Q&A For Main Turbine Assembly & Maintenance (Hitachi & Toshiba-800 MW Unit)

Corporate Operation Services – Steam Turbine
Question and Answer for Main Turbine

Assembly & Maintenance
(Hitachi & Toshiba – 800 MW Unit)
A compilation of Question and Answer for design and

maintenance aspect of Steam turbine with special focus on
Diaphragm type construction and advanced technology.
Main Turbine assembly & maintenance (Hitachi & Toshiba – 800 MW unit)
Summery
With the introduction of new fleet of super critical turbine of 660 and 800 MW unit,
there have been various turbine design installed in NTPC, supplied by various OEMs
like Hitachi, Toshiba, MHI, GE/Alstom apart from Siemens/BHEL. There have been
two broad category of turbine design, one is single casing, where blades are assembled
directly on the casing and another being Diaphragm type machine, where fixed blades
stages are made of individual ring installed in inner casings.
Apart from fixed blade design, there have been diverge assembly structure for turbine
casing, bearing pedestal and bearing design itself.
The main content of this ask and learn maintenance write up includes design and
maintenance philosophy of diaphragms type of machine with horizontally split double
shell construction. Bearing and pedestal design includes sliding pedestal design, tilting
pad and elliptical self-aligning bearings.
Capturing the learning from the beginning is important for future preparedness.
Improvement and refinement of learning will be ongoing process to gain complete
expertise.
Question No 1:
What are the different type of Governing?
Answer:
There are two types of Governing
1. Nozzle governing partial arc admission
2. Throttle governing full arc admission
Nozzle governing partial arc Throttle governing full arc admission

admission
CV#1, #2, #3 opens with sliding Control main steam flow by opening all
pressure. CV#4 opens further to control valve at same time.
control steam flow
Question No 2:
What is heat balance?
Answer:
Heat balance is a diagram, which shows the thermal condition of heat cycle of a power
plant. The HBD shows the steam flow quantities and their thermal condition for each
section. HBD is the basis for design of turbine cycle of
Question No 3:
What is heat rate?
Answer:
Heat rate is a number that shows performance of power cycle. It is expressed as Kcal
per kWh (KJ/kWh). It is the measure of how much energy is required to generate one
kWh power.
Turbine heat rate = (heat input to turbine)/(power output)
Question No 4:
What is a diaphragm?
Answer:
Partitions between pressure stages in a turbine's casing are called diaphragms. They
hold the vane-shaped nozzles and seals between the stages. Usually labyrinth-type
seals are used. One-half of the diaphragm is fitted into the top of the casing, the other
half into the bottom.
Question No 5:
What is the function fixed blade or Nozzle diaphragm?
Answer:
function fixed blade or Nozzle diaphragm is to convert the thermal energy into kinetic
energy. The steam expands through fixed blades and its speed becomes very high.
High speed steam flows on to the blades and moves them by its kinetic energy.
Question No 6: (level-2)
What are the different types of fixed blade or nozzle assembly structure?
Answer:
1. Fixed blade directly assembled to turbine casing.
2. Fixed blade assembled in diaphragms in stages. Diaphragm type nozzles is

further divided into two types
a) Assembly type where blades are assembled in the diaphragm ring. Blade
covers are integrally machined with blade and forms the inner ring of
diaphragms.
b) Welded type: Diaphragm are divided into three parts. Inner ring, nozzle
partition and outer ring. Blades are welded in between inner and outer
ring.
Question No 7:
What is a stage in a steam turbine?
Answer:
In an impulse turbine, the stage is a set of moving blades behind the nozzle. In a
reaction turbine, each row of blades is called a "stage." A single Curtis stage may
consist of two or more rows of moving blade.
Question No 8:
What are the different types of turbine seals?
Answer:
Following are the different type of turbine seals and description.
Seal Type Configuration Description
Labyrinth seal HI-LOW

fins are fixed on
Hi-Lo fin
Diaphragms outer ring
labyrinth Packing.
against the moving blade
(Moving blade tip. Mostly adopted in
tip) HP/IP section
Labyrinth seal straight fins

are fixed on Diaphragms
Straight Fin
outer ring against the
labyrinth packing
moving blade tip. Mostly
(Moving blade adopted in LP section
tip)
Labyrinth seal HI-LOW

fins are in removable
segments assembled on
Hi-Lo fin outer ring of the
labyrinth Packing. diaphragms. This is the
most maintenance friendly
arrangement.
Hi/Low fins are integrally

machined with moving
Hi-Lo fin
blade shroud. Abradable
abradable
coating are applied on
packing.
Diaphragm outer ring or
(Moving blade inner ring. Step is
tip) machined on outer ring as
parent material for coating
Hi-Lo fin Packing segments with

labyrinth Packing. high low fins are
assembled on diaphragms
inner ring or gland packing
head. Step cut on rotor
inter stage area against
high low fin.
High low fins are

Nozzle Blade integrally machined with
Hi-Lo fin
rotor inter stage area.
abradable Abradable Coating
Nozzle blade inner shroud
packing.
Rotor Inter stage ring also integrally
(Rotor Inter stage) machined with fixed blade.
Abradable coating are
applied on inner ring
Segment with straight fin

are assembled in
Straight Fin
Diaphragms inner ring or
Labyrinth packing
packing head against plain
rotor surface. Mostly
adopted in LP section of
the turbine.
Segment with slant fin are

assembled in Diaphragms
Slant Packing
inner ring or packing head
against plain rotor surface.
Mostly adopted in LP
section of the turbine.
Abradbale seal Segment with abradable

packing coating assembled in gland
packing head against high
low fin on rotor integrally
machined. Mostly adopted
in high pressure gland
section
Question No 9:
Which type labyrinth seals are adopted in LP turbine last stage and gland?
Answer:
Straight type see through seals are adopted in LP turbine last stage and gland area. LP
rotor has large differential expansion, adopting hi-low type labyrinth packing would
require large axial clearance.
Question No 10:
In which turbine is tip leakage a problem?

Answer:
Tip leakage is a problem in reaction turbines. Here, each vane forms a nozzle; steam
must flow through the moving nozzle to the fixed nozzle. Steam escaping across the
tips of the blades represents a loss of work. Therefore, tip seals are used prevent this.
Question No 11:
What is steam flow path clearance?
Answer:
Steam flow path clearance is the radial and axial clearance of rotating and stationary
component of steam turbine.
Question No 12:
Specify the area where steam flow path clearances are to be measured?
Answer:
Steam flow path clearances are generally mentioned in the clearance diagram provided
by the manufacturer. Generally following are the area where it is to be measured.
1. Radial clearances between moving blade tip to outer ring of fixed blade.
2. Radial clearances between rotor shaft to inner ring of the fixed blade. It is called
inter stage clearance.
3. Radial clearance of shaft to gland packing labyrinth fin.
4. Axial clearance of moving blade with fixed blade at root and shroud area.
5. Axial clearance between moving blade tip fin to fixed blade outer ring.
6. Axial clearance in inter stage area.
Following are the typical location for steam flow path clearance measurement
Fixed Blade Nozzle diaphragm
Moving
Rotor Blade
Question No 13:
What are two types of clearance in a turbine?

