OISD-121

Amended edition

FOR RESTRICTED
CIRCULATION

No.

INSPECTION
OF
TURBINES AND DIESEL ENGINES

OISD STANDARD 121

First Edition, April 1990
Amended edition, August, 1999

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum and Natural Gas
 OISD STANDARD - 121
First Edition, April, 1990
Amended edition,
August, 1999

FOR RESTRICTED
CIRCULATION

No.

INSPECTION
OF
TURBINES AND DIESEL ENGINES

Prepared by
COMMITTEE ON INSPECTION
OF ROTATING EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

2ND FLOOR, “KAILASH”
26, KASTURBA GANDHI MARG
NEW DELHI-110001
 NOTE

OISD publications are prepared for use in the oil and gas industry
under Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not
be reproduced or copied and loaned or exhibited to others without
written consent from OISD.

Though every effort has been made to assure the accuracy and
reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or
damage resulting from their use.

These documents are intended only to supplement and not

replace the prevailing statutory requirements.

Note1 in superscript indicates the

modification/changes/addition based on the
amendments approved in the 17th Safety Council
meeting held in July, 1999.
 FOREWARD

The Oil Industry in India is 100 years old. Due to various collaboration
agreements, a variety of international codes, standards and practices are in
vogue. Standardisation in design, philosophies and operating and maintenance
practices at a national level was hardly in existence. This coupled with feed back
from some serious accidents that occurred in the recent past in India and
abroad, emphasised the need for the industry to review the existing state of art in
designing, operating and maintaining oil and gas installations.

With this in view, the then Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by Oil Industry Safety Directorate (OISD),
staffed from within the industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence, standardising and
upgrading the existing standards to ensure safer operations. Accordingly, OISD
constituted a number of Functional Committees of experts nominated from the
industry to draw up standards and guidelines on various subjects.

The present standard on "Inspection of Turbines and Diesel Engines" was

prepared by the Functional Committee on "Inspection of Rotating Equipment."
This document is based on the accumulated knowledge and experience of
industry members and the various national and international codes and
practices. This standard is meant to be used as a supplement and not as
replacement for existing codes and practices. It is hoped that the provision of this
standard, if implemented objectively may go a long way to improve the safety
and reduce accidents in Oil and Gas Industry. Users are cautioned that no
standard can be a substitute for the judgment of a responsible and experienced
engineer. Suggestions are invited from the users after it is put into practice to
improve the standard further. Suggestions for amendments to this standard
should be addressed to the Coordinator, Committee on “Inspection of Rotating
Equipment" Oil Industry Safety Directorate, 2nd Floor, “Kailash”, 26, Kasturba
Gandhi Marg, New Delhi - 110001.

This standard in no way supercedes the statutory regulation of CCE,

Factory Inspectorate or any other Statutory body which must be followed as
applicable.
 COMMITTEE
ON
INSPECTION OF ROTARY EQUIPMENT

List of Members

_______________________________________________________________

S.No. Name Designation & Position in

Organisation Committee
_______________________________________________________________

1. Sh.K.Gopalakrishann Sr.Maint.MGR-CRL Leader

2. Sh.B.P. Sinha Chief Proj.MGR-MRL Member

3. Sh.Chotey Lal Ch.Engineer-ONGC Member

4. Sh.R.C. Chaudhary Office Engg. MGR-BPCL Member

5. Sh.K.M.Bansal Chief Maint.MGR-IOC Member

6. Sh.Ehsanuddin Director-OISD Member

7. Sh.R.M.N. Marar Joint Director - OISD Member

Co-ordinator.
___________________________________________________________________

In addition to the above several other experts from industry contributed in the
preparation, review and finalisation of this document.
 TURBINES AND DIESEL ENGINES

CONTENTS

SECTION

1.0 Introduction

2.0 Scope

3.0 Inspection of Steam Turbines

3.1 Predictive Maintenance Schedules

3.2 Inspection Schedules and Procedures
3.2.1 Inspection During Operation
3.2.2 Inspection During Shutdown
3.3 Testing and Commissioning After
Repairs/Overhaul
3.4 Procedure for Commissioning of
New Turbines
3.4.1 Prestart up checks
3.5 Starting of Turbine
3.6 Spares

