Professional Documents
Culture Documents
Serviceable Technology
All Steam Turbines serviced by Baker Hughes, including driven equipment and their auxiliary systems.
Classification
KS SAFETY
Nuovo Pignone Tecnologie S.r.l. con socio unico (Registro Imprese di Firenze, Codice Fiscale 06593380485 e Partita IVA di Gruppo 06872660482)
Capitale Sociale ϭ 100.000.000,00 i.v. - Società soggetta a direzione e coordinamento di Baker Hughes Company
Background
Access to turbo-units and the associated surroundings with the unit in operation bears certain risks. Hence,
it is important to be aware of such risks, in order to plan and apply the proper access and safety procedures
based on the specific risk factors inherent in the plant such as the installation type (for instance under a roof,
in an enclosed building, in a partially or fully enclosed space), the available space, the ambient conditions
and also all the existing risks inherent in the installed equipment.
Information relevant to access to Steam Turbines is normally provided in machine manuals. This bulletin
complements all the previously supplied information on this subject.
The guidelines in the manuals have been defined at different times and correspond to different maintenance
needs and unit configurations. Considering all the information accumulated over time and the evolution of
the understanding of the associated risks, the following document provides updated recommendations
regarding access to units in operation.
Baker Hughes turbo-units, though designed and manufactured applying state-of-the-art technology,
nevertheless include inherent risks associated with specific systems such as (but not limited to) the seal gas
system, lube oil system, process gas piping and other subsystems that are part of the scope of supply and, if
applicable, may also include unit enclosures. In general, it is imperative for personnel to be aware of and
trained to perform maintenance and inspection activities on units in operation consistent with Baker Hughes
guidelines on the frequency and duration of activities, to employ suitable personal protection devices and to
exercise appropriate caution when operating near subject turbo-units.
The sources and locations of specific hazards depend on the train configuration and may vary from site to
site. In general, for steam turbine driven units, the main sources of hazards are the steam turbines, the driven
machine/s and the relevant auxiliaries’ systems described below:
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Hazards Causes:
1. Flammable fluids (lube/control oil) at high pressure in the regulation, lubrication, and control systems.
2. Dangerous process gas.
3. High pressure / temperature steam.
4. Fluids at high temperature (oils, water) in the lubrication and cooling systems.
5. Surfaces at high temperature.
6. Gas at high temperature / pressure in the compressor and auxiliary systems.
7. Medium and high voltage items.
8. Loud noise.
9. Slippery surfaces around the machine and the auxiliary systems.
10. Crushing and impact hazards when opening the machinery enclosure doors if the internal
pressurization/depressurization system is on (pay particular attention to the note in paragraph 1.1).
11. Hazards due to the ejection of metal parts near the rotation plane of the coupling/shaft end.
12. Asphyxiation hazards inside the equipment enclosure room if the firefighting system switches on.
13. High vibration levels at the equipment and surfaces.
14. Pinching or crushing in case of Steam Turbine Emergency Shutdown Valve closure and/or control
valve operation.
15. Suspended loads.
16. High-speed rotating parts or moving parts.
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
1. Explosion
2. Hot surfaces
3. Fire
4. Unsafe high temperature environment
5. Asphyxiation
6. Slippery surfaces
7. Toxic gas leaks
8. Pinch points
9. Hot gas/steam/liquid leaks
10. Electrocution
11. High pressure steam/gas/liquid leaks
12. Sparking/discharge
13. Projectiles
14. Falling objects
15. High noise levels
16. Restricted workspace
Recommendations
Baker Hughes recommends following the indications relevant to the subject equipment described below.
In general, for all units, it is the responsibility of the end user to follow proper procedures when access to the
unit during operation, if necessary, and to identify and employ the proper personal protection equipment.
These safety measures must be based on a risk assessment, and consideration of the information included
in this document, the specific installation type (e.g., under a roof, in an enclosure, etc.), the type of driven unit
and process, and the type of auxiliary systems present.
Site personnel must:
be trained to understand the residual risks and procedures for accessing units in operation;
perform maintenance or inspection activities on units in operation consistent with the Baker Hughes
guidelines relevant to the type of activity, and the frequency and duration of such activity, which are
included in this document (see below);
employ personal protection devices, as required, and exercise appropriate caution relevant to the
specific unit and surrounding area, enclosure (if applicable) or other areas having sources of residual
risk associated with equipment provided by Baker Hughes.
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Nuovo Pignone Tecnologie S.r.l. Proprietary Information
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
This document also provides the recommendations relevant to access methods for units installed within an
enclosure.
