GE Triveni Ltd.

PROLANGED SHUTDOWN & STORAGE U1

LIST OF CONTENTS

10.0 PROLONGED SHUTDOWN

10.1.0 Preservation of Shut down Turbine Plants

10.1.1 Short shut-down up to 4 days
10.1.2 Shut-down longer than 4 days to 6 months
10.1.3 Shut-down of 6 to 8 months
10.1.4 Shut-down for indefinite period, longer than 6 to 8 months

10.2.0 RUST-PROTECTIVE TECTYL 506, 511

10.2.1 TECTYL 506

10.2.2 TECTYL 511-M
10.3.0 JOBSITE STORAGE OF GOODS

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U2

10.1.0 PRESERVATION OF SHUT-DOWN TURBINE PLANTS

GENERAL:

Shut-down the turbine plants are exposed to corrosion. Mostlyan electro-chemical process is
involved in which iron is converted to rust by presence of water and air (oxygen). Also the most
disadvantageous forming may occur. This process begins immediately after the turbine is shut-
down and has subsequently cooled–down. Air temperatures below dew point cause
condensation of air moisture on internal surfaces. The following measures were worked out
especially for steam turbine plants. The described measures are to be understood as
recommendations and must be decided upon on site according to actual operating conditions,
shut-down period costs plant location and plant size. For application and execution of such
measures GE Triveni 0.Ltd personnel should be employed. Leak steam and condensate
penetration to plant sections should be prevented first of all.

10.1.1 SHORT SHUT-DOWN (UP TO 4 DYAS)

The shut-down period counts from complete cooling-down. Special preventive measures are not
required. In turbines furnished with drying equipment the drying air is switched on after turbine
has cooled-down.
The turning gear can be disconnected in case down-period is longer than 72 h. prior to a restart,
check tenability of the turbine rotor and watch running smoothness at low speed.

10.1.2 SHUT-DOWN LONGER THAN 4 DAYS UPTO 6 MONTHS (plants which must be in
operation readiness after hour of preparation)

TURBINE:

Protect turbine against possible entering of leak steam. Do not use the emergency stop value as
a component of steam lock. It is not protected against corrosion. In turbines with furnished
drying equipment keep inner space of turbine dry by blowing air, the atmospheric humidity of
which is less than that of the air in the machine hall (less than 60%) or by lowing in pre-warmed
air to the effect that casing and rotor temperatures are kept above dew and freezing point. The
air supply is connected to the turbine exhaust nozzle. Drains are used for air exhaust.

Start the turning gear only shortly before restart and watch running smoothness.

PRESERVATION OF SHUT-DOWN TURBINE PLANTS

OIL SYSTEM:

Every 2 weeks put oil pump for 1 hour in operation. During this period all control devices shall
be moved once from COMPLETELY CLOSED to COMPLETELY OPEN. Turn turbine rotor
manually for approx. 2 turns; record in the turbine which provides good protection against
rusting after the above prescribed period before putting into operation.
Take oil samples as accustomed and drain, if applicable, accumulated condensate from the oil
tank.

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U3

SHUTDOWN 6 TO 8 MONTHS

The preventive measures described in this section are applied usually with seasonally operated
plants.

TURBINE:
Secure against entering of leak steam by closing the main stream isolation valve.

For internal preservation of the turbine, select one of the following described 4 procedures:
 Regular turbine overhaul by complete dismantling is planned to such cases preservation
of all internal components with VALVOLINE TECHNICAL 511 M is recommended.
 Keeping the turbine dry by blowing in dry air or pre-warmed air as follows: Keep the
inner space of the turbine dry by induction of air, the atmospheric humidity of which is
less than that of the air in the machine than 60%) or by the induction of pre-warmed air
to the effect that casing and rotor temperatures are kept in excess of dew point.

The air supply is connected to the turbine exhaust nozzle. The wheel chamber drain serves for
air exhaust. If there is a vent or a drain between emergency stop and control valves, then these
components can be used for an exhaust. Prior to a restart check rotation of the turbine rotor and
warm running smoothness at low speed.

PRESERVATION OF SHUT-DOWN TURBINE PLANTS

Inductions of a corrosion inhibitor in the steam system just before shutdown. An oil-steam
admixture is produced by means of portable injection equipment. After the oil-steam admixture
is being blown into the turbine, the oil is expected to form a protective coat on the walls when
hitting any internal surfaces. For pre-commissioning dismantling is not required.

