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S.

Rameshkumar

Mechanical Maintenance

Siemens, Wesel, Germany NG90/81/45-4IZ +WK80/90/0-3RHP Turb+SA21LP Turb


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TURBINE OVERHAULING
Scope of Work

INDEX
1.0 Work Related Documents :
1.1 1.2 List of drawings. Turbine Service Manual Siemens Ref : ESO/0689/86-05-13/KWU/la-mg.

2.0 3.0

Preparation for Inspection. Alignment Checks :


3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Open Bearing pedestal. Uncouple main oil pump. Uncouple Generator. Uncouple LP rotor. Check alignment between the Main Oil Pump and the HP Turbine. Check alignment between the HP Turbine and the LP Turbine. Check alignment between the Generator and the LP Turbine. Check internal alignment of the LP Turbine. Check internal alignment of the HP Turbine.

4.0

Disassembly :
4.1 4.2 4.3 4.4 HP Turbine. LP Turbine. Valve blocks. Lube oil system.

5.0 6.0

Non-Destructive Testing. Fact-Finding :


6.1 6.2 6.3 6.4 Components, Parts and Individual areas to be inspected. Component / Part findings checklist. List of Fact-Finding Tools, instruments and accessories. List of potential findings.

7.0

Reassembly :
7.1 7.2 7.3 7.4 7.5 LP Turbine. HP Turbine. Valve blocks. Alignment checks. Lube oil system.

8.0

Commissioning :

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2.0 PREPARATIONS FOR INSPECTION :


Evaluate latest operating records and related data. Check for availability of spare parts. Perform functional inspection of modular units. Perform leak checks in the form of visual and tactile inspections. Check shaft-line grounding. Check turbine-generator running behavior prior to shutdown; perform vibration measurements. Set up jobsite; ready all scaffolding, tools etc. Measure vacuum reduction rate. Shutdown the system. Cool turbine-generator via turning gear operation. Disconnect oil pumps, with the exception of the lift-oil pump. Remove turbine enclosure. Remove insulation. Remove vibration pickups. Protect ends of cables against damage.

General Recommendations :

Use only Silicon-free lubricants on the oil side. Observe all relevant accident prevention regulations. Observe all relevant fire prevention regulations. Exercise caution in the handling of cleaning agents and acids (Wear protective clothing). Observe manufacturers parts identification system at each step of assembly/disassembly. The following sealants are recommended : For the steam side : Birkosit. For the oil side : Hylomar. The followings lubricant is recommended : Gleitmo 160

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3.0 ALIGNMENT CHECKS : 3.1 Open Bearing Pedestal :


Procedure :

Record pedestal position indicator readings on the HP Turbine (Z 37, Z 38; View VI, Section U1U1) and LP Turbine (Z 58, Z 60; Detail V4). Record rotor position indicator readings on the LP turbine (Z 72; Part 3). Remove top of rear bearing pedestal (Z 22) Remove seal rings from the top and bottom halves of the bearing pedestal. Remove center top-half bearing pedestal (Z 15). Remove seal rings from the top and bottom halves of the bearing pedestal. Dismantle and store piping from the front top-half bearing pedestal. Remove front top-half bearing pedestal (Z 1). Remove seal rings from the top and bottom halves of the bearing pedestal. Remove top-half thrust bearing (Z 3). Remove thermocouples (Z 7) from the top and bottom halves. Check and record the rotor position in the bottom-half thrust bearing. Measure and record the alignment dimensions of the HP and LP turbines (cf. assembly data sheet). Remove bottom-half thrust bearing. Measure and record axial movement of the shaft line (cf. assembly data sheet). Reassemble bottom-half thrust bearing

3.2 Uncoupling Main Oil Pump :


Procedure :

Remove hall generators (Z 14) Remove enclosure (Z 10; part 60, 65) Check identification markings on the coupling parts (part 100) Remove centerpiece of sleeve. Remove circlip Pull both sleeve sections off of the hubs.

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Evaluation :

Teeth. Clean couplings parts, protect against corrosion and store.

3.3 Uncoupling Generator :


Procedure :

Check identification markings on the coupling flanges, bolts and nuts (Z 72.1) remove coupling nuts. Remove coupling bolts. Clean coupling nuts and bolts, protect against corrosion, and store. Turn jack screws in up to contact face. Continue turning the jack screws to push apart the coupling flange. Push the generator rotor up to stop in the positive direction.

3.4 Uncoupling L. P. rotor :


Procedure :

Position the lifting fixture (Z 21) Provide metal strips for the support bearing. Check the identification markings on the coupling flange, bolts and nuts (Z 72). Remove coupling nuts. Turn jack screws in up to the contact face. Continue turning jack screws to press the two halves of the coupling flange apart by 3mm. Hand-tighten the coupling nuts.

3.5 Check Alignment between the Main Oil Pump and the HP Turbine
Procedure :

Attach measuring instrument. Check and record the alignment between the pump shaft and the turbine rotor.

3.6 Check alignment between the HP Turbine and the LP Turbine Procedure :

Attach measuring instrument. Check and record the alignment between the HP rotor and the LP rotor.

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3.7 Check alignment between the Generator and the LP Turbine Procedure :

Attach measuring instrument. Check and record the alignment between the LP rotor and the Generator.

3.8 Check internal alignment of the LP Turbine Procedure :


Measure and record the exact values at the rear bearing pedestal measuring points (Z 22). Measure and record the exact values at the outer-casing circumferential profile measuring points. Check for full contact between the pedestal s upport brackets and the base plate (Z 85, 59, 60; Sections F2-F2, F4-F4). Remove coupling nuts (Z 72). Remove coupling bolts. Clean coupling nuts and bolts, protect against corrosion, and store. Use lifting fixture to support weight of rotor (Z 21). Press coupling flange apart by turning in the jack screws. Push rotor in the positive direction up to 1.0mm ahead of the stop. Install support bearing, take load off of and remove the lifting fixture. Mount rear top-half bearing pedestal.

3.9 Check internal alignment of HP Turbine Procedure :


Measure and record dimension L (assembly data sheet) on the front support bracket seats. Measure and record the exact values at the front and center bearing pedestal m easuring points (Z 71, 1, 15). Measure and record the exact values at the outer-casing circumferential profile measuring points. Check for full contact between the rear support brackets and the base plate (Z 37, 39; Section P3P3). Mount the center and front top-half bearing pedestals. Disconnect the lift-oil pumps.

4.0 DISASSEMBLY :

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4.1 HP Turbine

Open Outer Casing

Procedure :

Disconnect flange joints of upper steam inlet pipes; support weight of pipes as necessary. Dismantle the upper cross-around piping, incl. swing disk valves; plug openings, store piping, protect valves against corrosion and store. Remove and store wall temperature sensor (Z 36) Ream out (clean) taper-pin bores (Z 26, Part 14) Bring shoulder bolts into contact with the auxilia ry support brackets (Z 38, 30). Section P1-P1, Part

Remove spacer bolts, washers and disk springs from the front support bracket seat (Z 38, Section P1-P1, Parts 39-43). Insert one each additional washer between the spacer bolts and existing washers, and retighten the spacer bolts. Loosen joints bolts as per specification. Clean and screw in guide bolts. Clean jack screws; apply lubricant to the threads; screw in. Hitch up the top-half outer casing horizontally onto the proper lifting bosses. Turn in the jack screws to uniformly lift the top half outer casing by approx. 30 mm. Lift off top-half outer casing.

Evaluation :

Joint faces, guides, support brackets seat, spherical washers, L-rings. Protect top-half outer casing against corrosion and store. Protect spherical washers, spacer bolts, washers and disk springs (Z 38; Section P1-P1, Parts 3943) against corrosion and store. Remove upper spherical washers from the stationary blading carrier (Z 45; Section K1-K3, Part 7) and inner seal ring (Z 37; Section K-K, Part 287); protect against corrosion and store. Remove joint bolts from the bottom-half outer casing.

Open Stationary Blade Carrier

Procedure :

Sequence items 500, 525, 550 (Z 42).

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Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores. Clean jack screws, apply lubricant to threads; screw in Hitch up top-half stationary blade carrier, thereby maintaining a horizontal position. Turn in jack screws to lift top-half by about 30mm. Lift off stationary blade carrier.

Evaluation :

Joint face, blades, seal strips, spherical washers. Protect top-half stationary blade carrier against corrosion and store.

Open Inner Casing

Procedure :

Remove and store pressure-instrument lines (Z 40, Part 391). Remove spot welds from the joint nut bolts. Ream out (clean) taper-pin bores. Clean and thread-in the guide bolts. Unscrew joint bolts as specified. Clean jack screws; apply lubricant to threads; screw in. Hitch up top-half inner casing, thereby maintaining a horizontal position. Turn in jack screws to lift top half by about 30mm. Lift off top-half inner casing. Remove spot welds from the joint bolts of the gland busing (Z 30). Ream out (clean) taper-pin bores. Unscrew joint bolts as specified. Lift off top-half gland bushing.

