TDC TDC/02/202

TEIL DESIGN ENGINEERING INSTRUCTION SHEET 1 OF 13

BANGALORE
FORMAT AMENDMENT NO.: 0 DATE: 09.10.1996
SL NO. : DEI/0106/2009 RELATED PROCEDURE NO.: NIL

SUBJECT: MAINTENANCE OF CRITICAL COMPONENTS OF STEAM TURBINE

SUPERSEDES / SUPPLEMENTS:

I. Objective:

Objective of this document is to define the maintenance plan of Triveni Steam Turbines. This
document will outline inspection intervals and define the inspection methods for capturing the different
signs of aging, deterioration / damage, life consumption that the specific turbine component is
expected to show during the service life.

II. Maintenance Plan:

i. Complete monitoring of operating conditions.
ii. Determining the type of overhaul (planned shut-down / forced shut-down) based on severity
number / equivalent working hours.
iii. Customised training of process engineering.

III. Important Parameters to Monitor:

 Inlet Steam Parameters – Pressure, Temperature and Flow.

 Exhaust Steam Parameters – Pressure and Temperature.
 Operating Speed.
 Power.
 Wheelcase Pressure and Temperature.
 Casing Temperature at Top-half and Bottom-half.
 Bleed Steam Parameters – Pressure, Temperature and Flow.
 Extraction Steam Parameters – Pressure, Temperature and Flow.
 Shaft Vibration Response at Turbine DE and NDE, Gear-box and Alternator.
 Thrust Bearing Temperature.
 Governor signals.
 Lube oil – Pressure and Temperature.
 Hydraulic – Pressure and Temperature.
 Gland sealing – Pressure and Temperature.
 Steam Purity Levels.
 Number of Cold Starts.
 Number of Warm Starts.
 Number of Hot Starts.
 Number of Load changes - >30%.
 Number of Load changes – 10% - 30%.

ISSUED BY: RS APPROVED BY: PUG

DATE:
07.05.2009 07.05.2009

DISTRIBUTION TO: 1) TDC (MECH): 2) TDC (ELEC):

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The applicable parameters are to be logged and trend monitored wrt turbine frames
as per Table-1a, Table-2a, Table-3a, Table-4a and Table-5a.

Table-1a: Back Pressure Turbines – 0.5 MW to 10 MW

Parameters 525SS 525, FR2B, FR4H

14A, FR2,
14M, FR4.
14M3HB,
FR2S.
Inlet Steam Parameters Y Y Y Y
Exhaust Steam Y Y Y Y
Parameters
Operating Speed Y Y Y Y
Power Y Y Y Y
Wheelcase Pressure
and Temperature - - Y Y
Casing Temperature at
Top-half and Bottom- - - - -
half
Bleed Steam Y Y Y Y
Parameters
Extraction Steam
Parameters - - - -
Shaft Vibration Y Y Y Y
Response
Thrust Bearing Y Y Y Y
Temperature
Governor signals Y Y Y Y
Lube oil – Pressure and Y Y Y Y
Temperature
Hydraulic – Pressure Y Y Y Y
and Temperature
Gland sealing – Y Y Y Y
Pressure and
Temperature
Steam Purity Y Y Y Y
Table-1b: Turbine Frame and Operating Parameters – 0.5 MW to 10 MW

Turbine Frame Power Operating Parameters (Pressure /

Temperature / Speed)
525SS 1 MW 45 bar / 450 ˚C / 8250 RPM
525,
14A,
14M, 0.5 MW - 3 MW 45 bar / 450 ˚C / 8250 RPM
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14M3HB,
FR2S.
FR2B,
FR2, 4 MW -10 MW 65 bar / 490 ˚C / 8250 RPM
FR4.
FR 4H
4 MW -10 MW 85 bar / 515 ˚C / 8250 RPM

