Unit 3 OperationOPERATIONS Excessive Casing Pressure 1. For steam to flow through the turbine, there must be a pressure _______ between the inlet and the exhaust, 2. During startup of the turbine, the exhaust valve must be opened before the inlet valve, or excessive pressure may rupture the 3. If the inlet valve were opened before the exhaust val S would build up inthe. easing. 4, Turbines are sometimes equipped with safety valves to relieve excessive pressure. Safety valves loce (manually “automati ed In the exhaust piping oper cally) « 5. Sometimes the safely valve does not reset properly after it has opened. ‘The valve continues to leak through the relief line, and usuble steam is lost 10 the air. 6. Some turbines haye only a sentinel valve and not a safety vale. A sentinel valve sounds a warning when the nthe casing Is too high, The ope medial tor must the pressure im. ‘he sentinel valve by itselt (protects /does not protect) the casing against overpressuring: am to the turbine reduces the 8. Stopping the flow of st pressure The operator (opens /closes) the inlet valve immedi- ately to stop the flow of steam, 9. To start up, the (inlet/exhaust) valve is opened first, ‘To shut down, the — valve is closed first. 10. Large high-pressure turbines must operate at low. spees until they are warm, The inlet valve on these turbines should be (wide/ partially) open, Insulation LL. Insulation prevents the loss of —____ from the unit. [45] difference pressure automatically steam sure pre decrease ‘ioes not protect, closes exhaust inlet partially heat12, The turbine is insulated to prevent heat loss and pro tect the operator fram burns, The should be kept intact during operations, 13. If insulation is removed during repairs or inspection, it must ho ______before startup. Condensation of Steam 14. ‘Phe temperature of steam leaving the turbine is always lower than the temperature of sterm entering the turbin ‘Phe higher the inlet steam te less) likely the exhaust steam perature, the (more/ to be dry, 15, Condensing turbines have low exhaust temperatures, Usually some of the steam condenses as it passes through the later stages. ‘These turbines are designed so that 2 moderate mount of condensate does not cause erosion of the 16, If the inlet steam temperature falls helow the design temperature, too much steam condenses in the earlier stages. ‘These stages are not designed for condensate, This condensate may cause of time, over & period 17, Daring shutdown, the turbine evok steam left in the turbine or the lin nd any residual 18. Water collects in loy points in the inlet line, Steam at low velocity (piel up/aloes not pick up) the water as it passes over it. 19. During startup, many turbines operate at (low/high) speed, and the steam flowing to the turbine is at velocity. [46] insulation replaced buckets condenses does not piek up low low20. When the turbine is brought up to speed, the steam velocity is great enough to piek up and carry. with the steam, 21. A slug of water traveling through a nozzle could break a_______ ff the wheel. 22, Low points in the lines and in the turbine easing are equipped with drains, Low points should be before startup. 28. Drain valves should be opened and steam blown through them at (high/low) velocity. When the steam blows dry, (mast/all) of the water that can cause damage has been removed. 24. Some drains are equipped with steam traps, A steam trap automatically drains the hot condensate, If the line from the steam trap remains cold, the trap (is/is not) working properly Effects of Uneven Heating and Cooling 25. Steam enters the turbine at relative tures, high tempera- At startup after a long shutdown, the turbine is (hot/ cool). 