777A54D155403)

Manufacturer Fisher Rosemount

Range 0 to 200 KPa(A)

Scale Linear

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Instrument Data (Continued)

Action Direct

Output to MK V Controller 4 to 20 mA

Temperature Transmitter Tr-019

Manufacturer Fisher Rosemount

Range loo to 500°C

Scale Linear

Action Direct

Output to MK V controller 4to20mA

MARK V CONTROL SYSTEM GENERAL DESCRIPTION

The MARK V steam turbine control system is a microprocessor-based digital control system designed exclu-sively for GE-manufactured steam turbines. The product is built from the proven family of TC2OOO digital hardwarewhich has many successful years of field operations in applications such as gas turbine industrial control and paperand steel mills.

The Mark V combines this proven electronic hardware and software with GE’s EHC turbine control experi-ence to provide an advanced but proven digital control system.

The Mark V system has been designed for both new unit applications and retrofit of older analog controls.From a menu of control, protection, and monitoring lists, appropriate functionality is selected to meet the require-ments of each specific steam turbine application. Only those functions that are necessary and/or user-selected asoptions are implemented in the hardware and software. The software specified is prepared and installed in the equip-ment at the factory and is an integral part of the system when it is tested and shipped. However, it is relatively easyto program the Mark V System at site to change, delete, or add functions, as desired.

Plug-in circuit boards are manufactured under the highest industry standards. Quality is enhanced by highstandards of quality assurance, from incoming component burn-in and testing to card level burn-in and tests, fol-lowed by end product testing and other quality assurances.

The Mark V control system incorporates all closed loop controls, turbine/generator protection, and monitor-ing functions described below. The hardware includes a free-standing cabinet, with an integral emergency backupcontrol panel and with separate operator interface modules (OIM’s) or control panels, as required.

Basic Control Functions

Speed control over the range of 0 to 3075 RPM.

Speed adjustable from the Operator Panel (OIM) through the speed setpoint. An automatic feature al-lows a speed target to be selected along with an acceleration rate. These commands are then enabledusing the ENTER key on the OIM.

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Load (control valve position) control through the turbine control valve position loop.

Load is adjustable from the Operator Panel (OIM) through the turbine control valve load set point. Anautomatic feature allows a load target to be selected along with a load rate, and then enabled using theENTER key on the OIM.

Extraction pressure control provided with automatic extraction turbines.

Automatic pressure control at rated pressure with setpoint and proportional band adjustments alongwith “In” and “Out” (flow limit) functions are available to the operator, through keys and cursors atthe OIM.

l’hrbine/Generator Protective Functions

Overspeed Protection - Three levels are provided, with voting logic, relay drivers, and two (2) ElectricalTrip Devices (ETD’s). The speed control and overspeed system utilizes 2 sets of three identical speed pick-ups (oneset of primary probes, and one set of emergency overspeed probes) mounted in the turbine Front Standard and ex-haust bearing bracket. These are used as common inputs to the speed control system, and for the three levels ofprotection, as follows:

Level 1 - All turbine steam control valves close on a 5% (Typical) proportional overspeed, based ona high select signal from the primary speed measuring system (i.e., valves should be closed at 105%speed).

Level 2 - If primary overspeed trip speed is reached (approximately 1 lo%), the turbine Inlet TripThrottle Valve will trip closed, and the turbine conlroi valves will close, based on two of three speedcircuit voting. A RESET signal will be required from the Operator Panel (OIM) torestart the turbine.

Level 3 - If emergency overspeed trip speed is reached (approximately 112- 113%), the turbine InletTrip Throttle valve will trip closed, if not already tripped due to primary overspeedtrip, and the tur-bine control valves will close, based on 2 of 3 overspeed trip voting. A reset signal will be required fromthe OIM to restart.

Manual trip capability, lube and hydraulic system trip capability, exhaust vacuum and temperature tripcapability, and generator trip capability are, of course, also provided at the Mark V.

Monitoring Functions

The monitoring functions in the Mark V system are the analog variable and contact input/output signals uti-lized in controlling the turbine/generator. The variables and the alarm and trip status are displayed on the operator’sCRT (OIM). Variable signal and contact status are also provided as data on the standard RS-232 data link.

As an option, analog voltage or current signals and either NO or NC contacts are available at the Mark Vcabinet for customer use, as follows:

Variables: Speed, Speed setpoint, Load setpoint, Load Limit setpoint, Extraction Pressure(s)and Setpoint and Inlet Pressure(s) and Setpoint( plus other variables,as applicable.

Contacts: Trip and Reset status, Inlet Trip Throttle Valve status, Vibration, Axial Position,and Eccentricity and Differential Expansion Alarms/Trips (if applicable),Lube and Hydraulic Pressure Alarms and Trips, Exhaust Vacuum/Temperature

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Alarms and Trips (if applicable), power supply or computer failure,and other functions, as applicable.

Test Functions

On-line testing includes checking of the Primary and Emergency Overspeed Trip sub-systems, up to theETD’s.

Off-line tests include the Primary and Emergency Overspeed Trip systems, including the ETD’s.

Inlet TI’V and non-return valve testing is provided.

Hardware Configuration (See Fig. 3-7)

The Mark V steel control cabinet is 36” x 20” x 90” high with front access. The basic design is NEMA- 1 withcable entry from either the top or bottom. Allowable ambient is 0 to 45°C (113°F) temperature with up to 95% RI-I,NC. Dual 1 lo/220 Vat power input lines are recommended (one required) for power, with an optional 125 VDCsource if desired. The internal dc power supplies are redundant. A fan filter system is provided to eliminate dust anda temperature switch is provided to indicate high temperature.

The OIM consist of a table top industrial grade PC, 14”/ 15” monitor, keyboard, and track ball as a cursorpositioning device, see Fig. 3-7. This OIM can be located remotely up to 1500 feet (457 meters) away if desired.

A Back-up operator interface (BOI), LCD-type panel is mounted at the cabinet to provide the capability ofcontinuing turbine/generator operation or shutting down the system on failure of the primary OIM (see Fig 3-8). TheBOI also provides diagnostic capabilities to assist in troubleshooting and the determination of corrective actions.A manual trip PB is also provided at the cabinet.

A dedicated hardwired panel with TRIP pushbutton(s) is to be installed near the OIM, and a second TRIPPB(s) with optional 2nd remote OIM or panel, if supplied, and as desired.

Speed Sensing Probes

Speed sensing is accomplished by three passive speed probes, which produce pulses as the teeth of a 60-toothwheel pass by. These speed probes have proven to be virtually trouble free, and have an expected life of over 20 years.

Pressure Transducers

Steam inlet and extraction pressure transducers are supplied. These devices are rack mounted adjacent to theturbine for control functions or protection (see Fig. G28).

Input/Output Connections

All input and output signals are wired to the Mark V control system through terminations accessible fromthe front of the cabinet. For all connection information, see Mark V Interconnection I/O document (by GEMIS-Sa-lem), and Electrical Outline Diagrams (by TBO Engineering).

External Computer Or Hardwired Interfaces Available

The available interface to external computer equipment is an RS-232 connection for transmitting blocks ofpre-formatted data. This is a two-way link, permitting control of key variables from a remote location. “MODBUS

3-18

G E K 105&?2

STEAM TURBINE CONTROL SYSTEM (MARK V SIMPLEX)

14WS (IQ’ OPTIONAL)COLORCRT/PC

\

r-w ETHERNET DATA UNKI TO CUSTOMER’S; REMOTE MONITORING

- 36’--------1

PANEL (LCD)

TRIP 0P B

-2(y -

F&P&C

PROCESSORS

INTERFACE FORCONTROL/

SUPERVISORYFUNCTIONS

i STATION

OPERATOR’SINTERFACE MODULE (OIM) c l

P

INCLUDES:MONITOR, CPU.KEYBOARD,PRINTER. 6CURSOR POSITIONINGDEVICE, PLUS LOOSETRIP PB (BELOW)

TRIP PBMTD ON PANEL

------* TO SECOND OIM(OPTIONAL)

Figure 3-7. Control Center Configuration

3-19


I” protocol is normally used for formatting this interface. Ethernet protocol is also available as an option, based oncompatibility of customer’s DCS.

Alternatively, a hard-wired interface may be provided for monitoring and/or control of key variables froma remote location, when it is not planned to use the data link for control and/or monitoring.

CONTROL SUBSYSTEMS (SEE OIM DISPLAYS)

Standard And Optional (X) Features Provided

1. Speed Control - proportional control with 5% droop characteristic, plus primary overspeed tripprotection. Includes:

a . Three (3) redundant speed channels (Three Airpax passive-type probes).

b . Setpoint range (0%-102.5% rated speed, up to max capability) - cursors and displays (speed target,speed ramp rate, speed setpoint and speed ramp enable/disable keys and displays).

c. Digital Speed and setpoint display (RPM).

(Jo 2 . Automatic Isochronous Control - provides frequency control capability, with automatic reset to nm-ning speed (determined by the speed setpoint) following load changes during isolated operation. Ad-justs load setpoint when in service, so that operator does not have to adjust it when placing the system inor out of service. The action of the subsystem is automatically blocked if it attempts to adjust the loadsetpoint below that point corresponding to a load slightly above no-load. Includes In and Out of Servicekeys and displays. Requires input contact closure on loss of electrical tie.