4.0 Inspection of Gas Turbines

4.1 Definition of Terms
4.1.1 Normal Operating Point
4.1.2 Trip Speed
4.2 Predictive Maintenance Schedule
4.3 Inspection Schedules and Procedures
4.3.1 Schedules
4.3.2 Inspection at time of overhaul
4.4 Commissioning and testing Procedures
4.4.2 Prestart Operation
4.4.3 Start-up Operation

5.0 Diesel Engine

5.1 Scope
5.2.1 Inspection On-stream
5.2.2 After every 4000 hours
5.2.3 After every 8000 hours
5.3 Partwise Inspection

6.0 Differing Schedules

7.0 References
 TURBINES AND DIESEL ENGINES
1.0 INTRODUCTION
Rotary Equipment form integral parts in the
operation of any Oil Installation. Various fires
and accidents have been reported due to
failure of Rotary Equipment in Operation.
Timely Inspection and Preventive
Maintenance will go a long way in reducing
fires and accidents due to failure of Rotary
Equipment components.
2.0 SCOPE
This standard covers the minimum
requirements for inspection of Steam
Turbines, Gas Turbines and Diesel Engines
prior to commissioning and during operation
to ensure safe operations. This standard does
not cover the inspection requirements of
Electrical Motors which are separately
covered in OISD-STD-137 on Inspection of
Electrical Equipment.
3.0 INSPECTION OF STEAM
TURBINES
3.1 PREDICTIVE MAINTENANCE
i) Vibration signatures of all bearings of
the turbine shall be taken at the time of
first commissioning or after every
subsequent overhaul in order to
compare with subsequent reading and
to assess the condition for safe and
reliable operation.
ii) Vibration at all bearings shall be
measured every week and recorded as
outlined in OISD Standard 127 for
History recording. The frequency of
measurement should be increased
suitably in case of vibrations entering
rough range. Built in machine
surveyance system using non
contacting probes may substitute
external vibration measurements.
3.2 INSPECTION SCHEDULES AND
PROCEDURES
The following inspection checks shall be
carried out at frequencies outlined below. The
running hours prescribed may be reduced in
case the local situations demand but should
not be extended without inspection. The
opening of turbine for inspection of rotor
blades, diaphragms, labyrinths, etc. will be
decided on the basis of observations such as:
i) Leakage of steam from labyrinths
ii) Fall in vacuum due to air leak from
labyrinth and consumption of sealing
steam.
iii) Excessive vibrations.
iv) Reduced power of turbine.
3.2.1 Inspection During Operation
i) Wire mesh type strainers and oil filters
shall be checked after every 500 hours
of operation.
ii) Lube oil shall be tested for viscosity,
flash point, acidity etc. after every 1000
hours of operation. Test results shall
meet manufacturers recommendations.
3.2.2 Inspection During Shutdown
The turbine shall be taken out of service after
16,000 hours of operation. The following
checks shall be carried out:
i) Couplings
Couplings are prone to sludge deposits;
the problem being more acute in grease
lubricated couplings. The couplings shall
be checked for cleanliness. Condition of
"O" rings shall also be checked.
The coupling teeth and adjoining shaft
portion near key-ways should be checked
by D.P. for possible inner or hairline
cracks, if required. Note1
ii) Oil Coolers
The oil coolers are prone to clogging on
the waterside and hence shall be checked
for cleanliness.

