04 01 T6497 Prev Mainten A4 Color 2sided 2slides Each Side

For internal use only / Copyright © Siemens AG 2006. All rights reserved.
T6497 KERINCI
Steam Turbine Training
Maintenance
Preventive Maintenance
Preventive Maintenance
Schedule (Exampel)
No. Equipment/Module Test/Inspection / Maintenance Measuring / Fre- by
/Location Test Parameter / quency
Documentation
0400 Check of casing and internals WA
0400.1 Turbine Casing Check of bolt elongation LO max.; WA R K
0460 Check of shaft glands WA
0460.1 Shaft glands Check for escape of seal steam at WA d; A, S B
seal steam stack
0700 Check of bearing support WA
system(s)
0700.1 Thrust bearing Monitoring of babbitt metal WA, FL, IB h B
temperature
0700.2 Journal bearing Monitoring of babbitt metal WA, FL, IB h B
temperature
Slide 2 2007 - T6497 KERINCI Steam Turbine Operation and Maintenance Training Dieter Meyer PG I14314 Training
Test, Inspection and Maintenance intervalls:
Layout of the summary (1)
• The summary is broken down by the code numbers used in
the accompanying documentation (schematic diagrams,
equipment and function lists), as shown in column 1.
• Column 2 indicates the plant section, the item of equipment
or the measurement point.
• Column 3 specifies the tests and inspections to be
performed.
• Column 4 contains information about the measuring and test
parameters that are to be maintained and information about
pertinent documentation, with:
EIB = Initial commissioning
FL = Function list 0-2020-TNo.-16
IB = Commissioning data record
OEM = Manufacturer's documentation
WA = Maintenance instructions
Test, Inspection and Maintenance intervalls

• Column 5 shows the frequency with which the tests and inspections are to
be carried out, where
h = hourly
d = daily
w = weekly
m = monthly
y = yearly
Multiples of these frequencies are indicated by a prefixed number, e.g.:
3m = every three months
This column also shows whether tests are necessary on start up and
shutdown or, in special cases, during scheduled inspections:
A = on start up
S = on shutdown
R = during scheduled inspections.
Test, Inspection and Maintenance intervalls:
It is recommended that all important controls always be inspected for

proper functioning after scheduled inspections.
Column 6 indicates by whom the test/inspection and/or maintenance
actions are to be performed:
B = Operating personnel
W= Service/Maintenance personnel
K = PG service personnel
Monitoring the bearings

Work to be performed
Check the babbitt metal temperatures at the turbine thrust and
turbine journal bearings
Measured variable and test parameter
Refer to the functions list for permissible limits and the
Commissioning Data Record for setting values
Remarks, Notes
The babbitt metal temperature of the bearings must be monitored
continuously. If the temperature increases, the bearing must be
monitored more closely.
When limits are exceeded which allow the turbine to nevertheless be
run for a brief period, the turbine must then be shut down
immediately and the cause established.
Checking casing expansion
Check casing expansion at the indicator provided
for this purpose.
Refer to the Commissioning Data Record for the setpoints.
Remarks, Notes
The degree of heating can be approximated based on the
absolute expansion of the casing. The measurement results
also provide information about whether
Checking the shaft glands

Check visually shaft seal steam
There must be no escape of excessive shaft seal steam from the glands and
stacks.
Danger!
Risk of burns!
Do not touch the gland vapor stack when the turbine is hot.
Remarks, Notes
If the flow of escaping steam changes while all other conditions
remain the same, this usually indicates an increase in the seal strip
clearances.
The seal strips should be replaced as soon as possible to prevent an
unnecessary loss of steam. There is the risk that steam blowing into
the bearing casing and forms condensate in the oil system.
Checking the turbine shaft position
measuring device
Check the indication.
Measured and test variable
For reference values, please refer to the commissioning report.
Remarks, notes
The electrical measurement is continuous. The measured value allows
recognition of:
the thrust direction of the rotor,
displacement as a result of wear of the axial bearing and
any elasticity of the axial bearing
The rotor position at identical operating conditions should
always be the same
Measuring shaft vibration

