Siemens, Wesel, Germany                                                                                          NG90/81/4...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                    Page 30 of 75Blade ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                    Pag...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                         Page 35 of 75 ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine Overhauling - Scope of Work                                                                                       ...
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit
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Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit

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Turbine-Over-Hauling-Procedure - Siemens - Recommends Birkosit

  1. 1. Siemens, Wesel, Germany NG90/81/45-4IZS.Rameshkumar Mechanical Maintenance +WK80/90/0-3RHP Turb+SA21LP Turb Page 1 of 75 TURBINE OVERHAULING Scope of Work INDEX 1.0 Work Related Documents : 1.1 List of drawings. 1.2 Turbine Service Manual – Siemens Ref : ESO/0689/86-05-13/KWU/la-mg. 2.0 Preparation for Inspection. 3.0 Alignment Checks : 3.1 Open Bearing pedestal. 3.2 Uncouple main oil pump. 3.3 Uncouple Generator. 3.4 Uncouple LP rotor. 3.5 Check alignment between the Main Oil Pump and the HP Turbine. 3.6 Check alignment between the HP Turbine and the LP Turbine. 3.7 Check alignment between the Generator and the LP Turbine. 3.8 Check internal alignment of the LP Turbine. 3.9 Check internal alignment of the HP Turbine. 4.0 Disassembly : 4.1 HP Turbine. 4.2 LP Turbine. 4.3 Valve blocks. 4.4 Lube oil system. 5.0 Non-Destructive Testing. 6.0 Fact-Finding : 6.1 Components, Parts and Individual areas to be inspected. 6.2 Component / Part findings checklist. 6.3 List of Fact-Finding Tools, instruments and accessories. 6.4 List of potential findings. 7.0 Reassembly : 7.1 LP Turbine. 7.2 HP Turbine. 7.3 Valve blocks. 7.4 Alignment checks. 7.5 Lube oil system. 8.0 Commissioning : T-OH-procedure F.K. 24 November 2006
  2. 2. Turbine Overhauling - Scope of Work Page 2 of 752.0 PREPARATIONS FOR INSPECTION : ♦ Evaluate latest operating records and related data. ♦ Check for availability of spare parts. ♦ Perform functional inspection of modular units. ♦ Perform leak checks in the form of visual and tactile inspections. ♦ Check shaft-line grounding. ♦ Check turbine-generator running behavior prior to shutdown; perform vibration measurements. ♦ Set up jobsite; ready all scaffolding, tools etc. ♦ Measure vacuum reduction rate. ♦ Shutdown the system. ♦ Cool turbine-generator via turning gear operation. ♦ Disconnect oil pumps, with the exception of the lift-oil pump. ♦ Remove turbine enclosure. ♦ Remove insulation. ♦ Remove vibration pickups. ♦ Protect ends of cables against damage.General Recommendations : ♦ Use only “Silicon-free” lubricants on the oil side. ♦ Observe all relevant accident prevention regulations. ♦ Observe all relevant fire prevention regulations. ♦ Exercise caution in the handling of cleaning agents and acids (Wear protective clothing). ♦ Observe manufacturer’s parts identification system at each step of assembly/disassembly. ♦ The following sealants are recommended : ♦ For the steam side : Birkosit. ♦ For the oil side : Hylomar. ♦ The followings lubricant is recommended : Gleitmo 160T-OH-procedure {F.K.} 24 November 2006
  3. 3. Turbine Overhauling - Scope of Work Page 3 of 753.0 ALIGNMENT CHECKS :3.1 Open Bearing Pedestal :Procedure : ♦ Record pedestal position indicator readings on the HP Turbine (Z 37, Z 38; View VI, Section U1- U1) and LP Turbine (Z 58, Z 60; Detail V4). ♦ Record rotor position indicator readings on the LP turbine (Z 72; Part 3). ♦ Remove top of rear bearing pedestal (Z 22) ♦ Remove seal rings from the top and bottom halves of the bearing pedestal. ♦ Remove center top-half bearing pedestal (Z 15). ♦ Remove seal rings from the top and bottom halves of the bearing pedestal. ♦ Dismantle and store piping from the front top-half bearing pedestal. ♦ Remove front top-half bearing pedestal (Z 1). ♦ Remove seal rings from the top and bottom halves of the bearing pedestal. ♦ Remove top-half thrust bearing (Z 3). ♦ Remove thermocouples (Z 7) from the top and bottom halves. ♦ Check and record the rotor position in the bottom-half thrust bearing. ♦ Measure and record the alignment dimensions of the HP and LP turbines (cf. assembly data sheet). ♦ Remove bottom-half thrust bearing. ♦ Measure and record axial movement of the shaft line (cf. assembly data sheet). ♦ Reassemble bottom-half thrust bearing3.2 Uncoupling Main Oil Pump :Procedure : ♦ Remove hall generators (Z 14) ♦ Remove enclosure (Z 10; part 60, 65) ♦ Check identification markings on the coupling parts (part 100) ♦ Remove centerpiece of sleeve. ♦ Remove circlip ♦ Pull both sleeve sections off of the hubs.T-OH-procedure {F.K.} 24 November 2006
  4. 4. Turbine Overhauling - Scope of Work Page 4 of 75Evaluation : ♦ Teeth. ♦ Clean couplings parts, protect against corrosion and store.3.3 Uncoupling Generator :Procedure : ♦ Check identification markings on the coupling flanges, bolts and nuts (Z 72.1) ♦ remove coupling nuts. ♦ Remove coupling bolts. ♦ Clean coupling nuts and bolts, protect against corrosion, and store. ♦ Turn jack screws in up to contact face. ♦ Continue turning the jack screws to push apart the coupling flange. ♦ Push the generator rotor up to stop in the positive direction.3.4 Uncoupling L. P. rotor :Procedure : ♦ Position the lifting fixture (Z 21) ♦ Provide metal strips for the support bearing. ♦ Check the identification markings on the coupling flange, bolts and nuts (Z 72). ♦ Remove coupling nuts. ♦ Turn jack screws in up to the contact face. ♦ Continue turning jack screws to press the two halves of the coupling flange apart by 3mm. ♦ Hand-tighten the coupling nuts.3.5 Check Alignment between the Main Oil Pump and the HP TurbineProcedure : ♦ Attach measuring instrument. ♦ Check and record the alignment between the pump shaft and the turbine rotor.3.6 Check alignment between the HP Turbine and the LP TurbineProcedure : ♦ Attach measuring instrument. ♦ Check and record the alignment between the HP rotor and the LP rotor.T-OH-procedure {F.K.} 24 November 2006
  5. 5. Turbine Overhauling - Scope of Work Page 5 of 753.7 Check alignment between the Generator and the LP TurbineProcedure : ♦ Attach measuring instrument. ♦ Check and record the alignment between the LP rotor and the Generator.3.8 Check internal alignment of the LP TurbineProcedure : ♦ Measure and record the exact values at the rear bearing pedestal measuring points (Z 22). ♦ Measure and record the exact values at the outer-casing circumferential profile measuring points. ♦ Check for full contact between the pedestal s upport brackets and the base plate (Z 85, 59, 60; Sections F2-F2, F4-F4). ♦ Remove coupling nuts (Z 72). ♦ Remove coupling bolts. ♦ Clean coupling nuts and bolts, protect against corrosion, and store. ♦ Use lifting fixture to support weight of rotor (Z 21). ♦ Press coupling flange apart by turning in the jack screws. ♦ Push rotor in the positive direction up to 1.0mm ahead of the stop. ♦ Install support bearing, take load off of and remove the lifting fixture. ♦ Mount rear top-half bearing pedestal.3.9 Check internal alignment of HP TurbineProcedure : ♦ Measure and record dimension “L” (assembly data sheet) on the front support bracket seats. ♦ Measure and record the exact values at the front and center bearing pedestal m easuring points (Z 71, 1, 15). ♦ Measure and record the exact values at the outer-casing circumferential profile measuring points. ♦ Check for full contact between the rear support brackets and the base plate (Z 37, 39; Section P3- P3). ♦ Mount the center and front top-half bearing pedestals. ♦ Disconnect the lift-oil pumps.4.0 DISASSEMBLY :T-OH-procedure {F.K.} 24 November 2006
