Recommendations for the Inspection of Steam Turbines 1 Introduction 1.1 Scope 2 Basic Consideration for the Inspection of steam Turbine 2.1 Practical Consideration for Scheduling Inspection 2.2 Theoretical Consideration for scheduling inspection 2.3 Summary 3 Types of Inspections 3.1 Minor Inspection 3.2 Intermediate Inspection 3.3 Major Inspection 3.4 Module Inspection 4 Tests and Examination during Inspections 5 Inspection Strategy 6 Scheduling Strategy 6.1 Planned Inspection 6.1.1 Initial Service Period, Phase 1 6.1.2 Second and Third Service Periods, phases 2 and 3 6.1.3 Service Period between Major Inspections 6.2 Unscheduled Inspection Due to Irregularities 6.3 Unscheduled Inspection Damage 7 Planning for I Inspection and Overhauls Overhaul s 7.1 Spare Parts Planning 7.2 Planning for Intermediate and Major Inspections 7.3 Marginal Condition for the Execution of Inspections (Owner) 8 Inspection results and Conclusions 8.1 Documentation 8.2 Conclusions Drawn from Inspection Results 8.3 Conclusions in Respect of Further Operation 8.3.1 Conclusions in Respect of next Inspection 8.3.2 Conclusions for Manufacturer 9 References 10 Appendix (Attachments 1 to 3)
1 Introduction Economical operation of steam turbine plant is essentially determined by the thermal efficiency and availability of the unit. In the past, a through inspection of the steam turbinegenerator has proved to be an important tool for ensuring optimum and reliable operation. To permit an overall assessment of the condition of a steam turbine and its auxiliaries, an examination of the unit after disassembly is required in addition to the usual running routines and special tests. Special problems, e.g. crack initiation on highly stressed components, can normally be detected only during a major inspection i.e. after disassembly of the components. These recommendations contain guidelines for inspection scheduling which vary ac cording to the type of turbine, mode of operation, application and life expenditure of the unit. 1.1 Scope These Recommendations relate to -- Utility superheated steam turbines. -- Utility saturated steam turbines. -- Industrial steam turbines. And their auxiliaries, such as condenser and supply system. 2. Basic Consideration for the Inspection o f steam turbines It is the intent and purpose of inspection - To determine the present condition of the unit, and together and evaluate service experience. - To rectify deficiencies - To improve the availability and economics during the next service period - To obtain information for assessing t he remaining life and thus the requir ement for future inspection. 2.1 Practical Consideration for Scheduling Inspections The causes of deficiencies. Detected can be subdivided into two groups: a) Time-independent influences, such as: - Causes due to planning, plant structures into two groups: - Causes due to design, calculation and construction, - Negligence in execution of work, including defects in workmanship, - Defects in material or errors in materials selection, - Maloperation b) Time-dependent influences, such as: - normal wear and tear, corrosion and erosion damage, distortion, - life expenditure, - deposits of any kind, including consequential damage Time-independent influences are mostly due to human failures. They depend on the knowledge, skill, experience and diligence of the manufacturers and owners. It is known from experience that these influences become effective during initial operation after the inspection and must be anticipated in case of new developments. Time-dependent influences are due to the stressing of individual components during the service time of the unit, especially as a result of start-up and shutdown procedure, load changes and special modes of operation or operation at off-normal condition. They causes were and tear, and in the long run they are responsible for changes in the material leading to zero life expectancy It is therefore a recommended to schedule inspections over the predicted service time on the number of starts. The following relation defines equivalent operating hours. Tequiv = Tact + ns.Ts
Where Tequiv = equivalent operating hours Tact = actual operating hours Ns =number of starts, without differentiating between hot starts and cold starts Ts = numbers of additional operating hours to be consideration for one start. According to the present state of knowledge can be consideration in individual cases. If a unit is operated according to the principles of the Thermal Behavior of steam turbines and in conformity with the instruction supplied by the manufacturer. it is normally not necessary to consider any life expectancy problems when scheduling an inspection during the initial100 000 equivalent operating hours. Apart from the actual operating hours, frequent starts during this period may, however be the initiating causes of impending, detrimental changes resulting in the need for an inspection After completion of the first 100 000 equivalent operating hours, problems of material fatigue and remaining life expectancy are likely to gain significance from now on, these influences must be consideration when scheduling an inspection. There is a need for detailed discussions with the manufacturer The inspection intervals have been considerably lengthened in the course of time for the following reasons; - Improved calculation method, - Improved material and improved knowledge of materials, - Improved and dependable structural components, - Improved monitoring systems, - Greater experience and less inspection findings, - Higher risk due to time-independent influences