26. ‘The metal components of the turbine expand rapidly when heated, ‘The parts that contact the hot steam —____ rapidly 27, During startup of a condensing turbine, the condenser is put into operation before steam is admitted to the tur ‘The condenser keeps the exhaust temperature relatively (high/low) 28, The exhaust ond of condensing turbine Is designed to operate at (higher/lower) temperatures than the exhaust end of a non-condensing turbine, 29. If the exhaust temperature rises too high, the bolting on the casing flanges is stretched and may loosen when the temperature returns (o normal, ‘The casing Mange may __steam at the exhaust end. 30. During startup, the rotor comes up to operating tem- perature somewhat faster than the casing does. ‘The rotor expands (more/less) than the easing, (471 water bucket drained high all is not cool expand low lower Teak more81. The interstage diaphragms are positioned in the easing. Ifthe does not expanil, the diaphragms (change/ do not: change). position. 82, As the rotor expands, it lengthens, The wheels are so close to the diaphragms that the rub on the 2: _—if the rotor expands much taster than the easing. 88. During startup of a multistage turbine, the flow of steam through the turbine shonld be kept small so as o lot the casing and the rotor expand together. ‘The rotor (rubs/does not rub) on the diaphragms, Shaft Bow BA. As steam passes into the: tubine, the rotor must be turning, over slowly Whon the rotor is not turning, the hot steam contnets (the upper half/both halves) of the rotor. 85. The upper half _ more than the lowor half, 86. ‘The shaft __ from uneven heating. 37. When the steam supply is shut off, the turbine starts to 88 Metal components shrink or contract rapidly as they cool. ‘During shutdown the rotor shaft cools and 89. Uneven cooling is (more/less) of 2 problem in large turbines with long shafts than in small turbines. [48] do not change diaphragms does not rub the upper half expands bows, or bends ool contracts, or shrinks more40. 41. 48. 44. 48. 49. Look at the drawing. At shutdown the steam in the easing starts to The cooler, heavier steam (rises to the top/falls to the bottom) of the casing. . ‘The rotor then cools (faster/slower) at the bottom than at the top. The shaft then tends to ‘The Lurbine slowly cools until the entire rotor is all one tomperature. ‘The bow is greatest a short time after shutdown when 8 (large/small) temperature difference exists m the turbine, Because the wheels fit tightly to the shaft, the bow may remain, even when cooling is complete. The shaft may still be —_at startup, ‘ho metal parts —__ again at startup. |. Operating the turbine at low speeds for 2 period during startup lets the bowed shaft straighten, Because this bow straightens it is a (permanent/ temporary) bow. Starting at high speeds can turn a temporary bow into a — bow, ‘The slow turning with even expansion straightens the shaft during startup. ‘The turning “shakes” the out of the shat, [49] cool falls to the bottom faster bow bowed expand temporary permanent bow50. Centrifugal force pulling on the bowed shaft ean inerease the bow. Speeding up the turbine before the bow has straighten- ed causes the bow in a shaft to (inerease/decrease), 51, If the bow increases, the shaft rubs on a diaphragm. ‘The friction of the rubbing generates intense — 52. This intense heat may cause the shaft to take a set, ‘The turbine then has to be over- hauled. 58. In order to prevent uneven heating or uneven cooling, during shutdown, larger nits are equipped with a turning gear which rotates the rotor so that all sides cool 2 54. When the entire rotor is rotated, ull sides receive an equal amount of contact with the hotter layer of steam, ‘The whole assembly ________evenly. 55. Small single-stage turbines operating on moderate steam pressures have few problems with uneven heating, Many small turbines ean be brought up to speed (gradually immediate! 56. Larger multi-stage turbines should be run at 20% of operating speed for about 20 minutes before being brought up to speed. This slow run-in is to prevent expansion or shaft rub. Packing Box Leakage 57. At startup, the clearance botweon the shaft and pacl ing is greater than normal and some leakage occurs. As the shaft warms up, it __ is reduced. and the clearance 58. As the turbine and shaft warm up, leakage should (inerease/deerease). 89. Tf the packing is badly worn, leakage (decreases) oes not decrease) as the turbine warms up. [50) increase heat: evenly vols immediately uneven expands: decrease does not decrease60. Sometimes the leak-oif connections become plugged, or the valve in the steam line serving the leak-off is closed, LEAK-OFF LEAK-OFF Steam would ___ out of the casing to the air, leak GL. Por the packing box to seal, the - leals-off connections must be operating. 