Problem Cases - English PP

0
Training for Turbine Unit maintenance
Problem Cases
Copyright© Power Engineering and Training Services Co.,Inc. All rights reserved.
◎High/Low Temperature Deteriorated Parts/Factors 1
1. Degraded Parts and Factors
Parts Degradation Factor Parts Degradation Factor
・MSV, CV, CRV ・Creep Deformation/Damage ・Low Pressure Rotor Wheel ・Corrosion Fatigue (Rotor Surface)
・High/Medium Pressure Rotor ・Thermal Fatigue Damage Implant Section ・Stress Corrosion Cracking (SCC)
・High/Med. Pressure External Casing ・Softening, Embrittlement ・Embrittlement, Internal Defects
・High Pressure Internal Casing ・Central Hole Defect (Rotor Internal)
・Med. Pressure Internal Casing
Parts Degradation Factor Parts Degradation Factor

・High Pressure First Stage Nozzle ・Boiler Scale Erosion/Damage ・Low Pressure Rotor Blade ・Drain Erosion
・Medium Pressure First Stage Nozzle ・Moving Part Wear, Sticking * Ｌ－０
・Valve Rod, Bush * Tenon, shroud etc.
2. Updates related to Degradation Damage

*Aim to update facilities after 15-25 years.
◎Hot Section Deterioration Factors and Measures 2
3. High Pressure First Stage Nozzle Damage
(1) Causes of Damage
Oxide scale flows from the boiler
superheater, causing damage from the
collision of solid particles.
(2) Erosion Mechanism Lower Nozzle Box
①High Pressure First Stage Nozzle
Solid particles flowing into the nozzle cause erosion Nozzle Plate
by colliding at the ventral side of the nozzle outlet. Erosion Damage
(See Fig. 1) Oxidation (Ventral)
Scale
②Medium Pressure First Stage Nozzle
Solid particles passing through the nozzle produce Fig.-1
erosion in the back of the nozzle sue to rebounding
from the rotor blade. Nozzle Plate Rotor Blade
(See Fig. 2)
Oxidation
Scale Blade Damage
(3) Erosion Measures (Ventral)
①Boride treatment for high pressure nozzle.
②Anti-erosion measures on the medium pressure nozzle
plate or ceramic thermal spraying of the nozzle blade surface. Erosion Damage
Fig. -2 (Back side)
◎Low Pressure Rotor Degradation Factor and Measures 1 3
1. Low Pressure Rotor Life Factors ・Corrosion ・Corrosion
★Rotor Surface Corrosion fatigue in blade implant ・SCC
Fatigue
・SCC
Fatigue
L-1
hook L-2
L-0
L-3
★Rotor Internl Embrittlement and center hole
defects
★Rotor Blades Stress corrosion cracking
(crystal boundary cracking Center Hole Defect
due to materials, environment
Drain Erosion Drain Erosion
and stress) ・Corrosion fatigue
100%
30%
50%
・Drain Erosion
75%
Load
●：Reheat Inlet
2. Low Pressure Rotor Degradation (Corrosion) Locations ▼：Ｌ-3 Outlet
▲：Ｌ-2 Outlet
★Depending on variations on turbine load, it is appropriate that the ■：Ｌ-1 Outlet
● ：Ｌ-0 Outlet
steam changes through stages L-1 to L-3 (alternating wet and dry
states) as it changes from dry to wet. Dry Area
Saturation Line
Wet Area ●
●●
●
◎Main Steam Valve Sticking and Measures 4
1. Valve Rod Sticking
When used for a long time in high temperature steam, valve rods and bush surfaces have oxidized scale
generated on them, reducing the valve rod gap.
[Oxidized Scale]
・Oxide scale is a layer of oxide produced by steam oxidation at high temperatures, and it consists of two
layers, the inner surface scale (Cr oxide layer) on the inner surface of the base material, and the outer
surface scale (magnetite) on the outer surface. Valve Shaft Bush
Conventional 12 Cr Steel + Nitrade 12 Cr Steel + Nitrade
2. Scale Formation
Remodeled Incoloy Stellite Welding
・Until inner scale has grown sufficiently, 0.04
exterior scale grows on parabolic line. Conventional
Scale Growth Rate
ス
Scale Growth Rate
Comparison
ケ
Valve ー
ル
生 0.02 Stellite Bush
成
速
度
(mm)
Valve Rod Incoloid Valve Shaft
＋Stellite Bush
０
Bush ０１２３４
Operating Time (10,000 hrs)
運転時間(×万時間)
◎Turbine Shaft Alignment 5
1. Turbine Shaft Alignment Management
(1) So that the turbine generator does not create excessive moments in the coupling, and the
bearing load doesn’t overbalance, each bearing is positioned along a rotor deflection curve.
2. Alignment Change Factors

