University of Engineering and Technology, Lahore

Assignment # 1
Maintenance Engineering

Submitted to:
Sir. Haseeb
Submitted by:
2013-CH-65

Maintenance of Turbines
Achieving high steam turbine reliability and availability levels requires conducting the proper
maintenance and inspections in a timely manner.
Maintenance of turbines includes the inspection of the working turbine and ensuring that the
turbines are working with maximum efficiency.
This is to be done at different times:
1. Overhauling
2. Intermediate maintenance
Overhauling
Regular inspection of the different components which includes turbines bearing valves and
their working.
This is done for

every 2-3 years.

Intermediate

Maintenance

This is done if
problem at present
condition that is
generation,
less
etc.

there
is
a
working
more
heat
turbine
output

Possible Problems
Inspection

and
Method

Cracks in
Scale
the turbine
Shaft and
Corrosion and erosion in the blades

Their

the blades
accumulation in
blades
bearing failure

For Blades
Here we use non-destructive tests.
MPI (Magnetic Particle Inspect)
In this test blade is subjected to high magnetic field followed by fluorescent poured over the
blade which highlights it.
NFT (Natural Frequency Test)
In this test the natural vibrating frequency of the blade is being tested.
For Bearings
Two test are used for bearings are as followed
1. DTP (Dye-Penetration Test)
2. UST (Ultra-Sonic Test)

Scale Removal
As accumulation on the turbine blades cause loss of energy and decrease the efficiency of the
turbine and requires more energy for same work output. To avoid this abrasive jet cleaning is
used.
Abrasive Jet Cleaning
The removal of dirt from a solid by a gas or liquid jet carrying abrasives. In this method high
speed jet is sprayed on the blade surface which remove the accumulated mass.
Following abrasives are used
Aluminum oxide
Silicon carbide

Annual Steam Turbine Maintenance Frequencies and Tasks

Frequency
Daily or less

Weekly or less

Monthly or Less

Maintenance task
Conduct visual inspection of the unit
for leaks (oil and steam), unusual
Noise/vibration, plugged filters or
abnormal operation.
Cycle non-return valves
Trend unit performance and health.
Hand-held vibration readings should
be taken from the steam turbine and
gearbox if permanent vibration
monitoring system is not installed
Test emergency backup and
auxiliary lube oil pumps for proper
operation
Test the main lube oil tank and oil
low pressure alarms
Test the simulated over speed trip if
present
Cycle the main steam stop or throttle
valve
Cycle control valves if steam loads
are unchanging
Cycle extraction/admission valves if
steam loads are unchanging.
Sample and analyze lube oil and
hydraulic fluid for water,
particulates, and contaminants
Deferred weekly tests or valve
cycling that experience has indicated
sufficient reliability to defer them to

Annually or less

a one month interval.

Conduct visual inspection and
functional testing of all stop, throttle,
control, extraction and non-return
valves including cams, rollers,
bearings, rack and pinions,
servomotors, and any other pertinent
valves or devices for wear, damage,
and/or leakage.
Conduct visual Inspection of seals,
bearings, seal and lubrication
systems (oil and hydraulic), and
drain system piping and components
for wear, leaks, vibration damage,
plugged filters, and any other kinds
of thermal or mechanical distress.
Conduct visual, mechanical, and
electrical inspection of all
instrumentation, protection, and
control systems. Includes checking
alarms, trips, filters, and backup
lubrication and water cooling
systems
Test the mechanical over speed for
proper operation annually unless the
primary system is electronic and has
an OS test switch. For that system,
electronic over speed simulations
should be conducted weekly while
mechanical and electrical over speed
tests should be conducted every 3
years. For electronic systems
without an OS test switch, an over
speed test should be conducted
annually.
Conduct visual inspection of
gearbox (if installed) teeth for
unusual wear or damage, and
gearbox seals and bearings for
damage.
Internally inspect non-return valve
actuators for wear