Sufficient is 1 to 2 hours steam flushing operation via exhaust relief valve. (Flushing steam need
not to be dry and saturated.)
The so-called nitrogen procedure requires immediate expansion to atmosphere after shutdown
and subsequent air drying. Seal turbine by carefully closing of all valves; maintain slight nitrogen
over pressure of 5 to 10 mm (water column); nitrogen demand depends on the tightness of all
sealing and can be ascertained only by experiment. Nitrogen demand for a 35 MW turbine
amounts to approx. 8 m3 /h; control valves and emergency stop valves remain open. Check for
complete absence of nitrogen prior to restart to avoid accidents!
Check external coating and recoat if necessary. Apply VALVOLINE TECTYL 506 to bright
external components (prior to pre-commissioning use paraffin for removal), rub in MOLYKOTE
on valve stems.
Remove measuring instruments and electrical equipment, mark carefully and store wrapped in
oil paper.

OIL SYSTEM:

If during shutdown no power for the oil pumps is available, all the components of the oil system
were overhauled after shutdown; the measures should be taken as follows:
Regular turbine overhaul by complete dismantling is planned. In such cases preservation of all
internal components with VALVOLINE TECTYL 511M is recommended.

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U4
After this process, the periodical cut-in of the oil pumps as well as manually turning of the
turbine rotor may be omitted, proved that:

 Oil containing the usual corrosion inhibitors remains in the system.

 Oil lines and oil return lines are filled with oil and are isolated by slip plates.

PRECOMMISSIONING:

After previous preservation it is not necessary to dismantle the turbine before pre-
commissioning. Washing or flushing is carried out with steam. In case of condensing turbines it
is necessary to wash the condenser too by operating the turbine for about 1 or 2 hours and
draining the condensate. In a condenser being not washed remainders of the corrosion inhibitor
would deposit on the condenser tubes and as a consequence impair the heat transfer. The
washing process with steam must be carried out with turning rotor at slow speed. For
condensing turbines the exhaust steam temperature must not exceed 120 Deg C.

10.1.3 SHUT-DOWN FOR AN INDEFINITE PERIOD, LONGER THAN 6 TO 8 MONTHS

To protect turbine plants against corrosion for indefinite periods is rather extensive and
expensive. All measures overall overhaul of the complete turbo-set after shutdown. All
preservation in for 2 years intervals and renew if required. Prior to pre-commissioning the
corrosion inhibitors must be removed with steam or paraffin.

TURBINE:

Dismantle turbine latest after 4 days and remove rotor; check and clean internals; mark carefully
the components; apply TECYL 506 to all internals, bearings, joints, auxiliary drives, flange bolts,
etc. Bearings and joint surfaces should be additionally wrapped in oil paper. Apply TECTYL
511M to all inner casing surfaces. Dismantled components shall be wrapped in foils and stored
indoors or stored next to the turbine in cases.

Lift upper turbine casing, bearing cover, valve block by about 100 mm from the horizontal joint
by means of hardwood distance pieces. Wrap these in oil paper. Plug all turbine ports with
plastic covers well visible for everybody.

Clean and apply TECTYL 506 to all dismantled components like steam strainers, control and
emergency stop valves, valve chest, control components, barring gear etc.

Apply TECTYL 506 and preserve base plates, sliding surfaces, keys, guide pins. Remove
measuring instruments and electrical equipment and store them carefully marked and wrapped
in oil paper. Check external coatings, renew if required. Remove piping and clean and dry the
individual sections. Seal air-tight and apply a new external coasting. Order and keep on store
one set of new sealing rings and gaskets for pre-commissioning.

OIL UNIT:

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U5
The individual components are wrapped in foils and stored after cleaning, overhaul and
preservation.

PRESERVATION OF SHUT-DOWN TURBINE PLANTS

10.2.0 RUST-PROTECTIVE TECTYL 506, 511

Drain turbine oil and clean; take oil and if require provide a new external coating; apply TECTYL
511M internally above oil level. Due to the corrosion inhibitors usually contained in the oil refill
the oil tank so that preservation o the bottom part in the oil tank is provided. Remove piping fill
with oil seal and coat. Clean and overhaul the oil pumps and apply TECTYL 511 M internally
and apply TECTYCL 506 EXTERNALLY; oil pumps or store them indoors; clean immersion
pumps and reinstall.

Clean and dry the oil cooler on the oil and on the water side. On the oil side apply TECTYL
511M or refill with oil. If scaling off is expected in dry condition. Renew the internal coating on
the water side.
Oil filters; remove inserts, clean and apply TECTYL 511 M or fill oil and seal.
Remove and clean fittings, valves pressure switch, measuring gauges, etc.; wrap all equipment
in oilpaper.

10.2.1 RUST PROTECTIVE - TECTYL 506

PPOPERTIES:

TECTYL506 is a rust-preventive especially suitable for export of machines of various types.

When being supplied, product is liquid. The resulting wax film is not affecting any metal surfaces
and does not attack lacquer, plastics and rubber materials. This brown rust preventive is
resistant against temperature occurring in packing, which amount to 70-90 0C in some countries.
The wax film furthermore has an outstanding adhesion with minus temperatures. TECTYL 506
with its flexible protective film being tight and adhesive forms a good barrier between metal
surface to be protected and corrosive influences. Coverage amounts to 6-8 m2 per liter-
depending on the film thickness.

