SIEMENS OVERHA

TO : RAPP, PT. PANGKALAN KERINCI INDONESIA COPY TO :

FROM : KLAUS FELLEITER, SIEMENS ESSO R4 SIEMENS PGI INDO
FRANKENSTASSE 70 - 80, D - 90461 NURNBERG I14 MARKETING SU
TEL : +49 9 11 41 30 - 546 I14 ERECTION DEP
FAX : +49 9 11 41 30 - 9546 TURBINE LIFE BOO
E-MAIL : klaus.felleiter@siemens.com

PAGE :1/8 DATE : 22 . 05 . 2009

Preliminary Overhaul Report

Customer : : RAPP, PT. KERINCI INDONESIA

Turbinen Serial Number : 19308
Turbinen Type : GE 63
Year of Construction : 2000
Maximum Load Point : 100 MW
Inlet Steam Conditions : 82 BAR, 477DEG.CEL, 165KG/SEC
Operating Hours at May 2009 : 39.500 AT OPERATING HOURS COUNTER
Date of the Overhaul : 24 MARCH - 22 MAY 2009
OVERHAUL REPORT
COPY TO :
SIEMENS PGI INDONESIA
I14 MARKETING SUPPORT NURNBERG P.VOGEL
I14 ERECTION DEPARTEMENT
TURBINE LIFE BOOK FILE

DATE : 22 . 05 . 2009
SIEMENS ENERGY SECTOR SERVICES
Prepace :

During an inspection in October - November 2009 Steam Turbine Serial

findings with demaged sealing, cracked inlet nozzle welds, misalignme

Main overhaul work performed during March - May 2009 :

Turbine Rotor :
1 Sandblasting of the whole blade and labyrinth section
2 Crack testing was nor performed according to RAPP demand
3 Rotor was set and aligned at lathe machine in RAPP workshop
4 Run out check was performed, Run out deflection was measured by 0,03mm before blade ro
5 All sealing strips between all 26 blade rows were changed
6 All sealing strips at balance piston 1,2 and 3 were replaced
7 All Sealing strips at front and rear labyrinth section were replaced
8 All new sealing strip was machined according the actual dimension check of the stator and la
9 Blade row no 25 and 26 : key blade fixation was modified in order to privent further keyblade
10 Shroudings of blade row 25 and 26 was remachined in order to remove axial and radial defle
11 Vibration measurement section was polished
12 Journal bearing front and rear side was polished

Guide blade carriers 1 - 4

1 Sandblasting of GBC 1 - 4
2 Crack testing and US rivet test was not performed according to RAPP, PT. demand
3 Blue imprint check of the horizontal flanges, GBC 2 and 3 flange was reworked after this che
4 Re-Tapping of all thread at horizontal flanges
5 Clearance check between the casing fit and GBc fits, no rework was reguired
6 Polishing of all shrouding, measure of all shrouding diameter for the calculation of the new ro

Balance Piston 1, 2 Labyrinth :

1 Sandblasting
2 Inner gland diameter was measured with an ovality of 0,55mm
3 BP 1 + 2 Labyrinth inner glands was remachined to bring it back to round conditions
 4 Measure of the inner gland diameter for new rotor sealing strip calculation
5 Blue imprint check was performed and flange reworked manually

Balance Piston 3 Labyrinth :

1 Sandblasting
2 Polishing the gland castellations
3 Measure of the inner gland diameter for new rotor sealing strip calculation
4 Manufacturing of new flange connection elements

HP and LP Outer Gland Bushes :

1 Sandblasting
2 Measure of the inner gland diameter for new rotor sealing strip calculation

Axial Bearing :
1 Polishing of active and passive side axial bearing pads
2 Measurement of pad thickness, still in the design
3 Dye penetrates check, no findings
4 Re-assembly af axial bearing pads

Front HP end Journal bearing :

1 New journal bearing marked 18277 / 490 was installed

Rear LP end Journal Bearing :

1 New journal bearing marked 19277 / 490 was installed, but clearance rotor-bearing was meas
only with 0,18mm, nominal clearance 0,48mm ………. 0,55mm.

