AZUCARERA NACIONAL SA

SANTA ROSA INGENIO.

TECHNICAL REPAIR MANUAL FOR ELLIOTT TYPE

2CYR AND DYRT TURBINES.

BY: GUSTAVO GOMEZ T.

YO. M. AND.

YEAR 2003.
 Content.

Chapter N°1.- General Information.

P. No.
I. Introduction 4
II. Turbine Housing 6
III. Box of Gaskets and Carbon Rings 7
IV. Sentinel Valve 8
V. Nozzles and Deflectors – Stationary Guide 8
VI. Bearing Box and Supports 9
VII. Governor Woodward TG-10 and TG-17 10
VIII. Bearings 11
IX. Thrust Bearings 12
X. Over Speed Trigger System 13
XI. Turbine Rotor 13
XII. Steam Box 15
XIII. Field trial 16

Chapter N°2.- Disarmament, Cleaning and Review Practices.

I. Introduction 17
II. Procedures for Disassembling Elliott CYR and DYRT Turbines 17
1. Clean the work area 18
2. Decouple the Turbine from the Speed Reducer 18
3. Governor Woodward 18
4. Lift the Turbine Top Cover or Cover 19
5. Remove the Bearing Covers 21
6. Rotor Axial Play Measurement 22
7. Lift the Turbine Rotor 23
8. Disassembly of Manual Steam Valves 24
9. Disassembly of Steam Valve and Auxiliary Trip Valve 24
III. Cleaning and Inspection of Parts 25
1. Cleaning and Inspection of the Bearings and their Covers 25
2. Cleaning and Inspection of the Lower Case 26
3. Cleaning and Checking the Top Cover 27
4. Cleaning and Checking the Rotor Shaft 28
5. Cleaning and Checking the Carbon Rings 29
6. Cleaning and Inspection of Manual Valves 30

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7. Cleaning and Checking the Governor Steam Valve 30
8. Cleaning and Checking the Auxiliary Trigger Valve 30
9. Cleaning and Checking the Screws and Nuts Used in the Turbine 31

Chapter N°3.- Turbine Repairs and Assembly

I. Introduction 32
II. Repairs and Adjustments 32
1. Overspeed Trigger Mechanism Repair 32
2. Changing the Axial Thrust Bearing 33
III. Assembly Procedure 34
1. Manual Valves.- Only for DYRT Turbines 34
2. Turbine Rotor 35
3. Placement of the Upper Covers of the Bearings 36
4. Placement of the Carbon Rings 37
5. Placement of the Upper Turbine Cover 38
6. Steam Valve Assembly 39
7. Assembly of the Auxiliary Trigger Valve 40
8. Governor Woodward Installation 42
9. Steam Valve Travel Adjustment 43
10.Adjusting the Trigger Mechanism and Manual Trigger Lever 44
11.Turbine Firing Speed Adjustment 44

Chapter N°4.- Operation, Start-up and Common Problems.

I. Introduction 46
II. Turbine Startup 46
III. Common Problems in Turbines and Their Solution 48

Bibliography.

Chapter No. 1.

3
 General information.

Introduction.

The Elliott turbines type CYR and DYRT are single-stage back pressure
turbines, controlled by a steam inlet valve, with one pressure step and two
speed steps, which operate under the Curtis principle. We say that a turbine
is counter pressure when the exhaust steam from the machine is in
communication with some type of device that uses this low pressure steam for
its operation (case of the pre-evaporators in our mill). These turbines are
used in numerous applications, under different steam conditions. At the Santa
Rosa Mill they are specifically used to move the cane chopping blades, with
250 psi inlet steam, where we have two 800 HP CYR type turbines in the first
and second set of fixed blades. The second set is out of use due to the
installation of a 1200 HP DYRT type turbine that drives a set of tilting blades.
The CYR and DYRT turbines are similar in design and construction.
Figure N°1 shows a view of the Elliott turbine of the first set of blades before
beginning its repair and figure N°2 details all the parts that make it up.

Top Cover

Governor
Woodward

Bottom Shell
Fig. No.
1

4
 Longitudinal View of the Elliott CYR and DYRT
Sentinel valve Turbines.
Rotor
Top deck
thrust bearing
Trigger mechanism

II.- Turbine Housing.

Governor's
Exhaust side carbon Steam side coal cover Coupling
cover
Lubrication Coals Coals Governor
labyrinth rings Lubrication Governor's
stamps rings Linkage

rotor
shaft

Exhaust side
bearing Steam side
bearing box
labyrinth
stamps
steam
box
Exhaust side Governor
bearing Steam side steam valve
Steam side lower bearing
support
casing
Exhaust side Stationary Nozzle
lower casing blades ring Steam side
bearing support
Fig. No.

5
2
It contains the rolling and stationary elements of the turbine. The casing is
made up of the top cover, which when removed reveals the turbine rotor and
the carbon rings. The lower casing is made up of two sections bolted
together, which take their name according to the steam: inlet side or exhaust
side. The part that is located on the high-pressure steam inlet side contains
the nozzles and stationary blades, and the DYRT turbine has two auxiliary
steam valves. The other section contains the turbine steam outlet box.

Auxiliary valves in turbines are used to control the flow of steam through an
extra set of nozzles and serve three functions.
a. When closed, the turbine can work more efficiently at reduced loads, with
normal steam conditions, by reducing the nozzle area and controlling the
steam flow.
b. In some applications, manual valves open to return power to the turbine
when there is loss under normal steam conditions.
c. Open manual valves are used to obtain an increase in turbine power, with
steam under normal operating conditions.
Note.
Manual valves are not throttling valves. They work totally open or
totally closed. When the turbine is started, it is advisable to open the
valves until the entire machine reaches operating temperature, then they
can be closed if required.

Entry Side

Exhaust Side

Fig. No.
3

III.- Box of Gaskets and Carbon Rings.

The turbines are supplied with two sections of carbon rings located in the area
where the drive shaft passes through the casing. The first section of carbon

6
seals is located on the steam inlet side and the other on the outlet side. In
back pressure turbines, seals limit and control the flow of steam along the
shaft.

The CYR and DYRT turbines have four sets of carbons on each side of the
shaft. Each set of carbons consists of three segments, duly identified by
points that come from the factory to always assemble them the same. The
three segments are joined together by a spring that covers its entire
circumference and in which a metal piece is placed that fits into a slot in the
casing, preventing the carbons from rotating on the axis. The same casing has
a special machining where the carbons are housed that prevents them from
having axial movement.

In figure N°4 you can see the three segments of the carbon set, the marked
points to assemble them, the anti-rotation stop and the slot where it enters, as
well as the retention spring to keep the carbon segments together.