3 . Load Setpoint Control - provides a means of adjusting load setpoint Main Control Valve (MCV) posi-tion. At start-up, provides a means of adjusting speed/load setpoint for synchronizing. On line, providesload reference in parallel with other units. In isolated SPEED/LOAD operation, adjustment of load set-point is used to restore frequency at desired operating load.

Includes setpoint range O-100% (maximum capability) and cursors and displays Goad target, load ramprate, load setpoint, and load ramp enable/disable keys and displays).

4 . Load Limit-provides a means of placing an upper limit on speed/load command (Main Control Valveposition). Includes:

a . Setpoint control (O-100% maximum capability), load limit cursor and display.

b. Load limited display and alarm.

5 . Automatic Speed Runup Control - Permits start-up from turning gear to synchronous speed at aprede-termined rate with predetermined targets/hold points. Rates and targets are adjustable at OIM or panel.

6 . Automatic Load Runup Control - Permits loading from synchronization to max capability at a prede-termined rate with predetermined targets/hold points. Rates and targets are adjustable at OIM or panel.

7 . Control valve servo actuator control (Vl and V2) - provides closed loop control of power actuator(valve) position for each control valve actuator. Includes the following:

a. Control valve setpoint command software.

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Petropower G E K 1 0 5 5 3 2

b . Control valve servo amplifier hardware/software in MK V.

c . Actuator (valve) position feedback signal(s) for closed loop position control.

d . Servo valve for positioning actuator.

e. Actuator (valve) position displays.

(X) 8 . Extraction Pressure Control - Proportional pressure control with lag (2-5% droop, adjustable). In-cludes:

a . Pressure setpoint control - cursors and displays.

b. Flow limit setpoint control - cursors and displays.

c. Flow limited display and alarm.

d. Minimum (or maximum) stage flow (control limited) display and alarm.

e . Pressure transmitter (4-20 Ma output, Rosemount 115 1G smart type).

m 9 . Inlet pressure control -provides a means of controlling the turbine header pressure, usually at the ex-pense of speed/load control. Speed load control remains in pre-emergency “standby” mode, capable offunctioning ifan overspeed should occur. Inlet pressure control setpoint is adjustable. Nominal pressureregulation is approximately l-5%, adjustable. Includes:

a . IN and OUT of service keys and displays.

b. Setpoint adjustment.

c . Inlet pressure controlling display and alarm.

d. Pressure deviation alarm, set at flO% error.

e . Pressure transmitter (4-20 Ma output, Rosemount 115 1 G smart type).

10 . Fixed Inlet Flow (Sliding Pressure) Control - Optional with (9) - Provides Fixed Inlet Flow Refer-ence Mode for “Sliding Pressure” operation in combined cycle power .plants.

m 11 . Automatic transfer from Inlet Pressure Control to speed/load or Isochronous Speed Control -Providesa means of automatically transferring from INLET PRESSURE CONTROL to Speed/Load Control orIsochronous Speed Control, in response to a separation from electrical tie-line. Includes:

a . In/Out of Service keys and display.

b. Transfer complete status/display.

c . Tie line breaker contact input required.

00 1 2 . Inlet Pressure Limiter on speed/load/ control provides a means of protecting the turbine from water car-ryover from the unit heat recovery boiler, upon loss of inlet pressure. An upper limit is imposed onspeed/load capability proportional to inlet pressure. Setpoint adjusts the inlet pressure at which the lim-iter becomes active. Nominal regulation is approximately l-10%, adjustable. Includes:

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a . In and Out of service keys and displays.

b . Pressure Setpoint, usually tracking adjustable inlet pressure control setpoint, with offset of approxi-mately (-) S-15%.

c . Inlet pressure limiting display and alarm.

d . Uses same pressure transmitter signal as IP control.

(W 1 3 . Remote Monitoring and Setpoint Target Control - provides a means of monitoring and controlling set-points at customer’s control station or DCS, remote from the OIM. (RS232 data link).

a . Remote DCS/computer mode selection key and display.

b . Interface - consists of all monitoring signals, plus setpoint selection, setpoint targets, and setpointfeedback signals.

(X) 14 . Air Operated drain valve Control/Monitoring (5 valves) includes Open Command output signals andOpen/Closed input signals for following 5 air operated drain valves:

Main trip throttle valve above/below seat drains (2)

Steam chest drain (1).

Packing re-entry drains (2).

w> 15. MW Setpoint Control - Provides capability for controlling unit MW, on a closed-loop basis, in Speed/Load control mode. Includes:

a . MW signal (4-20 mA) to MK V system.

b. Internal setpoint and associated software.

c . Dedicated screen functions for In/Out and setpoint adjustment.

16 . Unit &r/Power Factor Control - Provides for control of the unit VarYPower Factor to a pre-determinedsetpoint. Requires MW and MVAR input signals and provides output signals to exciter AC voltage set-ting.

m 17 . Special 2nd breaker automatic synchronizing software with 3rd breaker manual closing capability inMK V (see generator engineering for details).

NOTE

For supervisory level control and monitoring functions and interfaces, and proto-col for programming these functions, contact GE Control Systems Engineering.“MODBUS I” protocol is standard.

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Petropower G E K 1 0 5 6 3 2

FUNCTIONAL TEST SUBSYSTEMS

Standard And Optional (X) Features

1 . Electrical Trip Device (ETD) Tests - Provides a means of independently testing the ETD’s prior tostarting and synchronizing the unit, usually on turning gear. The unit is actually tripped by the ETD be-ing tested. This test is disabled when the generator circuit breaker is closed. Includes:

a. ETD- 1 test Key/display.

b. ETD-2 test Key/display.

c. Test Sub-system software.

2 . Off-Line Overspeed Trip Tests - Provides a means of independently testing the primary and emergen-cy overspeed trips PRIOR to synchronizing the unit. The unit speed is ramped up and the unit is actuallytripped by the trip function being tested. While testing the emergency overspeed trip, the primary over-speed trip setpoint is raised above that of the emergency overspeed trip, by approximately 2%. Thesetests are disabled when the generator circuit breaker is closed. Includes:

a. Primary overspeed test key/display.

b. Emergency overspeed test key/display.

c. Test subsystem software/hardware.

3 . On-Line Overspeed Trip Logic Tests - Provides a means of testing the primary and emergency over-speed trip logic while the unit is on-line. Includes:

a. Primary overspeed test logic key/display.

b. Emergency overspeed test logic key/display.

c . Test subsystem software/hardware. (Disabled if an actual OVSPD occurs.)

m 4 . Inlet ‘kip Throttle Valve Test - provides means of exercising the inlet trip throttle valve to ensure clo-sure during emergency trip situations. Includes:

a . Solenoid operated exerciser on trip throttle valve.

b . Open, closed position display for inlet trip throttle valve.

5 . Extraction Non-return Valve Trip/Reset and Monitoring - for non-return valve(s) in extraction steamline(s). Includes:

a. Protective logic in Mark V.

b . Contract outputs to test solenoid(s), with “TEST” Cursor/Pushbutton(s) on OIM.

c . Contact inputs from Open/Closed non-return valve limit switches.

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GEK 105632 Petfo Pow

OPERATIONAL MONITORING - STANDARD AND OPTIONAL (X) FEATURES

1. Unit Speed (RPM).*

2 . Inlet Control Valve (V 1) Position Indicator (%).*

(X) 3 . Extraction Control Valve (V2) Position Indicator (%).*

(X) 4. Inlet Pressure (Kg/Cm2).*

(X) 5. Controlled Extraction Pressure (Kg/Cm2).*

$7, 8. Uncontrolled Extraction Pressure (3) (Kg/Cm2)

m(X)w00CQcmm(X)(W

9. First Stage Shell Pressure (Kg/Cm2).

10. Exhaust Pressure (JSgKm2).

11. Steam Seal Pressure (Kg/Cm2).*

12. Lube Oil Pressure (KgKm2).

13. Control Oil Pressure (Kg/Cm2).

14. Generator Power (MW).

15. Generator Vars (MVAR).

16 . Generator Power Factor (calculated).

17 . Steam bypass line steam temperature (“C) (special option).

(X) 18-25. Bearing No. 1 (X 8z Y) Vibration Indicator (microns).

Bearing No. 2 (X & Y) Vibration Indicator (microns).



(Vibration monitoring includes alarm/display for high level vibration and trip displayfor high hightrip level vibration, plus trip alarm/display. Keyphaser (reference probe) for vibration phase range also.Also includes reset function for resetting alarms at the OIM.)

(X) 26, 27. Thrust (Axial Position) Indicator (Two channels - mm)

(Axial position monitoring includes alarm/display for thrust wear and trip display forthrust failure,plus trip alarm/display. Also includes reset function.)

* Used for control functions ss well as display.

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Pem power G E K 1 0 5 5 3 2

TRIP FUNCTIONS WITH SIMULTANEOUS ALARMS - STANDARD AND OPTIONAL

1. Low low lube oil pressure.

2. Low low control oil pressure.

3, 4. Local manual (front standard - (HS300) and turbine gear panel (HS320) - hardwired pushbuttonswith monitoring contacts).