Oil Sealing Rings :

1 All 3 oil sealing rings were replaced, marked 19277
2 Dismantled LP end inner oil sealing ring was repaired in RAPP, PT. Workshop

HP servomotor V1 / 2 and V 3 / 4 drawing ; 38729.1 :

Following part were replaced :
1 Main closing spring Pos 5 and 6 , all O-ring and shaft sealing ring
2 Oil relay 38728.1 control pin and bush set Pos 2 , Spring pos 13 all O-ring, shaft sealing ring a
HP Control valves were overhauled already in november 2008, no spare

HP ESV left and right side 34905.0 Following part was replaced :
1 Main closing spring Pos 6, Pilot valve with spring and closing plug
2 All seats were lapped and checked with blue print
3 Steam strainer cleaned from foreign particles

ESV actuator left and right side 42163.1 Following part was replaced :
1 New spindle Pos 4, Spring Pos 14, Piston Pos 5, bolt and nuts Pos 7, 8, 9 and 11, 12, 13, and

Bleeding control Servomotor actuator 40828.1 Following part were repl

1 All O-Ring , shaft sealing ring , closing spring pos 2
2 In addition at the V 1 / 2 Oil relay : control pin and bush Pos 3, 48 and spring Pos 17

Dummy shaft measurement :

1 Turbine casing was alignment to pedestals front and rear end, casing was lowered 0,15mm HP
2 All GBC's Balance Piston 1, 2 and 3, HP and LP Gland was mounted and position inside turbin
Following part was aligned :
3 Turbine casing lowered to front pedestal by 0,15mm
4 Turbine casing was moved 0,45mm to right side , seen in steam direction view
5 Balance piston 1 - 2 was lowered by 0, 15mm
6 Guide blade carrier 1 was raised upwards by 0,20mm
7 Guide blade carrier 2 was raised upwards by 0,10mm, moved to right side by 0,15mm
8 Guide blade carrier 3 was raised upwards by 0,15mm
9 Guide blade carrier 4 was raised upwards by 0,20mm

Turbine casing horizontal flange :

1 Lower half of turbine casing flange was found with deep corrosion marks
2 Flange was manually reworked, repair welde at 6 locations with subsequent heat treatment an
3 Blue print checks were carried out untill sufficient contact matches were performed

Assembly of Turbine :
Clearances of Turbine Rotor - GBC's and Labyrinths : GBC 1 Section :
Rotor Seal - Stator Shrouding Stator Seal - Rotor Shrouding
Section 1
Row Actual Design Actual
Design
Left Right Left
 1 0,80 0,70 0,85 0,80 0,80
1 2 0,80 0,70 0,85 0,80 0,80
3 0,80 0,70 0,85 0,80 0,80
1 0,80 0,70 0,85 0,80 0,80
2 2 0,80 0,70 0,85 0,80 0,80
3 0,80 0,70 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
3 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
4 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
5 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
6 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
7 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
8 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80
1 0,80 0,75 0,85 0,80 0,80
9 2 0,80 0,75 0,85 0,80 0,80
3 0,80 0,75 0,85 0,80 0,80

GBC 2 Section :
Rotor Seal - Stator Shrouding Stator Seal - Rotor Shrouding
Section 2 Row Actual Design Actual
Design
Left Right Left
1 0,80 0,85 0,75 0,80 0,85
2 0,80 0,85 0,75 0,80 0,85
10
3 0,80 0,85 0,75 0,80 0,85
4 0,80 0,85 0,75 0,80 0,85
1 0,80 0,85 0,75 0,80 0,85
11
 2 0,80 0,85 0,75 0,80 0,85
11
3 0,80 0,85 0,75 0,80 0,85
4 0,80 0,85 0,75 0,80 0,85
1 0,80 0,85 0,70 0,80 0,85
2 0,80 0,85 0,70 0,80 0,85
12
3 0,80 0,85 0,70 0,80 0,85
4 0,80 0,85 0,70 0,80 0,85
1 0,80 0,85 0,75 0,80 0,80
2 0,80 0,85 0,75 0,80 0,80
13 3 0,80 0,85 0,75 0,80 0,80
4 0,80 0,85 0,75 0,80 0,80
5 0,80 0,85 0,75 0,80 0,80
1 0,80 0,85 0,75 0,80 0,80
2 0,80 0,85 0,75 0,80 0,80
14 3 0,80 0,85 0,75 0,80 0,80
4 0,80 0,85 0,75 0,80 0,80
5 0,80 0,85 0,75 0,80 0,80
1 0,80 0,80 0,75 0,80 0,80
2 0,80 0,80 0,75 0,80 0,80
15 3 0,80 0,80 0,75 0,80 0,80
4 0,80 0,80 0,75 0,80 0,80
5 0,80 0,80 0,75 0,80 0,80