Points to assemble
Segments
Retention spring

Points to
assemble

Fig. No. 4 Anti-rotation stop

IV.- Sentinel Valve.

It is installed on the top cover of the machine and serves only to indicate that
there is excess pressure in the turbine casing. When this happens, the sentinel
valve lets the vapor escape into the atmosphere, producing a visible cloud and

7
a certain noise that alerts personnel. At the Santa Rosa Mill we have seen
these valves open generally when there are sudden grinding stops or mill starts
that require leaving out of service a large part of the equipment that consumes
steam, especially the exhaust. At that moment, a pressure increase occurs that
causes the relief valves and sentinels to open to the atmosphere, letting excess
steam escape. It is clear that sentinel valves are not designed to function as
safety or relief valves, since they do not have the capacity to evacuate all the
excess steam inside the chamber.
On Elliott CYR and DYRT turbines the sentinel valves are factory set at 85
psi. You can see the valve in figure N°5.

Sentinel
Valve

Fig. No. 5

V.- Nozzles and Deflectors – Stationary Guide.

The nozzle chamber is the place where the steam enters and expands to a
lower pressure, the steam jet acquiring a high speed and giving up its kinetic
energy to the turbine rotor blades. The nozzles are mounted on plates
screwed to the turbine casing.
The CYR and DYRT type turbines have a nozzle plate that directs the steam
jet towards a first group of moving blades, followed by a diaphragm of
stationary blades that guides the steam to another group of moving blades.
The stationary blades are known in Elliott manuals as Reversing Blade
Assembly, and in them, both the pressure and the speed of the steam remain
constant as it passes. In the following illustration you can see the nozzles,

8
manual valves, mobile and stationary blades of a typical action turbine, with
one pressure step and two speed steps that works under the Curtis principle.

steam outlet Stationary blades

2nd row of
blades
1st row of
blades
nozzle
plate
steam
Valve No. Valve ring
2 No. 1

Inlet steam

Fig. No.6

VI.- Bearings and Supports Box.

The bearing box support, steam side, is bolted to the base of the turbine and
the casing. The case or housing contains the bearing, two lubrication rings,
the axial thrust bearing, the overspeed trip device, the coupling of the turbine
shaft with the Woodward Speed governor and the labyrinth seals that protect
the case. bearings against moisture, dust and any other type of foreign body.
The bearing box, exhaust side, is supported by a pedestal anchored to the
turbine casing and bolted to its base. Contains the bearing, two lubrication
rings and the labyrinth seals.
The bearing boxes come from the factory with a dial that indicates the oil
level. In the view we clearly see the bearing support on the exhaust side, both
bearings with the lubrication rings and the turbine shaft with its components.

9
 Steam side
bearing Exhaust side bearing

Lubrication
Steam side support rings

Exhaust side support

Fig. No.7

VII.- Governor Woodward TG-10 and TG-17.

Woodward governors are mechanical-hydraulic mechanisms used to regulate

the speed of the turbines, keeping it within the desired operating limits.
These Governors come adjusted at the factory and with the direction of
rotation of the equipment they will serve. It is always possible to adjust the
operating speed by moving the screw indicated for this in the instructions
supplied by the Governor manufacturer. Here at Ingenio we only make small
repairs to this equipment, such as changing the rotation of the hydraulic pump,
changing retainers, O'rings and bearings. When one of these equipment is
damaged, it is sent to the factory for repair and calibration. The model in the
photo corresponds to a TG-10 with counterclockwise or CCW rotation.

10
 Speed adjustment
screw.

Fig. No.8

VIII.- Bearings.

There are two bearings, one on the steam side and the other on the exhaust
side, whose function is to support the weight of the turbine shaft and its
components. These bearings have a Babbit metal jacket cast into a half-round
steel surface, capable of withstanding high loads and resistant to impact. The
bearings are divided into two parts so they can be removed or installed
without removing the shaft. The bearing boxes and covers are constructed
with a slot where a small ear or projection that is part of the bearing itself
enters, which prevents it from rotating or moving axially in the box or
housing. See figures N°55 and 56 on page 36.
In Elliott type CYR and DYRT turbines, the clearances between the shaft and
the bearings are from 0.006” to 0.010” with the machine cold.
These bearings are lubricated by rings that move when the turbine comes into
operation, splashing oil on the shaft and forming a film of lubricant between
both surfaces. At the speeds at which these machines move, damage to the
bearings can cause serious damage to the turbine and the personnel
responsible for its operation, hence the importance of good surveillance.
The box where the bearings are located is water cooled.
Note:
Babbit is an alloy based on tin and lead, which also contains antimony,
copper and arsenic, where the latter component provides better
performance at high temperatures and heavy loads.

In the following photo we can clearly distinguish the bearing on the steam
inlet side (1), the lubrication rings (2), the axial thrust bearing (3), the

11
overspeed trigger mechanism (4), the Goodward governor support (5) and a
labyrinth ring (6).

No. 5

No. 2 No. 3 No. 4

No.6 No.
1

Fig. No.9

IX.- Thrust Bearings.

The thrust bearing is located at the end of the shaft in the steam inlet part (see
previous photo) and its function is to prevent the axial movement of the
turbine rotor beyond the established limits, making it impossible for the
turbines to collide. moving parts with the stationary ones. This bearing
comes from the factory mounted in such a way that it places the rotor at the
optimal point where the collision of the steam jet with the blades should occur.
The axial play that these bearings have is from 0.005” to 0.015” depending on
their design and must be measured each time the turbine is disassembled for
maintenance, keeping a note that allows us to determine any wear. These
turbines have by design a minimum adjustment of 0.042" and a maximum of
0.072" between the nozzle plate and the rotor, so a location outside these
limits can cause loss of power and even destruction of the machine if it occurs.
the collision of moving and stationary parts. It is the thrust bearing that must
prevent axial travel beyond these established limits.

X.- Over Speed Trigger System.

12
The overspeed trigger mechanism is located at the tip of the shaft, steam side,
and is designed to stop the turbine when it reaches a speed predetermined by
the machine manufacturer, whether due to a mechanical failure or because we
are testing the system. .
This mechanism acts separately from the action of the governor and as
illustrated in figure No. 10 on the next page, it is made up of a trigger weight
(1), a spring (2), two U-type safety washers (3) , an adjustment nut (4), and a
weight (6). As the speed of the machine increases, the shooting weight, due
to the effect of the gravitational force, overcomes the resistance of the spring,
which causes the shooting weight to begin to move outward and rub against a
metal plunger (7) separated by 1/16” of the trigger mechanism. When
touching this plunger with the manual trigger arm (13), the lever (14)
connected to the auxiliary valve (15) falls, closing the flow of steam into the
turbine.
It is extremely important to test the trips of all the turbines before starting the
harvest, as well as during its development.

