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Turbine Over Hauling Procedure Siemens Recommendsbirkosit 111019222302 Phpapp01
Turbine Over Hauling Procedure Siemens Recommendsbirkosit 111019222302 Phpapp01
Rameshkumar
Mechanical Maintenance
TURBINE OVERHAULING
Scope of Work
INDEX
1.0 Work Related Documents :
1.1 1.2 List of drawings. Turbine Service Manual Siemens Ref : ESO/0689/86-05-13/KWU/la-mg.
2.0 3.0
4.0
Disassembly :
4.1 4.2 4.3 4.4 HP Turbine. LP Turbine. Valve blocks. Lube oil system.
5.0 6.0
7.0
Reassembly :
7.1 7.2 7.3 7.4 7.5 LP Turbine. HP Turbine. Valve blocks. Alignment checks. Lube oil system.
8.0
Commissioning :
Page 2 of 75
Evaluate latest operating records and related data. Check for availability of spare parts. Perform functional inspection of modular units. Perform leak checks in the form of visual and tactile inspections. Check shaft-line grounding. Check turbine-generator running behavior prior to shutdown; perform vibration measurements. Set up jobsite; ready all scaffolding, tools etc. Measure vacuum reduction rate. Shutdown the system. Cool turbine-generator via turning gear operation. Disconnect oil pumps, with the exception of the lift-oil pump. Remove turbine enclosure. Remove insulation. Remove vibration pickups. Protect ends of cables against damage.
General Recommendations :
Use only Silicon-free lubricants on the oil side. Observe all relevant accident prevention regulations. Observe all relevant fire prevention regulations. Exercise caution in the handling of cleaning agents and acids (Wear protective clothing). Observe manufacturers parts identification system at each step of assembly/disassembly. The following sealants are recommended : For the steam side : Birkosit. For the oil side : Hylomar. The followings lubricant is recommended : Gleitmo 160
Page 3 of 75
Record pedestal position indicator readings on the HP Turbine (Z 37, Z 38; View VI, Section U1U1) and LP Turbine (Z 58, Z 60; Detail V4). Record rotor position indicator readings on the LP turbine (Z 72; Part 3). Remove top of rear bearing pedestal (Z 22) Remove seal rings from the top and bottom halves of the bearing pedestal. Remove center top-half bearing pedestal (Z 15). Remove seal rings from the top and bottom halves of the bearing pedestal. Dismantle and store piping from the front top-half bearing pedestal. Remove front top-half bearing pedestal (Z 1). Remove seal rings from the top and bottom halves of the bearing pedestal. Remove top-half thrust bearing (Z 3). Remove thermocouples (Z 7) from the top and bottom halves. Check and record the rotor position in the bottom-half thrust bearing. Measure and record the alignment dimensions of the HP and LP turbines (cf. assembly data sheet). Remove bottom-half thrust bearing. Measure and record axial movement of the shaft line (cf. assembly data sheet). Reassemble bottom-half thrust bearing
Remove hall generators (Z 14) Remove enclosure (Z 10; part 60, 65) Check identification markings on the coupling parts (part 100) Remove centerpiece of sleeve. Remove circlip Pull both sleeve sections off of the hubs.
Page 4 of 75
Evaluation :
Check identification markings on the coupling flanges, bolts and nuts (Z 72.1) remove coupling nuts. Remove coupling bolts. Clean coupling nuts and bolts, protect against corrosion, and store. Turn jack screws in up to contact face. Continue turning the jack screws to push apart the coupling flange. Push the generator rotor up to stop in the positive direction.
Position the lifting fixture (Z 21) Provide metal strips for the support bearing. Check the identification markings on the coupling flange, bolts and nuts (Z 72). Remove coupling nuts. Turn jack screws in up to the contact face. Continue turning jack screws to press the two halves of the coupling flange apart by 3mm. Hand-tighten the coupling nuts.
3.5 Check Alignment between the Main Oil Pump and the HP Turbine
Procedure :
Attach measuring instrument. Check and record the alignment between the pump shaft and the turbine rotor.
3.6 Check alignment between the HP Turbine and the LP Turbine Procedure :
Attach measuring instrument. Check and record the alignment between the HP rotor and the LP rotor.
Page 5 of 75
3.7 Check alignment between the Generator and the LP Turbine Procedure :
Attach measuring instrument. Check and record the alignment between the LP rotor and the Generator.