GBC 3 Section :
Rotor Seal - Stator Shrouding Stator Seal - Rotor Shrouding
Section 3 Row Actual Design Actual
Design
Left Right 0,90 Left
1 0,90 0,80 0,85 0,90 0,95
2 0,90 0,85 0,85 0,90 0,95
16
3 0,90 0,85 0,85 0,90 0,95
4 0,90 0,80 0,85 0,90 0,95
1 0,90 0,85 0,85 0,90 0,90
2 0,90 0,85 0,85 0,90 0,90
17 3 0,90 0,85 0,85 0,90 0,90
4 0,90 0,85 0,85 0,90 0,90
5 0,90 0,85 0,85 0,90 0,90
1 0,90 0,80 0,85 0,90 0,95

18
 2 0,90 0,80 0,85 0,90 0,95
18 3 0,90 0,80 0,85 0,90 0,95
4 0,90 0,80 0,85 0,90 0,95
5 0,90 0,80 0,85 0,90 0,95

GBC 4 Section :
Rotor Seal - Stator Shrouding Stator Seal - Rotor Shrouding
Section 4 Row Actual Design Actual
Design
Left Right 0,90 Left
1 0,90 0,90 0,90 0,90 0,90
2 0,90 0,90 0,90 0,90 0,90
19
3 0,90 0,90 0,90 0,90 0,90
4 0,90 0,90 0,90 0,90 0,90
1 0,90 0,85 0,90 0,90 0,90
2 0,90 0,85 0,90 0,90 0,90
20
3 0,90 0,85 0,90 0,90 0,90
4 0,90 0,85 0,90 0,90 0,90
1 0,90 0,85 0,90 0,90 0,90
2 0,90 0,85 0,90 0,90 0,90
21
3 0,90 0,85 0,90 0,90 0,90
4 0,90 0,85 0,90 0,90 0,90
1 0,90 0,90 0,90 0,90 0,90
2 0,90 0,90 0,90 0,90 0,90
22
3 0,90 0,90 0,90 0,90 0,95
4 0,90 0,90 0,90 0,90 0,90
1 0,90 0,95 0,85 0,90 0,95
2 0,90 0,95 0,85 0,90 0,90
23
3 0,90 0,95 0,85 0,90 0,90
4 0,90 0,95 0,85 0,90 0,90
1 0,90 0,95 0,85 0,90 0,95
2 0,90 0,95 0,85 0,90 0,90
24
3 0,90 0,95 0,85 0,90 0,90
4 0,90 0,95 0,85 0,90 0,90
1 0,90 0,95 0,85 0,90 0,95
2 0,90 0,95 0,85 0,90 0,90
25 3 0,90 0,95 0,85 0,90 0,95
4 0,90 0,95 0,85 0,90 0,90
 25

5 0,90 0,95 0,85 0,90 0,95

1 0,90 0,95 0,90 0,90 0,95
2 0,90 0,95 0,90 0,90 0,95
26 3 0,90 0,95 0,90 0,90 0,95
4 0,90 0,95 0,90 0,90 0,90
5 0,90 0,95 0,90 0,90 0,90

Seal Strip Measurement Gaps HP / LP Labyrinth Bush

Labyrinth Actual
Position Design
Long Short Left Right
X 0,55 0,50 0,55
HP X 0,55 0,55 0,55
X 0,55 0,60 0,55
LP-Inside X 0,55 0,60 0,55
X 0,55 0,60 0,55
LP-Outside X 0,55 0,60 0,55

Seal strip measurement gaps Oil Retaining Ring Radial and Axial
Radial Actual Axial Actual
Position Design Design
Left Right Left Right
HP 0,30 0,35 0,30 4,80 5,00 4,95
LP-inside 0,30 0,25 0,30 7,20 7,00 7,00
LP-outside 0,30 0,30 0,35 8,80 8,75 8,75

Seal Strip Measurement Gaps Balance Piston

Labyrinth Actual
Section Design
Long Short Left Right
X 0,80 0,80 0,85
1
X 0,80 0,80 0,85
X 0,90 0,90 0,95
2
X 0,90 0,90 0,95
X 1,00 0,95 1,00
3
X 1,00 0,95 1,00

Axial Distance Nozzle - Curtis Row

Actual
Design Left Right
 3 2,90 2,95

Final Assembly of Turbine

Casing was closed and casing bolt tightened according design sequence and torque specification.
Bolt elongations was measured after heating and cooling down and all bolt were measured according desig

External measurement check was performed with following values ;

# Rotor to HP end Journal bearing : 046mm ( remark new bearing was installed )
# Rotor to HP end Journal bearing : 0,52mm ( remark old bearing was installed )
# Rotor to axial bearing total float : 0,48mm

# Rotor axial movement without axial bearing towards generator from o-point
# Rotor axial movement without axial bearing towards front pedestal from o-point
# Total float Turbine Rotor Without Axial Bearing