XI.- Turbine Rotor.

The rotor of the Elliott CYR turbine is formed by the shaft with two impellers
that have a row of blades each, separated from each other by spacers and
attached to the shaft by boxed wedges. The function of these935
spacers is only
to correctly locate the impellers when assembling them at the factory.
The DYRT turbine has a single rotor with two rows of blades.
A labyrinth ring, the axial thrust bearing, the overspeed trigger mechanism
and the governor coupling are mounted on the turbine shaft, steam inlet side.
On the exhaust steam side, the shaft has two labyrinth rings and the drive
coupling, which in our case is connected to a speed reducer.
936
In the photo on page N°15 we see a longitudinal view of the turbine shaft with
the components clearly visible and easy to identify.
All rotors are dynamically balanced at the factory to ensure safe, vibration-
free operation. If a repair is required in which we have to replace components
of the rotor (blades), the best way to do it is to send it to a specialized
workshop, with the complete shaft, including the couplings, so that once the
repair is completed, the unit is integrally balanced.

Overspeed Trigger Mechanism

13
 Manual trigger arm hitch lever
(13) (14)

Closing spring

Auxiliary
valve (15)

Entrance

steam
r

Shot housing

Fig. No. 10

View of the Shaft of an Elliott Turbine with its Components.

14
 Governor Coupling
Rotor with blades

Coupling

labyrinth
Axial thrust ring
bearing

Shooting
Lubrication
rings

Fig. No. 11

XII.- Steam Box.

Called in the manuals as the Steam Chest, it is screwed to the housing on the
steam inlet side. This box is the one that receives the steam jet that comes
from the main line and is made up of a strainer, the auxiliary trigger valve and
the governor valve.
Figure N°12 on page 16 shows the parts of the steam box of the Elliott turbine
of the pipe blades N°1 at the moment in which the nuts of the cover studs are
being loosened with a force lever. of the governor valve.

15
 Auxiliary trigger valve.
Inside is the steam
Screws that join it to the
strainer
lower casing

Governor valve housing

Fig. No. 12

XIII.- Field Test.

These turbines come assembled, tested and adjusted from the factory, where
They are tested for vibration, speed, triggering, adjusting the travel of the
governor and trigger valves, and the temperature of the bearings is monitored.
The tests are rigorous, as an example we can say that the steam box, like the
one in the previous photo, is subjected to pressures 3.5 times higher than those
of normal operation for a period of thirty minutes.
All of these tests are currently documented in the manuals and signed by those
responsible for carrying them out to guarantee the safety of the people who
operate this equipment.

Chapter No. 2.

16
 Disassembly, Cleaning and Review Practices.

Introduction.

Turbines are very delicate equipment that operate at high speeds, according to
the needs required for each job and must be given constant monitoring and an
adequate maintenance plan.

The maintenance period at the Santa Rosa Mill begins once the milling
process and factory liquidation are completed. The activities carried out
during the so-called down time are aimed at guaranteeing the proper
functioning of the machines during the harvest season, as well as the safety of
the company's workers. To really appreciate the importance of the work
carried out, it is enough to say that, in a period of a maximum of one hundred
days, we must produce all the sugar production for the next twelve months in
order to meet national demand and the export quota, which is why downtime
due to equipment damage must be minimized. This is achieved by doing
serious, responsible and efficient work.

II.- Procedures for Dismantling Elliott CYR and DYRT Turbines.

We are going to list and describe the steps we follow to repair these turbines,
based on the experience of our staff and respecting the recommendations,
adjustments and tolerances that appear in the manuals provided to us by the
manufacturers of this equipment. For many years we have carried out these
maintenance practices with great success and the purpose of this manual is to
preserve these Good Maintenance Practices for future generations of workers
of this Company.
The steps to repair Elliott turbines are detailed below and will be explained
and documented in more depth during this work for a better understanding.
 Cleaning the work area and the outside of the turbine.

 Uncouple the turbine with the reducer.

 Take out Governor Woodward.

 Remove the top cover of the turbine.

 Remove the covers from the bearings and remove the upper half of them.

 Measure the axial play of the turbine shaft.

 Lift the rotor and remove the lower half of the bearings.

 Remove the steam valve and auxiliary trip valve.

1.- Cleaning of the Work Area.

17
The repair of the equipment begins with a good cleaning of the area where we
are going to work, to leave it free of foreign materials, solid or liquid, which at
a certain moment could become a danger of accident for the personnel and for
the future operation of the plant. machine. For this cleaning we will use
brooms, rags, Spum soap and compressed air, making sure not to dirty the
surroundings of other machines and maintaining the following order.
a. Collect large solid waste and place it in a trash can.
b. Sweep all dust from the floor of the work area with a broom.
c. Clean oil and grease stains with a cloth using Spum soap mixed with a little
Diesel, in a bucket. This mixture is applied with a siphon that uses
compressed air as a driving medium. Every mechanic must carry a
container to collect the oil and another for the grease from the couplings to
avoid contaminating the environment. It is important to minimize the
spillage of oils and greases into drainage ditches. The ultimate goal
should be zero contaminants in drains.
d. Clean the floor using water to remove traces of dirt.
e. Dry the area to avoid accidents.

2.- Decouple the Turbine from the Speed Reducer.

In order to lift the turbine shaft we must first disassemble the turbine gear
coupling with the speed reducer. It is important that at the time of
disassembly, the coupling has a good amount of grease, which is what keeps
the gear teeth in perfect condition, since we consider that the unit is well
aligned.

3.- Governor Woodward.

a. Using a 3/8” allen wrench, remove the lower plug to drain the oil into a
container and deposit it in a used oil tank. Fig. No. 13.
b. Disconnect the Governor from the bar that connects it to the turbine steam
valve.
c. Using a 5/16” allen wrench, loosen the four screws that attach the
Governor to a special piece that attaches it to the turbine component.
d. When removing the Governor, it must be placed in a safe place, free of
possible knocks. In our case we placed it screwed to a base glued to a
column. The following figures show the operation.

18
 Connecting
rod

Drain
plug

Fig. No. 13 Fig. No.14

Fig. No. 15 Fig. No.16

4.- Lift the Turbine Top Cover or Cover.

a. Loosen the screws that join the top cover to the bottom of the casing, using
a 15/16” socket with a pry bar, or a hammer gun. Figure N°17 on page 20.
b. With the help of a ½” allen wrench, we loosen the screws on the carbon
sets on both sides of the turbine. Figure N°18.
c. Using a one-ton differential placed on a beam located above the turbine,
we place the differential hook on an eyebolt that is located at the factory in
the upper part of the cover and proceed to lift with great care, to prevent
the cover, Being subjected to an upward force, try to rise abruptly, causing
damage to the coals, or worse, hitting the turbine rotor. Figure N°19.
d. Once the operation of lifting the cover is completed, we place it in a place
where it will not interfere with the following disassembly tasks carried out
by the personnel.