Answer:
1. Radial - clearance at the tips of the rotor and casing.
2. Axial - the fore-and-aft clearance, at the sides of the rotor and the casing.
Question No 14:
Why is it important to maintain design clearance in turbine flow path?
Answer:
Design clearances are specified in the clearance diagram are the values measured at
cold condition. When the turbine components are heated up and operates at different
load condition, due to thermal growth of turbine components, clearances are changed.
If the cold values are not maintained, there is a chance of contact between stationary
and rotating parts if the clearance set are less than specified. On the contrary, excessive
clearance may lead to losses and decrease of efficiency.
Question No 15:
What is the function of a thrust bearing?

Answer:
Thrust bearings keep the rotor in its correct axial position.
Question No 16:
What is a balance piston?

Answer:
Reaction turbines have axial thrust because pressure on the entering side is greater than
pressure on the leaving side of each stage. To counteract this force, steam is admitted
to a dummy (balance) piston chamber at the low-pressure end of the rotor. Some
designers also use a balance piston on impulse turbines that have a high thrust. Instead
of piston, seal strips are also used to duplicate a piston's counter force.
Question No 17:
What are the different type turbine stage design?
Answer:
There are two type of turbine stage design
A. Impulse design
B. Reaction design
Question No 18:
What is difference between reaction and impulse design of stages?
Answer
Reaction stage: The force acting on the moving blade is a combination of pressure
difference and velocity force. There is both pressure and velocity drop across moving
blade. The ratio of force from velocity component and pressure components is called
degree of reaction.
Impulse stage: The force action on moving blade is the velocity of steam and there is
no pressure drop across the moving blade.
Comparison table given below:
Impulse stage Reaction stage
Velocity force acts on moving blade Reaction force due to pressure difference
Pressure drop and velocity increase Pressure drop and velocity increase across
across fixed blade. fixed blade.
Pressure remains constant and Pressure and velocity both reduces across
velocity reduces across moving blade moving blade
Throat gap remains constant Throat gap changes
Question No 19:
What are the different types of moving blade root fixation configuration?
Answer:
There are four different type of Blade root configuration
1. T root type
2. Outside dovetail
3. Fir tree straight profile
4. Fir tree curved profile
5. Fork type
T root type
Outside dovetail
Fir tree straight profile
Fir tree curved profile
Fork type
Question No 20:
Why should a steam or moisture separator be installed in the steam line next to a
steam turbine?
Answer:
All multistage turbines, low-pressure turbines, and turbines operating at high pressure
with saturated steam should have a moisture separator in order to prevent rapid blade
wear from water erosion.
Question No 21:
What are some conditions that may prevent a turbine from developing full power?
Answer:
1. The machine is overloaded.
2. The initial steam pressure and temperature are not up to design conditions.
3. The exhaust pressure is too high.
4. The governor is set too low.
5. The steam strainer is clogged.
6. Turbine nozzles are clogged with deposits.
7. Internal wear on nozzles and blades.
Question No 22:
Why is it necessary to open casing drains and drains on the steam line going to the
turbine when a turbine is to be started?
Answer:
To avoid slugging nozzles and blades inside the turbine with condensate on start-up;
this can break these components from impact. The blades were designed to handle
steam, not water.
Question No 23:
What is the operating principle of an impulse turbine?

Answer:
The basic idea of an impulse turbine is that a jet of steam from a fixed nozzle pushes
against the rotor blades and impels them forward. The velocity of the steam is about
twice as fast as the velocity of the blades. Only turbines utilizing fixed nozzles are
classified as impulse turbines.
Question No 24:
What is the operating principle of a reaction turbine?

Answer:
A reaction turbine utilizes a jet of steam that flows from a nozzle on the rotor.
Actually, the steam is directed into the moving blades by fixed blades designed to
expand the steam. The result is a small increase in velocity over that of the moving
blades. These blades form a wall of moving nozzles that further expand the steam.
The steam flow is partially reversed by the moving blades, producing a reaction on
the blades. Since the pressure drop is small across each row of nozzles (blades), the
speed is comparatively low. Therefore, more rows of moving blades are needed than
in an impulse turbine.
Question No 25:
What is a combination thrust and radial bearing?

Answer:
This unit has the ends of the Babbitt bearing extended radially over the end of the
shell. Collars on the rotor face these thrust pads, and the journal is supported in the
bearing between the thrust collars.
Following is thrust cum radial bearing for 500 MW KWU turbine
Question No 26:
What is meant by critical speed?

Answer:
It is the speed at which the machine vibrates most violently. It is due to many causes,
such as imbalance or harmonic vibrations set up by the entire machine. To minimize
damage, the turbine should be hurried through the known critical speed as rapidly as
possible. (Caution, be sure the vibration is caused by critical speed and not by some
other trouble).
Question No 27:
Besides lubrication, which are two functions of lubricating oil in some turbines?
Answer:
In large units, lube oil cools the bearings by carrying off heat to the oil coolers. Lube
oil in some turbines also acts as a hydraulic fluid to operate the governor speed-
control system.
Question No 28:
What is the difference between partial and full arc admission?

Answer:
In multi-valve turbine inlets, partial arc ad mission allows the steam to enter per valve
opening in a sequential manner, so as load is increased, more valves open to admit
steam. This can cause uneven heating on the high-pressure annulus as the valves are
individually opened with load increase. In full-arc admission, all regulating valves
open but only at a percentage of their full opening. With load increase, they all open
more fully. This provides more uniform heating around the high-pressure part of the
turbine. Most modern controls start with full-arc and switch to partial arc to reduce
throttling losses through the valves.
Question No 29:
By monitoring the exhaust steam temperature, how can the blade deposition be
predicted?
Answer:
1. Immediately after the 1st commissioning, the different values of exhaust
temperature for different steam flow rates are precisely determined and plotted
against steam flow. This will produce the first actual graph. This is for a clean
turbine.
2. Similar graphs are to be drawn at later periods for comparing with the initial
graph.
3. A rise in exhaust steam temperature under the same conditions refers to deposit
formation.
4. An increase of exhaust steam temperature by more than 10% in the range of 70 to
l00% steam flow, indicates inadmissible blade depositions. Shutdown is to be
taken and blades are to be washed off deposits.
Question No 30:
What are the different type of moving blade tip configuration?
Answer
1. Free standing blade, where each blade tip is extension of its aerofoil profile. Free
standing blades in a stage are sometimes connected to each other by lacing wire in the
midway of the blade section.
2. Integrally shrouded blade (ISB) or continuous cover blade (snubber type), where
shroud is integral part of blade profile. Every blade in a stage are connected to each
other.
3. Tenon type shroud, where group of blade of a stage are covered with tenon.
Following are configuration of above moving blade covers
Tenon shroud Continuous cover shroud Free standing blade
Question No 31:
What is Integrally shrouded blade (ISB) or continuous cover blade (snubber type)?
what are the advantages of ISB or CCBs
Answer:
Blades and covers are integrally machined from single forging.
A. Continuous coupling 360 degrees
B. Low vibration stress
C. Resistance to corrosion fatigue
D. Improved tip sealing
E. Easy to assemble and dismantling
 Pressure contact of the covers provides superior damping when excitation force
works
 Continuously coupled structure greatly reduces dynamic response of the blades to
harmonic stimulating forces, thus vibration stresses are much lower compare to
conventional tenon and shroud design.
 Continuously coupled integral covers provides an inter stage sealing with a
minimum of leakage losses.
 Mutli tip fin on covers substantially reduces the tip leakages flow.
Question No 32:
How Can Damaged Tenons Be Repaired?