62. ‘The packing at the exhaust end of a condensing turbine is steam-scaled. Steam is (put into/removed from) the packing box. pat into 63, If there fs too much sealing steam, the packing-box ejector cannot remove it all, and some stcam passes out of the —_____as leakage, casing, or packing box 64. If the scaling steam is turned on before the turbine is rolling, the steam heats up the rotor on one side more than on the other. ‘The shaft expands on that one side and may develop iz bow Vibration 65. ‘Two vibrational effects oceur: 1, The frequency (the number of vibrations or move- ments ina given period of time). ‘The amplitude (the distance the shaft or bearing moves). Proquoncy is the 2 ____of vibrations over a number period of time. [51]66. 57. 58, 69. 10, a. One complete vibration is a eyele. pressed in eyeies per minute, requency is ex- Vibrations of 800 cycles per minute have a greater than vibrations of 100 eyeles per minute. c The speed of vibration (number of vibrations for a given pariod of time) refers ta (freqneney /amplitude) Frequency is not related directly to the amplitude of the vibration. Increasing the frequency (increases /does not necessa ri ly inerease) the extent of shaft or beuring movement. Shafts A and B are vibrating at the same frequency. —_—— a ————————— ee ————= SS A 8 Shaft A moves (1vore/less) than shaft B, Amplitude is measured in mils (L mil equals 1/1000 ‘of an inch) A shaft vibrating: at 10 mils (1/100 of an inch) moves (more/less) than a shaft vibrating at 4 mils (1/250 of an inch). Amplitude is measured in three directions: one axial, and two radial. 5) Ou 2 3. VERTICAL RADIAL In J, the shaft is vibrating —_— In 2, the _vibration is being measured along the horizontal plane, In 3, the radial vibration is being measured along the plane. [52] frequeney frequency does not nee more more axially radial vertical sarily inevease2, In normal operation the amplitude of vibration is low. Increased amplitude of the vibration indicates an ab- normal condition which should be —— 78, Amplitude may increase if the shaft is out of balance. u 16. 1. . The couplings connecting the turbine to a pump m: LI MORE WEIGHT A bowed shaft may have more _____ on one side than on the other side, As 2 bowed shaft turns, centrifugal force pulls on the heavier side, This unbalanced force increases the am- litde of vibration When weight is unequally distributed, amplitude of vibration is (great/small) de misaligned. ALIGNED ANGULAR MISALIGNMENT PARALLEL MISALIGNMENT COMBINATION ‘The greater the misalignment the grester the of vibra A whet with a bucket broken off has an unequal di tribution of weight and causes excess If the rotor Is binding on something, vibration (ampli- tude) inereases, Newly installed on the shaft ma wears In, ‘bon-ring packing which is rubbinw cause some —_____ until it [53] corrected weight great vibration (amplitude) vibration‘he bearings must restrict axial and radial movement. A ___bearing does not restrict axial and radial worn movement enough. As the bearing, clearance increases through wear, vibra~ tion of the shaft (inereases/decresses). increases. In order to reduce the vibration, the be replaced. must Dearing, Critical Speed 81. 83. a 85. Bt. Look at the drawing. If the free end of a thin strip of spring steel is pulled back and released, it vibrates at one frequency (speed), He notural = frequency. ‘This natural frequency depends partly on the length of the strip. A longer strip vibrates at a frequeney (the same as/ different from) the frequeney of a shorter strip. different ¢rom A stiff strip also vibrates ata frequency different from a more flexible one, Like the metal strip, a shaft has a tendency to vibrate at its own natural, frequency A longer shaft has a lower natural freque shorter shaft of the same stiff ey than a A longer, multistage turbine shaft has a (higher/ lower) natural drequeney than a singlestage shaft. lower . Two shafts of the same length but different stiffness have different natural frequenc ‘The stiffer shaft has the (higher/lower) natural higher frequeney. Asa shaft turns, it sels up vibrations at the same rate id turns, ‘That is, a shaft rotating at 1000 RPM vibrates at a frequency of ______eycles per minute, 1000 Loa]88, 1 92. 