For all units, it is the end user’s responsibility to take the appropriate actions to ensure that site personnel
performing installation, commissioning, operation and maintenance have been properly trained in site
procedures for working with and around Baker Hughes supplied equipment, and to comply with site HSE work
practices.
The recommendations of this document are provided to the equipment users as a set of minimum
requirements that must be complied with. The equipment user/operator must review, improve and
supplement these minimum requirements as needed, based on specific local regulations, site specific rules,
plant lay out and risk factors, personnel level of qualification, equipment history and EHS best practices.
Contact your Baker Hughes representative for information and guidelines related to equipment
arrangements.
1. Enclosures
If the unit is installed within an enclosure, the enclosure separates the entirety or part of the unit external
areas. This configuration is represented in Figures 1 through 4, which show a representation of the typical
minimum and maximum extent of the equipment contained in the enclosure, and the associated enclosed
and external components.
In general, the enclosure types include on-base and off-base enclosures. In some cases, auxiliary systems
are installed in a shared area within the turbine enclosure while in other cases, they are placed external to
the enclosure. Depending on the installation, there may be a separation wall between different equipment
components in the enclosure.
Accessing operating units installed within enclosures includes specific hazards or an increased level of risk
for some types of hazards, and requires specific procedures for personnel access, as specified in the following
paragraphs.
It should also be noted that, in some cases, the equipment may be installed in a dedicated room whose
surface, volume, egress restrictions, enclosed systems (for instance firefighting), etc. can have access risks
typical of enclosures. The enclosure access recommendations reported below also apply to these cases and
must be adopted by end user.
The layout for site-specific applications may differ from the examples described below; in this case, refer to
the Operation & Maintenance manual and request specific recommendations from the Baker Hughes Service
Department.
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gno ne Tecno l o gi
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Figure 1 :Steam Turbine on-base enclosure configuration with Lube Oil Console external to the enclosure
(maximum case)
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
As already mentioned, entering the enclosure with the unit in operation is a potentially high-risk activity.
Therefore, access is strongly discouraged unless properly addressed in a risk assessment process based on
the specific application.
Important note: a positive pressurized on-base or off-base enclosure can be accessed while the ventilation system is
on if the access doors are equipped with a working door damping system such as the Recessed Lock System shown in
Figure 5 below.
Warning: the Recessed Lock System is considered a fully reliable damping system device only if used in accordance
with the correct procedure (see Annex A “Door Opening Procedure in case of recessed lock system” at the end of this
document).
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
On the other hand, in case access doors are NOT equipped with a damping system, it is possible to enter a positive
pressurized on-base or off-base enclosure when the ventilation system is on by following the recommendations
listed below:
1. If applicable, make sure the gas detectors are not in an alarm or fault condition and that the reading does not
indicate the presence of hazardous gas within the enclosure.
2. Temporarily shut down the ventilation fan for the time needed for the operator to enter the enclosure and close
the door; entering the enclosure must be done quickly (e.g., 2 minutes or less) to avoid the possibility of disrupting
the gas detection system and interruption of the cooling of hot parts with the associated risk of a trip for high
temperature, potential impacts in terms of mechanical parts damage and risks to personnel. This operation
might need a software modification.
3. Switch on the ventilation fan when the operator is inside the enclosure. Warning: a Direct On-Line (DOL) fan motor
initially at the rated load operating temperature cannot withstand more than a few consecutive restarts (e.g., 3
restarts) within a limited time period. Check the Motor Operation and Maintenance Manual for the specific motor
specifications.
4. An individual should be present outside the enclosure to monitor activities and take emergency action if a
hazardous situation arises. This external person must be in contact with the personnel in the control room. When
the enclosure door is closed, the external person should monitor activities from a position close to the door with
a line of sight to the activity being undertaken. The external person must have mechanisms and means for
monitoring personnel within the enclosure. Where a line of sight cannot be achieved, other methods must be
used to enable an alarm to be raised if an incident occurs.
5. When the operator exits from the enclosure, the external person shall stay away from the door to avoid the
potential hazard of impact or crushing by the door.
In addition, any other alternative procedure defined by the Customer HSE team that prevents the sudden or forceful
opening of the doors in positive pressurized enclosures can be considered.
In any case, if not already present, a warning label (see Figure 6) must be installed close to the door handle.
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
To avoid unauthorized opening of the enclosure doors, if equipped with a Lock Key, it must be locked to prevent any
operator access. Key management must be regulated as part of the Permit To Work (PTW) process. The doors must not
be locked with operators inside the enclosure.