Evaluation :

Joint faces, blades, seal strips, L-rings. Protect inner casing against corrosion and store.

Open Inner Gland Bushing :

Procedure :

Remove spot welds from the joint bolt nuts. Ream out (clean) taper pin bores.

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Unscrew joint bolts. Lift off top-half gland bushing.

Evaluation :

Joint face, seal strips. Protect top-half gland bushing against corrosion and store.

Open and remove Outer Gland Bushing :

Procedure :

Remove spot welds from the joint bolt nuts. Dismantle gland steam line. Unscrew joint bolts. Lift off top-half gland bushing. Swing out and lift off bottom-half gland bushing.

Evaluation :

Joint face, seal strips. Protect gland bushings against corrosion and store.

Dismantle Main Oil Pump and Speed Transducer

Procedure :

Detach oil lines from the main oil pump (Z 8) Remove taper pins and bolts (Z 38, Section Y1-Y1). Lift off main oil pump; remove spherical washers. Dismantle main oil pump.

Evaluation :

Impeller, shaft, bearing, spherical washers. Clean all parts, protect against corrosion and store. Pull off turbine-end coupling hub (Z 10, Part 100). Dismantle speed transducer (Z9, 10, 11)

Evaluation :

Coupling, governor impeller, auxiliary parts. Clean all parts, protect against corrosion and store.

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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.

Remove Bottom-Half Inner Casing

Procedure :

Remove thermocouples to facilitate extraction of the inner casing (Z 40). Suspend bottom-half inner casing horizontally and lift off.

Evaluation :

Joint face, blades, seal strips, L-rings, guides. Protect bottom-half inner casing against corrosion and store. Remove and store bottom-half gland bushing (Z 30).

Remove Bottom-Half Stationary Blade Carrier

Procedure :

Sequence : items 550, 525, 500 (Z 42). Suspend bottom-half stationary blade carrier in horizontal position and lift off.

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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 store. K1-K3, Part 7), protect against corrosion and

Remove Bottom-Half Inner Gland Bushing

Procedure :

Suspend bottom-half gland bushing in horizontal position and lift off.

Evaluation :

Joint face, seal strips, spherical washers, guides. Protect bottom-half gland bushing against corrosion and store. Remove lower spherical washers (Z 37, Secti on K-K, Part 287), protect against corrosion and store.

Remove Front Bearing Pedestal

Procedure :

Dismantle piping and store. Remove spot welds from the guides (Z 38, Detail T1 and Section M1-M1). Unscrew axial guide nuts (Z 38, Detail T1); turn stud bolts (Part 60) from protect stud bolts and nuts against corrosion and store. the outer casing;

Remove lock bolts and washers from the axial gui de (Z 38, Section M1-M1), unscrew calottes (Part 22) and remove spherical washers. Unscrew spacer bolts (Z 37, 38; Section 01-01, Part 16), remove brackets (Part 15). Suspend bearing pedestal in horizontal position and lift off.

Evaluation :

Slide surfaces, spherical washers. Protect bearing pedestal against corrosion and store. Protect hardware against corrosion and store.

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Remove Center Bearing Pedestal

Procedure :

Dismantle and store piping. Remove spot welds from the axial guide (Z 37, 39; Section M3-M3). Remove lock bolts and washers, unscrews calottes (Part 122) and extract spherical washers). Remove screw lock device (Z 37, 39; Section 03-03, Part 115) and loosen bolts (Part 116) Suspend bearing pedestal in horizontal position and lift off.

Evaluation :

Slide surfaces, spherical washers. Protect bearing pedestal against corrosion and store. Protect hardware against corrosion and store.

Remove Axial Casing Guides :

Procedure :

Remove spot welds from the guides Z 37, 38, 39; Sections W1-W1 and W3-W3). Remove lock bolts and washers; unscrew calottes; extract spherical washers.

Evaluation :

Slide surfaces, spherical washers. Protect hardware against corrosion and store.

4.2 L. P. Turbine
Open Outer Casing

Procedure :

Dismantle protective liners and rupture disks (Z 57) Ream out (clean) taper-pin bores (Z 50, Sections L-L and M-M) Put one each additional washer between the spacer Unscrew joint bolts. bolts and existing washers (Z 58, 59, 60); Sections F2-F2 and F4-F4) and tighten the spacer bolts.

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Clean and thread-in the assembly guides. Clean the jack screws; apply lubricant to threads; turn in jack screws. Suspend top-half outer casing horizontally from the intended lifting bosses. Turn in the jack screws to uniformly lift the top-half outer casing by about 30mm Lift off top-half outer casing.

Evaluation :

Joint face, guides, spherical washers, L-rings. Protect top-half outer casing from corrosion and store. Remove upper spherical washers from the stationary blade carrier (Z 58, 59, 60) and inner casing (Z 58, Section A-A), protect against corrosion and store. Remove joint bolts from the bottom-half outer casing.

Open Stationary Blade Carrier

Procedure :

Sequence : arbitrary. Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores. Clean and thread-in the guide bolts. Remove joint bolts. Clean jack screws; apply lubricant to threads; screw in. Suspend top-half stationary blade carrier in a horizontal position. Turn in jack screws to lift top half by about 30 mm. Lift off top-half stationary blade carrier.

Evaluation :

Joint face, blades, seal strips, spherical washers. Protect top-half stationary blade carrier against corrosion and store.

Open Inner Casing :

Procedure :

Dismantle and store the pressure-instrument lines (Z 58, Part 391) Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores.

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Clean and thread-in guide bolts. Remove joint bolts. Clean jack screws; apply lubricant to the threads; screw in. Suspend top-half inner casing in a horizontal position. Turn in jack screws to lift the top-half by about 30 mm Lift off top-half inner casing.

Evaluation :

Joint face, blades, seal strips, L-rings. Protect top-half inner casing against corrosion and store.

Open and remove Gland Bushings :

Procedure :

Remove spot welds from the joint bolt nuts. Dismantle gland-steam line. Unscrew joint bolts. Lift off top-half gland bushing. Swing out and lift off bottom-half gland bushing.

Evaluation :

Joint faces, seal strips. Protect gland bushings against corrosion and store.

Remove 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.

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Remove bottom-half journal bearing, including thermocouples (Z 7).

Evaluation :

Journal bearing. Protect journal bearing against corrosion and stores.

Remove Bottom Half Inner Casing

Procedure :

Suspend bottom-half inner casing in horizontal position and lift-off. Joint faces, blades, seal strips, spherical washers, L-rings, guides. Protect bottom-half inner casing against corrosion and store. Remove lower spherical washers (Z 58, Section A-A), protect against corrosion and store.

Evaluation :

Remove Bottom-Half Stationary Blade Carrier

Procedure :

Sequence : arbitrary. Suspend bottom-half stationary blade carrier in a horizontal position and lift-off.

Evaluation :

Joint faces, blades, seal strips, spherical washers, guides. Protect bottom-half stationary blade carrier against corrosion and store. Remove lower spherical washers (Z 58, 59, 60), protect against corrosion and store.

4.3 Valve Blocks :


Dismantle Emergency Stop Valves

Procedure : Oil side :


Remove lift indicator Remove and store ESV piping. Unscrew nuts of the bolts connecting the oil side and steam side; uniform ly loosen the tension-rod nuts, thereby relaxing the springs.

Remove oil-side assembly (Z 78, Part 2), in cl. spring and spring retaining plate; rem ove spring retaining plate, springs and piston (Part 13).

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Unscrew stem connection, remove piston plate (Part 12). Remove cover and extract actuation piston (Part 14).

Evaluation :

All dismantled parts, body. Clean all parts and protect against corrosion.

Steam Side :

Unscrew nuts on the mating flange and remove valve (Part 1) Remove valve seat (Part 10). Remove valve stem (Part 30) and valve cone (Part 11).

Evaluation :

All dismantled parts, body. Clean all parts and protect against corrosion.

Dismantle Control Valve

Procedure :

Check identification markings on all parts. Remove valve-lift monitor (Z 80). Remove and store complete control cylinder (Z 87). Remove lever (Part 46). Relax compression springs (Part 36) by unscrewing the top nuts (Part 40). Remove compression springs and the top and bottom springs retaining plates. Remove the taper pins (Part 19) and extract the drive rod. Remove stud bolt (Part 59); turn out set screws (Parts 31, 32, 33). Remove radiation shield. Unscrew nuts on valve cover; remove valve cover, incl. valve stem. Remove valve cone.

Evaluation :

All dismantled parts, valve block, valve seats. Clean all parts and protect against corrosion.

4.4 Lube Oil System :


Check Lube Oil System
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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 sy stem (4730) and finefiltration system (4830).

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Drain rest of oil out of filter shell; clean shell. Reinstall filter cartridges. Detach and dismantle oil pumps from the fine-filtration system (4810, 4812).

Evaluation :

Impellers, bearings, seal faces, couplings, electric motors. Reassemble and reinstall oil pumps.

Procedure :

Fill with clean operating oil.