after each inspection However, the inspection intervals should not be l engthened indefinitely, because: - The disassembly of parts in the hot steam path is often very difficult and can be connected with high expenditure after approximately 50 000 equivalent operating hours. - After approximately 50 000 equivalent operating hour, the initial stretch of hightemperature joint bolts may have decreased to a level requiring retightening - Fatigue and creep phenomena, such as crack initiation and distortion of diaphragms, do not occur suddenly, such effects must be closely watched and measured over a prolonged period of time for assessment of the remaining life expectancy. - The causes of service-induced failure increase after a high number of equivalent operating hours. Inspection intervals should be shortened. - Insufficient experiences is still available for the range above 20 0 000 equivalent operating hours. An assessment of the remaining life expectancy may be possible on the basis of inspection findings. Since the operating records for the entire life of a unit are not always available, an assessment by calculation is not always practicable. 2.2 Theoretical Consideration for Scheduling Inspections A turbine is a system consisting of numerous parts. Even if the reliability of the individual components is relatively high, the probability of the complete system increases with the number of component parts The service time of a turbine can be subdivided into three phases: Phase 1: Initial service period with predominantly time-independent disturbances. Phase 2: Main service period with mainly foreseeable and approximately constant were and tear of highly stressed components Phase 3: Period of increasing life expenditure due to increasing material fatigue. A graphic representation yields a so-called bathtub curve After the unit has completed a higher number of operating hours, the reliability obtained by performing inspection is higher than w ithout such inspections.
2.3 Summary A basic inspection programme for the entire service life of the turbine taking into account the above consideration is shown in figures
3 Types of Inspections The scope of an inspection is determined by the requirements .Inspections are classified by type into the following categories: -Minor inspection -Intermediate inspection - Major inspection -Module inspection 3.1 Minor inspection A “Minor inspection’ is performed as necessary during an outage caused by other plant components or during a failure-induced or planned outage of the turbine-generator. The primary objective is to prevent fo rced outage by systematic inspection and maintains. Information is obtained on the possible scop e of an “Intermediate Inspection” or of a “Major Inspection” . 3.2 Intermediate Inspection An “Intermediate Inspection’ is performed during a planned outage of the unit. If required a turbine section is opened. The need for o pening a casing is determined by the following criteria. Conclusions derived from long term monitoring. Service experience Recommendation given by manufacture and insurer
Detailed information is obtained on the possible scope of the next “Major Inspection”. 3.3 Major Inspection A “Major Inspection” is performed during a planned outage of the turbine-generator and permits through checking and examination of all components. All casing are opened. The duration of the outage depends on the rating and design of the turbine-generator, the scope of maintenances work and the manpower allocation. Additional details on the scope of components to be checked and wo rk to be performed during the various types of inspections are given on sheet 1 and 2 of attachment 1 3.4 Module Inspection Major inspection can also be performed in the form of inspection. Involving the opening of a particular casing in each case. This is in fact a sectionalized opening of the turbine. It is an essential requirement for module inspections that the inspection intervals recommended for the different turbine sections should not be sub stantially exceeded. Things are different in the case of duplicate turbine section operating under comparable condition, enabling the condition of the particular turbine section to be inferred from that of the other turbine sections Module inspections can also be performed after occurrence of a failure or disturbance at the turbine- generators, i.e. .by opening a particular turbine section. 4 Tests and Examinations during Inspections The following principal procedure, identified by code letters, is available for testing steam turbine-generator components. Details on their application are given in attachment 2 Code letter (see att.2, sheet 1 to 3) Functional Test 1 -Visual Examination (outside/inside) 2 -Unaided eye, good lighting and optical aids 2 -Bore scope( rigid and flexible; Auxiliary equipment: TV camera, monitor, video recorder) -Microscope -Inspection of surface structure (e.g. roughness). Surface Crack Detection 3 -Liquid reentrant method -Magnetic particle method (Not applicable to austenitic materials) -Eddy-current method Ultrasonic Examination 4 Radiographic Examination 5 X-ray Gamma-ray Determination of Crack Depth 6 As far as practicable by means of potential Probe or ultrasonic; possibly drilling And/ or grinding of cracks Impact Test 7 Mainly to determine frequency response of blading Determination of Natural Frequency of Components 8 Primarily to detect changes in natural frequencies Of moving and stationary blades. Detection Permanent Deformations 9 -Length measurements e.g. to determine clearance, Ovality, radial and circumferential growth.