5 . Manual trip @ Mark V control cabinet @IS350 - hardwired pushbutton with monitoring contacts).

6,7. Remote manual (OIM and customer’s DCS) - (HS302 and DCS trip - hardwired pushbutton withmonitoring contacts).

8 . Low low exhaust vacuum. (From software in Mark V).

9, 10. Generator electrical fault (SIMSEQ) trips - by others (86G1,8662).

11. Generator DGP trip (special).

12 . Primary overspeed (two of three logic - in Mark V software).

13 . Emergency overspeed (two of three logic - in Mark V software).

1 4 . Speed probe failure (two of three logic - in Mark V software).

15 . High high journal bearing vibration level (any bearing-in Mark V software).

16 . Thrust failure (two of two logic - in Mark V software).

17. Differential expansion trip (in Mark V software).

ALARM/STATUS FUNCTIONS - STANDARD AND OPTIONAL

1 . Emergency trip header tripped (sets Mark V internal trip condition).

2. Low lube oil pressure.

3. High lube oil level.

4. Low lube oil level.

5. Low control oil pressure.

6 . Lube oil cooler out temp high (MK V software, from RTD)

7, 8. Lube oil pump run signals (pressure switches for 2 AC pumps).

9 . DC Emergency lube oil pump running.

10, 11. DC Emergency lube oil pump/starter problems (starter fault and O/L).

12, 13. Control oil pump run signals (pressure switches for 2 AC pumps).

3-25


1 4 . Lube oil filter differential pressure high.

15, 16. Control oil filter differential pressure high (2).

17 . Exhaust vacuum low (MK V software, from analog signal).

18. Exhaust temp high (MK V software, from RTD).

19, 20. Steam seal pressure high/low alarms (MK V software).

2 l-22. Turning gear engaged/disengaged (2).

23. Unit at zero speed (in Mark V software).

24, 33. Extraction non-return valve Open/Closed (10).

34. Gen brkr status (by others) (52GX-1).

35. Tie line brkr status (by others) (52LX).

3 6 . High journal bearing vibration level. (In Mark V software).

3 7 . Thrust wear (axial position - in Mark V software).

3 8 . Eccentricity alarm (in Mark V software).

39. Differential expansion alarm (in Mark V software).

40. TMS probe failure (vibration, axial position, eccentricity - (in Mark V software).

4 1 . Mark V system fault alarms - includes:

a. Internal power supply failure.

b. Internal poiver supply buss deviation.

c. Primary speed channel fault.

d. Speed probe failure.

e . Other diagnostic alarms, as required and/or provided by design.

42. Load limited.

43. Inlet pressure controlling.

44. Automatic Transfer from INLET PRESSURE CONTROL to Droop or Isoch Speed Control.

45. Inlet pressure limiting.

46. Extraction control limited.

47. Extraction flow limited.

Petfo Power G E K 1 0 5 6 3 2

48-50. Turning gear motor, VXM, GXM starter status (3).

5 1,52. Generator cooler leak detectors (2).

53. Generator vapor extractor alarm.

54. Exciter ahums. (On EX2000 data link - see list.)

55. Generator control panel alarms (see list).

NOTE

Trip and alarm switches to the Mark V are to be rated 125 VDC, with contacts opento alarm and trip.

TEMPERATURE MONITORING/ALARM/TRIP FUNCTIONS (X) - PROVIDED

The following signals, from 100 OHM platinum RTD’s, with associated alarms and recommended trip set-points, are provided with the Mark V system:

(X) 1, 2. Lube oil cooler outlet and reservoir temperatures (2, plus spares).

(X) 3-6. High metal temperature - Thrust Bearing - positive face. (4 provided, with alarm and trip settings.)

(X) 7-10. High metal temperature-Thrust Bearing - negative face. (4 provided, with alarm and trip settings.)

(X) 11, 12. High metal temperature - Bearing No. 1. (2 provided, with alarm and trip setting).




(X) 19,28. Generator stator and cooler temperatures (10 temperature monitoring functions provided, with alarmand trip settings).

In addition, 6 TC’s, for inlet, exhaust and 4 extraction temperatures (1 controlled, 3 uncontrolled) are pro-vided, with alarms, as required.

NOTE

It is recommended that temperature trip settings be programmed to trip the unit,for maximum protection against possible damage.

BACKUP OPERATOR INTERFACE PANEL (SEE FIG. 3-8)

As noted earlier, the Mark V control system has an LCD-type backup panel, mounted on the cabinet door,which permits operation in an emergency mode, and shutdown capability in the event that the primary operator inter-face (OIM or panel) is not available.

3 - 2 7

Figure 3-8. Mark V Back-Up Operator Interface (OIM)

Access to all setpoints in the Mark V system is provided, so that settings can be varied in the on-line operatingmode, and a controlled shutdown can be executed. The unit can, of course, be tripped using the trip pushbuttonsmounted on the cabinet door. and at other locations.

Operation in the backup mode is initiated manually from the operator interface (OIM or panel), using the“Control Location” display, or from the backup panel itself. Re-establishment of the “Local” control mode can onlybe implemented at the “Local” panel, since that is considered the primary operator interface location.

STARTING AND OPERATING PROCEDURES

General

A functional description of the Speedtronic Mark V Simplex Turbine Control System used on this unit, andapplication and maintenance information, is contained in GEH 5979C, GEH 598OD, and GEH 6 195B. Informationconcerning the capabilities of the RS-232 data link with “MODBUS I” protocol for interfacing with a remote com-puter monitoring and control system is also contained in GEH 6 195B. All of these instructions are published by GEDrive Systems Operation, Salem, Virginia, and can be found in the Bulletins Section of this manual.

This section contains a summary of the Control System Operating Specifications and the Start-up OperatingProcedures. For reference, Table 1 lists key control system specifications for this unit.

Additional Reference Documents

The Operator Interface Module (OIM) which is described in detail in Vendor’s Instructions is the primaryinterface to the turbine control system and is the primary equipment to be used during the following operating proce-dures.

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Petm Power GEK 105fS32

1. For settings of all triphlaxmhtatus signals, see Bill Of Materials (Devices Data), drawing#/B777A23A155403

TABLE 1

CONTROL SYSTEM SPECIFICATIONS

Speed/Load Control and Protective Settings

Rated Speed

Proportional Speed Regulation

Primary Overspeed lXp

Emergency Overspeed Trip

Rated Load

Max. Capability

Inlet Pressure Controlling And Limiting

Transducer Rating

Design Pressure

Pressure Control Setpoint Range (if applied)

Pressure Limiter Setpoint Range(offset from Inlet Pressure Control)

Inlet Pressure Control Regulation (1%)

Inlet Pressure Limiter Regulation (1%)

Extraction Control Subsystem:

Transducer Rating

Design Pressure

Pressure Setpoint Range

Regulation

3000 RPM

-5%/ 100% load capability

3300 RPM

3360 RPM

Approx 68 MW

Approx 68 MW

160 Kg/Cm*

104 Kg/Cm’

79-111 Kg/Cm*

63-95 Kg/Cm*

approximately 5.2 Kg/Cm*

approximately 10.4 Kg/Cm*

60 Kg/Cm*

49.4 Kg/Cm*

45-58 Kg/Cm*

2.5 Kg/Cm*

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G E K 1 0 5 6 3 2 Petfo Power

PRESTART PROCEDURES

Preparations for Start-up

NOTE

Make sure that all procedures called for in Preparation for Starting, Loading, andOperating, described earlier in this section, have been accomplished.

1 . Check that bearing oil pressure is 20 psig (1.4 Kg/Cm*) minimum, with one AC lube oil pump running,and second AC lube pump and DC emergency lube pump in AUTO START.

2 . Check that the turbine is tripped. Press EMERGENCY TRIP pushbutton on front standard, or EMER-GENCY TRIP pushbutton at Mark V cabinet, or operator’s panel (OIM), prior to placing control oilsystem in operation.

3 . Engage the turning gear as follows:

a . The turbine shaft must be stationary (at zero speed), and TURNING GEAR DISENGAGED lightshould be displayed, on TURNING GEAR panel.

b . Start the turning gear motor, and manually or automatically engage the turning gear.

c . Once the turning gear is engaged and the turbine is turning, the TURNING GEAR ENGAGED lightwill appear and the TURNING GEAR DISENGAGED light will go out. Unit should be placed onturning gear at least 2 hours prior to start-up.

4 . Check that the INLET TRIP THROTTLE VALVE is closed, with steam up to the valve. Check that con-trolled extraction non-return valve is closed and other non-return valves are also closed.

5 . Check that all turbine casing, inlet trip throttle valve, and piping drain valves are open.

6. Check that the gland seal system is in operation. Refer to Preparations for Start-up, section entitled“Putting the Gland Exhaust System into Operation.”

7 . Check that the steam seals are in operation, as follows:

a . If steam seals have not been established, slowly open the manual valve, and adjust it to admit justenough low-temperature steam directly to the steam seal header to maintain a positive pressure of.5 to 2 psig (.05 to .14 Kg/Cm*) on the steam seal header.

b . For Warm or Hot starts, keep the steam seal system in operation with the turbine on turning gear.