iii) Condenser
The condenser shall also be checked for
cleanliness. Condition of electrodes, if
any, provided for cathodic protection shall
be inspected.
iv) Protective relays and trips
All relays and trips shall be checked for
performance.
v) Bearings
a) Radial Bearings
The condition of the Babbit lining shall
be checked. The oil seal shall be
inspected to ensure proper clearances.
The bedding of the bearing shell in
housing shall also be checked. All
clearances shall be as per
manufacturer's recommendations.
b) Thrust Bearing
Condition of thrust collar and thrust
pads shall be checked. All clearances
shall be maintained as per
manufacturer's recommendations.
c) Anti friction Bearing
Inspection of anti friction bearings shall
be carried out as specified in OISD-
Std-123 on Inspection of Rotating
Equipment components.
vi) Gear Box
The gear teeth shall be visually checked
for wear and cracks. A magnifying glass
shall be used to locate hairline cracks. If
any deposits are noticed on gear teeth the
source and type of deposits shall be
investigated. All clearances shall be
checked and maintained as per
manufacturer's recommendations.
The matching gears should be checked
for inner hairpin cracks by D.P. test, if
required. Note1
vii) Coupling and Alignment
The coupling teeth shall be checked for
deposits of sludge, wear, cracks etc. The
oil sealing arrangement shall be
inspected. The coupling bolts shall be
inspected for elongation, wear or cracks.
Alignment with the driven equipment shall
be checked.
viii) Steam Admission Valves
All steam admission valves shall be
inspected for wear and cracks. All valves
shall be tested prior to use after repairs.
ix) Main Stop Valve
The main stop valve shall be visually
inspected and hydraulically tested.
x) Servo Motors
Clearances shall be checked and
maintained as per manufacturer’s
recommendations.
xi) Protection System
All clearances and proper functioning of
protection systems shall be checked.
xii) Governing System
The Governing system shall be checked
for wear and clearances shall be checked
and restored as per manufacturer's
recommendations.
xiii) Rotor
The condition of the journals labyrinths,
rotor blades and rotor discs shall be
inspected. Labyrinth clearances shall be
checked.
xiv) Stator
The condition of diaphragms, labyrinths,
diaphragm flat springs and casing parting
plane (flange) shall be inspected.
3.3 TESTING AND COMMISSIONING
TURBINES AFTER REPAIRS/
OVERHAUL
Manufacturer provides instruction for
testing and commissioning of new
turbines. They also provide instructions
and procedures for starting turbines
during operation in normal course. The
instructions shall be strictly adhered to.
However, after major overhaul special
 checks are necessary before starting
the turbine. The following shall be
checked:
i) The area around the equipment shall
be cleaned. All scaffolding, tools and
other materials lying around should
be removed.
ii) The floor shall be mopped clean so
that there is no oil spillage or
possibility of an accident. All covers of
trenches shall be in position. All
instruments and gauges on the
turbine and its panel shall be
checked.
iii) Oil leakage from all joints shall be
checked and eliminated specially in
places where it may fall on insulation
or heated parts of steam turbines and
steam piping. All auxiliaries such as
condensate pumps, circulation
pumps, oil pumps, etc. shall be tested
for satisfactory operation.
iv) Oil is circulated through the bearing
governing system and oil level and
pressure drop across the filter shall
be checked. It is necessary that oil is
circulated through the system so that
all dust and foreign particles are
removed from the system. The quality
of the oil shall be checked and
centrifuged.
v) Proper Operation of the protection
system shall be tested to the extent
possible before starting the turbine or
at the first opportunity while starting
the turbine.
vi) Leakages in the steam condensate
system shall be checked and rectified
before starting the turbine.
vii) While starting the turbine on low
speed, gradual heating shall be
ensured. Constant watch should be
kept on the growth of the casing and
movement recorded.
Vibration reading shall be taken at
operating speed and just below trip
speed. Magnitude of vibration shall be
within the acceptable range. For
general purpose turbines:
Up to 400 rpm speed - 3.0 Mils
from 4000 rpm to 6000 rpm - 2.5 Mils
Over 6000 rpm - 2.0 Mils
Signatures of vibration should be
compared with master data obtained
at the time of commissioning and
deviations, if any, shall be analysed/
rectified.
vii) Special attention shall be paid to
bearing temperature, oil temperature
and oil flow through the bearing.
3.4 PROCEDURE FOR COMMISSIONING
OF NEW TURBINES
3.4.1 Prestart up checks
