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NG90/81/45-4IZ
S.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.
4.0 Disassembly :
4.1 HP Turbine.
4.2 LP Turbine.
4.3 Valve blocks.
4.4 Lube oil system.
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 :
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 : Led plate, Birkosit.
♦ For the oil side : Hylomar.
♦ The followings lubricant is recommended : Gleitmo 160
Evaluation :
♦ Teeth.
♦ Clean couplings parts, protect against corrosion and store.
3.5 Check Alignment between the Main Oil Pump and the HP Turbine
Procedure :
♦ Attach measuring instrument.
♦ Check and record the alignment between the pump shaft and the turbine rotor.
4.0 DISASSEMBLY :
4.1 HP Turbine
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.
Evaluation :
♦ Joint face, blades, seal strips, spherical washers.
♦ Protect top-half stationary blade carrier against corrosion and store.
Evaluation :
♦ Joint faces, blades, seal strips, L-rings.
♦ Protect inner casing against corrosion and store.
Evaluation :
♦ Joint face, seal strips.
♦ Protect top-half gland bushing against corrosion and store.
Evaluation :
♦ Joint face, seal strips.
♦ Protect gland bushings against corrosion and store.
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.
Remove Rotor
Procedure :
♦ 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.
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).
Evaluation :
♦ 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.
Evaluation :
♦ Joint face, seal strips, spherical washers, guides.
♦ Protect bottom-half gland bushing against corrosion and store.
♦ Remove lower spherical washers (Z 37, Section K-K, Part 287), protect against corrosion and
store.
Evaluation :
♦ Slide surfaces, spherical washers.
♦ Protect bearing pedestal against corrosion and store.
♦ Protect hardware against corrosion and store.
Evaluation :
♦ Slide surfaces, spherical washers.
♦ Protect bearing pedestal against corrosion and store.
♦ Protect hardware against corrosion and store.
Evaluation :
♦ Slide surfaces, spherical washers.
♦ Protect hardware against corrosion and store.
4.2 L. P. Turbine
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.
Evaluation :
♦ Joint face, blades, seal strips, spherical washers.
♦ Protect top-half stationary blade carrier against corrosion and store.
Evaluation :
♦ Joint face, blades, seal strips, L-rings.
♦ Protect top-half inner casing against corrosion and store.
Evaluation :
♦ Joint faces, seal strips.
♦ Protect gland bushings against corrosion and store.
Remove Rotor
Procedure :
♦ 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.
Evaluation :
♦ Journal bearing.
♦ Protect journal bearing against corrosion and stores.
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.
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.
Evaluation :
♦ All dismantled parts, valve block, valve seats.
♦ Clean all parts and protect against corrosion.
Procedure :
♦ 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 system (4730) and fine-
filtration system (4830).
Evaluation :
♦ Impellers, bearings, seal faces, couplings, electric motors.
♦ Reassemble and reinstall oil pumps.
Procedure :
♦ Fill with clean operating oil.
S# Method
Part Material Remarks
MPT DPT
1. Journal Bearing / thrust
bearing
ST52-3N/
TEGOSTAR 738
3 White Metal
5. HP Piping 14MoV63 /
GS-17CrMo511
3 Weld seams & elbows
7. HP Outer Casing
Upper part
GS-17CrMo55 3 Cross section crossings at inner surface.
6.1.1 HP Turbine
The following individual parts and areas require inspection :
6.1.1.1 Rotor
♦ A-Wheel blading.
FROM OUTSIDE :
♦ L-Ring grooves, main steam and overload.
♦ Nut support face.
♦ Cast casing.
FROM WITHIN :
♦ Steam admission channels, main 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).
FROM OUTSIDE :
♦ L-Ring grooves, main steam plus overload.
♦ Nut support face.
♦ Parts comprising lateral palm support and lower axial guide.
♦ Cast casing.
FROM WITHIN :
♦ Steam admission channels, main 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).
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
FROM OUTSIDE :
♦ Guide groove.
♦ Cast casing.
♦ Nut support face.
FROM WITHIN :
♦ Joint face.
♦ Stationary blades.
♦ Seal strips.
♦ Casing face between stationary blades.
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.
6.1.2 LP Turbine
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.
FROM OUTSIDE :
♦ Nut support face.
♦ Casing finish.
FROM WITHIN :
♦ Joint face.
♦ Casing finish.