-Run out tests, e.g. on pipe bends. -Bending angle measurement e.g. on pipe bands. Wall Thickness Measurements 10 By means of calipers or ultrasonic. Non-destructive Test 11 -On-site examination of surface structure by Means of optical microscope or replica method after Etching of surface, film or lacquer replica, DIN 54 150 -Hardness test, e.g. Brinell, Rockwell, Vickers. -Material identity test e.g. by means of Hand spectroscope. Destructive Tests with Test Specimens 12 -Tensile test for determination of yield strength, tensile strength, elongation after fracture and reduction of area Notched bar impact test. Chemical analysis. Metallographic examination of gain structure Determination of residual Stress13 -Ring core method. -X-ray goniometer. -Heat stabilization test Hydrostatic Test 14 Electrochemical Examination of Protective Coatings 15 e.g. on condenser tubes of copper alloy materials for potential/ resistance measurement. Resistance Measurement to check shaft earthing system 16 The scope of tests should be agreed between the manufacturer and owner under due consideration of experience available from comparable units and new finding derived from failure. The manufacture should indicate highly stressed areas of the components requiring examination. The scope of tests should be agreed between the manufacturer and owner under due consideration of experience available from comparable units and new findings derived from failure. The manufacture should indicate highly stressed areas of the components requiring examination. The scope of tests should be specified in c hecklists, taking into account the type of turbine, the mode of operation and the expended life of the machine. In many cases, it is advisable to subject a particular components classified according to steam turbine components, to be applied during inspections. They relate to tests on the turbine, condenser, heat exchangers and internal piping system of the turbine. The test results should be recorded and kept for the entire lifetime of the turbine( e.g. reports, sketches, drawing, photographs, radiograph and recalculation records) Planning for inspection should take into account the extra time and added expenses for the tests. Moreover, the long inspection intervals make it necessary to include a considerably larger numbers of parts in the test programmer than previously 5. Inspectional Strategy Inspection is planned according to technical and economic requirements under due consideration of the available generation, workshop and m anpower capacities of the owner. In addition to the actual cost of the inspection, the unit unavailability is an essential factor. It is determined by the duration of the outage due to disturbances or damage. Hence, lengthening
the inspection intervals is only useful if this does not result in a longer unavailability due to forced outage. A forced outage due to failure most likely result in a longer service interruption than a planned outage for inspection. An outage due to failure always occurs unexpectedly. I.e. normally at an unsuitable time. To analyses the condition, the owner must consider. - The aspects specified in section 2. - The need for inspection of associated larger components (steam generator/ generator) - The existing contracts for supply of energy - The own observations. - The recommendation for inspection and overhaul given by the manufacturer. - The exchange of experience information with other utilities. - The condition agreed upon with the insurer. - The literature. The result are in-house inspections schedules (Attachment 3.1 and 3.2 ) in the form of a bar chart for long-range planning or the loading schedule for short-range planning, showing the duration and year of the inspection. 6 Scheduling Inspection Planned inspections are scheduled on the basis o f the inspection strategy. Unscheduled inspection result from irregularities in the unit or from disturbances requiring a shutdown of the unit. 6.1 Planned Inspections There is a general interest in stretching the time between inspection, which are partly performed at fixed and comparatively short intervals. However, it cannot be recommended to satisfy this demand simply by lengthening t he current periodic interval. Attempts should be made to attain a higher flexibility in establishing periodic inspection intervals and to lengthen the service period between inspections dependent on the unit. In addition to taking into account the design and construction, the provision of monitoring and safety equipment and the mode of operation, the o perational performed of the unit and any changes as compared to its normal condition must be considered. In addition to the equivalent operating hours, the following criteria are available as tools when making decisions dealing with inspection scheduling. -Type of turbine e.g. – condensing turbines with high steam wetness, high-temp. Turbine section of austenitic material, Geared turbines. Mode of operation Continuous duty, off-nominal conditions, starting and loading mode, temperature transient and resulting stresses, sliding- pressure/ fixes-pressure operation. -Observations during operation e.g. vibrations, bearing temperature, Stage pressure and temperature, Leakage steam flow rates, Wear and tear. -S Special Measurements e.g. internal efficiency Heat consumption, Distortion of foundation. Life Expectancy Estimates -Turbine Life Expenditure Inspection Intervals of other Unit Components, Such as steam generator and generator
-