  6. 6. Turbine Overhauling - Scope of Work Page 6 of 754.1 HP TurbineOpen Outer CasingProcedure : ♦ Disconnect flange joints of upper steam inlet pipes; support weight of pipes as necessary. ♦ Dismantle the upper cross-around piping, incl. swing disk valves; plug openings, store piping, protect valves against corrosion and store. ♦ Remove and store wall temperature sensor (Z 36) ♦ Ream out (clean) taper-pin bores (Z 26, Part 14) ♦ Bring shoulder bolts into contact with the auxilia ry support brackets (Z 38, Section P1-P1, Part 30). ♦ Remove spacer bolts, washers and disk springs from the front support bracket seat (Z 38, Section P1-P1, Parts 39-43). ♦ Insert one each additional washer between the spacer bolts and existing washers, and retighten the spacer bolts. ♦ Loosen joints bolts as per specification. ♦ Clean and screw in guide bolts. ♦ Clean jack screws; apply lubricant to the threads; screw in. ♦ Hitch up the top-half outer casing horizontally onto the proper lifting bosses. ♦ Turn in the jack screws to uniformly lift the top half outer casing by approx. 30 mm. ♦ Lift off top-half outer casing.Evaluation : ♦ Joint faces, guides, support brackets seat, spherical washers, L-rings. ♦ Protect top-half outer casing against corrosion and store. ♦ Protect spherical washers, spacer bolts, washers and disk springs (Z 38; Section P1-P1, Parts 39- 43) against corrosion and store. ♦ Remove upper spherical washers from the stationary blading carrier (Z 45; Section K1-K3, Part 7) and inner seal ring (Z 37; Section K-K, Part 287); protect against corrosion and store. ♦ Remove joint bolts from the bottom-half outer casing.Open Stationary Blade CarrierProcedure : ♦ Sequence items 500, 525, 550 (Z 42).T-OH-procedure {F.K.} 24 November 2006
  7. 7. Turbine Overhauling - Scope of Work Page 7 of 75 ♦ Remove spot welds from the joint bolt nuts. ♦ Ream out (clean) taper-pin bores. ♦ Clean jack screws, apply lubricant to threads; screw in ♦ Hitch up top-half stationary blade carrier, thereby maintaining a horizontal position. ♦ Turn in jack screws to lift top-half by about 30mm. ♦ Lift off stationary blade carrier.Evaluation : ♦ Joint face, blades, seal strips, spherical washers. ♦ Protect top-half stationary blade carrier against corrosion and store.Open Inner CasingProcedure : ♦ Remove and store pressure-instrument lines (Z 40, Part 391). ♦ Remove spot welds from the joint nut bolts. ♦ Ream out (clean) taper-pin bores. ♦ Clean and thread-in the guide bolts. ♦ Unscrew joint bolts as specified. ♦ Clean jack screws; apply lubricant to threads; screw in. ♦ Hitch up top-half inner casing, thereby maintaining a horizontal position. ♦ Turn in jack screws to lift top half by about 30mm. ♦ Lift off top-half inner casing. ♦ Remove spot welds from the joint bolts of the gland busing (Z 30). ♦ Ream out (clean) taper-pin bores. ♦ Unscrew joint bolts as specified. ♦ Lift off top-half gland bushing.Evaluation : ♦ Joint faces, blades, seal strips, L-rings. ♦ Protect inner casing against corrosion and store.Open Inner Gland Bushing :Procedure : ♦ Remove spot welds from the joint bolt nuts. ♦ Ream out (clean) taper pin bores.T-OH-procedure {F.K.} 24 November 2006
  8. 8. Turbine Overhauling - Scope of Work Page 8 of 75 ♦ Unscrew joint bolts. ♦ Lift off top-half gland bushing.Evaluation : ♦ Joint face, seal strips. ♦ Protect top-half gland bushing against corrosion and store.Open and remove Outer Gland Bushing :Procedure : ♦ Remove spot welds from the joint bolt nuts. ♦ Dismantle gland steam line. ♦ Unscrew joint bolts. ♦ Lift off top-half gland bushing. ♦ Swing out and lift off bottom-half gland bushing.Evaluation : ♦ Joint face, seal strips. ♦ Protect gland bushings against corrosion and store.Dismantle Main Oil Pump and Speed TransducerProcedure : ♦ Detach oil lines from the main oil pump (Z 8) ♦ Remove taper pins and bolts (Z 38, Section Y1-Y1). ♦ Lift off main oil pump; remove spherical washers. ♦ Dismantle main oil pump.Evaluation : ♦ Impeller, shaft, bearing, spherical washers. ♦ Clean all parts, protect against corrosion and store. ♦ Pull off turbine-end coupling hub (Z 10, Part 100). ♦ Dismantle speed transducer (Z9, 10, 11)Evaluation : ♦ Coupling, governor impeller, auxiliary parts. ♦ Clean all parts, protect against corrosion and store.T-OH-procedure {F.K.} 24 November 2006
  9. 9. Turbine Overhauling - Scope of Work Page 9 of 75Remove RotorProcedure : ♦ Lift off front top-half bearing pedestal and store. ♦ Remove top-half journal bearing. ♦ Remove thrust bearing. ♦ Lift off and store rear top-half bearing pedestal. ♦ Remove top-half journal bearing. ♦ Suspend rotor horizontally at the points marked with U and Y (Z 46) and lift away. ♦ Dismantle overspeed trip device (Z 49).Evaluation : ♦ Blades, seal strips, shaft journal, auxiliary parts, overspeed trip device. ♦ Reinstall overspeed trip device (Z 49) ♦ Protect rotor against corrosion and store. ♦ Remove bottom-half journal bearing, including the thermocouples (Z 7)Evaluation : ♦ Journal and thrust bearings. ♦ Protect journal and thrust bearings against corrosion and store.Remove Bottom-Half Inner CasingProcedure : ♦ Remove thermocouples to facilitate extraction of the inner casing (Z 40). ♦ Suspend bottom-half inner casing horizontally and lift off.Evaluation : ♦ Joint face, blades, seal strips, L-rings, guides. ♦ Protect bottom-half inner casing against corrosion and store. ♦ Remove and store bottom-half gland bushing (Z 30).Remove Bottom-Half Stationary Blade CarrierProcedure : ♦ Sequence : items 550, 525, 500 (Z 42). ♦ Suspend bottom-half stationary blade carrier in horizontal position and lift off.T-OH-procedure {F.K.} 24 November 2006