8 . Check that exhaust vacuum is in the normal start-up range, i.e., better than 20 in Hg, (-0.67 Kg/Cm*)minimum.

9 . A minimum of 40% of design inlet steam pressure is required for starting the turbine, with aminimum of75’F (42OC) superheat. As steam inlet temperature, as well as length of shutdown, determines the typeof start, the following definitions apply:

a . For a Cold start, minimum temperature shall be 75’F (42OC) superheat.

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Petropower G E K 70!%32

b . For a Warm start, minimum steam temperature shall be in the range of design inlet temperature mi-nus 150” to 300’ F (83-167°C).

c . For a Hot start, minimum steam temperature shall be within 150°F (83OC) of design inlet tempera-ture.

10 . Pressure transducers should be connected to respective sensing lines for normal operation.

11 . Clear all trip/alarm condition faults prior to start-up, using ACKNOWLEDGE and RESET keys on op-erator panel (OIM).

12 . Check that all control valves are closed, that displays are correct, and that inlet trip throttle valve andextraction non-return valve are at closed positions, with CLOSED displays on OIM.

At Lube Oil / Control Oil System Control Panels

Check that the control oil system is ready, with one control oil pump running, and standby pump ready. Con-trol oil pressure should be normal, at approximately 1100 psig (76 Kg/Cm*). Check that oil temperature in tank isnormal, and cooling water flow is established.

At Excitation Control Cabinet

Check that all excitation power control breakers are closed to excitation equipment.

At Generator Control Panel

1 . Check that exciter field switch is in OFF position.

2 . Check that voltage control adjustment is at lowest voltage position, by holding the control switch in theLOWER position for several seconds.

3 . Check that generator circuit breaker is ready for operation.

NOTE

This unit has generator/exciter control/monitoring interfaces on OIM. See “Gener-ator/Exciter Monitoring and Control Options” described in previous section.

At Turbine Operator’s Control Panel (OIM)

1 . Press EMERGENCY TRIP pushbutton again to ensure the turbine is tripped.

2 . Check that the Speed, Load, and Extraction flow limit setpoints are at O%, with unit shut down.

3 . Check that Mark V control system is in LOCAL control mode, in which OIM is active for start-up.

4 . With inlet steam available up to inlet trip throttle valve, push RESET on OIM. The electrical trip devicesolenoids (ETD’s) should reset and inlet trip throttle valve should reset and remain closed. STCTRIPPED alarm at OIM should go out.

5 . If unit is cold, for uniform warm-up, perform the following procedure for pre-warming of valve chest:

3-31


a . Open trip throttle valve using handwheel.

b. Close trip throttle valve.

c . Slowly open the below seat drain to depressurize the chest. Repeat steps 1 thru 3 for about 30 minutesor until the steam chest is free of condensate.

6 . In cold start-up mode, the inlet trip throttle will be used for full arc start-up, and therefore will be leftclosed at this time.

7. In warm or hot start-up mode, the inlet control valves may be used for start-up, and inlet trip throttlevalve may be opened in preparation for start-up.

Electrical Trip Device (ETD) Trip Tests Prior To Startup

The ETD trip tests should be performed prior to the turbine being rolled off turning gear, as follows:

a . Make ETD- 1 off-line trip test by pushing ETD- 1 TEST key on the OFF-LINE TEST play at the oper-ator’s panel (OIM). Unit should trip, as indicated by alarm message on display. Reset the unit byoperating the RESET key.

NOTE

Check that inlet trip throttle valve, and inlet control valve trip quickly and fullyclosed when test is made.

b. Make ETD-2 off-line trip test by pushing ETD-2 TEST key on the OFF LINE TEST display at theoperator’s panel (OIM). Unit should trip, as indicated by alarm message on display. Reset by operat-ing the RESET key.

NOTE

Check that inlet trip throttle valve and inlet control valve trip quickly and fullyclosed when test is made.

c . Unit is now ready for startup.

START-UP, SYNCHRONIZING AND LOADING PROGRAM SEQUENCING

DETERMINING STARTING AND LOADING RATES

The type of start (defined as COLD, WARM, or HOT) will depend on the time of shutdown and will establishrotor acceleration rate at startup, as well as the loading rate, and time required to bring the turbine to rated speed.See Table 2 for parameters associated with various types of starts.

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TABLE 2

STARTUP PARAMETERS

I Hours IWarm 12-48 Hours 5 0 0

H o t Less than 12 500-750Hours

I Rzrt I - I 750

RecommendedSteam Inlet

Load Rate(%/minute)

1

ApproximateSteam ChestSoak Time(Minutes)

30-60

Design InletTemperature

-150 to 3OO’FDesign InletTemperature-150°F Max.

5 1 0

Design InletI

1 0I

0

Generally, the cold start is when the turbine is restarted after a shut down duration greater than approximately48 hours, the warm start condition is equivalent to the turbine shut down for duration of 12 to 48 hours, and the hotstart is equivalent to a turbine shut down for a duration of less than approximately 12 hours before restart. The abovetemperature and duration correspondence assumes the turbine is fully insulated.

During the down time period preceding a warm or a hot re-start, full condenser vacuum, full steam seal opera-tion, and continuous turning gear operation must be maintained. Failing any of these limitations, any re-start mustfollow the cold start time duration while maintaining the hot or warm start steam inlet conditions.

After determining the recommended type of start-up to be followed, refer to the appropriate “Hold Periods”as defined in Table 3.

TABLE 3

HOLD PERIODS

Type of StartCold

WarmHot

Low Speed Low Speed High Speed High SpeedHold Point Hold Duration Hold Point Hold Duration

[RPM1 [min.] [RPM1 [mN1 0 0 0 15 2500 3 01 0 0 0 2 2500 1 01000 2 2500 2

3-33


OPERATION OF STEAM LET DOWN STATION -TURBINE BYPASS VALVE ANDRELATED COMPONENTS

The turbine bypass system, described earlier, is supplied for operation when the quality of the steam is notsuitable for turbine startup, and/or for a load rejection, where the turbine and steam generator are maintained in astandby condition, available for operation, but the driven equipment is not available.

As described earlier, during startup the steam is taken from the steam generator through the high pressuresteam header, to valve PV-029. The main steam header pressure is detected by @T400), in the main steam header.PT400 outputs a 4 to 20 mA signal to the (MK V), proportional to the pressure range. If the pressure in the HP headeris greater than the setpoint, the (MK V) outputs a 4 to 20 mA signal to PV-029 to open and pass steam through thebypass line. The pressure is reduced to the level acceptable for admission to the Main Steam Turbine Surface Con-denser. The steam temperature on the LP side of the bypass system is detected by IT-019 downstream of the steamconditioning valve. IT-019 outputs a signal to the (MK V), which in turn outputs a 4 to 20 mA signal to TV-019,the cooling water temperature control valve. TV-019 will be modulated by the MK V to maintain the set temperature.

A solenoid valve, SV-029, is provided on the Steam Conditioning Valve PV-029, should it be desirable tooverride PV-029 closed on low pressure limit (MK V contact output).

RECOMMENDED START-UP AND SYNCHRONIZING PROCEDURE

The recommended start-up mode will depend on the length of the shutdown and inlet steam temperature,as indicated in Table 2 and Table 3. In the COLD start-up mode, it is recommended that the unit be started after firstopening and closing the inlet trip throttle valve to warm up the HP inlet valve chest for 30 minutes. In the WARMor HOT start-up modes, a warm-up period of l&15 minutes is used. For cold start-ups, after completing the pre-startwarm-up, the handwheel operated trip throttle valve should be used to slowly admit steam with the inlet controlvalves wide open, for a FULL ARC start. For warm/hot start-ups, the inlet trip throttle valve may be opened andthe inlet control valves used for start-up.

Zero Speed Checks Prior to Rolloff

1 . Prior to rolloff, with unit at rest (turning gear temporarily shut off), verify that ZERO SPEED signalexists, indicating that all three (3) primary speed probes are reading zero speed.

2 . With unit on turning gear (approximately 10 RPM running speed), verify that ZERO SPEED signal isnow off.

Rolloff & Acceleration to Rated Speed - Cold, Warm or Hot Start-up Mode

1 . If start-up is being made with unit in the COLD start-up condition, the inlet trip throttle valve should beopened and closed for inlet steam chest warm-up, for about 30 minutes prior to rolloff. At SPEED SET-POINT display on OIM set 1000 RPM speed setpoint reference. At LOAD LIMIT SETPOINT display,set 100% load limit reference, to apply an opening signal to the inlet control valves, for warm-up ofturbine inlet. Reset unit and slowly open inlet trip throttle valve and admit steam to the unit, for rolloffand accelerate toward 1000 RPM. Hold for another 15 minutes for uniform warm-up at 1000 RPM andproceed to step 3, if starting in cold mode.