Manufacture’s and Insurer’s Recommendations Exchange of Experience with other Utilized 6 6.1.1 Initial Service Period, Phase 1 It is advisable to check the unit for impending deficiencies and possible warranty claims prior to expiry of the warranty period. Casings of new design, an agreement can be reached between the manufacture and the owner. 6 6.1.2 Second and Third Service Period phases 2 & 3 If condition monitoring and operational testing detect no irregularities, it is recommended to perform the first major inspection after approximately 50000 equivalent operating hours. This major inspection interval is an empirical value and has been established on the basis of longterm experience in over-hauling steam turbines of different types and operating by different owners, taking into account the service experience gained during the last ten years. Important reasons for performing an inspection after this period are: Easy disassembly of parts in hot steam path. Relaxation of bolted joints in hot steam path. Blade checked, Wear and tear and erosion-corrosion of internal components (e.g. sealing element, keys, contact faces, casing) Planning for the next major inspection is dictated by the past inspection findings and the result of tests performed during the first major inspection. If no serious problems are detected, the next major inspection should be performed after the unit has completed approximately 100 000 equivalent operating hours. An interval of approximately 50 000 equivalent operating hours between two major inspections can be operating experiences available from comparable turbines indicate the need for short intervals. 6 6.1.3 Service Period between Major Inspections It is recommended to perform a minor or intermediate inspection after mutely 25 000 equivalent operating hours during the service period between two major inspection. This service is approximately equal to an interval of three and coincides with the inspection interval for the steam generator. 6.2 Unscheduled Inspections Due to Irregularities The inspection intervals indicated in section 6 .1 are applicable on the condition that performed monitoring and other specific measurement (e.g. efficiency, heat consumption or stage pressure measurements) and the inspection findings reveal no irregularities. However, if performance monitoring of the turbine-generator reveals irregularities (offnominal condition) which are substantiated by additional checks ( e.g. measurements), the deficiencies detected may it necessary to advance a planned inspection ( see Attachment 4 .1 & 4.2). This inspection is caused by irregularities and can be carried out in the form of a module inspection. Moreover, information provide by the manufacturer or the insure on indicates experienced on similar units where irregularities have resulted in disturbances can be lead to an unscheduled inspection of a particular plant components. If the inspection findings and test result indicate the need for a prolonged outage, advancing a planned inspection of the complete unit should be contemplated for economic consideration. 6.3. Unscheduled Inspection due to damage An unscheduled inspection may become necessary due to a ctual damage to the turbinegenerator or to a non-redundant plant components (steam generator, pressure vessel, unit connected transformer, etc.). In contact to an unscheduled inspection due to irregularities, which in most cases does not necessitate an immediate shutdown of the turbine-generator actual damage requires an immediate shutdown. If the time necessary for rectification o f the damage results in a
prolonged outage of the turbines generator, a planned inspection can be performed sooner than scheduled. 7. Planning for Inspection and Overhauls It is the goal of inspection and overhaul planning to find a favorable time / cost ratio for a defined scope of inspection work. This includes parts planning, implementation planning and consideration of the necessary marginal conditions. 7.1 Spare Parts Planning The spare parts considered necessary by agreement between the owner and t he manufacturer should be available in the number required for each unit prior to initial start-up. The decision on the purchase of additional manufacturers-recommended spares essentially depends on the following criteria. Significance of the turbine-generator in the utility system. Cost of outage due to unexpected failure. Probability of failure. Delivery time of spare parts. Operation of several identical units in the utility’s system. Consolidated spare parts inventory shared by several utilities. In additional to the manufacturer-recommended spares, which should preferably be ordered during the warranty period of the turbine-generator, there are spares which become necessary due to life expenditure and should therefore be purchased in due time. The spare parts must be stocked in such a way as to be protected against corrosion and damage and to be easily found. Any parts removed from stock should be replaced in due time either by ordering new parts or by reconditioning parts removed from the unit. In the event of the design of the turbine-generator being c hanged, the spare parts should be examined suitability. 7.2 Planning for Intermediate and Major Inspections. Approximately one year before the start of the inspection, the owner should inform the manufacture about the scheduled inspection indicating it’s kind and duration. The work required should be agreed upon during a meeting between the owner and the manufacturer, talking into account the experience available from pervious inspection and from the inspection of similar units. The scope of inspection activities should be defined in detail o n the basis of the owner’s/ operator’s observation and manufacturers schedules and lists of necessary work. In addition, the following points should be clarified. -Estimated spare parts requirements. -Spare parts stocked by owner must be checked for completeness and condition. Missing or unserviceable spare part must be ordered immediately. -Availability of tools and fixtures; items available, items to be made available by the manufacture. The following requirements depend on the kind, duration and scope of the inspection; Owner and manufacturer should jointly prepare a preliminary manpower and capacity schedule. A work schedule should be prepared showing the work to be performed at workshops (owner, manufacturer and outside contractors). Both the manufacturer and the owner should produce plans ensuring the availability of the necessary workshop and machinery capacity. The mode of transport and the provision of transport facilities should be agreed upon between the owner and the manufacturer Check measurements (e.g. pressure, efficiency, vibrations, foundation displacement, temperature rise of generator) should be performed in due time prior to commencement of the inspection in order to identify the actual condition of the turbine-generator for comparison with the initial condition (reference condition)