Protection period on clean steel surfaces

(Film thickness approx.100 Microns):

- Inside storage* 4-5years

- Outside storage* 18 months to years

APPLICATION:

TECTYL 506 can be applied by painting or spraying or airless to the parts to be protected.

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U6

SPECIFICATION:

TECTYL 506 fulfills US-Military

Specification MIL–C-16 173 D, Grade4

REMOVAL:

TECTYL 506 can be removed without difficulties by means of benzene petroleum, diesel oil or
wax solvents. In case of big surfaces steam jet cleaning device with special additives can be
used (prior to this use wax remover and wait for its reaction).

Spec. gravity DIN51757 0.88kg\dm3

Viscosity DIN53211 approx. 250 sec.

Flash point DIN51755 approx.40 Deg C

Class of danger as per VbF All

*without cover or packing outside. In case of additional packing protection period might be
longer.

10.2.2 RUST PROTECTIVE - TECTYL 511-M

PROPERTIES:

TECTYL 511-M is a fluid sloshing liquid. The resulting film is light-brown, nearly transparent and
soft.

Coverage amounts to 35-45 m3 per Liter. TECTYL 511-M is an especially water displacing and
creepable product. The film does not attack any metal surfaces. This product is very suitable for
temporary storage and sort time dispatch (metals being protected by TECTYL 511-M must be
covered o that neither rain water nor sunshine can affect them). It has a good separating effect
between metals and aggressive mediums so that steel is protected against rust and aluminum-
magnesium-alloys against efflorescence.

Protection period on clean steel surfaces

(Film thickness approx. 15 Microns):

-Inside storage * approx.18monts
-Outside storage*

APPLICATION:

TECTYL 511-M can be applied by spraying, painting or dipping the parts to be protected.

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U7
SPECIFICATION:

TECTYL511-M fulfills US-Military

Specification MIL –C-16 173 D, Grade 3and grade 5.

REMOVAL:

TECTYL 5011-M can be removed without any difficulties by gasoline,, petroleum, Diesel oil,
Wax solvents, alkali cleaner and stem.

Spec. gravity DIN 51757 0.865kg\dm3

Viscosity DIN 53211 12sec.

Flash point DIN 51755 approx. 40 Deg C

Class of danger as per VbF All

* without packing (Central Europe); in case of additional packing protection duration is longer.

PROJECT: USHA MARTIN LTD., 1x35MW

GE Triveni Ltd. PROLANGED SHUTDOWN & STORAGE U8

10.3.0 JOBSITE STORAGE OF GOODS

GENERAL

During storage before and during erection and first start certain precautions must be taken in
order to prevent corrosion damage to the plant equipment.
This instruction primarily covers the equipment delivered by GE Triveni Ltd , Bangalore. All
goods are packed for approximately two-three months storage (including transportation) when
leaving GE Triveni Ltd at Bangalore. Special Attention must be paid to the generator (see
generator manual). If the relative humidity of the environment is higher than 50%, the
recommended precautions must be taken immediately to prevent corrosion damage. If the
standstill period is expected to exceed 9-12 months, or if the environment is extremely
demanding, more extensive conservation procedure should be considered.

RECOMMENDED PRECUATIONS DURING STORAGE

All machinery, electrical and other sensitive parts shall be stored indoors. If the storage time
exceeds 2-3 months, the packages shall be opened and a dehumidifier unit connected to the
storage room in order to keep relative humidity below 50%. Other equipments, such as piping
and less sensitive materials, need not to be stored dry indoors, Instead, rust protection by use of
rust preventive agents e.g. Tectyl TM , water- soluble oils and silica gels inside sealed-off space
can be used. Weather protection and periodic inspections are recommended.

ARRIVAL AT SITE

 GENERAL

Place Crates and boxes so that they will not be exposed to water (rain, flooding etc.) and /or
physical damage.
Do not open any box or crate until the equipment in the specific box or crate is to be used. If an
opened box or crate is to be stored further, it must be carefully closed and resealed. At the
opening of the different boxes an inventory must take place using the packing list for each box,
in the presence of the GETL Site Representative

 SPARE PARTS

Spare Parts are to be placed indoors in a ventilated space with normal room temperature and
preferably low humidity. Rust inhibitors should not be removed until each part is intended to be
used.

 CONTROL CUBICLES

Do not remove or damage the plastic film that covers each cubicle. If an inspection of the
cubicles has to be made, the moisture absorbent (silica gel) must not be removed from inside
the cubicles. Welding as soon as possible should then hermetically reseal the plastic film.
Do not place the cubicles in their final space until the conditions are such that no condensation
will take place inside the cubicles.

PROJECT: USHA MARTIN LTD., 1x35MW