Measure shaft vibration

Refer to the Commissioning Data Record for the setpoints.
Remarks, Notes
The vibration meter monitors the running condition of the turbine.
Changes over time can be ascertained using recorders.
Running behavior is satisfactory when the magnitudes of the individual
vibration levels do not change substantially over an extended operating
period and under the same operating conditions and when these remain
reproducible.
In addition, deviation from the standard values and then the magnitude
of the measured value must be taken into account when evaluating the
vibration levels.
Checking the coast-down time
Determination of the coast-down time of the shaft assembly of the

turboset is described below:
Coast-down of the shaft assembly from rated speed to shaft standstill.
Boundary condititons must corresponding to the reproducibility

conditions, e.g. back pressure.
Test intervalls: Initial commissioning, after corrective maintenance,

each time the turbine is shut down
Shifting of Oil Coolers
Measures
) Check the water inlet and outlet valves are completely open.
) Open vent valve of the standby cooler
) Open the filling valve between the oil coolers
) Feel with the hand if the cooler becomes warm
) Move the change over valve slowly to take the cooler in
service.
Shifting of Lube or Control Oil Filters
Changing of the lube oil filter will be required if the differential pressure
over the filter is too high. This will release a warning.
Measures
) Open the filling valve between the oil filters
) Open the vent valve of the standby filter
) Feel with the hand if the filter and vent line becomes warm
) Move slowly the change over valve to take the filter in service.
) Close the vent valve
) Close the filling valve
Cleaning of Lube or Control Oil Filters
Measures
) Open the vent valve and depressurising the filter.
) Open the drain valve and emptying the filter
) Open the cover of the filter
) Pull out the filter element
) Clean the filter element and the filter housing carefully
) Install the filter element
) Close the cover.
) Close the drain valve
) Open the filling valve and filling the filter.
) Close the vent valve
) Close the filling valve
Check Gas Pressure in Oil Accumulators
Measures
) Close the control oil isolating valve 1 to the
accumulator for test
) Open partly the drain valve 2 until the oil pressure
PI 07501 decreases. At the responding of the gas
pressure the oil pressure suddenly drops down.
This oil pressure should be between 5 to 6 barg.
If the drop pressure is lower, then the bladder
must be topped with gas (Nitrogen N2).
) Close the drain valve 2
1 2 ) Open gradually the control oil isolating valve 1
Charging and testing unit
Filling
– Slowly open the nitrogen bottle valve so that the

nitrogen can flow into the accumulator.
– From time to time interrupt the process and read
the pressure achieved on the pressure gauge
(M).
– After temperature equalisation has taken place,
check the pre-charge pressure again and adjust
if necessary.
– If the pressure is too high, it can be reduced via
the pressure release (B).
– Close the isolation valve on the nitrogen bottle,
depressurise the FPU-1, and remove the
charging unit.
– Check the sealing of the gas valve with an
appropriate leak detector spray.
– Screw on the sealing cap (5) and valve
protection cap (6), and observe torque settings.
Checking the shaft glands
Check visually shaft seal steam
There must be no escape of excessive shaft seal steam from the glands and
stacks.
Danger!
Risk of burns!
Do not touch the gland vapor stack when the turbine is hot.
Remarks, Notes
If the flow of escaping steam changes while all other conditions
remain the same, this usually indicates an increase in the seal strip
clearances.
The seal strips should be replaced as soon as possible to prevent an
unnecessary loss of steam. There is the risk that steam blowing into
the bearing casing and forms condensate in the oil system.
Protection against stand still corrosion