①Change in condenser vacuum
②Bearing deformation, including
High Med. Low Pressure Rotor Generator Rotor
basic units due to generator Pressure Pressure
output changes Rotor Rotor
Level Standard Height
0
3. Impact of Changes to Alignment
①Changes to shaft vibration value and occurrence of unstable vibration due to
change in bearing load.
②Contact resulting from changed gap between rotating and stationary parts.
③Axis intensity due to excess bending moments generated by coupling.
◎Rotor Alignment Basics 6
1. Purpose of Turbine Rotor Alignment Adjustment
The axis is composed of multiple couplings. The bearing load changes due to axial differences,
changing the pressure (bearing surface pressure) applied to the bearing surface.
Center ring failure not only results in axial bending stress, but increased shaft vibrations damage
the bearing. In order to prevent this, the alignment is adjusted, straightening the axis.
2. Basics of Rotor Alignment Setting

The turbine takes time from startup to rated load operation, and changes to temperature and
pressure change the bearing position. An offset is set in consideration of this change.
Operating Rotor Alignment Diagram

HIP GEN
LP-1 LP-2
Cold State Rotor Alignment Diagram

Disk (HP down)
Disk (GEN down)
Cylinder (top open)
HIP LP-1 LP-2 GEN
◎Problem Case 1 (Rotor Blade Damage) 7
1. Damage to Turbine Medium Pressure Rotor Blade Med. Pressure Turbine
(1) Generation Status
・Sudden noise (humming) generated at high
pressure casing under load operation (100MW)
・Max. Turbine shaft vibration at same time
(setting: 5mil) ※ 1mil is 0.025mm
or warning of max. eccentricity (setting 5mil).
・After turbine emergency stop, external
inspection showed no abnormality.
・At confirmation, vibration increased (vibration:
12mil) at near 1400rpm rotational speed as a
result of turbine restart, due to overhaul.
(2) Load Operating Status

Before Problem Occurs When Problem Occurs
Eccentricity 1.3mil 5mil
Expansion Differential 200mil 200mil (no change)
Expansion 920mil 920mil (no change)
Bearing Oil Temperature 40℃ 40℃
(3) Inspection Findings
①Confirmation Immediately after Problem Occurs
・Turbine stopping time after hand tripping ‥‥26 minutes (normally about 25 mins)
・Turning motor current‥‥‥‥ ‥‥‥‥ ‥‥Start-up: 20A, Turning: 15A (normal current)
・Internal contact noise, abnormal noise‥‥‥ Contact noise, no noise
Restart Restart
Notes
1200rpm 1400rpm
②Restart to investigate causes
Bearing #1 2.0 4.5 ・Vibration meter full scale:15mil
・Rubbing check – no abnormalities #2 11.0 10.0 ・Rotor critical speed
・Vibration of 15mil or more at 1400rpm #3 7.5 12.0 1440rpm：GEN
rotational speed #4 2.0 3.5 2590rpm：LP
#5 12.5 15.0 2835rpm：HP
Eccentricity 0.8 1.5 4430rpm: GEN
【Restart Status】
(4) Opening Inspection/Survey Results
①Rotor Blades (Medium Pressure 6 Stage)
・Two blades broken off from vane deforming other tips.
・One broken blade results in partial loss of disk side
dovetail tooth surface.
・Withdrawal of 7 shrouds
②Diaphragms (Medium Pressure 6, 7 Stages)
・Small dents or strop fin wear, deformation 【Medium Pressure 6 Stage Grade Sketch】
(5) Likely Causes

From the results of inspections of fractured and
scattered rotor blade dovetail surface and withdrawn
blade,
・Processing defect in dovetail tooth surface Steam
・Fatigue damage from excessive stress due to
uneven contact.
7 Stage
Med. Pressure
6 Stage
Med. Pressure
(6) Handling, Preventive Measures
Treatment/Measures
Med. Pressure ・Replace with all new blades

Rotor Blade (Med. Pressure)
6 Stage ・Stop blade tooth loss inn disk dovetail with pin
High Pressure ・Correct dovetail curvature radius and implant Final Stage Rotor
Rotor 1 Stage ・Mount all new shrouds Blade Implant Section
Blade Med. Pressure
1/2 Stage
Med. Pressure
7 Stage
Med. Pressure ・Correct distortion, replace stripping pin
Diaphragm
6/7 Stage Low Pressure Turbine Final Stage Rotor Blade
◎ Problem Case 2 (Rotor Blade Shroud Damage) 10
1. Damage to Turbine Low Pressure Primary Rotor Blade Shroud
(1) State of Generation