  10. 10. Turbine Overhauling - Scope of Work Page 10 of 75Evaluation : ♦ Joint face, blades, seal strips, spherical washers, guides. ♦ Protect bottom-half stationary blade carrier against corrosion and store. ♦ Remove lower spherical washers (Z 45, Section K1-K3, Part 7), protect against corrosion and store.Remove Bottom-Half Inner Gland BushingProcedure : ♦ Suspend bottom-half gland bushing in horizontal position and lift off.Evaluation : ♦ Joint face, seal strips, spherical washers, guides. ♦ Protect bottom-half gland bushing against corrosion and store. ♦ Remove lower spherical washers (Z 37, Secti on K-K, Part 287), protect against corrosion and store.Remove Front Bearing PedestalProcedure : ♦ Dismantle piping and store. ♦ Remove spot welds from the guides (Z 38, Detail T1 and Section M1-M1). ♦ Unscrew axial guide nuts (Z 38, Detail T1); turn stud bolts (Part 60) from the outer casing; protect stud bolts and nuts against corrosion and store. ♦ Remove lock bolts and washers from the axial gui de (Z 38, Section M1-M1), unscrew calottes (Part 22) and remove spherical washers. ♦ Unscrew spacer bolts (Z 37, 38; Section 01-01, Part 16), remove brackets (Part 15). ♦ Suspend bearing pedestal in horizontal position and lift off.Evaluation : ♦ Slide surfaces, spherical washers. ♦ Protect bearing pedestal against corrosion and store. ♦ Protect hardware against corrosion and store.T-OH-procedure {F.K.} 24 November 2006
  11. 11. Turbine Overhauling - Scope of Work Page 11 of 75Remove Center Bearing PedestalProcedure : ♦ Dismantle and store piping. ♦ Remove spot welds from the axial guide (Z 37, 39; Section M3-M3). ♦ Remove lock bolts and washers, unscrews calottes (Part 122) and extract spherical washers). ♦ Remove screw lock device (Z 37, 39; Section 03-03, Part 115) and loosen bolts (Part 116) ♦ Suspend bearing pedestal in horizontal position and lift off.Evaluation : ♦ Slide surfaces, spherical washers. ♦ Protect bearing pedestal against corrosion and store. ♦ Protect hardware against corrosion and store.Remove Axial Casing Guides :Procedure : ♦ Remove spot welds from the guides Z 37, 38, 39; Sections W1-W1 and W3-W3). ♦ Remove lock bolts and washers; unscrew calottes; extract spherical washers.Evaluation : ♦ Slide surfaces, spherical washers. ♦ Protect hardware against corrosion and store.4.2 L. P. TurbineOpen Outer CasingProcedure : ♦ Dismantle protective liners and rupture disks (Z 57) ♦ Ream out (clean) taper-pin bores (Z 50, Sections L-L and M-M) ♦ Put one each additional washer between the spacer bolts and existing washers (Z 58, 59, 60); Sections F2-F2 and F4-F4) and tighten the spacer bolts. ♦ Unscrew joint bolts.T-OH-procedure {F.K.} 24 November 2006
  12. 12. Turbine Overhauling - Scope of Work Page 12 of 75 ♦ Clean and thread-in the assembly guides. ♦ Clean the jack screws; apply lubricant to threads; turn in jack screws. ♦ Suspend top-half outer casing horizontally from the intended lifting bosses. ♦ Turn in the jack screws to uniformly lift the top-half outer casing by about 30mm ♦ Lift off top-half outer casing.Evaluation : ♦ Joint face, guides, spherical washers, L-rings. ♦ Protect top-half outer casing from corrosion and store. ♦ Remove upper spherical washers from the stationary blade carrier (Z 58, 59, 60) and inner casing (Z 58, Section A-A), protect against corrosion and store. ♦ Remove joint bolts from the bottom-half outer casing.Open Stationary Blade CarrierProcedure : ♦ Sequence : arbitrary. ♦ Remove spot welds from the joint bolt nuts. ♦ Ream out (clean) taper-pin bores. ♦ Clean and thread-in the guide bolts. ♦ Remove joint bolts. ♦ Clean jack screws; apply lubricant to threads; screw in. ♦ Suspend top-half stationary blade carrier in a horizontal position. ♦ Turn in jack screws to lift top half by about 30 mm. ♦ Lift off top-half stationary blade carrier.Evaluation : ♦ Joint face, blades, seal strips, spherical washers. ♦ Protect top-half stationary blade carrier against corrosion and store.Open Inner Casing :Procedure : ♦ Dismantle and store the pressure-instrument lines (Z 58, Part 391) ♦ Remove spot welds from the joint bolt nuts. ♦ Ream out (clean) taper-pin bores.T-OH-procedure {F.K.} 24 November 2006
  13. 13. Turbine Overhauling - Scope of Work Page 13 of 75 ♦ Clean and thread-in guide bolts. ♦ Remove joint bolts. ♦ Clean jack screws; apply lubricant to the threads; screw in. ♦ Suspend top-half inner casing in a horizontal position. ♦ Turn in jack screws to lift the top-half by about 30 mm ♦ Lift off top-half inner casing.Evaluation : ♦ Joint face, blades, seal strips, L-rings. ♦ Protect top-half inner casing against corrosion and store.Open and remove Gland Bushings :Procedure : ♦ Remove spot welds from the joint bolt nuts. ♦ Dismantle gland-steam line. ♦ Unscrew joint bolts. ♦ Lift off top-half gland bushing. ♦ Swing out and lift off bottom-half gland bushing.Evaluation : ♦ Joint faces, seal strips. ♦ Protect gland bushings against corrosion and store.Remove RotorProcedure : ♦ Lift off and store rear top-half bearing pedestal. ♦ Remove top-half rear journal bearing. ♦ Suspend rotor in the vicinity of the coupling flanges (Z 65) and raise in a horizontal position.Evaluation : ♦ Blades, seal strips, shaft journal. ♦ Protect rotor against corrosion and store.T-OH-procedure {F.K.} 24 November 2006
  14. 14. Turbine Overhauling - Scope of Work Page 14 of 75 ♦ Remove bottom-half journal bearing, including thermocouples (Z 7).Evaluation : ♦ Journal bearing. ♦ Protect journal bearing against corrosion and stores.Remove Bottom Half Inner CasingProcedure : ♦ Suspend bottom-half inner casing in horizontal position and lift-off.Evaluation : ♦ Joint faces, blades, seal strips, spherical washers, L-rings, guides. ♦ Protect bottom-half inner casing against corrosion and store. ♦ Remove lower spherical washers (Z 58, Section A-A), protect against corrosion and store.Remove Bottom-Half Stationary Blade CarrierProcedure : ♦ Sequence : arbitrary. ♦ Suspend bottom-half stationary blade carrier in a horizontal position and lift-off.Evaluation : ♦ Joint faces, blades, seal strips, spherical washers, guides. ♦ Protect bottom-half stationary blade carrier against corrosion and store. ♦ Remove lower spherical washers (Z 58, 59, 60), protect against corrosion and store.4.3 Valve Blocks :Dismantle Emergency Stop ValvesProcedure : ♦ Oil side : ♦ Remove lift indicator ♦ Remove and store ESV piping. ♦ Unscrew nuts of the bolts connecting the oil side and steam side; uniform ly loosen the tension-rod nuts, thereby relaxing the springs. ♦ Remove oil-side assembly (Z 78, Part 2), in cl. spring and spring retaining plate; rem ove spring retaining plate, springs and piston (Part 13).T-OH-procedure {F.K.} 24 November 2006
  15. 15. Turbine Overhauling - Scope of Work Page 15 of 75 ♦ Unscrew stem connection, remove piston plate (Part 12). ♦ Remove cover and extract actuation piston (Part 14). Evaluation : ♦ All dismantled parts, body. ♦ Clean all parts and protect against corrosion. ♦ Steam Side : ♦ Unscrew nuts on the mating flange and remove valve (Part 1) ♦ Remove valve seat (Part 10). ♦ Remove valve stem (Part 30) and valve cone (Part 11). Evaluation : ♦ All dismantled parts, body. ♦ Clean all parts and protect against corrosion.Dismantle Control ValveProcedure : ♦ Check identification markings on all parts. ♦ Remove valve-lift monitor (Z 80). ♦ Remove and store complete control cylinder (Z 87). ♦ Remove lever (Part 46). ♦ Relax compression springs (Part 36) by unscrewing the top nuts (Part 40). ♦ Remove compression springs and the top and bottom springs retaining plates. ♦ Remove the taper pins (Part 19) and extract the drive rod. ♦ Remove stud bolt (Part 59); turn out set screws (Parts 31, 32, 33). ♦ Remove radiation shield. ♦ Unscrew nuts on valve cover; remove valve cover, incl. valve stem. ♦ Remove valve cone.Evaluation : ♦ All dismantled parts, valve block, valve seats. ♦ Clean all parts and protect against corrosion.4.4 Lube Oil System :Check Lube Oil SystemT-OH-procedure {F.K.} 24 November 2006