Table-2a: Back Pressure Turbines – 15 MW

Parameters FR1
Inlet Steam Parameters Y
Exhaust Steam Y
Parameters
Operating Speed Y
Power Y
Wheelcase Pressure Y
and Temperature
Casing Temperature at -
Top-half and Bottom-half
Bleed Steam Y
Parameters
Extraction Steam Y
Parameters
Shaft Vibration Y
Response
Thrust Bearing Y
Temperature
Governor signals Y
Lube oil – Pressure and Y
Temperature
Hydraulic – Pressure Y
and Temperature
Gland sealing – Y
Pressure and
Temperature
Steam Purity Y

Table-2b: Turbine Frame and Operating Parameters – 15 MW

Turbine Frame Power Operating Parameters (Pressure /

Temperature / Speed)
FR1 15 MW 65 bar / 500 ˚C / 7000 RPM
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Table-3a: Condensing Turbines – 1 MW to 8 MW

Parameters FR15,
FR13B,
FR13,
FR13E,
SCG1.
Inlet Steam Parameters Y
Exhaust Steam Y
Parameters
Operating Speed Y
Power Y
Wheelcase Pressure Y
and Temperature
Casing Temperature at -
Top-half and Bottom-half
Bleed Steam Y
Parameters
Extraction Steam Y
Parameters
Shaft Vibration Y
Response
Thrust Bearing Y
Temperature
Governor signals Y
Lube oil – Pressure and Y
Temperature
Hydraulic – Pressure Y
and Temperature
Gland sealing – Y
Pressure and
Temperature
Steam Purity Y

Table-3b: Turbine Frame and Operating Parameters – 1 MW to 8 MW

Turbine Frame Power Operating Parameters (Pressure

/ Temperature / Speed)
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FR15,
FR13B,
FR13, 1 MW – 8 MW 65 bar / 500 ˚C / 8250 RPM
FR13E,
SCG1.

Table-4a: Condensing Turbines – 15 MW to 18 MW

Parameters SCG3 ECD12

Inlet Steam Parameters Y Y
Exhaust Steam Y Y
Parameters
Operating Speed Y Y
Power Y Y
Wheelcase Pressure Y Y
and Temperature
Casing Temperature at
Top-half and Bottom-half - -
Bleed Steam Y Y
Parameters
Extraction Steam
Parameters - -
Shaft Vibration Y Y
Response
Thrust Bearing Y Y
Temperature
Governor signals Y Y
Lube oil – Pressure and Y Y
Temperature
Hydraulic – Pressure Y Y
and Temperature
Gland sealing – Y Y
Pressure and
Temperature
Steam Purity Y Y

Table-4b: Turbine Frame and Operating Parameters – 15 MW to 18 MW

Turbine Frame Power Operating Parameters (Pressure /

Temperature / Speed)
SCG3 18 MW 65 bar / 500 ˚C / 6850 RPM
ECD12 15 MW 65 bar / 500 ˚C / 8500 RPM
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Table-5a: Condensing Turbines – 20 MW to 30 MW

Parameters SCG3M1, HHECD13

SCG3M2,
HECD13,
HECD14.
Inlet Steam Parameters Y Y
Exhaust Steam Y Y
Parameters
Operating Speed Y Y
Power Y Y
Wheelcase Pressure Y Y
and Temperature
Casing Temperature at Y Y
Top-half and Bottom-half
Bleed Steam Y Y
Parameters
Extraction Steam Y Y
Parameters
Shaft Vibration Y Y
Response
Thrust Bearing Y Y
Temperature
Governor signals Y Y
Lube oil – Pressure and Y Y
Temperature
Hydraulic – Pressure Y Y
and Temperature
Gland sealing – Y Y
Pressure and
Temperature
Steam Purity Y Y

Table-5b: Turbine Frame and Operating Parameters – 20 MW to 30 MW

Turbine Frame Power Operating Parameters (Pressure /

Temperature / Speed)
SCG3M1, 15 MW 85 bar / 515 ˚C / 6850 RPM
SCG3M2, 20 MW 85 bar / 515 ˚C / 6000 RPM
HECD13, 24 MW 85 bar / 515 ˚C / 6850 RPM
HECD14. 30 MW 85 bar / 515 ˚C / 6225 RPM
HHECD13 30 MW 110 bar / 540 ˚C / 6850 RPM
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IV. Monitoring of Purity of Steam:

Triveni strongly recommends installing monitoring equipment at the inlet and exhaust
steam sides for continuous monitoring of the steam / water cycle by constantly
recording the electric conductivity at the local sampling point downstream of the
strongly acidic cation exchanger, and the determining of the silica content.