♦ Stationary blades.
♦ Seal strips.
FROM OUTSIDE :
♦ Guide faces, front / rear.
♦ Casing finish.
FROM WITHIN :
♦ Stationary blades.
♦ Casing finish up to diffuser outlet.
FROM OUTSIDE :
♦ Guide faces, front / rear.
♦ Casing finish.
FROM WITHIN :
♦ Stationary blades.
♦ Casing finish up to diffuser outlet.
♦ Lateral support and axial guide.
Blading :
♦ A-Wheel / C-Wheel blades.
♦ Stationary / moving blades.
Blade 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 ?
• 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 ?
Rotor Faces:
♦ Incipient cracking ?
♦ Scoring ?
♦ Deposits ?
♦ Corrosion ?
L-Ring Grooves :
♦ Scoring ?
♦ Scale formation ?
♦ Deformation ?
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 ?
♦ 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 determined via surface crack examination according to the liquid-
penetrant method ?
♦ 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 ?
Piston rod :
♦ Quality of finish ?
♦ Damage ?
♦ Functionability impaired ?
Piston :
♦ Quality of finish ?
♦ Damage ?
♦ Functionability impaired ?
Spiral springs :
♦ Quality of finish ?
♦ Damage ?
♦ Functionability impaired ?
Bars :
♦ Functionability impaired ?
Leverbar mount :
♦ Functionability impaired ?
Valve seat ?
♦ Quality of finish ?
♦ Damage ?
♦ Functionability impaired ?
How to inspect ?
Visual Inspection :
Typical accessories :
Typical accessories :
♦ Hand-hammer (200 – 300 gr)
♦ Screwdrivers (approx. 300mm long)
How to Measure ?
Manual measuring :
How to Test ?
Manual testing :
♦ Liquid Penetrant Test.
♦ Magnetic Particle Test.
♦ Ultrasonic Examination.
♦ Electric Crack-Depth Measurements.
♦ X-Ray Examination.
♦ 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.
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.
♦ 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 circumference 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.
Bearing Journals
♦ In order.
♦ Shallow scoring.
♦ Random scoring along the journal length.
♦ Scoring at the journal ends.
♦ Individual gouges (depth ?).
Rotor Faces
♦ In order.
♦ Scaled.
♦ Corroded.
♦ Eroded.
♦ Covered with deposits.
♦ Rub marks.
♦ Striated.
♦ Cracked (crack depth ?)
L-ring Grooves
♦ In order.
♦ Scaled.
♦ Oval deformation.
♦ Scoring.
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.
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.
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.
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.
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.
♦ In order.
♦ Torn
♦ Noticed
♦ Round foreign objects stuck in coiling strip.
♦ Signs of hammering.
♦ Broken out.
Bars
♦ In order.
♦ Bent.
Lever mount
♦ In order.
♦ Mount beater out.
Valve seat
♦ In order.
♦ Cracked.
♦ Broken.
♦ Indented by foreign objects.
♦ Blown out.
♦ Torn weld.
7.0 RE-ASSEMBLY :
7.1 L. P. Turbine :
Insert Rotor
Procedure :
♦ 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.
♦ 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 pedestal and the base plate (Z 58, 60; Section
N4-N4).
♦ Check alignment dimensions (Assembly 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 Rotor
Procedure :
♦ Remove top-half journal bearing.
♦ Remove and store rotor.
♦ Protect bottom-half journal bearing and support bearing against damage.
♦ Set up proper clearance between the spherical washers 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.
♦ With the aid of the adjusting elements (Z 58, 59, 60; Section A-A) vertically raise and lower the
inner casing up to stop in order to determine 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 marked
spherical washers.
♦ Set up proper clearance between the spherical washers 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.
♦ Degrease joint faces of the top and bottom halves; apply uniform coat of sealant to one joint face.
♦ Mount top-half stationary blade carrier and tighten joint bolts.
♦ Clean front and rear gland bushings and protect against corrosion.
♦ Apply lubricant to guides.
♦ Swing in bottom-half gland bushings.
♦ Degrease joint faces; apply uniform coat of sealant to one side of each pair of joint faces.
♦ Mount top-half gland bushings and tighten joint bolts.
♦ Secure all boltings with spot welds.
♦ Remove all taper pins, jack screws and guide bolts; protect against corrosion and store.
♦ Apply lubricant to top-half guides.
