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Operation & Maintenance

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OPERATION • • • STEAM PURITY OIL SPECIFICATION RELIABILITY & AVAILIBILITY OF TURBINE IS ASSURED WHEN ALL THE VITAL COMPONENTS AND MONITORING EQUIPMENT ARE IN IN THE SPECIFIED CONDITION. • CONTROLLERS • PROTECTIVE DEVICES • SAFTEY DEVICES • STOP AND CONTROL VALVES & OTHER IMPORTANT TURBINE VALVES • MONITORING EQUIPMENT 2 .

DM WATER SUPPLY .COOLING WATER FOR COOLERS .AUXILARY STEAM .CONDENSATE SYSTEM. VACUUM PUMP & EJECTORS 3 .• TESTING OF ALL COMPONENET AS PER SPECIFIED TESTING INTERVALS WEEKLY/MONTHLY/YEARLY START-UP OF TURBINE • READINESS OF EXTERNAL SYSTEM .CIRCULATING WATER FOR CONDENSER .

• READINESS OF OIL SYSTEM AND TURNING GEAR • • • • READINESS OF CONDENSING PLANT READINESS OF VACUUM PUMP. SEAL STEAM SUPPLY START OF BYPASS OPERATION MAIN STEAM LINE WARM UP • TURBINE WARMING UP • SPEEDING UP OF TURBINE • SYNCHRONISATION • LOADING 4 .

Damage & Damage initiation. Remaining life. Economy Forced outage. Safety. Reliability. Availability. Subsequent inspection Deficiencies.Why Maintenance? To Increase To Decrease Efficiency. Accident To Assess To Rectify / Replace Present condition. Major damage. damaged components 5 .

Criteria to increase inspection intervals • Improved Calculation methods • Better Knowledge of materials • More Dependable structural components • Sophisticated Monitoring systems • Improved Operational procedure • More Service experience However inspection intervals should not be lengthened indefinitely … 6 .

Criteria to decrease inspection intervals • Ease in dismantling • Thermal fatigue • Bolt relaxation • Blade check • Seal wear Turbine modules to be overhauled in 50. hours of operation 7 .000 eq.

Factors influencing turbine plant outage Time independent (Human failure) Planning & Design Material selection Manufacturing & Assy. Time dependent (Component stressing) Wear & tear Erosion & Corrosion Distortion Erection & Commissioning Operation & Maintenance Deposits Life expenditure 8 .

Failure probability 9 .

Maintenance Category Maintenance Routine Maintenance Capital Maintenance 10 .

Capital Maintenance • Operational History • Failure History • Pre-overhaul survey Execute Overhauling & Compare Performance • Identify Scope of work • Identify Corrective measures • Identify Spares requirement Plan & Start Dismantling Review identified Scope & Corrections Checks & Findings during dismantling 11 .

Capital Overhaul 12 .

Opening pedestal cover and upper half bearings. Measurement of bearing clearances. 13 • • • • • • . Swing check measurement on HPF end of the rotor. De-coupling of LP/Gen rotors. Measurement of catenery over the journal of the turbine rotors.SEQUENCE OF OVERHAULING ACTIVITIES • Stoppage of barring gear and oil system. Removal of HP/IP casing insulation after stoppage of oil circulation.

• Horn drop check of HP/IP casing. • If no loading is observed on any of the palm of the casing . 14 . • De-coupling of HP/IP/LP rotors.• Recording of CRO of the HP/IP and IP/LP coupling. • Bump check of HP/IP casing. and not by adjusting the thickness of the packer. • Necessary corrections based on Horn Drop values to be done by cutting / re-welding of pipelines . then it needs correction.

if required. if these are sliding pedestal. In absence of dummy shaft the position of casing centering between HP inner/outer is not known. Checking of pedestal level as per the centenary value and level of individual pedestal. • • 15 . Necessary correction in pedestal level is to be carried out . Dummy shaft to be used during overhaul of HP module. Checking of bearing contact between torus and its support and replacement of bearing . • • Removal of HP module for overhaul.• Check / Record mis-match of the HP inlet / exhaust pipe line before lifting of module for future reference.

No change in CRO and swing check of HP/IP rotor is permitted with the coupling of IP/LP rotor. • • • • • • Replacement of bearing with piano wire in place of directly with rotor. 16 . Re-finning of HP/IP rotor & casing as required. Checking of pedestal packers for their contact. Checking/correction concavity/convexity of rotor couplings.• Checking of pedestal centering with respect to piano wire. Afterwards IP/LP rotor to be coupled. Coupling of HP/IP rotor to be done first and record swing check and CRO.

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