Manufacturers of turbines give detailed
instruction for start up of turbines
supplied by them. Services of their
representatives are also available during
first start up of a new turbine. Therefore,
instructions supplied by them will over
ride the general instructions applicable to
all turbines given here. These
requirements are meant to supplement
requirements of the supplier and do not
absolve the responsibility of the
supplier's representative who
commission the turbines. During start-up
in addition to manufacturer's instructions
the following checks shall also be carried
out.
i) All pipe connections to the turbine shall
be checked to ensure that they are as
per drawing and are of proper rating.
ii) All valves and non return valves shall be
checked for correctness with reference
to direction of flow in the lines.
iii) It shall be ensured that blinds are
removed and gaskets are provided in all
joints.
iv) It shall be ensured that hydraulic test of
all lines are conducted as per
specifications and test certificates are
signed by a competent authority.
v) All steam lines to the turbine shall be
blown to remove foreign materials,
electrodes, welding slag and mill scale
from the line and the line shall be
certified to be free from foreign material.
vi) All other lines shall be flushed with water
and blown with steam/air to remove
foreign particles.
vii) All lube oil lines shall be flushed,
cleaned, pickled with acid to remove mill
scale and other deposits in the line and
treatment shall be given to make the line
passive.
viii) All auxiliary equipment such as
condensate pump, vacuum system,
auxiliary oil pumps shall be checked for
satisfactory operation.
ix) Tripping of auxiliaries and automatic start
up of stand by, if provided, shall be
checked.
x) The operation of motor operated valves,
their limit switches and remote operation
shall be checked.
xi) The instruments mounted on the turbine,
auxiliaries and turbine panel for proper
operation and calibration shall be
checked.
xii) Lube oil to the system shall be circulated
after fine mesh strainers are installed in
the turbine bearings and the quality of oil
shall be monitored.
xiii) The oil shall be replaced after circulation.
xiv) The operation of bearing gear motor
while circulating the oil through the
bearing shall be checked.
xv) The emergency trip gear shall be
checked for proper functioning, operating
the knob or level at the trip gear and by
remote operation. The responses of the
emergency stop valve, extraction valve
and servo valve shall be observed.
xvi) Open or close emergency stop valve by
means of the starting device. The
response shall be observed.
xvii) The operation of the spindles of control
valves shall be checked to ensure easy
and smooth operation.
xviii) The static characteristic of operation of
the valve shall be compared with the test
report.
xix) The oil strainers shall be replaced
periodically during circulation of the lube
oil if pressure drop exceeds limits
prescribed by the manufacturer.
xx) The washers or belleville washers shall
be used and gap spring bushes shall be
easily movable. The play between the
head of the bolt and the washers should
amount to approximately 0.1 mm so that
casing expansion takes place without
obstruction.
3.5 STARTING OF THE TURBINE
The starting procedures as prescribed
by the manufacturers of the turbine shall be
followed. The following observations shall be
made while starting the turbine, as these can
contribute to major damage during start up:
i) Unusual expansion
ii) Vibrations
iii) Lack of lubrication
iv) Over speeding
v) Abnormal rubs.
3.6 SPARES
Only spares obtained from supplier of
steam turbine shall be used for replacement
in governing and protection system of steam
turbine. However, in the case of obsolete
turbines spares from other sources can be
used but stringent inspection shall be carried
out to ensure that safety is not compromised.
4.0 GAS TURBINES
4.1 DEFINITION OF TERMS
4.1.1 Normal operating point
Normal operating point is the point at
which usual operation is expected and
optimum efficiency is desired.
4.1.2 Trip Speed
Trip speed is the speed at which an over
speed shall be approximately 105 per cent of
the maximum continuous speed.
4.2 PREDICTIVE MAINTENANCE
SCHEDULE
Since gas turbines are critical equipment
their condition shall be closely monitored as
outlined below:
 a) Vibration signatures on all bearings machine surveyance system the
shall be taken of a new gas turbine to vibrations shall be taken once a week
obtain baseline data for comparison. and recorded as required by OISD-
After every subsequent overhaul also STD-127 on History Recording.
the signatures shall be obtained to
compare with base line data. If
machine is not provided with built in
4.3 INSPECTION SCHEDULES AND PROCEDURES