5.0 NON-DESTRUCTIVE TESTING 5.1 Non-Destructive Inspection :


Test Procedure VT MT PT UT Test Result

S# 1. 2. 3. 4. HP-Rotor LP-Rotor

Object

Material 28CrMoNiV49 26NiCrMoV85 X20Cr13 ST52-3N / Tegostar 738

Remarks

LP-Rotor blades stage 5 +6 left and right Thrust / journal bearing

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Page 18 of 75 5. 6. 7. 8. 9. 10. 11. HP-outer casing-upper part Valve block casing B HP Joint flange bolts HP-inner casing HP piping 4 diffuser studs Main steam inlet GS-17CrMo55 GS-17CrMoV511 21CrMoV57 / 24CrMo5 GS-17CrMoV511 GS-17CrMoV511 /14MoV63 St52.3 N GS-17CrMoV511


with Baroscopic

VT-Visual Testing, MT-Magnetic Testing, PT-Penetrate Testing, UT-Ultrasonic Testing

5.2 Replica Tests :


S# 1. 2. 3. 4. 5. 6. 7. 8. 9. Part HP Piping Main steam inlet / elbow Elbow outer fiber Elbow inner fiber HP Piping, main steam inlet / elbow HP Piping Elbow / pipe Elbow outer fiber Elbow inner fiber HP piping main steam flange / elbow HP piping main steam inlet / pipe Material 14MoV63 / GS-17CrMoV511 14MoV63 14MoV63 GS-17CrMoV511 GS-17CrMoV511 / 14MoV63 GS-17CrMoV511 GS-17CrMoV511 14MoV63 / GS-17CrMoV511 GS-17CrMoV511 / 14MoV63 Position Remarks Weld seam

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Page 19 of 75 10. 11. 12. 13. 14. 15. 16. HP pipe, elbow / pipe Elbow inner fiber Elbow outer fiber HP Piping Pipe / Elbow Valve Block B HP Stop Valve / pipe Valve block B HP Stop valve / Control valve Valve Block B Control Valve GS-17CrMoV511 / 14MoV63 GS-17CrMoV511 GS-17CrMoV511 14MoV63 / GS-17CrMoV511 GS-17CrMoV511 / 14MoV63 GS-17CrMoV511 GS-17CrMoV511

5.3 Surface Cracks Tests :


S# Method MPT DPT

Part Journal Bearing / thrust bearing LP Rotor H. P. Rotor HP Inner Casing Upper and Lower Part HP Piping HP Joint flange bolts HP Outer Casing Upper part Valve Casing Block B Diffuser Studs

Material ST52-3N/ TEGOSTAR 738 26NiCrMoV85 28CrMoNiV49 GS-17CrMoV511 14MoV63 / GS-17CrMo511 24CrMo5 / 21CrMoV57 GS-17CrMo55 GS-17CrMoV511 ST52.3N

Remarks White Metal All transition radius including A-Wheel. Blades : Stage 5 & 6 left and right All transition radius including A-Wheel

1. 2. 3. 4. 5. 6. 7. 8. 9.

Complete Weld seams & elbows All Cross section crossings at inner surface. Cross Section Crossing Outside All

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5.4 Elbows wall thickness measurement :


90
o

STEEL ELBOWS (14MoV63)

Thickness as per drawing 8.8 mm Elbow nos. 5, 6, 11 at position 0O, 45 O, 90 O 0


o

45

INNER FIBER, OUTER FIBER, NEUTRAL FIBER.

CAST STEEL ELBOWS (GS-17CrMoV511)

Thickness as per drawing 27 mm Elbow nos. : 1, 2, 3, 4, 7, 8, 9, 10, 12, 13, 14, 15 at positions 0O, 45 O, 90 O Inner fiber, outer fiber, neutral fiber.

5.5 Boroscopy of Steam Inlet Pipes and emergency stop valves and control valves internal area. 5.6 Wall Thickness Measurement :

6.0 FACT FINDING : 6.1 Components, Parts and Individual areas to be inspected :
6.1.1 HP Turbine

The following individual parts and areas require inspection :


6.1.1.1 Rotor

A-Wheel blading.

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Moving blades of the first and second expansion lines. Seal strips : shaft, balancing piston, moving blades. Bearing journals, front and rear. Rotor face in the vicinity of bearing oil wiper rings, blading and admission. Coupling half section, generator end. Vicinity of mechanical and hydraulic shaft turning gear. Overspeed trip bolt.

6.1.1.2

Inner Casing : 6.1.1.2.1 Inner Casing, Top Section : FROM OUTSIDE :


L-Ring grooves, main steam and overload. Nut support face. Cast casing.

FROM WITHIN :

Steam admission channels, m ain steam plus overload, upto stationary blading. Nozzle blades. Stationary blades. Seal strips between stationary blades. Casing face between stationary blades. Joint face. Seal strips of gland bushing (Diaphragm / labyrinth seal).

6.1.1.2.2

Inner Casing, Bottom Section : FROM OUTSIDE :


L-Ring grooves, main steam plus overload. Nut support face. Parts comprising lateral palm support and lower axial guide. Cast casing.

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FROM WITHIN :

Steam admission channels, m ain steam plus overload, upto stationary blading. Nozzle blades. Seal strips between stationary blades. Casing face between stationary blades. Joint face. Seal strips of gland busing (diaphragm, labyrinth seal).

6.1.1.3

Stationary Blade Carrier-I : 6.1.1.3.1 Stationary Blade Carrier-I - Top Section : FROM OUTSIDE :

Guide groove. Cast casing. Nut support face.

FROM WITHIN :

Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

6.1.1.3.2

Stationary Blade Carrier-I - Bottom Section : FROM OUTSIDE :


Guide groove. Cast casing. Nut support face.

FROM WITHIN :

Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

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6.1.1.4

Stationary Blade Carrier-II : 6.1.1.4.1 Stationary Blade Carrier-II - Top Section : FROM OUTSIDE :

Guide groove. Cast casing. Nut support face.

FROM WITHIN :

Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

6.1.1.4.2

Stationary Blade Carrier-II - Bottom Section : FROM OUTSIDE :


Guide groove. Cast casing.

Nut support face. FROM WITHIN : Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

6.1.1.5

Stationary Blade Carrier-III : 6.1.1.5.1 Stationary Blade Carrier-III - Top Section : FROM OUTSIDE :

Guide groove. Cast casing. Nut support face.

FROM WITHIN :

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Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

6.1.1.5.2

Stationary Blade Carrier-III - Bottom Section : FROM OUTSIDE :


Guide groove. Cast casing. Nut support face.

FROM WITHIN :

Joint face. Stationary blades. Seal strips. Casing face between stationary blades.

6.1.1.6

HP Outer Casing : 6.1.1.6.1 HP Outer Casing - Top Section : FROM OUTSIDE :

Nut support face.

FROM WITHIN :

L-ring grooves, main steam plus overload. Joint face. Guide faces for stationary balancing piston. blade carriers, I, II and III, plus

Seal strips; shaft, front; balancing piston; shaft, read.

6.1.1.6.2

HP Outer Casing Bottom Section :


Joint face. Seal strips : shaft, front balancing piston, rear. Eccentric bushings, anti-rotation pin, seal covers for balancing piston, inner casing, stationary blade carriers I, II, III.

6.1.2

LP Turbine

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The following individual parts and areas require inspection :


6.1.2.1 Rotor

Moving blades. Seal strips between the blade rows and around the shaft seals. Balancing weights. Rotor face (in the steam section and in the area of the bearing oil wiper rings). Bearing journals. TE and GE coupling half sections. Couplings bolts and nuts.

6.1.2.2

LP Inner Casing : 6.1.2.2.1 LP Inner Casing - Top Section : FROM OUTSIDE :


Nut support face. Casing finish.

FROM WITHIN :

Joint face. Casing finish. Stationary blades. Seal strips.

6.1.2.2.2

LP Inner Casing - Bottom Section :


Joint face. Stationary blades. Seal strips. Casing finish. Lateral and axial guide.

6.1.2.3

LP Stationary Blade Carrier : 6.1.2.3.1 LP Stationary Blade Carrier - Top Section :

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FROM OUTSIDE :

Guide faces, front / rear. Casing finish.

FROM WITHIN :

Stationary blades. Casing finish up to diffuser outlet.

6.1.2.3.2

LP Stationary Blade Carrier - Bottom Section : FROM OUTSIDE :


Guide faces, front / rear. Casing finish.

FROM WITHIN :

Stationary blades. Casing finish up to diffuser outlet. Lateral support and axial guide.

6.1.2.4

LP Outer Casing 6.1.2.4.1 LP Outer Casing - Top Section :


Flange connection, admission. Rupture disk. Interior finish. Guide faces for stationary blade carrier. Seal strips, front and rear shaft seals. Casing finish between shaft seal strips.

6.1.2.4.2

LP Outer Casing - Bottom Section :


Flange connection, admission. Rupture disk. Interior finish. Guide faces for stationary blade carrier. Seal strips, front and rear shaft seals. Casing finish between shaft seal strips.