Not later than four months before the start of the inspection, a further consult ion should be identify the following additional requirement for completion of planning activities The result of the measurements and other operating data recorded should be evaluated to determine the need for additional inspection and overhaul activities. The manpower allocation and work schedules must be updated. The required manpower qualification levels as well as the composition of the overhaul. Working hours should be agreed upon. A time schedule should be prepared for the entire inspection period ( bar chart, critical-path chart, see Attachment 5.1 & 5.2). Note that dismantling without delay enables the owner and the manufacturer to o btained the inspection finding at an early date and facilities attending to unexpected damage. The authority of the turbine chief erector within the framework of the power station organization should be defined before the start of the inspection. All documents required for the inspection should be on hand before the start of the inspection and overhaul. If is recommended that owner and manufacturer should meet for an exchange of experience information as soon as the turbine has been restarted. 7.3 Marginal Condition for execution of Inspection (owner) Planning should include washrooms and lo cker rooms for outside contractor’s personnel as well as an adequate number of toilets and spaces. The availability of accommodation and catering facilities near the power station outside working hours and of rooms for having meals at the power station should be determined. Good lighting and electric power at the required supply voltages for the connection of the necessary electrical appliances must be available. The supply of compressed air to the job site must be ensured. Heating and welding equipment with an adequate supply of oxygen and gas c ylinder must be provided. A cleaning contractor and a thermal insulation contractor should be informed about and entrusted with the scope of work to be performed. An allocation plan of the powerhouse indicating the permissible loads should be prepared and handed over to manufacturer field supervisor before the start of the inspection. It is recommended to set up a tool and material crib in the vicinity of the steam turbinegenerator in order to eliminate long distance. Office and telephone facilities for manufacture’s field supervisor should be provide. The working time regulation and the rules of conduct at job site must be handed over to all persons concerned before the start of the inspection. The accident prevention rules must be put out. Lists of all ropes required and of all weights to be lifted should be available. It is advisable to store all ropes in a proper manner in a single location. It is recommended to provide tags with details of safe load capacity, description and length. Spreaders and ropes allowing for adjustment length should be made available. After completion of the inspection, the ropes must be restored to a serviceable from condition. Racks, cases or containers for small items should be provide on the errection floor for dismantled small items, such as, for i nstance, spring-loaded shaft glands, labyrinth seals, casing and bearing insert rings, bolts, etc., in order to ensure an orderly lay-down of the parts and to avoid confusion of parts manufacturer from different materials. In some cases, it is advisable to provide a lockable container for the storage of special parts. All-important special tools should be available in duplicate to prevent the loss of valuable time for obtaining replacement. Collecting pans and containers for the oil to be drained should be made available in adequate number.
Materials for the detection of cracks by the liquid penetrate method solvents lubricants in paste form, seal materials and shims of steel or brass should be made available. An adequate number of planks, support beams and trestles should be made available and checked for their usability before the start of the inspection. After completion of the inspection all tools and appliances used must be checked for completeness. It should be ensured that an efficient nearby workshop will be available for use at any time. The insurer should be informed in due time of the date and scope of the inspection. This will enable the insurers to make recommendations for improvement of the unit components on the basis of their accumulated failure and overhauled experience. A number of useful tools and auxiliary materials ( see attachment 6) should be available 8. Inspection Result and CONDITIONS 8.1 : Documentation Detailed documentation of the results is essential when performing an inspection. It is recommended that this documentation be prepared an cooperation between the owner and the manufacturer under due consideration of the actual requirements. The following heading are intended as a recommendation for the preparation and the contents of the documentation. The order selected is not intended to establish any priorities. Execution of Inspection Manpower and work schedules. Logging of each day’s activities, their sequence, and the required number of working hours together with a statements of overall condition on the basis of the operating data recorded. Inspection Findings Inspection finding should be described in details and, if possible, be supplemented by photographs, sketches, etc. Maintenance and Repair Work Kind and scope of maintains and repair work performed Replacement Parts List of replacement parts used. Modification for replacement parts to be specially recorded. Auxiliary Material and Consumables List of quantities consumed. Test Records for Components Parts. Test records and factory assembly records for replacement parts and components reconditioned at manufacturer’s works, materials test certificate. Setting Records and Functional Test Records Setting and testing of control, supervisory, safety and protective equipment, oil throttles, oil pressures, shaft lift oil pr essures. Assembly Records Records of all measurement taken. Plant Records Drawing, piping diagrams, operating instruction, etc. should be checked for facture validity and revised as necessary. Operating Records Operating date should be recorded under comparable steady-state conditions a before and after inspection. Data to be recorded include live steam condition and valve positions, stage pressures and temperatures, casing temperature , oil pressure and oil temperature, cooling water i nlet temperature and temperature rise in oil cooler, terminal temperature difference of oil cooler. Bearing temperature, expansion, vibration, data of gland sealing system and vacuum test, terminal temperature difference oc condenser.
