Triveni Turbine Ltd.

OPERATION AND
MAINTENANCE MANUAL

5000 KW.
BACK PRESSURE TURBINE

Customer

M/s.

M & H USA ENTERPRISE - FLORIDA, USA

A/C.

INGENIO LAZARO CARDENAS S.A DE CV

MEXICO.

INTRODUCTION

CLIENT

M & H USA ENTERPRISE -

END USER

INGENIO LAZARO CARDENAS S.A DE CV

MEXICO

TRIVENI W.O. NO.

C - 3041

TURBINE MODEL.

TST-1100

TURBINE POWER

5000 KW.

TURBINE TYPE

BACK PRESSURE TURBINE

DRIVEN EQUIPMENT

ALTERNATOR

1- No.

REFER TURBINE NAME PLATE

QUANTITY
YEAR OF MANUFACTURE

FLORIDA, USA

WHILST EVERY EFFORT HAS BEEN MADE TO ENSURE THAT THE INFORMATION
CONTAINED IN THIS MANUAL IS CORRECT AND FULLY UP-DATED,THE MNUFACTURER
M/s. TRIVENI TURBINE LTD. CANNOT BE HELD RESPONSIBLE FOR ANY ERRORS OR
OMISSIONS.

ANY QUERIES REGARDING THIS HANDBOOK SHOULD BE REFERRED TO M/s. TRIVENI

TURBINE LTD. QUOTING ORDER REFERENCE No. C - 3041

IMPORTANT
WHEN ORDERING SPARE PARTS, QUOTE THE ABOVE TRIVENI WORK ORDER No: C 3041
AND TURBINE SERIAL NO- REFER TURBINE NAME PLATE

INTRODUCTION

ENVIRONMENTAL MANAGEMENT SYSTEM

HELP AND CONTACT

DISCLAIMER
CAUTION
WARRANTY
INDEX

ENVIRONMENTAL MANAGEMENT SYSTEM

We, at Triveni Turbine Ltd., manufacturing Steam Turbines, related products and accessories
commit ourselves to:
1.

Comply with all applicable Environmental Legislation and Regulations.

2.

Continually improve our Environmental Management System.

3.

Prevent Pollution; reduce waste and the consumption of resources, especially electrical energy
and oil.

4.

Provide appropriate awareness/training to employees on the Environmental Management

System and importance of good operating practices.

5.

Create environmental awareness amongst our associates, i.e., Sub-contractors, Suppliers,

Transporters and Customers.

6.

Make the policy available to interested parties on their request.

Users are advised to take necessary measures to avoid environmental pollution and up keep of
environment.

Optimum loading to Turbo generator should be practiced.

Better oil cleaning practices should be adopted so as to reuse the oil to the extent possible.

Disposal of used oil, old battery, packing materials, etc., should be done in environment friendly
way.

For general maintenance follow the system maintenance given in the oil system chapter.

Environment (Protection) Act 1986

*

ENVIRONMENT includes water, air and land, and inter relationship which exists among and
between water, air and land, and human beings, other living creatures, plants, micro-organisms
and property Section 2 (a).

ENVIRONMENT POLLUTANT means any solid, liquid or gaseous substance present in such
concentration as may be, or tend to be, injurious to environment - Section 2(b).

ISO 14001
ENVIRONMENT
Surroundings in which an organization operates, including air, water, land, natural resources,
flora, fauna, humans and their inter-relation.
Surroundings in this context extend from within organization to the global system.
ENVIRONMENTAL ASPECT
Element of an organizations activities, products or services that can interact with the
environment.
A significant environmental aspect is an environmental aspect that has or can have a significant
environmental impact.
ENVIRONMENTAL IMPACT
Any change to the environment whether adverse or beneficial, wholly or partially resulting from an
organizations activities, products or services.

DISCLAIMER

DISCLAIMER

The purchaser should comply with the instructions and information in this manual and strongly
advised that all personnel to be associated with the equipment supplied under this contract
should be made familiar with the information contained herein

The equipment supplied by the Company to your Order must be correctly installed by technically
qualified and competent persons experienced in the class of work involved.

It is the Purchasers responsibility to ensure that access to this equipment is restricted to

authorized persons only.

The purchaser is responsible for the correct selection of lifting eye bolt to ensure thread form of
eye bolt matches the tapped hole thread form. Various items of equipment in our supply may
have tapped holes of differing thread form i.e. British Standard, ISO metric, Unified etc. for lifting
eye bolts.

If any further information is required relating to this equipment, please contact:

TRIVENI TURBINE LIMITED

Dear Customer,

Thanks for purchasing a TRIVENI steam turbine. It is a product developed

with quality and efficiency levels which ensure an outstanding performance.
Since the Steam turbine plays an important role in the comfort and well being of
mankind, it must be identified and treated as a prime mover, whose characteristics
involve certain care, such as proper storage, installation, operation, and
maintenance.
All efforts have been made to ensure that the information contained in this manual
is pertaining to the configuration and application of the steam turbine.
Therefore, we recommend that you read this manual carefully before proceeding with
the installation, operation or maintenance of the steam turbine in order to ensure
the safe and continuous operation and also the safety of your installations.
It is also recommended that you should read manual for Gear box, driven machine
and other accessories supplied along with this machine.
Keep this manual always close to the steam turbine, so that it can be referred to
when needed.
If you need any further information, please see HELP AND CONTACT.

HELP AND CONTACT

HELP & CONTACT

If you need any information, please contact :-

TRIVENI TURBINE LIMITED

Customer Care Cell
12A, Peenya Industrial Area,
Peenya, Bangalore-560058
Karnataka- INDIA
Phone -080- 22164000, 22164100
Website-www.triveniturbines.com

CAUTION
CAUTION
Danger may arise to operators and to the steam turbine generator (STG), while erecting,
installing, commissioning, operating and maintaining the STG because of the heavy
and bulky equipment, high temperatures, high speed, and high voltage involved.
Therefore, the individual equipment supplied, and the STG, must be handled with
care by fully trained staff, and no unauthorised personnel should be allowed near the
STG, during erection, commissioning or operation.
All power plant personnel should completely read and fully understand this manual,
before they are allowed to operate the STG, and should strictly adhere to all safety
procedures therein.
The O & M manual should be kept in a close location, accessible to all operating and
maintenance personnel.
A minimum of two trained operating personnel must be present when operating or
maintaining the STG.
An appropriate and complete first aid box should be kept and maintained near the
STG, and action planned and procedure laid down, in the event of any serious incident,
like burns first aid and subsequent treatment.
Necessary fire fighting equipment, in good order, should be maintained next to the
STG.
No adjustments or maintenance activity should be carried out on a running STG unless
it is approved by Triveni Turbine Ltd, and then utmost care taken to avoid any untoward
incident.
The STG has been provided with Protection Devices. These should be kept in good
operating condition at all times.
No modification of any part or equipment of the supplied STG should be made, unless
approved by Triveni Turbine Ltd.

WARRANTY
WARRANTY

Our Standard Warranty Clause is as follows:

The Company warrants that the equipments manufactured by it and delivered hereunder will be free of
defects in material and workmanship for a period as per the sale agreement. Any failure must be
confirmed to this warranty and must be reported in writing to the company within the stipulated period,
the company shall, as its option, correct such non-conformity, by suitable repair to such equipment or
furnish a replacement part F.O.B. point of shipment, provided the purchaser has stored, installed,
maintained and operated such equipment in accordance with good industry practices and has compiled
with specific recommendations of the company. Accessories or equipment furnished by the company,
but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the
company and which can be passed on to the purchasers. The company shall not be liable for any
repairs, replacements, or adjustments to the equipment or any costs of labour performed by the
purchaser or others without the companys prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded from the companys
warranty. Performance warranties are limited to those specifically stated within the companys proposal
or sale agreement. Unless responsibility for meeting such tests, the companys obligation shall be to
correct in the manner and for the period as indicated in sale agreement
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND
WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE AND ALL IMPLIED
WARRANTIES, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE HEREBY DISCLAIMED
Correction by the company of non-conformities whether patent or latent, in the manner and for the
period of time provided above shall constitute fulfillment of all liabilities of the company for such nonconformities, whether based on contract, warranty, negligence, indemnity, strict liability or otherwise
with respect to or arising out of such equipment.

INDEX

INDEX
ILLUSTRATION
INTRODUCTION OF MANUAL
SAFETY INSTRUCTIONS
SECTION - A.

INTRODUCTION

ARTICLE I

General Description

ARTICLE II

Description of Components

SECTION - B.

TECHNICAL DATA

ARTICLE I

Steam Turbine

ARTICLE II

Gear Box

ARTICLE III

Oil System

ARTICLE IV

General

ARTICLE V

Gland Condenser

SECTION- C.

INSTALLATION & COMMISSIONING

ARTICLE I

Erection- Mech

ARTICLE II

Pipe Connections

ARTICLE III

Pre-commissioning- Mech

ARTICLE IV

Erection- Electrical

ARTICLE V

Pre-commissioning- Elec.

ARTICLE VI

Commissioning.

ARTICLEVII

Installation & Alignment of Coupling

ARTICLE VIII

Steam Quality

ARTICLE IX

Recommented Cooling Water Analysis

INDEX
SECTION- D.

OPERATION

ARTICLE I

Standby State

ARTICLE II

Starting

ARTICLE III

Running

ARTICLE IV

Shutting Down

ARTICLE V

Guide line for Start up Curve

SECTION- E.

GOVERNING SYSTEM

ARTICLE I

Description

ARTICLE II

Speed Sensing & Governor System

ARTICLE III

Actuator

ARTICLE IV

Throttle Valve Gear

SECTION - F.

EMERGENCY TRIP GEAR

ARTICLE I

General Description

ARTICLE II

Stop & Emergency Valve

ARTICLE III

L.P Trip

ARTICLE IV

Security Trips General

ARTICLE V

Overspeed Trip

ARTICLE VI

Hand Trip

ARTICLE VII

Solenoid Trip

ARTICLE VIII

High Back Pressure Trip

SECTION - G.

OIL SYSTEM

ARTICLE I

Description

ARTICLE II

Main Low Pressure Oil Pump

ARTICLE III

Auxiliary Low Pressure Oil Pump

ARTICLE IV

Control Oil Pump

ARTICLE V

Emergency Oil Pump

ARTICLE VI

Control / Relay Oil System

ARTICLE VII

Oil Cooler

ARTICLE VIII

Oil Filter

ARTICLE IX

Hydraulic Accumulator

ARTICLE X

System Maintenance

ARTICLE XI

Turbine Grease Points

INDEX
SECTION - M.

SECTION - O.

SECTION - P

SHAFT SEALING SYSTEM

ARTICLE I

Labyrinth Glands

ARTICLE II

Oil Seals

ARTICLE III

Steam Drain System

ARTICLE IV

Gland Steam Condenser

OVERHAUL & INSPECTION

ARTICLE I

Overhaul & Inspection

ARTICLE II

Steam End Pedestal

ARTICLE III

Exhaust End Pedestal

ARTICLE IV

Turbine Casing

ARTICLE V

Steam End Pedestal Panting Plate

ARTICLE VI

Sequence of Bolt Tightening

ARTICLE VII

Malfunction - Cause and Remedy

SHUTDOWN AND STORAGE

ARTICLE I

Prolonged Shutdown

ARTICLE II

Rust Protective

ARTICLE III

Job Site Storage of Goods

SECTION- Q.

LUBRICANTS

SECTION- R.

TURBINE MAINTENANCE CHART

SECTION- S.

DRAWING / P & I DIAGRAMS

SECTION -T.

RECOMMENDED SPARES

SECTION- W.

ACCESSORIES

INDEX

ILLUSTRATION
Section

Fig No.

Description

General Arrangement of Turbine

Principal Components Of Turbine

Coupling Alignment Procedure

Coupling Alignment Procedure

High Speed Coupling

Low Speed Coupling

warming up diagram

10

Throttle Valve Assembly

10a
12

Throttle Valve Spring Setting

Turbine Performance Curve

13

Stop & Emergency valve assembly

14

Overspeed Trip Assembly

15

Overspeed Trip Removal

16
17

L P Trip Assembly
Hand Trip Assembly

20

Arrangement of Labyrinth Glands

22

Lifting Arrgt of Turbine

23

Rotor lifting Arrangement

24

Sectional Arrangement of Turbine

25

Arrangement of Thrust Bearing

26

Principle of Journal Bearing

27

Steam End Pedestal Assembly

28

Exhaust End Pedestal Assembly

29

Steam End Pedestal Panting Plate

30

Clearance Diagram

31

Probe Arrangement

32

Alignment of Turbine /GearBox & alternator

A
C

INTRODUCTION OF MANUAL
INTRODUCTION OF MANUAL
INTRODUCTION OF MANUAL
This instruction manual contains installation, operation, and maintenance instructions
for the TRIVENI Turbine identified on the Turbine technical data sheet included with
this manual. It should be reviewed thoroughly by the user before attempting to install
and operate the turbine and should be kept in a location convenient to the user for
ready reference during operation and maintenance.
WARNING
A complete reading of this manual by personnel in contact with the steam turbine is
Essential to safety. INCORRECT INSTALLATION, OPERATION, MAINTENANCE,
OR PARTS REPLACEMENT CAN RESULT IN INJURY TO PERSONNEL, AND
DAMAGE TO THE TURBINE, DRIVEN MACHINERY, AND PLANT.

The instructions contained in this manual do not attempt to cover all details, nor provide for
every possible contingency to be met in connection with installation, operation, or maintenance
of the supplied equipment.
The supplying of instructions does not imply in any manner that TRIVENI TURBINE LTD.
accepts liability for work carried out by a customer or contractor personnel.
Liability is limited to and stated in our terms & conditions of sale.
All inquiries regarding installation, operation, maintenance, spare parts or service should
be directed to TRIVENI CUSTOMER CARE CELL, or manufacturers representative

Precautions
This turbine has been designed to provide safe and reliable service within the designed
specifications. It is a pressure containing, rotating machine; therefore, responsible and
qualified personnel must exercise good judgment and proper safety practices to avoid damage
to the equipment and surroundings and /or possible serious or painful injuries.
It is assumed that your companys safety department has an established safety Program
based on a thorough analysis of industrial hazards. Before installing, operating or performing
maintenance on the turbine, it is suggested that you review your safety program to ensure it
covers the hazards arising from rotating machinery and pressure vessels.

INTRODUCTION OF MANUAL
It is important that due consideration be given to all hazards resulting from the presence of
electrical power, hot oil, high pressure and temperature steam, toxic gasses and flammable
liquids and gasses. Proper installation and continued maintenance of protective guards,
shutdown devices, and overpressure protection are also necessary for safe turbine operation.
The turbine should never be operated by bypassing, overriding or in any way rendering
inoperative guards, protective shutdown equipment. or other safety devices.
When internal maintenance work is in progress, it is essential that the turbine be isolated
from all utilities to prevent the possibility of applying power or steam to the turbine. When
performing internal turbine maintenance always ensure that isolating valves in the steam
inlet and exhaust lines are closed and tagged and all drains are opened to depressurize the
turbine casing and steam chest .
In general you should be guided by all of the basic safety rules associated with the turbine,
driven equipment and plant process.
This manual contains four types of hazard seriousness messages .they are as follows :
DANGER : Immediate hazards which will result in severe personal injury or death.
WARNING : Hazards which could result in serious injury to the turbine operator and others,
or extensive damage to the turbine, driven equipment, or the surroundings.
CAUTION: Hazards which could result in damage or malfunction to the turbine or its parts,
leading to subsequent down time and expense.
NOTE :A message to clarify or simplify an operation or technique ,or to avoid a common
mistake .

INTRODUCTION OF MANUAL
DANGERS
Do Not attempt to ADJUST, REPAIR, DISASSSEMBLE or MODIFY this turbine WHILE IT IS
IN OPERATION, unless such action is expressly described in this instruction manual.
Never disconnect Inlet or exhaust piping of the turbine without first CLOSING and TAGGING
the ISOLATING VALVES and then OPENING DRAIN VALVES SLOWLY to relieve any pressure
within the turbine .Failure to do so may expose PERSONNEL to SERIOUS INJURY if steam
were to be introduced into the piping or captured in the turbine .AS an added precaution,
always install blank flanges on inlet and exhaust lines after removing the turbine.
DO NOT REMOVE ANY COVERS, GUARDS, GLAND, HOUSINGS, DRAIN COVERS etc. while
the unit is operating.
Under no circumstances should the TRIP VALVE be blocked or held open to render the trip
system inoperative .Overriding the trip system ,and allowing the turbine to exceed the rated
(nameplate )trip speed ,may result in FATAL INJURY to personnel and extensive turbine
damage .In the event the trip system malfunctions, immediately SHUT DOWN the turbine
and correct the cause .
NEVER BLOCK OR DIASABLE THE TURBINE TRIP SYSTEM OR ATTEMPT TO ADJUST OR
REPAIR IT WHILE THE TURBINE IS OPERATING.
This turbine is equipped with an OVERSPEED TRIP to protect against dangerous over speeding.
It is absolutely essential that the complete trip system be maintained in such a condition
that it will operate perfectly if required. It must be thoroughly inspected and tested weekly.
Inspection must include all elements of the trip system Triveni Turbine recommends that all
TESTS BE RECORDED.
Keep body parts (fingers ,hands, etc.) away from shaft, coupling, linkage or other moving
parts to prevent contact and possible serious injury . NEVER WEAR NECKTIES OR LOOSE
CLOTHING while in the proximity of the turbine or auxiliary equipment. These could become
entangled in the shaft, coupling, linkage or other moving parts and cause serious injury.
A coupling guard must be installed at the coupling between the turbine and driven equipment.
Wear proper eye protection when working on or around the turbines
The turbine must be grounded.

INTRODUCTION OF MANUAL
Modification of, incorrect repair of, or use of non TRIVENI repair parts on this turbine could
result in a serious malfunction or explosion that could result in serious injury or death.
Such actions will also invalidate ATEX Directive &Machinery Directive certifications for
turbines that are in compliance with those European Directives.
Throughout this manual it is assumed that the motive flow applied at the turbine inlet is
high Pressure steam ,therefore the word steam is used in reference to various aspects of
turbine installation ,operation and maintenance .
DO NOT START OR OPERATE this turbine unless the INSTALLATION has been VERIFIED
TO BE CORRECT and all Pre-startup SAFETY AND CONTROL FUNCTIONS have been
CHECKED.
DO NOT START OR OPERATE this turbine unless you have a COMPLETE UNDERSTANDING
of the control system ,the over speed trip system, the drain and leak off systems, the
lubrication system and all auxiliary mechanical, electrical, hydraulic and pneumatic systems,
as well as the meaning and significance of all monitoring gages, meters, digital readouts, and
warning devices
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS that are not described in this manual.
WHEN STARTING the turbine, BE PREPARED TO execute an EMERGENCY SHUTDOWN
in the event of failure of the governor ,overspeed control systems, linkage or valves.
It is the USERS RESPONSIBILITY to INSTALL A FULL FLOW RELIEF VALVE in the bleed or
extraction line between the turbine bleed or extraction connection and the first shut-off
valve.
This relief valve should be sized to relieve the FULL AMOUNT OF STEAM THAT THE TURBINE
WILL PASS in the event that the bleed or extraction line is blocked .
VEREFICATION

of proper functioning and setting of the OVERSPEED TRIP SYSTEM

(mechanical and Electrical both)

during initial start-up is mandatory .This should be

accomplished with the turbine DISCONNECTED from the driven equipment .Turbine speed
should be increased SLOWLY in a controlled manner during trip testing .
If the turbine is operated on a motive fluid other than steam due consideration must be
given to safety issues that might relate to the medium used including but not limited to the
ignition explosion or poisoning of personnel.

INTRODUCTION OF MANUAL
The surface temperature of the turbine will become that of the steam inlet temperature. This
could exceed the ignition temperature of some gasses.
Therefore

if the turbine is installed where explosive gasses could be present it is the users

responsibility to insure that this does not create a hazardous situation.

Steam quality must be DRY AND SATURATED OR SUPERHEATED .
There must be provision to REMOVE MOISTURE AND CONDENSATE from the steam
supply system to AVOID DAMAGING the turbine. steam purity should meet or exceed as
given in SECTION-C. American Boiler Manufactureres Association Guidleline .
The surface temperature of the turbine and piping will become that of the steam inlet
temperature. Personnel should wear gloves and protective clothing to avoid burns.
Lighting must be provided in the installation to insure that the operators can see the turbine
and its controls.
Should an explosion occur in the vicinity of the turbine it is the user /installers responsibility
to halt it immediately and /or limit the range of the explosive flame and explosive pressures
to a sufficient level of safety.
Shown below are turbine noise levels that were measured at three feet (1 meter ) while
operating at a normal load and conditions. These noise levels are not guaranteed and are
published for informational Purposes only.
SOUND LAVEL FOR THIS MODEL TURBINE - 90-94 dba. ( Actual sound lavel shall be as per
contract agreement)
When the turbine is operated under actual field conditions, noise generated in or by the
piping foundation, base plate, couplings, driven equipment, background and other sources,
can add significantly to the turbine noise level and to the overall noise levels in the area.
It is recommended that the equipment user asses the noise levels of the completed installation
and determine if additional sound attenation and /or hearing protection for operating personal
is required .

SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
1a.

SAFETY INSTRUCTIONS
In the design and manufacture of the turbine all applicable harmonized standards, as
well as other relevant technical specifications have been duly taken into consideration.
The machine therefore is state of the art, providing a maximum of operational safety.
However, in practice this high level of safety can only be achieved if all relevant measures
are taken.
It is the users duty to plan these measures and to monitor their implementation.
In particular, the user has to make sure that

the machine is only used for the purpose it is designed for;

the machine is only used in perfect operative condition; in particular the safety devices
have to be checked regularly for proper functioning;

all requisite protective clothing or equipment for the operating, maintenance and repair
staff is available and is effectively worn by the staff in question;

the complete Operating Instructions are available on or near the machine and are kept
in good state;

only appropriately qualified and authorized staff is allowed to run, maintenance and
repair the machine;

such personnel is given regular instruction in all matters relating to workplace safety
and protection of the environment, and is familiar with the operating instructions,
especially with the safety rules therein contend:
Safety instructions or warnings placed on the machine itself are not removed and are
clearly readable.

1b.

Safety instructions and symbols used

The following pages contain a number of safety-related rules and hints dealing with the
inevitable remaining risks which occur in the operation of the machine.
These risks include hazards for

Personas

Products and machinery

The environment
The Symbols used in the Operating Instructions are primarily meant to draw attention to
safety related areas or problems.

SAFETY INSTRUCTIONS

DANGERSNon-observance of this warning may result in damage to persons (death,

injury)
WARNING Non-observance of this warning may result in damage to the machine
and respective material and to the environment.
The paramount goal of the safety instructions is to prevent injury to persons.
If a safety rule is marked by the above with the caption WARNING, this does not mean
that dangers to the machine, to material or to the environment are excluded.
On the other hand, safety hints marked by above with the caption CAUTION do not
normally indicate dangers for persons.
The symbol alone cannot replace a safety rule ! Consequently, always read the full text
accompanying the warning!
NOTE This symbol does not actually refer to safety hazards but is meant to provide
information for a better understanding of operations and processes linked to the machine.
1c.

Basic safety measures

The machine may only be operated by persons who have been adequately trained and hold
the requisite authorization.. Moreover, these persons must be familiar with the Operating
Instructions and able to use the equipment accordingly. Prior to switching the Turbine
on, the operator(s) must check that

no other persons are within the working range of the machine

no injuries can occur due to starting the machine.

Prior to, the machine has to be checked for visible damage. The machine may only be
operated in perfect conditions.
Any defects must be reported immediately to the person in charge!
Prior to starting the Turbine remove all material / objects from the working area of the
machine that are not required in the course of production!
Prior to starting the Turbine check that all safety devices are in perfect working
order!

SAFETY INSTRUCTIONS
1d. Basic safety measures for maintenance and repair
Always keep the inspection and maintenance intervals laid down in the Operating
Instructions!
Observe the instructions for maintenance and repair that you find in the description of the
individual components!
Prior to any maintenance/repair work, cut off machine from mains and secure main
switch with a padlock! The key to this padlock must be in the hands of the person
performing the maintenance or repair work!
When replacing heavy machine parts make sure to use adequate and safe lifting tackle,
ropes etc.
Prior to any maintenance and repair work, allow critical parts of the machine to cool
down to ambient temperature.
Observe relevant regulations for the disposal of lubricants or cleaning agents!
1e.

Maintenance / Repair of electrical equipment

Repairs of the electrical equipment of the machine may only be performed by appropriately
trained specialist!
Make regular checks of all electrical equipment!
Fix loose connections!
Immediately replace damaged lines / cables!
Always lock the switch cabinet! Access only to authorized personnel using appropriate
key/ too/!
Never hose down switch cabinets and other cubicles containing electric equipment!

1f.

Maintenance / Repair of hydraulic and pneumatic equipment

Maintenance and repair of hydraulic and pneumatic equipment may only be carried
out by appropriately trained staff!
Prior to any work on the pneumatic and / or hydraulic lines of the machine, the system
has to be de-pressurizes
Replace hoses at regular intervals even if no damage should be visible (preventive
maintenance)

SAFETY INSTRUCTIONS
Follow the instructions of the manufacturer.
Prior to machine re-start following any maintenance or repair work

Check screwed connections for tight fit

Make sure that lids or strainers /filters removed for maintenance purposes, are reinstalled

Properly.
After any maintenance or repair jobs and prior to re-start, make sure that

All equipment, tools and material used in the execution of the maintenance or repair
work are removed from the working area

Any spills have been removed, all safety devices have been re-installed and are in
perfect
Working conditions!

1g.

Protection of the Environment

NOTE-Any work carried out on or with the machine must take into consideration the
legal provisions on waste avoidance and waste disposal.
Special care must be taken in the course of installation, repair and maintenance work
to prevent hazardous substances such as

lubricating greases and oils

hydraulic oils

Cleaning agents containing solvents from getting into the soil or sewer system!
The above substances have to be stored, collected and removed in appropriate containers.
NOTE- Protective devices are there to prevent risks!
Immediately upon terminating any maintenance / repair work any safety equipment removed
for
Easier access shall be put back into place! Defective or unserviceable parts have to be
replaced

IIa.. Safety instructions

The machine has built according to the latest state of the art, meeting all requirements for
operational safety.
The machine can become a source of danger if:

the accompanying Operating instructions are not followed;

Untrained personnel is allowed to work on or with the machine;

SAFETY INSTRUCTIONS

The machine is used improperly or for purposes other than the ones intended by the
manufacturer
The may endanger:

the life and limb of staff,

the machine itself and other plant and equipment of the user,

the efficient working of the machine.

NOTE- Any person in the users works entrusted with setting-up operating,
maintaining and repairing the machine must observe both the operating and the SAFTY
INSTRUCTIOSN:
User should make sure that every operator has read and fully u n d e r
s t o o d these SAFTY INSTRUCTIONS.
If the machine is used for training purposes, make sure that the trainees are appropriately
informed about the possible dangers and safety rules prior to training
Whenever the machine is operated by trainees, and particularly those without previous
experience, the trainer has to make sure that he is able to intervene at any moment
Moreover, the trainer must point out the SOURCES OF DANGER AND POSSIBLE RISKS as
well as the ways Of AVOIDING THE8E

b.

Safety regulation
During the transport installation, operation, maintenance and repair of the turbine the
following rules and regulations shall apply as amended

i)

Connecting regulations of competent electricity board]

The purchaser is obliged to obtain these from the local electricity board.

ii)

Rules for accident prevention

These must be on display and freely accessible in every shop. They shall be binding
(including relevant amendments) on everyone working on the customers premises.

SAFETY INSTRUCTIONS
iii)

The principle of safety-conscious working

The machine may only be operated by appropriately trained and authorized personnel.
The maximum speed of the machine must not be higher than the admissible speed of
the clamping element used!
Competences for operating the machine must be clearly defined and adhered to, so that
safety is not impaired by conflicts of competences.
In all instances of setting-up, operation, reconditioning, adaptation, maintenance or
repair, the disconnection sequences listed in the Operating Instructions shall be followed.

c.

Detailed instructions for operators

Refrain from all actions that might impair the safety of the machine.
Do not operate the machine if you are taking drugs that reduce your concentration.
Make sure no unauthorized persons are working on the machine.
Immediately report any changes to the machine that may impair its safety.
The proprietor shall guarantee that the machine is only operated in perfect condition.
The proprietor shall oblige his personnel to wear appropriate protective clothes.
Make sure that no part of your clothing can get caught in turning machine parts. Shirt or
coat sleeves must either be buttoned up or rolled up (folding them inwards).
Particular attention is in order in the case of operators wearing long hair or scarves: use a
hairnet if necessary:
Tuck the ends of scarves or neckerchiefs into your clothes.
The proprietor shall use appropriate instructions and checks to make the place of work on
machine as neat and orderly as possible.
It is strictly forbidden to dismantle or put out of order any safety devices on the
machine!
However, there is an exception from this rule in the case of repairs or maintenance work
being earned out Safety devices may be dismounted if the machine is previously put out
of action following relevant instructions.
The protective devices have been designed to exclude health hazards and damage.
Upon terminating any maintenance or repair jobs on the machine, the safety devices
previously dismounted have to be reinstalled immediately! Make sure that defective or
unserviceable parts are replaced

SAFETY INSTRUCTIONS
d.

Special hazard warnings

Electricity
Memories the position of the EMERGENCY STOP button and the main switch so that no
time is lost in an emergency.
Pull out the mains plug before carrying out any work on the electric system if this
should not be possible cut the electricity supply in the fuse box.
Lock main switch in the OFF position
After cutting out the mains voltage an independent electric circuit is available in the
switch gear cabinet for servicing and similar jobs
Place a warning sing DO NOT CONNECT on the main switch!
Never rely on a circuit being broken always check
Rules in case of electric shocks

Proceed with caution so as not to endanger yourself.

Cut the electricity

Call a doctor (emergency doctor)

If the victim has stopped breathing apply artificial respiration.

Note that this requires first aid training

First aid, even given when given by trained persons, is no substitute for medical
assistance, but only a makeshift until a doctor arrives.
Central lubrication
The pipes and hoses are under pressure. Discharge pressure before carrying out any
work on the pressure lines

f.

Hydraulic unit
The pipes and hoses are under pressure. Discharge pressure before carrying out any
work on the pressure lines
The pressure accumulators mounted on this machine may only be operated and
maintained by qualified and reliable personnel, who have to be instructed by the
proprietor of the machine as to the relevant technical regulations for pressure
accumulators.

SAFETY INSTRUCTIONS
When replacing a pressure accumulator, make sure that the new accumulator has the
same nominal capacity and admissible operational overpressure as the old one.
Each pressure accumulator is to be subjected to a test according to the maintenance
programs to be carried out by a competent person.
Definition of competent persons: those persons acquainted with the design and operation
of the subject device; having professional experience as well as appropriate technical
knowledge based on their specialized training; possessing reliability and a sense of
responsibility; not subject to any directions with regard to the testing activity; and
actually working in their capacity as experts.
g.

Instructions concerning tools and testing or adjusting devices

Notice that no worn or damaged tools/special tools or testing/adjustment devices may be
used.

h.

Prohibition of unauthorized modifications or conversions of the turbine

WARNING- No such changes or adaptations may be effected without the previous consent
of the manufacturer. This applies especially to the use of spare parts or accessories
that have not been released by us! in these instances, the manufacturer will not
assume any responsibility.

j.

Warnings concerning addition risks

k.

Lubricants.
NOTE- Careless handling of these products or disregard of industrial safety rules and the
principles of industrial hygiene may lead to injuries to health, especially skin affections.
Avoid prolonged or intensive skin contact with said products!
Apply skin ointment before the job. After contact with lubricants, wash thoroughly with
water and soap, and apply salves with high fat content!
Do not inhale oil mist or fumes! If required, the user of the plant shall provide appropriate
exhaust devices.
Change oil-soaked clothing at once.

SAFETY INSTRUCTIONS
l

Water protection
Appropriate measures shall be taken to prevent any lubricants or similar fluids from
draining into the sewage system

m.

Commissioning

Before commencing commissioning work, you must familiarize yourself with the following:
The operating and control elements on the machine
The machine equipment
How the machine functions
The direct surroundings of the machine
The safely devices on the machine

Measures that must be taken in an emergency.

The following work must always be carried out before the machine is put into operation:
check all safety devices; ensure that they are fitted and that they function properly,
inspect the machine for visual signs of damage and rectify any faults that you find
immediately,

check again that only authorized persons are in the vicinity of the machine and that
nobody else will be endangered by the machine starting up.

Ensure that all objects and other materials that are not needed for operation of the machine
have been removed from the working area of the machine.

n.

Normal Operation
Safety devices must not be removed or deactivated while the machine is in operation.
While the machine is in operation, operating personnel may only enter the specified
working erase
The operating personnel must ensure that no unauthorized persons are allowed to
enter the working area of the machine.
When the machine is shutdown, operating personnel must wait until all the moving
parts have come to a standstill then may they move away form the machine.

p.