Answer:
By adopting modern welding techniques, tenons can be rebuilt This in some cases
results in extended blade life.
Question No 33:
What are the disadvantages of velocity compounding?

Answer:
Steam velocity is too high and that is responsible for appreciable friction losses.
Blade efficiency decreases with the increase of the number of stages.
With the increase of the number of rows, the power developed in successive rows of
blade decreases. For as much as, the same space and material are required for each
stage, it means, therefore, that all stages are not economically efficient.
Question No 34:
What are the basic causes of the problem of rotor failure?

Answer:
1. Normal wear.
2. Fatigue failure due to high stress.
3. Design deficiency.
4. Aggressive operating environment
Question No 35:
How do the problems of vibration and fatigue arise with steam turbine blades?
Answer:
1. These arise due to flow irregularities introduced because of manufacturing
defects, e.g. lack of control over tolerances.
2. System operating parameter, e.g. low flow may excite various modes of vibration
in the blades.
Question No 36:
What is the purpose of a turning gear?

Answer:
Heat must be prevented from warping the rotors of large turbines or high-temperature
turbines of 400°C or more. When the turbine is being shut down, a motor-driven
turning gear is engaged to the turbine to rotate the spindle and allow uniform cooling.
Question No 37:
What are the main causes of turbine vibration?

Answer:
1. Unbalanced parts
2. Poor alignment of parts
3. Loose parts
4. Rubbing parts
5. Lubrication troubles
6. Steam troubles
7. Foundation troubles
8. Cracked or excessively worn part
Question No 38:
How can the misalignment be rectified?

Answer:
The bolts holding the flanges together are to be tightened. The coupling is to be
checked for square between the bore and the face. At the same time axial clearance is
to be checked. Using gauge block and feeler gauges, the gap between coupling faces
90 deg apart is to be measured. After rotating the coupling-half 90 deg, the gap at the
same points is to be measured. After this, the other coupling is to be rotated 1800 and
the gap at the same points is to be re-measured. These measures should come within a
few thousands of an inch. Dividing the coupling faces into four intervals, the distance
between the coupling faces at this interval is to be measured with the aid of a gauge
block and feeler gauges. These gaps measurements should come within 0.005 inch for
proper angular shaft alignment. After proper alignment at room temperature, the two
halves of the coupling are to be connected.
Question No 39:
In which part of the steam turbine does corrosion fatigue occur?

Answer:
In the wet stages of the LP cylinder.
Question No 40:
In which part of the steam turbine does stress corrosion cracking (SCC) occur?
Answer:
In the wet stages of the low-pressure turbine
Question No 41:
What are the losses in steam turbines?

Answer:
1. Residual Velocity Loss - This is equal to the absolute velocity of the steam
at the blade exit.
2. Loss due to Friction - Friction loss occurs in the nozzles, turbine blades and
between the steam and rotating discs. This loss is about 10%.
3. Leakage Loss.
4. Loss due to Mechanical Friction - Accounts for the loss due to friction
between the shaft and bearing.
5. Radiation Loss - Though this loss is negligible, as turbine casings are
insulated, it occurs due to heat leakage from turbine to ambient air which is at a
much lower temperature than the turbine.
6. Loss due to Moisture - In the lower stages of the turbine, the steam may
become wet as the velocity of water particles is lower than that of steam. So a
part of the kinetic energy of steam is lost to drag the water particles along with
it.
Question No 42:
What are the stresses to which a steam turbine rotor is subjected during its service
life?
Answer:
1. Mechanical stress - The factors that contribute to mechanical stress in the
shaft are the centrifugal forces and torque’s generated due to revolving motion
of the shaft as well as bending arising during steady-state operation.
2. Thermal stress - Transient operating phases i.e. start-up and shutdown the
genesis of thermal stress induced to the turbine shaft.
3. Electrically induced stress - They originate due to short circuits and faulty
synchronization.
Question No 43:
What factors are responsible for turbine-blade failures?

Answer:
In the high pressure cylinder, the turbine blades are mostly affected by:
1. Solid-particle erosion (SPE)
2. High cycle fatigue
Whereas, in the last few stages of the low-pressure cylinder, the blade damage is
mainly afflicted by:
1. Erosion
2. Corrosion
3. Stress/fatigue damage mechanism
4. According to EPRI (Electric Power Research Institute, USA) data stress
corrosion cracking and fatigue are the chief exponents for turbine-blade failures
in utility industries.
Question No 44:
What are different checks to be performed in journal bearing assembly?
Answer:
The following checks are performed in journal bearing for assembly
Tilting pad journal bearing
1. Die penetration check of babbitt surface.
2. Die penetration check of babbitt pad back spherical support
3. UT check of babbitt surface.
4. Contact check for support pad with pedestal seating surface.
5. Contact check of journal and bottom support pads.
6. Top oil clearance.
7. Oil strip clearance
8. Deflection measurement during assembling of top half and parting plane studs
Elliptical journal bearing
1. Die penetration check of babbitt surface.
2. UT check of babbitt surface.
3. Journal contact check
4. Contact check for support pad with pedestal seating surface.
5. Inboard and outboard Side oil clearance
6. Inboard and outboard Top oil clearance
7. Inner ring and outer ring spherical contact check on bottom half
8. Ball seat clearance
9. Deflection measurement during assembling of top half and parting plane studs
Question No 45:
What is the catenary of the turbine?
Answer:
Catenary is defined as the bearing or shaft center line elevation at different bearing. It
is calculated based on the thermal growth, sinking of pedestal support and dynamic
load during steam admission and vacuum pulled condition ?
Question No 46:
What are the different type of bearing used in large steam turbine?
Answer:
Following are some of the variant of turbine bearing used for large steam turbines
1. Elliptical bearing with cylindrical support contact.
2. Elliptical bearing with spherical support contact.
3. Elliptical bearing with central groove
4. Elliptical overshot bearing
5. Direct lubrication Tilting pad bearing.
Question No 47:
What is the advantage and disadvantage of tilting pad bearing?
Answer:
The following are advantage of tilting pad bearing
Tilting pad bearing provides maximum stability and freedom from turbine vibration.
Tilting pad design consists of generally six pads with babbitt lining on the pad inner
surface. The pads are installed in inner of the bearing ring and can tilt in radial and
axial direction, therefore, pads moves smoothly and maintain correct alignment at all
condition.
Question No 48: (level-)
How can we measure the oil clearance for tiling pad bearing?
Answer:
Tilting pad bearing pads are normally loose and free to pivot in the shell, it is not
possible to measure the oil clearance in conventional manner. On the six pad bearing
design each pad and bearing inner ring is provided with tap holes, Temporary bolt can
be inserted through shell and screwed into the back of the pads. In this manner pads
can be pulled tightly against the shell. Bore diameter can be measured with this pad in
locked condition.
In three tilting pad design, where bottom three pads are tilting type and top pad is
fixed, Top oil clearance can be measured easily in conventional manner, However for
side oil clearance pads are to be pulled against the shell by locking screw.
Both the configuration are shown below.
Double tilting Pad
bearing with six pads.
The figure shows the