  16. 16. Turbine Overhauling - Scope of Work Page 16 of 75Procedure : ♦ Drain all operating oil out of the oil tank (4310), suction oil tank (4320), oil cooler (4400) and oil filter (4510). ♦ Detach and dismantle auxiliary oil pumps (4220, 4230) and emergency oil pumps (4240).Evaluation : ♦ Impellers, bearing, seal faces, couplings, electric motors. ♦ Reassemble oil pumps and reinstall in oil tank.Procedure : ♦ Detach and dismantle oil vapor exhauster (4340)Evaluation : ♦ Impeller, bearing, coupling, electric motor. ♦ Reassemble oil vapor exhauster and reinstall on the oil tank.Procedure : ♦ Remove inlet strainer from oil tank (4310) and clean. ♦ Clean interior of oil tank. ♦ Reinstall inlet strainer and close drain valve. ♦ Remove, inspect and clean suction-line foot valve. ♦ Clean interior of suction oil tank (4320). ♦ Reinstall valve and close drain valve. ♦ Detach and dismantle lift-oil pumps (4710)Evaluation : ♦ Gear wheels, bearings, seal faces, couplings, electric motors. ♦ Reassemble and reinstall oil pumps.Procedure : ♦ Remove, inspect and clean tube bundles in the oil coolers (4400) ♦ Inspect and clean water channels and return boxes. ♦ Reassemble oil cooler. ♦ Dismantle, inspect and reinstall dual three way rotary valve. ♦ Remove and clean filter cartridges in the duplex oil filter (4510), lifting sy stem (4730) and fine- filtration system (4830).T-OH-procedure {F.K.} 24 November 2006
  17. 17. Turbine Overhauling - Scope of Work Page 17 of 75 ♦ Drain rest of oil out of filter shell; clean shell. ♦ Reinstall filter cartridges. ♦ Detach and dismantle oil pumps from the fine-filtration system (4810, 4812).Evaluation : ♦ Impellers, bearings, seal faces, couplings, electric motors. ♦ Reassemble and reinstall oil pumps.Procedure : ♦ Fill with clean operating oil.5.0 NON-DESTRUCTIVE TESTING5.1 Non-Destructive Inspection : Test Procedure Test S# Object Material Remarks VT MT PT UT Result 1. HP-Rotor 28CrMoNiV49 2. LP-Rotor 26NiCrMoV85 3. LP-Rotor blades X20Cr13 stage 5 +6 left and right 4. Thrust / journal bearing ST52-3N / Tegostar 738T-OH-procedure {F.K.} 24 November 2006
  18. 18. Turbine Overhauling - Scope of Work Page 18 of 75 5. HP-outer casing-upper part GS-17CrMo55 6. Valve block casing B GS-17CrMoV511 7. HP Joint flange bolts 21CrMoV57 / 24CrMo5 8. HP-inner casing GS-17CrMoV511 9. HP piping GS-17CrMoV511 /14MoV63 10. 4 diffuser studs St52.3 N 11. Main steam inlet GS-17CrMoV511 with BaroscopicVT-Visual Testing, MT-Magnetic Testing, PT-Penetrate Testing, UT-Ultrasonic Testing5.2 Replica Tests : S# Part Material Position Remarks1. HP – Piping Main steam inlet / 14MoV63 / Weld seam elbow GS-17CrMoV5112. Elbow – outer fiber 14MoV633. Elbow – inner fiber 14MoV634. HP – Piping, main steam inlet / GS-17CrMoV511 elbow5. HP – Piping GS-17CrMoV511 / Elbow / pipe 14MoV636. Elbow – outer fiber GS-17CrMoV5117. Elbow – inner fiber GS-17CrMoV5118. HP – piping main steam 14MoV63 / flange / elbow GS-17CrMoV5119. HP – piping main steam inlet / GS-17CrMoV511 / pipe 14MoV63T-OH-procedure {F.K.} 24 November 2006
  19. 19. Turbine Overhauling - Scope of Work Page 19 of 7510. HP – pipe, elbow / pipe GS-17CrMoV511 / 14MoV6311. Elbow – inner fiber GS-17CrMoV51112. Elbow – outer fiber GS-17CrMoV51113. HP Piping 14MoV63 / Pipe / Elbow GS-17CrMoV51114. Valve Block B GS-17CrMoV511 / HP Stop Valve / pipe 14MoV6315. Valve block B GS-17CrMoV511 HP Stop valve / Control valve16. Valve Block B GS-17CrMoV511 Control Valve5.3 Surface Cracks Tests : S# Method Part Material Remarks MPT DPT 1. Journal Bearing / thrust ST52-3N/ White Metal bearing TEGOSTAR 738 2. LP Rotor 26NiCrMoV85 All transition radius including A-Wheel. Blades : Stage 5 & 6 left and right 3. H. P. Rotor 28CrMoNiV49 All transition radius including A-Wheel 4. HP Inner Casing GS-17CrMoV511 Complete Upper and Lower Part 5. HP Piping 14MoV63 / Weld seams & elbows GS-17CrMo511 6. HP Joint flange bolts 24CrMo5 / All 21CrMoV57 7. HP Outer Casing GS-17CrMo55 Cross section crossings at inner surface. Upper part 8. Valve Casing Block B GS-17CrMoV511 Cross Section Crossing Outside 9. Diffuser Studs ST52.3N AllT-OH-procedure {F.K.} 24 November 2006
  20. 20. Turbine Overhauling - Scope of Work Page 20 of 755.4 Elbows wall thickness measurement : o 90STEEL ELBOWS (14MoV63)Thickness as per drawing – 8.8 mm o 45Elbow nos. 5, 6, 11 at position 0O, 45 O, 90 O o 0INNER FIBER, OUTER FIBER, NEUTRAL FIBER.CAST STEEL ELBOWS (GS-17CrMoV511)Thickness as per drawing – 27 mmElbow nos. : 1, 2, 3, 4, 7, 8, 9, 10, 12, 13, 14, 15 at positions 0O, 45 O, 90 OInner fiber, outer fiber, neutral fiber.5.5 Boroscopy of Steam Inlet Pipes and emergency stop valves and control valves internal area.5.6 Wall Thickness Measurement :6.0 FACT FINDING :6.1 Components, Parts and Individual areas to be inspected :6.1.1 HP Turbine The following individual parts and areas require inspection : 6.1.1.1 Rotor ♦ A-Wheel blading.T-OH-procedure {F.K.} 24 November 2006
  21. 21. Turbine Overhauling - Scope of Work Page 21 of 75 ♦ Moving blades of the first and second expansion lines. ♦ Seal strips : shaft, balancing piston, moving blades. ♦ Bearing journals, front and rear. ♦ Rotor face in the vicinity of bearing oil wiper rings, blading and admission. ♦ Coupling half section, generator end. ♦ Vicinity of mechanical and hydraulic shaft turning gear. ♦ Overspeed trip bolt. 6.1.1.2 Inner Casing : 6.1.1.2.1 Inner Casing, Top Section : FROM OUTSIDE : ♦ L-Ring grooves, main steam and overload. ♦ Nut support face. ♦ Cast casing. FROM WITHIN : ♦ Steam admission channels, m ain steam plus overload, upto stationary blading. ♦ Nozzle blades. ♦ Stationary blades. ♦ Seal strips between stationary blades. ♦ Casing face between stationary blades. ♦ Joint face. ♦ Seal strips of gland bushing (Diaphragm / labyrinth seal). 6.1.1.2.2 Inner Casing, Bottom Section : FROM OUTSIDE : ♦ L-Ring grooves, main steam plus overload. ♦ Nut support face. ♦ Parts comprising lateral palm support and lower axial guide. ♦ Cast casing.T-OH-procedure {F.K.} 24 November 2006
  22. 22. Turbine Overhauling - Scope of Work Page 22 of 75 FROM WITHIN : ♦ Steam admission channels, m ain steam plus overload, upto stationary blading. ♦ Nozzle blades. ♦ Seal strips between stationary blades. ♦ Casing face between stationary blades. ♦ Joint face. ♦ Seal strips of gland busing (diaphragm, labyrinth seal). 6.1.1.3 Stationary Blade Carrier-I : 6.1.1.3.1 Stationary Blade Carrier-I - Top Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades. 6.1.1.3.2 Stationary Blade Carrier-I - Bottom Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades.T-OH-procedure {F.K.} 24 November 2006