・At test operation after low pressure turbine retrofit, abnormal
axis vibrations occur.
・Analyze axis vibration measurement data.
・Determined that there is an imbalance in the low pressure
turbine.
・Open the low pressure turbine and conduct internal inspection.
(2) Inspection Findings

①Damage to part of the low pressure turbine primary
rotor blade shroud ring.
・Governor Blades - 10
・Generator Blades - 6
Tenon Low pressure turbine
②Damage to part of the low
Tenon
pressure turbine primary rotor
blade seal fin.
Shroud Ring
◎Problem Case 2 (Rotor Blade Shroud Damage) 11
(3) Likely Cause Mechanisms
・Poor tenon caulking at manufacture
*Cold caulking adopted in manufacture due to lack of caulking management standards
・Minor contact and heat generation in shroud and seal fin from axis vibration
→ Shroud lifting
・Shroud ring damage due to stronger contact from lifting. Emergency Treatment
(12 day outage due to emergency measures)
(4) Emergency Treatment/Permanent Measures
・After cutting remaining tenon of damaged Repair Procedures Inspection Method
shroud ring parts, and weld new shroud ring. ○ Cut to leave healthy parts
・Increase heat of caulking for healthy shroud rings.
○ Annealing 〔550～650℃ 10 min〕
・Damaged seal fin replacement or gap adjustment
・At next periodic inspection, replace all low ○ Caulking ・PT
・Hardness
pressure first stage rotor blades
○ Overlay Welding ・PT
・Preheat 230～270℃ ・UT
(Ref) Manufacturer Preventive Measures ・Welding Rod WEL-Tig-309 ・Hardness
・Review caulking management standards,
○ Heat Treatment ・PT
and add blade conditions to cold caulking [600～650℃ 30min] ・UT
standards ・Hardness
◎Problem Cases 1 & 2 (Features of Scattering Imbalance) 12
1. Causes of Imbalance Vibration Amplitude Vibration Waveform
・Imbalance at fabrication of rotating body
・Imbalance due to loss/scattering of rotating body Amplitude 1 Revolution
・Imbalance due to scale adhesion and wear corrosion
2. Features of Imbalance Vibration

Rotations
・Vibrational frequency synchronized with rotational speed. Primary Rotation
・Stable with reproducible vibration. Critical Speed Frequency
・Size of vibration amplitude correlated to amount of
imbalance P-P #3BR
×1/100 Blade loss near G
＊Primary critical speed vibration increases. 10
#3BRG
Amplitude
8 #2BRG
3. Form and Features of Imbalance Vibration
・Wear/corrosion imbalance tends to gradually 6
increase. 4 #3BRG
・Gradual increase of foreign matter results in rapid #4BRG
2
increase of omissions.
・Defect/scattering differs depending on position and 0
Time
24 1
size, changing the vibration value and settling to a HP IP LP LP
constant value thereafter.
#1BR #2BR #3BR #4BR #5BR #6BR #7BR
G G G G G G G
◎Rubbing from Lack of Oil in Bearing 1 13
1．Causes of Rubbing High Temp.

Atmosphere
・Carbon deposition in oil cut seal fin groove Keep
Warm
2. Carbon Deposition Mechanism Vacuum Oil
① Negative pressure in bearing housing

(gas extractor) Oil Cut
② Suction of external air from surrounds

with increased gap Bearing
③ Insulation and debris deposition through

oil cut suction
④ Carbonized with oil to produce carbon at
high temperature atmosphere
(250℃ or more)
3. Carbon Features Gland
・Extremely hard, but weak impact
Oil deflector seal fin
◎ Rubbing from Lack of Oil in Bearing 2 14
4. Rotor and Carbon Contact
Amplitude
・Because carbon is very hard but brittle,
10
10
it falls off with contact with the rotor. #2 Bearing #3 Bearing
#4 Bearing
#1 Bearing
・New carbon growth on fallen carbon
5
parts.
・Fallen due to repeat contact of grown
０１２３４５６７８ Time (hr)
carbon with rotor.
[Oil Cut Rubbing Vibration Chart]
・As long as causes not removed, this
will repeat (cycling every few hours).
5. Handling
Gland
・Appropriate seal gap adjustment.
[Ref.]
Emergency Handling Gland Steam
・Bearing ambient temp. reduction measures
* Cooling by blower etc. No. 2 Bearing
◎Problem Case 3 (Coupling Misalignment) 15
1. Change in vibration due to low pressure turbine Before After
350MW 210MW
coupling misalignment.
No. 1 Bearing 12 14
No. 2 Bearing 8 6
(1) Generation
・For generator AFC operation near 300MW, No. 3 Bearing 27 23
changes to bearing vibration values for No. 5, 6 and 7. No. 4 Bearing 20 16
* No. 5 Bearing: 46μ → 56μ No. 5 Bearing 48 56