Special Measurements Efficiency, heat consumption, foundation distortion. Costs Determination of total cost of inspection, broken down according to personnel, material and outside-contractor costs. Desired/ Actual Valve Comparison Comparison of planning data with actual inspection activities. 8.2 Conclusions Drawn from Inspection Results 8.2.1 Conclusion in respect of further operation Normally no restrictions need to be observed for further operation if the component a) have been left in the condition as found due to the absence of deficiencies. b) Have been replaced by spare parts( e.g. parts subject to wear and tear, such as stems: normally small items which are usually kept on stock) c) Have been reconditioned at site, at manufacture’s works or at an outside contractor’s facility In case damaged components( e.g. casing with cracks) had to be left in the condition as found, it should be decided whether the operating mode must be changed for c ontinued operation of the unit. This decision may result from; - non-availability of replacement parts, - duration of repair, - envisaged remaining service life of unit. i.e. condition of the damaged components must be controlled and documented necessary, additional monitoring facilities should be provided. Any required spare parts should be ordered 8.2.2 Conclusions in Respect of Next Inspection i.e. inspections finding, if possible supplemented by a life expectancy calculation and operating and overhauling experiences available from other units of the amn type. May prompt a change in the current periodic inspection interval establishing for a particular turbine generator. Shorting the between inspections is always recommended if there ar e indication of particular components approaching zero remaining life expecincy although a replacement appears not absolute necessary. Even if damage components can initially be left in the condition as found, the previously established inspection intervals may not be retained. Critical analysis of the procedure details of the replacement parts, dealys in repair of am aged components, difficulties in procurement of material and tools. The root causes of these problems must be identified and eliminated to prevent their recurrence during the next inspection. Spare parts, consumables and auxiliary materials must be replaced at the earliest possible date. This applies particularly to replacement parts with long delivery times, unless their procurement is not justified for economic consideration and operational rest icons are acceptable. 8.2.3 Conclusions for Manufacturer Is the task of the manufacturer to evaluate the experience gathered when the inspection i s completed by comparing the result with those obtained during inspection of duplicate or similar units in order to established any facts that old true generally. This approach provide a wide basis for: a) Sharing preventive maintenance with other owner. b) Recommendations for optimizing periods. c) Recommendations for replacement parts to be stocked by owner. d) Preventive maintenance to be performed in additional to scheduled inspection in order to maintain high availability. e) Proposals for improvements and modification f) Hints for new designs.
9.References 1)“VDEW-Empfehlungen for the Revisionintervalle von Generation”( Vdew recommendations for the inspection intervals of Generators), VGB-RV, 809, 1980 EDITION 2) “Das thernische Verhalten von Dampfturbinen” ( The thermal behavior of steam turbines) 3) “Technische Richtlinie for Uberwachungs-,Sicherhelts-und Schutzeinrichtungen an Dampfturbinenanlagen”( Technical Guideline for steam turbine Supervisory, safety and protective Equipment) VGB-R 103 M 1977 edition 4) “Empfehlungen fur Schrauben im Be Reich hoper temperature” (Recommendation for high-temperature bolts) VGB-R 505 M 1980 EDITION. 5) “Richtlinien fur interne ROHRLEITUNGEN DES Turbosatzes, soweit site brennbare Medien further”VGB-R 503 M 1975 EDITION 6) VEB-Empfehlung “Anleitung zum uberwachen von Dampfturbinen durch Messe s des inner Wirkungsgrades” Vgb-r 118 m 1982 edition 10. Appendix Attachment 1/sheet 1 0= As necessary, X =required Work required during inspection Major inspection Intermediate Minor inspection
Remove coupling bolts, measure stretch elongation of coupling bolts-check axial & radial ligament, run out clearances. Disassemble bearing, check bearing metal, measure clearances, check bearing seat in bearing housing. Examine, overhaul and, if required, replace bearing of bearing housings. Inspect bearing housing and casing guides for contamination (oil choking). If binding is detected, remove clean overhauls keys. Examine sliding performance, remove and overhaul lubrite plates inserted below bearing housings. Lift off bearing housing as far as practicable for overhaul of sliding surfaces and guides. Check spacer bolts at bearing housing and casing brackets and, if required, correct clearances. Check emergency stop, control and bypass valves, if required, replace wearing parts of hydraulic and steam element. Remove steam strainers; check for foreign matter and damage and, if required, recondition strainers. Examine check valves of automatic and no automatic extractions. Renew gaskets if, required replace parts subject to wear and tear. Inspection drains for foreign matter, open and clean silt traps. Inspect admission chest for oxide deposits and unobstructed movement.