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Eccentric bushings and anti-rotation pin of the axial guide for the inner casing and stationary blade carrier.

6.1.3

Journal and Thrust Bearings

The following components, parts and individual areas must be inspected :


6.1.3.1 HP Journal Bearing 6.1.3.1.1 HP Journal Bearing Top-half Shell ;

Babbitt lining.

6.1.3.1.2

Spherical area of bearing shell. HP Journal Bearing Bottom-half Shell ; Babbitt lining. Spherical area of bearing shell.

6.1.3.2

LP Journal Bearing 6.1.3.2.1 LP Journal Bearing Top-half Shell ;


Babbitt lining. Spherical area of bearing shell.

6.1.3.2.2

LP Journal Bearing Bottom-half Shell ;


Babbitt lining. Spherical area of bearing shell.

6.1.3.3

Thrust Bearing 6.1.3.3.1 Thrust Bearing Top-half Shell ;


Babbitt lining of thrust bearing segments. Bearing body of top-half shell.

6.1.3.3.2

Thrust Bearing Bottom-half Shell ;


Babbitt lining of thrust bearing segments. Bearing body of top-half shell.

6.1.4

Bearing Pedestal

The following components, parts and individual areas must be inspected :


6.1.4.1 Front HP Bearing Pedestal 6.1.4.1.1 Front HP Top-half Bearing Pedestal

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Bearing oil wiper ring seal strips. Joint plane of top-half bearing pedestal.

6.1.4.1.2

Inside surface of top-half bearing pedestal. Front HP Bottom-half Bearing Pedestal Bearing oil wiper ring seal strips. Joint plane of bottom-half bearing pedestal. Inside surface of bottom-half bearing pedestal.

6.1.4.2

Rear HP Bearing Pedestal 6.1.4.2.1 Rear HP Top-half Bearing Pedestal


Bearing oil wiper ring seal strips. Joint plane of top-half bearing pedestal.

6.1.4.2.2

Inside surface of top-half bearing pedestal. Rear HP Bottom-half Bearing Pedestal Bearing oil wiper ring seal strips. Joint plane of bottom-half bearing pedestal. Inside surface of bottom-half bearing pedestal.

6.1.4.3

Rear LP Bearing Pedestal 6.1.4.3.1 Rear LP Top-half Bearing Pedestal


Bearing oil wiper ring seal strips. Joint plane of top-half bearing pedestal. Inside surface of top-half bearing pedestal.

6.1.4.3.2

Rear LP Bottom-half Bearing Pedestal


Bearing oil wiper ring seal strips. Joint plane of bottom-half bearing pedestal. Inside surface of bottom-half bearing pedestal.

6.1.5

Valve Blocks

The following components, parts and individual areas must be inspected :


6.1.5.1 Emergency Stop Valve 6.1.5.1.1 Emergency Stop Valves, Steam-side Insert

Valve stem. Valve cone.

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Valve stem bushing.

6.1.5.2.1

Valve cone bushing. Emergency Stop Valves, Drive-end Piston rod. Piston plate. Piston. Spiral springs. Piston rod guide sleeve.

6.1.5.2.3

Steam Strainers

Steam strainer coiling strip. Steam strainer basket. Steam strainer body.

6.1.5.2

Control Valve 6.1.5.2.1 Control Valves, Steam-side Insert


Valve stem. Valve cone. Valve stem bushing. Valve cone bushing.

6.1.5.2.2

Control Valves, Drive end


Bars. Compression springs. Leverbar mount. Parts of control cylinder.

6.1.5.2.3

Valve Block Body


Valve seats emergency stop and control valve Inside face of valve block. Stud bolts on valve block.

6.2

Component / Part Findings Checklist :

Blading :

A-Wheel / C-Wheel blades. Stationary / moving blades.

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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 ?

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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 stationary blades. Seal strip fracture ? Deformation ? Radial rubbing ? Axial rubbing ? Burring due to rubbing ? Unacceptable abrasion ? Scale formation ? Seal-strip elasticity?

between stationary blades, In rotor between

Bearing Journal :

Scoring ?

Thrust-bearing gland housings :


Scoring ? Parallelism ?

Rotor Faces:

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Incipient cracking ? Scoring ? Deposits ? Corrosion ?

Coupling half section : (Face area centering coupling bolt bore)


Frictional oxidation ? Scoring ?

L-Ring Grooves :

Scoring ? Scale formation ? Deformation ?

Nut Support Face :

Scoring ?

Cast Casing :

Incipient cracking ? Deposits ? Pitting or crevice corrosion ? Erosion corrosion ?

Nozzle Blades :

Solid-particle erosion ? Foreign-object damage ? Deposits ? Nozzle-blade fit ?

Joint faces :

Leak-tightness ? Deformation ? Damage ?

Design features Thermo-elastic Casing Guidance

Functionability impaired ?

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Deposits ? Scoring ? Abrasion ? Seat mobility ? Deformation ? Incipient cracking ? Fractures ? Leak-tightness ?

Coupling bolt :

Scoring ? Frictional oxidation ?

Balancing weights :

Fit in mounting groove ? Droplet-impact erosion ?

Flanged connections :

Functionability impaired ? Deformation ? Leak-tightness ? Damage ?

Rupture disk :

Damage ?

Bolts :

Fractures ? Incipient cracking ? Relaxation ?

Babbitt lining :

Visual damage to surface ? Damage to babbit lining determ ined via surf ace crack exam ination according to the liquidpenetrant method ?

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Unacceptable large areas without adequate bond between the lining and the bearing body determined via ultrasonic testing ? Functionability impaired due to : Unacceptable bearing contact angle ? Unacceptable lateral or top clearance ?

Bearing shell :

Quality of finish ?

Pedestal faces :

Corrosion ? Damaged ?

Valve stem :

Quality of finish ? Damage ? Functionability impaired ?

Guide sleeves / bushings :


Quality of guide bore finish ? Damage ? Functionability impaired ?

Piston rod :

Quality of finish ? Damage ? Functionability impaired ?

Piston :

Quality of finish ? Damage ? Functionability impaired ?

Spiral springs :
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Quality of finish ? Damage ? Functionability impaired ?

Steam strainer coiling strip :


Damage ? Foreign objects ?

Steam strainer basket :

Damage ?

Steam strainer body :


Damage ? Steam strainer support ?

Bars :

Functionability impaired ?

Leverbar mount :

Functionability impaired ?

Control cylinder assembly :

Functionability impaired ?

Valve seat ?

Quality of finish ? Damage ? Functionability impaired ?

6.3

List of Fact-finding tools, instruments and accessories : How-to Guide for inspection, measuring, testing.

How to inspect ?
Visual Inspection : Typical accessories :

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Flashlight (halogen lamp). Photoflood. Magnifying glass (5 10 x) Mirrors (with and without illumination). Endoscope (rigid or flexible).

Visual / Manual Inspection : Typical accessories :


Hand-hammer (200 300 gr) Screwdrivers (approx. 300mm long)

How to Measure ?
Manual measuring : Typical accessories (measuring tools) :

Tape measure (fabric or metal). Vernier and / or dial calipers. Feeler gages. Micrometers. Micrometer calipers. Depth gages. RC generators.

How to Test ?
Manual testing :

Liquid Penetrant Test. Magnetic Particle Test. Ultrasonic Examination. Electric Crack-Depth Measurements. X-Ray Examination. Typical accessories (test instruments / agents) :

Cleaning agents. Liquid penetrant.

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Developer. UV lamp. Yoke Magnet. Coil Magnet (fluorescent or black magnetic powder carrier fluid). Pulse-echo test instruments (transducers / sensors of various size). Potential Probe.

6.4

List of Potential Findings : Blades


Blades Tips

In order. Radial rubbing. Radial rubbing, scoring. Axial rubbing. Axial rubbing, scoring. Radial rubbing, scoring and measurable gap. Crevice corrosion. Fused-on foreign particles under shrouding. Broken rivet head. Broken rivet shank. Broken vane. Cracked vane. Axial rubbing on : Leading edge. Trailing edge Roughened Dented Notched Torn leading edge. trailing edge convex side. concave side convex side, concave side. thin, thick.

Vane

Foreign object damage :

Coatings (scale, deposit) : where ? extent ?

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color ? adhesion ? chem.. analysis-

rusty brown, grayish white. adherent, easily, removable, water soluble. completed ? by whom ? corrosive constituents ?

Pitting : On the convex side. On the concave side. Leading edge, convex side. Leading edge, concave side. Trailing edge.

Solid particle erosion :

Blade Root

Ring test in order (pure, clear sound). Ring test indicating loose fit (clanking sound). Measurable gap formation between 2 blades. Locking / end blade risen more than permissible (0.3 mm). Broken blade root. Cracked blade root.

Seal Strips

Broken off around the entire circum ference above caulking groove; broken out in part (%). Note : Rectangular fractures indicate stress corrosion. Curved fractures indicate vibration as the cause of cracking.