2000 hours 8000 hours 16000 hours 32000 hours inspection

inspection inspection inspection
i. analysis of lube combustion system complete gas Complete overhaul of
oil generator turbine

ii. cleanliness of control System & Internal Complete overhaul of

oil filters instrumentation seals accessory & main gear
boxes

iii. cleanliness of oil coolers casing Water system checking

air filter

iv. cleanliness of coupling & Gas generator

fuel filter alignment bearing

v. Relief Valves
Setting

vi. Fuel system

vii. Starting system

viii. Fire protection

system
ix. Inlet system
 viii) Lateral clearance between the rotor
4.3.1 Schedules and stator blades shall be checked.

The inspection shall be carried out as ix) Inlet guide vanes shall be inspected
per schedule given in table 4.3 for erosion and cracks.

All inspection data shall be carefully b) Combustion System

taken and compared with manufacturer's
data to ascertain if any changes have i) All combustors shall be minutely
occurred during operation. inspected for cracks and deposits.

If any part is found cracked damaged or ii) Combustion liners shall be thoroughly
the amount of wear is more than the inspected for cracks.
manufacturer's recommendations, the part
shall either be replaced or repaired using iii) Carbon deposits in flame failure
correct technique. viewing head and sight windows shall
be removed and cleaned.
Prior to 16000 and 32000 hours
inspection a complete operational test shall iv) The liquid and gas fuel burner shall
be made for reference operating be inspected.
parameters which shall serve as a means of
comparison with identical tests that shall be v) The transition pieces shall be
made immediately after the 16000 and inspected for cracks and wear at the
32000 hours repairs. points of contact.

The operational test shall end with an vi) Wear at the nozzle end of the
over speed trip test to indicate whether transition piece shall be checked as it
attention should be given to the governor or allows excessive vibration of the
tripping mechanism during inspection. transition piece which might lead to
cracking.
4.3.2 Inspection at time of overhaul
vii) Transition pieces shall be replaced if
50 per cent of inner or outer seal is
a) Compressor assembly reduced to half the original thickness.
i) The compressor inspection shall be viii) Ignitor plugs and leads shall be
conducted to determine the checked and replaced if necessary.
mechanical and aerodynamic
condition of the compressor. ix) Fuel valve and actuator settings shall
be checked.
ii) Holding bolts of stacked rotor shall be
inspected for looseness. x) Combustor clearance with respect to
fuel nozzle and igniters and baffles
iii) Both stator and rotor blades shall be shall be measured and compared with
cleaned and checked for cracks with manufacturer recommended figures.
dye penetrant.
xi) Thermocouple weld shall be checked
iv) Blade roots shall be closely inspected for cracks.
for severe pitting as this may lead to
structural failures. c) Turbine Section
v) Rotor blade tip clearance shall be i) Turbine rotor and stator blades for
measured and compared with each stage shall be cleaned and
manufacturer's recommended closely inspected for erosion and
clearances. cracks with non-destructive
examination.
vi) Rotor end float/thrust bearing axial
clearance shall be checked. ii) Rotor/stator blade tip clearances shall
be measured and compared with
vii) Labyrinth seals shall be inspected. manufacturer's recommendation.
iii) Perpendicular distance between the
trailing edges of each vane and the
surface of the next vane shall be
carefully measured to ensure equal
gas distribution of gas flow to the
rotating blading for elimination of
blade vibration.
iv) Entire turbine rotating blades shall be
replaced if several blades are fatigue
cracked.
i) Rotor with assembled blades shall be
dynamically balanced without the
coupling, but with half key.
ii) Dynamic balancing shall be done at
the operating speed range rather than
at low speeds.
However, in case it is not possible, the
same should be done as per
manufacturers’ recommendations.
Note1

v) Condition of labyrinths shall be iii) The maximum unbalance should not

checked. exceed:

vi) It shall be ensured that diaphragm 2.0 mils on rotors with speed below
cooling air supply lines are clean. 4000 rpm

d) Bearings 1.5 mils for speed between 4000-8000

rpm
During inspection of journal bearings the
following locations shall be checked for 1.0 mils for speed between 8000-12000
wear: rpm

i) Babbited shoe surface 0.5 mils for speeds above 12000 rpm

ii) Pivoting shoe surface and seat in These limits also include shaft run out
retainer ring. (API 616)

iii) Seal ring bore or end plates.

f) Lubricating oil system
Clearance check of bearing shall be carried
out as follows: i) Physical and chemical properties of
the lube oil shall be tested.
i) Housing outer diameter and inner
diameter shall be measured to make ii) Piping shall be inspected for clogging
sure it is even. and corrosion.

ii) Bore and face end plates shall be iii) Oil reservoirs and tanks shall be
inspected for full contact. cleaned and inspected.

iii) Pivoting surfaces of shoe and housing
ring shall be checked for scratches,
scoring, or erosion.
iv) For tilting pad bearings, blue shoe the
pivot surface and check for contact
area and positions. The contacting
surface shall be in center only and at
the bottom portion of the pivot bore in
the retainer.
v) Check to ensure that pins do not
bottom out in pads.
iv) Oil coolers and accumulators shall be
inspected, cleaned and hydrostatically
tested at one and one-half times
design pressure.
v) Oil strainer should be inspected and
cleaned.
vi) Oil pressure control valves, relief
valves and check valves shall be
tested as per testing procedures.
g) Gear Box

vi) Shaft clearance shall be checked. i) Gear teeth shall be checked for
cracks and wear.
e) Balancing
ii) Backlash shall be measured and
compared with manufacturer's
recommendation.