* No significant change to other bearing vibration No. 8 Bearing 17 17
values. No. 9 Bearing 10 9
・Stable at high vibration value after vibration change. No. 10 Bearing 3 3
No,1 No,2 No,3 No,4 No,5 No,6 No,7 No,8 No,9 No,1
0
ＨＰＩＰＡＬＰＢＬＰＧＥＮＡＣＥＸＨＦＧ
(2) Turbine Shaft Vibration Cause and Effect Diagram (FT Diagram)
Event Cause Evaluation Decision
（２）Inspection Findings 1
・Check turbine bearing oil draining temp., expansion differential, vacuum, steam temp etc
No abnormality
・Listen to main turbine, overhaul No abnormality
・Listening while turning No abnormality
・LP Manhole Open Blade Inspection No abnormality
・Earthquake, accident system No noise
・Vibrograph Inspection No abnormality 60.08
350
60.0
Problem Generated 59.96 Frequency
250 -96.0
Problem Generated
Output
150 -97.0
Vacuum
580 -98.0
13.0
550 Expansion Differential
530
12.5
Main Steam/reheat Steam Temp.
12.2
◎Problem Case 3 (Coupling Core Misalignment) 18
(2) Inspection Findings 2 A Low
Run-out
B Low
★Coupling Run-out Pressure Turbine
Measurement
Point
Pressure Turbine
Measurement Comparison High/Med.

Generator
(ALP – BLP, BLP – GEN)
Pressure
0 0
315 45 315 45
BLP
270 90 270 BLP 90

ALP
GEN
225 135 225 135
180 180
【ALP - BLP Coupling Run-out】 Units: 1/100mm 【BLP - GEN Coupling Run-out】 Units: 1/100mm
Periodic Inspection Run-out Periodic Inspection Run-out
Measurement Point Amount Direction Measurement Point Amount Direction
ALP 2.0 103 BLP 1.5 280
BLP 1.5 256 GEN 1.0 270
Run-out after Problem Run-out after Problem
Measurement Point Amount Direction Measurement Point Amount Direction

ALP 2.0 200 BLP 0.5 0
BLP 2.5 14 GEN 2.5 173
◎Problem Case 3 (Coupling Core Misalignment) 19
(3) Likely Causes
With a low likelihood of bearing abnormality from the vibration level, a change was confirmed in the
amount of coupling vibration.
Coupling core misalignment also occurred previously, 5 months after the end of a periodic inspection.
[Conclusion]
＊Determined that vibration occurred due to the core misalignment in the low pressure coupling.
(4) Handling/Preventive Measures
・Vibration adjustment reduces No. 5 bearing vibrations by 20 μ (56μ → 36μ).
・Increase the size of coupling bolts in next periodic inspection (through reamer).
Min. 3mm
Coupling Bolt
Spacer
Cover
Rotor A Rotor B
Nut
Effective Bolt
Length

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Training for Turbine Unit maintenance

Parts Degradation Factor Parts Degradation Factor

2. Updates related to Degradation Damage

2. Alignment Change Factors

Level Standard Height

2. Basics of Rotor Alignment Setting

Operating Rotor Alignment Diagram

Cold State Rotor Alignment Diagram

HIP LP-1 LP-2 GEN

(2) Load Operating Status

(5) Likely Causes

Med. Pressure ・Replace with all new blades

(1) State of Generation

(2) Inspection Findings

・Imbalance due to scale adhesion and wear corrosion

2. Features of Imbalance Vibration

1．Causes of Rubbing High Temp.

① Negative pressure in bearing housing

② Suction of external air from surrounds

③ Insulation and debris deposition through

Oil deflector seal fin

changes to bearing vibration values for No. 5, 6 and 7. No. 4 Bearing 20 16

* No. 5 Bearing: 46μ → 56μ No. 5 Bearing 48 56

ＨＰ ＩＰ ＡＬＰ ＢＬＰ ＧＥＮ ＡＣＥＸ ＨＦＧ

Measurement Comparison High/Med.

270 90 270 BLP 90

Measurement Point Amount Direction Measurement Point Amount Direction

ALP 2.0 103 BLP 1.5 280

BLP 1.5 256 GEN 1.0 270

Run-out after Problem Run-out after Problem

Measurement Point Amount Direction Measurement Point Amount Direction

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ＨＰＩＰＡＬＰＢＬＰＧＥＮＡＣＥＸＨＦＧ