ANALYSIS OF HIGH VIBRATION ON REAR

BEARING STEAM TURBINE GET-4R

STG BOILER PROJECT

JAKARTA, 3 NOVEMBER 2022

TURBINE OVERVIEW
1. MFR GE TRIVENI LTD

2. MODEL GET-4R

3. STANDARD : API 612-6TH ED.

4. AXIAL CONDENSING WITH

UNCONTROLLED EXTRACTION

5. STEAM RATE : 4,62 Kg/ kW-h

6. MAX. POWER : 40 MW

7. STEAM FLOW : 170 TPH

8. STEAM PRESS : 51 KG/CM2

9. STEAM TEMP : 482 C

10. SPEED 5338 RPM

I. TURBINE START UP & COMISSIONING
(14 MARCH – 5 APRIL 2017)
Vibration @ 22 March 2017
Vibration @ 22 March 2017
Time vs Power @ 22 March 2017
INSPECTION BEFORE DISMANTLING
INSPECTION BEFORE DISMANTLING
FAILURES OBSERVATION AFTER DISMANTLING

GBC  Heavy radial rubbing on lower halves stage 1 - 12

 FAILURES OBSERVATION

Rotor  Heavy radial rub on balancing piston and blade shroud stage 1-12
 SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON MARCH 22, 2017

MAIN SUSPECT ACTION PLAN EXPEDTED RESULT FOR NEXT

TRIAL

CONDENSATE 1. RE-ROUTING TURBINE DRAIN LINE 1. TO SOLVE CONDENSATE TRAP

ACCUMULATION  2. INSTALL ADDITIONAL CONDENSATE ISSUE
CASING DISTORTION RETURN PUMP 2. TO MONITOR DIFFERENTIAL
DUE TO THERMAL 3. INSTALL ADDITIONAL RTD CASING TEMPERATURE BETWEEN UPPER
TEMPERATURE MONITORING AND LOWER CASING
SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON MARCH 22, 2017
II. TURBINE LOAD TRIAL AFTER MAJOR REPAIR DUE TO ROTOR BOW
(16 NOVEMBER 2018)
 SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON NOVEMBER 16, 2018
SUSPECT ACTION PLAN EXPECTED RESULT FOR NEXT TRIAL
TURBINE THERMAL EXPANSION CHECK CLEARANCE, SETTING AND MONITORING OF MONITORING TURBINE CASING THERMAL
THE FOLLOWING POSITION AS PER DRAWING: ELONGATION
1. FRONT PEDESTAL L BRACKET
2. REAR CENTER KEY
3. REAR PEDESTAL HOLDING BOLT

START UP CURVE START UP PROCEDURE FOLLOW CURVE MONITORING CASING TEMPERATURE

DIFFERENCE
AXIAL ALIGNMENT DEVIATION GET CONFIRM STILL WITHIN TOLERANCE OF AS PER VIBRATION ANALISYS REPORT, NOT
FLEXIBLE COUPLING CREATING ANY ISSUE, TO BE ASSESSED AT
HIGHER LOAD
GOVERNOOR OPENING STROKE TEST OF GOVERNOOR CYLINDER AND AIR MONITORING INLET STEAM FLOW
BLEEDING
III. TURBINE LOAD TRIAL (20 FEBRUARY 2019)
 SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON FEB 20, 2019

SUSPECT ACTION PLAN EXPECTED RESULT FOR NEXT TRIAL

TEMPERATURE BLEED 3 LINE 2 HIGHER 1. PIPE STRESS ANALYSIS CHECKED PIPE EXPANSION ON HORIZONTAL DIRECTION IS
THAN DESIGN TEMPERATURE DUE TO 2. SUPPORT MODIFICATION ON DIRECTED AWAY FROM TURBINE AND WILL NOT
STEAM FROM BALANCING LINE BLEED 3 WEST SIDE AFFECT TO NOZZLE LOAD ON INLET BLEED 3