When approaching the units, Baker Hughes recommends that the environmental parameters and minimum
safety requirements listed below should be verified and met:
The ventilation system must be in operation with no anomalies detected. Deactivation of the
ventilation system is prohibited (except for the cases mentioned in the note of paragraph 1.1). This
recommendation is mainly applicable to unit equipped with an enclosure.
The gas detection system (if applicable) must be active, correctly maintained and with no anomalies
detected.
The following environmental parameters must be checked to verify that they are within the acceptable
range: oxygen content, gas detection including specialized detectors if specific gases are in the
system or suspected.
If there is an extinguishing device in the enclosure, that system must be mechanically disabled, the
block valves closed and locked, and the LOTO procedure applied.
The fire & gas detection and signalling system must be kept on. In the event of detection, it is necessary
to leave the enclosure immediately even if there is no fire.
After entering the turbine enclosure, the door shall be closed in order to ensure the proper operation
of the gas detection system. The door must be provided with a system for opening the door against
ventilation loads (see also the note in paragraph 1.1).
Access to the turbine enclosure shall be prohibited under running conditions, unless access routes are
provided for routine maintenance activities and adequate methods of escape exist.
A specific emergency plan and a dedicated rescue team must be established to manage any
emergency for involving operators.
Activities must be performed with a supervisor present to take any emergency action if a hazardous
situation should arise. Said additional person must be in contact with the personnel in the control
room.
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Said additional person should monitor activities from a position with line of sight to the activity being
undertaken.
Before performing activities, verify that the turbine is running normally and that no abnormal operation
or transient conditions are expected.
Access to any area, which is difficult to access or lack escapes routes is forbidden.
Avoid contact with hot parts and wear thermal insulated gloves.
Avoid contact with mechanical parts that rotate or may accidentally move. (i.e., parts rotating and
partially exposed, valves, actuators, linkages, etc.).
Be careful of all potential hot steam leakage points that may cause severe injuries to personnel; also
be aware of the difficulty of visually detecting superheated steam; be aware of whistling noises, the
sensation of hot air flows, turbine/steam system thermal insulation damage, for particular care must
be taken in these situations
The procedure must also guarantee that, after activities have been completed and the location
vacated, the fire protection system is reactivated.
Note: the opening of the door to the enclosure normally disturbs the enclosure ventilation flows, which causes the gas
detection system to be unreliable; also, in this circumstance, the use of personal detectors cannot guarantee effective
detection of process gas leaks (when applicable).
The general recommendation is to open the doors to enable access to the enclosure, limiting the time the doors must
remain open and closing them after entrance if possible.
Any access to control valve linkage is forbidden with the machine running.
Do not enter the enclosure or open the door after activation of the firefighting system for a minimum of 3
hours after the firefighting system has been shutdown (applicable to CO2 and water mist systems). This will
allow maximum concentration levels of the extinguishing material to be maintained, the surface to cool, and
prevention of oxygen from entering the enclosure, in order to reduce the risk of re-ignition and possible
injuries.
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
The minimum list of recommended personal protection equipment to be used is the following:
Flame-retardant and antistatic PPE, i.e.: Nomex
Hearing protection equipment
Helmet
Safety glasses
Heat protecting gloves
Safety shoes
Gas mask (when applicable)
Other situations different from those described above (e.g. process gas containing H2S) require the
preparation of a dedicated risk evaluation plan that indicates specific HSE prescriptions and access
restrictions to be implemented.
Note: Other and more restrictive regulations shall be agreed upon with the Customer HSE team and the Baker Hughes
HSE representative and activated at the specific plant level. Local regulations may require more restrictive prescriptions
and indications as well.
On-condition inspections: inspections performed after planned maintenance (1), unit modification,
first unit start-up (2).
On condition activities: activities to be performed only if required by certain condition (example:
switching oil filters after delta pressure increase across filters).
Routine inspections/activities: inspections performed on a time basis to reduce the risk by means of
inspections aimed at prevent issues from escalating.
Note (1): The terminology “planned maintenance” means planned maintenance such as a minor inspection (mi), or a major inspection
(MI).
Note (2): First start-up means the group of start-ups required to complete the commissioning and start-up of the unit., in this case,
specific recommendations will apply, and will be provided by Baker Hughes.
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Table 1 presents a list of activities along with the estimated execution time for steam turbine driven units.
It provides the maximum requirements, for activities applicable to mechanical drive units and power
generation units, and for various turbine layouts.