Maintenace
The maintenance work described in the operating manual, such as adjustments cleaning,
lubrication, maintenance and inspection must be earned out as scheduled.
please also observe the special instructions for individual components in this operating
manual.

SAFETY INSTRUCTIONS
Before commencing maintenance work, please note the following points:

Switch off the main power supply at the main switch, lock the main switch and attach a
warning notice to prevent it from being switched on again.

Ensure that at parts off the system from which pressure has been released are looked

to prevent them from being switched on again unintentionally,

Ensure that all the machine components have cooled down to room temperature,
Ensure that suitable load lifting devices and hosting gear are available for replacing larger
machine
Block off all access routes to the working area of the machine and ensure that there are
no unauthorized persons In the working area of the machine,
Replace all machine components that are not m perfect condition immediately,
Only use orginal spare parts,
Ensure that suitable catchments vessels are at hand for all substances that are a
potential risk to groundwater (oils, etc.).
On completion off maintenance work SOD1 before starting up the machine, please note the
following points
Check once again that all screw connections that have been release are securely lightened
again,
Check that any protective devices, covers, tank caps, sieves and fitters that have been
remove, are correctly installed again,
Ensure that all tools, materials and other equipment that was used has been removed
lam the working area of the machine,
clean the working area and clean off any fluids that have escaped and similar substances
Ensure that all the safety devices on the machine are in perfect working order again.

q.

How to react if fire breaks out

DANGERS- In cases of fire, trip the machine immediately and switch off the main
switch
Special fire fighting equipment must be provided for:

the oil used in the machine

the electrical leads.

r.

Potential dangers related to noise

Depending on the conditions on site, high sound pressure levels can occur, which can
cause deafness loss balance or impaired concentration in this case, operating personnel
must be provided with suitable personal protection equipment.
Please note that when the machine is in operation, spoken communication and the
perception of acoustic signals, e.g. the sounding of a vehicle horn, are impaired.

SAFETY INSTRUCTIONS
Please comply with the noise protection regulations in the operating manual for your
workplace and use the prescribed personal safety equipment.
s.

Potential danger of residual power

Please note that even when the machine has been switched off or has come to standstill,
various energy can still be present, for example in the form of:

machine components that are still running down,

Live electrically conductive leads.

III. Safety regulations

a.

Basic safety philosophy

The machine has been designed in accordance with applicable safety provisions any
properly instructed operator can handle this machine easily and safely.
However, if the operator has not received proper training and instructions.
Inappropriate operation may result in material damages.
NOTE- Some covers on the machine are locked with padlocks and are only
accessible for servicing
Purposes, i.e. they are not be tampered with by the operator. The user is obliged to keep
the keys in a safe place and to hand them over, if necessary, to the authorized servicing
staff.
The user shall also be responsible for observing the basic safety strategy.
All persons authorized to operate maintenance and repair the machine are obliged to
read the safety Protocol!

b)

Purpose
The machine has been designed and built to fulfill its defined function and purpose
(see machine documentation).
The manufacturer (Triveni Turbine Ltd.) declines any responsibility for any damage
resulting from any use of the machine that is not in accordance with its defined purpose.

SAFETY INSTRUCTIONS
c)

Inappropriate use
Any use other than the Defined Purpose requires the written consent of the manufacture
any operation outside the machines technical limits will be considered inappropriate.
Any inappropriate use of the device may cause injuries. Closely follow the instructions
contained in the Operating Manual!

d)

Operators
In order to guarantee the safety of the machine, the operators must fulfil certain minimum
standards.
The user of the machine is the contractual partner of the manufacturer, Triveni Turbine
Ltd.
Operators are those persons directly working on the machine.
Before an operator is allowed to work on the machine, he must receive instructions, either
from the manufacturer or the user, regarding the handling and operation of the machine.
The user shall ensure that the operator recognizes any residual hazards presented by the
machine.
Make sure that even foreign operators clearly understand all safety instructions!
The user is responsible for preventing any unauthorized persons from gaining access to
the machine, or
operating the same.
The user must ensure the use of the machine according to its Defined Purpose.
Moreover, he is responsible for properly instructing the operator(s).
Any maintenance/repair work on the machine and the respective control system is strictly
Reserved for the manufacturers servicing staff or authorized staff employed by the user

e.

Safety rules
Take note of the following additional safety rules
Beside the operating instructions, observe your own countrys laws or regulations in
the field of accident prevention and protection of the environment
Do not make any changes to your machine without written consent by the manufacturer.
It is strictly forbidden to operate the machine after removing or bridging safety devices
such as limit switches, emergency pushbuttons, sliding door locking systems or covers.
After any maintenance or repair job or similar action on the machine, the service
technician shall carry out a test run

SAFETY INSTRUCTIONS
IV

SAFETY REGARDSS TO TRANSPORT AND ERECTION

Inappropriate transport may cause damage to the machine or malfunction or
malfunctions there for which the manufacturer does not assume any responsibility or
guarantee. For this reason, appropriate care has to be used during the transport of the
machine.
Before the machine is delivered to your plant, the unloading, transport to the final
location installation and putting into operation should be carefully planned, and the
following instructions should be strictly observed.

a).

General hazards inherent in the transport

Transport and handling jobs may only be carried out by qualified and duly authorized staff.
Proceed judiciously and refrain from any perilous or risky maneuvers.
Ascents or slopes are particularly dangerous, and where taking roads with gradients is
inevitable, special circumspection is in order.
Make sure the machine cannot slip to one side while on the transport vehicle, and that the
latter has sufficient tractive and braking power.

b).

Dimensions and weights

Machine dimensions including weight can be taken from chapter 2.3 Condenser, CEP,
CVC
As units are concerned that are transported separately - such as old cooler, alternator the
relevant instructions of the unit manufacturers shall apply.

c).

Vehicles and lifting gear

For transporting the machine or single parts thereof, only sufficiently strong lifting gear
and means of transport may be used.
Notice that the transport devices, ropes, shackles and the like are not part of Trivenis
scope of delivery but will be readily placed at the purchasers disposal.

d).

Planning the transport and set-up

In order to exclude any hazards during the transport of the machine from the place of
unloading to the place of installation, all steps have to be carefully planned beforehand.
Always bear in mind the dimensions and weights of the various transport units.
For delivering the machine, adequate means of transport and lifting tackle must be
available.

SAFETY INSTRUCTIONS
Any obstacles existing along the route of transport must be removed prior to delivery.
The route has to be checked for sufficient bearing capacity and evenness as well as for
possible damaged to the road surfaced, deep transversal grooves, gradients and the
like.
Also check the clear height of gates and doors.
e).

Suitable vehicles / lifting gear / accessories

Cranes
Mobile cranes
Rollers
Armored rollers
Hydraulic jacks
Fork lifts (only for units transported separately, not for the bulk of the machine)

f).

g).

Space
Leave
Leave
Leave

requirements
sufficient free space around the machine.
sufficient manoeuvring space for the operator.
sufficient room for maintenance and repair work.

Floor; foundations
In order to set up the Turbine a proper foundation must be available.
The foundation shall be prepared in line with the foundation plan and must be well set.

h).

Disposal of waste utilities

The user must advised to clarify in good time how and where you can dispose of waste oil
and the like in line with anti-pollution regulations applicable to respective countries

j).

Protections of waters
The machine contains substances that may pollute surrounding water courses or ground
water in case of leaks caused by an accident.
Consequently, the location of the machine should be designed to prevent any risk of
pollution of the ground water or surface waters.
Precaution:
Install machine in leak- proof foundation

SAFETY INSTRUCTIONS
V.

Transport
Unload the machine as close as possible to the place of location. Short transport routes
will minimize risk of accidents.
For separate transport units such as the
The relevant instructions of the unit manufactures shall apply
Be careful not to cause any jolts or violent shakes when lifting the marching or setting
it down the floor.
WARNING-

Inorder to prevent serious injuries and damage to the machinery

during the transport, the following rules shall be observed:

All lifting gear, ropes, shackles etc. must be in accordance with applicable provisions
of the accident prevention regulations!

When choosing the lifting gear, ropes, shackles etc., the weight
of the machine hall be taken into account!

The handling zone shall be marked and sealed off in such a way as to prevent access
of unauthorized persons!

Keep clear of suspended load!

Transport work may only be performed by qualified and authorized personnel!

Advisably, the machine should be handled by means of a crane.
After setup, all transport safety devices have to be removed

a).

Foundation and setting up

In order to set up the turbine a proper foundation must be available.
The foundation shall be prepared in accordance with the foundation drawing and must
be well set.
The machines load point must also be taken into account.
When placing the machine on unsupported ceilings, a structural engineer must be
involved in the Calculations.

A1
I.

SECTION A-INTRODUCTION

A1

GENERAL DESCRIPTION
A steam turbine is a heat engine converting the heat energy of steam supplied to it, into useful
work.
The available heat energy or Heat Drop can be computed as the change in steam condition from
stop valve to exhaust branch.
Steam flow at high velocity results from expansion of the steam through a series of nozzles which
convert the heat energy into kinetic energy. This kinetic energy is transformed into useful work as
the steam mass progresses through the turbine. The change in direction experienced by the
steam as it impinges on the moving blades imparts a reactive force on the blades producing
torque on the rotor shaft.
In order to convert large amounts of energy into useful work with maximum efficiency, it is
necessary to expand the pressure energy of the steam flow in a series or stages. Each stage
comprises a set of nozzles followed by a fully bladed disc or wheel.

II.

DESCRIPTION OF COMPONENTS

Cylinder
The cylinder or casing is divided at the horizontal joint, and is arranged with center line support,
i.e. the support points are on the same horizontal plane as the center line of the turbine.
At each end-two right angles palm pieces are keyed and bolted to the casing on vertical
facings. The horizontal faces of the palms rest on pads equi-spaced about the pedestal centre
lines. A transverse key through each palm piece and its mating pad-serves to locate the casing
axially to each pedestal.
The exhaust end pedestal is anchored rigidly to the baseplate, whereas the steam end
pedestal sits upon a flexible panting plate. The latter provides rigidity in the vertical and lateral
planes, but allows flexibility in the axial (horizontal) plane of casing thermal expansion.
A key located vertically underneath the cylinder at the steam end, mates with a matching keyway
on the steam end pedestal, allowing free radial expansion of the casing whilst at the same time
restraining any transverse movement.

A2

INTRODUCTION

A2

The cylinder supported thus, moves axially away from the fixed exhaust end, the rotor thrust
bearing housed in the steam end pedestal therefore experiences this movement. The rotor located
by the thrust bearing, expands towards the exhaust end pedestal so that axial expansion of the
cylinder and rotor ensures controlled relative movement between moving blades and stationery
nozzles. Sufficient clearance between stationary and moving parts has been allowed for abnormal
operating conditions.
The exhaust opening of the cylinder is vertically upward or downward (see Fig-1) and is connected
to the exhaust main through a suitable bellows system.
Nozzle Chest
Function as a pressure vessel, the lower half being sub-divided internally into three separate
nozzle compartment. A flanged rectangular opening on top of the cylinder accepts the lower half,
which contains the first stage nozzle segments fitted to a common mean diameter.
The upper half visible on top of the casing, provides a facing for mounting the three throttle
valves, each controlling steam flow through its respective nozzle arc.
Rigid vertical flanges, cast integral at the extreme transverse ends of the upper half, provide
steam inlet facings for mounting the Stop and Emergency Valves.
Rotor
The turbine rotor is designed to be operated above its first transverse critical speed (see
ARTICLE I, SECTION B.) and is machined from a solid alloy steel forging. Straight sided discs
are gashed out of the forging with suitable heads formed profiled with grooves and side grips to
accept the blading.
Blade Gates are slotted radially into the disc heads and are staggered diametrically to minimize
the out of balance effect.
Special closing blades pinned in position after blading, blank off the gates to give a uniform
arc of blades without gaps or caulking pieces. Any such gaps would give rise to increased
bladebending stresses and cause harmonic vibrations.

A3

INTRODUCTION

A3

Balancing strips are formed integrally on all the discs, which permit metal to be removed for
dynamic balancing purposes without encroaching on the stressed disc profile.
Steam balance holes, carefully finished to avoid any local stress concentrations, are drilled axially
through the discs.
Suitable stepped diameters are provided at the interstage and shaft end gland areas which match
the high/low fins of the spring loaded labyrinth packings.
The rotor journals and thrust collar (integral with the shaft) are precision ground at one setting.
The output end is flanged as part of the forging to accept the high speed coupling.
High Speed Coupling
The coupling between turbine rotor and gearbox is a flexible element type
Overspeed Trip
At the steam inlet end of the rotor, an extension is bolted to the main shaft. This extension houses
the overspeed trip unit and also carries the pinion drive for the layshaft.

Nozzles and Diaphragms

The nozzles and diaphragms are built up from items machined out of solid metals.
The 1st stage nozzle profile is composed of straight lines and circular arcs, The shrouds are
provided with peripheral tenons which are straight radially, to fit into matching circular grooves
turned in the nozzle chest. The nozzle segments abut one to another and fit circumferentially into
the nozzle end pieces. These end pieces are secured to the nozzle chest to close the open
ends of the grooving. The abutting segment faces are completely steam tight, and the external
joints between nozzle segments and the nozzle chest are then sealed with a light run to weld.

A4

INTRODUCTION

A4

The Diaphragms consist of an inner and outer ring, split across the horizontal diameter, with a
circumferential groove turned in the inner edge
of the outer ring, and the outer edge of the inner ring. Into these grooves are fitted the matching
tenons of the fully machined nozzle segments. The nozzle segments are generally similar to the
1st, stage nozzles, again machined to form a nozzle profile comprising straight lines and radii with
integral top and bottom shrouds. The segments are carefully fitted into their respective inner and
outer rings riveted together thus forming a rigid structure. At the horizontal joint the diaphragm
assemblies are provided with radial keys to locate the two halves and prevent leakage across the
joint. The bores of the diaphragms are also grooved to accommodate spring backed segmental
labyrinth packing.
The diaphragm assemblies are located axially by internal circumferential grooves in the turbine
cylinder and centralized by means of three radial keys in each half two side keys and one
bottom or top key.
The top half casing has large head button screws fitted at the horizontal joints, which overlap the
diaphragms, thus preventing the latter dropping when lifting the top half casing.
Moving Blades
The moving blades are machined from bar material.
The roots are machined true radially and the tee profile broached to ensure accurate fitting to the
grooves turned circumferentially in the disc heads.
Circular or elongated blade tenons are employed according to the circumferential pitch of the
individual stages. Blade materials are selected to suit operating conditions, as is the compatible
shroud band. Due consideration is seen both in the design and manufacture to the avoidance of
stress raisers.
Labyrinth Glands
In order to restrict the leakage areas where the turbine rotor shaft passes through the casing,
non-contact glands are provided. These are of the stepped labyrinth high-low tooth type which
consist of a number of metal rings cut into segments with serrations or fins turned on the inside of
the rings.
The fins are positioned to match steps turned on the rotor shaft, the assembly thus presents a
tortuous, labyrinth path, against leakage.

A5

INTRODUCTION

A5

The many restrictions and corresponding spaces rapidly drop the pressure of the steam thereby
increasing its volume and limiting the quantity (mass) that can pass through the final restrictions.
The exhaust labyrinth is divided along its length and provided a separate pockets. This pocket is
connected to the gland condenser (if Provided) or to atmosphere.
At the steam end the wheel case pressure increases progressively with load on the turbine.
To break this pressure down, and to reduce steam leakage outwards from the wheel case, the
high pressure gland is provided with additional inner labyrinth rings and two leak off pocket.
The inner pocket leaks surplus steam back to the exhaust branch. The outer pocket is connected
to the gland condenser or vents to atmosphere.
The labyrinth rings are supported in T slots in the gland housings, and are held concentric with the
turbine shaft by radial leaf springs. The top half
gland housings are trapped in the top half casing by button screws similar to the diaphragm
arrangement. If rubbing occurs the segments are pushed outwards against the springs to a
larger diameter until the disturbance is over. Providing the turbine is warmed through, drained
correctly, and run up to speed slowly, the clearance will remain small and little or no labyrinth wear
will occur.
Oil Seals
The oil seals are of similar construction to the steam labyrinth glands, but have in addition:- a
thrower and catcher on the inner side of the pedestal housings. A large diameter thrower is
incorporated between the steam and oil seals at both steam and exhaust end pedestals.
End discharge of oil from journal bearings is baffled by splash guards fitted to the bearing housings,
guiding leakage oil down to the pedestal oil drains. The thrust bearing discharge is entrained in a
fabricated trunking on top of the bearing housing which again deflects oil flow downwards to
drain.

A6

INTRODUCTION

A6

Steam End Pedestal

The pedestal is of rigid fabricated box construction, housing the free end of the rotor shaft. The
horizontal joint is coincident with the turbine center line and provides a platform for the casing
palm pieces. Between this platform and the underside of the palm piece a shim is interposed to
provide adjustment on assembly. Substantial transverse keyways provide the necessary axial
location with the casing.
The panting plate assembly which supports and locates the pedestal, is given an initial cold draw
in the opposite direction to thermal expansion, this limits panting plate deflection in the hot running
condition. See FIG.29.
To the left of the center line is a layshaft, located in:- Pressure fed, steel backed, white metal
lined bearings and connected through reducing gears to the rotor shaft. Sometimes a layshaft
provides a power take-off for the governor and the high pressure oil pump through a worm and
wheel reduction. The tachometer generator (if fitted) is directly driven from slot and pin contact
at the outer end of the layshaft.
To the right a facing is provided for the relay cylinder, drainage from the relay is baffled internally
to avoid windage effect and vented externally to prevent air-locking.
The hand trip body bolts directly to the pedestal at the center line, providing the oil supply to the
OVERSPEED TRIP.
A fabricated cover carrying the speed governor encloses the top half of the pedestal. For viewing
the mesh and lubrication of the governor worm and wheel a Perspex window is provided below
the governor. Oil from the pedestal, drains directly back to sump through two large bore drain
pipes, situated below the bearing housing.
Exhaust End Pedestal
It is basically similar to the steam end pedestal with respect to the bearing housing, oil seal
housings and the horizontal joint platform for the casing palm pieces.
The fabricated box section has greater depth and is heavily ribbed fore and aft providing the
necessary rigidity to anchor the casing.

A7

INTRODUCTION

A7

Journal and Thrust Bearing

Journal bearings are white metal lined tilting pad type.
Axial thrust is taken by a tilting pad center pivot type thrust bearing. The separate pads
having white metal thrust faces superimposed on a steel backing.
The rotor shaft bearing (steam end) and the thrust bearing are combined in a single housing
readily accessible under the common bearing cap.
Combined Stop & Emergency Valve
Hydraulically operated stop and emergency valve is flanged and bolted to the inlet facing of
the throttle valve chest.
The valve incorporates a pilot valve for starting and a main valve for normal running. The
hydraulic piston which, operate the valve is spring loaded and supplied with control (relay) oil
from the control oil circuit. On loss of control oil pressure the valve closes rapidly under the
action of steam pressure and spring load. Loss of control oil pressure is initiated by operation
of the Low Pressure Oil trip valve in the supply line to the control oil circuit, should any running
fault materialize.
These units combine two functions:
(a)

That of isolating the turbine from the steam main when stationary.

(b)

To provide immediate steam cut-off should any security trip operate.

These single beat valve is designed with steam-on-top, so that when shut, the inherent steam out
of balance across the valve maintains a tight seal against steam leakage and provides in addition
a tamper-proof stop valve.
Steam Strainer
The steam strainer is cylindrical in shape, with perforated holes is fitted surrounding the
main valve thus preventing debris from reaching the valve or seat.

A8

INTRODUCTION

A8

Speed Governing (Refer Section E)

The system comprises:
1.

This is a Woodward 505 electronic governor which takes the input from the speed sensing unit
mounted on the Steam End Pedestal.
The operation of 505 Woodward Governor is described in governor publication.

a).

The governing system is an electronic type with an electrical signal being transmitted to a servo
actuator which in-turn controls the lift of Throttle valve & hence the steam entering the Turbine.

2.

Three single beat throttle valves operating in pre-set sequence are positioned by the power
piston and associated linkage until equilibrium is established, i.e. flow of steam through the first
stage nozzles is sufficient to sustain load at governed speed.
Control Arrangements
The governing system with an electrical signal transmitted to a hydraulic actuator for amplify the
turbine throttle valve. The turbo-generator can operate as a independent unit, in parallel with other
generating sets of known governing characteristic or in parallel with the main grid supply.
The speed setting can be adjusted locally (at the turbine) or remotely (from the control panel).
Security Trip Devices
In order to protect the turbine against certain faulty running conditions, an emergency trip system
is incorporated featuring L.P. trip valve.
The function of these devices is to stop the turbine automatically should certain faults develop.
This is achieved by cutting-off the supply of high pressure oil to the actuator and the stop and
emergency valve servo.
Throttle valve and stop valves close with the loss of control oil pressure by a combination of
spring load and steam out of balance.

A9

INTRODUCTION

A9

The following faults will result in automatic shut-down of the turbine:

(a)

Overspeed

(b)

Low lubricating oil pressure

(c)

High exhaust pressure by pressure switch.

(d)

High control oil pressure

(e)

Low control oil pressure

A solenoid trip is incorporated in the system to provide remote shutdown. At the steam end
pedestal a hand trip provides a local shutdown facility and is a convenient tool for testing action
of the L P trip and stop and emergency valve.

SECTION B-TECHNICAL DATA

B1
I.

TURBINE
Power Rated
Inlet Steam Pressure
Inlet Steam Temperature
Inlet Steam Flow
Wheel case Pressure
Steam Exhaust Pressure
Turbine Speed
Alternator Speed
Turbine Trip Speed Range
First Critical Speed Range
No. of Stages
Steam Inlet Size
Turbine Weight
Direction of rotation
from turbine end

II.

KW
BARA
oC
TPH
BAR(g)
BARA
RPM
RPM
RPM
RPM
Nos
Kg
-

5000
19.6
320
52.6
11.49
2.39
8303
1800
9133-9549
5300-6300
5
200 NB
27000
COUNTER CLOCKWISE

RPM
RPM

DOUBLE HELICAL
HSG500(DH)
8303
1800

LTRS
LTRS
LTRS
BAR(g)
BAR(g)

ISO VG 46
5583
6083
4921
1.8-2.0
25

GEARED
120
GEAR BOX
1800

GEAR BOX
Type
Model
Input Speed
Output Speed

III. OIL SYSTEM

Lubricating Oil Grade
Oil Tank Capacity
Quantity Reqd. for 1St fill
Quantity Reqd. for Flushing
Lube Oil Pressure Range
Control Oil Pressure Range
A.

MAIN LUBRICATING OIL PUMP

Type
Capacity
Driver
Speed

IGPM
RPM

B1

B2
B.

TECHNICAL DATA
AUXILIARY OIL PUMP
Type
Capacity
Discharge pressure
Speed
Motor

C.

IGPM
BAR(g)
RPM
HP

GEARED
120
3.5
1440
15

IGPM
BAR(g)
RPM
HP

GEARED
48
3
1440
5

IGPM
BAR(g)
RPM
HP

SCREW
25
25
1440
10

IGPM
oC
oC
m2
oC
oC
m3/Hr

SHELL & TUBE

120
60
45
244
26.7
26
34
27

DUPLEX
120
3.5
10

EMERGENCY OIL PUMP

Type
Capacity
Discharge Pressure
Speed
Motor

D. CONTROL OIL PUMP (2XCOP)

Type
Capacity
Discharge Pressure
Speed
Motor
E.

OIL COOLER
Type
Capacity
Oil Temperature Inlet
Oil Temperature Outlet
No. of Tubes
Surface Area
Cooling Water Temp. Inlet
Cooling Water Temp.Outlet
Cooling Water Flow

F.

OIL FILTER (LUBRICATING OIL)

Type
Capacity
Working Pressure
Filteration

IGPM
BAR(g)
-

B2

B3

TECHNICAL DATA

G. CONTROL OIL FILTER

Type
Capacity
Working Pressure
Filteration

IGPM
BAR(g)
Microns

DUPLEX
30
25
10

IGPM
BAR(g)
Microns

SIMPLEX
45
3
15

OIL
25 NB
3.55
25

OIL
40 NB x 50 NB
3.2
120

OIL
25 NB
1.8
10

OIL
25 NB x 50 NB
26
50

H. EOP FILTER
Type
Capacity
Working Pressure
Filteration
I.

PRESSURE RELIEF VALVE (MOP)

Duty
Size Inlet / Outlet
Set Pressure
Discharge Capacity

J.

BAR(g)
IGPM

PRESSURE RELIEF VALVE (AOP)

Duty
Size Inlet / Outlet
Set Pressure
Discharge Capacity

BAR(g)
IGPM

K. PRESSURE RELIEF VALVE (LUBE OIL)

Duty
Size Inlet / Outlet
Set Pressure
Discharge Capacity
L.

BAR(g)
IGPM

PRESSURE RELIEF VALVE (COP)

Duty
Size Inlet / Outlet
Set Pressure
Discharge Capacity

BAR(g)
IGPM

B3

B4

TECHNICAL DATA

M. PRESSURE RELIEF VALVE (COP)

Duty
Size Inlet / Outlet
Set Pressure
Discharge Capacity
N.

BAR(g)
IGPM

OIL
25 NB
25.5
45

LTRS BAR(g) BAR(g) -

20
25
18-20

inch
-

125V DC
3/4"NPTF
DE ENERGISE TO TRIP

inch
-

125 V DC
1/2"NPTF
DE ENERGISE TO TRIP

MM

FLEXIBLE
8GBH-180-S-140627
400

MM

FLEXIBLE
10GBH-315 S-140776
500

ACCUMULATOR
Capacity
Working Pressure
Pre Charged Pr.

O. SOLENOID VALVE
Volts
Connection
Action
P.

3 WAY SOLENOID VALVE

Volts
Connection
Action

IV. GENERAL
A.

HIGH SPEED COUPLING

Type
Model
DBSE

B.

LOW SPEED COUPLING

Type
Model.
DBSE

C.

TURBINE JOURNAL BEARINGS STEAM END

Type
Size
Quantity

SLEEVE
127
1

B4

B5

TECHNICAL DATA

D. TURBINE JOURNAL BEARINGS EXHAUST END

Type
Size
Quantity
E.

G.

SLEEVE
127
1

TILTING PAD
5

TURBINE THRUST BEARING

Type
No. of Pads per side

F.

GEAR BOX BEARING

Refer Manufacturers
Operations Manual

GOVERNOR
Manufacturer
Type

WOODWARD
505

H. SERVO-ACTUATOR
Manufacturer
Operating Pressure
I.

MOOG
25

BAR(g) Inch
-

STEAM
1.51 1.58
3/4" NPT

SENTINAL RELIEF VALVE

Duty
Set Pressure
Connection

V.

BAR(g) -

THROTTLE VALVE LIFT SETTING

Throttle Valve No. 1
Throttle Valve No. 2
Throttle Valve No. 3
Total Lift Reqd.

MM
MM
MM
MM

50.5
45
6
101.5

Kg/Hr
Kg/Hr
oC
oC
m2
kg
CFM
HP

Horizontal shell & tube

300
26,000
26
32
6.93
5
650 Air at 2" WC
3

VI. GLAND VENT CONDENSOR

Type
Steam Flow
Cooling Water Flow
C.W. Temp. Inlet
C.W. Temp. Outlet
Surface Area
Working Weight
Blower capacity
Blower motor

B5

B6

TECHNICAL DATA

VII.

B6

INSTRUMENT SETTINGS
D e s c ri p t io n

D i ff P r . In d i c a to r
c u m S w i tc h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h
P r e s s u r e S w it c h

P r e s s u r e S w it c h

S e r vi ce

R e co m m e n d e d
s e t t in g s
0 .7

R an g e
a v a il a b le
0 to 1 .0
Bar

P r . D i ff a c r o s s
fi l te r a la r m
A O P a u to
O N /O F F

1 .4
2 .2

A C O P - 1 A u to
O N /O F F

1 9 B a r (g )f o r c u t - in , 2 6
B a r ( g ) fo r c u t- o ff

0 .0 to 4 0 .0

A C O P - 2 A u to
O N /O F F

2 0 B a r (g ) fo r c u t - in , 2 7
B a r ( g ) fo r c u t- o ff

0 .0 to 4 0 .0

E O P a u to
O N /O F F

1 .0
1 .4

B a r ( g ) fo r c u t- i n ,
B a r ( g ) fo r c u t- o ff ,

0 .4 to 4 .

L u b e o il p r e s s u r e
low a larm
L u b e o il p r e s s u r e
v e ry low a larm
int erlo c k
B e tw w e n
A O P / A C O P /B G M
C o n tr o l o il
p res s u re low
a la r m
C o n tr o l o il
p res s u re v e ry
l o w t r ip

1 .4

B ar (g)

1 .2

B ar (g)

B ar (g)

(g)
B a r ( g ) fo r c u t- i n ,
B a r (g ) fo r c u t- o ff

0 .4 to 4 .0 B a r
(g)

Ba r (g)

Ba r (g)
Bar

(g)

0 .2 to 2 .0 B a r

(g)

0 .2 to 2 .0 B a r
(g)

1 .5 B a r ( g )

0 .2 to 2 .0

Bar

(g)

18

Bar (g)

1 7 B a r (g )

0 .0 to 4 0 .0
Ba r (g)

0 .0 to 4 0 B a r
(g)

T r i p o il p r e s s u r e
v e r y l o w t r ip
B e arin g
v i b r a ti o n s

0 .8 B a r ( g )
A l a r m 3 . 5 a n d t r ip 4 .5
m i ls

0 to 5 .0 m i l s .
P ro gra m m a ble

A x ia l d is p l a c e m e n t
in d ic a to r t u r b i n e
V ib r a ti o n M o n it o r

A x ial
d is p l a c e m e n t
G e a r b ox
H ig h s p e e d s h a f t

A l a r m + / - 1 0 a n d tr ip + /1 4 m il s
A l a r m 2 . 6 m il s .T r ip 5 .0
m i ls

+ /- 0 to 3 0 m il s

RT D

T u r b in e b e a r i n g s

RT D

G e a rbo x
b ea ring s
G e n e r a to r
b ea ring s
G e n e r a to r
w in d in g

A larm 95 d e g. C ,
T r i p :1 0 0 d e g . C .
A l a r m 1 0 0 d e g . C , T r ip
1 07 d e g. C
A l a r m 8 5 d e g . C , T r ip
9 0 d e g .C
A l a r m 1 2 5 d e g . C , T r ip
1 30 d e g. C

V ib r a ti o n m o n it o r
T u rbin e

RT D
RT D

NOTE:- Whichever is applicable

0 .2 to 2 .0 B a r

(g)

0 to 1 0 m i ls .
P ro gra m m a ble
P ro gra m m a ble
P ro gra m m a ble
P ro gra m m a ble
P ro gra m m a ble

SECTION C- ERECTION AND COMMISSIONING

C1

ERECTION AND COMMISSIONING

C1

IMPORTANT- THE POVIDED INFORMATION IS FOR REFERENCE ONLY, CUS

TOMER MUST CONTACTED TRIVENI SERVICE PERSONALS.
ALL THE EQUIPMENT REFERED IN THIS CHAPTER MAY NOT BE APPLICABLE
FOR INDIVIDUAL PROJECT.SELECT APPLICABLE ONLY
I

ERECTION- MECH
BEFORE COMENCING ERECTION, ALL NECESSARY DRAWING MUST BE
CAREFULLY STUDIED AND TOOLS MUST BE COLLECTED
UNLOADING AND FOUNDATION INSPECTION.
Procedure:
All the materials should be unloaded near the TG deck at site and maximum care
should be taken during unloading to prevent it from any damages. (Instruments to be
placed in the covered and protected Store area)
Foundation inspection should be done before placing the turbine (the packer plates
should also be grouted) i.e. perpendicularity of foundation holes should be checked
using a plumb and positions of holes should be checked by referring foundation block
diagram.
To help in the correct positioning of the turbine and driven equipment or any other
equipment, it is advisable to mark the centerlines of both driver and driven equipments
shaft lines from the foundation block bolt holes.
Check particularly the two lines are parallel to each other. Refer the GA and foundation
drawings of both driver and driven equipments for above markings. Piano wires can be
used for having a accurate position of the TG.
All holes should be clear from civil materials.
Documents Required:
Foundation Block Diagram
Tools required, typ only
Measuring tape
String (Plumb)
Tri square

C2

ERECTION AND COMMISSIONING

C2

Lifting and Placing of Turbine and Driven Equipments:

Lift the Turbine/ driven equipment using suitable crane and place them on the grouted
packer plates. (While lifting there might be requirement to open certain pipes of turbine/
cladding to avoid damage and also proper balancing of equipments while lifting)
Tools required:
Suitable Mobile crane
Chain Blocks
Slings/wire rope
Drawings required:
Foundation block diagram
GA drawing of turbine and driven equipment
Note :

Load test to be carried it for a period of 2 hours before lifting.

Leveling and Alignment of Turbine and Driven Equipments.