Measure and record the exact values at the rear bearing pedestal measuring points (Z 22). Measure and record the exact values at the outer-casing circumferential profile measuring points. Check for full contact between the pedestal s upport brackets and the base plate (Z 85, 59, 60; Sections F2-F2, F4-F4). Remove coupling nuts (Z 72). Remove coupling bolts. Clean coupling nuts and bolts, protect against corrosion, and store. Use lifting fixture to support weight of rotor (Z 21). Press coupling flange apart by turning in the jack screws. Push rotor in the positive direction up to 1.0mm ahead of the stop. Install support bearing, take load off of and remove the lifting fixture. Mount rear top-half bearing pedestal.
Measure and record dimension L (assembly data sheet) on the front support bracket seats. Measure and record the exact values at the front and center bearing pedestal m easuring points (Z 71, 1, 15). Measure and record the exact values at the outer-casing circumferential profile measuring points. Check for full contact between the rear support brackets and the base plate (Z 37, 39; Section P3P3). Mount the center and front top-half bearing pedestals. Disconnect the lift-oil pumps.
4.0 DISASSEMBLY :
Page 6 of 75
4.1 HP Turbine
Procedure :
Disconnect flange joints of upper steam inlet pipes; support weight of pipes as necessary. Dismantle the upper cross-around piping, incl. swing disk valves; plug openings, store piping, protect valves against corrosion and store. Remove and store wall temperature sensor (Z 36) Ream out (clean) taper-pin bores (Z 26, Part 14) Bring shoulder bolts into contact with the auxilia ry support brackets (Z 38, 30). Section P1-P1, Part
Remove spacer bolts, washers and disk springs from the front support bracket seat (Z 38, Section P1-P1, Parts 39-43). Insert one each additional washer between the spacer bolts and existing washers, and retighten the spacer bolts. Loosen joints bolts as per specification. Clean and screw in guide bolts. Clean jack screws; apply lubricant to the threads; screw in. Hitch up the top-half outer casing horizontally onto the proper lifting bosses. Turn in the jack screws to uniformly lift the top half outer casing by approx. 30 mm. Lift off top-half outer casing.
Evaluation :
Joint faces, guides, support brackets seat, spherical washers, L-rings. Protect top-half outer casing against corrosion and store. Protect spherical washers, spacer bolts, washers and disk springs (Z 38; Section P1-P1, Parts 3943) against corrosion and store. Remove upper spherical washers from the stationary blading carrier (Z 45; Section K1-K3, Part 7) and inner seal ring (Z 37; Section K-K, Part 287); protect against corrosion and store. Remove joint bolts from the bottom-half outer casing.
Procedure :
Page 7 of 75
Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores. Clean jack screws, apply lubricant to threads; screw in Hitch up top-half stationary blade carrier, thereby maintaining a horizontal position. Turn in jack screws to lift top-half by about 30mm. Lift off stationary blade carrier.
Evaluation :
Joint face, blades, seal strips, spherical washers. Protect top-half stationary blade carrier against corrosion and store.
Procedure :
Remove and store pressure-instrument lines (Z 40, Part 391). Remove spot welds from the joint nut bolts. Ream out (clean) taper-pin bores. Clean and thread-in the guide bolts. Unscrew joint bolts as specified. Clean jack screws; apply lubricant to threads; screw in. Hitch up top-half inner casing, thereby maintaining a horizontal position. Turn in jack screws to lift top half by about 30mm. Lift off top-half inner casing. Remove spot welds from the joint bolts of the gland busing (Z 30). Ream out (clean) taper-pin bores. Unscrew joint bolts as specified. Lift off top-half gland bushing.
Evaluation :
Joint faces, blades, seal strips, L-rings. Protect inner casing against corrosion and store.
Procedure :
Remove spot welds from the joint bolt nuts. Ream out (clean) taper pin bores.
Page 8 of 75
Evaluation :
Joint face, seal strips. Protect top-half gland bushing against corrosion and store.
Procedure :
Remove spot welds from the joint bolt nuts. Dismantle gland steam line. Unscrew joint bolts. Lift off top-half gland bushing. Swing out and lift off bottom-half gland bushing.
Evaluation :
Joint face, seal strips. Protect gland bushings against corrosion and store.
Procedure :
Detach oil lines from the main oil pump (Z 8) Remove taper pins and bolts (Z 38, Section Y1-Y1). Lift off main oil pump; remove spherical washers. Dismantle main oil pump.
Evaluation :
Impeller, shaft, bearing, spherical washers. Clean all parts, protect against corrosion and store. Pull off turbine-end coupling hub (Z 10, Part 100). Dismantle speed transducer (Z9, 10, 11)
Evaluation :
Coupling, governor impeller, auxiliary parts. Clean all parts, protect against corrosion and store.
Page 9 of 75
Remove Rotor
Procedure :
Lift off front top-half bearing pedestal and store. Remove top-half journal bearing. Remove thrust bearing. Lift off and store rear top-half bearing pedestal. Remove top-half journal bearing. Suspend rotor horizontally at the points marked with U and Y (Z 46) and lift away. Dismantle overspeed trip device (Z 49).
