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ME474
Turbo-Generator Damage
Technical committee

Ship type Ore Carrier

Date of build February 1986
Navigation route Japan - Australia
Trouble machinery
Category Turbo-generator
Name Turbine
Type MHI AT34M
Maker
Date of trouble September 2002

1. Process of breakdown Detection

Around 12:30 when the ship was in S/B in PORT HEADLAND and with both T/G and D/G units being
operated on power distribution of approx. 300 kW each, secondary boiler pressure began to fall. T/G
steam was switched from superheated steam to saturated steam, but superheated steam valve was in-
advertently closed before opening saturated steam valve. This reduced T/G RPM and voltage dropped to
trip T/G ACB. At the same time, T/G nozzle valve opened fully, and with this, T/G mixed pressure
steam valve automatically opened to feed mixed steam to the second stage of T/G, when T/G generated
unusual noise with abnormal vibration, and auto-shutdown device activate and shut down the system.

2. Damage Condition

1) Turbine blade
A broken blade in 1st stage
Crack in 3 places at the base of rotor blade of 1st stage
A deformed blade in 1st stage
Three missing shroud rings in 1st stage
Contact on blade edges of 3rd and 4th blades
2) Crack and bend in divider plate in 2nd stage and casing mating surface
3) A bent diaphragm in 2nd stage
4) A frayed and bent tip of labyrinth
5) Bearing
Strong impact on upper/lower part on exhaust side of turbine
Strong impact on upper/lower part on turbine side of pinion
Strong impact on generator side of pinion
Pitching in white section of thrust

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3. Repair

Most of damaged sections required replacement with new parts. As it takes time to prepare turbine rotor,
it was decided to suspend use of T/G until the part is received.
From Feb. 15 to Feb. 19, 2003, repair man came aboard ship to perform restoration work. In addition,
due to possibility of drain influx, the mixed pressure steam line, which was not effective in its function,
was suspended from use.

4. Probable Cause of Failure

The direct cause was a valve operation error. However, after detailed investigation of damaged sections,
a probable cause that led up to a serious damage to T/G was derived as follows:
(1) Drain that entered from mixed pressure steam line during past operation caused corrosion of
blade base, and cracks gradually developed from that section.
(2) With over-speed subsequent to the opening of mixed pressure steam valve as caused by this
accident, blades that could had withstood if in healthy conditions were damaged due to already
developed fatigue-rupture, which in turn damaged a turbine blade in first stage and shroud ring.
The broken pieces from this damage then damaged diaphragm and divider plate of second stage.

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Landed parts

Fig. 1
T/G Rotor
Damaged Blade in 1st Stage
Broken Turbine Blade
Missing Shroud
Crack in Rotor Blade Base

Fig. 2
Enlarged Image of the above

Fig. 3
Enlarged Image of the above
Crack

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 Fig. 4
Opposite side of the above
(Exhaust side)
A broken Blade
Crack in three places

Fig. 5
Divider Plate in Second Stage
(lower)

Fig. 6
Enlarged Image of the above
Pitching by Drain Attack