19
e. We immediately proceed to remove the coals and to do this we use a small
screwdriver to lift and unhook the spring that surrounds them and remove
the anti-rotation plate. Figure N°20.
f. We remove the three segments of the carbon set by rotating them around
the axis and then we remove the retention spring, we tie the assembly with
a thread and a tag (figure N°21) where we identify them with a number to
always place them back in the same place of work. We always carry out
the operation of removing coals starting from the first set next to the steam
inlet, towards the exhaust side.

Fig. No.17 Fig. No.18

Fig. Fig. No.20

No.19

20
 Fig. No.21

5.- Remove the Bearing Covers.

a. Remove the cooling water pipes from the bearing housings.

b. Remove the fixing pins and screws from the covers. Figure N°22.
c. Look for places where the caps protrude from the bottom casing and use a
screwdriver to press up and break the bond of the sealant used for the
gaskets. In Santa Rosa we use Permatex N°2.
d. Raise the cover approximately 1” and with the help of a screwdriver move
the upper bearing between the slot in the cover and the lug (figure N°23) so
that it comes off the cover and falls gently on the shaft. We must avoid
any impact that could distort the lubrication rings, which would result
in poor lubrication and damage to the bearing during turbine
operation.
e. Take off the cover and remove the upper bearing. Figure N°24.
f. Remove the piece where Governor Woodward is mounted.

guide pins
Slot to remove the bearing
Fig. No.22 Fig. from the top cover.
No.23

21
 Bearing covers

Removing the upper Governor Assembly

Fig. bearing. Fig. No.25
No.24

6.- Measurement of the Rotor Axial Play.

a. Place a dial indicator with a magnetic base on the turbine bed. Figure
N°26.
b. Move the turbine rotor towards the inlet steam side and set the dial
indicator to “0” so that we can measure the movement of the rotor in both
directions.
c. Push the turbine rotor toward the steam exhaust side and watch the dial
indicator reading, which should not be greater than 0.025”. Normal end
play is 0.010” to 0.018”.
d. Take note of the above for history and be prepared to change the bearing if
we get a reading too close to 0.025”.

Axial displacement

Fig.
No.26

22
7.- Raise the Turbine Rotor.

a. Lower the one-ton differential hook and place the tool indicated for this
operation, with its two cables at the ends. Figure N°27.
b. Pass one of the cables through the space between the thrust bearing and the
overspeed trip mechanism housing and the other, glued to the coupling of
the turbine with the reducer. Figure N°28.
c. Lift slightly level and remove the lower bearings. It is important to carry
the shaft level to avoid collisions between the moving and fixed parts. This
operation must be done very carefully, because impacts can loosen one or
more blades or damage a lubrication ring.
d. Lift the rotor shaft out of the lower housing and place it on stands in a safe
location. Figure N°30.

Fig. Fig.
No.27 No.28

Fig. Fig. No. 30

No.29

8.- Disassembly of the Manual Steam Valves.

23
The manual valves only have the turbine of the No. 2 sugarcane blades.

a) Remove the six allen screws that join the valve to the turbine body.
b) The valve cover has two threaded holes located at 180° into which two
square-headed studs are inserted, which, when turned clockwise, act as
an extractor and help us remove the valve from the lower casing.

9.- Disassembly of the Steam Valve and the Auxiliary Trigger Valve.

To disassemble the steam valve we follow the following steps.

a. Remove the arm that connects the governor to the steam valve, removing
the connection pins. Figure N°31.
b. Move the valve by the stem to be sure it is not stuck inside the cage.
c. Remove the nuts securing the valve cover to the turbine body.
d. Carefully remove the valve making sure not to bend the stem. Figure N°32.

Fig. No. 31 Fig. No.

32

To disarm the auxiliary trip valve, follow the following steps.

a. Place the valve in the firing position and remove springs No. 11 and 45
from the firing lever. See figure N°33.
b. Remove the #12 nut, #36 upper spring seat washer, #37 spring, #39
bushing, and #38 lower spring washer from the valve stem. See figure
N°84 on page 42.
c. Remove manual release lever No. 8.
d. Wiggle the valve to make sure it runs freely and unscrew the square
connecting block to remove it.

24
e. Remove the allen screws from the valve cover and lift it away from the
steam inlet box.
f. Pull the auxiliary trip valve out of the steam box. Figure N°34.

Washer No. 36 Nut No. 12

valve cover
Spring No. 37
Lever No. 8

Springs No. 11 and

45
Auxiliary valve

Fig. No. Fig. No.

33 34

III. Cleaning and Inspection of the Parts.

The process of cleaning and reviewing the turbine parts is one of the key
stages within the maintenance scheme of this equipment, since it allows us to
more thoroughly observe the condition of the parts and helps us make
decisions, which Which parts should continue working and which should be
replaced with new parts. Let us not forget to make decisions that guarantee
the physical integrity of the staff and take care of the best interests of the
Company for which we work.

1.- Cleaning and Inspection of the Bearings and their Covers.

a. Wash the Babbit bearings very well with diesel and then dry them with
gasoline. Do the same with the lids using a scraper to remove the material
used to seal the joints. Spray with an anti-oxidant.
b. Observe that the bearings do not have scratches, dents, cracks, slags or any
other damage that would prevent their proper functioning.
c. In case of small scratches on the bearings, we can try to eliminate them
with the help of a scraper or fine sandpaper, especially for these types of
materials. This is the case of the bearing in figure N°35.
d. With the help of a Mechanical Turner, calibrate the bearing to establish the
clearances with respect to the axis of the turbine where it works. In this
case we are talking about a tolerance of 0.007” to 0.010” in diameter, when
the turbine is cold (the shaft diameter in this section is 2.932”). Once this

25
 is done, the decision must be made whether or not to leave the bearings
working.
e. Check that the bearing covers are in good condition. These covers cannot
have deformations beyond 0.002” in diameter, against the lower bench or
pedestal of the turbine, on which they work.
f. With a knife or scraper, a straight grinder and a soft wire disc, clean the
part where the governor is mounted. Figures N° 36 and 37.
Note.
The wire disc used for cleaning with the straight grinder should be of a
soft material, which will not scratch the contact surfaces, but is capable of
removing slag. Personnel should protect themselves with safety glasses
and a long-sleeved shirt.