Bent due to foreign-object impact. Wavy deformation (rippling) due to radial rubbing Bent forward due to axial rubbing. Bent backward due to axial rubbing. Unacceptable abrasion due to radial rubbing. Perceptible burring. Residual strip height (measured). Scale formation : in which area.?. Scaly strips susceptible to brutal fracture. Elastic seal strips.

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Bearing Journals

In order. Shallow scoring. Random scoring along the journal length. Scoring at the journal ends. Individual gouges (depth ?).

Thrust Bearing Collar


In order Shallow scoring, randomly distributed around annulus. Pronounced scoring on the collar side accom modating residual axial thrust in positive direction (in negative direction). Deep individual gouges in the positive collar (in the negative collar). Thrust bearing collars located in parallel. Collar faces located in a conical attitude to each other (m echanical repair work necessary).

Rotor Faces

In order. Scaled. Corroded. Eroded. Covered with deposits. Rub marks. Striated. Cracked (crack depth ?)

Coupling Half Section


In order Frictional oxidation. Fretting corrosion. Scoring.

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Concave deformation of face area. Anti-rotation pins sheared off.

L-ring Grooves

In order. Scaled. Oval deformation. Scoring.

Nut Support Faces


In order. Deep galling.

Cast Casing

In order. Torn. Covered with deposits. Corroded. Eroded. Corrosion-erosion attach. Washed-out casting pores. Washed-out casting cavities. Oval deformation.

Nozzle Blades

In order. Solid particle erosion. Scaling. Foreign particle hammering. Torn seal welds. Loose nozzle-blade seat.

Joint Faces

In order. Scaling. Signs of steam leakage without material erosion.

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Signs of steam leakage with material erosion. Deformation.

Structural Elements : Thermo-elastic Housing Guide


In order. Unimpeded movement. Binding movement. Seized. Scaled. Torn. Deformed. Hammered. Fretting corrosion. Striated. Abrasion.

Coupling Bolt

In order. Fretting corrosion. Scored from dismantling. Unacceptable stretch.

Balancing Weights

In order. Droplet-impact erosion. Loose fit in mounting groove.

Flanged Connections

In order. Concave deformation of face area. Leaky. Steam erosion marks without material abrasion. Steam erosion marks with material abrasion. Torn. Contact face for seal grooved indented.

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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.

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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.

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Anti-rotation device worn.

Guide Sleeves / Bushings


In order. Scored. Beaten out on one side. Back seal indented. Back seal blown out. Clearance too large or too small.

Piston Rod

In order. Scored. Bent. Torn.

Piston Plate

In order. Damaged seal face. Torn seal face. Corroded. In order. Damaged seal face. Corroded.

Piston

Spiral Springs

In order Corroded. Broken.

Steam Strainer Coiling Strip

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In order. Torn Noticed Round foreign objects stuck in coiling strip. Signs of hammering. Broken out.

Steam Strainer Basket


In order. Torn Bent guide pins.

Steam Strainer Body


In order. Damaged.

Bars

In order. Bent.

Lever mount

In order. Mount beater out.

Control Cylinder Assembly

In order

Valve seat

In order. Cracked. Broken. Indented by foreign objects. Blown out. Torn weld.

7.0 RE-ASSEMBLY : 7.1 L. P. Turbine :


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Prepare Bottom-Half Outer Casing for Reassembly Procedure :


Remove fitted parallel keys from the front and rear axial casing guides (Z58, 59, 60; Detail Z2, Z4) Inspect fitted parallel keys and contact faces. Coat fitted parallel keys with lubricant and install. Check and record clearances (Z 58, 59, 60; Details Z2, Z4, Section G-G)

Prepare Rear Bearing Pedestal for Reassembly Procedure :

Install bottom-half bearing; protect journal surface areas.

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.

Replace Top-Half Outer Casing Procedure :

Suspend top-half outer casing in a horizontal slightly.

position from the intended lifting bosses and raise

Clean top-half outer casing and protect against corrosion. Install guide bolt in the bottom-half outer casing. Degrease top-half in the bottom-half outer casing. Apply uniform layer of bluing ink to the joint face of the top-half outer casing. Install top-half outer casing on bottom-half outer casing and tighten several joint bolts.

Align Bearing Pedestal and Outer Casing Procedure :

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Unscrew spacer bolts (Z 58, 59, 60; Section casing.

F2-F2, F4-F4) on the bottom -half outer

Check for full contact between the support brackets and the base plates (Z 58, 59, 60; Section F2-F2, F4-F4). Check for full contact between the bearing pede stal and the base plate (Z 58, 60; Section N4-N4). Check alignm ent dim ensions (Assem bly data sheet EI, EII) or ascertain via rotor displacement and record values. Measure and record the exact values at the outer-casing circumferential profile measuring points. Measure and record the exact values at the rear bearing pedestal measuring points. Record measured values and correct as necessary by way of rotor displacement. Tighten spacer bolts (Z 58, 59, 69, Section F2-F2, F4-F4)

Remove Top-Half Outer Casing Procedure :


Unscrew joint bolts. Remove and store top-half outer casing. Evaluate bluing imprint.

Install Outer Gland Bushing for clearance Check Procedure :

Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. Clean front and rear gland bushings and protect against corrosion. Apply lubricant to guides. Swing in front and rear bottom-half gland bushings. Measure, evaluate and record the horizontal a bushings and the rotor. nd vertical radial clearances between the gland

Measure, evaluate and record axial movement of rotor in the rear gland bushing. Remove and store front bottom-half gland bushing. Measure, evaluate and record axial movement of rotor in the rear gland bushing. Remove and store rear bottom-half gland bushing.

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Remove Rotor Procedure :


Remove top-half journal bearing. Remove and store rotor. Protect bottom-half journal bearing and support bearing against damage.

Install and Align Stationary Blade Carrier Procedure :


Sequence : items 500, 525. Suspend bottom-half stationary blade carrier in a horizontal position and raise slightly. Clean bottom-half stationary blade carrier and protect against corrosion. Coat stationary blade carrier guides with lubricant. Coat the contact faces of the calottes (Z 58, 59, 60; Sections C2-C2, C4-C4); position m spherical washers (Parts 507, 532) in the bottom-half outer casing. arked

Install bottom-half stationary blade carrier, thereby ensuring that the spherical washers are properly seated. Insert rotor. Check alignment dimension (Assembly data sheet EI, EII) or ascertain via rotor displacement. Measure and evaluate the exact values of the outer-casing circumferential profile measuring points and correct as necessary via rotor displacement. Measure and evaluate the lateral (horizontal) radi al clearance between the stationary blade carriers and the rotor and correct as necessary via the adjusting elements (Z 58, 59, 60; Section C2-C2, C4C4). Suspend top-half stationary blade carrier in a horizontal position and raise slightly. Clean top-half stationary blade carrier and protect against corrosion. Screw guide bolts into bottom-half stationary blade carrier. Degrease the joint faces on the top and bottom halves. Place top-half stationary blade carrier in position and tighten several joint bolts. With the aid of the adjusting elem ents (Z 58, 59, 60; Section C2-C2, C4-C4), vertically raise and lower the stationary blade carrier in position in order to determ ine the overall radial clearance between the stationary blade carrier and the rotor; evaluate; center the stationary blade carrier and record the values. Apply lubricant to the contact faces of the top calottes (Z 58, 59, 60; Section C2-C2, C4-C4) and apply marked spherical washers.

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Set up proper clearance between the spherical w

ashers and the outer casing;

secure adjusting

elements as specified in the drawing; check and record all values.


Remove spherical washers and keep ready for further reassembly. Measure, evaluate and record axial movement of the rotor. Unscrew joint bolts. Raise top-half stationary blade carrier, protect against corrosion and store. Check and record the lateral (horizontal) radial clearance between the stationary blade carriers and the rotor. Measure, evaluate and record the axial positive and negative direction. Remove top-half journal bearing. Remove and store rotor. Check bottom-half journal bearing and support bearing for damage. clearance between the rotating and stationary blades in

Install and align Inner Casing Procedure :


Suspend bottom-half inner casing in horizontal position and raise slightly. Clean bottom-half inner casing and protect against corrosion. Apply lubricant to inner casing guides. Apply lubricant to contact faces of bottom calottes (Z 58, 59, 60; Section A-A); position the marked spherical washers (Part 325) in the bottom-half outer casing.

Determine the horizontal L-ring movement in the outer casing. Install bottom-half inner casing, thereby ensuring that the spherical washers are properly seated. Insert rotor. Check alignment dimensions (assembly data sheet EI. EII) or ascertain via rotor displacement. Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. Measure and evaluate the lateral (horizontal) radial clearance between the inner casing and the rotor and correct as necessary via the adjusting elements (Z 58, Section A-A). Suspend top-half inner casing in a horizontal position and raise slightly. Clean top-half inner casing and protect against corrosion. Screw in guide bolts of the bottom-half inner casing. Degrease the joint faces of the top and bottom halves. Mount top-half inner casing and tighten several joint bolts.