iii) Bearings shall be inspected as per
procedure given in 4.3.2(d).
iv) Gears shall be inspected for proper
teeth contact.
v) Gear element shall be dynamically
balanced and maximum allowable
residual unbalance shall be as per
followings:
Max. unbalanced force x journal static
56,347 weight load
(ounce inches) ___________
NMC2
where, NMC = Maximum continuous speed,
revolutions per minute.
h) Coupling and Alignment
i) Gear couplings shall be inspected for
teeth breakage, scoring and pitting.
ii) Disc couplings shall be checked for
cracks by non-destructive test.
iii) Continuous lubricated type coupling
shall be inspected for corrosive wear
and coupling contamination.
iv) Cold alignment between shaft shall be
checked and ensured that the
readings are within the limits as
prescribed by manufacturer.
i) Control System and Instrumentation
i) All pressure gauges, switches,
temperature gauges, flow meters,
vibration detectors, control valves,
control loops, protection systems and
transmitters shall be tested and
calibrated once in a year.
ii) All control systems shall be tested and
calibration of alarm and trip points
shall be done to control specifications.
j) Starting System
i) Clearance of clutches jaws in
engaged and disengaged position
shall be checked.
ii) Tubing connection and hydraulic
hoses shall be checked for wear,
leakage and abrasions.
k) Fuel System
i) The following shall be checked while
inspecting the liquid fuel forwarding
system:
1) Centrifugal pump shall be inspected
as per pump inspection procedure
(OISD 119).
2) Fuel valve heaters shall be checked
for defective element.
ii) Fuel oil system shall be inspected
as per the following:
1) Stop valve shall be checked for
proper operation.
2) Stop valve shall be checked for trip
action with loss of hydraulic trip oil.
3) Fuel nozzle selector valve shall be
inspected for proper operation and
worn diaphragm in valve actuator.
iii) Gas control valve and control loop of
Fuel Gas System shall be checked
for proper operation, trip action and
calibration.
l) Inlet System
i) Air filter shall be ensured cleaned.
ii) Inlet compartment, inlet duct and
silencers shall be ensured cleaned.
m) Control Oil System Hydraulic Supply
i) Hydraulic supply pump shall be
checked for relief valve leakage at
shaft and mounting flanges.
ii) Air bleed valves shall be inspected for
proper operation.
iii) Hydraulic system piping shall be
inspected for corrosion and leakage.
n) Cooling and Sealing Air System
i) Orifice plates and unions of piping
shall be inspected.
ii) Compressor bleed valves shall be
checked for correct open/close
condition.