2 . If start-up is being made with unit in the WARM or HOT start-up condition, the inlet control valves willbe used for rolloff after the inlet trip throttle valve has been opened and steam chest has been heat soakedfor 10-15 minutes. Verify that Speed Setpoint is at 0 RPM, and Load Limit setpoint is at 0%. At OIMSPEED SETPOINT display, set 1000 RPM speed setpoint reference. At LOAD LIMIT SETPOINT dis-play, set 25% load limit reference. Reset unit and slowly open inlet trip throttle valve to full open posi- ~

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Petro Ponfef GEK 105532

tion. Unit should roll off on inlet control valves and accelerate to approximately 1000 RPM. Hold foruniform warm-up at 1000 RPM per “WARM or HOT” low speed hold duration shown in Table 3.

3 . Assuming automatic runup to rated speed is desired, proceed as follows, using SPEED SETPOINT dis-play:

a . Set Speed Target Setpoint at 2500 RPM, and set Speed Ramp Rate at 250-750 RPMMIN, (depend-ing on whether unit is Cold, Warm, or Hot) and push ENTER. Unit should accelerateat specified rateto specified target of approximately 2500 RPM. Unit should be held per high speed hold durationshown in Table 3. Check for any problem, such as rubs, etc., as indicated by high vibration, axialdisplacement, etc, before proceeding.

b . After the 2500 RPM hold period, with Speed Target Setpoint now set to 3000 RPM, speed rampshould be re-enabled. Unit will again accelerate at specified rate, to specified speed target, of approx-imately 3000 RPM.

c . If, during automatic nmup, it is desired to override the Speed Runup Ramp, this can be done by set-ting a limiting “Speed Target” value, at the value of the hold point speed desired, or the “HOLD”cursor, on the OIM screen.

4 . If manual runup to rated speed is desired, proceed as follows, using SPEED SETPOINT display:

a . Use SPEED SETPOINT and RAISE/LOWER keys to adjust Speed Setpoint at desired rate to de-sired value, to accelerate unit to approximately 1OOO RPM. Adjust speed setpoint in accordance withrates and hold times required, and within vibration and axial position alarm limits.

b . After the 1000 RPM hold period, adjust Speed Setpoint at desired rate to desired value, to bring unitto approximately 2500 RPM.

c . After completing the 2500 RPM hold period, adjust Speed Setpoint at desired rate to desired value,to bring unit to approximately 3000 RPM.

5 . If applicable, at approximately 90-96% of rated Speed Setpoint, check that FIELD FLASH PERMIS-SIVE~occurs, and associated relay contacts close, to provide an external signal to the excitation systemand/or operator.

6 . At approximately 3000 RPM Speed Setpoint, check that SYNC PERMISSIVE occurs, and associatedrelay contacts close, to provide an external signal to the excitation system and/or operator. Adjust SpeedSetpoint to approximately 3000 RPM, to bring unit to just below rated speed (approximately 3000RPM), ready for synchronization.

TABLE 4

SPEED/TIME-VIBRATION PROFILE AND AXIAL POSITION LIMITSFOR START-UP AND ACCELERATION

Final Acceleration Approximate Hold Vibration Vibration Axial Axial EccentricitySpeed Rate Time at Speed Aim Level Trip Level Position Position (See note below)0-p) @pm/m.@ (minutes) (micron) (micron) Alarm (mm) Trip (mm) Alarm (PO1000 240-720 3 75 150 f.2.54 f.508 50

3000 240-720 none 75 150 k.254 1.508 Disabled

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G E K 105632 Petro Power

NOTE

Eccentricity alarm is set 50 urn higher than the existing (background) rotor run outor eccentricity.

Cautions During Runup

1 . At 1000 RPM hold point, extend hold time if vibration readings exceed the ALARM limits. If bearingvibration has not returned to acceptable limits or exhibited a tendency toward reduction after 30 min-utes, turbine speed should be reduced to 3W500 RPM before repeating the start.

2 . During acceleration to speed above 1000 RPM, if vibration levels exceed acceptable limits, TRIP THETURBINE IMMEDIATELY by pressing the EMERGENCY TRIP pushbutton. Reset, and reopen theinlet trip throttle valve. Adjust the speed setpoint to hold the turbine speed to 300-500 RPM for 30 min-utes before attempting another start.

3 . As the turbine is accelerated, it is not uncommon for the generator shaft to increase in vibration level as itpasses through critical speeds, which can cause the turbine bearing to momentarily respond in part to theincrease in vibration. This increase should diminish rapidly as the generator exceeds critical speed. If itshould persist or continue to rise beyond the ALARM limit, TRIP THE TURBINE using the EMER-GENCY TRIP pushbutton at the operator panel (OIM).

Off-line Testing Of Overspeed Trip Subsystems(To be performed during startup or during shutdown)

At each start-up (or shutdown), and particularly if tests have not been run in the last three months, check thateach of the overspeed trip subsystems (PRIMARY and EMERGENCY) can independently trip the unit, as follows:

1 . Test the primary overspeed trip by pushing the PRIMARY OVERSPEED TEST on the OIM test dis-play. Unit will accelerate to the primary overspeed trip speed (3300 RPM), and should trip, as all three(3) primary speed probes indicate overspeed, and trip relays and ETD’s operate. Reset using “RESET”function, and bring to approximately 3000 RPM again.

2 . Test the emergency overspeed trip by pushing the EMERGENCY OVERSPEED TEST on the OIM testdisplay. The primary overspeed trip will be suppressed, and unit should accelerate to the emergencyoverspeed trip speed (3360 RPM) and should trip, as the three (3) emergency overspeed probes indicateoverspeed, and trip relays and ETD’s operate. Reset using “RESET” function, and bring to approxi-mately 3000 RPM again.

3 . These tests are all disabled when unit is on-line. Verify by attempting the tests after synchronization.

Synchronization For Independent Or Parallel Speed/Load Control Operation

1 . If the turbine is to operate independently, at the LOAD SETPOINT display use the RAISE/LOWERpushbuttons, as necessary, to adjust turbine speed to desired operating frequency (approximately 3000RPM or 50 HZ).

2 . If the turbine is to be operated in parallel with other units, synchronize with the electrical system, using“Manual” synchronizing procedure described below. Place the turbine on line, adjusting the Load Set-point as necessary.

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Petfo Power GM 105632

Automatic Vs Manual Synchronization

The Mark V system for this unit has the capability of providing either automatic synchronization, or a “SynchCheck” function in the manual synchronization mode.

If synchronizing is to be automatic, select “Auto Synch Mode” on display at OIM. Synchronization modewill occur automatically, with speed and voltage matching accomplished by the Mark V, phase checking, and issuingof a generator breaker close permissive (L25), when all requirements are satisfied. The successful synchronizationis checked by the Mark V through a feedback contact (52GX) sent to the Mark V from the breaker.

If synchronizing is to be manual, with the Mark V providing the “Synch Check” function, select “ManualSynch Mode,” and proceed as follows:

Manual Synchronization

1. Initial Conditions.

a . Armature circuit breaker is open.

b. Exciter field switch is in OFF position.

c. Voltage control adjustment is at lowest voltage.

d . Generator is within 5% of synchronous speed.

2. Before Synchrcnizing.

Increase generator voltage as follows:

a . Place exciter field switch in ON position.

b. Note generator voltage build-up to minimum voltage level.

c . Note that exciter field ammeter will now indicate field current.

3 . Set no-load excitation by placing voltage control switch in RAISE position to raise generator voltage toapproximately rated voltage.

NOTE

The exciter field ammeter will provide a proportional indication of generator fieldcurrent.

4. Synchronizing Manually

a . Match generator frequency to bus frequency. Adjust turbine speed by adjusting the Load Setpoint(LOAD SETPOINT display) using RAISE/LOWER functions to set synchroscope at ZEROchange; then increase the Load Setpoint slightly to obtain a very slow clockwise rotation of the syn-chroscope (as determined by station practices).

b . Use generator voltage control switch in RAISE or LOWER position to adjust generator voltage tomatch bus voltage.

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c . Match generator phase angle to bus phase angle. When synchroscope indicates ZERO, close circuitbreaker to synchronize unit.

5. Initial Loading After Synchronization

a . A small initial load setting (3-5%) will be applied automatically after unit is synchronized, to preventmotoring. Set initial turbine output at about 5% of turbine rated load immediately after synchronizing, ifdesired, using the LOAD SETPOINT and RAISE functions.

b . Use voltage control switch to adjust excitation to obtain desired power factor or vars. NEVER EXCEEDGENERATOR CAPABILITY CURVE LIMITS.

LOADING

1 . Partially close the above and below-seat drain valves at the turbine inlet trip throttle valve, to minimizeleakage of high-pressure steam.

2 . Check inlet steam temperature (per curves).

3 . Adjust Load Limit setpoint to a value greater than approximately %, as desired.

a . For automatic loading, set desired LOAD TARGET and LOAD RAMPRATE, from start-up Param-eters, Table 2. Start the load ramp by pushing ENTER and observe that the valves are openingsmoothly, as unit load increases.

b . For manual loading, use LOAD SETPOINT and RAISE keys to set the desired load on the unit.

4 . Close all turbine casing and piping drain valves when load reaches 10 to 15% of rated load.