94, 96. 98, A shaft rotating at 8500 RPM vibrates at a rate of eyeles per minute. the faster a shaft rotates, the faster it, When a shaft rotates at a speeil equal to its natural frequency, it is at its erities! speed. ‘That is, the vibration caused by rotation is equal to the frequency of the shaft at ila eritical speed. At most speeds, the vilaution caused by rotation is (different. trom/the same as) the natural frequency. At speeds other than the eritieal speed the amplitude of vibration is normally small. At the eritical speed, amplitnde heeomes A turbine thal must pass through a critical speed before reaching the operating speed is known as a flexible- shaft turbine. A flexibleshaft turbine has a critical speed (below/ above) its operating speed. A turbine which has 2 stiff sha?t does not have to pess through a eritical speed. A stiff-shaft turbine (has/does not eal speed below the operating speed. e) a cri A high speed, multi-stage {urbine usually has an oper- ating speetl above the critical speed. A high speed, multi-stage turbine usually has a shart Since shaft movement is restricted by bearings, exces sive vibration ____the hearings over a period of time. To avoid damage to the bearings, the turbine must not be permitted to run atthe for any length of time, If the shaft on a multi-stage turbine is bowed, its am- plitude of vibration is (greater/less) when passing through the critical speed, Vibration is detected by an instrument. Excessive vibration can also be detected by touching the [55] 3500 vibrates natural different from large below. does not have flexible damages critical speed greater turbine, or bearing housingBlading Deposits 100. If steam entering a turbine contains solids carried 10. over from the boiler, this material may eollect on the buckets and form — If enough deposit builds up on the bucket, the shape of the bucket changes. HIGHER PRESSURE DEPOSIT LOWER PRESSURE LOAD The path of steam through the buckets (remains the same/is reduced in size) when the deposit forms, 102. ‘The reduetion in flow causes steam. to build up on one side of the wheel. / 103. This change in steam flow acting on the bucket causes the rotor to push forward. This pushing increases the load on the (radial/thrust) bearing. 104. When deposits form on the buckets, they form evenly. on all the buckets, ‘The weight of the deposits is distributed (evenly/ unevenly) 105. If some of the deposits break off from the buckets, the distribution of weight heeomes (even/uneven) Vibration of the rotor eth Lubrication 106. All components which support or connect moving parts smust be lubricated. The bearings must be [56] THRUST deposits, is reduced in size pressure thrust evenly increases lubricated107. In the oilving sleeve bearing, a metal ring picks up oil from a reservoir and carries it up into the bearing. ‘The oil_________must be filled to the correct level before startup. 108. Oil is supplied under pressure to a pressure-lubrieated sleeve bearing. ‘The oi-circulating system supplying the oil must have sufficient oil 109. When the oil is too cold during startup, the ofl may be too (thick/thin). 110. Because cold, thick oil does not circulate well, too little oil may reach the bearing. Cold oil must be —_____up before st ‘turbine. rting the 111. Onee the turbine has started up, heat from the steam and bearing friction tends to heat the oil, After startup, oil temperature (inereases/decresses) , 112. If the oil temperature rises too high, the oil may break down (decompose). The oil (heater/ccoler) must be in service while the turbine is running. 113. Lf the temperature rises too high, the ofl thins out and does not maintain the film necessary between shaft and bearing. Cooling the oil maintains proper —_— of the oil. Water in the Oil System 11d. Water rusts bare steol surfaces, If wator gots into the oil eyatem, it~ ____ unpro- tected steel surfaces. 