Leveling Procedure:
After lifting and positioning of turbine and driven equipment on the TG deck, completion
of shrink fitting of coupling Hub to driven equipment shaft, match the center line of the
Turbine (X & Y), fix all the foundation bolts, anchor plates, nut and washers. Ensure
the contact area of Anchor plates with the foundation by 70 - 80%.
Level the turbine using the leveling pads (Jack bolts of the turbine) provided on the
turbine base frame by using the master level and necessary taper wedges/plates/
shims. Allowed limit is 0.1mm/ meter.
Final leveling to be checked by measuring the level on the gear wheel shaft for one axis
and on the joint face of the gearbox for the other axis. Leveling of the turbine can be
achieved by adjusting the jackscrew and by increasing or decreasing the packing.
Allowed limit is 0.05mm/per meter.
After leveling the turbine and driven equipment is leveled. The driven equipment along
with its sole plate is placed on the grouted packer plates. Sufficient height should be
provided so as to adjust with shim plates to match with the turbine center height and
care should be taken during positioning of the driven equipment that DBSE of the low
speed shafts is as per the drawing.
Also the driven equipment shaft is located in its magnetic center, this can be ensured
by checking the thrust face gap on either side of the drive and non-drive end bearings.

C3

ERECTION AND COMMISSIONING

C3

Alignment Procedure:
Open the gear box top cover, remove the top half of the gear wheel, pinion and rotor
after bearings. Remove high speed coupling and fix the clamp to check the high speed
alignment. (Clamping mandrels should be rigid and should does not show any sag in
the readings)
Alignment should be checked in both radial and facial direction between rotor and
pinion with dial on pinion flange. Use taper wedges and shim plates for alignment.(
DBSE to be ensured by keeping rotor and pinion in centre).
After achieving the required values (see fig-32) start tightening the foundation bolts in
sequence using a torque wrench. (Refer section O, Overhauling & inspection)
Ensure that all the packer plates are uniformly loaded by slightly tapping with hammer.
Similarly driven equipment alignment is done with dial on driven equipment shaft and
alignment should be checked in both radial and facial direction.
After achieving the required values (see fig-32) start tightening the foundation bolts in
sequence using torque wrench. (Refer section O, Overhauling & inspection)
Ensure that all the packer plates are uniformly loaded by slightly tapping with hammer.
Fix the spool piece to the turbine exhaust flange after the completion of alignment.(if
supplied)
Check & confirm the high-speed alignment as earlier.
Bellow to be welded/bolted to the spool piece taking care that the high-speed alignment
is not disturbed. Welding to be done diagonally to avoid distortion.
Erection of main driven equipment (If applicable)
1.
2.

Important-follow suppliers O & M Manual and,

Check whether all contractual drawings, specifications pertaining to erection are
available at site.
Check whether all components, parts, as per the packing list are available at site.
Check whether they are in good condition. Assemble them as mentioned in below
paragraphs.

C4

ERECTION AND COMMISSIONING

C4

3.

Ensure that proper tools & safety are gadgets available to handle the equipment.

4.

It is important to lift the machine /components by the lift arrangement provide on

them.
The positions in the concrete bed where the Packer plates are to be placed have to
be chipped as explained in Micro chipping and Grouting of Packer plates. Packer
plates, by the side of the foundation bolts & check their levels & height,

5.

Place the taper wedges (on the packer plates). Two taper wedges to be placed one above
the other with taper faces mating each other. Ensure that they do not slide off. Now
check their level and height.

6.

Now the place the main driven equipment with sole plates on the foundation. The sole
plate now rests on taper wedges. Check the level of the machine by placing spirit level
on the sole plates. Adjust the level if required, by adjusting the taper wedge below the
sole plate. It is necessary to jack the sole plate for adjusting the taper wedges.

7.

Ensure that required numbers of foundation bolts are placed in the foundation pockets.
The centre distance of these bolts should match with the fixing holes provided on the
driven equipment.

8.

Care to be taken to set the magnetic centre gauge position. Three basic operations of
the axial positioning, paralleling and centering of the shafts to be ascertained, after
ensuring these points tightens the nuts of the foundation bolts. After tightening also
ensure the above all points.

9.

Tighten the foundation nuts lightly first and align the driven equipment with respect
to turbine as explained in Leveling and Alignment of Turbine and driven equipment.

10. Adjust the taper wedges if necessary to align. Set the alignment between driven equipment
and reduction gearbox as explained in Leveling and Alignment of Turbine and driven
equipment.
11. If required the Lateral movement (along with axis of shaft) of Turbine can be adjusted
by moving wedge plates provided.

C5

ERECTION AND COMMISSIONING

C5

C6

ERECTION AND COMMISSIONING

C6

Fixing of Spool Piece and Expansion Bellow. (If Applicable)

Spool Piece to be bolted/welded with the turbine exhaust-mating flange, which is
supplied loose along with the turbine. (Welding procedure as attached below)
Then Full welding for Expansion Bellow (Spool piece end to be carried out.
There has to be edge preparation and also gap between the spool piece
per drawing before welding the coupler.

and bellow as

Before final welding the pocket grouting/final grouting and tightening of the fixed bolts
has to be carried out.
Tools required

Persian blue
Scrapper
Straight wedge/ glass (not less than12 mm thickness)
Ag-4 grinding machine
Diesel, cotton, emery paper.
Filler gauge, Dial gauge
Welding Machine
Drawings/Documents:

Foundation Drawings
GA Drawings of Turbine
Spool piece and Bellow drawing.

C7

ERECTION AND COMMISSIONING

C7

WELDING PROCEDURE
S l.
NO.

A c t iv i ty

E n s u r e t h a t th e
c i r c u m f e r e n c e o f th e p ip e
is c h a m f e r e d b y a r o u n d
30 / 3 5 0

In s t r u m e n t s /
EQ PTS/Prec a u t io n
to
be
ta k e n

R e m a rk s

P i p e c u tt in g
M / c , g r in d i n g
M /c / La th e u se
g o g g le s

Pipes to b e
ch a m fere d b y
grin d in g /
m a ch inin g (Tr i
sq u a re t o b e
u sed fo r
c h e c k in g
u n if o r m i n th e
grin d in g
p ro c es s)

I n c a s e p i p e s to b e
w e l d e d to a f la n g e ,
e n s u r e th e p ip e is i n s i d e
th e f l a n g e b o r e b y h a l f
th e t h ic k n e s s o f th e
f la n g e
S e t t h e v o lt a g e a n d
a m p e re in a c c or d a n c e t o
th e e l e c tr o d e b e i n g u s e d

R e fe r c a rb on o f
th e e l e c t r o d e s
bein g u se d fo r
d e t a il s .

C h o o s e p r o p e r e le c tr o d e
i. e . s i z e a n d ty p e i n
a c c o r d a n c e to th e n a t u r e
of t h e p ip e i.e . C .S . / S .S .
pipes

F o r S . S . p ip e s
u s e T IG / E 1 0 6
e le c tr o d e s a n d
fo r C . S . p i p e s
u s e , M IG / o v e r
ch or d S S
e le c tr o d e s

K e e p s p a r k p la t e r e a d y
f o r i n it i a l s p a r k i n g

D o n ot s p a r k o n
th e j o b in i ti a l ly

S ta r t w e l d i n g
c i r c u m f e r e n t ia l ly o v e r th e
p i p e a n d i t s m a ti n g p a r t

If a n y b low - ho l e o r c ra c k
is f o u n d t h e n th e w e ld b e a d is t o b e r e m o v e d b y
c h ip p i n g o r g r in d in g /
g o u g in g a n d to b e
d r e s s e d b e f o r e d e p o s i ti n g
th e n e x t s u c c e s s i v e b e a d .

A ll s l a g / s p a t te r s to b e
r e m o v e d b y c h ip p i n g a n d
to b e c le a n e d w i th w i r e
b ru s h .

U se h an d
gl ov e s , w e ld
s h ie ld , A p r o n

C h i p p in g
h a m m e r , w ir e
b ru s h

W e l d j o in t s to
b e n e a t ly
fo r m e d a n d w e l d
s p a t te r s to b e
rem o v e d

C8

ERECTION AND COMMISSIONING

C8

Grouting of Turbine, Driven Equipment

Recheck the final alignment of High speed and Low speed, which has been recorded
before.
Clean the grouting surface with air blower to avoid dust.
Clean the oily surface with caustic soda on grouting area before grouting.
Storage, usage and disposal of Caustic soda:
Caustic soda is to be stored in a plastic container.
The container should be labeled.
Face shield, gloves, breather mask are to be used by the individual while handling.
The collected caustic soda containers to be properly closed.
Check the availability of required quantity of grouting material as per civil engineer
assessment and suggestion.
Shuttering should be made around the equipment area properly. (Area of around 250mm
around the equipment to be considered)
Fill the mortar in the bottom of the Foundation hole to a height of 1 inch depth and
then sand in the sleeve up to the top of the deck.
Ensure for no leakage of grouting material in cutouts and holes during grouting
Grouting should be carried out as per civil engineer assessment and suggestion.
Ensure the grouting material is filled between turbine/driven equipment base frame
and foundation, and there is no air gap between the base frame and foundation. (To
ensure this grouting material can be poured from height and from only corner only so
that due to gravity material flow is maintained in all directions)
Suitable cutouts to be provided at turbine base frame oil doors for maintenance purpose.
Tools Required:

Air Blower
Concrete mixer
Wooden pieces or channels for shuttering
Caustic Soda

C9

ERECTION AND COMMISSIONING

C9

Placement of Auxiliaries.
(Oil Cooler, Oil Filter, Oil Centrifuge, GVC, (whichever is applicable)
Procedure:
Position the auxiliaries as per the drawing and also to ensure whether the location is
convenient for the ease of operation and maintenance.
Check the Dimension and elevation of the foundation as per the drawing.
Placing and orientation of the equipment w.r.t centerlines marked as per the drawing.
Half grouting (filling the foundation pockets) of foundation bolts after leveling. Leveling
is checked at the pedestal of the equipment and also the perpendicularity of the equipment
nozzles to be ensured.
After curing, equipment is to be leveled to maintain parallelity and perpendicular with
shims/packers at required elevation with the help of spirit level/plumb.
.
Ensure all the foundation bolts are tightened as per the torque recommended using a
torque wrench. (Refer section O, Overhauling & inspection)
Grouting should be carried out as per civil engineer assessment and suggestion.
Tools required:

D-clamps
Wire slings
Ropes
Chain blocks
Master level
Spirit level
Torque wrench
Welding Machine
Drawings required:

GA Drawing
Layout drawing
II.

PIPE CONNECTIONS :
All pipe connections to the turbine should be adequately supported and should not be
rigid. All points must be correctly matched and not sprung into place. All steam pipes
should have expansion bends and should be flexibly supported close to the turbine.
Rigid connections may result in malalignment of the casing and cause distortion and
rubbing of the labyrinth gland packings or even fatigue failure of the flexible coupling.

C10

ERECTION AND COMMISSIONING

DO NOT :
1.
Use the turbine as an anchor.
2.
Spring pipe flange together
3.
Accept mismatched flanges
4.
Alter the length of bellows unit tie bars (if fitted by clients in
5.
Fit sling hangers shorter than 508 mm
6.
Accept inadequate anchor points.
7.
Fit spring hangers incorrectly adjusted.
8.
Fit roller supports with pipe clearance
9.
Leave temporary ties or props in the system
10. Drill pressure tapings, drain connections, etc. in situ

C10

their pipe line)

Failure to observe the above may result in malalignment of the turbine casing and
cause distortion and labyrinth gland interference.
An inadequate piping system can be attributed to Vibration,thrust bearing wear and
coupling failure.
Steam pipes and isolating valves, especially when new, are liable to contain sand, mill
scale, weld spatter, jointing compound etc. Therefore, before connecting steam lines to
the turbine it is essential that the lines are thoroughly blown through with high pressure
steam. Chemical cleaning of a system does not ensure all pockets of debris are cleared
as efficiently as does a flow of high velocity steam. Steam strainers can be over-whelmed
by contaminants from new steam lines.
Should the strainer be ruptured and debris carried into the turbine, damage may be
caused to valves, valve seat, nozzles and blades with disastrous consequences.
All steam pipes should be well lagged and drained through automatic drain traps.
These should be fitted with isolating valves and a bypass to allow for inspection and/
or maintenance when running.
Slugs of water accumulating in un-drained lines are liable to impose serious shock
loads on the turbine. These shock loads may result in heavy vibration, uncontrollable
speed fluctuations, false operation of the over speed trip and severe over load of the
turbine thrust bearing, which can be of sufficient magnitude as to cause total failure of
the thrust bearing.
Fabrication of Piping Between Turbine, Auxiliaries, and Drain lines.
Procedure:
After completion of positioning of Auxiliaries, Turbine, Driven Equipment, Lube oil
piping between Driven Equipment /Turbine to cooler, cooler to filter, filter to lube oil
header,

C11

ERECTION AND COMMISSIONING

C11

The following procedure to be followed for fitment of pipelines before carrying out welding.
Ensure a gap of 2.5mm between two pipes. With edge preparation and gap to be
maintained on the thickness of welding rod/filler rod.
Ensure Slope of the pipeline towards the direction of flow for fast draining in
drainpipes.
Level of the pipes to be maintained using spirit level for all other pipelines.
TIG welding to be carried out for all the piping joints using Argon gas and filler wire no
70 S2 for CS and 308L for SS. Full welding with the TIG. Welding procedures attached.
GVC inlet and drain pipeline are to be fabricated as per P & I and isometric drawings.

Tools required:
Arc Welding Machine with Electrodes for welding process as per the
recommendation.7018 for CS pipe lines
Organ gas set. Filler wire dia 2.5mm, 70S2 for CS, and 308L for SS.
Tungsten Rod of 2.5mm dia.
AG4 &AG8 Grinding Machine with wheels.
AG4 Buffing Wheels
Right angle
Wire brush & chisel
Hand Gloves
Shield
Spirit Level
Ac Power Supply

Drawings required:
P & I Drawings for Lube oil.
Power house layout drawings
Vendor piping drawings
Auxiliary Foundation Drawings

Cleaning of Pipe Lines:

Procedure:
The oil pipelines fabricated at site are to be cleaned by acid pickling for CS pipelines
and by Caustic Soda for SS pipelines.
Before acid pickling the pipes should be thoroughly flushed with air for removing of
loose particles.
Acid pickling pipes should be dummied one end with rubber gasket and filled with acid
of 5 to 8% of concentrated HCL acid and keep the pipes filled with acid for 24 hours, so
that all loose metal particles will come out.

C12

ERECTION AND COMMISSIONING

C12

There after remove the acid from pipes & clean the pipes thoroughly with caustic soda
and air.
After the pipes are thoroughly cleaned, a small quantity of oil (VG 46) to be applied
inside the pipelines to avoid rusting.
If the pipelines are to be stored for long duration before fixing in the final position then
cover both the ends of pipes with plastics lids so that no dust particles can enter.
Storage, usage and disposal of HCL:
HCL is to be stored in a plastic container.
The container should be labeled.
Face shield, gloves, breather mask are to be used by the individual while pouring the
acid.
Acid is to be poured in a slow and steady manner into the pipelines.
Keep water source and caustic solution near acid pickling area to neutralize immediately
in case of any spillage.
Acids to be drained from pipeline and should be collected in a plastic container.
Face shield, gloves, breather mask are to be used by the individual while draining the
acid.

Tools/Material required:
Air Blower
HCl
Caustic Soda

C13

ERECTION AND COMMISSIONING

C13

III. PRE- COMMISSIONING- MECH

Oil flushing
Procedure:
First stage:
Clean Oil Tank thoroughly using sponge/Cloth, diesel and with compressed air.
Fill with flushing oil of correct grade see SECTION-Q, for quantity see SECTION B.
Any pipe work removed for transmit or erection, should be connected
Fill Oil Console
Cover both the filter elements using banyan cloth to avoid choking of filter elements
during initial flushing or bypass line to be made for bearings or the TG and alternator
bearings. Alternator and TG bearings to be bypassed during initial flushing. filters
having different filter screen having sizes from 50 mesh to 150 mesh & there is no need
to put banyan cloth & mesh at cooler outlet)
Note: The dummies used for bypassing the Bearings should be tagged, noted and
recorded
Remove top half of the bearings of Rotor, pinion, Gearbox. Clean the preservatives
(Grease) applied to rotating equipments before flushing. Replace the bearing cap and
its housing/cover in its position and ensure that oil will not spill out during flushing.
Oil from the cooler to be drained before flushing and mesh of 100 or 150 size to be
provided at the cooler outlet. Inlet to the PRVs to be blocked. Alternator lube oil inlet
line to be bypassed.
Put the oil centrifuge in line which can clean the system by collecting the scale and
foreign particles and also to maintain the oil temperature around

60 c through oil

heaters.
With the above mentioned condition switch on AOP and start oil flushing using one
filter and cooler in line.

C14

ERECTION AND COMMISSIONING

C14

During flushing lightly hammer the line so that all the loose materials will come out
with the oil.
After duration of half an hour to one hour, change over the filter to the second one and
check for the condition of the first filter. Check for cleanliness of the mesh at the cooler
outlet and if required replace the same. This process to be repeated by changing the
filters in line and mesh if required at intervals of duration of 2hrs, 4hrs, 8hrs.
(Thermal shock can also be provided for fast removal of the dirt and the particles. It can
be done by passing water in the Oil Cooler. It makes a steep drop in temperature and
temp can be increased).
Second stage:
Check for the cleanliness of 30 mesh after flushing continuously for intervals of 8Hrs
with each filter in line.
Through out the flushing ensure that oil centrifuge is in line, and oil temperature is
maintained at 60 c, and line is hammered continuously. Also cooler change over to be
done every 2 hrs.
When the system is clear ( 150 Mesh should be clear of impurities), take all the bearings
in line for oil flushing. Continue flushing further till system is clear.
Note : The dummies used for bypassing the Bearings should be removed and noted.
Once the system is clear, stop the AOP & reassemble the turbine bearings and gearbox
assembly, all pipelines to be reconnected.

This involves the following action.

Remove the bottom bearings and inspect. Clean/polish both top & bottom halves.
Ensure their correct fitting. Clean the holes provided in Thrust Bearings Pads holder &
Journal Bearing holes also.

Turbine and gearbox bearings clearances should be checked.

Position the bearing caps and tightens the cap studs as per torque recommended, ref
instruction manual for Torque details.

Rotor fronts, rotor rear pedestal covers, Gearbox cover to be positioned with silicon
sealant/Ana bond 666 T.

All the pressure, temperature gauges, vibration probes, etc. to be fixed.

Remove the mesh /PRVs to be taken in line. Replace the filter element with new one.

C15

ERECTION AND COMMISSIONING

C15

Ensure all joints are fitted correctly and are oil tight.

Drain the flushed oil from the oil tank, coolers and filters. Inspect/ clean the oil tank.
Fill the oil tank with fresh oil.
(Passing of oil to be ensured in all the bearing during/after final box up).
Documentation:

Oil flushing protocol.

Turbine Box-Up Protocol Formats

Tools/material required:

Dial gauge

Micrometer

Lead wire

Feeler gauge

Vernier Calipers
Open inspection:
Refer Section-O, Overhaul and inspection
Steam Blowing
A steam turbine is vulnerable to damage of the blading if any debris is fed into the
machine with the steam supply.
It is essential, therefore, that the steam line to the turbine is completely clean and free
of any clinging matter, particularly weld splatter, before steam is fed to the turbine on
commissioning. This also applies after any repairs to the piping or boiler.

The purpose of blowing the steam lines prior to starting up a new unit is to remove any
foreign matter remaining in the equipment (i.e., super heater) and steam piping after
erection is completed. Considerable damage could result if such foreign matter was
allowed to enter the plant steam system during initial operation.

On older units the need for steam line blowing should be considered following major
pressure parts repairs, where the possibility of introduction of foreign material into the
system exists.

C16

ERECTION AND COMMISSIONING

C16

Since prevention of damage to the plant steam system is the prime concern, the
responsibility for determining the effectiveness of the steam line blowing operation
rests with the plant operator. During the steam line blowing process the unit should be
operated in accordance with the vendor recommended procedures, with all control
systems & protective interlocks functioning.

It is strongly recommended that blowing of steam to be witnessed by a Triveni

service engineer.

The principle behind steam blowing lines clean is that the thermal cycling (heating/
cooling) and high velocity gas flowing through the line will shock the pipe & tend to
break the mill scale & weld slag away from the pipe wall. Ideally, steam blowing should
be done prior to the system being insulated to maximum the thermal cycling of the
equipment. If the system is insulated, a greater time between blows may be necessary
to allow the system to cool.

Ideally, to obtain optimum cleaning, the flow conditions in the system during
steam line blowing should equal those during normal operation at maximum load.
Since it is impossible to exactly duplicate these conditions when blowing through
the piping to atmosphere, it is desirable to produce equivalent conditions by using
lower pressure steam with a flow rate such that the product of steam flow times
velocity will equal that under normal full load conditions. The determination of the
total obtainable flow quantity must be based on flow resistance in the entire system,
including the temporary piping. This determination is normally made by the designer
of the blowing system.

The temporary piping is normally equipped with a shutoff valve that is used as a
blowing valve. With this arrangement, the super heater
and the upstream portion of the temporary piping are maintained at drum pressure at
all times when not actually blowing.
SAFETY WHILE STEAM BLOWING
Safety Precautions
Necessary safety precautions must be taken such as fencing off the area and providing
ear protection against the inevitable noise generated during the blowing down
process.
The process of steam blowing imposes abnormal and severe conditions upon the boiler,
steam equipment and steam piping. Large, rapid temperature changes occur during
each blowing cycle. This cycling of temperature is far more severe than is incurred in
normal operation. Thermal stresses may be excessive in the heavy wall portions of the
system such as steam drums, headers and piping. It is prudent to consider this fact
when performing the blowing procedure and to limit the number of blows to the minimum
consistent with cleaning the system.

C17

ERECTION AND COMMISSIONING

C17

Since the temporary steam blowing piping may be designed for lower pressure than the
boiler, care must be used to prevent over pressuring this piping during the entire steam
line blowing operation. The pressure in the temporary piping should be monitored
continuously and operators are alert to prevent over pressure.
It is recommended that a means of over pressure protection be provided in the temporary
piping, such as, safety valves set at the design pressure of the temporary piping.
Noise levels will be very high during the steam blow.
Hearing protection is mandatory
for those in the immediate vicinity of the steam outlet. An area at least 100m from the
blow point must be roped off to prevent personnel from approaching too close.
Equipment:

The following will be required for steam blowing

Temporary piping
Temporary piping support a restraints
Blow off valve with quick opening actuator
Silencer
Target Plate Aluminum plate with mirror finish
Procedure:
The unit is started in the normal manner. All normal recommendations and limitations
with respect to fuel firing equipment, air handling equipment, drains and vents, etc.,
should be followed, as if the unit were being started for normal operation. As for any
new unit, the steam blowing operation is the first occasion that the unit is fired at any
significant rate. Consequently, the startup as well as the steam line blowing must be
conducted with great care. The normal startup rate does not apply; the unit must be
brought up much slower, while all equipment is checked and expansion movements
monitored closely. If the unit is equipped with a fired super heater, the 1000 deg. F
(538deg.C) furnace exit gas temperature limitation must not be exceeded when the unit
is fired. The same general precautions taken on any new unit for this period of operation
apply equally here.
General pre cleaning Procedure:

Check all pipe anchors and the pipes for the adequate support of piping, including the
temporary vent pipe.
Insure that all the lines have been inspected and hydro tested.
Remove all the control valves, de-super heater nozzles, flow elements, thermo well,
pressure gauge, orifice plate, safety valves and instruments that may be damaged during
the steam blow.

C18

ERECTION AND COMMISSIONING

C18

Insure all vents pipes have adequate drains and that these drains are routed to a safe
location.
Install temporary pressure gauge as required to monitor the progress of the steam blow
and make arrangements for to record pressure reading.
Establish adequate radio communication between the control room and the operator at
the shutoff valve. Back this up with a system of visual communication, such as lights
or flags, since audio communication may be difficult due to high noise levels at the
steam shutoff valves.
Insure personnel controlled in area during steam blow. Insure the area near the vent
pipe is clear of personnel during the steam blow. Project neighboring equipment from
damage due to the steam vents.
Individuals operating the steam blow valves (especially near the vent pipe) should wear
double ear protection.
STEAM BLOW OPERATION
Maximum effectiveness of steam blowing operation will be achieved by starting
the blow at maximum possible flow.
Caution:
The first blow should be done at reduced pressure, In order to check the temporary
piping system, its supports and the anchors.
With no target plate in place, bring the boiler up to working pressure. Generally there
is always issue for rated pressure and temperature during blow down. Blow steam
down the line for 20 minutes or until pressure has dropped to 50% of initial pressure
and then allows the line to cool (half to one hour for bare pipes, 1 to 2 hours for
lagged pipes).
Repeat this Three times as the heating & cooling helps to loosen clinging matter from
the internal pipe surface due to thermal expansion and contraction.
Now place the Mirror finished Aluminum target plate. Run a series of blow downs for
10 minutes allowing cooling between each cycle. Stamp the cycle number on the receiving
face of the target piece.
Post Cleaning Procedures:
Drain the temporary and permanent piping.
Remove temporary spools, blind flanges, temporary bend piping, etc, and re-install all
components removed prior to steam blow.

C19

ERECTION AND COMMISSIONING

C19

Cleanliness criteria:
Two successive targets must result in mirror finishes that meet the specified criteria.
After a cooling down period of at least 12 hours, two more successive steams blows
must result in mirror surfaces that meet the specified criteria.
Criteria:
No indentation exceeding 0.8 mm diameter.
Indentation exceeding 0.4 mm diameter to number not more than 2 per 2500 mm2 of
the target plate surface.
Indentations exceeding 0.2 mm to number, not more than 10 per 2500 mm2 of the
target plate surfaces.
Indentation less than 0.2mm to be well dispersed and nowhere present in concentration.
If a separator is included in the steam inlet pipe to the turbine then it should be
emptied after the last Blowdown.
Checking of Safety Trips
Procedure:
Before starting AOP, ensure all oil pipeline instruments are fitted and final box up of
the turbine is completed.
Check the functioning of AOP and discharge pressure is set to as per Data provided in
the Technical Data in the Instruction Manual.
Ensure visually that there is no oil leakage in the oil system.
Set the control oil pressure and lube oil pressure through pressure relief valve. (Refer
Turbine Operation and Maintenance Manual).
Check the functioning of L.P Trip, SEV and Throttle valve. (Reset the LP trip ,open the
SEV hand wheel manually & lift the linkages assembly to check the throttle valve
operation . check the LP trip pressure by moving the hand trip to trip position slowly
ensure the LP trip pressure is around 0.5 to 0.8 Bar (g). Also ensure closing of SEV &
throttle valve when hand trip is activated to trip position).

C20

ERECTION AND COMMISSIONING

C20

Check the functioning of SEV and TV when Hand trip actuated.

Check the functioning of vibration monitoring system and the alarm and trip set points
are configured as recommended, (Refer SECTION-B INSTRUMENT SETTINGS).
Check the function of all the pressure switches and pressure transmitter at TCP with
reference to field mounted instruments.
Set the pressure switch set points given in the instruction manual (Refer SECTION-B
INSTRUMENT SETTINGS).
(Trip circuit oil pressure to be less by 0.3/0.4 Bar (g), from the lube oil pressure).
AOP, COP, Barring gear & EOP inter locks & function to be checked and ensure.
Check the function of GVC blower.(if applicable) (Check the rotation of motor & airflow
at the out let).
Barring Gear Trials (If applicable)
Procedure:
Start AOP and check the oil pressure and oil flow to Turbine, Gear Box and Alternator
bearings is as per recommendations mentioned earlier.
Check the functioning of barring gear and lube oil pressure interlocks. (Ensure barring
gear motor should not be started when AOP in off mode.
Switch off AOP when barring gear motor in operation, ensure the barring gear get
stopped because of low lube oil pressure.
Check the functioning of EOP. (Check the discharge pressure as per recommendation
given in manual & ensure the flow to all bearings by watching flow glass.

Ensure EOP get switched off when AOP get started &vice versa)

Ensure all the Bearing temperatures, vibration system are inline and ready for
monitoring.

C21

ERECTION AND COMMISSIONING

C21

Start the barring gear motor and check the vibration level, speed and bearing temperatures
are within the specified limits mentioned earlier.
Check for any abnormality at barring motor, Turbine gearbox, Turbine bearings and
casing.
Continue the barring gear operation as per recommendation given in (refer SECTIOND, start-up curve) before starting the Turbine with steam.
IV.

ERECTION-ELECTRICAL ACTIVITIES (WHICHEVER IS APPLICABLE)

BEFORE COMENCING ERECTION, FOLLOW SUPPLIERS O & M MANUALS,
INSTRUCTIONS AND ALL NECESSARY DRAWING MUST BE CAREFULLY STUDIED
AND TOOLS MUST BE COLLECTED
Leading and Positioning of Panels

Procedure:
Check the physical powerhouse layout with the designed layout drgs and take corrective
action if required.
Open the packing and make visual & dimensional inspection of individual panel.
Check for any physical damage of cabinet or mounted item.
Verify the panel mounting dimensions (base channel & GA) with the cutouts provided
in the powerhouse layout drawing.
Use rope & Sling to bind the panel using the I- bolts provided on top of the panel if
crane is to be used.
By using wooden sleepers, rollers or Crane lift & move the panel. Care should be taken
not to secure the slings on the front of the panel and while lifting or moving jerks
should not be given.
Bring the Panel to proper position either on cutout or on frame in case of false flooring,
after positioning check for leveling of the panel using water tube or spirit level.
Once all the panels are placed front alignment or back alignment to be checked and
adjusted if necessary. Care should be taken to ensure that no gaps come between the
panels. If required slight adjustment to be made sacrificing the level. Fix the panels
with the base or frame using bolts and nuts or tack (stitch welding).

C22

ERECTION AND COMMISSIONING

C22

Visual inspection of Loose supplied items.

Tools, instruments and machineries used:

Measurement Tape, water level/spirit level
Crane, wooden sleepers, rollers, rope, slings & chain pulley blocks.
Bolts and nuts.
Welding machine & its accessories.
Reference documents:

Power House Layout drawing

Panel dimensional (GA) drawing
Master Bill of Material (BOM)/Panel BOM
Erection of Cable Trays
The cable trays for erection is classified into the following categories
LT/HT Power Cable tray Ladder type
Control Cable tray perforated type
Instrumentation / Signal cable tray perforated type
Procedure:
Check the cable routing as per tray routing drawing & powerhouse drawing.
Based on the above inputs, determine the cable tray length and supports as per drawing.
Fabricate Tray supports as per drawing / requirement.
Fixing of cable tray supports are done by Insert plates (provided during civil construction)
Mounting plates (fixed by Anchor fasteners if insert plate not provided).
The tray support to be fixed at regular intervals & in same level. Straightness can be
checked using plumb block. Runs to be laid referring cable tray routing drawing &
Cable schedule.
Level to be checked by water level or any convenient method applicable. Support welding
to the insert should be full welding. Lay the cable trays on the support and if required
trays can be stitched welded to the supports for safety and aesthetic look.
For interconnection of trays use fishplate with nut & bolts or by welding.
Tray earthlings to be done throughout the length using earth strips. Painting to be done
for tray support & welding point.

C23

ERECTION AND COMMISSIONING

C23

Tools, instruments and machineries used:

Measurement Tape/water level
Welding machine & its accessories.
Cutting machine.
Plumb block

Reference documents:
Power House Layout drgs.
Cable tray routing drawings
Master BOM
Materials required:
Iron angle & channels,
Inset plates/ mounting plates
Anchor fasteners & paints.
Erection of Junction Boxes and LPBS.
List of Junction Boxes - As per JB schedule. Typically:
Vibration Junction Box
RTD JB for Turbine and Gear Box
Condensers JB i.e. for level switches if applicable
RTD JB for cooling water lines & instrument JB if applicable.
JBs for pressure and temperatures of steam lines.
List of

LPBS:

(IF APPLICABLE ONLY)

AOP MOTOR
VEM MOTOR
DCMSP MOTOR
BARRING GEAR MOTOR
ACOP MOTOR
GVC MOTOR (if applicable)
PROCEDURE:
Fabricate the frames using iron angle / channel as per LPBS & JB dimension.
Paint the frames & supports.
Mount the equipments on the frame by bolting.
Fix the LPBS frames nearest to motor as applicable. For JB mounting refer JB location
details document.

C24

ERECTION AND COMMISSIONING

C24

Height of the frame should be between 1.2 mts to 1.5 mts / instruments to be mounted
at a height of 1.2mts to 1.6 mts
Termination should be done as per cable schedule.
Labeling / description to be provided for individual JB & LPBS.
Tools, Instruments and Machineries used:

Measurement Tape
Spanners & Cutting accessories
Welding machine & & its accessories
Screw Driver & Allen Key set.

Reference Documents:
P& I diagram for Steam, Oil, Cooling water & pneumatic system
Power house drawings.
Cable schedule & BOM.
JB location drawing.
Cable laying and Termination.