¾ No steam vapour or condensate may enter the turbine.
¾ The plant should be isolated from the steam and condensate
networks by monitored check lines or blanking plates
Hot-air conservation
Heated ambient air is blown into the turbine and as a result the relative air
humidity is lowered and at the same time the inner parts of the casing are
dried. This air takes up the moisture from inside the turbine and heats the cold
casing components to a temperature higher than that of the ambient air.
Dry-air conservation
A better and more economic solution for conservation of the turbine casing is
achieved by introduction of air, which has been previously dried. This
method has the advantage that the plant can be conserved for any length of
time and can, moreover, be made ready for renewed operation within a very
short time.
Diagram of Conservation Scheme
Schematic diagram of a hot-air

or dry-air conservation
scheme
1 Check line or blanking plate
2 Air outlets
3 Hot-air or dry-air connection
4 Turbine control valves
5 Turbine emergency stop valve
Nitrogen conservation
In addition to hot-air and dry-air conservation, filling up of the turbine

casing with an inert gas, in this case nitrogen, has been proven in
practice. Before blowing in the nitrogen, the turbine has to be dried.
The turbine must be subsequently carefully made gas-tight. All steam
and drainage connections must be closed, the shaft bushings in the
region of the sealing cups and the valve spindle bushings should be
sealing using "Densobinde".
The turbine should be filled with nitrogen so as to obtain a slight
continuous overpressure of approx. 0.5 to 1 mbar in the housing. The
nitrogen can be introduced through the exhaust casing or via a drain
line. Since the nitrogen consumption is dependent on the quality of all
the seals, it can be determined solely by means of experimentation.
Danger of suffocation!
Conservation of bearings and oil system
No special measures must be taken for conservation of the control

and lubricating oil system including the bearings, since the anti-
corrosion additive in the types of oil employed usually provides
adequate protection against corrosion.
Care must only be taken to ensure that the parts exposed to oil are
constantly wetted. The oil circuit should therefore be put into service
for some hours every 2 to 4 weeks. In order to fully wet the rotor
ends, the jacking oil pump and the rotor turning gear must be taken
in operation.
The oil should be analysed with respect to its water content at

regular intervals.
It is recommended to keep the oil tank heater always in operation to

prevent condensation due to high atmospheric humidity.
Protective coatings
The internal parts of the turbine can be adequately protected against

corrosion by means of a protective coating only after opening the
casing. Generally available anti-corrosion protection agents are
employed.
In the case of turbines which are to be shutdown over longer time
periods, we recommend additional use of the following protection
measures:
All the control elements (actuator cylinder, speed controller, etc.)

should be dismantled and carefully conserved.
The bearings including all accessible parts (bearing housing,
control valve linkage, rotor up to the casing, etc.) should be
carefully conserved.
It should be ensured in so doing that the conservation agent
employed forms a thin continuous film, since otherwise crevice
corrosion can occur.
Removing deposit: Different procedures
¾ Wet steam flushing

• Removing deposits that are soluble in water.
¾ Condensate flushing
• Removing deposits soluble in water in Cu and Fe deposits.
In the case of condensate flushing, the turbine is filled with condensate
and the turbine’s rotor is turned by means of the manual turning gear.
¾ Flushing with caustic soda hydrated

• Not recommended for turbines with inner casings and blade carriers
¾ Cleaning with the turbine uncovered

• Removing deposits both soluble and insoluble in water. Blade deposits
are scraped off manually with scrapers (very time-consuming) or by
cleaning with blasted material (flue ash, blasted sand or glass beads).
Removing Blade deposits
Turbine soiling has a considerable influence on the performance and,

in particular,on the operating reliability of the turbine, and must
therefore be removed.
The cleaning methods depending on the nature of the deposit.
Wet steam flushing is generally recommended,
apart from a few special cases where Cu or Fe deposits have been

discovered on the blades.
Wet Steam Flushing
During the course of wet steam flushing, the turbine is operated with wet
steam.
The steam temperature must be adjusted so that the casing and rotor
temperature is always lower than the steam temperature, thus additionally
producing condensate as the result of surface condensation.
Before flushing is begun, the casing must have cooled down approximately to
the temperature of the introduced flushing steam, thus ensuring that no
inadmissible deformations will occur.
Wet Steam Flushing
Every turbine flushing operation should be monitored by water analysis, thus

