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TECHNICAL REPORT

TURBINE INSPECTION
TANJUNG JATI #3

Reported By :

Muhammad Nasruddin
Mechanical engineer
PT. PJB

August 2015

B Class Planned Outage PLTU Tanjung Jati B unit #3


1. General
Unit

: Tanjung Jati B coal fired power plant unit no.3

Type of inspection

: B-class inspection

Service period

: August 2-25, 2015

2. Technical Specification of Steam Turbine


Manufacture

: TOSHIBA

Type

:TC4F

Rated output

: 695700 kW

Rated speed

: 3000 RPM

Steam condition
Initial pressure

: 167.0 bar (abs)

Initial temperature

: 538 C

Reheat pressure

: 35.3 bar (abs)

Reheat temperature

: 538 C

Exhaust pressure

: 72.0 mbar (abs)

Machine number

: T-6214

Manufactured year

: 2010

3. Work Scope Check list


Equipment

Section

Component

Control valve

Turbine

Valve

Main stop
valve

Combine
reheat valve

Work Scope

Check

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Review

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B Class Planned Outage PLTU Tanjung Jati B unit #3


Equipment

Section
LP Rotor

Component

Check

Review

*1
*2

Last blade

Visual Inspection

Level
Bearing
journal

Measurement

Visual inspection

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Dis-assembly

Cleaning

Check and measurement

Re-assembly and setting

Base plate

Regreasing

Welded joint

PT Check

Visual inspection

Bearing No. 1
Bearing
Bearing No.2
Turbine
Bearing No.3
Bearing
Thrust Bearing

Front Pedestal
Main Steam
Lead Pipe
HP Casing

Work Scope

*3

*4

*Review :
1. Last blade condition

Fig.1. Last blade condition


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B Class Planned Outage PLTU Tanjung Jati B unit #3


Comment :

Stellite metal coating on the tip of the last blade eroded by water
droplets but still in acceptable condition. it is reasonable on condensing
steam turbine but its value should be monitored because of excessive
wear can reduce turbine efficiency. Keep to maintain water quality.

Recommendation : Highly recommended to measure the depth of erosion accurately at


time of upcoming major outage. If the depth of erosion was approaching
the specified value hence needs to be planned corrective actions to be
undertaken such as re-stellite

2. Shaft casing leveling check (partially)

MEASUREMENT LOCATION

0.05

Fig.2. Shaft position

Comment :

Accurate measurement can be carried out when the upper casing


opened and coupling are disengaged. At this outage period, leveling
check used as initial reference to see shaft position against turbine
casing and taken only in bearing no #2 of HP turbine adapted to the
scope of work using 200mm precision level. There are no abnormalities
found for shaft or casing position.

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B Class Planned Outage PLTU Tanjung Jati B unit #3

Fig.3. Shaft and casing level measurement


Recommendation : Perform measurement at HP, IP, LP-A ,LP-B shaft against it casing while
upcoming major outage to see if there are any abnormalities at turbine
foundation, turbine centering position or any changes that occur during
operation.

3. Thrust bearing monitoring

Wear on shoe liner/pivot

Wear on thrust bearing leveling plate

Fig.4. wear check measurement

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B Class Planned Outage PLTU Tanjung Jati B unit #3


Comment :

Thrust bearing are inspected and measured during outage. Thrust


bearing clearance not measured adapted to the scope of work (shaft
coupling do not disengaged). Collar, shoe pad of thrust bearing in good
condition but liner wear contact needs to be addressed. Wear contact at
generator side wider than governor side. Maximum wear contact
reaches 10 mm.

Recommendation : We suggest to replace the shoe pad while upcoming major outage (class
C inspection) because it hard to adjust the axial position of shaft without
open the upper half casing and the coupling of the turbine shaft are
engaged. Base on our experience in 200 MW steam turbine that using
same type of thrust bearing, the maximum wear of liner value is 10
mm but we replace the shoe pad while next major outage. The shoe pad
must be replaced while their line contact reaches 20mm due to the
axial vibration tend to rise at this value. See the manufacturers manual
book to find out the maximum allowable of liner contact wear value.
It is important to check the run out of the assembled collar and shaft
prior to installation. The collar wobble may cause axial vibration
increased.
Keep monitoring end plays/thrust clearance in every outage period.
Thrust bearing clearance/shaft ends play is best checked by jacking the
shaft forward and backward with the force noted on the accompanying
instruction, the thrust housing cap must be first be doweled or bolted in
its exact position, and measuring accurately the change in position. If
direct measuring by jacking the shaft considered to harmful, alternate
method can be conducted by monitoring part that through wear during
turbine operation, such as shoe thickness and liner contact, at every
outage period.

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B Class Planned Outage PLTU Tanjung Jati B unit #3


4. Gland packing casing leakage
Leaks between turbine
casing and gland packing
casing

Gland packing casing


bolt leakages are
found at August 12th,
2015
Fig.5. Steam leakage at gland packing casing of HP turbine hvertical joint

Comment :

Gap still consist after retightening circumferential bolt. Leakage found at


vertical joint bolt of gland packing lower half too.

Recommendation : Perform complete disassembly and repair the vertical and horizontal
joint of gland packing casing. It must be no gap between gland packing
casing and turbine casing due to steam leaked. Steam leak is feared will
enter into the bearing pedestal (vacuumed by oil vapor extractor) and
affect the bearing temperature and degrade the performance of the oil
due to condensation of water.

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B Class Planned Outage PLTU Tanjung Jati B unit #3

Additional recommendation
1.

Adapted to the work scope of B-class planned outage at journal bearing inspection, we
suggest to monitoring shaft centering by perform run out measurement on each
couplings (couplings are engaged) using dial indicator. Measuring is taken before and
after bearings rolled out for inspection. While re-install bearings after complete
inspection, pay attention to ensure that the bearings are rolled-in at proper place and
sit back on previous installation.
See manufacture manual book to find out maximum allowable of coupling run out. If
run-out data out of range, need to be considering to checking the alignment of the
shaft. Mis-alignment may caused by excessive wear on the babbit of journal bearing
during operation.

Fig.6. Coupling run-out


2.

We suggest to use an additional/special tool to support the rotor while bearing has
being rolled out for inspection. The use of the tool is expected to make bearing rolling
out process became easier and saver. Hydraulic jack are designed to lift any load but it
does not recommend for continues prop because of possibility of oil deflated.

Fig.7. Lift up rotor to rolled out/in the bearing for inspection using hydraulic jack
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B Class Planned Outage PLTU Tanjung Jati B unit #3

Lower casing
pedestal

Lower casing
pedestal

shaft

Fig.8. Illustration rotor support to rolled-out/in bearing using special tools

Fig.9. Special tool to support the rotor that used at Gresik Power Plant (PJB company)

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