o) Compressor Cleaning System
i) Flow meter shall be calibrated.
ii) Stop valve shall be checked for proper
operation.
p) Fire Detection System and Ultraviolet
Detectors
i) Fire detectors shall be inspected for
damage and proper operation.
ii) Ventilation dampers shall be checked
for free operation.
iii) High pressure storage cylinders shall
be checked for loss of cylinder weight.
q) Water system
i) Water pump shall be inspected as per
pump manufacturer's instructions.
ii) System shall be checked for fouling
condition.
iii) All valves shall be checked for proper
operation.
4.4 COMMISSIONING AND TESTING
PROCEDURES
4.4.1 Initial Preparation
The following checks shall be made prior to
the first operation or after periodic repair and
long period of non-operation of the gas
turbine:
a) Assembly of all the piping shall be in
accordance with the Flow diagrams' and
the Piping assembly drawings.
b) Tightening of all the nuts and screws
shall be checked with suitable torque
wrenches.
c) All air and fuel piping shall be checked
for cleanliness.
d) Air intake duct shall be checked for
cleanliness.
e) The lubrication system shall be properly
flushed.
f) Check Valves provided for lubrication
system shall be checked for correctness
of direction.
g) It shall be ensured that coupling(s) and
other naked rotating parts are protected
by the coupling guard or suitable cover.
h) All temperature and pressure gauges
shall be calibrated.
i) All alarm/trip devices shall be calibrated.
j) All controllers, transmitters and control
valves shall be tested.
4.4.2 Pre-start Operation
a) Before commencing the prestart
operation it shall be ensured that the
steps in the preceding section have
been completed.
b) Operation of the cool down and
emergency lube oil pumps, water pumps
shall be checked.
c) Lubrication unit should be started and
inspected to see that oil is flowing from
the bearing drain. Unless oil flow is
visible at each sight point, the turbine
should not be started.
d) Condition of all thermocouples on the
temperature indicator shall be checked
and ensured that readings are close to
ambient temperature.
e) Spark plug shall be checked for proper
arcing.
f) It shall be ensured that the cooling water
system is in operation.
g) It shall be ensured that oil cooler and oil
filter venting are carried out.
h) Before the turbine is coupled to drive
equipment, the following tests shall be
carried out to check the following trip
system:
- Start fail at specified time (Dynamic)
- Low lube oil temperature (Dynamic)
- Flame failure (Dynamic)
- Emergency stop (Dynamic)
- Operating temperature (Static)
- High Lube Oil Temperature (Static)
- Governor fail (Static)
- Over speed
 - Fuel change over
- High demister level
- Fire and gas detection system failure
4.4.3 Start - up Operation
Before starting the turbine the following shall
be ensured.
a) that items listed in the preceeding
section have been completed.
b) that sufficient fuel (gas/oil) pressure is
available.
c) that minimum lube oil temperature is
reached.
d) that hydraulic, pneumatic pressure trip
system is available.
e) that sufficient instrument air supply
pressure is available.
f) Check the fuel lines and area around
the fuel nozzle for leaks after start-up.
g) During turbine cranking, the following
points should be checked:
i) Listen for rubbing noise.
ii) Temperature of the lube oil in bearing
drain.
h) After satisfactory cranking, firing shall be
done and the following checked:
i) It shall be ensured that each
combustion chamber is fired.
ii) The vibration shall be checked.
i) After attaining the operating speed,
wheel space temperature shall be
checked and compared with
manufacturer's recommendations.
j) During the running condition, fuel
consumption for specific load shall be
compared.
k) Vibration readings at various points on
turbine and gear boxes shall be well
below the alarm limits given by
manufacturer.
l) While turbine is operating all parameters
shall be recorded in the log sheet/log
book.
m) Bearing metal temperatures and drain
temperatures shall be within the limits
as specified by manufacturer.
5.0 DIESEL ENGINES
5.1 SCOPE
This section covers the maintenance
systems and procedures to be followed for
maintenance of diesel engines which are
used as prime movers for fire water pumps,
instrument air compressors and emergency
generators in oil industry. Generators having
a capacity of 500 KVA and above are not
covered in the standard.
5.2 INSPECTION SCHEDULES
5.2.1 Inspection On-stream
i) The following checks shall be done
weekly:
1. Fuel, oil, water and exhaust shall be
checked for leaks.
2. Air cleaner oil level shall be checked.
3. Oil level in hydraulic governor shall be
checked, if provided.
4.
Record Oil Pressure. Note1
5.
Check fuel tank & drain water contents.
Note1
ii) The following checks shall be carried
out after every 250 hours.
1. Condition of entire oil
2. The filter elements for metal particles
and oil sludging.
3. Element holes and tears. Gaskets and
'O' rings for damage.
4. Coolant PH value. Change corrosion
resistor element if PH value is below
normal range of 8.5- 10.5.
5. Oil in aneroid control, if provided.
6. Belts; new belts will stretch within one
hour of use. These shall be readjusted.
7. Fan hub and drives.