# Rotor HP end radial check upwards

# Rotor HP end radial check downwards
# Total HP end Rotor to Labyrinth Clearances

# Rotor LP end radial check upwards

# Rotor LP end radial check downwards
# Total LP end Rotor to Labyrinth Clearance

Alignment Turbine to Generator

# Alignment Turbine to Generator was checked and corrected to following value :
# Turbine Stands 0,11mm higher than generator
# Turbine Stands 0,06mm left side from generator

# Coupling bolts between Turbine Rotor and Specer with Turning Gear Wheel In between was tightened to
# weight of new nut and old coupling bolts ( only 1 coupling bolt was replaced due to demaged bolt during d

# Coupling bolts between spacer and generator rotor was tightened with 1,750Nm according to Brush Instr

Turning Gear Modification :

The modification of TG was carried out.
Following New parts were mounted :
# Additional control block for engaging during run out ( engaging at 20 - 30 RPM )
 # Additional coil for reverse turning ( deblocking in case of jamming )
# Pipes and Fittings
The logic and wiring in TCC have been changed in accordance to new functions.
The TG was successfully tested.

Load Test
# During commissioning alls safety interlock and trip criterion were tested ( over speed trip 3330 RPM )
# The overspeed test was carried out.
# The Turbine has been loaded up to 85 MW with and without bleeding in operation
# Load operation at Friday 22 may 2009 without any problems
# Turbine is steam and oil tight
# Shaft vibration axial and relative position of rotor and bearing temperatures are in good range

SIEMENS
Energy Services Sector
Nurnberg Germany Esso R4 Nbg2

i.v. Absenger i.v. Klaus Felleiter

 PRELIMINARY OVERHAUL REPORT 19308 RAPP, PT

Steam Turbine Serial No. 19308 was opened due to some major
zle welds, misalignment of front pedestal.

y 2009 :

completed good
no reguired good
completed good
ured by 0,03mm before blade row no. 1. completed good
completed good
completed good
completed good
ension check of the stator and labyrinth bushes completed good
order to privent further keyblade movement completed good
r to remove axial and radial deflections completed good
completed good
completed good

completed good
to RAPP, PT. demand not reguired good
nge was reworked after this check by hand completed good
completed good
ork was reguired completed good
for the calculation of the new rotor seals completed good

completed good
completed good
ck to round conditions completed good
p calculation completed good
completed good

completed good
completed good
p calculation completed good
completed good

completed good
p calculation completed good

completed good
completed good
completed good
completed good

completed good

earance rotor-bearing was measured completed good

completed good
P, PT. Workshop completed good

completed good
13 all O-ring, shaft sealing ring and gaskets. completed good
 ember 2008, no spare spindles and cages were available at this time.

was replaced :
completed good
completed good
completed good

g part was replaced :

s Pos 7, 8, 9 and 11, 12, 13, and all rings and shaft sealing rings completed good

lowing part were replaced :

completed good
, 48 and spring Pos 17 completed good

casing was lowered 0,15mm HP end for this completed good

mounted and position inside turbine casing measurement completed good
good
completed good
am direction view completed good
completed good
completed good
to right side by 0,15mm completed good
completed good
completed good

sion marks completed good

th subsequent heat treatment and crack testing completed good
ches were performed completed good

hs : GBC 1 Section :
eal - Rotor Shrouding
Actual
Right
 0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,80
0,80
0,80
0,85
0,85
0,85
0,85
0,85
0,85

eal - Rotor Shrouding

Actual
Right
0,85
0,85
0,85
0,85
0,85
 0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75

eal - Rotor Shrouding

Actual
Right
0,95
0,95
0,95
0,95
1,00
1,00
1,00
1,00
1,00
1,00
 1,00
1,00
1,00
1,00

eal - Rotor Shrouding

Actual
Right
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
0,85
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
 1,00
1,15
1,15
1,15
1,15
1,10

adial and Axial

nd torque specification.
were measured according design values.

h following values ;
was installed ) intoleransi
was installed ) intoleransi
intoleransi

2,60mm intoleransi
2,45mm intoleransi
5,05mm intoleransi

0,75mm intoleransi
0,50mm intoleransi
1,25mm intoleransi

0,67mm intoleransi
0,38mm intoleransi
1,05mm intoleransi

eel In between was tightened to reach an elongation 0f 0,45mm. New coupling nuts were assembled,
ced due to demaged bolt during dis-assembly ) were equalized.

750Nm according to Brush Instruction.

- 30 RPM )
over speed trip 3330 RPM )

es are in good range