♦ Install spherical washers in the stationary blade carrier and inner casing.
♦ Install journal bearing for bluing imprint; lower rotor; bolt down bearing bracket; make bluing
imprint.
♦ Remove bearing bracket; raise rotor slightly; remove journal bearing; evaluate bluing imprint;
clean bluing ink off of bearing and shaft journal.
♦ Install journal bearing; lower rotor; thereby ensuring that the journal surface areas are coated with
viscous oil; bolt bearing bracket and install thermocouples (Z 7).
♦ Check for full contact between the support brackets and the base plates (Z 58, 69, 60; Section F2-
F2, F4-F4).
♦ Check measuring points on the rear bearing pedestal.
♦ Check outer-casing circumferential profile measuring points.
♦ Check and record clearances in the front and rear support bracket bolts (Z 58, 59, 60; Section F2-
F2, F4-F4).
♦ Check zeroing of casing axial-position indicator (Z 58, 59, 60; Detail V4).
7.2 H. P. Turbine
♦ Insert spherical washers of the axial casing guide and bring into contact with the guide face via the
calottes.
♦ Apply lubricant to the threads of the hexagon head bolts; screw in and tighten hexagon head bolts
carrying tab washers (Z 37, 39; Section 03-03, Parts 115, 116).
♦ Install bottom-half journal bearing (Z 16) and protect journal surface area against corrosion.
Insert Rotor
Procedure :
♦ Suspend rotor in horizontal position and raise slightly.
♦ Clean complete rotor and protect against corrosion.
♦ Set down rotor in the bearing pedestal, thereby ensuring that both journal surface areas are coated
with viscous oil.
♦ Mount top-half journal bearing.
♦ Apply lubricant to the contact faces of the calottes of the front support bracket seat (Z 37, 38;
Section P1-P1); install marked spherical washers.
♦ Suspend top-half outer casing from the lifting bosses provided and raise slightly.
♦ Screw guide bolts into the bottom-half outer casing.
♦ Degrease joint faces of top-half and bottom-half outer casing.
♦ Apply uniform layer of bluing ink to the joint face of the top-half outer casing.
♦ Mount the top-half outer casing on the bottom-half outer casing and tighten several joint bolts.
♦ Unscrew bolts of auxiliary support brackets (Z 37, 38; Section P1-P1, Part 30).
♦ Check for full contact of the front support brackets (Z 37, 38; Section P1-P1) and record values.
♦ Check for full contact of the rear support brackets (Z 37, 39, Section P3-P3) on the base plates.
♦ Evaluate recorded values and correct as necessary, either via shims between the support brackets
and base plates (Z 37, 39; Section P3-P3) or on the adjusting elements (Z 37, 38, 39).
♦ Secure adjusting elements as per drawing (Z 37, 38, 39).
♦ Tighten spacer bolts (Z37, 38, 39; Section 01-01, P3-P3).
♦ Unscrew coupling nuts (Z 72).
♦ Remove coupling bolts.
♦ Accommodate weight of the LP rotor with the aid of the lifting fixture (Z 71).
♦ Push coupling flange apart by turning in the jack screws.
♦ Push rotor in the positive direction by about 1.0mm ahead of the stop.
♦ Install support bearing; take load off of lifting fixture.
Remove Rotor
Procedure :
♦ Remove front top-half bearing pedestal; remove bottom-half thrust bearing; remove top-half
journal bearing.
♦ Remove rear top-half bearing pedestal; remove top-half journal bearing.
♦ Remove and store rotor.
♦ Protect bottom-half journal bearing against damage.
♦ Apply lubricant to the contact faces of the upper calottes (Z 45, Section K1-K3, Part 9); install
marked spherical washers.
♦ Adjust clearance between spherical washers and outer casing; secure adjusting elements; check and
record all values.
♦ Remove spherical washers and keep ready for further assembly.
♦ Remove bottom-half thrust bearing.
♦ Measure, evaluate and record the axial movement of the rotor.
♦ Reinstall bottom-half thrust bearing.
♦ Unscrew joint bolts.
♦ Lift off top-half stationary blade carrier, protect against corrosion and store.
♦ Check and record the lateral (horizontal) radial clearance between the stationary blade carrier and
the rotor.
♦ Measure, evaluate and record the axial clearance between the rotating and stationary blades in
positive and negative direction.
♦ Remove bottom-half thrust bearing.