It is also recommended to check steam purity by at least once in 3 months.

It may be needed to check every week depending upon the variation in wheelcase
pressure.

Factors affecting Steam Purity:

 Steam chemistry.
 Leakage of condenser tubes.
 Condensation.
 Efficiency of separator.
 Leakages of DM water.
 Moisture.
 Water system efficiency.
 Boiler cleaning.
 Operating conditions.
 Makeup water quality.

Steam Purity Impacts:

 Damage of stationary and rotating components of steam turbine.

 Corrosion of steam handling equipment.
 Fouling of heat exchanger.
 Maintenance and repair of steam path includes blades, nozzles, diaphragms,
disks, rotor and seals.
 Increase in water levels.
 Problems related to separator.
 Load fluctuations.
 Variation in wheelcase pressure.
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Table-6: Steam Purity Limits during Start-up and Continuous Operation

Start-up Continuous Operation

Conductivity (Micromhos/cm at 25˚C)
Drum 1.00 0.30
Once through 0.50 0.20
SiO – ppb (max) 50.00 20.00
Fe – ppb (max) 50.00 20.00
Cu – ppb (max) 10.00 3.00
Na+K – ppb (max)
Up to 800 PSI 20.00 20.00
801 -1450 PSI 10.00 10.00
1451 – 2400 PSI 5.00 5.00
>2400 PSI 3.00 3.00

V. Monitoring of Water Induction:

The back flow of steam into the turbine or entering of cool water into the turbine can
cause severe damage to both rotating and stationary parts.

If entry of cool water or back flow of steam occurs during operation – it leads to
increase in vibration of rotor / blades, high bending loads and thermal stresses and
thereby failure of blades when it reaches peak vibration amplitudes limit.

If entry of cool water or back flow of steam occurs during start-up – it leads to
thermal shocks and thereby damage of blades and cause seal rubbing.

If entry of cool water or back flow of steam occurs during shut-down (after circuit
breaker opened) – it may leads to ovrespeed of the rotor and thereby damage of the
stationary and rotating components of turbine.

For detecting and prevention / reduction of Steam Back Flow and Induction of Cool
Water:

 Monitoring of Wheelcase temperature.

 Regular monitoring of Non-Return Valve fitted at bleed and extraction lines.
 Regular monitoring of Temperature of bleed and extraction lines – sudden
variation in temperature indicates the water induction or steam back flow.
 Feed water levels to desired set point / level.
 Continuous monitoring of temperature at top-half and bottom half of casing.
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VI. Overhauling / Maintenance Schedule based on Severity Number:

Table-7: FMEA based Severity Numbers for Turbine Components.

Component Potential Failure Mode Potential Effects of Failure Severity Number

Outer Casing / Scale formation Clogging of drain holes
Inner Casing Erosion High wear rate
Corrosion Wear of casing, 18
diaphragms, inner casing

Misalignment Higher Vibration

Erosion High vibration, Wear Rate,
Rotor Unbalance 12
Corrosion Wear
Fatigue Blade Fracture

Erosion Vibration, Fracture, Wear

Rate
Blades Crack Blade Breakage 18
Scale formation Drop in efficiency, Mass
flow drop, Higher Vibration

Bearings Fracture Bearing damage 16

Wear Higher Vibration

Seals Rubbing Higher Wear Rate

Erosion Performance degradation 8
Corrosion Performance degradation
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VII. Overhauling / Maintenance Schedule based on Equivalent Working Hours:

The data related to turbine start-up and loading conditions are useful to predict the
life of the turbine component subjected to Low Cycle Fatigue (LCF) and CREEP.