bearing installed in
Toshiba 800 MW unit 1
to 4 bearing.
Here oil is supplied to

parting plane oil groove
Double tilting pad

bearing with three tilting
pad on bottom half.
The figure shows the

bearing installed in
Toshiba 800 MW unit 1
to 4 bearing. Here oil is
directly supplied to each
pad
Question No 49: What is PIN check
Answer: Pin check is the reference reading of outer casing with respect to rotor in
radial direction. It is measure at both end of the casing at packing case area.
Refer to following figure for Pin Check details
Rotor
Lower Packing case
After disassembling of bearing cover, Upper packing case on outer casing is
dismantled. Position of rotor and casing is confirmed with pin check.
Question No 50:
What is seal bore check and what is its significance?
Answer:
Seal bore check is the position check of rotor with respect to pedestal bearing
housing. Since pedestal is the support for both rotor and turbine casing, the seal bore
reading indicates the position of rotor w.r.t common support. It is measured in the oil
guard / oil deflector area. Rotor position can be adjusted with a change in shim on the
support pad of the bearing. Any change in rotor position is reflected on the seal bore
reading. Reading shall be recorded every time after any modification of bearing
position and rotor positioning. It can be confirmed from the seal bore reading that
rotor and bearing are correctly positioned or not.
Figure: Seal bore position check: It is measured in left, right and bottom from
Seal Bore
reading
Rotor
Bearing
Pedestal
Question No 51:
What is centering of in diaphragm type turbine
Answer:
In diaphragm type machine, fixed blade are assembled in individual ring. Diaphragms
are assembled into inner casing or holders and finally inner casing are assembled
inside outer casing. Centering is the process where diaphragms and gland packing
case are set at equidistant or offset design position with respect to shaft centre line.
Question No 52:
How centering of casing and diaphragms are carried out in turbine?
Answer:
Centering is the process where diaphragms are set at equidistant or offset design
position with respect to shaft center line. Before starting the centering process
following two activity must be completed
 Alignment of rotor is completed.
 Bearing support contact check completed.
 Pedestal reference surface are properly cleaned.
 Inner casings, Diaphragms and packing cases are properly cleaned
Special T&P requirement
 Centering measurement inside micrometer set up with buzzer or light

indicator.
 Piano wire.
 Piano wire positioning Jig/Fixture.
 Hand light
 Marker pen
NB: Centering can be carried out with laser alignment machine. However, most
OEMs prefer piano wire centering as the proven technique with required quality
control.
Following are the steps for carrying out centering process:
Left, right and bottom marking shall be done on smooth surface. Make sure that
bottom marking is at centre position.
Set piano wire on pedestal

parting plane.
Piano wire shall be set as per

seal bore reading to ensure that
it coincide with the shaft centre
line
Measurement of packing case,

Individual diaphragm left, right
and bottom distance from piano
wire.
NB: There are three sets of centering reading t be taken with following conditions
1. Tops off condition
2. Tops on condition (only top half outer casing in position. Parting plane stud to be
hot tightened and ensure that 0.03 filler does not pass through parting plane joint)
Parting plane gap and contact check also gets completed during the process)
3. Again after dismantling Tops off condition reading. Tops off reading shall be taken
only after cooling down of casing into ambient temperature.
Tops off to tops on variation to be recorded and incorporated for final correction of
diaphragms and packing case position.
Piano wire sag to be calculated for incorporation into centering reading.
Following are the guideline for calculation of piano wire sag.
 Right and left are determined when viewed from the turbine front toward
generator.
 Use 0.50 mm diameter piano wire and exact 20 kg plumb weight
 Piano wire sag: [X]=[A] x {[L]-[A]} x (W/2P)
Where X=Sag (1/100 mm), A= Distance from the support (mm)
L=Total length of Piano wire (mm), W=Weight of piano wire per unit (kg)
0.00154 kg/m for 0.5 dia wire.
P=Weight of the plumb (1 piece)
Incorporate Rotor static sag value in to the corrected centering reading with Piano
wire sag.
Finally based on tops off to on variation and corrected centering reading with piano
wire and rotor sag.. Target value is calculated for correction of diaphragm and
packing case position on tops off condition.
Following format shall be used for calculation of final target value
Position Rotor Piano Tops off Tops on Tops off Tops on/off Target
sag wire sag Reading reading reading variation Centering
Calculation of centering correction with Example. (all values are in 1/100 mm)
T: 20
L:30 R:70
B:70
Measured value 20
10
T:
L:40 R:60
B:60 10
Target Value
Explanation:
Diaphragms is towards left side by 0.20 mm and toward top side by 0.20 mm as per
measured value. However, Diaphragms shall be towards left side by 0.10 mm and
toward top side by 0.10 mm as per measured value. SO we need to correct the
position of diaphragms and shift the position towards right side by 0.10 mm and
towards bottom side by 0.10 mm.
Diaphragm construction and correction plane are described below:
Centering correction key

for vertical adjustment
of diaphragm position Centre locating pin
For vertical shifting of diaphragms add required shim of 0.10 mm at both left and
right side centering correction key. For Toshiba turbine diaphragms is adjusted by
adjusting screw provided in centering support key as shown in figure
Vertical adj
Shim plate
Diaphragm Adjustment for Hitachi Diaphragm Adjustment for Toshiba

Turbine Turbine
For left right adjustment of diaphragm center, addition and subtraction of shim to be
done from left and right support plate. For example if we want to shift diaphragm
towards right side we need to add move right side up and equal amount left side down
as described in the following figure
Down 0.10 Up 0.10 mm

mm
Shifting 0.10 mm right
Question No 54:
What is coupling run out?
Answer:
In multi rotor tandem compound turbine shafts are coupled together after carrying out
alignment. In the process of coupling both the rotor centre are to be matched to align
the center line. However, in practical it is always difficult to perfectly align the
coupling centre. To limit the misalignment of center coupling run out is measured at
the circumference of each rotor along with journal. Set up is prepared to put dial
guage from the top position as indicated in the picture. Dial reading are measured at
30-degree interval from zero position. For some manufacturer it is recommended to
take reading against each coupling bolt position. Recorded reading are plotted in a
polar plot sheet and distance between two shaft center point is measured. The
measured value shall be within the target value in terms of distance and angle between
the shaft center.
Following precaution shall be taken
 All the dial used shall be properly calibrated.
 Coupling circumferential surface shall be properly cleaned
 Fixture for dial set shall be rigidly fixed.
 Rotor shall be centered in tilting pad bearing by putting soft wooden or