Procedure:
Group the cables into three categories i.e. Power, control and Instrumentation. Suitable
cables can be identified by checking with cable specifications sheet.
Measure/estimate the distance between panel & equipment, panel& panel, estimate
the required cable length by referring to tray routing & powerhouse layout drawing.
Panel internally around 2.5 Mts minimum to be considered above the gland plate or
1.5Mts from the point of termination for proper dressing of the cores inside the panel.
Cut the cable as estimated above. Cable numbering to be provided on both ends as per
cable schedule.
Lay the corresponding cables in the corresponding cable tray. Ex, Power cable in power
cable tray.
Gland the cable at one end and dress the cable in the tray using cable ties, finally gland
the cable at the other end.
Cable numbering tag to be provided on both ends as per cable schedule.
Skin the cable to the required length. For screened cable connect shield/screen to
earth through sleeves at one end only preferably at panel end or to the terminals
provided in the panels. In JB shield connection to be taken to the unused TB. Dont
connect to ground.

C25

ERECTION AND COMMISSIONING

C25

Ferruling to be done on both ends for individual cores of the cable. Ferruling must
describe the panel name and TB details from where it is coming & TB details of where
it connecting.
Spare cores of the terminated cable to be bunched together and for one core cable No
ferule to be put for easy identification in the future. Spare cores should not be cut.
Dress individual cable inside the panel up to TB and then lugs to be crimped at the core
ends and to be terminated at the corresponding TBs. Ferules should be readable after
the core is terminated. For single strand cable core lug is not required.
For T/C cables direct connection to the end instrument in the panel is preferred.
For H T cable kit installation and termination, follow the procedure provided in the HT
Kit instruction manual. Cable to be properly
dressed & supported. Required bending inside the terminal box to be made before or
during the installation of kit.

Minimum distance of 500mm should be maintained between the gland plate and
termination point.

Proper phase identification to be provided on the core/cable before and after kit
installation by using insulation tape.

For HT cable proper support to be provided at regular intervals, typically 1.5 Mts. Sharp
bends to be avoided.
Care should be taken to ensure after termination the load/stress of the cable should
not get transferred to the terminals. Cable should be securely supported before entering
the terminal box.
After proper termination and tightening, open the termination and check whether the
cable core can be pulled out and put back easily. This ensures that there is no stress
on the terminals from the cable.
Tools, instruments and machineries used:
Measurement Tape
Cutting accessories
Marker pens /stickers

Reference documents:
Cable Schedule
Panel as built wiring drawing.
P& I drawing
Junction Box location details
JB schedule
Cable Specifications.

C26

ERECTION AND COMMISSIONING

C26

Materials required:
Lugs & ferrules.
Cable crimping Kit.
Insulation tape & cable ties
Aluminum cable tags & its accessories
Cable binding & clamping material.
Erection of Field Instruments (WHICHEVER IS APPLICABLE)

Procedure:
Exact physical location of instruments to be finalizing / decided by referring P&I,
powerhouse layout drawings and instrument mounting drawing if any.
Support to be fabricated for instruments mounting. (For PT, TT, FT, I/P & PS)
Mount the field instruments using mounting clamps & brackets.
Fabricated item

& support to be painted.

Instruments to be fixed in such a way that it is easy for maintenance & troubleshooting.
Provide impulse line/ instruments tapping as per P& I diagram & hookup drawings.
Mount the instruments like Pressure, Temperature gauges, RTD & TC.
Mount all turbovisory instruments like speed probes, vibration probes & RTD & T/c as
per standards.
For MPU minimum 1mm gap to be maintained from the sensing point. For radial
vibration probe mounting a gap in terms voltage 9 to 10 V DC should be maintained.
For axial, rotor should be centered and probe should be adjusted to achieve zero reading
in the vibration monitor and at the same time voltage should be around 10 V DC.
Mount all the level switches and level transmitter as per P&ID and connect all the
instruments to the nearest JB, refer JB schedule using proper instrument cables and
lugs.
All instruments to be wired/ terminate up to JB or Panel as applicable. (Ferule should
indicate the instrument name)
Provide instrument tag numbers as per P&I diagram.
Tools, Instruments and Machineries used:

Measurement Tape
Spanner, Cutting accessories & Screw driver set
Allen key set.
Welding machine & & its accessories
Multimeter
Soldering gun

C27

ERECTION AND COMMISSIONING

C27

Documentation: Calibration report of all measuring instruments

Reference Documents:
P& I diagram for Steam, Oil, Cooling water & pneumatic system
Power house drawings.
Instruments manuals.
BOM of instruments & its accessories.
Impulse Piping

PROCEDURE:
Ensure all the instruments are mounted and the required tapings provided.
Decide the routing as per powerhouse layout drawing.
Connect the instruments and the tapping points using proper pipes and fittings referring
to hook up drg and P&ID drg.
Proper supports for the lines to be provided at regular intervals. Provide the drain lines
wherever necessary.
Tools, Instruments and Machineries used:

Measurement Tape
Spanner & Cutting accessories
Welding machine & & its accessories
Pipe bending machine.
Reference Documents:

P& I diagram for Steam, Oil, Cooling water & pneumatic system
Instrument hook up drgs.
Instrument Manual
BOM of Instruments
Powerhouse layout.
Earthing-

(IF APPLICABLE ONLY)

PROCEDURE:
Ensure all the panels and instruments are located in their respective locations.
Confirm the location of earth pits as per layout.
Select the earth strip size & run as per earthing layout drawing.

C28

ERECTION AND COMMISSIONING

C28

For Control and LT power panels, make separate earth grid by using earth strip.
For HT panels and alternator body make a separate earth grid .
In NGR, (Neutral) earthed separately by routing to two separate earth pits. Both the
Earth pits should be interconnected by a strip.
In LASCPT, (LA &SC) should be earthed separately by routing to two separate earth
pits. Both the Earth pits should be interconnected by a strip.
Cable tray earthing and all motors and JBs earthing can be combined with control
panel body earthing.
The connections between the earth strip and equipment will be bolted type.
The connections between one earth strip and other will be of bolted type or welding as
per site conditions. If joints are welded type put the paints at welding points.
For Instruments, separate earthing to be provided, preferably isolated from the body
earth/common earth.
After completion of earthing, Earth resistance to be checked by Earth tester and recorded.

Tools, Instruments and Machineries used:

Measurement Tape.
Spanner & Cutting accessories.
Welding machine & & its accessories.
Bending machine & its accessories.
Earth Tester.
Reference Documents:

Instrument Manual & BOM.

Powerhouse layout.
Earthing Layout .
Earth pit dwg.
Earth Resistance certificate.

C29
V.

ERECTION AND COMMISSIONING

C29

PRE-COMMISSIONING.ELECTRICAL
LIST OF PANELS:

(WHICHEVER IS APPLICABLE)

MOTOR CONTROL CENTER (MCC)

BATTERY CHARGER CUM DCDB
AC DISTRIBUTION BOARD (ACDB)
TUBINE CONTROL PANEL (TCP)
TUBINE GAUGE PANEL (TGP)
DC MOTOR STARTER PANEL (DCMSP)
GENERATOR RELAY PANEL (GRP)
METERING CUM SYNCHRONISATION PANEL (MCSP)
LIGHTNING ARRESTOR AND SURGE CAPACITOR AND POTENTIAL TRANSFORMER
PANEL (LASCPT)
NEUTRAL GROUNDING RESISTOR PANEL (NGR)
TG INCOMING BREAKER PANEL
EXCITATION CONTROL PANEL (AVR)
Alternator
HT Cables
PLC PANEL
Reference Documents:
As built drawings of panels
Instrument Manuals
Cable Schedule
Program and setting chart
Pre-commissioning & Commissioning Format
TOOLS, Instruments and Machineries used:
Multimeter
Continuity tester
Tongue tester
500V Megger
Motorised Megger up to 5 KV
High Voltage testing kit
Primary and Secondary injection kit
Documents:
Test & Calibration certificates of electrical switchgears and used instrumentations.
MOTOR CONTROL CENTER:
1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule
Pre-commissioning format

C30

ERECTION AND COMMISSIONING

C30

PROCEDURE:
Ensure loop checking and termination to be completed before charging panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the bus bar system & control circuit.
Charge the panel with appropriate supply voltage.
Check the operation of MCC incoming breaker / SFU operation and indication circuit
& set MCC switchgear settings.
Check individual feeder logic & operation without connecting load/motor. Check & set
individual feeder switchgear settings.
Take the individual motor trials through interlocks.
BATTERY CHARGER & DCDB:
1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule
Pre-commissioning format
PROCEDURE:
Ensure loop checking and termination to be completed before charging panel.
Check the IR value of incoming & out going supply terminal
If IR value zero check the bus bar system & control circuit.
Charge the panel with appropriate supply voltage.
Connect the battery bank to the terminals.
Switch on the AC supply to the panel, check the FC & FCBC operation as per manual.
Check the MIMIC or annunciation circuit.
Check the FC & FCBC auto operation.
Check the voltages at outgoing terminals.

C31

ERECTION AND COMMISSIONING

C31

AC DISTRIBUTION BOARD :
1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule
Pre-commissioning format
PROCEDURE:
Ensure loop checking and termination to be completed before charging panel.
Check the IR value of incoming & out going supply terminal.
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage.
Check the voltage at each feeder end by switching on the respective MCBs.
TURBINE CONTROL PANEL :

1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule.
Programming & setting chart.
Pre-commissioning format
PROCEDURE:
Mount the loose items like Woodward Governor, Vibration monitor and Level Controller
etc.,
Ensure loop checking and termination to be completed before charging panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage. By switching on the respective MCBs
on ACDB and DCDB Switch on the individual
equipment / instrument, Program the individual instruments as per programming
chart & setting to be done as per setting chart.
Check the turbine trip logics (solenoid circuit) by simulating individual fault & check
the annunciation for the same.

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C32

Check the solenoid operation & indication circuit.

Check the function / operation of individual equipment after connecting the MPU,
vibration probe, level transmitter & RTD, etc.
Check the motor logics in Auto/ DCS/ Manual mode & take the Motor trails with
necessary interlocks and check the corresponding indication.
TURBINE GAUGE PANEL:
1.
2.
3.
4.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule.
Programming & setting chart.
Pre-commission format
PROCEDURE :
Ensure loop checking & termination to be completed before charging panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger Cum DCDB.
Set the pressure switches as per the setting chart.
Impulse lines to be completed for all instruments .
Check the TT and PTs using the communicator for proper range and check for operation.
Check the operation of all indicators and gauges
DC MOTOR STARTER PANEL:

1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule.
Pre-commission format
PROCEDURE :
Check the IR value of incoming and outgoing supply terminal.
Ensure loop checking & termination to be completed before charging panel.
If IR value zero check the power wiring & control circuit.

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C33

Charge the panel with appropriate supply voltage.

Check the contactor, timer & indication operation sequence by connecting lamp load at
armature and field terminal of panel.
Take the motor trials through interlock (provided in TCP) and check the OLR operation
GENERATOR RELAY PANEL:
1.
2.
3.
4.

Reference drgs
Vendor supplied Schematic drg.
Cable schedule
Trip logic & setting chart
Pre-Commissioning format
PROCEDURE:
Ensure loop checking & termination to be completed before charging panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and DCDB.
Set the relay settings as per the relay-setting chart.
GPR- All functional test & trip simulation of different relay in the microprocessor base
GPR by secondary injection of current & voltage. All individual protection annunciations
to be checked in MCSP/DCS.
Electromechanical / conventional relays test done by individually by injecting secondary
current & voltage.
While injecting the current in CT primary & voltage in PT primary in NGR & LAPT
respectively, check the corresponding secondary values at respective terminals of panels.
Check the Class A,B & C(86G,86T & 86L) trip logic & observe the individual annunciation
in MCSP/ DCS.

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C34

METERING AND SYNCHRONISATION PANEL :

1.
2.
3.
4.

Reference drgs :
Vendor supplied Schematic drg
Cable schedu
SLD
Pre-commissioning format
PROCEDURE:
Ensure loop checking & termination to be completed before charging panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger.
Mount & wire the loose supplied items like, Auto Synchronizer etc.
Program & set the necessary instruments.
Check the meters & transducers by injecting secondary Voltage & current.
Check the synchronization circuit as per scheme. Check the dead bus & live bus
closing if individual breaker, observe the operation feedback.
While injecting the current in CT primary & voltage in PT primary in NGR & LAPT
respectively, check the corresponding secondary values at respective terminals of panels.
Check indication circuit & annunciation Circuit.
LASCPT PANEL:

1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Cable schedule
Pre-Commissioning format
PROCEDURE:
Ensure loop checking & termination to be completed before charging panel.
Check the IR value between phases & earth. (> 20 mega ohm) for primary bus & (> 1 M
Ohm for control circuit.
If IR value zero check the power wiring & control circuit.

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C35

Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger.
Measure the distance between phases and phase to panel body (earth). The minimum
distance should 125mm between phases & 75 mm for phase to earth.
Visual inspection of lightning arrester, Surge Capacitor, CT & PT for any physical damages.
Insulation resistance test of primary w.r.t earth, primary with respect to core 1, primary
with respect to core 2, core1 with respect to ground, core 2 with respect to earth and
core1 with respect to core2 .
Simulation of ratio test by injecting primary voltage to measure its secondary equivalence.
Check CT polarity & IR values as mentioned in NGR.
Measure the Magnetizing current for differential CTs.
By injecting primary rated current at CT terminal measure all the secondary equivalence.
NGR PANEL :
1.
2.
3.

Reference drgs :
Vendor supplied Schematic drg
Cable schedule
Pre-Commissioning format
PROCEDURE:
Ensure loop checking & termination of control cables are completed before charging
the panel.
Check the IR value between phases & earth. (> 1 mega ohm for control circuit & >20 M
ohm for primary bus).
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger.
Measure the distances between the phases and phase to panel body.
Insulation resistance test for (CT) primary with respect to ground, primary with respect
to secondary and secondary with respect to ground for all CTs .
Check the polarity for individual CTs.
Primary injection in steps up to its rated current to measure its secondary equivalence
for all CTs.

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ERECTION AND COMMISSIONING

C36

Knee point voltage test to be by injecting 50% of given knee point voltage across the
secondary terminals of CT and recording the current to analyze its saturation. (Applicable
only for PS class CT).
Visual inspection of grounding resistor and measure resistance value should be nearer
to the value mentioned in the name plate of the Panel.
Check the operation of Neutral isolator switch and observe the indication in MCSP
TG INCOMING
1.
2.
3.

BREAKER PANEL:

Reference drgs :
Vendor supplied Schematic drg
Cable schedule
Pre-Commissioning format
PROCEDURE:
Ensure loop checking and termination of control cables is complete before charging
panel.
Check the IR value between phases & earth. (> 1 mega ohm for control circuit and >20
M ohm for primary bus).
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger.
Rack out the Breaker to Test position and check the closing and tripping of the breaker
from local.
Check the breaker operation from remote by operating from MCSP.
Check interlocks like auto trips and indication circuits on the breaker and remote end
in MSC panel/DCS etc.
EXCITATION CONTROL PANEL:

1.
2.
3.

Reference drgs :
Vendor supplied Schematic drg
Cable schedule
Pre-Commissioning format

C37

ERECTION AND COMMISSIONING

C37

PROCEDURE:
Ensure loop checking & terminations of control cable are complete before charging
panel.
Check the IR value between phases & earth. (> 1 mega ohm)
If IR value zero check the power wiring & control circuit.
Charge the panel with appropriate supply voltage by switching on the respective MCBs
on ACDB and Battery Charger.
Check the interlocks and tripping as per schematic.
Power up and program the AVR as per dwg and setting chart.
By removing the generator field cabling check the output from AVR using lamp load.
Check the Annunciation, selector switches and push button operation.
Check the interlocks and AVR change over.
While injecting the current in CT primary & voltage in PT primary in NGR & LAPT
respectively, check the corresponding secondary values at respective terminals of panels.
ALTERNATOR :
1.
2.
3.

Reference drgs:
Vendor supplied Schematic drg
Alternator Manual and test certificates.
Pre-Commissioning format
PROCEDURE:
Ensure phase connections between alternator and LASCPT and NGR panels.
By removing the cables check the IR value between phases and phase to earth (>100 M
ohm with 5 KV megger)
Check the Polarization Index (PI) Value of the alternator. The value should be more
than 2.
PI = 10th minute IR Value/ 1st minute IR value
Check air gap of exciter
Ensure slip rings, carbon brushes & RRA are properly fitted.
Check the resistance of field and IR value.

C38

ERECTION AND COMMISSIONING

C38

HT CABLES :
Check IR value phase to phase and phase to earth for each run before and after high
voltage test. (> 100 M ohm)
High voltage test to be carried out for each core in case of multi core and each cable in
case of single core.
Ensure Phase identity.
BACK CHARGING WITH RUNNING SUPPLY :
Isolate the Terminals at the Aternator End ( Phase Side) and with all the PT,s in line
close the respective breakers to charge the Running supply upto the HT cables at the
Alternator Phase side. Check for phase sequences at all the Synchronising PTs and
note down the same.
PLC PANEL:
1.
2.
3.
4.
5.

Reference drgs:
Vendor supplied Schematic drg
I/O List
Motor logic
Trip logic
P&I dwg
PROCEDURE:
Ensure loop checking & terminations of control cables, communication cables, and
data cables for engineering station, operator station & printers are complete before
charging panel. Ensure body Earthing & Instrument earthing.
Switch on the AC supply MCB (UPS) & check AC supply circuit. Switch on the converter
MCB, check the out put voltage at respective terminals. Switch on the individual rack
(processor) supply with respective MCB.
Power up the Engineering Station & establish communication with processor. Down
load the rack (processor) configuration to the engineering station.
Download the same data to operator station also.
Check the all inputs & out put ranges, tags & type as per P&I and I/O list.
Compare all logics in the processor with logic scheme provided by M/s TEIL, do the
modification if necessary, up load to processor.
Check the screens compatibility with the P&I drawings. Modify if necessary.

C39

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C39

Set the alarm & trip values for inputs, outputs as per setting chart. Check the alarm
& trip annunciation, logic by simulating I/O. Power up all the instruments.
Check the operation system through instruments, check the logics by simulating I/P
from field, and take the motor trial through interlocks.
Check the configuration of the alarm data logging screens and modify if required as per
site condition.
Configure the RS485 Communication port for communication and program the registers
of the instruments to be communicated.
Check the hot change over of the processors from first to second and back to first.
VI.

COMMISSIONING MECH & ELECTRICAL

This document covers the following activities:

Checking the parallelity of the steam lines

Coupled running of the Turbine Generator and over speed test.

Voltage build up, synchronization and loading of the TG set.

CHECKING THE PARALLELITY OF THE STEAM LINES
Procedure:
After steam blowing is completed connect the inlet steam line back & install all the
permanent supports.
Without bolting the inlet flange to the turbine check the gap between the inlet flange
and the turbine flange. The gap should be less than 0.20mm variation all round the
circumference.
(All supports of the steam line to be in cold condition).
Complete the bleed steam line piping and install all the permanent supports, without
bolting the bleed flange to the turbine check the gap between the bleed flange and the
turbine flange. The gap should be less than 0.20mm variation all round the
circumference.
Also ensure that all the bolts can be installed freely without any difficulty.

C40

ERECTION AND COMMISSIONING

C40

Sealing Steam pipeline to be connected with all the instrument and control valves
installed in position that were removed for steam blowing.
After all the pipelines are finalized, check the high speed and low speed alignment to
confirm that no disturbance has occurred.
Refer O & M Manual chapter D- operation
Coupled Running of the TG Set. ( Over speed test)
Procedure for starting and mechanical over speed test:
Oil should be filled in the tank as specified.
Check functioning of EOP cut-in & cutoff before starting of the set, correct it if not
working.
Run without circulation of cooling water & ensure the oil cooler outlet temperature
around 35C is achieved before rolling the Turbine Generator set. If centrifuge is supplied
take centrifuge inline & heat the oil through the centrifuge to increase the temperature
to 35C.
Run barring gear and record/check for vibration and sound. Run barring gear minimum
for 8 hrs before starting warming of the turbine by crack opening of SEV & admitting
steam in to the turbine.
For warming up at barring gear speed please refer start up curves. If online vibration
instrument like Bentley Nevada/ Shin kava is not provided record vibration with IRD
instrument.
Ensure all the steam drains are open.
Start cooling water circulating pump at cooling tower and check pressure and temperature
with respect to specified values in turbine coolers & to GVC cooler wherever applicable.
To warm up the turbine at barring gear speed, crack open the main steam valve. Before
crack opening the main steam valve, all steam piping/header should be fully warmed
up and free from water by steam flushing.
Start warming up of turbine and open all the drains, observe that all water particles are
completely drained & steam is visible from the drains.
Steam inlet pressure and temperature should be close to rated pressure and temperature.
Ensure casing is sufficiently heated up after allowing steam to casing before rolling the
turbine while barring gear in operation.
Start GVC blower motor.(if applicable)

C41

ERECTION AND COMMISSIONING

C41

Reset solenoid and lube oil/ Low pressure trip, check the safety tripping like low lube
oil. Axial, over speed rip by manual. Hand trip to ensure free movement of SEV and TV.
Ensure EOP is in auto mode.(If motor driven)
Start rolling of turbine gradually around 800rpm, through SEV after meeting the above
mentioned points & soak at this speed as per the start up curve.
Ensure barring is cut off.
Throughout soaking period monitor the vibration levels, bearing temperature readings
and any unusual sound.
Follow instruction according to start up curves as provided by design for further
increasing of speed.
In the above process ensure governor take over speed & gradually take the turbine to
rated speed. Ensure that AOP is cut off.
Ensure once again that all the running parameters such as bearing temperatures, oil
pressures, vibration levels, cooling water temperature/pressure/flow, etc.. are within
satisfactory limit.
After attaining the nominal speed the turbine should be run for 10 minutes for
stabilization of bearing temperatures & vibrations. Exhaust temperature should be
monitored.
Slowly raise the speed through governor/PB to the maximum governor speed. Press F2
button in the governor and raise the speed through governor/PB to the maximum.
When speed is in the band of 10 15% above the nominal speed the mechanical over
speed trip will occur. S&E valve will trip & the throttle valve will also trip.
Cut off the inlet steam supply by closing the line valve, open all the drains of the
turbine and line, allow the turbine to come on barring speed
Voltage build up, synchronization and loading of the TG set
Procedure:
Refer SECTION-D Operation for complete turbine operation and loading. Once the
nominal speed is attained, check the bearing temperatures and vibrations are normal.
During running record all the parameters in Log Book at regular intervals i.e. after
every half an hour.

C42

ERECTION AND COMMISSIONING

C42

Important parameters to be observed on regular basis during running are listed below:
Bearing temperatures
Lube oil and control oil pressures
Vibration levels
Cooling water temperature/pressure/flow

Inlet steam pressure/temperature

Extraction & Bleed pressure
Exhaust temperature and pressure
DP across lube oil filter.
DP across cooling water.
Voltage Build up.
Procedure:

Check the residual voltage of the Alternator in relay panel, MSC panel and AVR panel.
This also ensures the continuity of the signal. Record the values as this can be used as
a future reference.
Ensure that all the interlocks are in line for the excitation control and are not active ex
86G/T master trip relay is not tripped, 90 % speed relay in TCP is picked up.
Switch on all the required MCBs in all the panels. Ensure that all the panels are
powered up.
Check all the MCBs are on in the AVR Panel. Check the PMG voltage. Ensure the
required voltage and Phase is available.
Select remote through the local remote selector on the keypad.
Select the manual mode through mode selection on the Excitation control panel.(if
applicable) Press the excitation on slowly increase the voltage by set point raise in
steps of 1 KV until the nominal voltage is attained. During the build up if any abnormality
is observed press Excitation OFF .
Once nominal voltage is attained record the no load excitation voltage and current.
Check voltages of all three phases on the voltmeter by rotating the voltage selector
switch.
Ensure that the all the three phases are balance. Slowly bring down the voltage by
pressing the set point lower. Once the voltage is Zero press the excitation OFF .
Select the auto mode through. Press excitation ON . Voltage should build up to 90% of
the nominal voltage. Slowly raise the voltage to nominal by set point raise PB . Check
the no load excitation voltage & current. Press the excitation OFF PB.

C43

ERECTION AND COMMISSIONING

C43

Change over to AVR 2 and check for the above functions.(if applicable)
During the voltage build up time the vibrations & bearing temperatures are to be observed
for any abnormality. Should be same as it was in nominal speed operation.
Build up the voltage again in auto mode (either of the two channels), check the secondary
voltages in all the panels.
Check phase sequence in all synchronizing PTs and note down the same. This sequence
should match with that of the sequence checked with Incoming voltage. It should be
Typically RYB.
Check the voltmeter in metering panel is displaying the nominal voltage. GPR in relay
panel is also displaying the nominal voltages.
Proceed for synchronization. Ensure that the TG incomer VCB panel control supplies
are on. Breaker is in test position.
Synchronizaton in Manual Mode
Procedure:
Select the appropriate switches for manual synchronization in synchronizing panel.
Put the local/remote switch in remote position in the Excitation control panel for
synchronization.
Check the double voltmeter and double frequency meters are displaying the bus and
generator parameters for synchronization.
Adjust the generator voltage and frequency w.r.t the bus voltage by the speed raise/
lower and voltage raise/lower PBs as applicable. Once both frequency & voltages are
matched.
Check the rotation of the synchronoscope, it should be clock wise (Red LEDs will lit up)
which ensures that the TG Frequency is little higher than the bus. If not adjust the
frequency and voltage such that the rotation of the synchronoscope is clock wise and
very slow. When the 12 Oclock position is reached the synchronoscope LED will become
green and at the same time Check synchronization relay should give permission for
breaker closure. This signal can be seen on the front panel when the LED SKE acted is
lit up. Once the rotation has crossed the 12 Oclock position this LED will get OFF.

C44

ERECTION AND COMMISSIONING

C44

Allow one cycle of rotation of the synchronoscope just to ensure that the system is
working Ok and to tune the response of the governor & AVR if required.
In the Next cycle try to close the breaker in test position if the provision is available in
the breaker. This ensures that the closing circuit is OK.
Rack in the breaker to service position start synchronization activity, close the breaker
through the breaker TNC Switch when SKE permitted. Return all the switches to off
position except the auto manual switch.
Synchronization in Auto Mode.
Procedure
Select the appropriate switches for auto synchronization in synchronizing panel. Put
the local/remote switch S8 in remote position in the Excitation control panel for
synchronization.
Observe the system as the auto synchronizer takes control of the system and starts
adjusting the speed and voltage to match the bus parameters. Once the parameters are
matched the synchronizer will give the breaker close command.
In TTL system the check synchronization relay will be in series with the auto closing
command. For breaker closing, both commands should come at a time. If not tune the
auto synchronizer to achieve the same.
After breaker closing the loading pattern will be same as above.
Dead Bus Closing
Procedure
After build up of voltage in auto mode (nominal voltage), select appropriate switches
for dead bus selection in the synchronizing panel, ensure voltage & frequency at nominal,
confirm that the generator voltage and frequency is only present and the bus voltage &
frequency are not getting displayed on the double voltmeter & frequency meter. Close
the respective breaker through TNC switch. Switch on the load feeder one by one as per
load curve, if vibration & temperatures are found within limit.

C45

ERECTION AND COMMISSIONING

C45

Loading of the TG Set.

Procedure:
Slightly increase the speed through the speed raise PB to take KW load on the machine
around 500-700 KW. Observe the power factor(PF) of the TG set. To adjust the PF to the
desired value, voltage raise/lower PB can be used to decrease/increase the PF. Ideally
the PF should be maintained around 0.8 0.9 lag. Note the vibration readings and
bearing temperatures.
Bearing Vibrations and Temperatures should be stable within the limits.
Alternator cooling water can be kept closed for this operation, as the temperature raise
will help in removing any moisture content left out in the alternator.
After observing for few minutes go to load control mode in the governor/droop mode &
after load is increased to above 15% auto PF control can be taken in to line by pressing
PF control ON PB on the Excitation control panel. Ensure the local/remote switch is in
local mode. To adjust the PF set point, Set point raise or lower PB should be used.
Check all the operating electrical parameters like voltage, current, power etc are displayed
on the respective meters in the metering panel and also the parameters are being
displayed on the GPR in the relay panel.
When the winding temperatures reach around 65 70 Deg C open the cooling water for
alternator.
Slowly raise the load in accordance with the loading curve submitted by M/s Triveni
and in consultation with the Boiler operating personnel.
Note:
The loading of the TG set should be done with strict adherence to the
loading curves submitted by M/s TRIVENI TURBINE LTD (see Section-D) and with
consultation of the boiler operating personnel. This is to avoid any unnecessary
stress on the boiler and TG set due to impact loading.
VII. INSTALLATION AND ALIGNMENT INSTRUCTIONS FOR COUPLING (Also Refer Gear
box O & M Manual)
Correct careful assembly and centering at the initial stage enables couplings to provide
maximum performance, compensates for misalignment and increases service life.
NOTE
The coupling bolts are torqued at factory and these should not be disturbed under any
circumstances.

C46

ERECTION AND COMMISSIONING

C46

Alignment Procedure:
In general, the fewer the bolts used in the coupling drive the greater the allowance
which can be made for initial set up. It is suggested that, unless specific instructions
are given, the following limits should be used when measuring the distance between
flange faces.
4 bolt couplings
6 bolt couplings
8 bolt couplings and over

+0.50 mm
+0.40 mm
+0.3 mm

Since the fitted couplings are of 8 bolt design, the Flange end gap (DBSE) shall be as per
the cold setting and is to be maintained within 00 + 0.3 mm.
Radial and Angular Alignment:
An initial and rough radial alignment can be made by laying a straight edge across the
flanges of the two sides. Remember to check in the vertical as the horizontal plane.
Having brought the two ends into a roughly correct position the final alignment achieved
as follows:Clamp two dial gauges as shown in Fig.3 align the equipment within the Recommended
TIR of 0.05 mm as shown.
Disassemble the gagging screws and bushes from the transmission unit. Then compress
the transmission unit by using the gagging screw.
Drop the compressed transmission unit between the flanges. Care should be taken to
ensure that both flange spigot and the Adaptor
Recess is properly located. Remove the gagging screws and allow the transmission unit
to expand upto its free length.
Install the attachment bolts and fully tighten upto the rated torque Fig 5 & 6. All
attachment bolts are weigh balanced and no serial numbers are provided.
Final Checking: Clamp dials as shown in Fig.4 and ensure that the TIR is within the
values shown 0.05mm for each dial.
WARNING
IMPORTANT
Remove gagging screws and bushes before the attachment bolts are fully tightened.
Store the gagging screws and bushes securely for future use at the time of coupling
dismantling.

C47

ERECTION AND COMMISSIONING

C47

Summary of Alignment and Setting up

1.
2.
3.

Maintain Flange end face to Flange end face is to be + 0.30 mm

Bring Flanges into rough radial alignment.
Set axial face to face dimension

4.

Align as per Fig. 3

5.

Remove gagging screws & compress the transmission unit by Tightening of gagging screws.

6.

Drop the transmission unit in between the two Flanges.

7.

Remove gagging screens and bushes and allow to expand.

8.

Check and adjust radial misalignment both ends of coupling as per Fig. 4

9.

Check axial dimension and adjust if necessary

General Notes for Low Speed Coupling
Parallel and Tapered bored hubs should be fitted so that the shaft end is flush with the hub face
unless otherwise instructions are given.
Hubs are bored for interference fit over the shafts and are to be heated in an oil bath based on
the amount of interference and quickly positioned on the shaft. Heating temperature in this
coupling should be 140-160 deg C.
NOTE
DO NOT SPOT HEAT THE HUBS, AS IT WILL CAUSE LOCAL DISTORTION.

VIII. STEAM QUALITY

I.

NEED FOR QUALITY STEAM

Apart from selecting the steam generating equipment of sufficient capacity to suit the turbine
demand, the quality of the steam has to be maintained for better and prolonged life of turbine and
other equipment.

2.

EFFECTS OF POOR STEAM QUALITY

i)

Damage of Internals
The water used for steam generation may contain scale-forming materials, solids, oxygen and
other impurities. Therefore it is necessary to remove the impurities for trouble free operation. The
trouble created by undesirable quality are scaling, corrosion, foaming, priming and embrittlement
etc.

C48
ii)

ERECTION AND COMMISSIONING

C48

TV Sticking
Sticking of valve steam in common if solids are present in the steam. Salt from the boiler water
will settle on the inside surface and cause pitting even on the stainless steel blading.

iii)

Loss of Power
Loss of power is generally a result of inadequate water treatment, because of which salts stay in
solution while the steam is superheated. After the steam becomes saturated, after expansion
through stages, these salts with condensate get deposited on the blading.
Even with low solid contamination of steam, deposits on Turbine blades are noticed. Silica gets
deposited on turbine blades which may cause reduction in flow area and at times unbalance. The
stage pressure increases, load drops, the thrust increases and the thrust bearing may even fail.
Hence the carry over of solids in steam should not be allowed.
RECOMMENDED STEAM PURITY LIMITS
Technically pure steam is of such quality, that it does not cause deposits in the steam pre-heaters,
in the fittings, heaters as well as in the turbine, which might require the intentional shut-down of
the boiler or some part of the equipment, for their cleaning, outside of the normal equipment
maintenance program.