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With the aid of the adjusting elem ents (Z 58, 59, 60; Section A-A) vertically raise and lower the inner casing up to stop in order to determ ine the overall radial clearance between the inner casing and the rotor; evaluate; center the inter casing and record all values. Apply lubricant to the contact faces of the top calottes (Z 58, Section A-A) and install m spherical washers. Set up proper clearance between the spherical w ashers and the outer casing; secure arked

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 positive and negative direction. Remove top-half journal bearing. Remove rotor and store. Check bottom-half journal bearing and support bearing for damage. clearance between the rotating and stationary blades in

Install Inner Components Procedure :

Clean interior of bottom -half outer casing and associated inner com ponents and protect against corrosion. Insert rotor. Check alignment dimensions (Assembly data sheet EI, EII) or ascertain via rotor displacement. Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary via rotor displacement. Loosely mount rear top-half bearing pedestal. Suspend top-half inner casing in horizontal position and raise slightly. Clean top-half inner casing and protect against corrosion. Degrease joint faces of top and bottom halves; apply uniform coat of sealant to one joint face. Mount top-half inner casing and tighten joint bolts as specified. Install pressure-instrument lines (Z 58, Part 391) Suspend top-half stationary blade carrier in a horizontal position and raise slightly. Clean top-half stationary blade carrier and protect against corrosion.

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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.

Close Outer Casing Procedure :


Screw in joint bolts on bottom-half outer casing. Screw in guide bolts on bottom-half outer casing. Suspend top-half outer casing from the lifting bosses provided and raise slightly. Clean top-half outer casing; degrease joint faces of top and bottom sealant to one joint face. halves; apply uniform coat of

Determine horizontal movement of L-rings (Z 58, Detail X-Y) in the top-half outer casing. Mount top-half outer casing. Remove guide bolts and jack screws; protect against corrosion and store. Tighten joint bolts. Remove taper pins, protect against corrosion and store. Install rupture disks and shielding pipes.

Check Alignment and Clearances Procedure :

Unscrew spacer bolts (Z 58, 59, 60; Section F2-F2, F4-F4) on the bottom remove extra washers and retighten the spacer bolts.

-half outer casing;

Check and record the minimum axial movement (Assembly data sheet) of the rotor. Remove rear top-half bearing pedestal; raise Section K4-K4). rotor slightly ; rem ove journal bearing; degrease 58, 60; bearing and journal area; check and record radial clearance of the journal bearing (Z

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Install journal bearing for bluing im print; lowe r rotor; bolt down bearing bracket; m ake bluing imprint. Remove bearing bracket; raise rotor slightly ; remove journal bearing; evaluate bluing im print;

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 F2F2, 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 F2F2, F4-F4). Check zeroing of casing axial-position indicator (Z 58, 59, 60; Detail V4).

7.2 H. P. Turbine
Prepare Bottom-half Outer Casing for Reassembly Procedure :

Apply lubricant to threads and contact faces of axial casing guide calottes (Z 37, 38, 39; W1-W1 and W3-W3); turn in calottes such that they no longer protrude out of the bore. Insert spherical washers into the axial guides calottes.

Section

and bring into contact with the guide face via the

Install Center Bearing Pedestal Procedure :


Suspend center bearing pedestal in horizontal position and raise slightly. Clean bearing pedestal and protect against corrosion. Apply lubricant to contact faces of the calottes in the shoulder (Z 37, 39; Section 03-03, Part 111); install marked spherical washers. Apply lubricant to the threads and contact faces of the axial casing guide calottes (Z 37, 39; Section M3-M3, Part 122); turn in calottes such that they no longer protrude from the bore. Apply lubricant to the eccentric bolt guides (Z 37, 39; Section 03-03, Part 110). Set bearing pedestal down on the spherical washers of the shoulder.

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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.

Install Front Bearing Pedestal Procedure :


Suspend front bearing pedestal in a horizontal position and raise slightly. Clean bearing pedestal and protect against corrosion. Apply lubricant to contact faces of calottes in the shoulder (Z 37, 39; Section 01-01, Part 11) and install marked spherical washers. Apply lubricant to the threads and contact faces of the axial casing guide calottes (Z 37, 39; Section M1-M1, Part 22) and turn in calottes such that they no longer protrude from the bore. Mount bearing pedestal on the spherical washers of the shoulder and center the bearing pedestal axially (Z 37, 38; View V2). 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 stud bolts (Z 37, 38; Detail T1, Parts 60-63); screw stud bolts into the outer casing and secure with lock nuts; screw on but do not tighten the adjusting nuts. Mount brackets (Z 37, 38; Section 01-01, Part 15); apply (Section 01-01, Part 16). lubricant to threads of spacer bolts

Apply additional washer to spacer bolts (Z 71, Detail E); screw in spacer bolts hand-tight. Install bottom-half journal bearing (Z 2); protect journal surface area from 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.

Replace Top-Half Outer Casing Procedure :


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Apply lubricant to the contact faces of the calottes of the front Section P1-P1); install marked spherical washers.

support bracket seat (Z 37, 38;

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).

Align Bearing Pedestal and Outer Casing Procedure :


Position and apply load to lifting fixture (Z 21). Remove support bearing. Connect LP rotor to HP rotor with at least 4 coupling bolts (Z 72) Pull coupling flange halves to within 3 mm and hand-tighten the coupling nuts. Take load off of lifting fixture (Z 21). Unscrew spacer bolts (Z 37, 38, 39; Section 01-01, P3-P3) on the front bearing pedestal and outer casing. Measure and evaluate the shaft alignment between the HP and LP turbines and correct as necessary via HP turbine displacement. Check the dimension L (Assembly data sheet) on the front support bracket seats. Measure the exact value at the front and rear bearing pedestals. If the values deviate by more than 0.1mm from the values listed in the assembly data sheet, the bearing pedestal must be re-aligned. The prelim inary alignment status, including any corrections, must be noted. Then, the rotor can be turned.

Check Alignment dimensions (Assem bly data sheet, E1, EII, EIV) and correct as necessary displacement of the front bearing pedestal; record all values.

via

Apply and tighten nuts on the longitudinal guide (Z 37, 38; Detail T1) as specified on the drawing. Install bottom-half thrust bearing, thereby ensu ring that the journal surface areas are coated viscous oil. Mount and bolt down the front and center top-half bearing pedestal. Check and record the HP/LP turbine alignment (coupling check). Measure and record the exact values at the LP outer casing circumferential profile measuring point. Measure and record the exact values at the front and center bearing pedestal measuring points. Measure and record the exact values at the outer casing circumferential profiles measuring points. with

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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 shim s 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 Top-Half Outer Casing Procedure :

Screw in bolts against the auxiliary support brackets of the bottom -half outer casing (Z 37, 38; Section P1-P1, Part 30). Unscrew joint bolts. Remove and store top-half outer casing. Evaluate bluing imprint.

Install Outer Gland Bushing for Checking Clearances Procedure :

Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary by adjusting the screws on the auxiliary support bracket. Clean front and rear gland bushings and protect against corrosion. Apply lubricant to guides. Swing in front and rear bottom-half gland bushings. Measure, evaluate and record the horizontal a bushings and the rotor. Remove front top-half bearing pedestal. Remove bottom-half thrust bearing. Measure, evaluate and record the axial movement of the rotor in the front gland bushing. Remove and store front bottom-half gland bushing. Measure, evaluate and record the axial movement of the rotor in the rear gland bushing. nd vertical radial clearance between the gland

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Remove and store rear bottom-half gland bushing.

Remove Rotor Procedure :

Remove front top-half bearing pedestal; rem journal bearing.

ove bottom-half thrust bearing; rem ove top-half

Remove rear top-half bearing pedestal; remove top-half journal bearing. Remove and store rotor. Protect bottom-half journal bearing against damage.

Install and Align Stationary Blade Carrier Procedure :


Installation sequence : Items 500, 525, 550 (Z43). Suspend bottom-half stationary blade carrier in horizontal position and raise slightly. Clean bottom-half stationary blade carrier and protect against corrosion. Apply lubricant to stationary blade carrier guides. Apply lubricant to contact faces of the calottes (Z 45, Section K1-K3). Position marked spherical washers (Z 45, Section K1-K3, Part 7) in the bottom-half outer casing. Install bottom-half stationary blade carrier thereby ensuring that the spherical washers are properly seated. Insert the rotor. Install bottom-half thrust bearing. Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary by adjusting the screws on the auxiliary support brackets. Measure and evaluate the lateral (horizontal) radi al clearance between the stationary blade carriers and the rotor and correct as necessary by way of the adjusting elements (Z 45, Section K1-K3) Suspend top-half stationary blade carrier in a horizontal position and raise slightly. Clean top-half stationary blade carrier and protect against corrosion. Degrease joint faces of top-half and bottom-half stationary blade carrier. Mount top-half stationary blade carrier; tighten several joints bolts. With the aid of the adjusting elem ents (Z 45, Section K1-K3), vertically raise and lower the stationary blade carrier in order to determ ine and evaluate the overall radial clearance between the stationary blade and the rotor; center the stationary blade carrier and record the values.