16, Tf water-laden oil absorbs these chemicals from the air, they combine with the and become corrosive. 116. Water mixed with oil forms a thick emulsion. An oil-water emulsion can an oil filter. tov] reservoir pressure thi heated, or warmed increases cooler thickness, or viscosity. rusts water plug117, Water, oil, and air mixed together form « foam. If the oil-water mixture passes through « bearing and then mixes with air in the bearing housing, the oi water-air mixture forms a foam 9118, ‘This foam may overflow from the bearing housing: to the outside of the turbine and soak into the insulation If the oil absorbed in the insulation reaches a high enough temperature, it may ignite, or flash 119. If sufficient water collects in the bottom of the oil reservoir, instead of oil may be pumped water to the bearings. 120. Since oil floats on water, water can be drained from the reservoir at the (top/bottom) of the reservoir, bottom 121. Pressure drop across the oil filter should be watehed, 0 thal it does not become too high . The governor spindle bearings must also be kept lubricated, Tf the lyball governor is not __, tt couta lubricated fail and permit the turbine to overspeed or shutdown, Overspeed Trip 128. The overspeed trip mechanism must be ready to oper- ate in case the turbine —__________, overspeeds 124. Before startup, the hand trip lever should be pyshed to see whether the trip valye responds and _____ closes properly. 125. ‘The trip and alarm cireuits should be checked perlodi- cally to make cortain that they are working, ‘Phe most opportuno times to make these checks are when the turbine is (idle/running). idle [584126. When the turbine is to he shut down, it is brought to a stop by hitting the hand trip lever. ‘The steam is shut off by hitting the —__ hand trip lever. 127. Larger iurbines are equipped with hydraulic and elee- trical trip mechanisms, Vor these hydraulic trips to work, the hydraulic system must be operating. oil Turbine Speed Adjustment 128. Look at the drawing of the direct-acting flyball governor. SPEED CHANGER GOVERNOR SPRING SHAFT FLYBALL PIVOT GOVERNOR by LINKAGE ———*I ) poo Unfil the turbine reaches operating speed, the governor holds the flyballs together. spring STARTUP. spring 129, Connected to the governor linkage is another whose tension ean be varied ta change the speed sot- point. 130. The centrifiyral foree of the flyballs is balanced against the tension of these two 1 springs ‘181, The tension of the speed-changer spring ean be varied by turning the knob. Increasing the spring tension makes the flyballs turn (faster/slower) to move the governor valve, faster 182, Increasing the tension of the speed changer makes the valve close at higher speeds and_________ the inereases operating speed. {591133, 184. 135, 136, 137. 138, ‘This is tho hydraulie governor. NEEDLE VALVE LEAK.OFF OIL PUMP SHAFT RETURN LINE TO RESERVOIR = ott eee a =—— | | presstine n | t DIAPHRAGM As the turbine speed increases, (more/less) oil is more pumped into the governing system, As more oil is pumped, the pressure increases and the governor valve (opens/closes). closes Increasing the opening of the needle valve reduces resistance to the flow of oil from the governing system, Gil pressure. decreases ‘The governor pump has to ran faster to deyelop enough pressure 1 close the valve. Opening the needle yalve (increases/decren inereases turbine speed setting. Reducing the opening of the needle valve __ decreases the turbine speed setting. The oil leak-off on the hydraulic governor allows & greater change in speed than the speed changer on the fyball governor, ‘The (lyball/hydeaulic) governor offers a greater of speeds. se hydraulic 60)189. In the oil r ing the pilot iy, the speed setting is changed by adjust fale. INLET OIL OUTLET fy t ‘ADJUSTING PILOT VALVE OUST Adjusting the pilot valve changes the oil inlet and settings without ehanging the flyball setting, outlet Instrumentation 110. In the eirevlating-oil ayatem, proper lemperature and pressure must be maintained, GOVERNOR PRESSURE GAGE —»i J<-OIL RELAY GOVERNOR OIL TO DRAIN—>| |<—OIL TO GOVERNOR | yc HIGH PRESSURE OIL GAGE i FILTER shart —- Gaal OIL