Bearing with Steam side cover

scratches

Fig N°35 Fig. No.36 Fig. No.37 Fig. No.38

2.- Cleaning and Inspection of the Lower Housing.

a. Blow air into the cooling water pipe of the bearing housings. The nipple
that enters the interior of the chamber must be washed with Spum soap and
cleaned with a rod to remove the scum. Fig. No. 39.
b. Blow air into the cooling chamber.
c. Circulate water and Spum soap until the mixture runs clean.
d. Dry the chamber with air.
e. Disconnect all bleed pipes from the casing.
f. Blow all purge pipes with air from outside to inside.
g. Blow out the steam inlet box and the turbine nozzles with air.

26
h. Clean any residue of condensed water from the different sections of the
casing with a cloth due to its high corrosive power, a product of acidity.
i. Clean with a scraper, or with a straight grinder, depending on the size of
the section, the entire top of the housing to remove the material used as a
gasket sealant.
j. Clean all the threaded holes in the housing, as well as the threaded bolts
fixed to it. The fig. No. 40 shows the section to be cleaned.
k. Clean the entire casing with diesel and blow all parts again.
l. Check steam valve cages, nozzles, stationary vanes, and bearing housings.
m. Spray an anti-oxidant with a spray gun on all sections of the casing.

cooling chamber

Fig. No.39 Fig. No.40

3.- Cleaning and Checking the Upper Cover.

a. Clean the cover inside and out with diesel.

b. Use a straight grinder with a soft wire wheel to clean the contact surface of
the cover with the lower casing.
c. Clean the holes where the screws that fit the cover against the lower casing
go through.
d. Clean the labyrinths where the coals are placed.
e. Blow with air to remove any signs of trash.
f. Apply an anti-oxidant to the inside of the casing.
g. Check that the lid has no dents on the gasket surfaces. In figure N°41 you
can see the cover completely clean and ready to be installed.

27
 Fig N°41

4.- Cleaning and Checking the Rotor Shaft.

a. Clean the shaft with diesel in the parts where the carbons work, the
bearings, the thrust bearing, the overspeed trigger mechanism, the rotor and
the blades.
b. Clean the labyrinth rings that are mounted on the shaft and check for wear
that could allow dust, moisture, debris to enter, or oil to escape from the
bearing housing.
c. Check the impellers and blades to verify that there are no dents, excessive
wear, cracks or any other damage that could jeopardize the proper
functioning of the unit. In case of damage to this section, the axle must be
sent for repair to a specialized workshop abroad.
d. Check the shaft in the sections where the bearings work, which must be
free of scratches. Clean with special sandpaper wet with diesel to
eliminate any roughness on the shaft.
e. Measure the diameter of the shaft in the working section of both bearings,
which should be 2.932”
f. Check the thrust bearing that collects the axial play of the turbine, to be
sure that there are no rust stains, pits on the race or the bearings, or axial
displacement outside the permitted limits. In case of changing the bearing,
the steps indicated below must be followed.
g. Check the trigger mechanism for overspeed, pushing the weight with a
rounded object on the tip and pouring oil on it to clean and eliminate any
dirt on the internal parts of the mechanism. In case of system change, the
steps indicated below must be followed.

28
 Fig.
No.42

5.- Cleaning and Inspection of the Carbon Rings.

a. Wash each set of carbon rings individually, using a bucket of clean diesel
fuel and a 2” brush to remove any dirt. Check that the side faces of the
carbons and the groove where the spring works are clean and the part that
comes into contact with the shaft is free of scratches.
b. Wash the spring and the anti-rotation plate with diesel.
c. Check that the spring tension is adequate.
d. Place the three segments of the carbon set, joined by the spring that
surrounds them, on a piece of steel that has a ring machined to 2.932”
which is the shaft diameter measurement on which the carbons work. The
segments must be placed in the same position in which they work,
respecting the dotted marks on the coals. Figure N°44.
e. Measure with a blade caliper the play between the carbon rings and the
metal part to check the existing clearance, which should not be greater than
that established by the manufacturer. When cold, the clearance between
the shaft and the carbon rings is 0.003” to 0.004”, which means that the
internal diameter of the carbons is between 2.935” minimum and 2.936”
maximum
f. If the carbon rings are within the allowable tolerance, then rewrap them for
when the turbine is assembled. If not, install a new set, or adjust
according to the procedure detailed below.
Note.

29
When the turbine is in operation during the harvest, you can see if the
coals are leaking steam through the drainage pipe, which is the best proof
of its operation.

Fig. No.43

Fig N°44 Fig. No.45

6.- Cleaning and Checking the Manual Valves.- DYRT Turbines

a. Clean the valves with diesel and tighten the gaskets. Replace gaskets if
adjusting nut is overtightened.
b. Clean the inside of the housing and check the valve seat.
c. Tap the threads of the housing where the valve goes and blow with air.

7.- Cleaning and Checking the Governor Steam Valve.

a. Blow out the inside of the steam chamber with compressed air to
remove any remaining moisture. See figure N°46.
b. Clean the inside of the vapor chamber with diesel.
c. Clean the steam valve with diesel and check that the seat and bar are in
good condition.
d. Carefully clean and check all bars and pins that engage the valve.
e. Check that the seat of the steam chamber is free of knocks and that the
valve fits well on the seat.
f. Spray the valve and steam chamber with anti-oxidant.

8.- Cleaning and Checking the Auxiliary Trigger Valve.

a. Blow out the inside of the steam inlet chamber with compressed air.
b. Check the steam strainer and verify that it is in good condition.
c. Clean the auxiliary steam valve and check that the rod and seat are
good.
d. Clean and check all springs, arms and pins that act with the valve.

30
 e. Spray the auxiliary valve and steam inlet parts with anti-oxidant.

9.- Cleaning and Checking the Screws, Studs and Nuts.

a. Use a bucket with clean diesel and proceed to wash the screws with the
help of a steel brush. The screws have been previously classified
according to their workplace.
b. Check that the threads of the nuts, screws and studs are in good condition,
as are the hexagons.
c. Spray with anti-rust and store the screws in a safe place, preferably
wrapped in manila paper.
d. Wash all nuts and bolts on the machine.
e. Spray with rust preventative and save the nuts.

Clean the nuts, studs, steam

chamber and the contact surface
with the lid.

Clean all mating surfaces

where both valve caps sit.
Fig. Fig. No.47
No.46

Clean all lever bars and

joints

Valve cleaned and checked

Fig. No.48 Fig.

No.49
Chapter No. 3.
Turbine Repairs and Assembly.

Introduction.