5 . Further operation of the turbine-generator, in terms of load and flow changes, is now a function of sta-tion procedures and the application of the other controlling subsystems incorporated in the Mark V con-trol system.

ECONOMY OPERATION VS STRAIGHT CONDENSING OPERATION

This unit has been programmed with Economy operating mode software, start-up, synchronization, and ini-tial loading (above approximately lO-20%). It is accomplished with the valves in the Economy mode positions-thatis, with inlet (v 1) valves controlling, and extraction (V2) valves essentially fully open, so that they do not impedesection flows and affect unit output. When programmed, this mode is normally automatically preset at start-up andmaintained until generator breaker is closed. It is intended that the operator will manually remove the Economymode, as desired, after synchronization and minimum loading, assuming that operation at this point is to be in thespeed/load and/or process pressure control modes.

To remove economy mode, select and enter ECONOMY OUT at the OIM. The V2 control valves will rapidlyramp closed to their normal straight condensing positions, ready for the application of extraction control mode.

ISOCHRONOUS SPEED/LOAD CONTROL IN ISOLATED MODE

In order to apply isochronous control mode, the turbine is assumed to be operating at 3ooO RPM in speed/loadcontrol mode with nominal 5% speed regulation for a maximum capability load change. It must be operating isolatedfrom the utility grid (tie line breaker open), with IS0 OUT display on.

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Petropower GEK 105632

1 . With utility tie breaker open, and unit isolated, enable isochronous control by pushing IS0 IN on IS0CONTROL display. Isochronous control should begin to operate, as unit load changes, by automaticallyraising or lowering Load Setpoint to exactly match unit speed to Speed Setpoint at all times, and therebycontrol frequency within a narrow deadband (&.05%).

2 . If tie line breaker to utility grid is now closed, observe that isochronous control is disabled, but that IS0IN message still appears on display. If left in this mode, isochronous control will resume automaticallywhen tie line breaker reopens.

EXTRACTION PRESSURE AND FLOW LIMIT CONTROL DISPLAYS AND OPERATION

The Setpoints for Extraction Pressure and Flow Limit Controls are adjusted at the Extraction Displays onthe Operator Interface Module.

In these Displays, the various functions are used as follows:

1 . EXTR PRESS is adjusted by using the RAISE/LOWER keys to increase or decrease the value of EXTRPRESS SETPOINT. Alternatively, the setpoint may be set at a preselected value by typing in and enter-ing that value.

2 . EXTR FLOW LIMIT is adjusted by using the RAISE/LOWER keys to increase the value of EXTRFLOW SETPOINT. Alternatively, a preset value may be typed in and entered.

The Operator can use either the RAISE/LOWER Functions to change any Setpoint at a rate determined bythe rate at which the keys are “pulsed” or “jogged” manually, or can type in and enter a preselected value.

EXTRACTION CONTROL OPERATION

The Extraction Pressure Control subsystem can not be put into service at very low loads, (V 1 valve positionbelow minimum flow), because at low load levels, HP turbine section cooling flow may still be a problem. Alsoextraction pressure control will usually be sacrificed to maintain speed/load control. Assuming that above conditionsare satisfied and an EXTRACTION steam demand exists, proceed as follows.

1 . Initially, EXTR FLOW LIMIT display will be on and EXTR CONTROL LIMITED display will be off,indicating the subsystem is out of service. Extraction pressure regulation may be at any value between 2and 5%, depending on the regulation desired, but it is recommended that it be programmed initially forapproximately 5%.

2 . Check that valve is open in sensing line of extraction pressure transducer, (PT408).

3 . On the EXT PRESS SETPOINT display adjust, using RAISE/LOWER keys to raise or lower the Ex-traction Pressure Setpoint to 50% as shown on the EXT PRESS SETPOINT-PERCENT display (or setto any other pre-established setpoint, is desired). (See Table 1 for range of Setpoint values).

4 . At EXTFLOW LIMIT display, use RAISE keys, to increase the Extraction Flow Limit Setpoint, slowly.As the Extraction Flow Limit Setpoint increases, V 1, and V2 valve gear will move proportionally (V 1open, V2 closed). The non-return valve in the extraction header will open to pass extraction flow. Con-tinue increasing this setpoint towards lOO%, (or to any other desired limiting value). Extraction flowwill increase as the V 1, and V2 valve gear move to positions determined by the Extraction Pressure Set-point and extraction flow demand. The EXT FLOW LIMIT display will go out when the subsystembegins to actively control extraction pressure.

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5, If there is no movement of the V 1, and V2 valve gear as the Extraction Flow Limit Setpoint is increased,this means that HP extraction pressure is higher than the Extraction Pressure Setpoint. This can also benoted by the fact that the EXT FLOW LIMIT display will go out immediately as the Extraction FlowLimit Setpoint is increased above 0%. If this occurs, increase the Extraction Flow Limit Setpoint to100% or to any other desired upper limit, and leave in a standby mode.

6 . Adjust Extraction Pressure Setpoint to the desired pressure level by using RAISE/LOWER functions,or setpoint target.

7 . If the Extraction Flow Limit Setpoint is set at a position below lOO%, upper limits are imposed on thevalue of extraction flow which the turbine can pass. If extraction flow should reach its limiting value, theEXT FLOW LIMIT display will go on, to alert the operator that limiting has occurred.

8 . If desired, extraction flow can be manually limited for any reason, such as when excessive demandcauses extraction control limiting due to closure of the V2 valves and appearance of the EXT CON-TROL LIMITED (MIN FLOW) display. This manual limiting is done by reducing the Extraction FlowLimit Setpoint until extraction pressure and flow drop slightly. At this time, the EXT CONTROL LIM-ITED (MIN FLOW) display will go off (if on) and the EXT FLOW LIMIT display will go on. The ex-traction control subsystem is now temporarily out of service, since the demand is being limited by theExtraction Flow Limit Setpoint. However, if extraction flow demand falls below the Flow Limit Set-point, the subsystem will then return to service, and the EXT FLOW LIMIT display will go off.

9 . During operation in extraction pressure control when excessive flow requirements tend to close the ex-traction valves completely, the EXT CONTROL LIMITED (MIN FLOW) display will go on and thealarm will occur. These signals warn the operator that the flow in the intermediate pressure section hasreachedthe minimum level required for adequate wheel cooling. When this occurs, extraction flow and/or load should be shifted to clear the condition.

To clear the minimum stage flow condition, proceed as in 8, above:

At EXT FLOW LIMIT display adjust LOWER function to limit extraction flow signal, and therebyopen the extraction valves and decrease actual extraction flow, to clear alarm. When warranted, both theload and extraction flow may require readjustment to compensate for changing load-flow patterns.

10. To remove extraction pressure control subsystem from service, at EXT FLOW LIMIT display useLOWER function to adjust setpoint to the desired fixed operating level, or to zero, as desired.

INLET PRESSURE CONTROL (IPC) OPERATION (IF APPLICABLE)

Inlet pressure control is provided for unit control of inlet header pressure, in the event that inlet pressure isnot being controlled by other means. It is placed in service by selecting IPC IN on OIM display, and deselectingSPEED/LOAD control mode. In this mode, speed/load control is sacrificed as the unit follows the available boilersteam supply. Range of inlet pressure settings for this unit is from approximately 80% of design pressure to 105%.

For Inlet Pressure Control (IPC) operation, it is assumed that the pressure of the inlet steam source is to becontrolled by the steam turbine, which will operate in the flow-following mode. The Inlet Pressure Control subsys-tem can be placed in operation when the following conditions exist:

1 . The turbine-generator must be connected to the electrical network, which is controlling frequency, andrunning at approximately rated speed (3000 RPM), and should be loaded to 20% (or greater) of ratedload.

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#wropower G E K 105632

2 . Inlet pressure regulation for this unit is programmed for approximately 5%, calling for 5% inlet pressuredroop for maximum capability inlet flow change. It can be changed if desired, by changing IP regulationsetpoint.

To place Inlet Pressure Control (IPC) in service:

1 . Check that the valve is open in the inlet pressure transducer sensing line (PT4OO).

2 . In Inlet Pressure Control OIM display, check that “Inlet Flow Limit” is adjusted to lOO%, or a maximumlimit and adjust if necessary.

3 . On IPC SETPOINT display use RAISE/LOWER functions as necessary, to raise or lower the Inlet Pres-sure Setpoint to the desired operating level, as indicated by the IPC SETPOINT display (see Table 1 forInlet Pressure Setpoint range).

4 . Select and enter IPC mode, in place of SPD/L.D control mode. IPC IN display will come on, IPC OUTdisplay will go off. As the IPC subsystem is ramped into service, the Inlet Pressure Controlling displaywill go on as operating mode is transferred from SPEED/LOAD to IPC.

5 . If pressure regulation or “droop” is too low or too high with the regulation programmed for 5%, InletPressure (IP) regulation may be increased or decreased to obtain the desired droop and still maintainstable pressure control.

To remove Inlet Pressure Control (IPC) subsystem from service:

1 . Deselect Inlet Pressure Control, and select and enter SPEED/LO QD control mode. IPC IN and CON-TROLLING displays will go out, and SPD/LD control will be resumed, as Inlet Pressure Control isramped out of service automatically.