copper wedge behind the tilting pad.
 Dial indicator shall be set at journal for checking left right movement
especially for tilting pad bearing.
 Rotor shall be rotated multiple times before taking the reading.
 When rotating the shaft by overhead crane and JOP lift, Reading shall be
taken after stopping JOP and releasing the crane sling.
 Dial indicator reading shall be taken from straight position to avoid angular
error.
Figure: Set up for Coupling run out
Figure: Coupling Run out calculation
Question No 55:
What is elliptical journal bearing?
Answer:
Journal bearing is a bearing with babbitt liner for supporting rotating shaft on fluid
film. For elliptical journal bearing total vertical diametrical clearance is 0.0013
mm/mm of journal diameter and total horizontal diametrical clearance is 0.0026
mm/mm of journal diameter thus making the internal bore of the bearing elliptical.
Elliptical bore is achieved by machining internal bore on major axis i.e. horizontal
diameter after inserting shim on parting plane. Shim is then removed for assembly.
Question No 56:
What is elliptical overshot bearing?
Answer:
Elliptical journal bearing where oil is circulated through overshot groove machined on
top half of the bearing. The oil is fed to the rotor upcoming side of the journal and
flow towards top half and reach to opposite side parting plane. From ther part of oil is
drained through drain hole and part of the oil enter bottom for forming oil wedge.
Following is the example of Elliptical overshot bearing
Figure: Elliptical overshot bearing
Question No 57:
What is thrust float of turbine, how it is measured?
Answer:
Turbine rotor is anchored in thrust bearing for taking up residual unbalanced thrust or
thrust coming during transient condition. Thrust float is the axial gap between rotor
collar and thrust bearing. Thrust float is designed based on oil flow and clearance
requirement. Following is the figure representing thrust float.
Question No:
Why it is required to have all running load on turbine during carrying out final
alignment?
Answer:
Turbine cold alignment value is calculated based on the static load on TG deck,
dynamic load due to thermal growth, steam flow and condenser vacuum.
Cold condition alignment setting must include all the static loads on TG deck.
Question No 58:
What is offset alignment? Why alignment is kept offset intentionally?
Answer:
Alignment of multi-bearing turbine rotors are carried out during cold condition.
However the coupled rotor is subjected to dynamic load and thermal growth due to
steam force and condenser vacuum. Cold alignment offset is kept in radial and axial
face to compensate the dynamic force.
Following is the simple figure showing the change in rotor position during on load
condition.
Question No 59:
What is the effect of excessive oil clearance in elliptical journal bearing?
Answer:
Excessive clearance in elliptical type journal bearing can create oil whrill and oil whip
resulting sub synchronous vibration of the shaft, where dominant frequency of
vibration spectrum is half of the shaft speed.
Question No 60:
How nozzle diaphragms are supported inside inner casing?
Answer:
Nozzle diaphragm are supported inside inner casing or holders. It is supported on the
parting plane pocket at left and right side of the casing. Further to vertical support it is
axially locked in the slot of inner casing. Diaphragm also located on the bottom with a
center pin for restricting left-right movement. Top half of inner casing further lock the
diaphragms support key for restricting the vertical movement.
Following is the figure showing support structure of 800 MW Hitachi HP/IP

Diaphragms
Locked by top half

inner casing
Horizontal
support on
bottom
inner casing Left right Centering pin
Question No 61:
How outer casing of HP turbine is supported in Toshiba/Hitachi make 800 MW

turbine?
Answer:
HP outer casing is mounted on both the front standard and No.2 middle standard, and
keyed to the front standard and No.2 middle standard in direction both axial and
perpendicular direction to the turbine axis with gib key structure
Question No 62:
What is assembly key and running?
Answer:
Toshiba and Hitachi turbine HP/IP module are double shell construction with
horizontally split casing. Top half outer casings of HP/IP are supported on its
horizontal center line at both end and keyed to the bearing standard at the vertical
center line for location in the traverse direction. Outer casing lower half is securely
fastened to upper half. As the support is attached to upper half, during OH and
Inspection support is required to be transferred to lower half for dismantling of upper
half. Support key for upper half during unit running is called running key and support
key for lower half for OH/Inspection is called assembly key.
Question No 63:
Why color contact is checked between bearing support to pedestal? what will be
effect of lack of proper contact?
Answer:
Journal bearings are supported with adjusting pad on bottom half along the
circumference. Generally, there are 3 or 5 support pads for each bearing based on the
design philosophy of different OEMs. In some of the design oil is fed and drained
through hole on the support pad and bearing shell. The load of rotor on journal
bearing is transferred to the pedestal through these pads. Lack of proper contact will
result high point on the contact surface and load is concentrated to limited area. This
reduces bearing stiffness and lead to vibration of the bearing.
Question No 64:
What is hold down bolt? What is the function of hold down bolt?
Answer:
Hitachi and Toshiba make turbine HP/IP module is simply supported on bearing
standard. Most of the steam pipes are connected to lower half of the casing which can
push the casing in vertical direction. Hold down bolt is installed on lower half outer
casing arm and fastened securely the casing with bearing standard.
Following is the figure for Hold down bolt
Question No 65:
What is horizontally split double shell construction for turbine casing?
Answer:
High and intermediate pressure turbine of large size turbine are assembled with inner
and outer casing. Inner casing holds diaphragms or fixed blades are directly
assembled. Inner casing is further supported inside outer casing. Outer casing, inner
casing and diaphragms are also split into two halves at horizontal centre line.
Following is the schematic diagram for Horizontally split double shell construction
Question No 66:
What is pre alignment of rotor, why pre alignment of rotor is carried out?
Answer:
In diaphragms type of machine casing and diaphragms are centered based on shaft
center line position. Pre alignment of rotor shall be carried out with tops on and tops
off correction factor for determining shaft center line for measurement and correction
of casing and diaphragms position.
Question No 67:
How top and bottom radial clearances are measured in diaphragm type turbine?
Answer:
Top and bottom radial clearance are measured with lead wire. Following are the
requirement for carrying out lead wire clearance measurement.
 Lead wire diameter shall be two times of expected clearance value
 Lead wire shall be locked properly with medical tape.
 For inter stage clearance lead wire shall be fixed on diaphragm inner ring.
 For moving blade tip clearance lead wire shall be fixed on moving blade
shroud.
 Packing ring segment shall be locked with wooden wedge.
 For fast and accurate measurement thickness micrometer with digital display
dial shall be used
Lead wire set up for measuring

bottom radial clearance
Question No 68:
What is tops on centering measurement?
Answer:
Tops on centering measurement indicates the measurement of casing, diaphragms and

gland packing case position with respect to rotor center line (piano wire set at rotor
center line) when top half of casings are in position and fastened with parting plane
studs and support is transferred to upper casing.
Question No 69:
What is Tops off centering measurement?
Answer:
Tops off centering measurement indicates the measurement of casing, diaphragms and
gland packing case position with respect to rotor center line (piano wire set at rotor
center line) when top half of casings are not in position and support is transferred to
lower casing
Question No 70:
What is the significance of tops on and tops off centering reading?
Answer:
Tops on and tops off centering reading is taken to measure the variation in radial
clearance due to loading and unloading of top half casing and support shifting from
lower to upper casing. As the turbine clearances can only be measured in tops off
condition, change in radial clearances due to tops on and tops off variation shall be
incorporated.
Question No 71:
What is diaphragm parting plane elevation?
Answer:
Diaphragms are supported on inner casing at left and right side just below the parting
plane. Diaphragm top half is assembled over the lower half. Part of diaphragms left
right support key protruded and locked between inner casing lower and upper half.
Diaphragm parting plane elevation
Question No 72:
What is the technical requirement for diaphragm parting plane elevation? what is the
typical value?
Answer:
Diaphragms are supported on horizontal planer and keyed at bottom centre. Protruded
part of horizontal support key is locked between inner casing top and bottom half.
With this support arrangement diaphragm are free to expand radially. Parting plane
elevation is the clearance between protruded part of support key and lower half inner
casing parting plane. The diaphragm key shall be 0.15 to 0.20 mm lower than the
casing parting plane. This clearance will ensure following two technical requirement
 Diaphragms will remain free to expand radially
 Inner casing horizontal parting plane contact shall remain intact
Question No 73:
What is diaphragm centering pin?
Answer:
Diaphragms centering pin is located at bottom half of inner casing. The purpose of the
centering key to hold the diaphragms at left and right horizontal centre
Question No 74:
What is diaphragm slip?
Answer:
Diaphragms are keyed at bottom with center pin for restriction horizontal movement.
The clearance on the center pin is called diaphragm slip. It is measured as actual with
physical left and right movement with gentle push at parting plane with dial set from
inner casing to diaphragm.
Question No 75:
What is thermal clearance of turbine diaphragm and casing?
Answer:
In a diaphragm type turbine assembly, the diaphragms, casing and packing head are
subjected to different steam temperature and have different thermal expansion due to
different material. Thermal clearance are kept radially between diaphragms to inner
casing and inner casing to outer casing.
Question No 76:
How steam is entered into inner casing from outer casing?
Answer:
Main steam pipe from CV is connected to outer casing. Inner casing is connected to
outer casing for steam entry through sleeve pipe with bimetallic seal ring.
Question No 77:
How thrust balance is carried out in HP turbine of Toshiba make 800 MW unit?
Answer:
In Toshiba Make 800 MW Turbine HP module is single flow with balance drum
arrangement. Packing seal installed before the balance drum allows controlled leakage
rate on balance drum and packing ring clearance around the drum regulates further
steam flow to outer casing. By controlling the steam flow across these seals thrust can
be balanced. Following is the schematic representation of the above.
CRH Pressure
b/w Inner and
Outer casing
Thrust is Steam flow through