C49

ERECTION AND COMMISSIONING

C49

The recommended or limit values of the purity of steam are stated in the following table.
STEAM PURITY LIMITS.

Conductivity
Micromhos/cm at 25oC
Drum

0.3

Once through

0.2

SiO2, ppb, max

20

Fe, ppb, max

20

Cu, ppb, max

Na +K, ppb, max

Pr. up to 56 Bar (g)

20

Pr. above 56 to 100 Bar (g)

10

Pr. above 100 to 165 Bar (g)

NH3, Mg/Litre

The above values are in conformance with NEMA SM 23 1991 guidelines

Note: Contamination of the steam by agents which might promote stress corrosion
cracking, solids build up, erosion and corrosion. Containments such as Sodium,
hydroxides, chlorides, sulfates, copper, lead and silicates may result in shortend life
and failure of internal parts of the Turbine.
Triveni strongly recommend to install a monitoring equipment on the inlet and
exhaust steam sides for continuous monitoring of the water / steam cycle by
constantly recording the electric conductivity at a

local sampling point

downstream of the strongly acidic cation exchanger, and the determination of

the silica content.

C50
IX.

ERECTION AND COMMISSIONING

C50

PREPARATION FOR RUNNING

When erected, the turbine and all associated services should be systematically examined to
ensure correct fitting and tightness of joints etc.
Before running a machine, it is of the utmost importance to ensure that the oil system is thoroughly
clean. Prior to dispatch, the system is flushed, dried out and thoroughly examined before the
application of a preservative. Maintain as a sealed unit until oil flushing commences. Covers and
pipe work taken off during erection will inevitably attract debris.
Make sure that the sump is clean, check tightness of all cleaning doors and drain plugs renew
cleaning door joints should any have been damaged.
Fill with clean fresh oil of correct grade see SECTION Q, for quantity see SECTION B. Using
the auxiliary pump, flush the system till the system became clean. Any pipe work removed for
transit or erection, should be reconnected into the system with fine mesh strainers fitted at the
downstream point of reconnection.
During this period, (flushing should continue until satisfied that the system is clean, check that oil
in sufficient quantities is reaching all bearings, auxiliary drives, sprayers, etc.
To ensure complete flushing of bearing supply lines, take the weight of shafting and support
with substantial chocks, then remove the top half bearing shells. The bottom halves should be no
more than as specified in clearance data section. Replace covers and run the pump.
Occasionally to check line filters and the main filter elements : Slave elements should be used
if available. When satisfied that the system is clean, wash and clean the bearings and ensure
they are correctly fitted, remove temporary shaft supports, replace and tighten bearing caps
and replace covers. Remove slave filter elements and replace for service elements.
Remove all line filters and replace pipe work : ensure all joints and covers are correctly fitted and
oil tight. Check system pressure. If steam piping has been blown through and re-connected,
check all drain lines and traps. Debris will be washed to the lowest points of the system.

C51

ERECTION AND COMMISSIONING

9.

C51

RECOMMENDED COOLING WATER ANALYSIS

U N ITS

C IRC U L AT I N G
W AT ER W ITH
COC 4

TU RB ID IT Y
TE M PE R ATU RE

NT U
oC

4 0 (max)
3 0 (max)

C OL OU R
TO TA L DISSO LVE D SO LID S

P tC o
m g/l

10
6 04

TO TA L SUSPE N DE D SO LID S

m g/l

4 0 (max)

7 .20

TO TA L HAR D N ESS
C aC O 3
C ALC IU M H AR DN E SS C aC O 3

m g/l
m g/l

1 80 .00
1 24 .00

M g . H AR DN E SS

CaC O 3

m g/l

5 6.0 0

M . ALK ALIN ITY

C aC O 3

m g/l

1 26 .84

P. ALK ALI NIT Y

C HL OR ID E

C aC O 3
Cl

m g/l
m g/l

0 .00
4 8.0 0

F RE E C O 2
K M nO4

as suc h
as suc h

m g/l
m g/l

1 4.0 8
2 8.9 6

F RE E C H LO RIN E
N ITR ITE

as suc h
NO 2

m g/l
m g/l

0
0 .02 4

P AR AM ET ER

P H YS IC AL

C H EM IC A L
pH

N ITR AT E

NO 3

m g/l

SULP H ATE

SO4

m g/l

1 80 .12

SILIC A
TO TA L IRO N

SiO2
Fe

m g/l
m g/l

1 27 .48
0 .4

500 DBSE
X

DRIVE END

NON DRIVE END

10 11 12 13 14 15

19

Gagging Screw

STD

20

18

Gagging Bush

BS970 080 M40

20

17

Alternator hub

BS970 080 M40

Note:- 1. Tightening torque of bolts having threads lubricated with MOS2.

16

Adaptor # 3

BS970 080 M40

1
1

Item No: 5 Coupling bolt tightening torque = 1050 Nm.

15

Bearing shaft

BS970 080 M40

14

Screw

STD

13

Adaptor # 2

12

Shear pin

BS970 080 M40

BS970 817 M40

11

Bearing

STD

10

Grub Screw

STD

9
8

Spacer

BS970 080 M40

Lock nut

BS970 817 M40

1
20

Ring nut
Lock washer

STD
STD

1
1

Element assembly
Coupling bolt

AISI 301
BS970 817 M40

2
20

Adaptor # 1

BS970 080 M40

Attachment screw

STD (B/O)

40

Gear box hub

BS970 080 M40

16

17

Item No: 3 Attachment bolt tightening torque = 200 Nm.

2. Gagging Screws & Bushes (Item No 19 & 18) are only for Transportation
purpose and need to be removed prior to installation. Coupling not to

19

18

operate with gagging screws in position.

3. For compressing Membrane Unit assy to clear the spigot on the hubs,
tighten gagging screws (without bush in position)
4. Do not disturb factory assembled Coupling bolts. (Item No:4)

7
6
5
4

4.5 mm

Axial

1.8 mm

Radial

0.25

Angular

MAX. MISALIGNMENT

DETAIL-X

S.No.

DESCRIPTION

MATERIAL

QTY

D1

SECTION D-OPERATION
The following description of the start up, operating and shut

D1
down procedure for the

turbine is to be read in conjunction with the arrangement drawings diagram included

in this manual.
I.

STANDBY STATE
In order that the Turbine can be brought up to speed and loaded with the minimum of
delay the following notes and conditions must be observed:Steam stop valves, after even relatively short periods of service are seldom Bottle tight
and some leakage has often to be tolerated.
The corrosive effect of moisture and some boiler treatment chemicals which may be
deposited in the turbine is far worse in a standing turbine open to atmosphere (via the
glands) than under running conditions.
It is good practice, therefore, to prevent as much leakage as possible from getting
through to a standby machine.

1.

The isolating valves V-1 (Fig-7) between the boiler and the turbine stop valve also the
isolating valve of exhaust line should be shut.

2.

The main turbine stop valve should be closed (This is a combined stop and emergency
valve).

3.

Check that the drain valves for the following points are open:Turbine Stop & Emergency Valve
Wheel case drain
Inlet throttle valve chest

4.

Close the gland condenser (if supplied) circulating water inlet and outlet valves.

5.

Close the driven equipment cooler circulating water inlet and outlet valves. (IF
APPLICABLE)

6.

Close the oil cooler circulating water inlet and outlet valves.

7.

The oil in the tank should be maintained at the correct level and any water present
should be drained off through to the purifier and returned.

8.

The oil filters should be clean.

9.

With the BOILER ISOLATING VALVE CLOSED, check the freedom of all other valves
by fully opening and closing once a week:-

D2

OPERATION

D2

II. STARTING
A. CHECK POINTS BEFORE STARTING:1.

Check that the 2-way solenoid operated remote trip is not in the tripped state (ie. Energized
position).

2.

Turn the hand trip lever, situated on the steam end pedestal, to the RUN position.

3.

Check oil level in the oil tank through the level glass.

4.

Admit cooling water to the oil cooler and auxiliaries.

5.

Reset the Low Pressure Oil Trip Valve.

6.

Start motor driven AOP & ACOP.

7.

Check that the control (relay) oil accumulator is charged with nitrogen to the correct
pressure.(see SECTION-B)
DO NOT LUBRICATE the throttle valve or stop valve spindles.
These spindles operate in hardened and ground nitride steel guides and must be kept
free from all deposits.

Check for Operating of Throttle valve.

The governor in service mode, increase & decrease the governor out put. This would
cause the Throttle valves to open & close.
This is because the actuator can be governed & controlled to open or close .Throttle
Valves even when turbine is at Zero RPM, with Control Oil available.

Check for Operation of SEV.The SEV is ON/OFF type, The 3- way solenoid valve in the
control oil line can be deactivated for open & activated for closing the SEV, This can be
repeated for 2- 3 times

10. If any of the valves or controls referred to above, particularly the throttle valve or SEV
stick or operate jerkily, then DO NOT attempt to run the turbine except in an
emergency.Should such an emergency condition exist DO NOT leave the set unattended

D3

OPERATION

D3

If the turbine is left standing for long periods, pressurize the lube oil system and
initiate the turning gear for approximately I hour every two or three days. This will
prevent the rotor remaining in the same position for long periods.
B.

WARMING FROM COLD START

WARNING
Before attempting to run the machine, the operator should be certain that
he is familiar with all the controls of the turbine and its auxiliaries and
that he understands their function.
These instructions should be read right through in conjunction with the P&I diagrams
and drawings supplied.

1.

Ensure that all Drains on turbine (Throttle Valve Drain, Stop Valve Drain, Wheel Case
drain) are opened.

2.

Ensure all the Check points (mentioned in section II) are done.

3.

Start the motor driven barring gear. An interlock ensures that the barring gear cannot
be started before bearing oil pressure is established.
IMPORTANT: MINIMUM PERIOD OF BARRING REQUIRED FOR THIS TURBINE IS
8-9 HRS BEFORE

4.

REFERING START-UP CURVE.

To start, open the isolating valve in steam line after boiler. (if fitted) and open vent line
valve V2 & V3, (refer Fig -7) crack open the main valve (V-1 ) in the main header. This
would warm up the steam pipe to the turbine & up stream of turbine stop valve. (Since
at this condition the SEV will be in closed position). The excess steam would be vented
through V-2 & V3.

5.

When the steam temperature consistently maintained around rated design temperature
(or less 50 o C of rated temperature) and evidence of steam coming out of from SEV drain
(with out water is visible for 10-15 minutes) reset 3-way solenoid valve to allowing the

D4

OPERATION

D4

control oil into the hydraulic system to open the stop & em. valve, which in turn admit
steam in to SEV & nozzle chest for warming-up process.
6
7

Observe the nozzle Chest body temperature.

After Nozzle Chest is completely warmed, set the governor to service mode to crack
open the throttle valve.This would allow the steam to pass to the steam casing for
warming.The differential temperature between the top & bottom steam casing

should

be not more than 50 o C.

8.

The Soaking time to be followed as indicated in cold start diagram.

With the above the turbine is ready to start.

C.

STARTING AFTER WARMING

The following operations for starting should be carried out in the proper sequence.

1.
2

Ensure governor is programmed as per start-up curve

After Steam casing has achieved the desired temperature.Close all the valves
inventing line (V-2 to V-3 ) and open main inlet valve (V-1 ) fully .

Re-set governor in RUN mode, the turbine starts following as per the programmed
start-up curve.

Checks should continue to be made on oil pressures, temperatures and vibration

readings.
WARNING
The turbine speed MUST NOT be held steady with the CRITICAL
SPEED BRAND, but must always be steadily increased through this
region.

During run up, check that the barring gear has stopped and declutched automatically
at a preset speed.

D5
6

OPERATION

D5

At any speed other than the critical speed band, the run up may be halted from
the Governor Keypad to investigate any unusual circumstances.

If the turbine starts to vibrate, possibly due to unevenness of warming through the
rotor causing a temporary bend, reduce speed immediately to 1000 rpm and

soak

for approximately 30 minutes before commencing run up procedure again. Any attempt
to run through a vibration condition by increasing the speed could cause permanent
deflection of the rotor.
NOTE
7

Once the turbine is running satisfactorily at rated speed it may be desirable to

test both electrical and mechanical overspeed trip devices.

The mechanical overspeed trip must now be tested. Test the overspeed trip by increasing
the speed above rated speed through governor.
DANGERS
Under no circumstances go beyond the maximum trip speed rating.

When the main stop valve trips, It should be noted that until the turbine has run
down to half speed any attempt to ON the stop valve will be futile. This is because
the overspeed trip valve will not return to its inner position and furthermore, the low
pressure oil trip is held in the tripped position by relay oil.

10

When turbine speed has fallen to half speed, reset the low pressure oil trip.

11

Repeat the start up sequence given from Point 3 onwards.

12

The turbine/driven equipment unit is now ready to take on load.

13

If possible, it is advisable to apply load gradually taking 20-30 minutes to reach full
load.(refer load curve) Whilst the set is designed to withstand full load instantaneously,
the sudden steam demand on the boiler may result in carry over water and possible
damage to the turbine.

D6

OPERATION

D6

III. RUNNING
1.

In addition to keeping a regular Log of instrumentation data, it is good practice to

develop a checking routine similar to that suggested in ARTICLE II. With time, one
develops a feel for the equipment which can give a turned in Operator, advance
warning of something untoward happening, thereby taking the appropriate action to
avoid what could be expensive down-time.
Cleanliness is of utmost importance, oil leakage is not only unsightly, but also constitutes
a fire hazard. All pipe fittings and cover joints should be tackled immediately leaks
appear.

2.

Water service lines should get similar attention, especially where out of sight under
the operating platform.

3.

Check the labyrinth gland vents, adjust the gland condenser duty to prevent excessive
discharge from vents and spindle glands.

4.

Ensure that all drain traps are operating satisfactorily.

5.

If the wheel case/bleed (if applicable) pressure isgradually increasing beyond the design
value, it is IMPORTANT to check the steam quality by analyzing drain water from the
turbine. Chocking may occur due to scaling at nozzles and blades.

6.

Bearing nearer the steam end will normally run hotter than the exhaust end because of
the temperature gradient across the turbine. Pinion bearings likewise, tend to run
hotter than gearwheel bearings because of the high speed of the pinion.

7.

The turbine rotor journal bearing metal temperatures should

normally be 80 90 oC

and bearing oil outlet temperature should normally be 60 80 oC at full load and maximum
steam conditions.The steam end turbine bearing will normally run hotter than the
exhaust end bearing because of its proximity to the inlet end of the turbine.

D7

OPERATION

D7

If a bearing metal temperature exceeds 95 oC observe this bearing closely until certain
that this is a stable temperature and not gradually rising. An alarm should be activated
at 95 oC temperature.
WARNING
Rising temperatures in excess of 100 oC call of IMMEDIATE SHUTDOWN
AND EXAMINATION.

The turbine should trip when bearings reach

this temperature.

8.

The turbine rotor thrust bearing temperature is measured by resistance temperature

detectors embedded in the pad metal.
Normal temperatures should be in the range 80-90 oC. Alarm should be activated at 95
C and the turbine tripped at 100 oC.In an emergency an Operator should be stationed

at the turbo-alternator and the bearing opened up as soon as possible if temperatures

exceed 95oC

9.

Running oil pressures can be found in SECTION B. These are design requirements,
established on test and will be set accordingly during commissioning, thus merit
examination if any noticeable drop in pressure persists during service.

IV.

SHUTTING DOWN
Normal shut-down is basically the reverse of the start-up procedure.

1.

Reduce and remove the load from the turbine in accordance with the instructions given
in the manuals for the driven equipment and the other plan and equipment.

2.

Trip the main stop valve by the operating solenoid trip button. Check that the AOP &
ACOP starts during the turbine run-down.

3.

When speed is low enough the barring gear will cut-in automatically to keep the shafts
turning during the cooling down period.

D8

OPERATION

D8

4.

Close the isolating valve in the steam line.

5.

Close the HP steam isolating valves.

6.

Shut down the Gland sealing system.

7.

Open the turbine drains.

set its resting.

8.

The motor driven barring gear should be allowed to run until all bearing
temperatures have fallen to ambient levels to ensure the turbine shaft does not
bend while cooling.The oil pump must be run to the same period to lubricate the
bearings and carry away the heat soakage along the shaft. Circulating water to
the oil cooler should be allowed to continue for the same period.

9.

Wipe off any boiler compound deposits which may have formed on the throttle valve

It is most important to leave these open whilst the

spindles. If the valves have been operating in one position for a long period, proceed as
follows while the turbine is cooling.
We need to Increase & then Decrease the governor speed settings, this would cause the
Throttle valves to open & then close.
This is because the actuator can be governed & controlled to open or close
Throttle Valves even when turbine is at Zero RPM, with Control Oil available.
Repeat these three steps several times.

10. Shut down any supplies to the generator (see manufacturers manual.
11. Please observe the conditions set out in Article I. Standby State of this section, in order
to ensure that the turbo-alternator set is maintained in good working order and may be
brought into service with minimum effort and delay.
For Warm & Hot Start follow the same start procedure.

D9

OPERATION

V.

GUIDELINES FOR USING START UP CURVE

1.

The importance of following a start up curve is to ensure that:

i)

The vibration levels are within acceptable levels throughout its speed and load

D9

increase.
ii)

There are no mechanical rubbings either of axial or in radial types.

iii)

There is no water carryover into the turbine which will cause bending of the rotor
and also may damage thrust bearing.

2.

Starts up curves provided are generic in nature. They give insight into proper starting
of turbine. However validity of the curves is to be done during commissioning of turbine
and corrections required have to be done by commissioning personnel.

3.

Primarily it is the responsibility of the operating personnel to see that the above
points 1 and 2 are fulfilled even by modifying the start up curves.

4.

During soaking period of turbine vibration levels have to be closely monitored. Vibration
levels should be same or improved but should not deteriorate. Deterioration can be
attributed to bends, axial or radial rubbing. In such case time period for soaking can be
increased

WARNING
5.

Customer is advised to check the functionality of mechanical over speed tripping

mechanism at least once in a year, if the TURBINE is running continuously. If it is
intermittently run, then test is advised at first start up time. However checking of
the over speed tripping mechanism may be limited to a maximum of 5 to 8 times in
a year.

6.

Loading rate of turbine after attaining rated RPM should be as per load curve
provided. Gradual loading is also required as sudden demand on boiler for steam
can lead to water carry over to turbine, which can damage turbine parts. Essence is
the load curve to be followed is a minimum requirement while ensuring that there is
no considerable fluctuation in steam inlet pressure and temperature as fall in
pressure and temperature can cause water carryover into the turbine.

Triveni Turbine Ltd.

Note: Refer "Guidelines for using start up curves" before following this curve

ISSUE : 00

COLD START DIAGRAM

(for >/= 10 hours stoppage)

10000
Project :

M&H USA A/C INGENIO LAZARO CARDENAS

Power :

8000

19.6

Inlet Temperature :

320

TURBINE SPEED (RPM)

Exhaust Pressure :

Normal Speed 8303

KW

5000

Inlet Pressure :

RPM

BARA
DEG C
BARA

2.39

Doc No. :

TDC/C-3041/START

6000
Sudden jump from -500 to +500
rpm of CS= 5800 RPM
CS - 1st critical speed

4000

This time to be considered with

respect to stabilisation of TG set at
rated operating speed. Further ,
refer Load curve for loading turbine
at rated speed.

2000
Soaking

Barring

0
0

10

20

30

40

50

60

70

80

TIME (MINUTES)
PREPARED BY:

RUPALI

CHECKED BY:VM

6/25/2014

Triveni Turbine Ltd

Note: Refer "Guidelines for using start up curves" before following this curve

ISSUE :00

WARM START DIAGRAM

(FROM 6-10 HOURS STOPPAGE)

TURBINE SPEED (RPM)

10000

Project :
M&H USA A/C INGENIO LAZARO CARDENAS
KW
5000
Power :
19.6
BARA
Inlet Pressure :
320
DEG C
Inlet Temperature :
BARA
2.39
Exhaust Pressure :
TDC/C-3041/START
Doc No. :

8000

Normal Speed 8303

Sudden jump from -500 to +500 rpm of CS=

5800 RPM
CS - 1st critical speed .

6000

RPM

This time to be considered with

respect to stabilisation of TG set
at rated operating speed. Further
, refer Load curve for loading
turbine at rated speed.

4000

2000

Soaking
Barring
0

PREPARED BY:

10

RUPALI

20

30

TIME (MINUTES)

40

50

CHECKED BY:

VM

Triveni Turbine Ltd.

Note: Refer "Guidelines for using start up curves" before following this curve

ISSUE :00

HOT START DIAGRAM

(FROM STANDBY STATE, < / =6 Hrs STOPPAGE)

10000

Project :
M&H USA A/C INGENIO LAZARO CARDENAS
5000
KW
Power :
BARA
19.6
Inlet Pressure :
320
Inlet Temperature :
DEG C
BARA
2.39
Exhaust Pressure :
TDC/C-3041/START
Doc No. :

TURBINE SPEED (RPM)

8000

Normal Speed

This time to be considered with

respect to stabilisation of TG set
at rated operating speed.
Further , refer Load curve for
loading turbine at rated speed.

Sudden jump from -500 to +500 rpm of CS=

5800 RPM
CS - 1st critical speed range.

6000

8303 RPM

4000

2000

Soaking
Barring
0

0
PREPARED BY:

5
RUPALI

10

15
TIME (MINUTES)

20

25

30
CHECKED BY:

VM

Triveni Turbine Ltd

Note: Refer "Guidelines for using start up curves" before following this curve

ISSUE :00

LOAD CURVE

(FOR COLD, WARM, HOT CONDITIONS)

COLD START

WARM, HOT START

LOAD CURVE IS TO BE
USED WITH
REFERENCE TO
START UP CURVES
ONCE THE TURBINE IS
RUNNING AT RATED
RPM

6000

LOAD (KW)

5000
4000
3000

Project :
M&H USA A/C INGENIO LAZARO CARDENAS
KW
5000
Power :
19.6
BARA
Inlet Pressure :
320
DEG C
Inlet Temperature :
BARA
2.39
Exhaust Pressure :
TDC/C-3041/START
Doc No. :

2000
1000
0
0

10

20

30

40

TIME (MINUTES)
PREPARED BY:

RUPALI

CHECKED BY:

VM

TRIVENI TURBINE LTD.

BANGALORE

INLET PRESSURE CORRECTION CURVE

1.020

1.000

Correction Factor

0.980

0.960

0.940

ORDER NUMBER

C-3041

:
M/S
M&H INGENIO LAZARO
19.60
INLET PRESSURE (Bara)
:
PROJECT

0.920

INLET TEMP (deg C)

EXHAUST PRESSURE (Bara) :

0.900

SPEED (RPM)

320
2.390
8303

0.880

0.860
16

17

18

19

20

21

Inlet Pressure (Bara)

PREPARED BY : DS

APPROVED BY : VM

12/19/2014

TRIVENI TURBINE LTD.

BANGALORE

INLET TEMPERATURE CORRECTION CURVE

1.010

1.000

Correction Factor

0.990

0.980

0.970
ORDER NUMBER
PROJECT

0.960

C-3041
M/S
: M&H INGENIO LAZARO CARDENAS

INLET PRESSURE (Bara)

INLET TEMP (deg C)

0.950

0.940
300

305

310

315

19.60

:320

EXHAUST PRES (Bara)

: 2.390

SPEED (RPM)

: 8303

320

325

330

Temperature (deg C)

PREPARED BY : DS

APPROVED BY : VM

12/19/2014

TRIVENI TURBINE LTD.

BANGALORE

EXHAUST PRESSURE CORRECTION CURVE

1.010

1.000

0.990

Correction Factor

0.980

0.970

0.960

0.950

ORDER NUMBER
PROJECT :

0.940

0.930

C-3041

M/S M&H INGENIO LAZARO CARDENAS

INLET PRESSURE (Bara)

19.60
320
EXHAUST PRESSURE (Bara) : 2.390
INLET TEMP (deg C)

SPEED (RPM)

0.920
2.20

2.30

8303

2.40

2.50

2.60

2.70

2.80

Exhaust Pressure (Bara)

PREPARED BY : DS

APPROVED BY : VM

12/19/2014

TRIVENI TURBINE LTD.

BANGALORE

SPEED CORRECTION CURVE

1.01

Correction Factor

0.99

0.98
ORDER NUMBER
PROJECT

M/S M&H INGENIO LAZARO CARDENAS

INLET PRESSURE (Bara)

0.97

C-3041

INLET TEMP (deg C)

19.60

:
:

EXHAUST PRESSURE (Bara) :

SPEED (RPM)

320
2.390
8303

0.96

0.95
93%

94%

95%

96%

97%

98%

99%

100%

101%

Speed (rpm)

PREPARED BY : DS

APPROVED BY : VM

12/19/2014

E1
I.

SECTION E-SPEED

GOVERNING SYSTEM

E1

DESCRIPTION
The speed governing system comprises :A Speed Sensing Unit & Governor.
Actuator.
A THROTTLE VALVE ASSEMBLY

II.

SPEED SENSING & GOVERNOR SYSTEM

This is a Woodward 505 electronic governor which takes the input from the speed
sensing unit mounted on the Steam End Pedestal.
The operation of 505 Woodward Governor is described in governor publication.
a). The governing system is an electronic type with an electrical signal being transmitted
to servo actuator which in-turn controls the lift of Throttle valve & hence the steam
entering the Turbine.

III. ACTUATOR (make, see Section-B)

SYSTEM includes servo actuator is a

high performance cylinder, servo valve

and transducer assembly specially designed for position close loop application. To
move in both directions, the system uses an external hydraulic power supply (24-25
Bar (g).
For further details refer manufacturers instruction manual
IV.

THROTTLE VALVE GEAR (refer to Fig. 10)

A.

Description
The nozzle or throttle valve chest is sub-divided internally into the three separate nozzle banks.
Each group of nozzles has steam flow controlled by its respective throttle valve.
The valves are of the single beat, seat obturated type, with spindle and valve head guides.

E2

SPEED GOVERNING SYSTEM

E2

To resist scoring and pick-up from scale carried through the strainer, the guiding surface of head
and spindle have a nitrided finish.
Loaded throttle valve springs (16) resist valve opening in addition to the steam out of balance
forces when closed, (the latter is reduced to acceptable levels on No. 1 valve by pressure balance
holes drilled through the valve head).
The upper end of each valve spindle is screwed and pinned into a spring carrier, which also
houses a spherical bearing. A separate throttle valve lifting spindle (23) is retained within the
spherical bearing housing by a flange turned on its lower and Screwed bearing retainer (19)
prevents withdrawal of the bearing and spindle (23).
Each of the three valve levers has trapped at the extremely a second spherical bearing through
which the upper portion of spindle (23) till slide.
The outer end of spindle (23) is threaded, with adjusting nut (40) positioned at some fixed point to
provide the correct valve phasing.The valves lift against spring load etc., when sleeve (25) fitted
to the spherical bearing contacts adjusting nut (40).
Cross shaft (29) provides the necessary upward motion to the lever, spherical bearing (47) and
sleeve (25) rotating anti-clockwise in bearing blocks (30).
B.

Operation
The turbine being a nozzle governed set, has three nozzle banks, each with its respective throttle
valve. These open in sequence relative to the load carried, reducing throttling losses to a minimum
at the C.M.E.R. point it follows that the valves should be arranged to operate in the correct
sequence. Valve pick up points can be determined statically, but final settings can only be achieved
by plotting the droop line on site.
All three valves are phased to open sequentially by means of lift arms from a common rocker
shaft. The latter located in spherical bearings is rotated by direct mechanical linkage from movement
of the power piston, which has sufficient muscle from the oil relay to overcome combined spring
and steam loads.

E3
C.

SPEED GOVERNING SYSTEM

E3

Adjustment (refer to Fig. 10)

Refer to adjustment of power piston stroke.
If travel of the rocker arm and valve levers are correct proceed with the valve settings.

1.

At No.1 valve lever trap a shim 1.27 1.52 mm thick for clearance V. Hold in this position and
run adjusting nut (40) down spindle (23) of valve No. 1. Bottom spindle (23) in carrier (31).]

2.

Check that sleeve 25 is seated correctly in spherical bearing 47, just touch the top of sleeve 25
with the underside of adjusting nut 40,42 and set dimension Z clearance as Refer Fig 10a:
NOTE: Valve No.1 is at the main stop valve side and Valve No. 3 at Centre. Generally the
main stop valve No.1 shall be at Right hand side viewing from steam pedestal end.

3.

Pressure the auxiliary oil systems and check operation of the valve gear. Ensure that valve travel
is smooth and full lift as above is available.

4.

Shut down check clearance between nut 40 and sleeve 25 on No.1 valve this should be 1.5
1.8mm.

5.

Adjusting nuts 40 on No.2 and No.3 valves cannot be finally pinned until the droop line has
been plotted.
Throttle Valve Gland Leakage Setting

1.

Nut 18 will not be fully lightened in the initial stage.

2.

After admitting steam and witnessing some fumes of leakage of steam, nut 18 may be lightened
slowly such that the steam leakage just stop.

3.

Fine tuning of nut 18 may be attempted once again if it is leak.

D.

Maintenance

1.

Disconnect vertical relay link

2.

Screw adjusting nuts 40 and locknuts 42 off spindles 23 and storer.

E4

SPEED GOVERNING SYSTEM

E4

3.

Swing rocker arm 26 anti-clockwise over spindles 23.

4.

Carefully release the spring load using long studs 11, 39. Ensure all compression is off before
removing spring retaining plate 10.

5.

Remove spring, plates, etc, identifying each item for re-fitting.

6.

Check that TV lifting spindles 23 dim. have the requisite dimension at X =0.50 1.0 mm vertical
clearance at the lower end.

7.

Bottom, each spindle in spring carrier 31 taking up all clearance checked in step 6. Check that all
valves are seated.

8.

Swing rocker arm 26 back over spindles 23 until valve lever No.1 contacts the arm stop 17. Hold in
this position.

9.

Set a dial indicator on the spring carrier 31 and zero.

10.

Carefully lever up each valve in turn to check gap W which should have reduced to 1.65
2.66mm.

11.

Clearance W is important at all three valves to prevent contact of TV collar 24 and spherical
bearing 47.

12.

Should this occur full servo effect would be applied to clamp plate 28 and retaining screws 37.

13.

With clearances checked swing levers out of position for individual valve lifting spindle inspection.

14.

Remove grubscrew 36 locking bearing retainer 19 unscrew retainer and withdraw bearing 47.
Examine bearing (renew if necessary) and spindles 23 check that the latter has had sufficient
working clearance inside the bore of retainer 19. Likewise, at the upper end check there has
been no contact with the bore of spring retaining plate 10.

15.

Replace :- Spindle, bearing and retainer lock with grubscrew.

E5
16.

SPEED GOVERNING SYSTEM

E5

Examine the spherical bearings contained in the ends of each valve lever, these should be free
but not slack. Check that sleeve 25 is peened securely into the bearing. (Spherical bearing and
sleeve 25 must remain locked in this fashion to ensure correct valve settings). Check that clamp
plate 28 is face to face on the lever and not nipping the bearing housing if this occurs, the
bearing will seize in the housing.

17.

Examine cross shaft spherical bearings 46, these should allow free movement of valve levers,
any binding should be investigated. Excessive clearance requires renewal of bearings.

18.

Check that lifting spindles 23 are free to allow displacement about the center line when operating.
Examine the portion traversed by valve lever(s), this section should be smooth and free of
burrs, on which sleeve 25 could latch.

19.

Disconnect valve spindle drain manifolds, release valve column flange nuts and withdraw column
assembly. COVER VALVE CHEST OPENINGS.

20.

Hold assembly secure on wooden blocks, remove split taper pin 34 and unscrew spring carrier
body from valve spindle.

21.

Carefully withdraw valve head and spindle. Check that pressure balance holes are clear. Examine
guided sections of valve head spindles, any scratches or burrs should be removed with a smooth
carborundum stone. Hard marking or indications of malalignment should be investigated. Any
sign of wire-drawing on valve or seat, requires grinding out.

22.

Examine spindle and valve head guides these being nitrided items should require nothing more
than cleaning remove all trapped scale and chemical deposits.

23.

Check that the spindle drains are clear, examine flange joint faces, rectify any damage likely to
create leakage.

24.

Examine the TV column raised joint face and mating recess in the valve chest. Both should be
free from damage indication of leakage requires the two faces grinding together. (NOTE: these
are face-to-face joints). When reassembling ensure these faces are pulled down square.

25.

Examine valve chest clean out and double check that no nuts, Allen keys, rule etc. have dropped
through the valve seats. When satisfied, reassemble valve and valve column and refit.