Clarifier Desludging Pump

Clarifiers are expensive, to buy or repair, and their downtime can be costly in fines imposed
by regulatory agencies. Regular maintenance, an annual inspection of the mechanism and an
occasional touch-up of the paint or coating system are simple and inexpensive proactive steps
that will usually prevent most problems.
Three components of all clarifiers require maintenance:
1. The effluent system
2. The sludge removal system
3. The drive
The effluent and sludge removal systems require maintenance only occasionally, whereas the
drive requires regular maintenance.
Effluent System
The effluent system usually consists of a V-notched weir attached to a launder. The weir must
be kept level, and the weir and launder must be clean and free of algae. Regular cleaning with
brushes and even some chlorine will accomplish this. Some operators coat the launders with
epoxy paint to aid in cleaning.
One cleaning system consists of spring-loaded brushes attached to the rotating mechanism
which clean the weir, launder walls and scum baffle. An effective method of preventing algae
growth is to install opaque launder covers to prevent the entry of growth-promoting light.
Sludge Removal System Maintenance
Most sludge removal systems have squeegees that sweep the tank floor. It is important that
they sweep the floor clean. Therefore, they should be inspected and adjusted whenever the
tank is drained. Suction clarifiers have seals at all rotating/stationary points. "Shortcircuiting" occurs when influent is drawn directly into the underflow through leaky seals.
This can be prevented by replacing the seals as they become worn.
Suction clarifiers are also susceptible to plugging. Riser pipe valves can plug if the flow rate
is low. Suction header orifices can also plug with foreign debris. The tank should therefore be
cleaned regularly. Some operators schedule tank cleaning for fall to remove dead leaves.
Clarifier Drive Maintenance
Good drive maintenance requires attention to six things:
1.
2.
3.
4.
5.
6.

Condensate removal
Lubrication
Proper functioning of the torque control
Maintenance and/or replacement of reducer bearings and seals
Chain maintenance
Strip liner wear monitoring

Condensate Removal
Water condenses and collects in all clarifier drives and, if allowed to accumulate, can cause
the main gear and bearing to rust and fail quickly. The regular removal of this water is,
therefore, the single most critical aspect of drive maintenance. Clarifier drives have cock-type
valves through which condensate is drained. The operator should drain the condensate at least
weekly and more often in areas of high rainfall or humidity. The operator should monitor how
quickly condensate accumulates in a particular drive and drain the condensate accordingly.
Lubrication
The primary and secondary reducers and the main gear and bearing require lubrication. The
reducers and main bearing run in grease or oil and may share a common oil bath with the
main gear, which usually runs partially immersed in oil. The reducers, main bearing and main
gear casing have grease fittings or oil fillers and oil drains. An oil sight glass or dipstick is
usually provided for checking the oil level.
The operator should grease the reducers, where possible, and check all oil levels weekly and
should also drain and replace the main gear oil every 6 months. In an increasing number of
drives, the main bearing and gear run in grease rather than oil and condensate drains
continually from the drive casing through small "weep" holes.
This system has two advantages over the conventional, oil-lubricated main gear. First, it
prevents condensate accumulation and eliminates oil changes altogether. Second, grease is a
better lubricant than oil for slow-moving gears and bearings, and its stickiness prevents water
and other contaminants from coming in contact with gear and bearing surfaces.
Proper Torque Control Functioning
An occasional check to ensure that the torque control is functioning properly can prevent
catastrophic damage to the drive and clarifier that might occur in the unlikely event of a
malfunction. Many torque control mechanisms have a manual bypass and a visual torque
indicator that make it easy to check their functioning.
The operator should work the bypass through the range of the visual indicator while the drive
is running. If the torque alarm or the motor cutout fails to actuate at the designated torque
levels, the torque control mechanism should be repaired immediately.
Maintenance and/or Replacement of Reducer Bearings and Seals
In all types of primary and secondary reducers, bearings and seals must be lubricated
regularly and replaced when necessary. When seals and bearings wear out, they must be
replaced according to manufacturer's instructions. Worn seals will leak oil or grease. Worn
bearings will make noise or get hot. They should then be replaced before they damage the rest
of the drive mechanism.
Chain Maintenance
Many newer drive units have cycloidal or planetary-gear reducers that are coupled directly to
the drive motor and main gear. Such designs are safer, more efficient and reliable and require
less maintenance than old-fashioned drive chains. Older drive units, however, link the
primary reducer to the secondary reducer through a drive chain and sprockets. The drive

chain must be lubricated and tensioned and the alignment of the sprockets checked. Improper
lubrication can cause the drive chain to wear out prematurely and improper tensioning and/or
sprocket misalignment can cause it to come off the sprockets.