balanced by balance drum seal
regulating
Pressure
across
Steam flow through Balance
balance seal Drum
Question No 78:
What is diaphragms ovality?
Answer:
Diaphragm ovality is the diametrical difference in bore. In normal case it shall be

without any deformation or ovality.
Question No 79:
State the main reason for diaphragm ovality?
Answer:
Diaphragms are radially free to expand without any relative axial movement and and
lateral movement w.r.t inner casing. Horizontal and vertical diameter shall remain
same in all operating condition. However due to any of the following reason
diaphragm ovality can occur,
 Restricted movement of radial expansion of diaphragms
 Less thermal clearance
 Lack of uniform thermal clearance.
 Differential top bottom temperature
 Moisture accumulation and uneven heating and cooling.
 Rubbing with moving parts
Deformation of diaphragm can occur because of any of the above reason. Extreme
care must be taken to identify any restriction during assembly. Any all thermal
clearances must be measured and corrected for any deviation.
Question No 80:
What is the impact of ovality of diaphragms?
Answer:
Diaphragm ovality can reduce radial clearances between diaphragm and rotor. With
present day super critical turbine with high pressure and optimized turbine radial
clearance to reduce leakage losses, any change in radial clearance due to deformation
of diaphragms can lead to contact between stationary and rotating components and
severe damage to turbine component, prolonged outages and high repair cost.
Question No 81:
Why there is offset in left and right radial clearances of turbine rotor?
Answer:
Turbine is supported on fluid film journal bearing, during full speed operation turbine
position moves up due oil wedge pressure gradient and at the same time rotor also
moves towards upcoming side of the bearing. Thus based on the rotor direction of
rotation radial clearances are kept offset to have equal radial clearances during on
load operation.
Question No 82:
Which guage is used to measure axial clearances of turbine rotor?
Answer:
Axial guage or taper guage is used for measuring axial clearances between rotor and
stationary parts.
Question No 83:
What is preparation is required to measure radial clearances of turbine rotor with

segmented packing ring?
Answer:
Segment packing ring are installed with coil spring or plate spring behind the
segment.
Following precaution shall be taken for measuring radial clearances with lead wire.
 Lead wire diameter shall be approximately two times of the radial clearance
to be measured.
 Packing segment shall be locked with wooden wedges for restricting the
movement.
 Rotor shall be positioned slowly and lift the rotor immediately in the same
way.
 Lead wire chart shall be prepared for keeping the lead wire stage and position
wise.
 Lead wire reading shall be taken with digital push back micrometer with flat
line contact thimble
Question No 84:
Why anti seize compound is used during turbine assembly?
Answer:
High temperature anti seize compound are applied on threaded connection to avoid
seizure of stud and bolts threads. Anti-seize compound forms a lubricating layer on
the surface and adhesive in nature and assists dismantling of equipment for
maintenance even after long operating hours.
Question No 85:
Specify the location where, anti-seize compound are to be applied?
Answer:
High temperature anti seize compound are widely used Turbine and valves especially
threaded fasteners including keys, packers, parting plane stud and nut of HP & IP
turbine, stop & control valve of HP /IP, LP-Bypass stop & control valves etc in high
temperature zone of Turbine area.
Question No 86:
Is it necessary to apply anti seize compound during trial assembly checks?
Answer:
Anti-seize compound must be applied ever time during trial or final assembly as it
protects the contact surface by providing lubrication and less friction for threaded
components.
Question No 87:
What precaution to be taken during handling of large size vortex gasket?
Answer:
Vortex gaskets are spirally wounded stainless strip with layer of graphite in between.
Steel strips are spot welded in first and last two round. Handling and assembly of the
gasket must be done carefully especially the large size used for cross over pipes.
 The gasket shall be packed in hard shell box and cardboard paper.
 The gasket shall be locked in different position around the circumference with
suitable spacing.
 Lifting of the box shall be done on horizontal position only
 During assembly gasket shall be held minimum at 6 to 8 position and after