E6

SPEED GOVERNING SYSTEM

E6

26.

Reposition valve operating gear check clearances X and W (Steps 6-10).

27.

Check valve springs before refitting for Refer Fig. 10a.

28.

Reassemble individual valve gear, check valve settings, connect to oil relay and check operation.

E7

SPEED GOVERNING SYSTEM

Ref.

Description

1.

Throttle valve column Nos. 1 & 2

2.

Throttle valve column No. 3

3.

Throttle valve spindle guide

4.

Throttle valve guide bush top

5.

Spindle gland packing closed & open

6.

No.1 Valve head guide

7.

Throttle Valve No. 1

8.

Throttle valve No. 2

9.

Throttle valve No. 3

10.

Spring retaining plate

11.

Special stud

12.

Special stud

13.

Spacer-Short

14.

Spacer-Long

15.

Heat shield

16.

Valve spring

17.

Lever stop

18.

Gland packing Adjusting nut

19.

Bearing retainer

20.

No.1 Throttle valve seat

21.

No. 2 Throttle valve seat

22.

No. 3 Throttle valve seat

23.

Throttle valve lifting spindle

24.

Throttle valve spindle collar

25.

Sleeve

26.

Rocker arm

27.

Valve spring

28.

Clamp plate

E7

E8

SPEED GOVERNING SYSTEM

29.

Cross shaft

30.

Bearing block

31.

Spring carrier

32.

Sleeve

33.

Locknut

34.

Set screw

35.

Split pin

36.

Grub screw

37.

Grub screw

38.

Washer

39.

Nut

40.

Adjusting nut

41.

Spindle Locknut

42.

Locknut

43.

44.

Support column

45.

46.

Spherical bearing

47.

Spherical bearing

48.

T.V Guide Bush

Fig. 10 Assembly of Throttle Valves

E8

E9

SPEED GOVERNING SYSTEM

E9

F1
I.

SECTION F-EMERGENCY TRIP GEAR

F1

GENERAL DESCRIPTION
The functions of the EMERGENCY TRIP GEAR is to stop the Turbine as rapidly
as possible, should any running fault occur.
The system comprises:

(a)

Stop and Emergency valve with hydraulic servos, providing steam isolation for the
Turbine.

(b)

Low Pressure Trip valve, to control supply of high pressure oil to the Stop and
Emergency Valve servo system.

II.

STOP AND EMERGENCY VALVE (SEV) -See Fig. 13

GENERAL DESCRIPTION
As indicated this unit combines two functions, viz:That of a

remote operated steam stop valve, together with an emergency shut down

facility. The complete assembly is horizontally mounted to the inlet flange of the nozzle
chest. The front part houses the main steam valve and the rear part comprises the
hydraulic oil cylinder sub assembly. valve body (1 ) contains:-valve seat ( 3 ) steam
strainer ( 2 ) and operating parts:- main steam valve ( 4 ) spindle ( 5 ) the SEV column
( 19 ) and oil cylinder ( 15 ) house the oil piston( 16 ) bolted to the oil spindle (18 ) which
is coupled with the main spindle ( 5 ) by means of indicator half coupling( 7 ) they are
controlled by the hydraulic servo system which comprises of plunger ( 8 ),plunger
housing ( 20 ) and plunger housing cover ( 21 ).limit switch spindle( 10 ),which is
guided with limit switch spindle guide bush( 23 ) and is connected to oil spindle ( 18 )
on one side and on the other side is connected with limit switch indicator
plate( 24 ) ,which is housed inside the end cover ( 12 ).helical spring ( 9 ) is mounted
to the bottom of the oil piston( 16 ).the spring mounting and removal is supported by
cylinder mid cover( 13 ) and cylinder end cover( 12 ).

F2

EMERGENCY TRIP GEAR

F2

OPERATION
Pilot valve which is integral with main spindle ( 5 ) is

provided to pressure balance

the main steam valve ( 4 ).on start up, inlet steam exerts full pressure on the main and
pilot valve and the force required from the oil piston to move the main valve against
this pressure exceeds the effort available.

where as the pilot valve lift can be readily

achieved by the hydraulic effort. With the pilot valve full open sufficient steam can be
Having reduced pressure

passed to reduce the out of balance force of the main valve.

drop across the main valve ample force can be exerted from the servo to lift the main
valve.
The valve operating mechanism works as follows:Control oil through the oil inlet enters the servo assembly moving the plunger towards
oil piston, which pressurizes the oil in the oil cylinder (15), which enters through the
main oil inlet.

Thus sufficient pressure is developed in the oil cylinder required to

lift the pilot valve initially. The pilot valve movement helps in pressure balancing of the
emergency stop valve ( 4 ).
The steam enters from the main steam inlet and passes

through the pilot valve up

to throttle valve, steam flow through the pilot valve has reduced the pressure drop
allowing continued travel of spindle( 5 ) which lifted the main valve to the full open
position. Thus the steam flows from inlet to outlet of valve.
Under operating conditions the spindle movement can be checked periodically
with the help of check valve assembly (14).
Position feed back of SEV is given by limit switches for remote indication.
For onboard manual testing of this spindle (5) movement, unscrew check valve cap
(32) and push screw valve(28) towards inside and hold it for few seconds to open the
small port to drain oil cause reduce pressure under piston, result to move piston slowly
towards closing position.
Release hand pressure, the screw valve (28) comes back to its original seat. Due to oil
pressure, the piston (16) moves towards valve opening position. Repeat this pushing
& releasing of screw valve (28) at 4 -5 times. (see fig-13A )
This function ensures the spindles (5 &18) free movement and avoiding sticking
of the stop valve due to any progressive silicate deposit on the spindle surface in
operation.

F3

EMERGENCY TRIP GEAR

F3

NOTE
This manual testing can be done while the turbine is at running and the user must
test this function weekly once minimum.

When any of the security trips provided and described in this section operate the
control oil pressure under plunger (8)

collapses, immediately the L.P trip block and

dump spool valve moves to the trip position. additional to the L.P trip another threeway solenoid valve is provided in the downstream of the L.P trip in trip oil inlet line of
the servo system, which quickly drains the control oil by upsetting the plunger and in
turn helps for tripping of the SEV by the effect of collapse of control oil pressure, the oil
piston, oil spindle, coupling, pilot valve and main steam valve all close under the
action of steam pressure and compression of spring.

When starting up again after

tripping the same method is followed as described above.

The turbine can only be started after resetting the trip signal of the valve.

MAINTENANCE

TO DIS-ASSEMBLE OF THE VALVE (SEV):ENSURE that the valve has been ISOLATED from the boiler steam supply and that all
drains are open.
Remove steam leak off pipes, oil supply and drain piping from each valve.
Remove screws fixing the two halves of indicator coupling (7) together, and lift coupling
out. Place sling around the hydraulic unit and dismantle SEV column and hydraulic
unit as a whole from SEV body by removing the hexagonal Cap Nut (26).
The SEV assembly is separated into 3-Sub-assemblies:
Hydraulic cylinder assembly.
SEV Column assembly
SEV valve body

F4

EMERGENCY TRIP GEAR

F4

HYDRAULIC CYLINDER ASSEMBLY

1.

Cylinder end cover (11) is detached from the oil cylinder ( 15 ) initially, so that hexagonal
bolts provided for spring dismantling are visible.

2.

With the release/Opening of the nuts on the cylinder end cover, gradually the spring
reaches to its complete stretched position.
Note: Before removing the end cover plate ensure that limit switch assembly is
dismantled completely.
Remove the end cover plate, spring, oil piston and oil spindle respectively. Ensure that
seals are not damaged. If damaged to be replaced suitably.

4.

The flange ( 21) is removed from the plunger housing then followed by plunger, ensure
that seals are not damaged. If damaged to be replaced suitably.

5.

Check whether the valve assembly can be separated from the hydraulic cylinder
assembly. Ensure that spring here is replaced during assembly.
SEV COLUMN ASSEMBLY

SEV column assembly which is isolated from the main assembly is removed along with
the strainers (2 ).
Note:-Care to be taken that strainer is not rested on the ground. Also ensure that it is
free from foreign particles.

2.

Clean and polish all remaining parts, then completely reload the column assembly.
SEV VALVE BODY

1.

Remove screws from spindle support (25 ) & isolate spindle from main valve.

2.

Examine the pilot and main valve seats and if necessary regrind using fine parts.

3.

Clean and polish spindle, main valve and the bore of the spindle guide, remove any
hard markings. Check for the freedom of each items with its mating part.

4.

Re-assemble the steam portion of the valve completely.

F5
5.

EMERGENCY TRIP GEAR

F5

Dont lubricate the valve Spindle ( 5 )Check the freedom of valve assembly by lifting the
spindle up and down several times. The movement should be quite free.

6.

Replace coupling ( 7 ) and all pipe work.

7.

Refit Prop and spring support ,wind the jacking screw up until the load corresponds
with that recorded-lock with locking nut.

III.

LOW PRESSURE OIL TRIP (L.P TRIP)

A.

Description
This trip has the combined function of :

a)

Low lubricating oil pressure trip.

b)

Master control oil trip.

The unit is shown in this section (Fig. 16) from which its operation can be explained.
Low lubricating oil pressure trip provides protection against damage to bearings
in case of fall in the oil pressure below the acceptable limits. It also takes signal from
the other safety devices.
It provides safety by cutting off the supply of control oil to the servo mechanism
thereby, stopping the turbine.

A.

Operation:
Oil at bearing pressure is fed to the underside of the L.P. trip plunger (1) the upward
force so produced is opposed by the force of valve spring (2) Whilst the oil pressure
under the valve is greater than 0.6-0.8 Bar (g)
It remains lifted position and the control oil continues to pass through and reaches
the servo-mechanism. However, should lubricating oil pressure, for any reason, fall
below the limit, then the plunger will drop down and control oil supply to the servo
mechanism is cut-off. Once the plunger drops down, it get locked because of the
plunger spring (2) force acting on the plunger and catch trip (4).

F6

EMERGENCY TRIP GEAR

F6

After restoring the lubricating oil pressure, the system can be brought into operation.
For this give signal to RESET the L.P Trip which would pull the knob (5). The plunger
moves up, and admit oil to main stop & em. valve power piston.
B.

Maintenance
A wide margin of safety exists between normal lubricating oil pressure and pressure
initiating Turbine shutdown.
A gradual fall in oil pressure over a period may not invite investigation if normal
running of the machine remains unimpaired, but reducing the margin of safety
could induce a TRIP condition during transient fluctuations in oil pressure which
would, under normal conditions not result in Turbine shutdown.
Any change in pressure or unexplained SHUTDOWN should be investigated
and the following considered:Incorrect gauge readings.
Loose oil feed connection especially internal ones.
Air leaks in oil pump suction lines
Choked cooler oil side
Relief and reducing valves sticking
Auxiliary pump non-return valve stuck allowing back flow.
Chocked orifice feeding the trip circuit.
Damaged seal on oil feed fitting to the overspeed trip valve.
Hand trip leaking to drain
Excessive clearance between L.P. trip spool valve and sleeve.
Excessive clearance between relay pilot valve and liner.
Wiped bearings.

F7

EMERGENCY TRIP GEAR

F7

Sticking & Non Tripping of L.P. Trip in cold & hot running condition
Reason & remedial action:1.

Dent scoring formation at piston spindle 4 at catch tail Clean, polish & re-assemble,
check satisfactory function

2.

Tripping spindle 11 is bend- Replace the spindle , re-assemble, check satisfactory

function

3.

Dent scoring formation at top tripping spindle bush 10 Clean ,polish & re-assemble,
check satisfactory function

IV. SECURITY TRIPS

TURBINE SHUT DOWN will be initiated by any one, or a combination of the
following:
(a)

Overspeed

(b)

Low lubricating oil pressure

(c)

High relay oil pressure

(d)

Low relay oil pressure

(e)

Hand trip / Manual trip (local).

(f)

Solenoid trip (remote)

(g)

High exhaust pressure (by pressure switch).

(h)

Through Electronic Governor (Refer manufacture Instruction Manual)

The individual trips are connected in series to a trip oil circuit branched via an
orifice from the lubricating supply.

V.

OVERSPEED TRIP
MECHANICAL OVERSPEED TRIP

A.

Description
In order to prevent the turbine unit accelerating to a dangerous
Overspeed trip is fitted.
Overspeed can be caused by:
Seizure of throttle valves.
Rapid changes in exhaust conditions.

speed, an

F8

EMERGENCY TRIP GEAR

F8

Sudden loss of load or a governing system resetting too late to compensate for
unusual circumstances.
Dirt in the oil, stiction, lost motion or a combination of all three can result in the
steam flow through the throttle valves being greatly in excess of requirements which
will rapidly accelerate the turbine.
The Overspeed trip is of the unbalanced valve type illustrated in (Fig. 14).
An unbalanced steel valve (3), located in the rotor shaft extension, is held into the
valve seat by means of a helical spring (2), while the speed of the rotor shaft remains
below tripping speed.

If the speed increase 10 15% above the turbine rated speed, the centrifugal force
exerted by the trip valve at this higher speed, overcomes the spring force and moves
rapidly away from the valve seat.
This allows the low pressure oil which is fed into the center of the shaft extension
downstream from the orifice to escape, creating an instant pressure drop which
operates the Low pressure oil trip.
B.

Maintenance
NOTE
IT IS VITAL TO MAINTAIN THE OVERSPEED TRIP IN COMPLETE WORKING
ORDER.
TEST THE OVERSPEED TRIP GEAR BEFORE PUTTING THE
TURBINE ON LOAD.

If the overspeed trip falls to shut down the turbine, this may be due to :
i.

The trip valve failing to move out.

ii.

The trip valve may move out but the oil fails to drain.

F9

EMERGENCY TRIP GEAR

iii.

Despite movement of both trip valve and L.P TRIP the throttle valves may fail to

F9

close.
Before proceeding with the correction of such faults let us consider why any defects
in such a vital apparatus can exist.The trip valve, cap and rotor shaft hole are all
precision ground to fine limits.Precision rate springs are used.The trip valve assembly
is tested several times in a test rig before fitting the new turbine.Considering case (i).
This is due to a combination of dirt in the oil and temperature.
When a turbine unit is running normally, the heat generated in the bearings is
carried away by the lubricating oil.Likewise, the heat generated in the turbine by
windage and disc friction is being carried away by the steam flow. Gearbox losses, in
the form of heat, are carried away by cooling oil sprays.
When a turbine runs down the residual heat in the rotor escapes as the rotor cools
through the turbine shaft and bearings.
As a result, if no oil, (or a comparatively reduced quantity) is being circulated, the
bearings and shaft end, including the trip valve, will reach a much HIGHER
TEMPERATURE than under NORMAL running conditions.
This induced heat reduces the viscosity of the oil and promotes oxidation and formation
of deposits.
The trip valve being near the end and being buried in the center of the hot shaft is
susceptible to such deposits.
CLEAN OIL coupled with ADEQUATE LUBRICATION when SHUTTING DOWN will
prevent such deposits.
It is good practice to operate the oil pump(s) for some considerable time after the
turbine has stopped. Cooling water should, of course, be left on.

F10

EMERGENCY TRIP GEAR

F10

NOTE
DO NOT under any circumstances stop the oil pump(s) until the TURBINE
has CEASED to ROTATE.
Considering case (ii), i.e. the L.P.OIL TRIP failing to operate this is due mainly to dirt
in the oil causing the valve to stick. Reference should be made (Article II B) of this
section for maintenance instructions, with reference also to Section G. Oil System.
Case (iii), i.e. trip valve and L.P. OIL TRIP operating but the throttle valves failing to
fully close. This could be due to boiler treatment compound deposits between the
throttle valve head and guide. If the throttle valves fail to close this should be
apparent from examination of the valve operating gear. For maintenance instructions
refer to Section E. Speed Governing System.
AFTER CLOSING the COMBINED STOP AND EMERGENCY VALVE, the freedom
of the throttle valves may be checked by stroking from Governor in off line. Refer to
Section D.
C.

Adjustment and Setting

Referring to Fig. 15.
BEFORE EXAMINING the trip gear mechanism CHECK that the turbine speed
mechanism is READING CORRECTLY.

1.

Insert the removal tool provided into the hexagonal hole in the overspeed trip cap.

2.

Press the trip cap down against the trip spring to disengage the

3.

While holding down the trip cap, turn the removal tool through 90o and disengage

locking peg.

the trip cap retaining lugs.

4.

Release the pressure on the removal tool and remove the trip cap.

5.

Lift out trip spring

6.

Lift out trip valve.

7.

Examine the trip valve and shaft hole for deposits. The deposits usually appear as
an amber brown translucent film. Clean and polish as necessary and check the
freedom of the trip valve in the trip cap.

F11
8.

EMERGENCY TRIP GEAR

F11

Re-assemble in reverse order to the foregoing.

If when tested, the overspeed trip valve operates at a speed less than 10% above
maximum running speed, i.e. the valve trips below the required setting it is extremely
likely that the spring is fatigued. If a new spring is fitted of the correct specification
then no adjustment to the overspeed trip should be necessary.
If, however, the overspeed trip is not operating at the required speed then the
following ADJUSTMENTS should be considered in an EMERGENCY ONLY:To INCREASE the tripping speed place circular steel or brass shim material between
the end of the trip spring and underside of cap.
To REDUCE the tripping speed the trip spring must be reduced in length by careful
grinding.
As a guide when making adjustments a shim thickness or reduction in spring
length of 0.1 mm will make an approximate tripping speed change of 1%.
It is however, recommended that where possible the overspeed trip be replaced by a
complete and tested unit.

9.

To remove the rotor shaft extension, which houses the trip valve,

first remove the

oil supply pipe and hand trip.

10.
11.

Remove the supply nozzle and withdraw it from its housing.

Remove the pedestal cover and then the rotor axial position indicator transducer (if
fitted). The rotor shaft extension can be detached by first removing the securing
setscrews and withdrawing the shaft extension off its spigot.
When replacing the shaft extension ensure that the spigot is mated correctly and
that the spur gear runs true to the rotor shaft. A reference band adjacent to the gear
teeth is provided for this purpose.

12. The trip should now be tested (see Section D. Operation).

F12

EMERGENCY TRIP GEAR

F12

ELECTRONIC OVERSPEED TRIP

This consists of a Woodward Protect device which is completely dedicated device to
sense the over speeding of turbine for additional safety. For this purpose 3- speed
sensing probes are mounted on Steam End Pedestal.
VI.
A.

HAND TRIP (FIG. 17)

Description
The hand trip is provided as a means of tripping the machine manually, should
the operator deem it necessary, for example if excessive bearing temperature or
vibrations occur and as a convenient means of testing the action of the L.P TRIP and
COMBINED STOP AND EMERGENCY VALVE.
Referring to Fig. 17 the operation of the trip can be explained:The Body (1) of the valve is bolted to the front of the steam end pedestal over the
overspeed trip valve inlet oil fitting (4).
Low pressure oil is supplied to the underside of the valve via the control orifice from
the oil trip circuit. Oil enters the counter bored-end of the trip valve (2) through an
elongated circumferential hole machined on to the lower periphery of the valve. This
oil then feeds the overspeed trip valve through the inlet fitting (4).
The two position selector handle (5) is bolted to the square end of the valve (2).
Positive location of the handle is obtained by the spring loaded ball in the handle,
registering with hemispherical drillings on the body (1) for RUN and TRIP positions.
The valve drain is through internally drilled holes on the horizontal center line of the
valve body to the steam end pedestal.
It is prevented from leaking by pressure forcing the machined shoulder on the valve
(2) against the register machined normally in the body (1). A further safeguard being
the O ring seal housed in the body (1) around the shank of valve.

F13

EMERGENCY TRIP GEAR

F13

In the RUN position the valve (2) covers the drain hole in body (1). In the TRIP
position the drain hole is uncovered and trip circuit oil is opened to drain. The
elongated circumferential hole on the periphery of the counter-bored end of the
valve, ensures that the oil supply to the valve and hence to the overspeed trip, is
open in both the RUN and TRIP positions.
B. Maintenance
The function of the valve is such that very little wear will occur and maintenance will
consist of stripping down the cleaning Refer to Fig. 17.
1.

Remove the body of the valve (1), complete with handle, from the pedestal facing by
unscrewing capscrews (10).

2.

Remove lever (5) from the valve (2) after noting their relative positions.

3.

The valve (2) can now be removed and the valve and body cleaned and polished.
Check that the valve rotates freely in the body.

4.

Examine oil seal (8) and renew if necessary.

5.

Re-assemble all items, noting that the handle must point vertically downwards in
the RUN position and that the spring loaded ball bearing in the handle is locked into
position.

6.

With the hand trip removed the oil inlet fitting to the overspeed valve can be withdrawn
and cleaned.
Check the clearance between this bearing and the shaft bore. (Fig. 17). If the clearance
is found to be greater than this, examine the bearing and shaft for scoring and polish
with finest grade emery cloth.
Excessive clearance between the oil inlet fitting and shaft is not detrimental provided
the resultant oil leakage is not sufficient to cause the master trip to operate.
Where excessive wear is observed a replacement oil fitting is required.

F14

EMERGENCY TRIP GEAR

F14

VII. SOLENOID TRIP

A.

Description
The solenoid trip is fitted downstream from the control orifice in the low pressure trip
circuit (See Section -S).
It is basically a block and dump type valve, normally closed, and opens to drain
when the solenoid coil is de-energized.
Details of the valve can be found in Section B. Technical Data.

B.

Operation
Under normal running conditions the solenoid valve is energized and closed.
Should remote shutdown be required the valve is de-energised, oil in

the trip

circuit then flows to drain, which produces a drop in oil pressure beneath the spool
valve of the L.P TRIP initiating TURBINE SHUTDOWN.
C.

Maintenance
The function of the valve is such that normal usage is minimal.
Therefore whenever possible, the trip should be operated to ensure reliability, as it
provides an alternative method of testing SHUTDOWN response of machine.

VIII. HIGH BACK PRESSURE TRIP

High Back Pressure trip is initiating through a pressure switch. Turbine exhaust line is
connected to a pressure switch, which is set for a required set pressure is normally
above 10 / 15% of the normal exhaust pressure.
A.

Operation
Under normal running conditions the exhaust pressure will be maintained when the
back pressure reaches to the set limit, the pressure switch initiate the solenoid valve
through electrical signal to de-energize to trip, oil in the trip circuit to produces a drop
in oil pressure beneath - spool valve of the master trip initiating both stop and emergency
valve to shut down the turbine.

F15

EMERGENCY TRIP GEAR

REF.

DESCRIPTION

1.

Valve Body

2.

Steam Strainer

3.

SEV Seat

4.

Main Valve-SEV

5.

SEV- Spindle

6.

SEV- Spindle Guide

7.

Coupling

8.

Plunger

9.

Spring

10.

Limit Switch spindle

11.

Cover S/valve End

12.

Cylinder End cover

13.

Cylinder Mid cover

14.

Check Valve Assembly.

15.

Cylinder

16.

Piston

17.

Spindle guide bush

18.

SEV oil cylinder spindle

19.

SEV column

20.

Plunger housing

21.

Plunger Cover

22.

Limit Switch

23.

Limit switch guide bush

24.

Limit switch indicator plate

25.

Spindle support

26.

Hexagonal Cap Nut.

27.

Check Valve Body

28.

Screw valve

29.

Check Valve Button

30.

Spring

31.

Oil Seal

32.

Check Valve Cap

Fig. 13: Stop & Emergency Valve Assembly

F15

EMERGENCY TRIP GEAR

28

31

27
30
29

32
14

CHECK VALVE ASSY.

IMPORTANT:ONLINE CHECKING OF STOP & EMERGENCY VALVE






&K


t

Z



FIG-13A - STOP & EMERGENCY VALVE



F16

EMERGENCY TRIP GEAR

Ref.

Description

1.

Plunger

2.

Spring

3.

Trip Catch Spring

4.

Catch Trip Spindle

5.

Reset Knob

6.

L.P. Trip Body

7.

Bottom Cap

8.

Cover Trip Catch

9.

Cap, Oil Trip

10.

Bush

11.

Spindle

12.

Manual Tripping Knob

13.

Liner

14.

Gasket

Fig. 16: Assembly of Low Pressure Oil Trip

F16

F17

EMERGENCY TRIP GEAR

Ref.

Description

1.

Hand Trip Body

2.

Hand Trip Valve

3.

Indicator Plate

4.

Oil Inlet Fitting

5.

Selector Valve Handle

6.

Compression Coupling

7.

Torque Pin

8.

Nulip Seal

9.

O Ring Seal

10.

Capscrew

Fig. 17: Hand Trip

F17

G1

SECTION G-OIL SYSTEM

G1

CAUTION
When opening up any part of a turbine lubricating oil system e.g. gear unit, bearing covers, relay
system in fact any part that contains oil subject to running temperatures.
DANGERS
DO NOT SMOKE OR USE NAKED LIGHTS IN THE IMMEDIATE VICINITY AS A
MIXTURE OF HEATED OIL VAPOUR AND AIR IS EXTREMELY INFALMMABLE.

This applies EVEN WHEN THE OIL IS COLD until the compartment being opened has been
WELL VENTILATED.
I.

Description :(Refer Lubricating and Control Oil P & I. Sec.S)

Oil is contained in a separate or a combined reservoir which forms the turbine and gear box
baseplate. The reservoir is provided with necessary fittings like cleaning doors, breathers, drain
points etc. The oil level indicator is marked for maximum normal and minimum oil level.The main
oil pump is driven from the low speed line of main gear unit and the auxiliary oil pump by an
electric motor.
Since the main and auxiliary oil pumps are positive displacement type and also to ensure constant
oil pressure over a large range of turbine speed (when only main oil pump is working), pressure
relief valve is provided just after the pump discharge point.
II.

MAIN LOW PRESSURE OIL PUMP

The main oil pump, which maintains the normal continuous running lubricating and governor oil
supply is a positive displacement gear type.It is driven from low speed line of main gear unit.
The quantity delivered to the individual bearings, sprayers, etc., is fixed by pipe and orifice sizes
and should not be altered.

III.

AUXILIARY LOW PRESSURE OIL PUMP :

As the main oil pump is driven from the main gear unit, it cannot supply oil when the set is
stationery or running at low speeds.A motor driven auxiliary oil pump is therefore provided for use
when starting up and shutting down.

G2

OIL SYSTEM

G2

This is a gear type pump similar to the main oil pump.It is driven directly by an electric motor and
the combined unit is mounted on the turbine oil tank.
Cut in and Cut out switch is fifed to this pump and it automatically switched itself off as the
turbine speed rises and the main oil pump is delivering sufficient oil.
Similarly, when running down the pump will switch off when the main oil pump ceases to deliver
sufficient oil to the set.A push turn and lock type manual switch is also provided near the turbine
for manually starting and stopping of the auxiliary oil pump. However, this switch after initial
commissioning should be left in the ON position for automatic cut-in and cut-out of the auxiliary oil
pump.Ensure that the pump is delivering oil when switched ON.
If no oil being delivered, it will not be possible to start the turbine as pressure is required to set the
low pressure oil trip to operate the throttle valve relay.
If no oil is supplied as the turbine comes to rest. OVER HEATING of the bearings with possible
VIBRATION and DAMAGE to the LABYRINTH PACKINGS may occur.
As the motor driven oil pump is used only intermittently and for short periods little or no maintenance
is required EXCEPT for periodic GREASING of the motor BALL BEARINGS.
Providing that sufficient pressure is available to set the low pressure oil trip and operate the
throttle valve relay, the gearbox bearing etc. will receive adequate lubrication whilst starting up
and shutting down.The pump supplied is always adequate for the duty.
The oil now goes to one of the shell & tube type oil cooler, which is sized to bring down the oil
temperature. Also provided a thermometer at cooler outlet to give the cold oil temperature.
The cool oil is sent to filters. The filters are designed for 100% efficiency in 16 microns range.
For normal operation, only one filter is required and the second can be opened out for routine
maintenance. The change over valves fitted at the filter discharge side ensure complete isolation
of the filter being services.

G3

OIL SYSTEM

G3

The oil is now divided into two separate channels. One branch caters to the control or relay
requirements and the other for lubrication purposes.

IV.

CONTROL OIL PUMP

Two x 100% duty motor driven control oil pump is fitted in the oil tank which, maintain
the normal continuous high pressure oil supply. (Refer See Section-B).

One oil pump considered as main oil pump and the other one means for auxiliary
(stand by) control oil pump.
At a time only one pump is in operation. If for any reason pre-set pressure is not
attained and control oil pressure has not reached its normal reading, a pressure switch
situated in the control oil circuit will keep the auxiliary (stand by) control oil pump
running
and the main control oil pump is switched-off.
V.

EMERGENCY OIL PUMP

If the auxiliary oil pumps fails to operate on turbine rundown for any reason then the lubricating oil
pressure will fall off leaving the turbine, gearbox and alternator bearings with only the decreasing
amount of oil as generated by the main oil pump. This could lead to overheating of the bearings
with possible vibration and damage to the labyrinth packings.

G4

OIL SYSTEM

G4

A DC motor driven emergency pump is therefore provided for use under these conditions to
provide a reduced quantity of oil sufficient for bearing lubrication only.Technical data on the pump
can be found in Section B. It is driven by a DC electric motor and the combined unit is mounted
on the turbine oil reservoir.The pump starter is connected via a pressure switch in the lubricating
oil supply line thereby causing the pump to start automatically when the lubricating oil pressure
fails to a preset value.
As the use of the emergency oil pump is very limited and in fact it should never be required at all,
little or no regular maintenance is required by the opportunity should be taken to run the pump
occasionally during standby periods. (Say about 15 minutes every month). Manual start and stop
buttons are provided for this purpose.
It should be noted that no overload protection is provided on the emergency pump motor. It is
considered that the cost and time involved in replacing a pump motor is a lot less than refurbishing
the turbine rotor journals and replacing the bearings which may have been damaged due to the
loss of oil pressure if the pump cuts out on overload.

NOTEThis pump is used for emergency purpose only (say for one hour
operation max,) and should not use for flushing or lubricating purpose.

VI.

CONTROL OR RELAY OIL :

This oil is for use in servo-mechanism employed to amplify the actuator output signal and also
damp out the linkage and mechanical oscillations. This system is designed for satisfactory
operation in the pressure range of 24 - 25 Bar (g) and is capable of giving unimpaired service.

G5

OIL SYSTEM

G5

The oil discharged from control oil pumps goes to the actuator through L P trip assembly.This
assembly generally does not interfere with relay oil system but on receipt of relevant low lube Oil
pressure, drains control oil to sump, thus closing the turbine down.A pressure gauge is used to
indicate this pressure locally and is fitted with necessary isolating cocks.
Lubricating Oil :
The second branch discharged from the filter is led to a low pressure oil manifold. This low
pressure oil manifold is also fitted with relief valve. This keeps an accurate control over pressure
in the manifold and acts as
a safety valve, also lube oil pressure at this manifold may be 1.5 - 2 Bar (g)
A line is fed to the pressure switch, which gives signal to the electric motor driven auxiliary oil
pump to start if the lubricating oil pressure falls below the pre-set value. This pressure switch
ensures that at no time the lubricating oil pressure will fall below the minimum safe working oil
pressure for bearings (See Section-B).
Another line taken through a fixed orifice is used to balance a spring loaded spool valve interposed
in the relay oil system, the complete assembly being known as low lube oil trip. If the lube oil
pressure, because of any reasons, falls below the minimum pressure requirement, the spring
force overcomes the balancing oil force and by pushing the spool valve down drains the control
oil to sump through a port which is normally blanked off by the spool valve.
A third line used for relaying the OVERSPEED TRIP signal to the turbine control valve. This is
passed through the fixed orifice and is generally a dead end at normal running speeds. However,
should the turbine overspeed, this oil is drained off to the sump thus initiating the low lube. oil trip
and in turn the relay oil pressure drain causing the turbine to shut down.Various lines go to different
lubrication points in the turbine from the low pressure oil manifold.
These are as below:;
1.

Oil to turbine thrust and steam end journal bearing.

2.

Oil to turbine exhaust end bearing.

3.

Oil to Gearwheel fore and after bearings.

4.

Oil to Pinion fore and after bearings.

5.

Oil to Layshaft drive worm spray.

6.

Oil to Layshaft Gears spray.

7.

Oil to Main gears spray.

G6

OIL SYSTEM

G6

The pressure in the low pressure oil manifold is indicated locally on the turbine gauge panel by a
pressure gauge.The speed indication of the turbine is done by a Governor Speed Probe.
Another line is taken off and used for solenoid trip, which is two way dump type valve. On receipt
of electrical signal, this opens the drain to sump and initiates low lube. oil trip.
VII.