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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 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. clearance between the rotating and stationary blades in

Install and Align Inner Casing Procedure :


Suspend bottom-half inner casing in a horizontal position and raise slightly. Clean bottom-half inner casing and protect against corrosion. Apply lubricant to guides and contact faces of the inner casing. Determine the horizontal movement of L-rings in the bottom-half outer casing (Z 37, Section Y-Y) Install bottom-half inner casing, including thermocouples (Z 41). Insert rotor (cf. 2.8.2.4). Install bottom-half thrust bearing. Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary by adjusting the screws on the auxiliary support brackets. Mount measuring instrument on the rotor. Suspend top-half inner casing in a horizontal position and raise slightly. Clean top-half inner casing and protect against corrosion. Degrease the joint faces of the top-half and bottom-half inner casing.

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Install top-half inner casing and tighten several joint bolts. Measure and evaluate the inner-casing measuring points; correct as necessary eccentric guide (Z 37, Section L-L and Part 335) corrections. Measure and evaluate the clearance between the 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 inner casing; protect against corrosion and store. Clean bottom-half gland busing (Z 30) and protect against corrosion. Coat guides with lubricant. Swing bottom-half gland busing into the inner casing. Measure, evaluate and record the horizontal and vertical radial clearance between the inner casing and the rotor. Measure, evaluate and record the horizontal and vertical radial clearance between the bottom-half gland bushing and the rotor. Measure, evaluate and record the axial clearance be tween the rotating and stationary blades in the positive and negative direction. Remove bottom-half thrust bearing. Measure, evaluate and record the axial movement of the rotor in the gland busing. Remove top-half journal bearing. Removed and store rotor. Protect bottom-half journal bearing against damage. via shim s or ; record m easuring values subsequent to any upper shim (Z 37, Section L-L) and the outer

casing and correct as necessary via shims; record measured values following any corrections.

Install and align the Inner Gland Bushing Procedure :


Suspend bottom-half gland bushing in a horizontal position and raise slightly. Clean bottom-half gland bushing and protect against corrosion. Apply lubricant to the guides on the gland bushing. Apply lubricant to the contact faces of the calottes (Z 37, Section K-K, Part 288). Install marked spherical washers in the bottom-half outer casing. Install bottom-half gland bushings, thereby ensuring that the spherical washers are properly seated.

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Insert rotor. Install bottom-half thrust bearing. Measure and evaluate the exact values at the out er-casing circumferential profile measuring points and correct as necessary by adjusting the screws on the auxiliary support brackets. Measure and evaluate the lateral (horizontal) ra dial 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 elem ents (Z 37, Section K-K), vertically raise and lower the gland bushing up to stop in order to determ ine 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 spheri cal 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 Inner Components Procedure :

Clean interior of the bottom corrosion. Insert rotor (cf. 2.8.2.4).

-half outer casing and all

inner components and protect against

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Install bottom-half thrust bearing. Check and record alignment dimension (Assembly data sheet EII). Loosely mount front and center top-half bearing pedestals. Suspend top-half stationary blade carrier in a horizontal position and raise slightly. Clean top-half stationary blade carrier and protect against corrosion. Degrease the joint faces of the top-half and bottom-half stationary blade carrier and apply uniform layer of sealant to one of the faces. Install top-half stationary blade carrier and tighten joint bolts as specified. Clean top-half gland bushing (Z 30) and protect against corrosion. Degrease joint faces of the top-half and bottom lubricant to one face. -half inner casing and apply uniform lay er of

Install top-half gland busing and tighten joint bolts as specified. Remove taper pins and secure joints bolts with spot welds. Suspend top-half inner casing in a horizontal position and raise slightly. Clean top-half inner casing and protect against corrosion. Degrease joint faces of top-half and bottom-half inner casing and apply uniform layer of sealant to one face. Install top-half inner casing and tighten joint bolts as specified. Install pressure-instrument lines (Z 40, Part 391). Suspend inner top-half gland bushing in a horizontal position and raise slightly. Clean inner top-half gland bushing and protect against corrosion. Degrease joint faces of the top-half and bottom sealant to one face. ha lf gland bushing and apply uniform coat of

Install inner top-half gland bushing and tighten joint bolts as specified. Clean front and rear gland bushing and protect against corrosion. Apply lubricant to guides. Swing in bottom-half gland bushing. Degrease joint faces of top-half and bottom -half gland bushing and apply uniform coat of sealant to one face of each gland bushing. Install top-half gland bushing and tighten joint bolts as specified. Secure all boltings with spot welds. Remove 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 carriers and inner gland bushing.

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Close Outer Casing Procedure :


Screw in joint bolts of bottom-half outer casing. Screw in guide bolts. Suspend top-half outer casing in a horizontal slightly. position from the lifting bosses provided and raise

Clean top-half outer casing; degrease joint faces of top-half and bottom -half outer casing; apply a uniform layer of sealant to one of the faces. Determine the horizontal movement of L-rings (Z 37, Section Y-Y) in the top-half outer casing. Install top-half outer casing. Remove guide bolts and jack screws, protect against corrosion and store. Tighten joint bolts as specified. Remove taper pins, protect against corrosion and store. Loosen auxiliary support bracket bolts (Z 37, 38; Section P1-P1, Part 30), turn back at least 3mm and secure with counternuts. Bolt down upper steam inlet lines. Install upper cross-around lines incl. swing disk valves. Install wall temperature sensor (Z 36).

Check Alignment and Clearances Procedure :

Unscrew spacer bolts (Z 37, 38, 39; Section 01-01, Section P3-P3) on the front and outer casing, remove extra washers and retighten spacer bolts. Dismantle front top-half bearing pedestal; remove bottom-half thrust bearing.

bearing pedestal

Raise rotor slightly ; rem ove journal bearing; degrease bolt bearing and shaft journals; check and record clearance in the journal bearing (Z 37, 39; Section K1-K1). Install journal bearing and thrust bearing for getti ng bluing imprints; lower rotor; bolt on top-half bearing pedestal and make bluing imprint. Check and record axial clearance of the thrust bearing (Z 37, 38, Detail X1). Remove front top-half bearing pedestal and check alignment dimensions (Assembly data sheet, EI, EIII and EIV). Remove thrust bearing; raise rotor slightly ; remove journal bearing; evaluate bluing imprints and clean bluing ink from bearing and journals.

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Install journal bearing; lower rotor; install thru st 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 K3-K3). Install journal bearing for getting a bluing im pedestal and make bluing imprint. the journal bearing (Z 37, 39; Section down top-half bearing evaluate

print; lower rotor; bolt

Dismantle center top-half bearing pedestal; raise roto r slightly; rem ove thrust bearing; 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 P3P3). Check the front and rear bearing pedestal measuring points. Check the outer-casing circumferential profile measuring points. Install manual turning gear; check and record th e clearance between the fram e and the gear wheel (Z 37, 39; Section U3-U3). Unscrew cover of front top-half bearing pedestal lock in place. Z1, Item 169/165); turn turbine rotor to the Z88) and

proper measuring position; pull level of em ergency trip gear (into operating position;

Check and record the radial clear ance between the ratchet lever and the overspeed trip bolt (Z 37, 38; Section S1-S1). Check and record the axial clear ance 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 M1M1, M3-M3).

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Check and record the clearances on the longitudinal gui des 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.

Install Speed Transducer and Main Oil Pump Procedure :


Assemble speed transducer (Z 9, 10, 11). Install turbine-end coupling hub (Part 100). Clean main oil pump, protect against corrosion and store. Apply lubricant to the contact faces of the calottes (Z 37, 38; Section Y1-Y1); install m spherical washers. Install main oil pump on front-end support brackets. Measure alignment between the main oil pum p and the HP rotor (Z 37, Section C-C) and correct as necessary via the adjusting elements (Z 37, 38; Section Y1-Y1); record all values. Couple main oil pump. Install the oil lines. arked

7.3 Valve Blocks :


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.

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Install steam -end com ponents in the body (without the steam strainer); hand-tighten nuts; make bluing imprint. Remove nuts. Remove steam -end com ponents with stem ; evaluate bluing imprint; clean bluing ink from valve cone and valve seat. Clean steam strainer and m ount on steam end, device. thereby threading in the anti-rotation

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.

Remount Control Valves Procedure :


Install valve stem (Chapter III 2.1.2; Part 5) with valve cone (Z 91, Part 2) in the valve cover. Do not lubricate the valve stem for installation. Pack valve stem as specified. Prepare valve cone for bluing imprint. Run valve stem into the open position. Install valve cover in the body; hand-tighten nuts; make bluing imprint. Unscrew nuts, rem ove valve cover with valve spindle, evaluate bluing im print, clean bluing ink from valve cone and valve seat. Reinstall valve cover in the body and tighten nuts. Bolt down radiation shield.

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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)

7.4 Alignment Checks :


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 coup and hand-tighten the coupling nuts. ling bolts (Z 72); pull coupling flange halves together to within 3 m m; install all coupling bo lts, thereby heeding the identification m arkings, 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).