The enclosure access times reported for routine and on condition activities and inspections must be
considered as a reasonable, reference average value and differences may apply according to the specific
unit Operating and Maintenance (O&M) manual. The duration/frequency for the various activities are
estimated based on tolerable risk, per Baker Hughes criteria and assuming that all safeguards and safety
practices are correctly planned and performed. Although execution of the activities described below may
expose personnel to a relative increase in risk, for the limited time required to perform the activities, these
activities will help in the early detection of issues such as minor defects, assembly errors, small leaks, etc.,
increasing the probability of avoiding the escalation of issues. As a general recommendation, Baker Hughes
suggests aggregating activities where possible, to further limit the exposure of personnel.
For units not confined in an enclosure the listed times for intervention are recommended.
Table 1 - List of activities with associated estimated frequencies and execution times
Allowed time
Activities Activity category Allowed recurrence [#/year]
[minutes]
On condition As required
Seal gas panel filter replacement 30
activity
(Typically once a year)
On condition As required
Seal gas panel filters swap 10
activity (Typically, once a year)
Routine
Grounding brush wear scale check 41 10
Inspection
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KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Allowed time
Activities Activity category Allowed recurrence [#/year]
[minutes]
On Condition
Measure the wheel chamber pressure As required (Typically, once a year) 10
Activity
On Condition
Lube Oil filter swap2 As required (Typically, once a year) 10
Activity
On Condition
Lube Oil filter replacement2 As required (Typically, once a year) 120
Activity
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io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Allowed time
Activities Activity category Allowed recurrence [#/year]
[minutes]
Routine
Weekly1,5 10
Inspection
Check for steam/air/gas/oil/water leaks
On Condition Once after maintenance and/or unit
10
Inspection modification (i.e.: CM&U)
Routine
121 10
Lube Oil sampling for water content or other Inspection
analysis, including water separator
operation monitoring On Condition Based on trend of water content in the
10
Inspection oil 6
Note 1: The reported frequency represents an average reference value considering the entire ST life cycle. The inspection frequency
may be increased or decreased based on maintenance requirements. For example, approaching scheduled maintenance or after a
major overhaul the inspection may be more frequent.
Note 2: Filter swap and filter replacement may be performed together or as separate activities.
Note 3: Greasing of other items/systems should preferably be performed during unit shutdown at the first opportunity.
Note 4: Some actions, such as manual barring gear operation, even if performed with the unit stopped present similar risk exposure
as the above mentioned activities and shall be performed taking the same care, safety measures, protections and precautions.
Note 5: For the first week after a new unit start up and after a minor or major inspection It is recommended the inspection frequency
be increased to daily
Note 6: On condition inspection is also recommended in case of gland steam system upsets that may result in oil contamination by
water or in case of the oil tank level showing an abnormal increase trend during operation
15 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
Contacts
For units under warranty or covered under a Contractual Service Agreement (CSA) please refer to your BH
Project Manager.
Expense Policy
The recommendations contained in this Technical Bulletin are for information only. Unless otherwise indicated
in a Contractual Service Agreement (CSA) in force between the parties, a specific Purchase Order must be
agreed to, and all costs associated with the implementation of the recommendations shall be paid by the
Customer.
16 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
ANNEX A
Door Opening Procedure
in case of Recessed Lock System
17 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
In case of pressurized enclosures, the following instructions for opening the doors must be followed.
18 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
STEP 3: Position your body away from the swing of the door as much as possible.
19 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
STEP 5: Turn the door handle slowly and be ready for the release of the door.
STEP 6: Release your hands from the door as soon as begins to open while holding it as little as necessary.
Pay attention to avoid being bumped or crushed by the door as it opens since the door may swing
violently.
20 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.
KNOWLEDGE SERVICE
FPB 22.17 Rev.02
September 06, 2023
STEP 7: Finish opening the door and lock it in the opened position.
21 / 21
Nuovo Pignone Tecnologie S.r.l. Proprietary Information
The i
nfo rm at
io n co nt
ained i
nthi
s Techni
cal Bu l l et
ini
s co nfi
dent
ial and pro pri
etary.Thi
s Bu l l et
in and t
he i
nfo rm at
io n co nt
ained i
nitare pro t
ect
ed by co pyri
ghtand/o ro t
her
i
ntel l ect
u al pro pert
y ri
ght
s.Thi
s Bu l l et
in and i
nfo rm at
io n are pro vi
ded fo rau t
h o ri
zed u se o nl y,and m ay no tbe u sed by o rdi
scl o sed t
o ot
hers w i
tho u tt
he pri
o rexpress w ri
tten
co nsento fNu o vo Pi
gno ne Tecno l o gi
e S.
r.
l.