AUTOMATIC TRANSFER OPERATION - INLET PRESSURE CONTROL (IPC) TO SPEED/LOADCONTROL (SPD/LD CONTROL)

This unit has the ability to be transferred automatically from the Inlet Pressure Control mode (when con-nected to utility) to either the Proportional Speed/Load Control mode, or, if desired, to the Isochronous Controlmode, upon opening of the customer’s tie line breaker, which provides an opening contact to the MARK V.

1 . If transfer from Inlet Pressure Control to Proportional Speed/Load Control is desired, leave ISOCHCONTROL out of service when in Inlet Pressure Control mode. At AUTO TRANSFER CONTROLdisplay, select AUTO TRANSFER READY. When tie line breaker opens, unit will transfer to Speed/Load Control, and load will be reset to the required value for Isolated Speed/Load control operation,with proportional speed error, depending on operating load.

2 . If transfer from Inlet Pressure Control to Isochronous Control is desired, place ISOCH CONTROL inservice when in Inlet Pressure Control mode, with Load Setpoint at 100%. At AUTO TRANSFERCONTROL display, select AUTO TRANSFER READY. When tie line breaker opens, unit will transferto Isochronous Control, and frequency will be controlled by automatic adjustment of Load Setpoint,within *.05% deadband.

3 . To remove auto transfer from READY status, select AUTO TRANSFER OUT key on AUTO TRANS-FER CONTROL display. AUTO TRANSFER OUT display will appear.

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INLET PRESSURE LIMITER (IPL)

The Inlet Pressure Limiter is provided to protect the unit against water induction. Place in service by selectingIPL IN on OIM display. On this unit, the Inlet Pressure Limiter operates, if called upon, at an adjustable offset ofabout (-) 15% below design inlet pressure, and with proportional band of about 10% of design pressure, for closingVl control valves to their minimum flow position.

Note that on this unit, IP limiting will occur on the SPEED/LOAD control output, so that electrical load issacrificed on loss of inlet pressure, before extraction flow. (Extraction flows will, of course, eventually be sacrificedas well, as electrical load is reduced, after V2 control valves have closed to minimum flow setting.)

In any case, limiting will stop when V 1 control valves have reached their minimum (no load) flow setting,to prevent motoring.

For Inlet Pressure Limiter protection against water induction, Inlet Pressure Limiting may be placed in stand-by service, as follows.

1 . Check that the valve is open in inlet pressure transducer sensing line (PT4OO).

2 . On Inlet Pressure Limiter Setpoint display use RAISE/LOWER functions, as necessary, to raise or low-er the Inlet Pressure Setpoint to the desired level, as indicated by the Inlet Press Setpoint display (seeTable 1 for Inlet Pressure Setpoint range). The Inlet Pressure Limiter Setpoint will be automatically es-tablished at approximately (-) 15% (of design pressure), below the Inlet Pressure Control setpoint val-ue.

3 . On the Inlet Pressure Limiter display, select IPL IN. IPL IN display will come on, IPL OUT display willgo off. As the Inlet Pressure Limiter subsystem is ramped into service the Inlet Pressure Limiting dis-play may go on or may remain off, depending on the pressure level; i. e., whether pressure setpoint isgreater than operating pressure, and therefore whether limiting is required at the time.

4 . During operation in Speed/Load control mode, if inlet pressure falls below the Inlet Pressure Limitersetpoint, the control valves will close proportionally to protect the unit against water induction, andSpeed/Load control and load will be temporarily sacrificed. If pressure falls far enough, the unit will goto minimum flow condition. If pressure falls to setpoint of low inlet pressure alarm and/or trip, systemwill alarm and then unit will trip.

5 . If pressure “droop” is too narrow or too broad at the design setting of approximately lo%, Inlet PressureLimit Regulation may be changed to obtain the desired “droop”.

To remove Inlet Pressure Limiter (IPL) from service:

1 . At Inlet Pressure Limiter display, select IPL OUT, IPL OUT display will appear and IPL IN display willgo off.

OPERATION UNDER EMERGENCY CONDITIONS

If, in the course of operation, an emergency condition develops - including especially, an uncontrolledoverspeed - which requires intervention by the operator, the turbine should be tripped for protection against dam-age. The primary means of tripping the turbine is by pressing the EMERGENCY TRIP pushbutton at the operator’sCONTROL panel (OIM), the TRIP PB on the Mark V cabinet, or the TRIP pushbutton on the turbine gage rackadjacent to the turbine and front standard, any of which operates to trip both the turbine inlet trip throttle valve and

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Pea? power G E K 1 0 5 6 3 2

all extraction NRV’s. THE TURBINE SHOULD ALWAYS BE TRIPPED IN THIS MANNER IN THE EVENTOF AN EMERGENCY.

Except in very special circumstances which may be dictated in a particular situation, the electrical loadshould not be removed from the turbine prior to an emergency trip. The emergency trip system itself is designedto open the generator breaker when the turbine has tripped, for maximum turbine and electrical system protection.

There are various mechanical, hydraulic, and electrical trip functions in the plant which can operate theETD’s and electrically trip the turbine. Some of them are characterized as “sequential trip” functions, wherein it issufficient to trip the turbine and then, through inlet trip throttle valve closure, open the generator breaker. Othersare characterized as “simultaneous trip” functions, wherein it is important to open the breaker at the same time thatthe turbine is being tripped, for electrical system protection. For further discussion on these and related subjects,the operator is referred to GE1 90368 on Protective Relaying and Electrical-Circuit Protection, found in the BulletinSection of this manual.

PROTECTIVE FUNCTIONS - TRIP/ALARM/STATUS SIGNALS

For information concerning the various Trip/Alarm/Status functions applied for the protection and properoperation of this unit, see the following:

1. Trip and Alarm/Status lists in this document.

2 . Bill of Materials Drawing, Fig. A23.

3. Cabinet connection and Electrical Diagrams.

ON LINE TESTS

1 . On-Line Overspeed Trip Logic Tests - Provides a means of testing the primary and emergency over-speed trip logic, while the unit is on-line.

a . Use primary overspeed test logic command on OIM to test primary trip logic. Primary trip relays(PTR’s) will be locked out of ETD trip circuit, and will indicate primary trip logic test complete, onOIM display.

b . Use emergency overspeed test logic command on OIM to test emergency trip logic. Emergency triprelays (ETR’s) will be locked out of ETD trip circuit, and will indicate emergency trip logic test com-plete, on OIM display.

2 . Inlet Trip Throttle Valve Test -provides a means of testing the inlet trip throttle valve to ensure that itwill be capable of closing during emergency trip situations.

a . Use “TEST” to test inlet trip throttle valve, by closing through partial stroke, to test position.

b . Observe inlet trip throttle valve open, closed, position displays (“OPEN” goes out during test).

3 . Extraction non-return valve test(s). The valves are tested from the OIM to insure that they will close inthe event of an emergency trip. (Periodic local observation of the valves during testing for smoothnessof operation is recommended).

a . Use “TEST’ command on OIM to test valves, by closing through partial stroke.

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G E K 105W2 Petro Power

b . Observe that “OPEN” display goes out and “CLOSED” display goes on when test is run.

MONITORING CHECKS

Check operation and scaling of all monitoring functions periodically (vibration, axial position, pressures,temperatures, etc.) and correct any problems, at first opportunity.

SHUTDOWN PROCEDURE

NOTE

The following instructions are for turbine controls only. They do not represent theentire shutdown procedure nor do they indicate a required sequence of operations.They are intended to call attention to factors which should be considered duringshutdown and are suggested as supplements to, accepted shutdown practices.

Consider the type of operation and shutdown - whether the shut down is to be of long or short duration,for parts replacement or repair, etc., so that the equipment and systems can be prepared accordingly.

Normal Shutdown

a . Establish a pre-shutdown Load Setpoint (minimum load recommended) and remove the followingsubsystems from service by operating the following functions on appropriate displays:

Inlet Pressure Control OUT

Extraction Pressure/Flow Controls OUT

b . Make sure that the standby lube oil pump(s) have a ready source of electric power and that the controlswitch(es) are in the AUTO START position so that a continuous flow of oil will be maintained whilethe turbine coasts to a stop, after tripping.

c . Using the LOAD setpoint and RAISE/LOWER keys, reduce the load setpoint to slightly above theno-load setpoint position.