31
This stage of Maintenance must be carried out very carefully, otherwise all the
previous work can be spoiled and the consequences can be very serious.
During the assembly process we must take extreme cleaning measures to
avoid contaminating the moving parts of the machine with dust, garbage or
dirty oil. The pieces must enter their workplace smoothly, without shocks
that could loosen, unbalance or damage the installed parts. The turbine shaft
must rotate freely at all times; to do this, we will constantly keep moving it
until the stage of placing the upper cover arrives.

II.- Repairs and Adjustments.

In this section we will see some repairs and adjustments that must be carried
out when, after reviewing the parts, we realize that they do not guarantee the
minimum requirements for efficient operation during the harvest period.
The Turbine Mechanic must be a person with a high sense of responsibility,
technical knowledge in the matter, precise in measuring, observant and, above
all, reliable. When the machine is in operation, it is advisable to observe its
operation, check for any variation in the oil in the bearings, if there is
vibration, irregular movement in the adjustment of the governor linkage and
the steam valve, in short, take note of everything you can. help us always do
better repair work, since it will always be easier to do it in downtime than in
the harvest, when heat and high temperature conditions make any type of
work difficult.

1.- Repair of the Overspeed Trigger Mechanism.

a. Remove the U-clip securing the spring adjustment nut. You can see
figures N°50 and 55, as well as figure N°10 on page N°14.
b. Remove the adjusting nut, spring, and washers (optional). Write down the
number of turns the nut makes to come off.
c. Rotate the turbine shaft 180° and remove the U-clip securing the trigger
weight and remove it from the housing.
d. Insert the new shot weight into the mechanism housing.
e. Attach the U-type clip to hold the shooting weight.
f. Rotate the shaft 180° and place the new trigger spring on the threaded side
of the weight. If the mechanism has washers, they must be installed.
g. Place the adjustment nut, turning the same number of turns as you did to
remove it.

32
h. Place the U-type clip into the slot to secure the nut and check that both
clips are secure.
i. Using a bar with a rounded tip, push the trigger weight to ensure it runs
freely within the housing.
Note.
If the repair is during the harvest, it can be done by removing the upper
cover of the bearings. The speed of the machine should be tested before
allowing it to operate continuously.

Adjustment nut Shooting weight

U-Clamp
U-Clamp

Fig. No. 50 Fig. No.

51

2.- Change of the Axial Thrust Bearing.

a. Remove the captives from the overspeed trigger mechanism housing. See
photos from the previous section.
b. Heat with a torch, applying heat as quickly as possible, on the firing
mechanism, to prevent growth of the turbine shaft. The firing mechanism
should have been disassembled previously.
c. Remove the firing mechanism housing.
d. Remove the circlip using needle-nose pliers.
e. Use a puller to remove the defective bearing.
f. Heat the new bearing in a container with oil. This is a bearing with a
single metal seal, which when assembled must face the governor side. See
photo N°51 in the previous section.
g. Install the new bearing on the shaft, using a tube that only allows it to hit
the inner race of the bearing, making sure that the bearing reaches the stop.
Figure N°52 shows the bearing in its position.

33
h. Replace the retaining ring with a new one to prevent any wear on the old
ring.
i. Heat the firing mechanism in oil not to exceed 500°F and place it on the
turbine shaft, taking care to align the stud bore in the dimple marked on the
shaft.
j. Tighten the stud in the correct position, one or two turns and allow the
mechanism to cool. Tighten the stud completely.
k. Check that the mechanism is completely glued to the shaft stop and if not,
the separation should not be greater than 0.003”

Prisoner

Fig. No. 52

III.- Arming Procedure.

1.- Manual Valves.- Only for DYRT Turbines

a) Make sure the inside of the steam box is clean and spray with anti-
oxidant.
b) Apply graphite to the valve seat against the housing.
c) Apply graphite to the screws, position the valve and tighten it into the
housing.
2.- Turbine Rotor.

a. Blow the entire lower casing of the turbine with dry air and check that
there are no traces of debris, dust or moisture.
b. Spray anti-rust all over the bottom casing.
c. Check that the rotor shaft and all its components are in position and clean.

34
d. Proceed to place the piece to lift the turbine rotor with the help of the one-
ton differential. Figure N°53 and N°54.
e. Raise the shaft very gently, as many times as necessary, until you see that it
is level.
f. Place the shaft on the turbine bed, in a centered position.
g. In the YR turbines of the No. 1 pipe blades, insert the metal plate that goes
into the thrust bearing housing.
h. Begin to lower the shaft gently, making sure that the impeller does not hit
the stationary parts and when the lubrication rings enter their groove,
install the lower bearings, taking care to put them in position. Remember
that the casing has a slot machined into it where a small ear that carries the
bearing must enter.
i. Put oil in the bearings and lower the shaft until it seats in place. Turn the
shaft and add more oil. Figure N°56.
j. Install the upper bearing, lifting the lubrication rings and rotate the shaft.
Figure N°57.
k. Place the piece where the turbine governor is mounted in its place, taking
care to leave it well level. Figure N°58.

Fig. No. Fig. No.

53 54

35
 Lower bearing -
Ear that enters the
Machined groove in
casing.
Fig. No. housing Fig. No.
55 56

Fig. No. Fig. No.

57 58

3.- Placement of the Upper Covers of the Bearings.

a. Using a clean bucket, pour new ISO 68 oil over the bearing housings until
it overflows through the level cup. Fig. No. 59.
b. Apply Permatex No. 2 sealant to the mating surfaces of the caps and
housing. Figure N°60.
c. Verify that the upper bearing is positioned correctly so that the slot
machined in the cover fits into the protruding ear of the bearing.
d. Place the locating pins or guides into the caps and lower them gently.
Rotate the turbine shaft. Figure N°61
e. Tighten the cap screws with a pry bar. Figure N°62.
f. Rotate the turbine shaft and apply anti-oxidant. Figure N°63.
Note.
As a commonly used lubricant for the screws, carbons and the contact
surface of the top cover, we use a mixture of fine powdered graphite,

36
Dixon brand No. 620, with oil. This is an old practice at the Santa Rosa
Mill that has given very good results.

Fig. Fig. No.60 Fig.

No.59 No.61

Fig. Fig. No.63

No.62

4.- Placement of the Carbon Rings.

a. Start placing the carbons in order, from the tip of the shaft where the thrust
bearing goes, towards the coupling side.
b. Apply the graphite mixture to the place on the shaft where the carbons go
and to the casing box where they are housed.
c. Insert the spring into the machined slot in the lower casing, where the
carbon is housed. In fig. No. 64 you can see a spring ready to place the
coals.

37
d. Put graphite on the carbons and place them in the groove of the casing by
rotating them around the axis. Care must be taken to place the coals
according to the points marked on the segments. Figure N°65.
e. Insert the anti-twist device into the spring and place it in the slot with one
of the carbon segments. Figure N°66.
f. Link the spring tips and rotate the carbons until the device is located inside
the machined slot in the housing. Figure N°67 and N°68.