Evaluation :
Blades, seal strips, shaft journal, auxiliary parts, overspeed trip device. Reinstall overspeed trip device (Z 49) Protect rotor against corrosion and store. Remove bottom-half journal bearing, including the thermocouples (Z 7)
Evaluation :
Journal and thrust bearings. Protect journal and thrust bearings against corrosion and store.
Procedure :
Remove thermocouples to facilitate extraction of the inner casing (Z 40). Suspend bottom-half inner casing horizontally and lift off.
Evaluation :
Joint face, blades, seal strips, L-rings, guides. Protect bottom-half inner casing against corrosion and store. Remove and store bottom-half gland bushing (Z 30).
Procedure :
Sequence : items 550, 525, 500 (Z 42). Suspend bottom-half stationary blade carrier in horizontal position and lift off.
Page 10 of 75
Evaluation :
Joint face, blades, seal strips, spherical washers, guides. Protect bottom-half stationary blade carrier against corrosion and store. Remove lower spherical washers (Z 45, Section store. K1-K3, Part 7), protect against corrosion and
Procedure :
Evaluation :
Joint face, seal strips, spherical washers, guides. Protect bottom-half gland bushing against corrosion and store. Remove lower spherical washers (Z 37, Secti on K-K, Part 287), protect against corrosion and store.
Procedure :
Dismantle piping and store. Remove spot welds from the guides (Z 38, Detail T1 and Section M1-M1). Unscrew axial guide nuts (Z 38, Detail T1); turn stud bolts (Part 60) from protect stud bolts and nuts against corrosion and store. the outer casing;
Remove lock bolts and washers from the axial gui de (Z 38, Section M1-M1), unscrew calottes (Part 22) and remove spherical washers. Unscrew spacer bolts (Z 37, 38; Section 01-01, Part 16), remove brackets (Part 15). Suspend bearing pedestal in horizontal position and lift off.
Evaluation :
Slide surfaces, spherical washers. Protect bearing pedestal against corrosion and store. Protect hardware against corrosion and store.
Page 11 of 75
Procedure :
Dismantle and store piping. Remove spot welds from the axial guide (Z 37, 39; Section M3-M3). Remove lock bolts and washers, unscrews calottes (Part 122) and extract spherical washers). Remove screw lock device (Z 37, 39; Section 03-03, Part 115) and loosen bolts (Part 116) Suspend bearing pedestal in horizontal position and lift off.
Evaluation :
Slide surfaces, spherical washers. Protect bearing pedestal against corrosion and store. Protect hardware against corrosion and store.
Procedure :
Remove spot welds from the guides Z 37, 38, 39; Sections W1-W1 and W3-W3). Remove lock bolts and washers; unscrew calottes; extract spherical washers.
Evaluation :
Slide surfaces, spherical washers. Protect hardware against corrosion and store.
4.2 L. P. Turbine
Open Outer Casing
Procedure :
Dismantle protective liners and rupture disks (Z 57) Ream out (clean) taper-pin bores (Z 50, Sections L-L and M-M) Put one each additional washer between the spacer Unscrew joint bolts. bolts and existing washers (Z 58, 59, 60); Sections F2-F2 and F4-F4) and tighten the spacer bolts.
Page 12 of 75
Clean and thread-in the assembly guides. Clean the jack screws; apply lubricant to threads; turn in jack screws. Suspend top-half outer casing horizontally from the intended lifting bosses. Turn in the jack screws to uniformly lift the top-half outer casing by about 30mm Lift off top-half outer casing.
Evaluation :
Joint face, guides, spherical washers, L-rings. Protect top-half outer casing from corrosion and store. Remove upper spherical washers from the stationary blade carrier (Z 58, 59, 60) and inner casing (Z 58, Section A-A), protect against corrosion and store. Remove joint bolts from the bottom-half outer casing.
Procedure :
Sequence : arbitrary. Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores. Clean and thread-in the guide bolts. Remove joint bolts. Clean jack screws; apply lubricant to threads; screw in. Suspend top-half stationary blade carrier in a horizontal position. Turn in jack screws to lift top half by about 30 mm. Lift off top-half stationary blade carrier.
Evaluation :
Joint face, blades, seal strips, spherical washers. Protect top-half stationary blade carrier against corrosion and store.
Procedure :
Dismantle and store the pressure-instrument lines (Z 58, Part 391) Remove spot welds from the joint bolt nuts. Ream out (clean) taper-pin bores.