♦ Remove top-half journal bearing.
♦ Remove and store rotor.
♦ Protect bottom-half journal bearing against damage.
♦ Insert rotor.
♦ Install bottom-half thrust bearing.
♦ Measure and evaluate the exact values at the outer-casing circumferential profile measuring points
and correct as necessary by adjusting the screws on the auxiliary support brackets.
♦ Measure and evaluate the lateral (horizontal) radial clearance between the gland bushing and the
rotor and correct as necessary via the adjusting elements (Z 37, Section K-K).
♦ Suspend top-half gland bushing in a horizontal position and raise slightly.
♦ Clean top-half gland busing and protect against corrosion.
♦ Degrease joint faces of top-half and bottom-half gland bushing.
♦ Install top-half gland bushing and tighten joint bolts.
♦ With the aid of the adjusting elements (Z 37, Section K-K), vertically raise and lower the gland
bushing up to stop in order to determine and evaluate the overall radial clearance between the
gland bushing and the rotors; center the gland bushing and record all values.
♦ Apply lubricant to the contact faces of the upper calottes (Z 37, Section K-K, Part 289) and install
marked spherical washers.
♦ Adjust the clearance between the spherical washers and the outer casing; secure
adjusting elements; check and record all values.
♦ Remove the spherical washers and keep ready for further assembly.
♦ Remove bottom-half thrust bearing.
♦ Measure, evaluate, record the axial movement of the rotor.
♦ Reinstall bottom-half thrust bearing.
♦ Unscrew joint bolts.
♦ Lift off top-half gland bushing, protect against corrosion and store.
♦ Check and record the lateral (horizontal) radial clearance between the gland bushing and the rotor.
♦ Remove bottom-half thrust bearing.
♦ Remove top-half journal bearing.
♦ Remove and store rotor.
♦ Protect bottom-half journal bearing against damage.
♦ Install journal bearing; lower rotor; install thrust bearing, thereby ensuring that the journals of
both bearings are coated with viscous oil.
♦ Install thermocouples (Z 7).
♦ Install and bolt down front top-half bearing pedestal.
♦ Dismantle center top-half bearing pedestal; raise rotor slightly; remove journal bearing degrease
bearing and journal; check and record radial clearance of the journal bearing (Z 37, 39; Section
K3-K3).
♦ Install journal bearing for getting a bluing imprint; lower rotor; bolt down top-half bearing
pedestal and make bluing imprint.
♦ Dismantle center top-half bearing pedestal; raise rotor slightly; remove thrust bearing; evaluate
bluing imprint and clean bluing ink from bearing and journal.
♦ Install journal bearings; lower rotor; thereby ensuring that the journal is coated with viscous oil.
♦ Install thermocouples (Z 7).
♦ Install and bolt down center top-half bearing pedestal.
♦ Check front support bracket seat (Z 37, 38; Section P1-P1).
♦ Check for full contact between the rear support brackets and the base plates (Z 37, 38; Section P3-
P3).
♦ Check the front and rear bearing pedestal measuring points.
♦ Check the outer-casing circumferential profile measuring points.
♦ Install manual turning gear; check and record the clearance between the frame and the gear wheel
(Z 37, 39; Section U3-U3).
♦ Unscrew cover of front top-half bearing pedestal Z1, Item 169/165); turn turbine rotor to the
proper measuring position; pull level of emergency trip gear (into operating position; Z88) and
lock in place.
♦ Check and record the radial clearance between the ratchet lever and the overspeed trip bolt (Z 37,
38; Section S1-S1).
♦ Check and record the axial clearance between the ratchet lever and the stopping cam (Z 37, 38;
View R1).
♦ Return lever to its original position; reinstall cover on the front top-half bearing pedestal.
♦ Check the maximum and minimum clearances at the front and rear support bracket bolts (Z 37, 38,
39; Section P1-P1, P3-P3).
♦ Check and record the clearances at the casing guides (Z 37, 38, 39; Section W1-W1, W3-W3).
♦ Check and record the clearances at the lower bearing pedestal guides (Z 37, 38, 39; Section M1-
M1, M3-M3).
♦ Check and record the clearances on the longitudinal guides of the front bearing pedestal (Z 37, 38;
Detail T1).
♦ Check and record the clearance between the brackets and spacer bolts on the front bearing pedestal
(Z 37, 38; Section 01-01).