INSTALLED SPRING SUPPORT ON INLET INSTALL SPRING SUPPORT AS PER PIPE EXPANSION ON VERTICAL DIRECTION (MOVE
BLEED 3 HAVE HIGHER LOAD THAN DESIGN DESIGN LOAD DOWN) WILL NOT BE RESTRAINED BY SPRING
LOAD LOAD
SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON FEB 20, 2019
SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON FEB 20, 2019
SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON FEB 20, 2019
SUSPECT & ACTION PLAN
AFTER TURBINE TRIP ON FEB 20, 2019
PIPE STRESS ANALYSIS AND SUPPORT MODIFICATION ON BLEED 3
PIPE STRESS ANALYSIS AND SUPPORT MODIFICATION ON BLEED 3
FINDING ITEM (SPRING SUPPORT INLET BLEED 3)

BLEED 3
DESIGN LOAD (Fy) INSTALLED SPRING SUPPORT LOAD
EAST SIDE 1050 kg 2500 kg
WEST SIDE 1200 kg 2500 kg

P I P E S U P P O R T D R A W I N G I S N O T M AT C H E D W I T H S T R E S S A N A L I S Y S A N D I S O M E T R I C D R A W I N G .

S P R I N G S U P P O R T I N L E T B L E E D 3 S H A L L B E E X C H A N G E D W I T H S P R I N G S U P P O R T I N L E T L P H E AT E R 1
IV. TURBINE LOAD TRIAL (MAY 2019)

RESULT ON LOAD TRIAL (MAY 28, 2019)

1. PIPE LOAD ON INLET BLEED 3 WITHIN ALLOWABLE NOZZLE LOAD

2. NO EXCESSIVE LOAD ON TURBINE REAR CASING
3. NO EXCESSIVE LOAD ON REAR BEARING HOUSING, SINCE REAR BEARING HOUSING IS SUPPORTED ON REAR CASING.
4. VIBRATION ON REAR BEARING WITHIN ACCEPTABLE LIMITS.
5. LOAD TRIAL SUCCESFULLY DONE UP TO 19 MW (AS PER AVAILABLE LOAD IN PUSRI GRID) AND CONTINUE RUNNING.
 V. CONCLUTION

1. TURBINE HIGH VIBRATION ON REAR BEARING SIDE IS CAUSED BY EXCESSIVE PIPE LOAD FROM BLEED 3 LINE 2
2. EXCESSIVE PIPE LOAD IS DUE TO BALANCING LINE TEMPERATURE IS NOT CONSIDERED IN PIPE STRESS ANALYSIS AND
INSTALLED PIPE SUPPORT HAVE HIGHER LOAD THAN DESIGN.
 VI. LESSON LEARNED

1. TURBINE’S DRAIN SYSTEM DESIGNED SHALL BE CONSIDERED GRAVITY FLOW TO CONDENSER AND IT’S PREFERED TO BE
INCLUDED IN VENDOR SCOPE OF SUPPLY.
2. BALANCING LINE CONNECTION IS PREFERED TO BE CONNECTED INTERNALLY IN THE STEAM TURBINE EXHAUST CASING.
3. VENDOR REVIEW & COMMENT ON PURCHASER’S PIPING DESIGN.
4. MAKE SURE DESIGN TEMPERATURE FOR PIPING STRESS ANALYSIS HAVE BEEN CONSIDERED FOR ALL OPERATING
CONDITION FROM TURBINE MINIMUM LOAD UP TO FULL LOAD.
5. MAKE SURE SPRING SUPPORT DRAWING IS MATCHED WITH ISOMETRIC DRAWING AND PIPE STRESS ANALYSYS.
TERIMAKASIH
DESIGN SPRING SUPPORT LOAD INLET BLEED 3 (STRESS ANALISYS)
DESIGN SPRING SUPPORT LOAD INLET BLEED 3 (ISOMETRIC DRAWING)
DESIGN SPRING SUPPORT LOAD INLET LPH 1 (ISOMETRIC DRAWING)
SUPPORT DRAWING SPRING SUPPORT INLET BLEED 3 EAST SIDE
SUPPORT DRAWING SPRING SUPPORT INLET BLEED 3 WEST SIDE