arriving at information about the composition of deposits, the quantity flushed
and the necessary flushing time. To determine when flushing can be broken
off, it suffices to measure the conductivity of the draining water when flushing
with pure condensate or saturated steam.
If the water quality is good, the cations should only contain the sodium ion. If
there may also be other cations, for example calcium or magnesium ions,
these must also be determined. It is advantageous to plot the values found
during testing as a function of time in a double logarithmic scale (example of
the flushing findings of a steam turbine).
Example of the flushing findings
of a steam turbine
Note: Steam Flushing
After flushing, the steam turbine should be dried or started up as soon as

possible again, thus preventing standstill corrosion.
The success of flushing is verified by measuring the stage pressures or by

calculating the characteristic figures.
Flushing can be done in accordance with these flushing instructions, but you
are advised to have this procedure monitored by our assembly and
commissioning engineers.
Requirements For Steam Flushing
For flushing, approximately 2 to 3% of the nominal main steam quantity is

needed as wet flushing steam at a pressure of approximately 6 bar.
Wet steam flushing is only effective whenever the flushing steam is introduced
unthrottled into the turbine and thus has an adequate share of moisture before it
reaches the blading.
It is not possible to check the amount of humidity in the wet steam. This is why it
is necessary to additionally measure the pressure and the temperature of the
flushing steam shortly before the turbine inlet.
In the case of back pressure turbines, it must be possible to vary the pressure
between atmospheric pressure and the maximum back pressure.
The turbine and the steam system must be run manually.
The drains before the turbine connection are used to discharge surplus water
and to monitor the steam state before the turbine during the flushing operation.
Requirements For Steam Flushing II
It must be possible to freely and reliably discharge accumulated condensate in

a suitable location. During flushing, the condensate salt solution must be
discharged via the normal drains backpressure line as well as through any
specially arranged drains. During flushing, the conductivity of the condensate
must be checked continuously.
It is necessary to pay attention to ensuring that a slight amount of condensate

always verifiably emerges out of the drain before the main steam flange.
According to experience, this is the case with wet steam because the injected
condensate or feed water is not always completely absorbed by the steam.
Preparing control systems for further cold
operation and flushing
By means of suitable measures taken in the control system, make sure that
all shutdown signals and protective interlocks from the speed regulator, the
exhaust pressure monitoring system, the main steam pressure and
temperature monitoring system are set so that they permit operation of the
turbine at low main steam pressures and temperatures and high exhaust
steam pressures. Any existing electronic axial bearing monitoring,
electronic overspeed tripping and temperature monitoring of the exhaust
casing must fundamentally remain operable.
For turbines with an electronic regulator, i.e. servo valve control by

converter, a signal input from the control system must be installed that
permits a 20 mA signal at all times, by connection or switching over, for
opening the main steam servo valves to 100%.
Flushing the turbine
Wet steam flushing in a constant steam state is not very effective. After a
certain time, the turbine blading reaches the temperature of the flushing steam
and the surface condensation that produces the flushing effect stops. To
achieve the best possible flushing success in the shortest possible time, it is
necessary to increase the flushing steam temperature in steps over the
flushing steam pressure during the flushing operation. The turbine speed will
increase according to the pressure increase at the flushing steam inlet.
The flushing operation is begun with the lowest possible exhaust steam
pressure and at a speed of approximately 10% to 15% of the rated speed.
There is no reason to limit the turning speed in the upward direction during
flushing, except by the rated speed. However, attention should be paid to
avoiding any existing barred ranges! In the event of steam saturation at the
turbine inlet, the steam saturation temperature will also set in on the exhaust
connection when the turbine has cooled down. If the temperature is higher,
operation must be continued in this state until the lowest possible temperature
has set in, i.e. for the time being the turbine is cooled down further.
Flushing the turbine II
As soon as the turbine casing and the rotor have assumed the steam
temperature, no further surface condensation occurs, and thus no further
flushing effect. Only the pressure rise at the steam saturation temperature in
the turbine casing achieves the desired flushing effect because the
necessary moisture then comes into being on the undercooled sections of the
turbine.
The steam pressure, and thus the saturation temperature and the speed are
slowly increased.
This operation is continued maximally until the rated speed has been
reached. Depending on local possibilities, the exhaust pressure and thus the
temperature in the turbine are raised and the speed drops.
The speed must now be raised by further increasing the pressure after the
steam converting station, and thus the saturation temperature.
The flushing effect stops if the maximum exhaust pressure has been
reached. The turbine must be cooled down further before the next flushing
operation.
According to experience, flushing must be repeated 2 to 3 times. Take a
suitable sample in the condensate system to check the result of flushing.
End of Flushing
Once flushing has ended, the turbine should be started up and loaded
immediately again, after cancelling the control system interventions that
were necessary for flushing. It can be expected that deposit residues
remaining on the blading that are not soluble in water will be removed as
the result of the increased steam velocities.
Flushing schematic: back pressure or
condensation turbine
1 Main shut-off valve 2 Emergency Stop valve 3 Turbine servo valve