♦ Check the zeroing of the shaft position indicator (Z 37, 38; View V1) on the front bearing
pedestal.
Procedure :
Steam End :
♦ Clean valve seat (Part 10); coat mating surfaces with lubricants; install and secure valve seat.
♦ Install valve stem with valve cone (Part 30). Do not lubricate the valve stem for installation.
♦ Prepare valve cone for bluing imprint; run valve stem to “open” position.
♦ Install steam-end components in the body (without the steam strainer); hand-tighten nuts;
make bluing imprint.
♦ Remove nuts.
♦ Remove steam-end components with stem; evaluate bluing imprint; clean bluing ink from
valve cone and valve seat.
♦ Clean steam strainer and mount on steam end, thereby “threading in” the anti-rotation
device.
♦ Install steam end with steam strainer in the body and bolt down; the gland steam and leakage
oil bores must point downwards.
Oil End :
♦ Push piston plate (Part 12) onto valve stem and connect bolted joint.
♦ Install actuation piston (Part 14) in the body; coat sealing surfaces with sealant, and install
cover.
♦ Arrange oil end with opening showing upwards and install piston (Part 13).
♦ Check valve strokes (valve cone, pilot cone, piston.)
♦ Install spring with spring retaining plate; coat seal face with sealant; mount oil end on steam
end as per drawing and tighten nuts onto the spring-loaded tie rods.
♦ Apply uniform torque to the tie rod nuts in order to generate evenly distributed tension in the
springs; screw nuts onto the other bolts and tighten all nuts.
♦ Attach the valve-lift monitor.
♦ Bolt on and pin the drive rod (Chapter III 2.1.2, Part 19); adjust and secure set screw (Chapter III
2.1.2, Part 31) as specified in the setting sheet.
♦ Install compression springs (Chapter III 2.1.2, Part 36) with spring retaining plates; screw on nuts
(Chapter III 2.1.2, Part 40) and pre-stress the compression springs.
♦ Attach lever (Chapter III 2.1.2, Part 46).
♦ Remount control cylinder (Z 87).
♦ Install valve lift monitor (Z 80)
Procedure :
♦ Prepare lift-oil pumps ready for operation.
HP / LP Turbine
Procedure :
♦ Dismantle center top-half bearing pedestal (Z 15). Caution ! first remove the manual turning gear.
♦ Position the lifting fixture (Z 21).
♦ Connect LP and HP rotors with at least 4 coupling bolts (Z 72); pull coupling flange halves
together to within 3 mm; install all coupling bolts, thereby heeding the identification markings,
and hand-tighten the coupling nuts.
♦ Take load off of lifting fixture (Z 21)
♦ Remove support bearing shims, protect against corrosion and store.
♦ Remount center top-half bearing pedestal (Z 15) and bolt down tight.
♦ Check, evaluate and record alignment between HP and LP turbines (coupling inspection).
♦ Pull coupling flange together; tighten coupling bolts as specified; secure coupling nuts.
♦ Remove lifting fixture (Z 21), protect against corrosion and store.
♦ Measure, evaluate and record turbine runout (runout check).
♦ Check, evaluate and record the alignment between the main oil pump (Z 8) and the HP turbine (Z
8) (= coupling inspection).
♦ Assemble coupling sleeve (Z 10, Part 100).
♦ Check and record axial clearance of the coupling sleeve.
♦ Check and record radial clearance in the toothing.
HP Turbine :
♦ Dismantle front top-half bearing pedestal (Z 1).
♦ Check and record the alignment dimensions (Assembly data sheet, EI, EIII, EIV).
♦ Remove thrust bearing; check and record minimum axial movement of rotor; reinstall thrust
bearing, incl. thermocouples (Z 7).
♦ Measure and record dimension “L” (Assembly data sheet) on the front support bracket seats.
♦ Mount and bolt down front top-half bearing pedestal.
♦ Check and record the exact values at the front and rear bearing pedestals.
♦ Check and record the exact values at the outer casing circumferential profile measuring points.
♦ Dismantle front and center top-half bearing pedestals.
♦ Install bearing oil wiper rings (Z 2, 17, 24); check and record the radial and axial clearances (Z 37,
38, 39; Details H1. H3).
♦ Check and record the radial and axial clearances between the blade disk and bearing pedestal of the
hydraulic turning gear (Z 37, 38, 39; Detail L3).