Main Oil Pump / HP Turbine Procedure :

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Check, evaluate and record the alignm ent 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.

Check Alignment and Other Clearances Procedure : 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 m inimum axial m ovement 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.

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7.5 Lube Oil System :


Inspect Control System : Inspect Speed Governor (1110) : Procedure : Dismantle Speed Governor :

Remove electric motors (Z 81, 82; Parts 150, 270) and control operators. Remove all covers from the governor housing. Remove and store complete position transducer. Screw in manual follower-piston adjuster up to stop (clockwise). Remove electric follower-piston adjuster (Z 81, 82; Part 220). Turn m anual follower-piston adjuster out to amplifier casing. stop; relax and unhook tens ion spring; rem ove

Extract all lever arms without unscrewing the threaded studs. Remove and dismantle follower-piston with sleeve. Remove guide frame and rods of the reference setter (Z 81, 82; parts 120-122). Remove set point spring (Z 81, 82; Part 45) and spring retaining plate. Remove comparator beam. Remove and dismantle complete transducer. Remove bottom mount and compression spring of the start-up setter. Remove guide frame with switching rod and compression spring. Remove slider and compression spring.

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Evaluation :

Follower piston, sleeve, transducer, other parts. Clean all parts and protect against corrosion.

Reassemble Speed Governor :


Lubricate slider and install start-up setter together with compression spring. Check for free movement of slider. Install guide fram e with switching rod and com pression springs; reinstall bottom compression spring; check for free movement of switching rod. Reassemble transducer and install in governor housing. Install comparator beam, thereby ensuring that the transducer rod is properly seated. Lubricate and assemble the follower piston, thereby checking for free movement. Install follower piston in the amplifier housing. Install all levers and check for free movement hook up and tauten the tension springs. Screw in manual follower-piston adjuster up to stop. Mount amplifier housing on the governor housing, thereby linking up the follower-piston sleeve to the comparator beam. Check for free movement of the comparator beam and follower-piston sleeve. Reinstall electric follower-piston adjuster. Install setpoint springs with rod and guide frame. Install position transducer. Plug all openings on the governor and amplifier housing. Reinstall control operators and electric motors. mount with

Inspect Electro-hydraulic Controller (1825, 1826) Procedure : Disassemble EHC :


Disconnect all electric leads (pull plugs). Dismantle piping.

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Plug all openings and store pipes. Remove all covers from the controller housing. Disconnect plunger coil. Open union between plunger coil (Part 35) and control sleeve (Part 9). Remove and store plunger coil with governor pedestal (Part 27). Remove hood (Part 30) and control sleeve. Unscrew spring retaining plate (Part 10) and rem spring and thrust bearing. Extract pilot valve (Part 1) Detach position indicator with spacer piece (Part 15) from the piston rod (Part 16). Detach amplifier lever from the piston rod. Unscrew converter housing; unscrew spacer plate (Part 24). Pull piston rod and piston out of the housing. Extract amplifier lever with follower-piston sleeve. Remove and dismantle follower-piston. Clean all parts and protect against corrosion. ove along with the compression

Evaluation :

Pilot valve, control sleeve, governor pedestal, power piston, piston rod seal, follower piston, other parts.

Reassemble Electro-Hydraulic Controller


Lubricate and assemble the follower piston, thereby checking for free movement. Install follower piston in the amplifier housing. Attach lever with follower-piston sleeve and check for free movement. Lubricate and install power piston. Attach position indicator. Attach spacer plate to converter housing. Check for free movement of power piston. Set converter housing on bracket and secure. Attach amplifier lever to piston rod. Check for freedom of movement and proper stroke. Lubricate and install the pilot valve (Part 1). Install thrust bearing, compression spring and spring retaining plate.

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Secure spring retaining plate. Check for free movement of pilot valve. Lubricate control sleeve and slide on over pilot valve. Insert hood. Mount and secure plunger coil and pedestal; attach control sleeve to the plunger coil. Connect plunger coil. Plug all openings. Install piping. Connect electric supply line.

Inspect Valve Stroke Operator (1910, 1911) Procedure : 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.

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Inspect Swing Disk Valves (1912-1915) Procedure : Dismantle Rotary-Piston Control Cylinder :

Detach rotary-piston control cylinder (Z 77) from the swing disk valve. Uncouple and remove the lift monitor. Remove the feedback lever (Z 77, Part 97). Remove cover (Z 77, Part 18). Remove thrust bearing. Remove pilot valve.

Evaluation :

Pilot valve, control sleeve, rotary piston, bearings, other parts. Clean all parts and protect against corrosion.

Reassemble Rotary-Piston Control Cylinder :


Lubricate and install pilot valve and check for freedom of movement. Install thrust bearing, spring retaining plate, spring and pin. Install and secure cover of servo valve. Lubricate and install rotary piston; install and secure cover; check for free m piston. Attach feedback lever and check for freedom of movement. Install lift monitor. ovement of the

Inspection Swing Disk Valve :

Remove stem seal (Z 76, Part 11) and check for free movement of valve disk.

Evaluation :

Valve disk, housing, bearing. Replace stem seal.

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Attach rotary-piston control cylinder to swing disk valve.

Inspect Constant-Value pressure Controller (1820, 1821) Procedure : Disassemble Constant-Value Pressure Controller :

Remove hood (Z 85, Part 14), unscrew counter-nut (Z 85, Part 12) and remove cover (Z 85, Part 1). Remove and disassemble follower piston (Z 85, Part 3).

Evaluation :

Follower piston, other parts. Clean all parts and protect against corrosion.

Reassemble Constant-Value Pressure Controller :

Lubricate and reassem ble follower piston; check for free m housing. Install and secure cover; tighten counter-nut; replace hood.

ovement of piston and install in

Inspect Control Cylinders of Check Valves (2440-2452) Procedure :

Remove and disassem ble check-valve control cy linders (2440, 2442, 2444, 2446, 2448, 2450, 2452). Open housings and remove seal plate, shaft and bearing liners.

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.

Inspect Check Valves (2443-2449) Procedure :

Open check valve housings (2443, 2445, 2427, 2449).

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Remove seal plate, shaft and bearing liner.

Evaluation :

Seal plate, bearing, housing. Reassemble check valve; check for free movement of seal plate.

Inspect Plate-type oil strainer (4520-4523) Procedure :


Remove and clean filter cartridges (4520, 4521, 4522, 4523). Drain remaining oil out of the filter shells. Clean shells. Reinstall filter cartridges.

Inspect Emergency Trip Gear (2210) Procedure :

Remove emergency trip gear (2210, Z 86, 88); open shell and remove valve.

Evaluation :

Valve, lever, other parts. Reinstall valve; check for free movement of valve and lever; reinstall emergency trip gear.

Inspect Steam Pressure Monitor (2310) Procedure :

Remove and disassemble steam pressure monitor (2310, Z 84).

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.

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Check Control Valves (0801, 0802) : Inspection quick-closing Gate Valve (2301, 2302) : Inspect Speed Transducer (1111) : Inspect Main Oil Pump (4210) :

Clean Lube Oil System Procedure :


Remove front, center and rear top-half bearing pedestals (Z 1, 15, 22). Remove top-half thrust and journal bearings (2, 3); protect against corrosion and store. Disconnect lift-oil pipe connections on the bottom-half journal bearings. Clean interior of bearing pedestal. Clean the joint faces of the bearing pedestals; apply a uniform layer of sealant to one of the faces, replace the top-half bearing pedestals and bolt down tight. Plug all openings for instrumentation and control equipment (oil tight). Detach lube oil line leading to the m ain oil pum p bearings and connect up oil tight to a drain line with the aid of a specially prepared auxiliary line. Completely open the lube-oil throttles upstream of the bearing pedestals. Install fine-mesh screens (m esh size 0.025 m m or fine r) upstream of the bearing pedestals in all lube-oil lines. Close emergency isolating gate valve (5201). Cut in emergency oil pump, thereby taking note of the direction of rotation. Observe current consumption and reduce flow rate as necessary. Check all oil-filled pipes and subassemblies for leak tightness and reseal as necessary. Cut in auxiliary oil pum p no. 1, thereby taking not e of the direction of rotation; observe current consumption and reduce flow rate as necessary. Cut in high-pressure pum p no. 1 of the lift-oil sy rotation. stem, thereby taking note of the direction of

Briefly open the power oil valve, throttle the flow, and close after approximately 5 hours. Cut in the fine-filtration system (4800) and oil centrifuge system (4850). Cut in auxiliary oil pump no. 2, thereby taking note of the direction of rotation. Cut out auxiliary oil pump no. 1.

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Cut in high-pressure pump no. 2 of the lift-oil sy stem, thereby taking note of the direction of rotation. Cut out high pressure pump no. 1. Heat the operating oil up to about 70 OC (if possible), hold at that tem perature 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 sy 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 m ating surfaces of the top-half bearing pedestals and bolt down ready operation. Remove, clean and reinstall the oil tank inlet strainer (4310). for stem (4730) and

T-OH-procedure {F.K.} 24 November 2006

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