4 Back pressure gate valve 5 Safety valve 6 Condenser
7 Non-return valve 8 Steam converting station D Main steam
D1 External steam
The End

04 01 T6497 Prev Mainten A4 Color 2sided 2slides Each Side

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

04 01 T6497 Prev Mainten A4 Color 2sided 2slides Each Side

Uploaded by

Copyright:

Available Formats

For internal use only / Copyright © Siemens AG 2006. All rights reserved.

Test, Inspection and Maintenance intervalls

Layout of the summary (3)

It is recommended that all important controls always be inspected for

Monitoring the bearings

Checking the shaft glands

Measuring shaft vibration

Measured variable and test parameter

Determination of the coast-down time of the shaft assembly of the

 Coast-down of the shaft assembly from rated speed to shaft standstill.

 Boundary condititons must corresponding to the reproducibility

 Test intervalls: Initial commissioning, after corrective maintenance,

Shifting of Oil Coolers

Cleaning of Lube or Control Oil Filters

1 2 ) Open gradually the control oil isolating valve 1

Charging and testing unit

– Slowly open the nitrogen bottle valve so that the

Protection against stand still corrosion

Schematic diagram of a hot-air

In addition to hot-air and dry-air conservation, filling up of the turbine

 No special measures must be taken for conservation of the control

 The oil should be analysed with respect to its water content at

 It is recommended to keep the oil tank heater always in operation to

The internal parts of the turbine can be adequately protected against

 All the control elements (actuator cylinder, speed controller, etc.)

¾ Wet steam flushing

¾ Flushing with caustic soda hydrated

¾ Cleaning with the turbine uncovered

Removing Blade deposits

Turbine soiling has a considerable influence on the performance and,

The cleaning methods depending on the nature of the deposit.

Wet steam flushing is generally recommended,

apart from a few special cases where Cu or Fe deposits have been

Wet Steam Flushing

Every turbine flushing operation should be monitored by water analysis, thus

Note: Steam Flushing

After flushing, the steam turbine should be dried or started up as soon as

The success of flushing is verified by measuring the stage pressures or by

For flushing, approximately 2 to 3% of the nominal main steam quantity is

Requirements For Steam Flushing II

It must be possible to freely and reliably discharge accumulated condensate in

It is necessary to pay attention to ensuring that a slight amount of condensate

For turbines with an electronic regulator, i.e. servo valve control by

Flushing the turbine

1 Main shut-off valve 2 Emergency Stop valve 3 Turbine servo valve

You might also like

Coast-down of the shaft assembly from rated speed to shaft standstill.

Boundary condititons must corresponding to the reproducibility

Test intervalls: Initial commissioning, after corrective maintenance,

No special measures must be taken for conservation of the control

The oil should be analysed with respect to its water content at

It is recommended to keep the oil tank heater always in operation to

All the control elements (actuator cylinder, speed controller, etc.)