The start-up and loading data can be used to calculate Equivalent Working Hours
and thereby maintenance schedule.

The Equivalent Working Hours calculated using following equation,

𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐻𝑜𝑢𝑟𝑠 = 𝑊𝐴 + 12 × 𝑆𝐶𝑜𝑙𝑑 + 6 × 𝑆𝑊𝑎𝑟𝑚 + 3 × 𝑆𝐻𝑜𝑡 + 25 × 𝐿

Where,

𝑊𝐴 = Actual Working Hours

𝑆𝐶𝑜𝑙𝑑 = Number of Cold Starts
𝑆𝑊𝑎𝑟𝑚 = Number of Warm Starts
𝑆𝐻𝑜𝑡 = Number of Hot Starts
𝐿 = Number of Load Fluctuations

Example:

Equivalent Working Hours calculated as follows,

WA 24,000
SCold 12
SWarm 84
SHot 360
L 600

Equivalent Working Hours 41,556

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Table-8: Recommended Overhauling / Maintenance Schedule based on Equivalent

Working Hours.

Equivalent Working Hours Type of Maintenance

12,000 Inspection

24,000 Level-1 Maintenance

48,000 Level-2 Maintenance

72,000 Level-1 Maintenance

96,000 Level-2 Maintenance

1,20,000 Level-2 Maintenance

1.5 3 4.5 6 7.5 9 10.5 12 14 15

Yrs Yrs Yrs Yrs Yrs Yrs Yrs Yrs Yrs Yrs

Inspection Inspection Inspection Inspection Inspection

Level-1 Level-2 Level-1 Level-2 Level-2

Maintenance Maintenance Maintenance Maintenance Maintenance
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Level-1 Maintenance: A Level-1 Maintenance is performed as necessary during the

shut-down caused by other plant components or during a failure-induced or planned
shut-down of the unit.

Level-2 Maintenance: A Level-2 Maintenance is performed during a planned shut-

down of the steam turbine generator and allows through checking and a fact-finding
inspection of all components. The casings are opened.

VIII. Inspection and Maintenance Description:

The tasks involved during inspection and maintenance / overhaul are as follows,

 Inspection Tasks:
o Functioning of ESV, TV, and Control valves, Extraction, Bleed and
NRVs.
o Visual Inspection of seals, bearings and lube oil system, drain system.
o Electrical inspection of all instrumentation, protection and control
systems.
o Visual inspection of gearbox teeth and its seals and bearings.

 Level-1 Maintenance Tasks:

o Last stage blades inspection – using boroscope to inspect erosion,
damages.
o Journal and Thrust bearings – clearances, wear.
o Axial and Radial clearances between stationary and moving
components.
o Coupling inspection – bolts, alignment, clearances.
o Control system – calibration check.
o Inspection of lube and control oil pumps.
o Functioning of ESV, TV and Control Valves, Extraction, Bleed and
NRVs.

 Level-2 Maintenance Tasks:

o Turbine casing opening for inspection, checks and necessary tests.
o Analyse the scale formation.
o Grit blasting of stationary and rotating components of turbine (grit size
and material is based on MOC of component and severity of scale / pit
marks / damage).
o Moving and stationary blades check for any pit marks, rubbing, scaling
and erosion.
o Non Destructive Testing of turbine components based on the Triveni
expert decision (DP, UT in the selected areas).
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o Low speed or high speed balancing of rotor (if vibration is high).

o Sealing fins at balancing drum and steam path -check for rub and
bending.
o Checking of the flange parallelism of all turbine components.
o Finite Element Analysis and Non Destructive Test based Remaining
Life Assessment (RLA) and recommendations by Triveni based on
machine conditions.

IX. Predictive Maintenance Chart:

The component wise details of predictive maintenance are explained in Annexure-1

(Predictive Maintenance Chart_07052009_Rev0).