Fig. Fig. Fig.

No.64 No.65 No.66

Set of coals located in position.

The anti-twist device is seen inside the
slot in the casing.

Linking the spring

Fig. No.67 Fig.

No.68

5.- Placement of the Upper Turbine Cover.

a. Check that there are no foreign materials inside the turbine casing.
b. Rotate the shaft and spray anti-oxidant to the inside of the housing and
rotor.
c. Clean the contact surfaces between the housing and the top cover and apply
the graphite mixture. See figure N°69.

38
d. Put graphite on all the screws on the top cover.
e. Place the locating pins, or guides, on the top cover and using the one-ton
differential, carefully lower the cover until it seats in the lower casing.
Figures N°70 and 71.
f. Tighten the lid screws, starting with the charcoal cover screws. Use a pry
bar or impact wrench. Fig N°72.

Fig. Fig. No.

No.69 70

Fig. Fig. No.

No.71 72

6.- Assembling the Steam Valve.

a. Put graphite on the studs that are screwed into the steam inlet box.
b. Check that there are no foreign matter inside the steam chamber and spray
anti-oxidant.
c. Lift the valve with the lid and carefully put it into the steam box. See
figure N°73.
d. Install the nuts and tighten with a torque wrench. Figure N°74.
e. Verify that the valve runs smoothly into the chamber.

39
 Fig. Fig. Fig.
No.73 No.74 No.75

7.- Assembling the Trigger Valve.

As a complement to help understand the installation of the parts of the

auxiliary trip valve, we show figure N°84 on page N°42, where you can see
the different parts that make up this section.

a. Clean the contact surface between the valve cover and the steam box body.
b. Spray with anti-oxidant and insert the release valve into the steam box (fig.
#76 and 77) Place the 1/16” thick copper gasket on the clean surface of the
box.
c. Put the top valve cover on and tighten the screws. Remember to use
graphite on the screws. Figures N°78 and 79.
d. Attach the manual release arm (26). Figure N°80.
e. Thread the square block through the valve stem.
f. Place the trip lever connecting it to the upper valve cover through the
connection pin (5) and insert the two sockets (41) and washers (40) into the
slots of the square block. Figure N°81.
g. Hook the release lever (8) over the latch (10) of the manual release arm
(26). Turn the valve bar until it rises and touches the lower carbon
bushing of the cover (fig N°82), then lower the bar 1/8” by turning in the
opposite direction. This ensures that when the turbine fires, we can raise
the lever 1/8” above the manual release arm latch and engage it.
h. Position lower spring seat washer (38), bushing (39), spring (36), upper
seat washer (36) and tighten nut (12) until spring is compressed against
bushing.
i. Lower the trigger lever to position springs 11 and 45 and reengage the
lever. Figure N°83 shows the trip valve, armed and in the closed position.
j. Trigger the turbine by tilting the manual arm to verify that the mechanism
acts properly. Re-engage the system.

40
Fig. Fig. Fig.
No.76 No.77 No.78

No.26

Fig. Fig. Fig.

No.79 No.80 No.81

No.8

Armed trip valve

Fig. Fig.
No.82 No.83

41
 Governor and Auxiliary Steam Valve Parts

Fig.
No.84

8.- Installation of Governor Woodward.

a. Make sure the studs on both coupling halves are securely tightened over
the shims.
b. Check that the rubber spider of the coupling has some flexibility, otherwise
it may cause vibration in the governor. Change the spider if necessary.
c. Put both halves of the coupling in line and proceed to place the governor
on the connecting piece.

42
d. Tighten the allen screws to secure the governor to the turbine.
e. Proceed to fill the interior of the governor with turbine oil up to the
inspection window.
f. Place the arm that enters the spline shaft of the governor outlet, along with
the connection bar that has the articulated ball bearing and screw it to the
steam valve arm.

9.- Adjustment of the Steam Valve Travel.

With the steam valve and governor connected, proceed as indicated.

a. With the governor arm in the all-open position, rotate the steam valve stem
until it closes against the seat. Figure N°85.
b. Loosen the jam nut until it has a 7/16” clearance against the round threaded
connector on the valve stem.
c. Rotate the valve stem until the lock nut fits against the round threaded
connector. Figure N°86.
d. Tighten the counter nut.

Governor's arm in wide

open position

valve rod
threaded
connector
Locknut

Fig. Fig.
No.85 No.86

10.- Adjustment of the Trigger Mechanism and the Manual Trigger

Lever.

43
As a reference for this section you can see figure N°10 on page N°14.

a. Remove the inspection plug on the bearing cover, governor side. In photo
N°87, the turbine is disassembled for maintenance.
b. Turn the turbine shaft by hand until the trigger mechanism adjustment nut
is positioned upwards (see fig. N°50 and 51 on page N°34). This tells us
that the rounded head of the trigger weight is facing down.
c. Hook the release valve lever on the manual release arm and loosen the lock
nut (9) of the adjustment screw located on this arm.
d. Push plunger (7) up until you feel it make solid contact with the rounded
head of the shot weight.
e. Adjust the screw (8) until there is 1/16” clearance with the bottom of the
plunger (7) and tighten the lock nut.

Plunger No.
7

Screw N°8 and

Fig. counter nut N°9
No.87

11.- Turbine Firing Speed Adjustment.

a. Remove the inspection plug located on the bearing cover, governor side.
b. Turn the turbine shaft by hand until the trigger spring adjusting nut is
facing up. Use the same figures from the previous section as reference.
c. Engage the trigger lever.
d. Using a rounded punch on the tip, push the firing spring adjusting nut until
it touches the plunger and the turbine fires.
e. Reengage the trigger lever.

44
f. Set the turbine speed to minimum by loosening the adjustment screw on
the governor.
g. Start the turbine slowly and measure the speed until the governor regulates
the steam valve. Increase speed slowly until reaching operating speed.
h. If the turbine has not fired, push the steam valve lever to increase the speed
of the machine. If it fires at very low speed or reaches firing speed and
does not fire, then stop the turbine.
i. With the turbine shaft stopped, remove the bearing cover, steam side.
j. Partially remove the U clip until you are sure you can move the spring
adjustment nut.
k. Turn the nut to change the firing speed. Turn the nut counterclockwise to
decrease the speed, or clockwise to increase the speed.
l. Place the U-clip in place and make sure the trigger weight moves freely.
m. Start the turbine and test the firing speed until you reach the desired point.
Trigger the turbine three times to be sure the mechanism is working
properly.

Chapter No. 4.
Operation.- Start-up and Common Problems in Turbines.