CAUTION

If the turbine cannot be unloaded to slightly above the no-load position bymeans of the LOAD and RAISE/LOWER functions, do not trip the unit and/oropen the generator or tie line circuit breakers until an attempt has been madeto locate and correct the cause of the control system malfunction. If the problemcannot be located and corrected in a reasonable amount of time, the turbine gen-erator should remain on line until all sources of steam entering the turbine havebeen located and shut off. Failure to follow the above could result in an uncon-trolled overspeed of the steam turbine generator.

d . Assuming operation is normal, with the Load Setpoint at a value slightly above the no-load positionand the turbine at rated speed, open the generator circuit breaker only when load reaches approxi-mately zero.


e . Reduce generator voltage to minimum value with voltage control switch in LOWER position. Aftergenerator voltage reaches the minimum value, turn exciter field switch to OFF and exciter field cur-rent will go to zero.

f. Adjust water to the generator air coolers as necessary to maintain generator temperatures.

g . Trip the turbine by pressing EMERGENCY TRIP pushbuttons (OIM or local to turbine). When theturbine coasts to a stop and the zero speed signal appears, start the turning gear motor, and press theTG ENGAGE PB , or operate engage lever, to activate the turning gear. The TG DISENGAGED in-dicator will go out and the TG ENGAGED indicator will light.

h. Operate the oil pump for at least four (4) hours after shutdown, to cool the journals and bearings.The lube oil must remain on until the turning gear motor is shut off.

i. Secure condenser air removal system. Condensate pumps should be stopped only after the glandcondenser system is secured, (the gland condenser can be damaged by steam without cooling fromcondensate).

j. Secure steam seal gland exhaust system.

k . All turbine casing drains should be open. This should occur automatically on a turbine trip or waterinduction event control and supply by others.

1 . Secure the steam supply to the turbine and auxiliary equipment.

m. Shut off the water to the lube oil coolers.

n. Leave one (1) lube oil pump running, if duration of shutdown is to be relatively short (i. e. 1 or 2days).

Emergency Shutdown

In an emergency situation, TRIP the unit using EMERGENCY TRIP PB on operator’s panel, and secure unit,as described above.

GE/ 706788Feluuary 1997

GE Power SystemsSteam Turbine

Allowable Pressure and Temperature Variation

(For rated pressure and temperature - See Header sheet in Section 1)

I. ALLOWABLE VARIATIONS FROM RATED STEAM PRESSUREAND RATED STEAM TEMPERATURE

Rating, capability, steam flow, speed regulation and pressure control are based on operation at rated steamconditions. The turbine shall be capable of operating under the following variations in initial steam pressure andinitial steam temperature and exhaust steam pressure, but performance may not necessarily be in accordance withstandards established for operation at rated steam conditions.

II. VARIATION FROM RATED INITIAL STEAM PRESSURE

The initial steam pressure shall average not more than rated pressure over any 12-month operating period.

The turbine shall be capable of operating without injury at less than rated steam flow to the turbine with anaverage initial pressure of 105 percent of rated pressure. (This permissible variation recognizes the increase in pres-sure with decrease in steam flow encountered in operation.)

The initial steam pressure shall not exceed 110 percent of rated pressure in maintaining these averages, ex-cept during abnormal conditions.

During abnormal conditions, the initial steam pressure may swing momentarily to 120 percent of rated value,but the aggregate duration of such swings shall not exceed 12 hours per 1Zmonth operating period.

III. VARIATIONS FROM RATED INITIAL STEAM TEMPERATURE

The initial steam temperature shall average not more than rated temperature over any 1Zmonth operatingperiod.

In maintaining this average, the temperature shall not exceed rated temperature plus 15’F (8T) except dur-ing abnormal conditions. During abnormal conditions, the temperature shall not exceed rated temperature plus 25°F(14T) for operating periods not more than 400 hours per 1Zmonth operating period, nor rated temperature plus50°F (28OC) for swings of 15 minutes duration or less, aggregating not more than 80 hours per 1Zmonth operatingperiod.

These instructions do not purport to cover a/i &a/is or vatWions in equipment nor to provi& for every possibleconthgsncy to be met in connection with Astaiiation, opetation ormaMenance. Should further information be desitsd orshouidpattiwkwptiiems ake which 811) not covered sufficiently for the purchaser’s purposes the matter shouidberefemd to the GE Company. 0 1993 GENERAL ELECTRIC COMPANY

GEI 706788 Allowable Pressure and Temperature Variation

Iv. VARIATIONS FROM RATED EXHAUST PRESSURE ON NON-CONDENSING TURBINES

In addition to the foregoing pressure and temperature variation clauses, the following exhaust pressure varia-tions apply to NON-CONDENSING TURBINES ONLY.

The exhaust pressure shall average not more than rated exhaust pressure over any 1Zmonth operating period.

The turbine shall be capable of operating without injury at less than rated steam flow to the turbine, providedthat the exhaust pressure shall not exceed 110 percent, nor drop below 80 percent, of rated exhaust pressure.

GE Power Systems

General Eiectrk CompanyOne River Road, Schenectady NY 12345518* 385*2211 TX: 145354

155403-l

THROTTLE FLOW VS GENERATOR LOADFoster Wheeler / Pet ro Power

D i r e c t D r i v e T G S e t105 .49 KG/XI CM GAGE - 540 C - 47.24 MM HG ABS

AE AT “Oj;;oK; ;Q CM GAGE4

LOCUS OF VALVE POINT PERFORMANCE

3c I-. _-:_ ..-

81 0 2 0 3 0 4 0 70 80

GENERATOR OUTPUT(Kw;oIN THOUtfANDS

09/20/96 - R A C

155403-2

AUTOMATIC EXTRACTION ENTHALPY VS THROTTLE FLOW Foster Wheeler / Petro Power

Direct Drive TG Set 105.49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS

AE AT 50j/QOK; ;Q CM GAGE f:

EXPECTED DATA - NOT GUARANTEED

09/19/96 - RAC

155403-3

THROTTLE FLOW VS 1ST STAGE SHELL PRESSUREFoster W h e e l e r / Pet ro Power

D i r e c t D r i v e T G S e t105.49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS

AE AT 50j;JoK; ;Q CM GAGE6


5 5 8 5 7 0 8 0 8 51ST STA:E SHELL PRESSURE - KG,SQ7:M GAGE

09/19/96 - R A C

155403-4

APPARENT LP SECTION FLOW VS 5TH STAGE SHELL PRESSUREFoster Wheeler / Pet ro Power

D i r e c t D r i v e T G S e t105.49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS

AE AT 50.42 K G SQ CM GAGE3000 6R M


. ---.- ~.. , .,-.. w-n

::$PVI$~rTHROTTL-E-. I-rAT ‘OEs;tGW- CoNDt-T I

5 05TH STAGE SHELL PRESSURE - KG/SQ CM GAGE

09/19/96 - RAC

155403-5

CORRECTION FACTOR FOR INLET PRESSUREAUTOMATIC EXTRACTION OPERATION

Foster Wheeler / Pet ro PowerD i rec t Dr ive TG Set

105.49 KG/W CM GAGE - 540 C - 47.24 MM HG ABSAE AT 50i;;,KE

6;Q CM GAGE


5 106 107 108 109 1-10 1-11I NLET PRESSURE - KG/W Chi GAGE

09/19/96 - RAC

0

1 5 5 4 0 3 - 6

CORRECTION FACTOR FOR INLET TEMPERATUREAUTOMATIC EXTRACTION OPERATION

Foster Wheeler / Pet ro PowerD i r e c t D r i v e T G S e t

105.49 KG/% CM GAGE - 540 C - 47.24 MM HG ABSAE AT 50jMOKg ;Q CM GAGE

6EXPECTED DATA - NOT GUARANTEED

1 7 . 5 558.0 5 3 0 . 5 5 3 9 . 0 5 3 9 . 5 5 4 0 . 0 540.5INLET TEMPERATURE - C

09/19/96 - R A C

155403-7

CORRECTION FACTOR FOR AUTO. EXTRACTION PRESSUREAUTOMATIC EXTRACTION OPERATION


105.49 KG/W CM GAGE - 540 C - 47.24 MM HG ABSAE AT 50j;;,K; ;Q CM GAGE

6EXPECTED DATA - NOT GUARANTEED

‘44 45 50 52A U T O . EXiR. P R E S S U R E - KG/SO C M G A G E

$4 5s

09/19/96 - RAC

155403-6

CORRECTION FACTOR FOR EXHAUST PRESSUREAUTOMATIC EXTRACTION OPERATION


105.49 KG/W CM GAGE - 540 C - 47.24 MM HG ABSAE AT 50j;;OK;

6;Q CM GAGE


EXHAUST PRESS - Id HG ABS

09/19/96 - R A C

155403-9

APPARENT FLOW TO FOLLOWING STAGE VS STAGE 11 SHELL PRESSUREFoster Wheeler / Pet ro Power

D i r e c t D r i v e T G S e t105.49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS -

AE AT 50j;MoKE ;Q CM GAGE6


STAGE ii SHELL PRESSURE - KG/SQ CM Jdii3~

tll(24{97 - RAC.

APPARENT

1 5 5 4 0 3 - l 0

FLOW TO FOLLOWING STAGE VS STAGE 13 SHELL PRESSUREFoster Wheeler / Pet ro Power

D i r e c t Drive T G S e t105.49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS

AE AT 50j;MoKg6

;Q CM GAGE


STAGE 13 SHELL PRESSURE - KG/% CM GAGE ,I .:i

;&24{97 - RAC

155403-11

APPARENT F

105.

‘LOW TO FOLLOWING STAGE VS STAGE 14 SHELL PRESSUREFoster Wheeler / Pet ro Power

D i r e c t D r i v e T G S e t49 KG/SQ CM GAGE - 540 C - 47.24 MM HG ABS -

AE AT 50j;doK~ ;Q CM GAGE6


;3<24h97 - RAC.

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