PUMP DISCHARGE i i PRESSURE GAGE HIGH PRESSURE TOR BRC. ‘ACCUMULATO BEARINGS ( J+ RESERVOIR BEARING PRESSURE GAGE MAIN OIL PUMP Se eneten Several pressure ____ throughout the oi! system sages indicate ofl pressure. (61)ILL. ‘The gaze al the main oil-pump discharge measures the oil-pump discharge pressure. ‘Phe oil then passes through a eT JAZ. Another gage is on the other Side of the filter. If this gage vesords a significantly lower oil pressure, the is beginning to plug with dirt or oil emulsion. M8, Gages also indieute governor oil pri oil pressure, sure ani bearing: Because of the forve required to position the oil relay system, pressure te the bearings should he (more/less) than oil pressure in the governor oil system. 144. Bearings are often equipped with to indicate bearing temperature 145, Lanwe turbines usually h sure (high/low) lube-oil pres- ‘ms and automatic shutdown dey Visual Inspections Before Startup 116, Before starting a turbine, the operator should carefully Took over the external parts of the turbine. Governor linkage should be adequately to avold friction or binding of the parts. 117, The linkage (should/should not) he loose fitting. 148. Auxiliary piping and instruments should be in place and the instruments should be, 149. Flange bolting should be in place and (loose tight) 150, No should be leaking from the oil system, 151, Lubricant should not be —_______ from the shaft coupling. REVIEW AND SUMMARY 152. During turbine startup, the (inlet/exhanet) valve should be opened first. At shutdown, the__ valve should he closed first. 158, (A small singrlo-stago/A large multi-stage) turbine is more likely to develop a bowed shaft, [62] filter filter less thermometers low lubvieated should not. operating, or funetioning: tight oil leaking exhaust inlet A large mulli-stage199, 160. Speeding up the turbine too rapidly at startup inereases the in an already ___ shaft. how, bowed (fvequeney/Amplitude) of vibration is excessive in a Amplitude bowed shatt. AL critical speed: 1. The shafttis rotating at the speed of its natural frequenc; —of vibration becomes excessive Amplitude It a shaft is bowed, brought through its the turbine (can/eannot) be cannot tical speed. A (stiff/lexible) shaft turbine must pass through its flexible ‘tical speed to get to its operating speed, A (stiff/Mlexible) shaft is usually found in small single- stitt stage turbines. Steam traps remove condensate from the drains (qutomatically/manvally), automatically: Look at the drawing. OUTLET OIL PRESSURE INLET OIL, PRESSURE ‘The oil filter shown (is/is not) plugged, is not 63]PILOT EIGHT — PUMP AND COMPRESSOR DRIVER UNIT FIVE COUPLINGS, GEAR TRAINS, AND V-BELT DRIVES SECTION 1: COUPLINGS pave An Introduction to Power Transmission . , 3 Couplings 5 Transferring Force from One Machine to Another | ao How Machines Ate Connected to Each Other Teron Rigid Couplings Seo ie dedienseety aia) Review and Summary a Sere How Shaft Alignment Is Maintained . ,. lees sitll How Machines Become Misaligned i eos de Flexible Couplings... : 216 End Float ie +18 Gear Couplings: +19 Torque and Toraue-Cushioning Couplings = a1 Review and Summary. ........ +++ +24 Couplings with Removable Centers 225 Lubrication of Couplings £26 Review and Summary... cscs 27 SECTION 2: GEAR TRAINS Gear Trains -.....0.. Seon 29 Introduction, 29 Force and Power « 33 How Gears Affect Power 36 Why Gears Ate Used. . ; 38 240 How Gear Trains Are Used As Speed Changers. Compound Gear Trains .. Z Gear Trains for High-Torque Loads Gears for Parallel Shafts 2 Spur Gears Helical Gears... . Double-Hislicsl Gears Review and Summary Gears for Perpendicular Shaits, Bovol Gears : Worm Gears . Lubrication... Shock Loads... 1... Review and Summary ....... SECTION 3: V-BELT DRIVES V-Belt Drives... or - 64 Introduction... . e su ssa V-Belt Drives Can Be Used As Speed Chargers. 00.66 Variable-Speed V-Belt Drives BS eo V-Belt Slippage. ...... \entoedaccemncer ah ieg eee MURTY! How V-Belts Are Constructed <0) s sss) 2» How Belts Are Adjusted ae ce Belt Replacement, aoe a $ 79. The V-Belt Drive in Oper ‘ 80 Review and Summary... ila Comparison of Gear and Belt Drives Race enlceare H satanic Oe