  23. 23. Turbine Overhauling - Scope of Work Page 23 of 75 6.1.1.4 Stationary Blade Carrier-II : 6.1.1.4.1 Stationary Blade Carrier-II - Top Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades. 6.1.1.4.2 Stationary Blade Carrier-II - Bottom Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades. 6.1.1.5 Stationary Blade Carrier-III : 6.1.1.5.1 Stationary Blade Carrier-III - Top Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN :T-OH-procedure {F.K.} 24 November 2006
  24. 24. Turbine Overhauling - Scope of Work Page 24 of 75 ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades. 6.1.1.5.2 Stationary Blade Carrier-III - Bottom Section : FROM OUTSIDE : ♦ Guide groove. ♦ Cast casing. ♦ Nut support face. FROM WITHIN : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing face between stationary blades. 6.1.1.6 HP Outer Casing : 6.1.1.6.1 HP Outer Casing - Top Section : FROM OUTSIDE : ♦ Nut support face. FROM WITHIN : ♦ L-ring grooves, main steam plus overload. ♦ Joint face. ♦ Guide faces for stationary blade carriers, I, II and III, plus balancing piston. ♦ Seal strips; shaft, front; balancing piston; shaft, read. 6.1.1.6.2 HP Outer Casing – Bottom Section : ♦ Joint face. ♦ Seal strips : shaft, front balancing piston, rear. ♦ Eccentric bushings, anti-rotation pin, seal covers for balancing piston, inner casing, stationary blade carriers I, II, III.6.1.2 LP TurbineT-OH-procedure {F.K.} 24 November 2006
  25. 25. Turbine Overhauling - Scope of Work Page 25 of 75 The following individual parts and areas require inspection : 6.1.2.1 Rotor ♦ Moving blades. ♦ Seal strips between the blade rows and around the shaft seals. ♦ Balancing weights. ♦ Rotor face (in the steam section and in the area of the bearing oil wiper rings). ♦ Bearing journals. ♦ TE and GE coupling half sections. ♦ Couplings bolts and nuts. 6.1.2.2 LP Inner Casing : 6.1.2.2.1 LP Inner Casing - Top Section : FROM OUTSIDE : ♦ Nut support face. ♦ Casing finish. FROM WITHIN : ♦ Joint face. ♦ Casing finish. ♦ Stationary blades. ♦ Seal strips. 6.1.2.2.2 LP Inner Casing - Bottom Section : ♦ Joint face. ♦ Stationary blades. ♦ Seal strips. ♦ Casing finish. ♦ Lateral and axial guide. 6.1.2.3 LP Stationary Blade Carrier : 6.1.2.3.1 LP Stationary Blade Carrier - Top Section :T-OH-procedure {F.K.} 24 November 2006
  26. 26. Turbine Overhauling - Scope of Work Page 26 of 75 FROM OUTSIDE : ♦ Guide faces, front / rear. ♦ Casing finish. FROM WITHIN : ♦ Stationary blades. ♦ Casing finish up to diffuser outlet. 6.1.2.3.2 LP Stationary Blade Carrier - Bottom Section : FROM OUTSIDE : ♦ Guide faces, front / rear. ♦ Casing finish. FROM WITHIN : ♦ Stationary blades. ♦ Casing finish up to diffuser outlet. ♦ Lateral support and axial guide. 6.1.2.4 LP Outer Casing 6.1.2.4.1 LP Outer Casing - Top Section : ♦ Flange connection, admission. ♦ Rupture disk. ♦ Interior finish. ♦ Guide faces for stationary blade carrier. ♦ Seal strips, front and rear shaft seals. ♦ Casing finish between shaft seal strips. 6.1.2.4.2 LP Outer Casing - Bottom Section : ♦ Flange connection, admission. ♦ Rupture disk. ♦ Interior finish. ♦ Guide faces for stationary blade carrier. ♦ Seal strips, front and rear shaft seals. ♦ Casing finish between shaft seal strips.T-OH-procedure {F.K.} 24 November 2006
  27. 27. Turbine Overhauling - Scope of Work Page 27 of 75 ♦ Eccentric bushings and anti-rotation pin of the axial guide for the inner casing and stationary blade carrier.6.1.3 Journal and Thrust Bearings The following components, parts and individual areas must be inspected : 6.1.3.1 HP Journal Bearing 6.1.3.1.1 HP Journal Bearing – Top-half Shell ; ♦ Babbitt lining. ♦ Spherical area of bearing shell. 6.1.3.1.2 HP Journal Bearing – Bottom-half Shell ; ♦ Babbitt lining. ♦ Spherical area of bearing shell. 6.1.3.2 LP Journal Bearing 6.1.3.2.1 LP Journal Bearing – Top-half Shell ; ♦ Babbitt lining. ♦ Spherical area of bearing shell. 6.1.3.2.2 LP Journal Bearing – Bottom-half Shell ; ♦ Babbitt lining. ♦ Spherical area of bearing shell. 6.1.3.3 Thrust Bearing 6.1.3.3.1 Thrust Bearing – Top-half Shell ; ♦ Babbitt lining of thrust bearing segments. ♦ Bearing body of top-half shell. 6.1.3.3.2 Thrust Bearing – Bottom-half Shell ; ♦ Babbitt lining of thrust bearing segments. ♦ Bearing body of top-half shell.6.1.4 Bearing Pedestal The following components, parts and individual areas must be inspected : 6.1.4.1 Front HP Bearing Pedestal 6.1.4.1.1 Front HP Top-half Bearing PedestalT-OH-procedure {F.K.} 24 November 2006
  28. 28. Turbine Overhauling - Scope of Work Page 28 of 75 ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of top-half bearing pedestal. ♦ Inside surface of top-half bearing pedestal. 6.1.4.1.2 Front HP Bottom-half Bearing Pedestal ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of bottom-half bearing pedestal. ♦ Inside surface of bottom-half bearing pedestal. 6.1.4.2 Rear HP Bearing Pedestal 6.1.4.2.1 Rear HP Top-half Bearing Pedestal ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of top-half bearing pedestal. ♦ Inside surface of top-half bearing pedestal. 6.1.4.2.2 Rear HP Bottom-half Bearing Pedestal ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of bottom-half bearing pedestal. ♦ Inside surface of bottom-half bearing pedestal. 6.1.4.3 Rear LP Bearing Pedestal 6.1.4.3.1 Rear LP Top-half Bearing Pedestal ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of top-half bearing pedestal. ♦ Inside surface of top-half bearing pedestal. 6.1.4.3.2 Rear LP Bottom-half Bearing Pedestal ♦ Bearing oil wiper ring seal strips. ♦ Joint plane of bottom-half bearing pedestal. ♦ Inside surface of bottom-half bearing pedestal.6.1.5 Valve Blocks The following components, parts and individual areas must be inspected : 6.1.5.1 Emergency Stop Valve 6.1.5.1.1 Emergency Stop Valves, Steam-side Insert ♦ Valve stem. ♦ Valve cone.T-OH-procedure {F.K.} 24 November 2006
  29. 29. Turbine Overhauling - Scope of Work Page 29 of 75 ♦ Valve stem bushing. ♦ Valve cone bushing. 6.1.5.2.1 Emergency Stop Valves, Drive-end ♦ Piston rod. ♦ Piston plate. ♦ Piston. ♦ Spiral springs. ♦ Piston rod guide sleeve. 6.1.5.2.3 Steam Strainers ♦ Steam strainer coiling strip. ♦ Steam strainer basket. ♦ Steam strainer body. 6.1.5.2 Control Valve 6.1.5.2.1 Control Valves, Steam-side Insert ♦ Valve stem. ♦ Valve cone. ♦ Valve stem bushing. ♦ Valve cone bushing. 6.1.5.2.2 Control Valves, Drive end ♦ Bars. ♦ Compression springs. ♦ Leverbar mount. ♦ Parts of control cylinder. 6.1.5.2.3 Valve Block Body ♦ Valve seats “emergency stop and control valve” ♦ Inside face of valve block. ♦ Stud bolts on valve block.6.2 Component / Part Findings Checklist :Blading : ♦ A-Wheel / C-Wheel blades. ♦ Stationary / moving blades.T-OH-procedure {F.K.} 24 November 2006
  30. 30. Turbine Overhauling - Scope of Work Page 30 of 75Blade Tip Integrated Shrouding : ♦ Radial rubbing ? ♦ Axial rubbing ? ♦ Pitting ? ♦ Gap formation ? ♦ Fused-on foreign particulars ?Riveted Shrouding : ♦ Radial rubbing ? ♦ Axial rubbing ? ♦ Pitting ? ♦ Rivet-tenon damage ? ♦ fused-on foreign particles ?Milled Edges : ♦ Radial rubbing ? ♦ Axial rubbing ? ♦ Foreign-object damage ?Vane : ♦ Fractures ? ♦ Incipient cracks ? ♦ Axial rubbing ? ♦ Foreign-object damage ? ♦ Deposits ? ♦ Pitting or crevice corrosion ? ♦ Solid-particle erosion ? ♦ Droplet-impact erosion ?Blade Root : ♦ Blade fit ?T-OH-procedure {F.K.} 24 November 2006