0
X
X
0
X
X
0
X
X
0
X
X
0
X
X
-
0
X
x
x
X
0
x
X
-
x
X
x
x
X
o
x
X
-
0
X
-
0
X
-
0
X
-
0
X
-
0
x
Measure casing distortion, checks joints for erosion, perform cracks testing. Alignment checks of turbine casing and bearing housing. Check inner casing guides for unobstructed movement and wear. Overhauling work. Measure permanent elongation of high-temp.joint bolts. Inspect bolts for embitterment. Inspect bolts for cracks.
Attachment 1/sheet 2 Work required during inspection Check shaft glands and labyrinth seals for were and oxide deposit. Examine springs of resilient segment.
Major inspection -
Check rotors for cracks. Perform run out checks Remove scores on shaft journals. Check coupling Clean complete balding and inspect blades for damage. Check seal strips for oxide deposits. Perform cracks and vibration test of freestanding LP BLADES. Visual examination of last stage of condensing turbines( crack testing as necessary) Examine ear thing brush and contact face on shaft. Open main oil pump, check baring, seal rings, haft, impeller, etc. Open auxiliary oil pumps only if necessary. Examine control and protective equipment, giving particular attention to parts subject to wear and tear and to parts susceptible to contamination. Replace parts as necessary.
Intermediate 0
Minor inspectio X
0
X
-
0
X
x x
x x
X X
0
0 X
x
x
X
x
x
X
x
x
X
Drain oil tank, separate oil, if required. Checks oil tank clean strainers.
-
0
X
Check oil filters for leaks. Remove and clean filter element and examine for damage.
x
x
X
-
o
X
x
x
X
-
0
X
-
0
x
Perform functional testing of supervisory equipment for proper mechanical, electrical and hydraulic condition. Overhaul and recalibrate equipment as necessary. Inspect condenser interior, tubes and water boxes for damage perform leakage tests on cooling water and steam sides.
Remove tube bundles of oil coolers; examine tubes for mechanical damage and corrosion. Clean sump.etc. Inspect oil pipes for damage. Remove oil leaks. Inspect steam pipes in turbine interior for cracks, distortion and expansion. Check dimensions of pipes supports and correct as necessary. 0= as necessary x= required
Attachment 2/Sheet 1 Test procedure to be applied to steam turbine components inspection Component Inspection findings Test procedure Rotors
Radial/ axial rubbing deformation of blade grooves surface cracks Mechanical damage Erosion, corrosion Internal defects Perament deformation Damage to shaft journals
Coupling
Looseness of coupling halve Eccentricity Permanent deformation Cracks
2,3,(4),(11),(13) 2,3,9 2,3,(4),6 2.3.(9) 2,(3) 4.5 9,11 2,3,9 2 (4) 7 9 9.11 1.3
Non-contacting seal element
Mechanical damage Fracture Erosion, corrosion Permanent deformation Radial/ axial rubbing Deformation of blade grooves Loose shrink fit of discs Surface cracks Mechanical damage Erosion, corrosion Internal defects
2.3.(9) 2 2 2.11 2.11 2,3,9 2,(4),7,9,13 2,3,(4),6 2.3.(9) 2,(3) 4,5
Radial/ axial rubbing Mechanical damage Deposits Erosion, corrosion Surface cracks Change in blade attachment Permanent deformation Radial/ axial rubbing Mechanical damage Deposits Erosion, corrosion Surface cracks Change in blade attachment Permanent deformation
2,3,7,(11) 2,3,9 2,11,12 2,3,(8) 2,3,4 2,(4),7,8,(9) 2,9,(11) 2,3,7,(11) 2.3.(9) 2,11,12 2,3,(8) 2,3,4 2,(4),7,8,(9)
Discs
Nozzles stationary blades, diaphragms
Moving blades
Remark Including central and radial boars as well as welds
Also check for possible damages to bolt holes
Primarily disc bore
Blade root, air foil, damping element, lacking wires, should tension pins of pinned fork blades
2,9 *) Code numbers according to section 4. Test procedure in parentheses should only be applied if preceding tests have revealed a deficiency or if recommended by the manufacture. Attachment 2/ sheet 2 Test procedure to be applied to steam turbine components inspection
Component
Inspection findings
Test procedure
Remark
Outer casing , inner casing, admission chest, valve casing (ESV/ Control valves), bearing housings Flange and joints bolts