OIL COOLER :
The oil cooling unit is a 100% duty, water cooled, shell & tube type.The unit is situated
adjacent to the turbine alternator unit.
The position of the oil cooler is shown schematically on the P& I Diagram in Section S,
which illustrates that bearing oil and control oil is passed through the cooler.The
change over valve is used to regulate the oil passing through or by-passing the cooler
to give the desired temperature at the discharge.
Frequency of cleaning will depend on operating conditions and the degree of water contamination
tolerated.
With an initially clean and well kept system, an inspection (and possible cleaning) after 2,000
running hours is suggested and thereafter according to conditions or refer SECTION- R
For more details Refer manufacturers instruction manual

VIII. OIL FILTER :

ALMOST ALL TURBINE WEAR AND FAULTS ARE DUE TO DIRTY LUBRICATING OIL.
The oil tank and all components are chemically cleaned to ensure SCRUPULOUS CLEANLINESS
after manufacture.
NO PRECAUTIONS WHICH AIM AT CLEANLINESS OF THE OIL SYSTEM CAN BE
CONSIDERED TO BE TOO ELABORATE.
The low pressure oil filter is a duplex type with bolted on covers and flange connections.Basically
it comprises two filter units with an inter-connecting valve block.

G7

OIL SYSTEM

G7

The valve is designed to enable one element at a time to be used. Priming positions are provided
together with full flow ports to both filters with the valve in the mid position.All stop positions are
indicated.
Removal of the top cover permits access to the insert assembly without disturbing pipe connections.
The insert assembly after removal through the top of the filter can be readily dismantled to allow
renewal of filtering elements.
Frequently of renewal of elements will depend on operating conditions.
The high pressure governor relay oil filter, is a duplex type.
The insert, element and end pads are of similar construction to the main lubricating oil filter and
similar maintenance instruction apply.
IX.

HYDRAULIC ACCUMULATOR :
The position of the accumulator is shown in Governing System diagram. It is described in detail
in the Manufacturers Manual.
The working of pneumatic accumulator is based on Boyles law, making use of the considerable
difference in compressibility between a gas & a fluid.
Its function is to store oil at control oil pressure within the body of the accumulator, which is
surrounded by a rubber bag contained nitrogen at a pre-charged pressure of 18-20 Bar (g)
Under steady load condition, there is sufficient oil being delivered from the main oil pump to
supply the control oil circuit. Under conditions, such as sudden full load application or rejection,
the demand for oil at the throttle valve relay cylinder is transiently greater than the total capacity of
the pump. The deficiency is made up the discharge of oil from the accumulator.

X.
1.

SYSTEM MAINTENANCE
KEEP RECORDS of temperatures, cleaning times, running hours, oil renewal and purification
times.

2.

STOP LEAKS of oil or water.

G8
3.

OIL SYSTEM

G8

MAINTAIN CORRECT LEVEL. When renewing or topping up, it is advisable to add not more
than about 10% of the sump capacity.

4.

TAKE OIL SAMPLES WEEKLY FOR VISUAL INSPECTION. Investigate the presence of water
and solid impurities.

5.

Replace filter elements when blockage indicators show red.

6.

CLEAN COMPLETE SYSTEM including the tank as found necessary. Use sponges for cleaning
out the sump after draining NOT RAGS, CLOTHS, WASTE or any FIBROUS MATERIALS.

7.

PURITY at regular intervals.Continuous purification is recommended where equipment is available.

If not, periodic settling is desirable.

8.

SUBMIT SAMPLES of oil for CHEMICAL ANALYSIS.

XI.

TURBINE GREASE POINTS :

Grease nipples are provided on

1.

Steam end pedestal angle bracket

2.

Relay Linkage

3.

Stop & Emergency Valve handwheel

SECTION M-SHAFT SEALING SYSTEM

M1
I.

M1

LABYRINTH GLANDS
In order to restrict the leakage area where the turbine rotor shaft passes through the casing, noncontact glands are provided.
These are of the stepped labyrinth high-low tooth type which consists of a number of metal rings
cut into segment with serrations or fins cut on the inside of the rings.
The fins are positioned to match high - low grooves turned in the rotor shaft.
The assembly presents a tortuous, labyrinth path against leakage.
The many restrictions and corresponding spaces drop the pressure of the steam thereby
increasing its volume and limiting the quantity (mass) that can pass through the final restrictions.
Details of the glands are shown in Fig. 20.
The low pressure (exhaust end) labyrinth is divided along its length into four separate groups of
fins.
The outer pocket connected to a gland vents condenser or vents to atmosphere.
The gland condenser should operate at Vacuum and removes excess steam from the glands to
improve habitability. See Section B
Labyrinths, pockets, and connections are provided at the high pressure (inlet) end of the turbine.
High pressure end gland sealing operates in a manner generally similar to that described for the
exhaust end, except that in this case the wheel case (i.e. 1st stage of the turbine casing) pressure
is a variable and is also much higher than the pressure existing at the exhaust end.
The wheelcase pressure increases progressively with the load on the turbine.
To break this pressure down, and to reduce steam leakage outwards from the wheelcase, the
high pressure gland is provided with an additional inner labyrinth ring and pocket.

M2

SHAFT SEALING SYSTEM

M2

This pocket is connected to the low pressure stage or the exhaust volute.
The outer pocket connected to a gland vents condenser or vents to atmosphere.
The labyrinth rings are supported in T slots in the gland housings, and are held concentric with
the turbine shaft by radial leaf springs.
If rubbing occurs the segments are pushed outwards against the springs to a larger diameter until
the disturbance is over.
After erection the turbine parts are carefully aligned so that the labyrinth packing clearances and
consequent leakage, will be small.
Providing, that the turbine is warmed through and run up to speed slowly (as detailed under
SECTION D. OPERATION, Article II. STARTING) the clearances will remain unaffected and little
or no labyrinth wear will occur.
II.

OIL SEALS
The turbine shaft oil seals see Fig. 20, one at the steam end pedestal and two at the exhaust
end are identical.
They are similar in construction to the steam labyrinth glands, i.e. segmental fin type with tee
roots, held concentric to the rotor shaft with leaf springs. As they perform under less arduous
conditions.
A thrower and catcher is incorporated on the inner side of the shaft, where it passes from the
housing to atmosphere. The seal at the pedestal is protected from coupling windage by a double
baffle guard which prevents formation of a low pressure area adjacent to the seal.

III.

STEAM DRAIN SYSTEM

A arrangement of the drain system is shown in Fig. 20. From H.P. gland and L.P. gland, can be
seen the :- outer vent lines to atmosphere or to the gland condenser manifold (if supplied) to and
in addition, at the H.P. gland, the line connecting the innermost pocket to the exhaust branch.

M3

SHAFT SEALING SYSTEM

M3

Steam from the high pressure stop valve spindle leak off connections in addition to the H.P. leak
off steam from the throttle valve spindle leak offs are led to the exhaust casing separately.
The low pressure spindle drains from the stop valves and throttle valves are collected by L.P.
manifold which connects to the gland condenser system (if supplied) or to the atmosphere
To improve habitability and conserve feed water it is important that all drain connections are tight
and well maintained. Gland condenser duty should be regularly checked.
IV.

STEAM GLAND CONDENSER

Description
The unit is employed mainly to condense the steam discharged from the turbine rotor shaft
glands. Various other drains, e.g. from the throttle and stop valve spindles, are also led to this unit
for convenient disposal.
The gland steam condenser unit consists basically of a heat exchanger, divided into suitably
baffled compartments, and fitted with tubes located in tube plates.
The ends of each tube are expanded into the tube plates.
A divided water box is fitted at the fan end to contain and direct the flow of circulating water which
passes through the inside of the tubes.
In order that the rotor shaft glands of the turbine will always remain clean, it is advisable to assist
the drainage from the glands by maintaining a slight vacuum, of say 25-51 mm Hg, within the shell
of the gland steam condenser.
This is accomplished by means of the extractor fan bolted to the side of the unit.
The gland steam condenser unit operates as follows:
Individual steam drains from the various points on the turbine are led to a manifold on the baseplate
of the unit. This manifold is connected to the steam shell of the gland condenser and passes via
the inlet baffle plate to condense on the outside of the tubes.

M4

SHAFT SEALING SYSTEM

M4

The suction of the extractor fan is situated on top of the gland condenser shell, where the entrained
air released on condensation of the gland steam is drawn away. Any vapour entrained with the air
is condensed on the tubes enclosed by the such on baffle.
To maintain vacuum within the condenser shell the condensate drain line should be as short as
possible, have an adequate fan to the conservation tank and be fitted with water seal as close to
the condenser as possible.
Maintenance
The fan motor is continuously rated and periodic attention to the bearings in accordance with the
manufacturers instruction is all that is required.
Deterioration of the condenser tubes after prolonged service can only be remedied by replacement
of the complete shell and tubes as a unit. In an emergency, leaking tubes can be blanked off at
both ends by use of plugs or welding.

O1
I

SECTION O-OVERHAUL AND INSPECTION

O1

OVERHAUL AND INSPECTION

If considered necessary, after the first year of operation and thereafter according to regulations,
the turbine casing should be lifted and the rotor examined.
WARNING
BEFORE commencing work on the turbo-alternator, MAKE CERTAIN THAT ALL
STEAM AND EXHAUST ISOLATING VALVES ARE SHUT. Open all drains and
preferably fit line spades downstream of isolating valves.

1.

Remove the canopy plates at the Main steam lines, stop valve hand wheels, pedestals and relay
front cover.Disconnect the canopy frame from the baseplate and lift off.

2.

Disconnect the stop valve oil supply and drain lines, Stop valve body and spindle drains, steam
pressure and temperature gauge connections.

3.

Remove the steam line bellows unit (if fitted).

4.

Take the weight off valve in turn.

5.

Disconnect throttle valve spindle drains, exhaust gauge and Low Pressure Trip connections.
Remove the actuator vertical link

6.

Rig up lifting arrangements to support the casing evenly. Separate slings with bottle screw adjusters
or pull lifts from the casing bollards are ideal. Additional slings with individual adjustment should
be used to support the nozzle chest.
The nozzle chest and valve gear can be removed as a single unit, if this facilitates lifting
arrangements. However, this could require breaking off finished lagging at the nozzle chest/
casing joint, which may not be desirable.

7.

Take off all the horizontal joint cap nuts and store. Remove the four locating dowels.

8.

If not already in position fit the guide pillars. Tension the slings and break the joint.

O2
9.

OVERHAUL AND INSPECTION

O2

Use the jacking point midway along the casing to break the joint. DO NOT FORCE STEEL
WEDGES OR CHISELS INTO THE JOINT.

10.

Jack the rotor hard on to the thrust bearing.

11.

Lift the casing evenly the guide pillars are marked with equal divisions to facilitate this.

12.

The top halves of the gland housings are retained in the casing by button screws, as are the top
half diaphragms.

13

When clear of the guide pillars, traverse away from the working area and place on wooden blocks.

14.

NOTE that the horizontal joint is a face to face seal a graphite based spray is used for protection
and separation, which can be wiped off with suitable cleaning fluid. Any hard deposits should be
removed with smooth emery cloth

DO NOT FILE OR SCRAPE THE FACES.

15.

Pressurise the L.P. oil system and bar the rotor slowly to inspect all blading.

16.

Look in particular for cracks in the blading especially near the roots. Check also the tightness of
shroud bands, and examine the blade rivets ensure that these are sound and no cracks have
developed in the shrouding at this area. The shrouding knife edges should be intact and run true.
Examine closely, the fit of all closing blades any indication that these are lifting requires immediate
expert attention.

17.

Any cracks or looseness cannot be rectified in position, it is necessary to remove the rotor for
expert attention. Major bruises or dents in the blades leading edges caused by scale, etc., passing
through the turbine, are best left alone.

18.

Minor bruised edges may be lightly dressed using a brass dolly to support the blade edges while
dressing.Chipped blade edges may be lightly dressed with a smooth file to round off notches
which cause stress concentrations and ultimate fatigue failures.
DO NOT USE COARSE FILES which may introduce further stress raisers. If in doubt and no
cracks or looseness can be found leave well alone. All blading is designed with adequate
stress margins and blade frequencies removed as far as possible from resonance.

O3

OVERHAUL AND INSPECTION

O3

A considerable amount of erosion of blade profiles can therefore be tolerated before re-blading
is necessary.
19.

To remove the rotor, proceed as follows (See Fig. 23):Remove the hand trip body (1) (Fig. 17) to
extract the oil supply fitting (4).

20.

Disconnect the flexible coupling.

21.

Remove the steam end pedestal inboard cover, the governor drive housing cover can be left in
place. Ensure that the top half oil seal remains behind.

22.

Lift the exhaust end pedestal cover. Safeguard the top half oil seals.

23.

Remove the bearing caps and top half bearing shells (Look for and note the assembly witness
Marks).

24.

Refer Fig. 23 Rotor Lifting Arrangement.

25.

Arrange for individual tensioning of slings to provide a level lift. Just take the rotor weight.

26.

Push the rotor hard on to the thrust bearing and

check the thrust bearing axial float. Use a

clock indicator for reliable readings. Fig. 30 gives the required data.
27.

Force all diaphragm assemblies on to their respective location faces, (steam pressure positions
the diaphragms when running) and with the rotor hard up to the thrust bearing check all blade/
diaphragm clearances.

28.

Slide out the bottom half thrust and surge bearing rings complete - note which is which.

29.

Lift the rotor SLOWLY AND EVENLY, making sure that blades/shrouding and labyrinth packings
are not damaged.

30.

When the rotor is clear, traverse to a safe area and land in a substantial cradle, with wooden
padded Vee blocks to support the rotor at its journals. Protect the blading.

O4

OVERHAUL AND INSPECTION

O4

WARNING
DO NOT REST THE ROTOR ON ITS BALDES.

31.

Before landing, clean the journals and thrust collar. Examine closely for scoring or hard running
marks. Any such marks should be removed by lightly stoning. Use a fine carborundum stone and
liberal amount of paraffin.Very heavy scores call for regrinding of journals and thrust faces.

32.

Details of the thrust bearing are shown in Fig. 25 also refer to Manufacturers Manuals..
If any significant amount has to be machined off the thrust collar, the thrust bearing shim must be
increased accordingly.

Always use a single steel shim that can be ground to the required

thickness. NEVER a build-up of brass shim stock.

33.

Using a micrometer, determine the journal diameters compare with dimensions tabled in Fig.
26.

34.

Examine the layshaft drive pinion for worm or chipped teeth. Signs of irregular meshing should
be investigated.

35.

Check the tightness of shaft end fitted bolts and locknuts.

36.

Land the rotor in padded Vee blocks.

Clean the gland and interstage labyrinth lands.
Using a micrometer measure the steam and exhaust lands, record the dimensions.

II.

STEAM END PEDESTAL (refer to Fig. 27)

1.

The separate thrust and surge bearing assemblies should be examined (Fig. 27). ENSURE
THAT THE SEPARATE CARRIER RINGS CAN BE IDENTIFIED AND RETURNED TO THEIR
ORIGINAL POSITIONS. Failure to observe the importance of correct assembly will result in
displacement of the rotor, and/or incorrect axial clearance.

O5

OVERHAUL AND INSPECTION

O5

All pads whilst constrained within the carrier rings, should be free to rock on their respective
pivots.
2.

Pad faces may show signs of light scores or bright marking. Providing white metal has not been
extruded off the edges, the pad faces can be carefully dressed using a small flat scraper.

3.

Check the dimension (using an accurate micrometer), from the center of each pad face to the
back of the shim plate. This dimension should be identical for each pad on the thrust side (top
and bottom halves) a variation of no more than 0.127 mm must be maintained.
The surge side should be checked in like manner a different dimension is to be expected, but
the tolerance of individual pad thickness is again + 0.06 mm.This check is especially important
when fitting new pads,

4.

When satisfied, wrap each item in soft cloth and store safely. Clean out the bearing housing and
check that all drilled holes:- Oil feed, drain and temperature bleed holes are clear.

5.

Check that the bearing cap transverse keys (12) and keyways provide positive axial location of
the cap. Likewise check the transverse location of cap to pedestal.

6.

The bearing cap set bolts are locked in position.

7.

Clean and examine the main bearing shells (6). Dress lightly, with a scraper, to remove any
surface scratches or hard markings.

8.

Strap together and measure accurately the major and minor bore diameters. Compare with table
(Fig. 26).

9.

Repeat the procedure with thrust oil seal (11) note the extra clearance required.

10.

Check the witness marking of the bearings, wrap for protection and store.

11.

Oil baffle plate protects the oil seal from direct impingement of oil from the main bearing. Clearance
around the shaft is a nominal 0.75/0.80 mm.

12.

The oil seal packing rings (7) should be individually displaced against leaf spring (9) to ensure
freedom of movement. Investigate any eccentric rub marks.

O6

13.

OVERHAUL AND INSPECTION

O6

Check the seal clearances by strapping the housing tightly together, in this way the segments
form the true running diameter. With an internal micrometer measure the fin diameters and
subtract shaft dimensions. Compare with those indicated (Fig. 30). Clear all drain holes.

14.

Lift off the lay shaft cover complete.

15.

Blow through the oil lines from the pedestal supply point with DRY COMPRESSED AIR.

16.

Reassemble the Bearings, layshaft, oil supply block (Check tightness of pipe fittings), cover.

17.

Check that both pedestal drain pipes are clear clean inside of sight glass sections.

III.

EXHAUST END PEDESTAL (Fig. 28)

1.

The bearing cap set bolts are locked as is the steam end pedestal.

2.

The bearing housing should be cleaned and the oil supply blown through.

3.

Clean the bearings, check bearing clearance and store (Note witness marking).

4.

Baffles each side of the bearing assembly protect the oil seals from direct oil impingement. The
shaft clearance is a nominal 0.76 mm.

5.
6.

The oil seals are identical check freedom of the segments and fin clearance.
The oil seal housing (coupling end) carries an external double baffle to protect the seal from
coupling windage. If this unit is dismantled, check on re-assembly, that the baffle with 0.76 mm
shaft clearance is placed nearest the oil seal.

7.

Check that the pedestal drain is clear.

O7

OVERHAUL AND INSPECTION

O7

IV.

TURBINE CASING

1.

Check the freedom of steam and exhaust labyrinth packings, using a hammer shaft to spring the
segments. Axial location is required with adequate radial freedom if tight, push out of the housing,
clean segments and housing grooves, coat with anti-seize compound at location faces and replace
in correct order. Relace any obviously weak springs.

2.

Blow through all gland leak-off pockets and check gland clearances (clean housing butts, strap
together, etc.)

3.

The diaphragm should be lifted to examine the casing location grooves. Button screws trap the
diaphragms and radial keys centralize each half. (Check tightness of keys).

4.

Diaphragms must be returned to their correct positions.

5.

Check that all casing drains and interstage slots drain holes are clear.

6.

Leakage across diaphragms sealing faces should be lapped out with a flat dummy diaphragm,
before wire drawing undercuts the faces.
Do not increase any groove width more than 0.25 mm. Top and bottom location faces must be in
line.

7.

Check interstage packing for freedom etc. and dress any damage sustained by nozzle outlet
edges.

8.

Run down casing joint studs with appropriate cap nuts to ensure free running threads. Die-nut
damaged threads.

9.

If studs need replacing USE HIGH TENSILE STEEL SUITABLE FOR THE DUTY.

10.

Clean horizontal joints of all casing assemblies, blow out casings and re-assemble :- Diaphragms,
bottom halves of labyrinth housings, bearings, oil seals etc.Before fitting the steam and exhaust
TOP half gland boxes into the casing, place on the respective bottom halves to ensure that the
labyrinth packing segments match-up.

O8

OVERHAUL AND INSPECTION

O8

11.

CHECK THAT NO DIRT IS TRAPPED between housings and packing boxes, bearings etc.

12.

CHECK THAT NOTHING LOOSE HAS DROPPED INTO THE BOTTOM HALF CASING.

13.

Clean the rotor and lower slowly and evenly into position.

14.

Correctly locate the bottom half THRUST and SURGE rings before removing slings.

15.

Check the matching of: Oil seal, steam and interstage labyrinth fins to rotor lands through entire
assembly.

16.

Check axial float and diaphragm/blade clearances. (Fig. 30)

17.

Jack the rotor into the running position and lower the top half casing on to the guide pillars.

18.

Spray the horizontal joint and gland housing butts evenly with the recommended anti-seize
compound.

19.

Lower the casing evenly into position. Before fitting the dowels, check all round the joint with a
0.05 mm feeler. Weight alone should close the gap. (If the joint does not close lift immediately
check joint faces and interstage packing sequence).

20.

Coat dowels with anti-seize compound and tap into position.

21.

Coat studs liberally with Rocol and screw down cap nuts.

22.

Use the correct joint tightening sequence and torque settings as indicated below.

23.

Flush oil system as outlined in SECTION C.

24.

Check that the rotor spins freely.

25.

When satisfied, box up and replace pedestal covers.

26.

Fit stop & emergency valve to correct location, release spring supports.

O9

OVERHAUL AND INSPECTION

27.

Check high-speed coupling alignment refer to SECTION C.

28.

Replace gauge piping, drain piping, governor and relay linkage, etc.

29.

Pressurise L.P. and H.P. oil systems check system pressures and fix any leaks.

30.
V.

O9

Replace turbine canopy.

STEAM END PEDESTAL PANTING PLATE (Fig. 29)
During normal overhaul there would be no reason to disturb the panting plate assembly. Should it
be necessary at any time to do so it must be noted that an initial cold draw Dimension X is
built into the cold alignment see Fig. 29 COLD DRAW FOR THIS MACHINE See Fig. No.32.
Fine adjustment jacking gear applied to the pedestal horizontal flange will be necessary to extract
or re-fit the location keys.

WARNING
DO NOT CARRY OUT THIS OPERATION WITH THE ROTOR IN POSITION.
VI.

SEQUENCE OF BOLT TIGHTENING

TURBINE CASING
For the purpose of closing the horizontal joint bolts are numbered starting from the governor end
towards the alternator end. Hence looking along the turbine axis in the direction of the gearbox
(alternator) the numbering of bolts is as follows:-

a)

on the RHS : RHS1, RHS2, RHS3, etc.

b)

on the LHS : LHS1, LHS2, LHS3, etc.

The sequence for both initial and final tightening is as follows:

1.

Initial Tightening, using torque settings of :86 kgf m (625 ft lbf) for 1 in. capnuts
50 kgf m (360 ft lbf) for 1 in. capnuts
19 kgf m (140 ft lbf) for 1 in. capnuts

O10

OVERHAUL AND INSPECTION

O10

(a)

Nip first all consecutive odd numbers alternating between RHS & LHS starting from steam end.

(b)

i.e. RHS1, LHS1, RHS3, RHS5, LHS5, etc. until the end.
Nip all even numbers again alternating between RHS & LHS
i.e. RHS2, LHS2, RHS4, LHS4 RHS6, LHS6, etc. until the end

2.

Final Tightening
Repeat the sequence as for initial tightening. Using torque settings of:173 kgf m (1250 ft lbf) for 1 in. capnuts
99 kgf m (720 ft lbf) for 1 in. capnuts
39 kgf m (280 ft lbf) for 1 in. capnuts
MAXIMUM TIGHTENING TORQUE VALUES OF BOLTS FOR DIFFERENT
APPLICATIONS OF STEAM TURBINES (OTHERWISE STATED)

SCREW MATL

YIELD P OINT (Mpa)

A 193 GR B 1 6 /

0 80M40

070M20

E QUIT

(EN8)

(EN3A)

606

275

23 0

S CRE W THREAD

TO RQUE (N.m )

M 12

50

24

19

M 16

118

56

45

M 20

226

108

86

M 24

421

195

16 2

M 30

842

399

32 3

M 33

1176

550

44 2

M 36

1542

723

58 3

M 42

2697

1273

10 25

M 48

4208

1975

15 96

M 52

4898

2298

18 67

O11

OVERHAUL AND INSPECTION

Ref. Description
1

Main Oil Pump

Lay Shaft

Bearing Shell (Lay Shaft)

Bearing Cap(Lay Shat Loc.)

Bearing Cap (Lay Shaft Loc.)

6.

Bearing Cap

10

11

Oil Feed Block

12

Laby Packing Stm End

13

Laby. Packing Holder Stm End

14

Bearing Cap- Thrust Brg

15

Rotor Bearing Shell

16

Thrust Bearing

17

Laby Packing Exh End

18

Over Speed Trip Shaft

19

Pinion

20

Gear Wheel

21

Oil Inlet Fitting

22

Laby. Packing Holder- Exh End

23

Pedestal Base

24

Panting Plate

25

Alignment Key

26

Over Speed Trip Valve

27

Rocker Shaft

28

TV Seat

29

Actuator

30

Throttle Valve

31

Nozzle

32

Nozzle Chest

33

Laby Gland

O11

O12

OVERHAUL AND INSPECTION

34

Inter Stage Labyrinth

35

Steam Casing (Top Half)

36

Steam Casing (Bottom Half)

37

Diaphragms

38

Turbine Rotor

39

Blade

40

Oil Seal

41

End Cover

42

Exhaust Bearing Cap

43

Journal Bearing

44

Alignment Key

45

Base Plate

46

High Speed Coupling

47

Coupling Guard

48

Pinion Shaft

49

Oil Baffle (P/S)

50

Bearing Cap (P/S)

51

Bearing Shell (P/S) D End

52

Bearing Cap (P/S Thrust)

53

Barring Gear Arrangement

54

Gear Box (Top Half)

55

Gear Box (Bottom Half)

56

Breather

57

Gear Wheel Shaft

58

Gear Wheel

59

Bearing Cap (G. W/S)

60

Bearing Shell (G.W/S) N D End

61

Bearing Cap (G.W./Thrust)

62

Bearing Shell P/S N D End

63

Bearing Shell G/S D End

Fig. 24: Sectional Arrangement

O12

O13

OVERHAUL AND INSPECTION

Ref

Description

1.

Steam end pedestal

2.

Rotor

3.

Overspeed trip shaft

Gearwheel

5.

Thrust bearing

6.

Journal bearing

Labyrinth packing oil seal

Labyrinth housing

Leaf spring

10

Locating key

11

Thrust oil seal

12

Bearing cap locating key

13

Bearing cap

14

Oil inlet fitting

15

Pedestal transverse key

16

Axial Probe

17

Hand trip

18

Overspeed trip

Fig. 27 Steam end pedestal assembly

O13

O14

OVERHAUL AND INSPECTION

Ref

Description

1.

Pedestal

2.

Breather 1" BSP

3.

Oil Seal locating ring

4.

Vertical Key

5.

Laby Spring

6.

Horizontal Key

7.

Laby Packing

8.

Oil Seal Holder

9.

Thermowell

10.

Bearing Cap

11.

Collar Bolt

12.

Exhaust end Bearing

Fig. 28 Exhaust End Pedestal Assembly

O14

O15

OVERHAUL AND INSPECTION

VII.

O15

MALFUNCTION CAUSE AND REMEDY - TYPICAL

NOTE:- GENERALISED INDICATIVE INFORMATION AND WHICHEVER IS
APPLICABLE.
Malfunction

Bearing
temperature rises

Cause
Cooling water deficiency in
cooler
Cooling water inlet
temperature too high
Oil deficiency

Insufficient lube
oil pressure

Auxiliary oil pump shuts off

too early
Poor alignment (increase
heat due to friction)
Damage to Babbitt metal
due to mixed friction
Damage to Babbitt metal
due to carry-over
Riser bore obstructed
Heat radiation from turbine
casing
Main lube oil pump supply
insufficient

Oil filter plugged

Oil cooler plugged
Leakage in oil system
Rising oil temperature

Exhaust steam
temperature
too high

Labyrinth damage

Emergency trip
due to
Over speed

Turbine operated too long

at idle or low load operation

Remedy
Increase cooling water flow.
Oil cooler is dirty, switch over
and clean. Vent oil cooler
Increase the Cooling water flow.
Check oil level top up if required.
Vent cooler and filter. Check
overflow valve
Switch back on and correct
setting
Check alignment and correct if
necessary
Increase oil pressure and quality
Enlarge scavenging ports
Scrape bearing (observe max.
nominal clearance)
Clear bore
Provide shielding
Auxiliary pump switched off to
soon switch back on; main oil
pump defective, repair; suction
line not tight, check suction line
and shaft seal for tightness
Switch twin oil filter and clean
plugged side
Switch twin oil cooler to clean
plugged side
Eliminate leakages
Increasing oil temperature
reduces viscosity; Reduce oil
temperature
Load turbine further

Blade damage
Defective balance piston or
interstate labyrinth

Repair by manufacturer
Check & Replace

Turbine Scaling

Wash the turbine

Rotor distortion due to

unilateral heating or
cooling during standstill
followed improper start-up
Damaged radial and thrust
bearings
Control valve spindle
seized

Allow turbine to cool until rotor

can
be turned manually
Repair bearings and overhaul
labyrinths if necessary
Check valve spindle for scaling;
loosen gland packing if too tight

O16

OVERHAUL AND INSPECTION

O16

Malfunction

Cause

Emergency trip
due to
Over speed

Control valve spindle

seized

Check valve spindle for scaling;

loosen gland packing if too tight

Improper setting in the governor

output Vs valve opening

Check the adjustment in the

actuator w.r.t governor output.
Tune the PID in the governor for
better response.
Set the impulse pressure to 1214 kg/cm2 to WW TG17E (If
applicable)
Correct interconnections check
the oil drain ports.

Emergency stop
valve does not
operate properly,
closes too slowly,
impossible to
open
Sticking of SEV
Spindle

Impulse oil pressure in

actuator might have
changed / reduced
Incorrect interconnection
between safety devices
(solenoid valve, three-way
Valve). No pressure drop
Sticking of SEV Spindle due to :
Scale deposits in spindle
Bend of Spindle
Lesser Clearance

Emergency stop valve

control unit switching
function defective
Jamming of SEV Spindle
No pressure build-up
behind the main piston
Control Oil pressure too low
Electric pump
(AOP) do not start

Incorrectly wired
Pressure switch incorrectly
set

Oil characteristics
changed (oil
analysis)

Deaeration

Foaming

Impurities
Axial shift
increase

Bearing damage
Probe malfunction

Remedy

-The throttle should be

dismantled. Moving parts should
be checked for free and smooth
movement. Using very finegrained emery paper, the throttle
valve seats and valve spindle
should be polished.
-Ensure Steam Purity
-Replace spindle
-Ensure correct clearances
Check for friction, lap in valve
seat.
Check the spindle/piston
freeness.
Close control valve block
Drain & check control valves /
LP Trip for leakage
Increase the oil pressure &
check for oil leakages
Check wiring; check fuse or
breaker
Re-adjust setting

Consult oil supplier in case of

severe changes in the
deaeration capacity the oil
must be changed
Consult oil supplier from
conditions can be improved by
additives (this should only be
carried out by the oil supplier
as too high a dosage of the
antifoam inhibitor can reduce
the deaeation capacity)
Oil need to test change with
new if required
Probe mal functioning
Check filter chocking & Bearing

O17

Malfunction

OVERHAUL AND INSPECTION

Cause

O17

Remedy
inspection

Erosion/corrosion
in blades and
nozzles attacks
trailing edges,
Edges chipped off

Foreign-particle
impacts in blades
and nozzles.
Solid-particle
erosion.
Deep Dent marks.
Edges chipped off

Water damage to
Blades and rotor
thrust areas
Rubbing of Rotor
disc and bending
of blades in LP
stages
Erosion,
blowholes
Pre mature
breakage of
Shroud / Blades /
Nozzles when
deviation of
operating
conditions are not
significant

Foreign-particle damage of turbine

blades impact on blades by
foreign particles (debris) left in the
system following outages and
become steam-borne later
Solid-particle erosion, i.e. in the
high-pressure blades. And it takes
place when hard particles of iron
exfoliated by steam from
superheated tubes, reheated
tubes, steam headers and steam
leads strike on the surface of
turbine blades
Condensate water is carried over
to steam path and impacts the
blade, thermal-fatigue failure can
occur within a short period.
System operating parameter, e.g.
low flow may excite various
modes of vibration in the blades
Moisture-impingement and
washing erosion encountered in
the wet sections of the steam
turbine
A. Failures may also arise due to
flow irregularities introduced
because of Design or
manufacturing defects, e.g. lack of
control over tolerances,
geometrical accuracies & Faulty
manufacturing practices.
B. Material Defect

Other Electrically
induced stresses
& Damages

Electrically induced stresses occur

in steam turbine rotors and
casings originate due to short
circuits and faulty synchronization.