  31. 31. Turbine Overhauling - Scope of Work Page 31 of 75 • loosening? • incipient cracks ? • fracture ? ♦ Finger-pin root connections ?Measurements : ♦ Static Natural Frequency. ♦ Dimensions.Tests / Examinations : ♦ Magnetic Particle Test. ♦ Liquid penetrate Test.Seal Strips : ♦ In shaft seals, In balancing piston, In casing between stationary blades, In rotor between stationary blades. • Seal strip fracture ? • Deformation ? • Radial rubbing ? • Axial rubbing ? • Burring due to rubbing ? • Unacceptable abrasion ? • Scale formation ? • Seal-strip elasticity?Bearing Journal : ♦ Scoring ?Thrust-bearing gland housings : ♦ Scoring ? ♦ Parallelism ?Rotor Faces:T-OH-procedure {F.K.} 24 November 2006
  32. 32. Turbine Overhauling - Scope of Work Page 32 of 75 ♦ Incipient cracking ? ♦ Scoring ? ♦ Deposits ? ♦ Corrosion ?Coupling half section : (Face area – centering – coupling bolt bore) ♦ Frictional oxidation ? ♦ Scoring ?L-Ring Grooves : ♦ Scoring ? ♦ Scale formation ? ♦ Deformation ?Nut Support Face : ♦ Scoring ?Cast Casing : ♦ Incipient cracking ? ♦ Deposits ? ♦ Pitting or crevice corrosion ? ♦ Erosion corrosion ?Nozzle Blades : ♦ Solid-particle erosion ? ♦ Foreign-object damage ? ♦ Deposits ? ♦ Nozzle-blade fit ?Joint faces : ♦ Leak-tightness ? ♦ Deformation ? ♦ Damage ?Design features “Thermo-elastic Casing Guidance” ♦ Functionability impaired ?T-OH-procedure {F.K.} 24 November 2006
  33. 33. Turbine Overhauling - Scope of Work Page 33 of 75 ♦ Deposits ? ♦ Scoring ? ♦ Abrasion ? ♦ Seat mobility ? ♦ Deformation ? ♦ Incipient cracking ? ♦ Fractures ? ♦ Leak-tightness ?Coupling bolt : ♦ Scoring ? ♦ Frictional oxidation ?Balancing weights : ♦ Fit in mounting groove ? ♦ Droplet-impact erosion ?Flanged connections : ♦ Functionability impaired ? ♦ Deformation ? ♦ Leak-tightness ? ♦ Damage ?Rupture disk : ♦ Damage ?Bolts : ♦ Fractures ? ♦ Incipient cracking ? ♦ Relaxation ?Babbitt lining : ♦ Visual damage to surface ? ♦ Damage to babbit lining determ ined via surf ace crack exam ination according to the liquid- penetrant method ?T-OH-procedure {F.K.} 24 November 2006
  34. 34. Turbine Overhauling - Scope of Work Page 34 of 75 ♦ Unacceptable large areas without adequate bond between the lining and the bearing body , determined via ultrasonic testing ? ♦ Functionability impaired due to : • Unacceptable bearing contact angle ? • Unacceptable lateral or top clearance ?Bearing shell : ♦ Quality of finish ?Pedestal faces : ♦ Corrosion ? ♦ Damaged ?Valve stem : ♦ Quality of finish ? ♦ Damage ? ♦ Functionability impaired ?Guide sleeves / bushings : ♦ Quality of guide bore finish ? ♦ Damage ? ♦ Functionability impaired ?Piston rod : ♦ Quality of finish ? ♦ Damage ? ♦ Functionability impaired ?Piston : ♦ Quality of finish ? ♦ Damage ? ♦ Functionability impaired ?Spiral springs :T-OH-procedure {F.K.} 24 November 2006
  35. 35. Turbine Overhauling - Scope of Work Page 35 of 75 ♦ Quality of finish ? ♦ Damage ? ♦ Functionability impaired ?Steam strainer coiling strip : ♦ Damage ? ♦ Foreign objects ?Steam strainer basket : ♦ Damage ?Steam strainer body : ♦ Damage ? ♦ Steam strainer support ?Bars : ♦ Functionability impaired ?Leverbar mount : ♦ Functionability impaired ?Control cylinder assembly : ♦ Functionability impaired ?Valve seat ? ♦ Quality of finish ? ♦ Damage ? ♦ Functionability impaired ?6.3 List of Fact-finding tools, instruments and accessories : “How-to” Guide for inspection, measuring, testing.How to inspect ? Visual Inspection : Typical accessories :T-OH-procedure {F.K.} 24 November 2006
  36. 36. Turbine Overhauling - Scope of Work Page 36 of 75 ♦ Flashlight (halogen lamp). ♦ Photoflood. ♦ Magnifying glass (5 – 10 x) ♦ Mirrors (with and without illumination). ♦ Endoscope (rigid or flexible). Visual / Manual Inspection : Typical accessories : ♦ Hand-hammer (200 – 300 gr) ♦ Screwdrivers (approx. 300mm long)How to Measure ? Manual measuring : Typical accessories (measuring tools) : ♦ Tape measure (fabric or metal). ♦ Vernier and / or dial calipers. ♦ Feeler gages. ♦ Micrometers. ♦ Micrometer calipers. ♦ Depth gages. ♦ RC generators.How to Test ? Manual testing : ♦ Liquid Penetrant Test. ♦ Magnetic Particle Test. ♦ Ultrasonic Examination. ♦ Electric Crack-Depth Measurements. ♦ X-Ray Examination. Typical accessories (test instruments / agents) : ♦ Cleaning agents. ♦ Liquid penetrant.T-OH-procedure {F.K.} 24 November 2006
  37. 37. Turbine Overhauling - Scope of Work Page 37 of 75 ♦ Developer. ♦ UV lamp. ♦ Yoke Magnet. ♦ Coil Magnet (fluorescent or black magnetic powder carrier fluid). ♦ Pulse-echo test instruments (transducers / sensors of various size). ♦ Potential Probe.6.4 List of Potential Findings : Blades Blades Tips ♦ In order. ♦ Radial rubbing. ♦ Radial rubbing, scoring. ♦ Axial rubbing. ♦ Axial rubbing, scoring. ♦ Radial rubbing, scoring and measurable gap. ♦ Crevice corrosion. ♦ Fused-on foreign particles under shrouding. ♦ Broken rivet head. ♦ Broken rivet shank. Vane ♦ Broken vane. ♦ Cracked vane. ♦ Axial rubbing on : • Leading edge. • Trailing edge ♦ Foreign object damage : • Roughened - leading edge. • Dented - trailing edge • Notched - convex side. • Torn - concave side ♦ Coatings (scale, deposit) : • where ? - convex side, concave side. • extent ? - thin, thick.T-OH-procedure {F.K.} 24 November 2006
  38. 38. Turbine Overhauling - Scope of Work Page 38 of 75 • color ? - rusty brown, grayish white. • adhesion ? - adherent, easily, removable, water soluble. • chem.. analysis- completed ? by whom ? corrosive constituents ? ♦ Pitting : • On the convex side. • On the concave side. ♦ Solid particle erosion : • Leading edge, convex side. • Leading edge, concave side. • Trailing edge. Blade Root ♦ Ring test in order (pure, clear sound). ♦ Ring test indicating loose fit (clanking sound). ♦ Measurable gap formation between 2 blades. ♦ Locking / end blade risen more than permissible (0.3 mm). ♦ Broken blade root. ♦ Cracked blade root. Seal Strips ♦ Broken off around the entire circum ference above caulking groove; broken out in part (%). Note : Rectangular fractures indicate stress corrosion. Curved fractures indicate vibration as the cause of cracking. ♦ Bent due to foreign-object impact. ♦ Wavy deformation (rippling) due to radial rubbing ♦ Bent forward due to axial rubbing. ♦ Bent backward due to axial rubbing. ♦ Unacceptable abrasion due to radial rubbing. ♦ Perceptible burring. ♦ Residual strip height (measured). ♦ Scale formation : in which area….?. ♦ Scaly strips susceptible to brutal fracture. ♦ Elastic seal strips.T-OH-procedure {F.K.} 24 November 2006