positioning the gasket in position it shall be secured with paper tape.
Question No 88:
What are the important measurement to be carried out during assembly of vortex
gasket?
Answer:
Vortex gasket are placed in the groove between flanges with metal to metal contact in
turbine assembly especially in valve and crossover pipe assembly. The thickness of
the gasket and depth of the groove are the two important measurement for ensuring
proper compression of the gasket after assembly.
Question No 89:
What is the different stage of measurement for ensuring required extension of Turbine
casing parting plane?
Answer:
Turbine casing studs and coupling bolts are extension tightened based on the design
and operation requirement. Uniform and recommended extension of stud/bolt must be
done to ensure uniform loading of each stud/bolt and clamping force across the
parting plane and coupling. Following are the stages to be adopted to avoid repeat of
the process and uniform value in one go in case of parting plane.
 Measure the parting plane gap in free condition.
 Clean stud/bolt and nut properly to remove all dirt, rust and sticky material
especially in thread portion.
 Measure the cold length of each stud and record the same.
 Apply anti-seize compound on stud and nut thread.
 Install the bolts and hammer tight each stud/bolt to close the parting plane gap in
such a way that 0.05 filler does not pass through the parting plane
 Again measure the stud/bolt length to check any extension during hammer
tightening.
 Calculate revised value from the design value after incorporating any extension
happened during hammer tightening.
 Remove all the previous marking on the stud/bolt, nut and nearby casing.
 Record the temperature of casing and stud
 Mark the nut rotation length required.
 Mark the reference position on other side of the stud in case of double not stud.
 Now hot tighten the stud/bolt as per the sequence recommended in the O&M
manual.
 Allow the stud/bolt cool down to ambient temperature as measure earlier.
 Measure the elongation and compare with the recommended value.
 The process to be repeated on the specific stud/bolt which does not meet the
extension criteria.
Question No 90:
What is the procedure for carrying out extension tightening of Coupling bolt ?
Answer:
Turbine rotor Coupling bolt are extension tightened to impart uniform and additional
clamping force across coupling flange of rotor. Extreme care shall be taken to ensure
that there is no change in coupling run out (CRO) during the process. A small
deviation is also not acceptable.
The following step wise process to be adopted during coupling bolt extension
 Clean the coupling bolt and nut thoroughly
 Measure the length of the coupling bolt in free condition with outside
micrometer.
 Ensure that coupling bolt run out is within acceptable value.
 Hardness of coupling bolt is within acceptable value.
 Coupling bolt diameter is within the tolerance.
 Coupling run out has been achieved within the design requirement.
 Measure the coupling bolt length again after coupling and check for any
extension.
 Coupling bolt extension shall be done with hydraulic torque wrench. Manual
extension with OH crane is not permitted.
 Carry out 25% extension of four coupling bolt diagonally opposite and 90 deg
apart with hydraulic torque wrench. Record the torque required for 25 %
extension.
 Take CRO reading and there shall be no change in reading.
 Carry out 50 % extension of same four bolt and check CRO reading for any
change. Record the torque required for 50% extension.
 Repeat the process for another four diagonally opposite bolt equally spaced from
earlier four bolt.
 Complete extension of all the coupling bolt up to 50 % extension and ensure there
is no variation in CRO reading.
 After completion of 50% extension Carry out 100 % extension and check for
CRO reading deviation after extension of four bolt each time.
Question No 91:
What are the checks to be carried out after lifting of turbine casing before assembly?
Answer:
Check the lower outer casing.
(a) Make sure that there are no damages and burrs on the horizontal joint surfaces.
(b) Make sure that there are no damages and burrs on the tongue-groove joint surfaces
and the horizontal joint surfaces. To make flat on the tongue-groove joint surfaces,
use oilstone, if required.
(c) Make sure that the casing has no foreign substances.
2. Coat the horizontal joint surfaces with linseed oil. Coat the tongue-groove joint
surfaces and touched surfaces between dowel pins and seal rings with lubricants.
3. Provide safety-lifting equipment.
4. Lift the upper casing as specified in the drawing
Adjust level of the horizontal joint surfaces by the use of chain block while the casing
is kept lifted by crane.
Question No 92:
How correction is carried out if radial clearances of turbine rotor against a diaphragm
found less in one side only? (all other side as per requirement)
Answer:
If there is no margin for adjustment of radial clearances found less in one side,
Scrapping of packing segment fin shall be done to increase the clearance.
Question No 93:
How piano wire is set for measurement of centering reading?
Answer:
Reference rotor position reference seal bore reading is recorded during pre-centering
of rotor. Piano wire of 0.5 mm dia with 20 kg plumb block shall be used. Piano wire
shall be set at rotor seal bore position to replicate rotor center line along the casing
and diaphragms.
Question No 94:
What is piano wire sag? How it is calculated?
Answer:
Piano wire sag to be calculated for incorporation into centering reading.
Following are the guideline for calculation of piano wire sag.
 Right and left are determined when viewed from the turbine front toward
generator.
 Use 0.50 mm diameter piano wire and exact 20 kg plumb weight
 Piano wire sag: [X]=[A] x {[L]-[A]} x (W/2P)
Where X=Sag (1/100 mm), A= Distance from the support (mm)
L=Total length of Piano wire (mm), W=Weight of piano wire per unit (kg)
0.00154 kg/m for 0.5 dia wire.
P=Weight of the plumb (1 piece)
Question No 95:
How HP inner casing is supported inside outer casing? (Toshiba/Hitachi Turbine)
Answer:
HP inner casing is mounted on the HP outer casing at 4 points, and HP inner casing
height is adjusted with liner structure at the 4 points. HP inner casing is keyed to HP
outer casing in turbine axial direction with rebbet fit structure.
HP inner casing is keyed to the HP outer casing in perpendicular direction to the
turbine axis with gib key structure and center key structure
Question No 96:
What is thrust key for HP/IP outer casing?
Answer:
HP/IP outer casing is keyed to the axial direction on bearing standard. In Hitachi and
Toshiba make turbine Bearing standard 1, 2 are sliding pedestal and Bearing standard
3 is fixed one. Expansion of IP casing push the standard 2 towards HPT and
Expansion of HP casing further pushes the standard 1 towards turbine side. Axial key
basically transfer thermal expansion to thrust force to slide the pedestal in the
direction of expansion
Question No 97:
What is the difference tap stud and through stud? (far casing parting plane fastener)
Answer:
Tap stud and through stud both are mainly fasteners for Turbine casing and
diaphragms parting plane joint. Tap stud are directly threaded to the casing in one end
and other end is secured with nut. Through studs are secured with nuts at both ends
and stud are through from one end to other end.
Question No 98:
What is bench marking for turbine deck? what is its significance ?
Answer:
Turbo machinery are installed on Concrete deck, Turbine deck are sometimes isolated
from its column support by vibration isolation spring set. Due to thermal growth and
different load condition decks are settled from the initial position. Bench marks are
various reference points installed in protected enclosure at both side of the turbine
deck. The elevation of each bench mark reading with reference point gives the change
and deflection of the deck from time to time. This change in position in different
condition and its effect on turbine running parameter helps to predict operating
parameter and corrective actions.
Question No 99:
How assembly key to running key change over done? what is the check point while
carrying out the change over?
Answer:
Assembly key and running key are also called Tops off and Tops on Key. Change of
Running key to assembly Key for Outer casing vertical support from upper half to
lower half. After change over casing support from running key assembly key the
change in dial indicator shall remain same. If the dial indicator put on centre of the
upper casing to rotor is changed, suitable correction shim shall be added to assembly
key to ensure that the casing position remain same,
Question No 100:
What is the advantage of spacer type turbine coupling?
Answer:
In spacer type turbine coupling spacer is installed between rotor coupling flange. The
advantage of spacer type of coupling is rotor axial position can be adjusted in case of
correction is required to achieve axial clearance.
Spacer
Question No 101:
What is journal slope? What is the technical requirement for measuring journal slope?
Answer:
Turbine rotor of large steam turbine are simply supported on journal bearing. In static
condition due to static sag of rotor and different elevation of bearing, rotor journal has
different inclination at different journal position. Based on the catenary and static sag
journal slope is calculated and indicated in the alignment diagram. Measurement of
journal slope indicates rotor position and elevation of different bearing.
Question No 102:
What are the important checks to be carried out in elliptical type journal bearing?
Answer:
Following important checks are carried out in elliptical journal bearing.
Check for babbitt material
 Visual check for Babbitt metal for wipe or recess & for scratch.
 Liquid penetrant test Babbitt metal for crack.
 Visual inspection Contact to journal of shaft on both upper and lower bearings.
 Ultrasonic testing for babbitt material bonding with parent material
Assembly checks
 Bearing housing support pad contact check with pedestal seat.
 Spherical contact check between inner and outer ring.
 Top and side oil clearance in both in board and out board side.
 Ball seat clearance check
 Bearing deflection measurement during HJF bolt tightening
 Bolt torque measurement during assembly of top half.
Side oil clearance measurement
Top oil clearance measurement
Ball seat clearance measurement
Question No 103: (level-)
What is ball seat clearance in elliptical journal bearing?
Answer:
Ball seat clearance in self-aligning elliptical journal bearing is the clearance between
babbitt liner inner ring to bearing housing outer ring clearance. This clearance allow
spherical movement of bearing with the movement of rotor.
Ball seat clearance
Journal to bearing bottom half contact requirement
Question No 104:
What are the checks to be carried out in turbine coupling bolt?
Answer:
The following checks shall be carried out in turbine coupling bolt:
 Visual inspection for surface scoring and roughness.
 DPT for cracks
 Hardness check
 Run out check
 Dimensional tolerance check with respect to coupling hole.
 Weight of each set of coupling bolt and nut
Question No 105:
How run out coupling bolt carried out?
Answer:
Run out of coupling bolt shall be carried out on a surface plate after placing it on V
block. Dial is set on top surface of the bolt and run out measured along the length.
Set up for measuring coupling bolt run out
Question No 106:
What is the reference check required for rotor before taking alignment and CRO
reading for rotor supporting of tilting pad bearing?
Answer:
In tilting pad bearing rotor position can be changed during rotation. While taking
measurement for alignment and Coupling run out rotor shall be in centre position of
the bearing.
Set up for rotor fixation
Question No 107:
What is the acceptance criteria for top oil and side oil clearance?
Answer:
Following is the Standard oil clearance for elliptical journal bearing
Top oil: Diametrical 0.0013mm/mm of journal diameter
Side oil: Diametrical 0.0026 mm/mm of journal diameter
Any clearance above 0.0002 mm/mm of journal diameter is not acceptable
Question No 108:
What is guide rail w.r.t pedestal? what shall be the ideal clearance on guide rail?
Answer:
Guide rail is required for sliding type of pedestal, which is sliding along with casing
expansion. Normally the clearance between guide rail and pedestal base shall be 0.13
to 0.18 mm
Question No 108:
What is sensitized packing ring ? What are the advantage of sensitized packing ?
Answer:
Sensitized packing are labyrinth packing ring segment with high low fin, for turbine
moving blade tip, inter stage and gland packing are.
Sensitized packing ring is supported on weaker spring in place of conventional plate