8. Throttle linkage.
iii) The following checks shall be done after
1500 hours/ 2years whichever is earlier
Note1
a) All maintenance checks mentioned in
the 250 hours maintenance schedule
shall be repeated.
b) Thermostat operation. It should start
opening and closing fully within the
range prescribed by the manufacturer.
c) Fan hub and drive. Mounting bolts and
bearing endplay shall be checked.
d) Water pump, i.e. check the impeller and
bearings.
e) Turbocharger oil leaks.
f) Exhaust and inlet manifold nuts and cap
screws.
g) Vibration damper for eccentricity.
(iv) After every 4000 hours/ 3years
whichever is earlier Note1
The following checks shall be done
a) All the checks mentioned in 1500 hours
maintenance schedule shall be
repeated.
b) Turbocharger bearings, impeller and
diffuser check and float.
c) Crankshaft end float. If in excess of
recommended limit take corrective
action.
(v) After every 8000 hours/ 5years
whichever is earlier Note1
i) Repeat all the checks mentioned in the
4000 hours schedule.
ii) Carry out complete overhauling of
the engine carrying out the following
checks:
a) Check crank shaft-main bearing
journals, bearings, big end bearing
journals and big end bearings.
b) Check connecting rod, piston and piston
rings
c) Check all valves
d) Check cam shaft and drive gears
e) Overhaul lube oil pump.
iii) Calibrate fuel injectors & timing
device Note1
5.3 PARTWISE INSPECTION
i) Cylinder head valves
The following shall be checked:
1) Valves seats and, if required, carry out
grinding.
2) Valve guides, if required, replace it.
3) Valve rocker shafts and bushes; if worn
out or distorted replace the same.
4) Check valve spring stiffness.
ii) Cylinder block
Cylinder liner bores be checked for
wear. Measure the ovality of the cylinder
liner. If it is not within the manufacturer's
recommendation, replace the same.
Check piston and piston rings. While
replacing liners, replace piston and
piston rings also.
iii) Connecting rods
Check connecting rods for distortion.
Gudgeon pin bushes are to be renewed
along with the pistons during major
overhaul.
iv) Crankshaft
Main and connecting rod journals shall be
measured and ground to the next under size
if found necessary. After grinding, use, new
under size bearings. Check end-float. Check
bearing clearance, replace if necessary.
Check bedding and locking arrangement.
v) Fuel injection system
The fuel pump shall be inspected and
overhauled.
vi) Cam Shafts
The following shall be checked:
1) Cam wear and tear.
2) Journals and bushings.
3) Cam shafts shall be checked for
straightness. Note1
vii) Cooling systems
The following inspection shall be carried out:
1) Inspect radiators for leaks.
2) Inspect radiator hoses.
3) Open heat exchangers, clean the tubes
and pressure test the same.
4) In case of tube leakages beyond 10 per
cent of the number of tubes, the tube
bundle shall be replaced.
viii) Chassis overhaul
1) The chassis shall be checked for
distortion.
2) All spring hanger brackets shall be
checked for wear.
3) It shall be ensured that spring check
cambering are done as recommended
by the manufacturer.
6.0 DIFFERING SCHEDULES Note1
In case of differences between this standard
and the manufacturers' recommendations,
the instructions given by the manufacturers
shall govern. The maintenance schedules
given in this standard are very broad based
on present experience and practices and
may be modified from time to time. The
schedule indicates the maximum interval of
time between two inspections.
Organisations, on the basis of historical
records and analysis of failures may alter
the inspection interval accordingly. All
organisations shall maintain records of
history cards and specification sheets, with
respect to problems on equipment in
different services. Based on the feed back
so obtained, the committee will attempt to
further sophisticate inspection schedules
and producers.
7.0 REFERENCES Note1
This Standard shall be read in conjunction
with the following standards, codes and
publications.
i) API Standard 611 - General purpose
steam turbine for Refinery Services.
ii) API Standard 612 - Special purpose
steam turbine for Refinery Services.
iii) Project Specifications as specifically
applicable to the installation.
iv) Manufacturer's instruction manuals
v) OISD 123 Inspection and maintenance--
Rotating equipment components.
vi) OISD 124 Predictive maintenance.
vii) OISD 126 Specific Maintenance
Practices
viii) OISD 127 History recording.
ix) API 613 - Special purpose Gear Units
for Refinery Services.
x) API 614--Lubrication, Shaft--sealing and
control oil system for special purpose
applications.
xi) API 615--Sound Control of mechanical
equipment
xii) API 616--Combustion Gas Turbine
for General Refinery Services
xiii) API 670--Non contacting vibration and
axial position monitoring system.
xiv) API 678--Accelerometer based vibration
monitoring system.
xv) ISO 3977--Gas Turbine Procurement
xvi) Gas Turbine Engineering Handbook by
Dr. M.P.Boyce Gulf Publishing Co.,
Houston, Texas.
xvii) OISD Standard 152 on Instrumentation.
xviii)Maintenance manual of Cummins
Diesel Engines
xix) Maintenance manual of international
Harvestor Diesel Engines
xx) Maintenance manual of Nissam Diesel
Engines.