  39. 39. Turbine Overhauling - Scope of Work Page 39 of 75 Bearing Journals ♦ In order. ♦ Shallow scoring. ♦ Random scoring along the journal length. ♦ Scoring at the journal ends. ♦ Individual gouges (depth ?). Thrust Bearing Collar ♦ In order ♦ Shallow scoring, randomly distributed around annulus. ♦ Pronounced scoring on the collar side accom modating residual axial thrust in positive direction (in negative direction). ♦ Deep individual gouges in the positive collar (in the negative collar). ♦ Thrust bearing collars located in parallel. ♦ Collar faces located in a conical attitude to each other (m echanical repair work necessary). Rotor Faces ♦ In order. ♦ Scaled. ♦ Corroded. ♦ Eroded. ♦ Covered with deposits. ♦ Rub marks. ♦ Striated. ♦ Cracked (crack depth ?) Coupling Half Section ♦ In order ♦ Frictional oxidation. ♦ Fretting corrosion. ♦ Scoring.T-OH-procedure {F.K.} 24 November 2006
  40. 40. Turbine Overhauling - Scope of Work Page 40 of 75 ♦ Concave deformation of face area. ♦ Anti-rotation pins sheared off. L-ring Grooves ♦ In order. ♦ Scaled. ♦ Oval deformation. ♦ Scoring. Nut Support Faces ♦ In order. ♦ Deep galling. Cast Casing ♦ In order. ♦ Torn. ♦ Covered with deposits. ♦ Corroded. ♦ Eroded. ♦ Corrosion-erosion attach. ♦ Washed-out casting pores. ♦ Washed-out casting cavities. ♦ Oval deformation. Nozzle Blades ♦ In order. ♦ Solid particle erosion. ♦ Scaling. ♦ Foreign particle hammering. ♦ Torn seal welds. ♦ Loose nozzle-blade seat. Joint Faces ♦ In order. ♦ Scaling. ♦ Signs of steam leakage without material erosion.T-OH-procedure {F.K.} 24 November 2006
  41. 41. Turbine Overhauling - Scope of Work Page 41 of 75 ♦ Signs of steam leakage with material erosion. ♦ Deformation. Structural Elements : “Thermo-elastic Housing Guide” ♦ In order. ♦ Unimpeded movement. ♦ Binding movement. ♦ Seized. ♦ Scaled. ♦ Torn. ♦ Deformed. ♦ Hammered. ♦ Fretting corrosion. ♦ Striated. ♦ Abrasion. Coupling Bolt ♦ In order. ♦ Fretting corrosion. ♦ Scored from dismantling. ♦ Unacceptable stretch. Balancing Weights ♦ In order. ♦ Droplet-impact erosion. ♦ Loose fit in mounting groove. Flanged Connections ♦ In order. ♦ Concave deformation of face area. ♦ Leaky. ♦ Steam erosion marks without material abrasion. ♦ Steam erosion marks with material abrasion. ♦ Torn. ♦ Contact face for seal grooved indented.T-OH-procedure {F.K.} 24 November 2006
  42. 42. Turbine Overhauling - Scope of Work Page 42 of 75 Rupture ♦ In order. ♦ Damaged Bolts ♦ In order. ♦ Torn. ♦ Broken off. ♦ Unacceptable stretch. ♦ Scaled thread flanks. ♦ Galled. Babbitt Lining ♦ In order. ♦ Colored oil deposits. ♦ Full-width scoring. ♦ Scoring at front and rear. ♦ Scoring in the vicinity of lift-oil pressure relief hole. ♦ Round foreign objects stuck in Babbitt metal. ♦ Isolated wide / deep scoring. ♦ Cavitations at front of out-let side oil groove. ♦ Smearing. ♦ Babbitt fretting. ♦ Surface pores. ♦ Crack in Babbitt lining. ♦ Bond in order. ♦ Unacceptably large areas without adequate bond between the Babbitt lining and the bearing body. ♦ Bearing contact angle in order. ♦ Bearing contact angle too wide. ♦ Clearances in order. ♦ Lateral or top clearance too small or too large.T-OH-procedure {F.K.} 24 November 2006
  43. 43. Turbine Overhauling - Scope of Work Page 43 of 75 Bearing Shell ♦ In order. ♦ Spherical area damaged by frictional oxidation. ♦ Spherical area dispels evidence of hammering due to bearing vibration. ♦ Evidence of hammering on the pedestal guide faces. Pedestal Faces ♦ In order. ♦ Rusty. Valve Stems ♦ In order. ♦ Scaling. ♦ Axial scoring. ♦ Gland corrosion. ♦ Radial vibration marks. ♦ Torn at cone. ♦ Surface cracks in the hard-facing. ♦ Torn in the spindle. ♦ Torn at the coupling. ♦ Unacceptable bending. Valve Cones ♦ In order. ♦ Foreign objects pressed into valve seat. ♦ Valve seat torn. ♦ Valve broken. ♦ Valve blow out. ♦ Back seal blown out. ♦ Taper shank scored. ♦ Hard-facing torn at taper shank. ♦ Taper shank scaled. ♦ Pilot cone leaky. ♦ Pilot cone seized. ♦ Signs of hammering on the anti-rotation device. ♦ Anti-rotation device in order.T-OH-procedure {F.K.} 24 November 2006
  44. 44. Turbine Overhauling - Scope of Work Page 44 of 75 ♦ Anti-rotation device worn. Guide Sleeves / Bushings ♦ In order. ♦ Scored. ♦ Beaten out on one side. ♦ Back seal indented. ♦ Back seal blown out. ♦ Clearance too large or too small. Piston Rod ♦ In order. ♦ Scored. ♦ Bent. ♦ Torn. Piston Plate ♦ In order. ♦ Damaged seal face. ♦ Torn seal face. ♦ Corroded. Piston ♦ In order. ♦ Damaged seal face. ♦ Corroded. Spiral Springs ♦ In order ♦ Corroded. ♦ Broken. Steam Strainer Coiling StripT-OH-procedure {F.K.} 24 November 2006
  45. 45. Turbine Overhauling - Scope of Work Page 45 of 75 ♦ In order. ♦ Torn ♦ Noticed ♦ Round foreign objects stuck in coiling strip. ♦ Signs of hammering. ♦ Broken out. Steam Strainer Basket ♦ In order. ♦ Torn ♦ Bent guide pins. Steam Strainer Body ♦ In order. ♦ Damaged. Bars ♦ In order. ♦ Bent. Lever mount ♦ In order. ♦ Mount beater out. Control Cylinder Assembly ♦ In order Valve seat ♦ In order. ♦ Cracked. ♦ Broken. ♦ Indented by foreign objects. ♦ Blown out. ♦ Torn weld.7.0 RE-ASSEMBLY :7.1 L. P. Turbine :T-OH-procedure {F.K.} 24 November 2006
  46. 46. Turbine Overhauling - Scope of Work Page 46 of 75Prepare Bottom-Half Outer Casing for ReassemblyProcedure : ♦ Remove fitted parallel keys from the front and rear axial casing guides (Z58, 59, 60; Detail Z2, Z4) ♦ Inspect fitted parallel keys and contact faces. ♦ Coat fitted parallel keys with lubricant and install. ♦ Check and record clearances (Z 58, 59, 60; Details Z2, Z4, Section G-G)Prepare Rear Bearing Pedestal for ReassemblyProcedure : ♦ Install bottom-half bearing; protect journal surface areas.Insert RotorProcedure : ♦ Suspend rotor in the vicinity of the coupling flanges (Z 65) and raise slightly. ♦ Clean rotor and protect against corrosion. ♦ Set down rotor in the support bearing at front and bearing pedestal at rear, thereby ensuring that the journal surface areas of both bearings are coated with viscous oil. ♦ Install top-half journal bearing.Replace Top-Half Outer CasingProcedure : ♦ Suspend top-half outer casing in a horizontal position from the intended lifting bosses and raise slightly. ♦ Clean top-half outer casing and protect against corrosion. ♦ Install guide bolt in the bottom-half outer casing. ♦ Degrease top-half in the bottom-half outer casing. ♦ Apply uniform layer of bluing ink to the joint face of the top-half outer casing. ♦ Install top-half outer casing on bottom-half outer casing and tighten several joint bolts.Align Bearing Pedestal and Outer CasingProcedure :T-OH-procedure {F.K.} 24 November 2006
  47. 47. Turbine Overhauling - Scope of Work Page 47 of 75 ♦ Unscrew spacer bolts (Z 58, 59, 60; Section F2-F2, F4-F4) on the bottom -half outer casing. ♦ Check for full contact between the support brackets and the base plates (Z 58, 59, 60; Section F2-F2, F4-F4). ♦ Check for full contact between the bearing pede stal and the base plate (Z 58, 60; Section N4-N4). ♦ Check alignm ent dim ensions (Assem bly data sheet EI, EII) or ascertain via rotor displacement and record values. ♦ Measure and record the exact values at the outer-casing circumferential profile measuring points. ♦ Measure and record the exact values at the rear bearing pedestal measuring points. ♦ Record measured values and correct as necessary by way of rotor displacement. ♦ Tighten spacer bolts (Z 58, 59, 69, Section F2-F2, F4-F4)Remove Top-Half Outer CasingProcedure : ♦ Unscrew joint bolts. ♦ Remove and store top-half outer casing. ♦ Evaluate bluing imprint.Install Outer Gland Bushing for clearance CheckProcedure : ♦ Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. ♦ Clean front and rear gland bushings and protect against corrosion. ♦ Apply lubricant to guides. ♦ Swing in front and rear bottom-half gland bushings. ♦ Measure, evaluate and record the horizontal a nd vertical radial clearances between the gland bushings and the rotor. ♦ Measure, evaluate and record axial movement of rotor in the rear gland bushing. ♦ Remove and store front bottom-half gland bushing. ♦ Measure, evaluate and record axial movement of rotor in the rear gland bushing. ♦ Remove and store rear bottom-half gland bushing.T-OH-procedure {F.K.} 24 November 2006