spring. Steam can enter through the slot cut on outer ring provides further sealing of
the steam leakage
Following are the advantage of sensitized packing
 As the packing float on weaker spring, there is less impact force and avoid severe
packing fin damage.
 Reduce risk of rubbing and eliminate local heating of rotor. Less transient
vibration.
 Optimum clearance can be maintained for long period of operation.
Conventional vs Sensitized packing
Sensitized packing operating condition during unit start up and on load operation
Question No 109:
What is vortex shedder, special feature of Hitachi make diaphragms seals ?
Answer:
Vortex shedder are applied on labyrinth packing, it lowers the pressure on the
upstream side of the seal. This is accomplished by creating turbulent flow or vortices.
Question No 109:
What is active pad for thrust bearing?
Answer:
Thrust bearing active pad indicates the working pad, the normal tendency op rotor is
to move toward working when turbine loading is done.
Question No 110:
What is the zero position for coupled rotor train? (for Toshiba/Hitachi Turbine)
Answer:
The zero position is the position of rotor when pushed toward front pedestal and the
gap between thrust collar and generator side thrust pad is zero.
Question No 111:
What is the process to be adopted for elliptical bearing outer ring support pad to
pedestal colour contact check?
Answer:
Elliptical bearing is divided into two parts, one is inner ring in which babbitt material
is lined another is outer ring with spherical contact surface with inner ring and
spherical pad support on pedestal housing.
For checking the outer ring support pad contact with pedestal housing, following steps
are taken.
1. Outer ring is dismantled from inner ring.
2. Color is applied on outer ring pads
3. Only outer ring with support is placed on pedestal support.
4. Outer ring top half is placed and parting plane bolt are fastened.
5. 0.03 mm filler checked on support pad contact area
6. If 0.03 mm does not pass through any of the pad, then dismantle and check the
contact area.
7. If 0.03 filler pass through any of the pad, add 0.03 mm shim on that pad and repeat
the procedure again.
The acceptance criteria for contact area is shown below.
Question No 112:
How much minimum rotor lifting is required for removal of bearing?
Answer:
Minimum 0.20 to 0.50 mm rotor lifting is required for easy removal of bearing
Question No 113:
State the operation factor affecting the bearing load?
Answer:
The following are the main factor for changing the bearing load during unit operation
1. Condenser vacuum
2. Thermal growth of rotor
3. Steam static force
Question No 114:
What is temporary bow of rotor? how it occurs?
Answer:
Temporary bow of rotor can occur due to annular contact with stationary component.
Once rotor contacts localized heat is generated and because of thermal gradient
temporary bow of rotor occurs. Generally the rotor bow died out once contact point
rubs out.
Question No 115:
What is the significance of inner and outer surface temperature of inner casing of
HP/IP turbine ?
Question No 116:
What is synchronous vibration?
Answer:
When the vibration frequency is same as rotor rotating frequency it is called

synchronous vibration

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Corporate Operation Services – Steam Turbine

Question and Answer for Main Turbine

(Hitachi & Toshiba – 800 MW Unit)

A compilation of Question and Answer for design and

What are the different type of Governing?

There are two types of Governing

1. Nozzle governing partial arc admission

2. Throttle governing full arc admission

Nozzle governing partial arc Throttle governing full arc admission

What is heat balance?

What is heat rate?

Turbine heat rate = (heat input to turbine)/(power output)

What is the function fixed blade or Nozzle diaphragm?

1. Fixed blade directly assembled to turbine casing.

2. Fixed blade assembled in diaphragms in stages. Diaphragm type nozzles is

What is a stage in a steam turbine?

What are the different types of turbine seals?

Following are the different type of turbine seals and description.

Seal Type Configuration Description

Labyrinth seal HI-LOW

Labyrinth seal straight fins

Labyrinth seal HI-LOW

Hi/Low fins are integrally

Hi-Lo fin Packing segments with

High low fins are

Segment with straight fin

Segment with slant fin are

Abradbale seal Segment with abradable

In which turbine is tip leakage a problem?

What is steam flow path clearance?

3. Radial clearance of shaft to gland packing labyrinth fin.

6. Axial clearance in inter stage area.

Fixed Blade Nozzle diaphragm

What are two types of clearance in a turbine?

Why is it important to maintain design clearance in turbine flow path?

What is the function of a thrust bearing?

What is a balance piston?

What are the different type turbine stage design?

There are two type of turbine stage design

Comparison table given below:

Impulse stage Reaction stage

Throat gap remains constant Throat gap changes

There are four different type of Blade root configuration

3. Fir tree straight profile

4. Fir tree curved profile

Fir tree straight profile

Fir tree curved profile

What is the operating principle of an impulse turbine?

What is the operating principle of a reaction turbine?

What is a combination thrust and radial bearing?

What is meant by critical speed?

What is the difference between partial and full arc admission?

What are the different type of moving blade tip configuration?

Following are configuration of above moving blade covers

Tenon shroud Continuous cover shroud Free standing blade

How Can Damaged Tenons Be Repaired?

What are the disadvantages of velocity compounding?

What are the basic causes of the problem of rotor failure?

What is the purpose of a turning gear?

What are the main causes of turbine vibration?

How can the misalignment be rectified?

In which part of the steam turbine does corrosion fatigue occur?

What are the losses in steam turbines?