♦ Mount and bolt down the front and center top-half bearing pedestals.
LP Turbine :
♦ Check and record the alignment dimensions (Assembly data sheet EI, EII).
♦ Check and record the exact values at the rear bearing pedestal (Z 22).
♦ Check and record the exact values at the outer casing circumferential profile measuring points.
♦ Install bearing oil wiper rings; check and record radial clearances (Z 58, 59, 60; Details H4, R4).
♦ Mount and bolt down rear top-half bearing pedestal.
Evaluation :
♦ Follower piston, sleeve, transducer, other parts.
♦ Clean all parts and protect against corrosion.
Disassemble EHC :
♦ Disconnect all electric leads (pull plugs).
♦ Dismantle piping.
Evaluation :
♦ Pilot valve, control sleeve, governor pedestal, power piston, piston rod seal, follower piston, other
parts.
Disassemble Operator :
♦ Remove feedback lever (Z 87, Parts 30, 32, 42).
♦ Remove servo valve cover.
♦ Remove pin, spring retaining plate, spring and thrust bearing.
♦ Extract pilot valve.
♦ Detach stem head piece (Z 87, Part 7) over the control cylinder (Z 87, Part 1).
♦ Open control cylinder and remove piston and piston rod.
Evaluation :
♦ Pilot valve, control sleeve, piston rod seal, other parts.
♦ Clean all parts and protect against corrosion.
Reassemble Operator :
♦ Install piston and piston rod.
♦ Close Control Cylinder.
♦ Check for free movement of piston.
♦ Reinstall stem head piece.
♦ Lubricate and install pilot valve and check for freedom of movement.
♦ Install thrust bearing, spring retaining plate and pin.
♦ Install and secure cover of servo valve.
♦ Install feedback lever.
Evaluation :
♦ Pilot valve, control sleeve, rotary piston, bearings, other parts.
♦ Clean all parts and protect against corrosion.
Evaluation :
♦ Valve disk, housing, bearing.
♦ Replace stem seal.
Evaluation :
♦ Follower piston, other parts.
♦ Clean all parts and protect against corrosion.
Evaluation :
♦ Seal plate, bearing, housing, other parts.
♦ Reassemble check valve, check for free movement of seal plate and shaft.
♦ Reassemble control cylinder and mount on check valve.
Evaluation :
♦ Seal plate, bearing, housing.
♦ Reassemble check valve; check for free movement of seal plate.
Evaluation :
♦ Valve, lever, other parts.
♦ Reinstall valve; check for free movement of valve and lever; reinstall emergency trip gear.
Evaluation :
♦ Slide valve, lever, diaphragms, other parts.
♦ Reassemble steam pressure monitor and check for free movement of slide valve, lever and bars.
♦ Check function of associated equipment while resetting the control set points.
♦ Cut in high-pressure pump no. 2 of the lift-oil system, thereby taking note of the
direction of rotation.
♦ Cut out high pressure pump no. 1.
♦ Heat the operating oil up to about 70OC (if possible), hold at that temperature for approximately 4
hours and allow to cool to about 30OC.
♦ Switch oil cooler and lube-oil filter over to the other chamber.
♦ The above procedure must be repeated a number of times.
♦ Oil flushing must be continued until no appreciable amount of soil collects in the strainers.
♦ Extract and clean the filter cartridges of the double oil filter (4510), lift-oil system (4730) and
fine-filtration system (4830).
♦ Drain remaining oil out of filter shell.
♦ Clean shell.
♦ Reinstall filter cartridges.
♦ Remove fine-mesh screens upstream of the bearing pedestals.
♦ Set lube-oil throttles to the values stated in the assembly data sheet and record the settings.
♦ Dismantle the special auxiliary line leading from the lube-oil/oil drain line and reconnect both lines
to the main oil pump (ready for operation).
♦ Remove front, center and rear top-half bearing pedestals and clean the interior of the pedestals.
♦ Remove bottom-half thrust and journal bearings, clean, protect against corrosion and reinstall.
♦ Install top-half thrust and journals bearings ready for operation.
♦ Reassemble lift-oil piping ready for operation.
♦ Tighten thermocouples ready for operation.
♦ Apply sealant to the mating surfaces of the top-half bearing pedestals and bolt down ready for
operation.
♦ Remove, clean and reinstall the oil tank inlet strainer (4310).