  48. 48. Turbine Overhauling - Scope of Work Page 48 of 75Remove RotorProcedure : ♦ Remove top-half journal bearing. ♦ Remove and store rotor. ♦ Protect bottom-half journal bearing and support bearing against damage.Install and Align Stationary Blade CarrierProcedure : ♦ Sequence : items 500, 525. ♦ Suspend bottom-half stationary blade carrier in a horizontal position and raise slightly. ♦ Clean bottom-half stationary blade carrier and protect against corrosion. ♦ Coat stationary blade carrier guides with lubricant. ♦ Coat the contact faces of the calottes (Z 58, 59, 60; Sections C2-C2, C4-C4); position m arked spherical washers (Parts 507, 532) in the bottom-half outer casing. ♦ Install bottom-half stationary blade carrier, thereby ensuring that the spherical washers are properly seated. ♦ Insert rotor. ♦ Check alignment dimension (Assembly data sheet EI, EII) or ascertain via rotor displacement. ♦ Measure and evaluate the exact values of the outer-casing circumferential profile measuring points and correct as necessary via rotor displacement. ♦ Measure and evaluate the lateral (horizontal) radi al clearance between the stationary blade carriers and the rotor and correct as necessary via the adjusting elements (Z 58, 59, 60; Section C2-C2, C4- C4). ♦ Suspend top-half stationary blade carrier in a horizontal position and raise slightly. ♦ Clean top-half stationary blade carrier and protect against corrosion. ♦ Screw guide bolts into bottom-half stationary blade carrier. ♦ Degrease the joint faces on the top and bottom halves. ♦ Place top-half stationary blade carrier in position and tighten several joint bolts. ♦ With the aid of the adjusting elem ents (Z 58, 59, 60; Section C2-C2, C4-C4), vertically raise and lower the stationary blade carrier in position in order to determ ine the overall radial clearance between the stationary blade carrier and the rotor; evaluate; center the stationary blade carrier and record the values. ♦ Apply lubricant to the contact faces of the top calottes (Z 58, 59, 60; Section C2-C2, C4-C4) and apply marked spherical washers.T-OH-procedure {F.K.} 24 November 2006
  49. 49. Turbine Overhauling - Scope of Work Page 49 of 75 ♦ Set up proper clearance between the spherical w ashers and the outer casing; secure adjusting elements as specified in the drawing; check and record all values. ♦ Remove spherical washers and keep ready for further reassembly. ♦ Measure, evaluate and record axial movement of the rotor. ♦ Unscrew joint bolts. ♦ Raise top-half stationary blade carrier, protect against corrosion and store. ♦ Check and record the lateral (horizontal) radial clearance between the stationary blade carriers and the rotor. ♦ Measure, evaluate and record the axial clearance between the rotating and stationary blades in positive and negative direction. ♦ Remove top-half journal bearing. ♦ Remove and store rotor. ♦ Check bottom-half journal bearing and support bearing for damage.Install and align Inner CasingProcedure : ♦ Suspend bottom-half inner casing in horizontal position and raise slightly. ♦ Clean bottom-half inner casing and protect against corrosion. ♦ Apply lubricant to inner casing guides. ♦ Apply lubricant to contact faces of bottom calottes (Z 58, 59, 60; Section A-A); position the marked spherical washers (Part 325) in the bottom-half outer casing. ♦ Determine the horizontal L-ring movement in the outer casing. ♦ Install bottom-half inner casing, thereby ensuring that the spherical washers are properly seated. ♦ Insert rotor. ♦ Check alignment dimensions (assembly data sheet EI. EII) or ascertain via rotor displacement. ♦ Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. ♦ Measure and evaluate the lateral (horizontal) radial clearance between the inner casing and the rotor and correct as necessary via the adjusting elements (Z 58, Section A-A). ♦ Suspend top-half inner casing in a horizontal position and raise slightly. ♦ Clean top-half inner casing and protect against corrosion. ♦ Screw in guide bolts of the bottom-half inner casing. ♦ Degrease the joint faces of the top and bottom halves. ♦ Mount top-half inner casing and tighten several joint bolts.T-OH-procedure {F.K.} 24 November 2006
  50. 50. Turbine Overhauling - Scope of Work Page 50 of 75 ♦ With the aid of the adjusting elem ents (Z 58, 59, 60; Section A-A) vertically raise and lower the inner casing up to stop in order to determ ine the overall radial clearance between the inner casing and the rotor; evaluate; center the inter casing and record all values. ♦ Apply lubricant to the contact faces of the top calottes (Z 58, Section A-A) and install m arked spherical washers. ♦ Set up proper clearance between the spherical w ashers and the outer casing; secure adjusting elements as specified on drawing; check and record all values. ♦ Remove spherical washers and keep ready for further assembly. ♦ Measure, evaluate and record the axial movement of the rotor. ♦ Unscrew joint bolts. ♦ Lift off top-half inner casing, protect against corrosion and store. ♦ Check and record the lateral (horizontal) radial clearance between the inner casing and the rotor. ♦ Measure, evaluate and record the axial clearance between the rotating and stationary blades in positive and negative direction. ♦ Remove top-half journal bearing. ♦ Remove rotor and store. ♦ Check bottom-half journal bearing and support bearing for damage.Install Inner ComponentsProcedure : ♦ Clean interior of bottom -half outer casing and associated inner com ponents and protect against corrosion. ♦ Insert rotor. ♦ Check alignment dimensions (Assembly data sheet EI, EII) or ascertain via rotor displacement. ♦ Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. ♦ Loosely mount rear top-half bearing pedestal. ♦ Suspend top-half inner casing in horizontal position and raise slightly. ♦ Clean top-half inner casing and protect against corrosion. ♦ Degrease joint faces of top and bottom halves; apply uniform coat of sealant to one joint face. ♦ Mount top-half inner casing and tighten joint bolts as specified. ♦ Install pressure-instrument lines (Z 58, Part 391) ♦ Suspend top-half stationary blade carrier in a horizontal position and raise slightly. ♦ Clean top-half stationary blade carrier and protect against corrosion.T-OH-procedure {F.K.} 24 November 2006

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