Mechanical damage Distortion Surface cracks (inner, outer surface) Erosion corrosion
2,3,9(11) 2,9 2,3,(6) 2,(3)
Sealing fitting and sliding faces
Permanent deformation Mechanical damage Surface cracks Erosion corrosion
2,3,9(11) 2,9 2,3,4,(12) 2,(3)
VGB-R 505 M(4)
Valve seats Valve stems. Valve cones
Mechanical damage Surface cracks Permanent deformation Erosion corrosion Deposits
2,3 2,3,6 2,9 2,3 2,12
Supervisory Limiting and protective equipment control system Component Bearings
Impaired performance Mechanical damage Corrosion Deposits Mechanical damage Surface cracks Corrosion Cavitation Damaging currents Deposits Loose white metal Seat contact Change in support Surface cracks Permanent deformation Change in support
1 2,3 2,3 2,12 2,3 2,3, 2,3 2,3 2,3,16 2,12 2,4,7,(14) 2,(9) 2,9 2,3,10,11,(12) 2,9,11,(12) 2,9
External steam pipes (hp and IP)
Including clearance changes
Primarily at welds and bends, if necessary, dimensional control of pipes
*) Code numbers according to section 4. Test procedure in parentheses should only be applied if preceding tests have revealed a deficiency or if recommended by the manufacture. Attachment 2/sheet 3 Component Inspection findings Test procedure Remark Internal, steam pipes, conn. Element, Expansion joints; Drain pipes
Impaired performance Surface cracks Abrasion Permanent deformation Erosion corrosion Changes in cold pull
1,2 2,3 2,3,10,(11) 2,9,10, 2,9,10 2,9,
Primarily at welds
Steam strainers, incl.housing
Surface cracks
2,(3),11
Including
Mechanical damage Permanent deformation Control & bearing oil piping
2,3 2,9
material embitterment and solid-particle erosion VGB-R 503 M (5)
Leakage 2,14 Abrasion 2,3,10,11 Surface cracks 2,3 Deposits 2,12 Corrosion 2.12 “Primarily at welds Condenser heat exchangers Disturbed flow path 1,2 For instant protective Surface condition 2,(3),(10),(15) coating, Mechanical damage 2,(3),(12) Deposits Cracks 2,(3),(12) Erosion corrosion 2,10 Leaks 2,14 Gear Tooth contact pattern 2,3,11 Surface cracks 2,3 Mechanical damage 2,3 Deposits 2,12 Damaging currents 2,16 Change in clearances 2,9 *) Code numbers according to section 4. Test procedure in parentheses should only be applied if preceding tests have revealed a deficiency or if recommended by the manufacture. Attachment 3 List of tools and Auxiliary Materials Heaters for loosening and shrink-fitting of joints bolts Special fixtures(e.g. for removing valve seats and grinding) Surface grinder for machining all keys and shims to required size. Lathe with magnetic faceplate and adequate length between centers for run out check of pump shaft Machinist’s tools( pneumatic screwdriver for bolt loosening) Corundum blocks with handles for work to casing joints Work benches in sufficient number in turbine area Electric scrapers, hand scrapers of different design Measuring taps Special dial gauges with supports for gear and alignment checks Measuring tools for shaft gland Alignment shaft with inductive pickup Fixture for spring-loaded inter stage and cylinder glands Cleaning brushes Blast cleaning equipment ( water, glass beads, dust) Grinding pastes Chemical de-rusting and rescaling agents Oil-resistant blue,blueing plate Temperature- indicating crayons Means for detecting and revealing cracks Spreaders and suitable attachment devices Portable hydraulic jacks Lifting tackle in sufficient number Skids for rotors and facilities for on-site handling of heavy plant components
Oil purification plants( centrifuges, filter presses) Oil heating devices or equipment Lint-free absorbent cloth, oil binding agent Special lubricant( aerosol sprays, assembly compounds) Anti-corrosion agreement ( paints and protective compounds) Sealing material in board or sheet form of sufficient size Shims ( brass and steel) Lead wire of different diameter. Suitable planks for covering joints of lower half turbine casing after opening wood blocks and planks for setting down heavy machinery parts Tables for drawing and files