Shroud Band
Damages

Steam borne solid particles and

moisture strike the shroud band
continually and in that process
they remove material from rivet
heads until the rivet becomes too

Advise Design/manufacturing for

upgrading & improving design
and manufacturing factors that
vary from one turbine to other

Review of electrical protection

and Synchronization

Ensure steam/water chemistry,

System operating parameters,

O18
Malfunction

Rubbing &
Subsequent
Damages

Rubbing &
Subsequent
Damages
Bursting of
Extraction line
Bellows

Steam Leakage
from Throttle
Valves
Steam Leakage
from Labyrinth
Holders

High Vibrations
and Abnormal
Sound from
Turbine casing

OVERHAUL AND INSPECTION

Cause
weak to exercise its clamping
effect whereupon it fails to hold
the band in place
Thermal stress occur in the steam
turbine rotors
Transient operating phases i.e.
startup and shutdown the genesis
of thermal stress induced to the
turbine shaft. The temperature
strains set up in the casings and
rotors by such rapid heating have
a harmful effect. The turbine, in
larger units especially, should be
warmed slowly by recommended
warm-up ramp rates (Start up and
Loading curves) because of close
clearances.
Sticking of valves, Failure of Valve
control System and over speed
1. Whenever there is change over
from no load-to-load condition, the
grid valve closes due to stoppage
of actuator drive motor. Due to
sudden flow of steam in extraction
line condensate accumulated in
line resulting failure of bellow.
2.No proper drainage system
provided. 3.Proper support for
Extraction line not provided
High spindle bush clearance
Bushes loose (Carbon glands)
Bushes worn out
Spindle worn out
High labyrinth clearance w.r.t
holder and rotor
Labyrinths (Holder) worn
out/rubbed
Labyrinths (Rotor) worn
out/rubbed

O18
Remedy

Recommended Barring Gear

Run(if provided)
Start up and Loading curves

Replace/rectify as applicable
Ensure steam/water chemistry
operating parameters,
Once in a week inspection
/cleaning of valve spindles

Replace spindle
Tighten bushes
Change Bushes
Replace spindle
Replace labyrinths (Rotor or
Holder
or both)

Labyrinth Rubbing
Misalignment (Pedestal-Casing or
Casing-Gear Box / Concentricity
of bearing and labyrinth bore on
as per specification
Pipe line strains coming on turbine
Lesser labyrinth clearance

Rectify areas as applicable.

The inlet as well as exhaust

steam lines Should be firmly

O19

OVERHAUL AND INSPECTION

Malfunction

Cause

O19

Remedy
supported to avoid strains from

Insufficient Barring Period

being imposed on the turbine.
Improper Heating
Recommended Startup and
loading procedure not followed
Rotor Bend

TV popping up
Misalignment
Pedestal-Casing
& Casing-Gear
Box

Spring lost its properties

Improper Inlet/Extraction/Exhaust
piping Lay out
Deformation of HP LP housing of
casing

Adequate allowance as
permissible should be made for
expansion of steam pipes due to
heat.

Replace Spring
Rectify areas as applicable.
Correction of LS Misalignment
The bolts holding the flanges
together are to be tightened.
The coupling is to be checked
for squareness between the
bore and the face. At the same
time axial clearance is to be
checked. Using gauge block and
feeler gauges, the gap between
coupling faces 180o apart is to
be measured. After rotating the
coupling-half 180o the gap at the
same points is to be measured.
After this, the other coupling is to
be rotated 180o and the gap at
the same points is to be remeasured. Dividing the coupling
faces into four intervals, the
distance between the coupling
faces at this intervals is to be
measured with the aid of a
gauge block and feeler gauges.
These gap measurements
should come within 0.005 inch
for proper angular shaft
alignment. After proper
alignment at room temperature,
the two halves of the coupling
are to be connected.
Refer O& M Manual of Turbine
for permissible limits
Coupling to the driven machine
is to be disconnected.
If misalignment is the probable
cause of excessive vibration.

O20
Malfunction

OVERHAUL AND INSPECTION

Cause

O20
Remedy

The turbine is to be run alone.

Oil Leakage from

coupling Guard

Oil leakage from

Oil labyrinths

Pressure
Drop/Malfunction
from PRV

Oil leakage from

Alternator Oil
labyrinths

Turbine not
developing rated
power






Improper fitment
Uneven Fasteners tightening /
Looseness of fasteners
High temperature of coupling
guard
Frequent start up/shut downs
Rubber packing worn-out
Chocking of drain holes
Drain Holes not provided
Labyrinth fins worn out
(Holder/Rotor)
Excessive clearance wrt rotor and
Labyrinth seal
Failure of Diaphragm
Malfunction of Oil System and
NRVs
Improper PRV adjustment &
Setting
Chocking of drain holes
Drain Holes not provided
Labyrinth fins worn out
(Holder/Rotor)
Excessive clearance wrt rotor and
Labyrinth seal
The machine is overloaded.
The initial steam pressure and
temperature are not up to design
conditions.
The exhaust pressure is too high.
The governor is set too low.
The steam strainer is clogged.
Turbine nozzles are clogged with
deposits.
Internal wear on nozzles and
blades.

If the turbine runs smoothly,

misalignment, worn coupling or
the driven equipment is the
cause of the trouble.
Proper fitment
Evenly Tighten Fasteners
Establish Vapor release
Apply recommended Start
up/Shut down procedure
Replace rubber diaphragm
Cleaning of holes
Holes to be provided
Replace labyrinths
Replace labyrinths
Replace Diaphragm/Gasket as
applicable
Establish Pump discharge flow,
Check NRVs
Proper adjustment/
Setting
Cleaning of holes
Holes to be provided
Replace labyrinths
Replace labyrinths
An increase of exhaust steam
temperature by more than 10%
in the range of 70 to l00% steam
flow indicates inadmissible blade
depositions. Shutdown is to be
taken and blades are to be
washed off deposits.

SECTION P-SHUTDOWN AND STORAGE

P1

SHUTDOWN AND STORAGE

P1

SHUTDOWN & STORAGE

I.

PROLONGED SHUTDOWN

a.

Preservation of Shut down Turbine Plants

b.

Short shut-down up to 4 days

c.

Shut-down longer than 4 days to 6 months

d.

Shut-down of 6 to 8 months

e.

Shut-down for indefinite period, longer than 6 to 8 months

II.

RUST-PROTECTIVE TECTYL 506, 511

a.

TECTYL 506

b.

TECTYL 511-M

III. JOBSITE STORAGE OF GOODS

a.

General

b.

Recommended Precuations During Storage

Ia.

PRESERVATION OF SHUT-DOWN TURBINE PLANTS

GENERAL:
Shut-down the turbine plants are exposed to corrosion. Mostlyan electro-chemical
process is involved in which iron is converted to rust by presence of water and air
(oxygen). Also the most disadvantageous forming may occur. This process begins
immediately after the turbine is shut-down and has subsequently cooleddown. Air
temperatures below dew point cause condensation of air moisture on internal surfaces.
The following measures were worked out especially for steam turbine plants. The
described measures are to be understood as recommendations and must be decided
upon on site according to actual operating conditions, shut-down period costs plant
location and plant size. For application and execution of such measures Triveni Turbines
Ltd (TTL) personnel should be employed. Leak steam and condensate penetration to
plant sections should be prevented first of all.

b.

SHORT SHUT-DOWN (UP TO 4 DYAS)

The shut-down period counts from complete cooling-down. Special preventive measures
are not required. In turbines furnished with drying equipment the drying air is switched
on after turbine has cooled-down.

P2

SHUTDOWN AND STORAGE

P2

I c. SHUT-DOWN LONGER THAN 4 DAYS UPTO 6 MONTHS

(plants which must be in operation readiness after hour of preparation)
TURBINE:
Protect turbine against possible entering of leak steam. Do not use the emergency stop
value as a component of steam lock. It is not protected against corrosion. In turbines
with furnished drying equipment keep inner space of turbine dry by blowing air, the
atmospheric humidity of which is less than that of the air in the machine hall (less than
60%) or by lowing in pre-warmed air to the effect that casing and rotor temperatures are
kept above dew and freezing point. The air supply is connected to the turbine exhaust
nozzle. Drains are used for air exhaust.
Start the turning gear only shortly before restart and watch running smoothness.
PRESERVATION OF SHUT-DOWN TURBINE PLANTS
OIL SYSTEM:
Every 2 weeks put oil pump for 1 hour in operation. During this period all control
devices shall be moved once from COMPLETELY CLOSED to COMPLETELY OPEN. Turn
turbine rotor manually for approx. 2 turns; record in the turbine which provides good
protection against rusting after the above prescribed period before putting into operation.
Take oil samples as accustomed and drain, if applicable, accumulated condensate
from the oil tank.
Id.

SHUTDOWN 6 TO 8 MONTHS
The preventive measures described in this section are applied usually with seasonally
operated plants.
TURBINE:
Secure against entering of leak steam by closing the main stream isolation valve.
For internal preservation of the turbine, select one of the following described 4 procedures:

Regular turbine overhaul by complete dismantling is planned to such cases preservation

of all internal components with VALVOLINE TECHNICAL 511 M is recommended.
Keeping the turbine dry by blowing in dry air or pre-warmed air as follows: Keep the
inner space of the turbine dry by induction of air, the atmospheric humidity of which
is less than that of the air in the machine than 60%) or by the induction of pre-warmed
air to the effect that casing and rotor temperatures are kept in excess of dew point.

P3

SHUTDOWN AND STORAGE

P3

The air supply is connected to the turbine exhaust nozzle. The wheel chamber drain
serves for air exhaust. If there is a vent or a drain between emergency stop and control
valves, then these components can be used for an exhaust. Prior to a restart check
rotation of the turbine rotor and warm running smoothness at low speed.
PRESERVATION OF SHUT-DOWN TURBINE PLANTS
Inductions of a corrosion inhibitor in the steam system just before shutdown. An oilsteam admixture is produced by means of portable injection equipment. After the oilsteam admixture is being blown into the turbine, the oil is expected to form a protective
coat on the walls when hitting any internal surfaces. For pre-commissioning dismantling
is not required.
Sufficient is 1 to 2 hours steam flushing operation via exhaust relief valve. (Flushing
steam need not to be dry and saturated.)
The so-called nitrogen procedure requires immediate expansion to atmosphere after
shutdown and subsequent air drying. Seal turbine by carefully closing of all valves;
maintain slight nitrogen over pressure of 5 to 10 mm (water column); nitrogen demand
depends on the tightness of all sealing and can be ascertained only by experiment. (For
reference, Nitrogen demand for a 35 MW turbine amounts to approx. 8 m3 /h;) control
valves and emergency stop valves remain open. Check for complete absence of nitrogen
prior to restart to avoid accidents!
Check external coating and recoat if necessary. Apply VALVOLINE TECTYL 506 to
bright external components (prior to pre-commissioning use paraffin for removal), rub
in MOLYKOTE on valve stems.
Remove measuring instruments and electrical equipment, mark carefully and store
wrapped in oil paper.
OIL SYSTEM:
If during shutdown no power for the oil pumps is available, all the components of the
oil system were overhauled after shutdown; the measures should be taken as follows:
Regular turbine overhaul by complete dismantling is planned. In such cases preservation
of all internal components with VALVOLINE TECTYL 511M is recommended.

After this process, the periodical cut-in of the oil pumps as well as manually turning of
the turbine rotor may be omitted, proved that:
Oil containing the usual corrosion inhibitors remains in the system.

Oil lines and oil return lines are filled with oil and are isolated by slip plates.

P4

SHUTDOWN AND STORAGE

P4

PRECOMMISSIONING:
After previous preservation it is not necessary to dismantle the turbine before precommissioning. Washing or flushing is carried out with steam. In case of condensing
turbines it is necessary to wash the condenser too by operating the turbine for about 1
or 2 hours and draining the condensate. In a condenser being not washed remainders
of the corrosion inhibitor would deposit on the condenser tubes and as a consequence
impair the heat transfer. The washing process with steam must be carried out with
turning rotor at slow speed. For condensing turbines the exhaust steam temperature
must not exceed 120 Deg C.
Ie.

SHUT-DOWN FOR AN INDEFINITE PERIOD, LONGER THAN 6 TO 8 MONTHS

To protect turbine plants against corrosion for indefinite periods is rather extensive
and expensive. All measures overall overhaul of the complete turbo-set after shutdown.
All preservation in for 2 years intervals and renew if required. Prior to pre-commissioning
the corrosion inhibitors must be removed with steam or paraffin.
TURBINE:
Dismantle turbine latest after 4 days and remove rotor; check and clean internals;
mark carefully the components; apply TECYL 506 to all internals, bearings, joints,
auxiliary drives, flange bolts, etc. Bearings and joint surfaces should be additionally
wrapped in oil paper. Apply TECTYL 511M to all inner casing surfaces. Dismantled
components shall be wrapped in foils and stored indoors or stored next to the turbine
in cases.
Lift upper turbine casing, bearing cover, valve block by about 100 mm from the horizontal
joint by means of hardwood distance pieces.
Wrap these in oil paper. Plug all turbine ports with plastic covers well visible for
everybody.
Clean and apply TECTYL 506 to all dismantled components like steam strainers, control
and emergency stop valves, valve chest, control components, barring gear etc.
Apply TECTYL 506 and preserve base plates, sliding surfaces, keys, guide pins. Remove
measuring instruments and electrical equipment and store them

P5

SHUTDOWN AND STORAGE

P5

carefully marked and wrapped in oil paper. Check external coatings, renew if required.
Remove piping and clean and dry the individual sections. Seal air-tight and apply a
new external coasting. Order and keep on store one set of new sealing rings and gaskets
for pre-commissioning.
OIL UNIT:
The individual components are wrapped in foils and stored after cleaning, overhaul
and preservation.
If.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
II.

RE-STARTING AFTER LONG SHUTDOWN:

After preservation it is necessary to dismantle the turbine before re-starting.
NOTE:- It is important to consult Triveni service persons before opening the turbine.
Overhauling is carried out, for this contact Triveni customer care cell
All resting must be removed and check the function of each components are performing
satisfactory
Check the function of all laby packing, oil seals and stiffness of their leaf springs
Check the function and stiffness of all springs including Throttle valve, Stop & Em.
Valve springs etc.
Function of all linkages
Replace all oil seals (except mechanical seals)
Replace all oil and steam gaskets
Replace all foot valves rubber oil seal or oil gaskets
Check the function of all pumps & motors
Check the function of all electrical equipments
Oil flushing to be carried out see section C
Prewarming the live steam pipline or Steam blowing should be done as illustrated in
section-C
For staring the turbine follow section D, Article-II
Barring to be carried out for 12-18 hrs with the oil pump in operation
RUST-PROTECTIVE (TECTYL 506, 511 )
Drain turbine oil and clean; take oil and if require provide a new external coating; apply
TECTYL 511M internally above oil level. Due to the corrosion inhibitors usually contained
in the oil refill the oil tank so that preservation o the bottom part in the oil tank is
provided. Remove piping fill with oil seal and coat. Clean and overhaul the oil pumps
and apply TECTYL 511 M internally and apply TECTYCL 506 EXTERNALLY; oil pumps
or store them indoors; clean immersion pumps and reinstall.
Clean and dry the oil cooler on the oil and on the water side. On the oil side apply
TECTYL 511M or refill with oil. If scaling off is expected in dry condition. Renew the
internal coating on the water side.

P6

SHUTDOWN AND STORAGE

P6

Oil filters; remove inserts, clean and apply TECTYL 511 M or fill oil and seal.
Remove and clean fittings, valves pressure switch, measuring gauges, etc.; wrap all
equipment in oilpaper.
a.

RUST PROTECTIVE - TECTYL 506

PPOPERTIES:
TECTYL506 is a rust-preventive especially suitable for export of machines of various
types. When being supplied, product is liquid. The resulting wax film is not affecting
any metal surfaces and does not attack lacquer, plastics and rubber materials. This
brown rust preventive is resistant against temperature occurring in packing, which
amount to 70-90 0C in some countries. The wax film
furthermore has an outstanding adhesion with minus temperatures. TECTYL 506 with
its flexible protective film being tight and adhesive forms a good barrier between metal
surface to be protected and corrosive influences. Coverage amounts to 6-8 m2 per literdepending on the film thickness.
Protection period on clean steel surfaces
(Film thickness approx.100 Microns):
- Inside storage*
4-5years
- Outside storage*
18 months to years
APPLICATION:
TECTYL 506 can be applied by painting or spraying or airless to the parts to be protected.
SPECIFICATION:
TECTYL 506 fulfills US-Military
Specification MILC-16 173 D, Grade4
REMOVAL:
TECTYL 506 can be removed without difficulties by means of benzene petroleum, diesel
oil or wax solvents. In case of big surfaces steam jet cleaning device with special additives
can be used (prior to this use wax remover and wait for its reaction).

P7

SHUTDOWN AND STORAGE

Spec. gravity

DIN51757

0.88kg\dm3

Viscosity

DIN53211

approx. 250 sec.

Flash point

DIN51755

approx.40 Deg C

Class of dangeras per VbF

P7

All

*without cover or packing outside. In case of additional packing protection period

might be longer.
II b. RUST PROTECTIVE - TECTYL 511-M
PROPERTIES:
TECTYL 511-M is a fluid sloshing liquid. The resulting film is light-brown, nearly
transparent and soft.
Coverage amounts to 35-45 m3 per Liter. TECTYL 511-M is an especially water displacing
and creepable product. The film does not attack any metal surfaces. This product is
very suitable for temporary storage and sort time dispatch (metals being protected by
TECTYL 511-M must be covered o that neither rain water nor sunshine can affect
them). It has a good separating effect between metals and aggressive mediums so that
steel is protected against rust and aluminum-magnesium-alloys against efflorescence.
Protection period on clean steel surfaces
(Film thickness approx. 15 Microns):
-Inside storage *
approx.18monts
-Outside storage*
APPLICATION:
TECTYL 511-M can be applied by spraying, painting or dipping the parts to be protected.
SPECIFICATION:
TECTYL511-M fulfills US-Military
Specification MIL C-16 173 D, Grade 3and grade 5.

P8

SHUTDOWN AND STORAGE

P8

REMOVAL:
TECTYL 5011-M can be removed without any difficulties by gasoline,, petroleum, Diesel
oil, Wax solvents, alkali cleaner and stem.
Spec. gravity

DIN 51757

0.865kg\dm3

Viscosity

DIN 53211

12sec.

Flash point

DIN 51755

approx. 40 Deg C

Class of danger

as per VbF

All

* without packing (Central Europe); in case of additional packing protection duration is

longer.
II c. RUST PROTECTIVE - OKS 2160
Application Areas
For protection of machinery shafts, forgings, castings, stampings, pipes, fasteners,
structurals, dies, valves etc., during storage and shipping in outdoor environments
including harsh marine atmosphere and offshore conditions. Useful for corrosion
preventive applications in the automotive field also

Advantages and Benefits

Effective for a wide range of applications, under a wide variety of outdoor conditions

The film is thermally stable.

It has excellent salt spray rating and is resistant to acid fumes.

Free from silicones, phosphates and heavy metals.

Mode of Application
By brush, spray or dip Repeat the process for higher film thickness, after drying. Surface
to be treated should be free of loose rust, oil dirt, grease and waxy deposits.
Mode of Removal
With mineral spirits, alkaline cleaners or other common solvents

P9

SHUTDOWN AND STORAGE

P9

OKS 2160 Technical Data

Parameter
Appearance
Density at +25C
Film Type
Drying time
Film thickness
Corrosion Protection (Outdoor
conditions)
Humidity Cabinet Resistance
Metals protected

Specification
Dark Brown Liquid Visual
0.85 0.88 g/cc In house
Semi Dry and Waxy
Above 60 Minutes
10 to 14 Microns In house
Up to 2 years
Above 792 Hours ASTM D
1748
Ferrous

III. JOBSITE STORAGE OF GOODS

a.

GENERAL
During storage before and during erection and first start certain precautions must be
taken in order to prevent corrosion damage to the plant equipment.
This instruction primarily covers the equipment delivered by Triveni Turbines Ltd
(TTL), Bangalore. All goods are packed for approximately two-three months storage
(including transportation) when leaving Triveni Turbines Ltd works at Bangalore. Special
Attention must be paid to the generator (see generator manual). If the relative humidity
of the environment is higher than 50%, the recommended precautions must be taken
immediately to prevent corrosion damage. If the standstill period is expected to exceed
9-12 months, or if the environment is extremely demanding, more extensive conservation
procedure should be considered.

P10
a.

SHUTDOWN AND STORAGE

P10

RECOMMENDED PRECUATIONS DURING STORAGE

All machinery, electrical and other sensitive parts shall be stored indoors. If the storage
time exceeds 2-3 months, the packages shall be opened and a dehumidifier unit
connected to the storage room in order to keep relative humidity below 50%. Other
equipments, such as piping and less sensitive materials, need not to be stored dry
indoors, Instead, rust protection by use of rust preventive agents e.g. Tectyl TM , watersoluble oils and silica gels inside sealed-off space can be used. Weather protection and
periodic inspections are recommended.
ARRIVAL AT SITE

GENERAL
Place Crates and boxes so that they will not be exposed to water (rain, flooding etc.) and
/or physical damage.
Do not open any box or crate until the equipment in the specific box or crate is to be
used. If an opened box or crate is to be stored further, it must be carefully closed and
resealed. At the opening of the different boxes an inventory must take place using the
packing list for each box, in the presence of the TTL Site Representative

SPARE PARTS
Spare Parts are to be placed indoors in a ventilated space with normal room temperature
and preferably low humidity. Rust inhibitors should not be removed until each part is
intended to be used.

CONTROL CUBICLES
Do not remove or damage the plastic film that covers each cubicle. If an inspection of
the cubicles has to be made, the moisture absorbent (silica gel) must not be removed
from inside the cubicles. Welding as soon as possible should then hermetically reseal
the plastic film.
Do not place the cubicles in their final space until the conditions are such that no
condensation will take place inside the cubicles.

Q1

Q1

SECTION Q-LUBRICANTS

TU RB IN E O IL

(A ST M -D4 30 4)

S l.N o.

M a nufa c tur er /s up pli er

P r odu ct Na m e

Cl as s

1.

In dia n O il C or por a tion

S e rv op ri m e 4 6

46

2.

B ha ra t P e tr ole um

Tu rb ol 46

46

3.

C as tr ol

P e rfe c to T 4 6

46

4.

M ob il

M ob il DT E

46

M e diu m V G 4 6 /
M ob il DT E -84 6
(z in c fre e )
5.

H ind us tan P e tro le um C or pn.

Tu rb ino l 46

46

Tu rb ino l X T 4 6
6.

G S Ca lte x

G S Tur bi ne O i l 4 6

7.

To tal P e tro le um In dia P v t. Ltd.

S he ll In dia .

O i l for Ba r ri ng G ea r
U nit (If Ap pli ca bl e)

10

O i l fo r Ac tua tor

P r es li a 46
S he ll Tur bo -T4 6

Re duc ti on IS O -V G . 3 20

O i l fo r Co nde ns a te E xtr n. P um p

46
46
9
Ltr s

IS O -V G . 46

3
Ltr s /
Ac tu
at or

IS O -V G . 46

2L tr s
/C E P

(If Ap pli ca bl e)

11

46

(If Ap pli ca bl e)
Not e : E quival ent gra des can a lso be use d for Sl . No. 9 ,10 & 11.

Molytex
Grease 2

Molytex
Grease 2

Regal
A.F.B. 2

B.P.
Energrea
se HTB-2

B.P.
Energrea
se AS 11

B.P.
Energrea
se LS 3

Manual
Applicatio
n

Manual
Applicatio
n

Grease
Packed

Governor
Lever
Point Pins

Sliding
Compone
nts

Motor
Bearings

Beacon 2

Shell
Alvania
Grease 2
with
Molybden
um

Beacon 3

Beacon 2

Shell
alvania
Grease 2
with
Molybden
um
Disulphide

Shell
Alvania
Grease 3

Teresso
T46

Shell
Turbo Oil
T46

DO NOT USE interior lubricants of unknown origin.

8 Indian oil Corporation

5 Mobil Oil Co. Ltd.

6 Burmah Castrol Co. Ltd.
7 Kuwait Petroleum Lubricants

Regal Oil
R&O 46

B.P.
Energol
THB46
(ISO)

Governor
Actuator

1 The British Petroleum Co. Ltd.

2 Texaco Ltd.
3 The Shell Petroleum Co. Ltd.
Ltd.
4 Esso Petroleum Co. Ltd.

Application

Description
Mode

Moilux
Grease
No.3

Mobil
Grease
Super

Mobil
DTE
Oil
Medium
(VG 46)
Mobil
Temp
Grease
No. 1

Castrol
Impervia
AS

Castrol
Impervia
AS

Castrol
Spheerol
LMM

Castrol
Perfecto
T46

Q8
Super
Lithium 3

Q8
Molythiu
m
EP2

Q8
Molythiu
m
EP2

Q8
VanGogh
46

Servogram HT

Non
Siezing
Compoun
d

Servogerm HT

ISO
VG46
Servo
Prime

Q2
LUBRICANTS
Q2

Q3

LUBRICANTS

Q3

GENER A L LUB E O IL SPECI FIC A TIO NS

SLNO

1
2

P RO PE RTY
Kinem atic Viscosity at
40 C , ISO VG 46

VALUE

UNIT

TE ST ME THO D
DIN/ ISO

TEST M ETH O D
AST M

41.4 -50.6

m m/S

DIN 51 562-1

ASTM D 445

DIN 51 381

ASTM D 3427

Air release at 50 C
Neutralization Number
a) Oil with out EP/AW
additives
b) Oil with EP/AW
additives

=4

m in

= 0.20

mg KOH/g

= 0.30

mg KOH/g

Water content

= 100

m g /Kg

DIN 51 777-1

ASTM D 1744

Foam ing at 25C

Tendency
Stabil ity

= 400
= 450

ml
s

ISO 6247
(seq.1)

ASTM D 892
(seq.1)

Water S eparability

= 300

DIN 51 589-1

Demulsibility

= 20

m in

DIN 51 599

Densit y at 15C

= 900

Kg/m 3

DIN 51 757

ASTM D 1298

Flash P oint, ISO VG 46

> 185

DIN ISO 2592

ASTM D92

10

Pour point

= -6

ASTM D 97

11

Cleanl iness level

= 17/14

ISO 3016
Test : ISO 5884
Result : ISO 4406

12

Colour

=2

DIN ISO 2049

13

Corrosion effect to
copper

DIN EN ISO 2160

14

Corrosion Protection
against Steel

DIN 51 585

15

Ageing Characteristics :
increase of neut ralization
number after 2500 h

mg KOH/g

DIN 51 587

DIN 51 558 -1

= 2-100
A3
0-B
(DIN )
pass
(ASTM)
= 2.0

ASTM D 974

ASTM D 1401

ASTM D 1500
ASTM D 130
ASTM D 665

ASTM D 943

SECTION R-TURBINE PREDICTIVE MAINTENANCE

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TURBINE PREDICTIVE MAINTENANCE CHART

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SECTION S - DRAWINGS

SECTION -S
DRAWINGS / P & I DIAGRAMS

IMPORTANT NOTE:-

DOCUMENTS PLACED IN THIS SECTION CONTAINED

THE REVISION OR UPDATIONS MADE AT THE TIME OF
PREPARATION OF THIS MANUAL.

&
USERS ARE ADVISED TO REFER ONLY THE LATEST
REVISIONS OR UPDATED AVAILABLE WITH THEM.

TURBINES

TURBINES

TURBINES

TURBINES

TURBINES

TURBINES

TURBINES

TURBINES

TURBINES

T1

SECTION T-RECOMMENDED SPARES

1.
2.

DIAPHRAGM ASSY.
RUBBER OIL SEAL FOR COUPLING GUARD

Qty. as per design requirement

1.000

3.

BREATHER FOR COUPLING GUARD

2.000

4.

THRUST BEARING FOR ROTOR

1.000

5.

LEAF SPRING FOR OIL SEAL

4.000

6.

ROTOR JOURNAL BEARING S/END

1.000

11. GEAR WHEEL

1.000

13. OIL SEAL PACKING.

1.000

14. OIL BAFFLE

1.000

16. BREATHER FOR PED.

1.000

19. ROTOR JOURNAL BEARING EX.END

1.000

20. OIL SEAL PACKG.

2.000

21. BREATHER

1.000

22. LEAF SPRING

8.000

23. LEAF SPRING FOR INTERSTAGE PACKING

28.000

24. SENTINAL VALVE

1.000

25. PACKING RING FOR LABY

4.000

26. PACKING RING

1.000

27. PACKING RING

1.000

28. LEAF SPRING

24.000

29. PACKING RING

1.000

30. PACKING RING

2.000

31. PACKING RING

1.000

32. LEAF SPRING

16.000

39. PLUNGER

1.000

40. VALVE LINER

1.000

41. SPLINDLE

1.000

42. COVER

1.000

43. SPRING

1.000

44. BUSH

1.000

45. SPRING

1.000

46. RESETTING SPINDLE

1.000

47. RESETTING KNOB

1.000

48. BOTTOM COVER

1.000

49. BODY

1.000

50. TRIP KNOB

1.000

T1

T2

RECOMMENDED SPARES

T2

51. MANUAL TRIP VALVE

1.000

52. SPRING

1.000

53. O RING

1.000

54. BALL 6 DIA

1.000

55. TRIP SHAFT

1.000

56. FITTED BOLT

6.000

57. TRIP VALVE

1.000

58. SPRING FOR OVER SPEED TRIP

1.000

59. OIL INLET FITTING

1.000

60. O-RING & SEAL

1.000

61.

SEV SEAT

1.00

62.

STOP VALVE

1.00

63.

SPINDLE SUPPORT

1.00

64.

STRAINER SEV

1.00

65.

SPINDLE- SEV

1.00

66.

SPINDLE GLAND -1

1.00

67.

SPINDLE GLAND -2

1.00

68.

COUPLING -SEV

1.00

69.

SPINDLE HYDRAULIC CYLINDER

1.00

70.

PISTON

1.00

71.

HELICAL COMPRSSION SPRING

1.00

72.

SPINDLE- LIMIT SWITCH

1.00

73

LIMIT SWITCH

1.00

74.

LIMIT SWITCH STOPER

1.00

75.

GUIDE, LIMIT SWITCH

1.00

76.

PLUNGER

1.00

77.

CHECK VALVE SPRING

1.00

78.

SEAL OIL SPINDLE

2.00

79.

SEAL FOR PLUNGER COVER-1

1.00

80.

SEAL FOR PLUNGER COVER -2

1.00

81.

SEAL FOR CHECK VALVE

1.00

82. BEARING RST NR-28B

2.000

83. BEARING BLOCK

2.000

84. SLEEVE

3.000

T3

RECOMMENDED SPARES

T3

85. BEARING RST 16

6.000

86. SPRING -TV No.1 & 2

2.000

87. TV LIFTING SPINDLE

3.000

88. SPRING -TV No.3

1.000

89. GLAND ADJUSTING NUT

3.000

90. BUSH TOP FOR T.V NO.1 & 2

2.000

91. BUSH BOTTOM FOR T.V NO. 1 & 2

2.000

92. BUSH TOP FOR T.V NO.3

1.000

93. BUSH BOTTOM FOR T.V NO.3

1.000

94. SEALING RING OPEN FOR T.V NO.1 & NO.2

1.000

95. SEALING RING CLOSED FOR T.V NO.1 & NO.2

6.000

96. SEALING RING OPEN FOR T.V NO.3

4.000

97. SEALING RING CLOSED FOR T.V. NO.3

2.000

98. BUSH

1.000

99. BLADE SHIELD

1.000

100. T.V. SPINDLE NO.1

1.000

101. T.V. SPINDLE NO.2

1.000

102. T.V. SPINDLE NO.3

1.000

103. GUIDE NO.1

1.000

104. GUIDE NO.2

1.000

105. GUIDE NO.3

1.000

106. T.V. SEAT ASSY.No.1

1.000

107. T.V. SEAT ASSY.No.2

1.000

108. T.V. SEAT ASSY No.3

1.000

109. PROBE ARRGT STM END-set

1.000

110. PROBE ARRGT EXH.END- set

1.000

111. FOOT VALVE 1 1/2" BSP FOR EOP

1.000

112. FOOT VALVE 4" MOP & AOP

2.000

113. MANUAL TRIP ASSY.

1.000

114. LABY PACKING. ASSY. S/End

1.000

115 LABY PACKING ASSY.E/End

1.000

116. ROTOR SHAFT ASSY.

1.000

117. OVER SPED TRIP ASSY.

1.000

118. NITROGEN CHARGING KIT

1.000

119. ADAPTOR FOR NITROGEN CHARGING KIT

1.000

T4

RECOMMENDED SPARES

T4

120. WIRE SLINGS POLYSTER FOR ROTOR LIGHTING

2.000

121. PRESSURE RELIEF VALVE FOR CONTROL OIL

1.000

122. PRESSURE RELIEF VALVE MOP

1.000

123. PRESSURE RELIEF VALVE EOP

1.000

124. PRESSURE RELIEF VALVE FOR AOP

1.000

125. OIL COOLER

1.000

126. OIL FILTER ASSY. FOR EOP

1.000

127. OIL FILTER ASSY FOR CONTROL OIL

1.000

128. ACCUMULATOR

1.000

129. OIL FILTER ASSY LUBE OIL

1.000

130. EMERGENCY OIL PUMP

1.000

131. AUXILARY OIL PUMP

1.000

132. CONTROL OIL PUMP

2.000

133. VAPOUR EXTRACTOR WITH MOTOR

1.000

134. ACTUATOR

1.000

135. PROBE MAGNETIC PICK UP UNIT

2.000

136. DIFFT PR SWITCH WITH INDICATOR

1.000

137. 2 WAY SOLENOID VALVE

1.000

138.3 WAY SOLENOID VALVE

1.000

139. HIGH SPEED COUPLING

1.000

140. LOW SPEED COUPLING

1.000

RECOMENDED SPARES