Page 13 of 75
Clean and thread-in guide bolts. Remove joint bolts. Clean jack screws; apply lubricant to the threads; screw in. Suspend top-half inner casing in a horizontal position. Turn in jack screws to lift the top-half by about 30 mm Lift off top-half inner casing.
Evaluation :
Joint face, blades, seal strips, L-rings. Protect top-half inner casing against corrosion and store.
Procedure :
Remove spot welds from the joint bolt nuts. Dismantle gland-steam line. Unscrew joint bolts. Lift off top-half gland bushing. Swing out and lift off bottom-half gland bushing.
Evaluation :
Joint faces, seal strips. Protect gland bushings against corrosion and store.
Remove Rotor
Procedure :
Lift off and store rear top-half bearing pedestal. Remove top-half rear journal bearing. Suspend rotor in the vicinity of the coupling flanges (Z 65) and raise in a horizontal position.
Evaluation :
Blades, seal strips, shaft journal. Protect rotor against corrosion and store.
Page 14 of 75
Evaluation :
Procedure :
Suspend bottom-half inner casing in horizontal position and lift-off. Joint faces, blades, seal strips, spherical washers, L-rings, guides. Protect bottom-half inner casing against corrosion and store. Remove lower spherical washers (Z 58, Section A-A), protect against corrosion and store.
Evaluation :
Procedure :
Sequence : arbitrary. Suspend bottom-half stationary blade carrier in a horizontal position and lift-off.
Evaluation :
Joint faces, blades, seal strips, spherical washers, guides. Protect bottom-half stationary blade carrier against corrosion and store. Remove lower spherical washers (Z 58, 59, 60), protect against corrosion and store.
Remove lift indicator Remove and store ESV piping. Unscrew nuts of the bolts connecting the oil side and steam side; uniform ly loosen the tension-rod nuts, thereby relaxing the springs.
Remove oil-side assembly (Z 78, Part 2), in cl. spring and spring retaining plate; rem ove spring retaining plate, springs and piston (Part 13).
Page 15 of 75
Unscrew stem connection, remove piston plate (Part 12). Remove cover and extract actuation piston (Part 14).
Evaluation :
All dismantled parts, body. Clean all parts and protect against corrosion.
Steam Side :
Unscrew nuts on the mating flange and remove valve (Part 1) Remove valve seat (Part 10). Remove valve stem (Part 30) and valve cone (Part 11).
Evaluation :
All dismantled parts, body. Clean all parts and protect against corrosion.
Procedure :
Check identification markings on all parts. Remove valve-lift monitor (Z 80). Remove and store complete control cylinder (Z 87). Remove lever (Part 46). Relax compression springs (Part 36) by unscrewing the top nuts (Part 40). Remove compression springs and the top and bottom springs retaining plates. Remove the taper pins (Part 19) and extract the drive rod. Remove stud bolt (Part 59); turn out set screws (Parts 31, 32, 33). Remove radiation shield. Unscrew nuts on valve cover; remove valve cover, incl. valve stem. Remove valve cone.
Evaluation :
All dismantled parts, valve block, valve seats. Clean all parts and protect against corrosion.
Page 16 of 75
Procedure :
Drain all operating oil out of the oil tank (4310), suction oil tank (4320), oil cooler (4400) and oil filter (4510). Detach and dismantle auxiliary oil pumps (4220, 4230) and emergency oil pumps (4240).
Evaluation :
Impellers, bearing, seal faces, couplings, electric motors. Reassemble oil pumps and reinstall in oil tank.
Procedure :
Evaluation :
Impeller, bearing, coupling, electric motor. Reassemble oil vapor exhauster and reinstall on the oil tank.
Procedure :
Remove inlet strainer from oil tank (4310) and clean. Clean interior of oil tank. Reinstall inlet strainer and close drain valve. Remove, inspect and clean suction-line foot valve. Clean interior of suction oil tank (4320). Reinstall valve and close drain valve. Detach and dismantle lift-oil pumps (4710)
Evaluation :
Gear wheels, bearings, seal faces, couplings, electric motors. Reassemble and reinstall oil pumps.
Procedure :
Remove, inspect and clean tube bundles in the oil coolers (4400) Inspect and clean water channels and return boxes. Reassemble oil cooler. Dismantle, inspect and reinstall dual three way rotary valve. Remove and clean filter cartridges in the duplex oil filter (4510), lifting sy stem (4730) and finefiltration system (4830).
Page 17 of 75
Drain rest of oil out of filter shell; clean shell. Reinstall filter cartridges. Detach and dismantle oil pumps from the fine-filtration system (4810, 4812).
Evaluation :
Impellers, bearings, seal faces, couplings, electric motors. Reassemble and reinstall oil pumps.
Procedure :
S# 1. 2. 3. 4. HP-Rotor LP-Rotor
Object
Remarks