Introduction

The start-up and operation of a turbine is a process that requires great care and
in which we must establish a pattern or protocol that guarantees faithful
compliance with certain safety standards, aimed at eliminating possible
failures.
In the maintenance process, we have guaranteed that the turbine is in perfect
mechanical condition to operate, but until it comes into operation, we will not

45
be able to notice possible common failures, which usually affect the proper
functioning of a turbine and which are often not It depends on the personnel
who performs the repair, but it does require their experience and knowledge to
react immediately and prevent failures from occurring that affect the
installation and the personnel who work in them. In this sense, we must
mention that the quality of the steam supplied is essential for the proper
functioning of a turbine, which is why it must be free of humidity, pieces of
welding rod, slag and contaminating materials that could destroy the blades
and nozzles. At the Santa Rosa Mill there is a strict Boiler Feed Water
Quality Control Plan and an adequate operating system, which guarantees
delivery of good quality steam, eliminating the possibility of water shocks and
polluting waste, however, we must always be prepared to face any eventuality
and make the right decisions.

II.- Startup of the Turbine.

Before the start of the harvest period, a general test is carried out on all the
steam-powered equipment to check the condition of the machines and ensure a
smooth start-up in the area of the turbines and the equipment they move, such
as reducers, pumps. , mills and sugarcane blades. It is about giving approval
to the equipment after the maintenance that was given and correcting any
failures in time, since generally this test is done ten days before the start of
grinding.

To test the Elliott turbines, which move the sugarcane blades, we followed the
following steps during the steam test.
a. Verify that the turbine exhaust steam valve is open.
b. Make sure the auxiliary trip valve operates freely.
c. Check the oil level in the bearings, the governor and the equipment that
will be moved by the turbine.
d. Check that the bearing cooling water is open.
e. If the turbine has manual steam valves, then they must be opened.
f. Open the main steam line drain valves, exhaust valves and all purges in the
turbine body. We also opened the purge valves on the steam traps a little.
g. Slowly open the steam valve until reaching 500 RPM and start the turbine,
checking that it stops. Close the steam valve.
h. Engage the trigger lever and reopen the valve until the turbine reaches
approximately 1000 RPM.
i. Check that the lubrication rings are working and that the speed reducer
lubrication pump has pressure.

46
 j. Open the steam valve until the Woodward governor regulates the turbine
operating speed. Since it is working without load, the speed must remain
constant.
k. Open the steam valve manually and test the firing rate. If the speed is
correct and the turbine fires without problems, reengage the lever and try
two more times.

The start-up procedure described below is for a turbine that is operating during
the harvest and stops on maintenance Mondays.

a. Verify that the turbine exhaust steam valve is open.

b. Make sure the auxiliary trip valve operates freely.
c. Check the oil level in the bearings, the governor and the equipment that
will be moved by the turbine.
d. Check that the bearing cooling water is on.
e. If the turbine has manual steam valves, then they must be opened.
f. Open the main steam line drain valves and all vents in the turbine body and
exhaust line.
g. Gently open the main steam valve and increase the turbine speed until the
governor regulates. Observe that there is no vibration in the machine or in
the steam line.
h. Turn off the steam purges when you are sure there is no water in the line.
i. Leave open only the manual valves that the turbine requires for its
operation.
j. Check the temperature of the bearings and cooling water.
k. Keep checking the equipment periodically.

III.- Common Problems in Turbines and Their Solution.

Problem Cause Solution

Excessive vibration Misalignment between the axles
Excessive play in bearings
Bearings damaged due to lack of oil
Deformed shaft
unbalanced rotor
Fatless or defective couplings
Lack of Power Excessive play in thrust bearing
Auxiliary valves improperly opened
Clogged nozzles
Poorly adjusted valve travel
Align the shafts following the recommendations of the
turbine and coupling manufacturers.
Change the bearings
Replace the bearings, check the shaft for scratches and
repair damage from poor lubrication.
It may be the result of very hot bearings. Repair, send the
axle to a specialized workshop.
Clean scale on the blades
Lubricate the coupling or replace them with new ones
Change the bearing that adjusts the axial play
Use the auxiliary valves according to the required load.
The Elliott DYRT turbine works with both valves open.
Take out the rotor and check with a piece of wire.
Calibrate to 7/16” as indicated in the manual

47
 Low inlet steam pressure.
High exhaust steam pressure
Load exceeds turbine capacity
Excessive steam Too many manual valves open
consumption.
Low inlet steam pressure.
Worn nozzles and blades
Excessive play in thrust bearing
Hot and worn bearings Scratched surface of bearings
Water in the oil
Misalignment between the axles
Use of inappropriate oil
Cooling water too hot
The speed increases too Leaking governor valve
much when the load is
lowered and may trip.
Governor responds slowly
Governor does not completely close Adjust the valve travel to 7/16” or slightly less.
steam valve
Instability Governor, valve or valve rod sticking Clean or replace connecting blocks and keep linkage well
The shot does not work Poorly adjusted firing mechanism and the
properly turbine does not fire at the indicated
speed
Damaged firing mechanism
Auxiliary trip valve does Poor adjustment of the emergency release
not close properly mechanism, springs or triggers.
Check the pressure in the boilers.
Verify that the automatic valves open to the atmosphere.
If the load cannot be reduced, consult the manufacturer to
change the nozzle ring and increase the power.
Close manual valves that are open without being necessary.
Maintain the correct pressure in the boilers. When the
pressure drops the governors open the inlet valve.
Repair in a specialized workshop
To maintain operating power, the turbine opens its steam
valve. Change the axial thrust bearing
If the bearings fit well, use a scraper to polish the work
surface.
Adjust carbon rings and labyrinth seals. Change the oil
regularly if repair is not done.
It causes excessive wear that can lead to cracks.
Align according to the manufacturer.
Always use the oil recommended by the manufacturer
This can cause the oil to break down and we can notice this
by a change in the color of the oil and bearing.
Repair or replace governor valve. To repair we use emery
paste to polish the flaws in the valve seat.
Replace worn connection blocks and pins. Apply high
temperature grease to joints
lubricated.
Adjust the mechanism as indicated in this Manual to the
turbine manufacturer's firing rate
Change damaged parts and adjust firing
Repair the mechanism and trigger the turbine manually.
Make sure the machine stops.
48
 Bibliography

Technical Manual
Elliott Company.

Instruction Book N° 100-J Type YR Turbines.

Elliott Company

Instruction Manual for Installation, Operation and Maintenance of Turbodyne

Brand Steam Turbines.
Mcgraw-Edison

Energy Through Steam, Air or Gas.

WH Severns – H.E. Degler – J.C. Thousands.
Edit Reverté SA - 1976

49