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Turbine Over Hauling Procedure PDF
Turbine Over Hauling Procedure PDF
NG90/81/45-4IZ
S.Rameshkumar Mechanical Maintenance +WK80/90/0-3RHP
Turb+SA21LP Turb
Page 1 of 75
TURBINE OVERHAULING
Scope of Work
INDEX
1.0 Work Related Documents :
1.1 List of drawings.
1.2 Turbine Service Manual Siemens Ref : ESO/0689/86-05-13/KWU/la-mg.
4.0 Disassembly :
4.1 HP Turbine.
4.2 LP Turbine.
4.3 Valve blocks.
4.4 Lube oil system.
6.0 Fact-Finding :
6.1 Components, Parts and Individual areas to be inspected.
6.2 Component / Part findings checklist.
6.3 List of Fact-Finding Tools, instruments and accessories.
6.4 List of potential findings.
7.0 Reassembly :
7.1 LP Turbine.
7.2 HP Turbine.
7.3 Valve blocks.
7.4 Alignment checks.
7.5 Lube oil system.
8.0 Commissioning :
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 : Led plate, Birkosit.
For the oil side : Hylomar.
The followings lubricant is recommended : Gleitmo 160
Evaluation :
Teeth.
Clean couplings parts, protect against corrosion and store.
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.
4.0 DISASSEMBLY :
4.1 HP Turbine
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 39-
43) 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.
Evaluation :
Joint face, blades, seal strips, spherical washers.
Protect top-half stationary blade carrier against corrosion and store.
Evaluation :
Joint faces, blades, seal strips, L-rings.
Protect inner casing against corrosion and store.
Evaluation :
Joint face, seal strips.
Protect top-half gland bushing against corrosion and store.
Evaluation :
Joint face, seal strips.
Protect gland bushings against corrosion and store.
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.
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.
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).
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 K1-K3, Part 7), protect against corrosion and
store.
Evaluation :
Joint face, seal strips, spherical washers, guides.
Protect bottom-half gland bushing against corrosion and store.
Remove lower spherical washers (Z 37, Section K-K, Part 287), protect against corrosion and
store.
Evaluation :
Slide surfaces, spherical washers.
Protect bearing pedestal against corrosion and store.
Protect hardware against corrosion and store.
Evaluation :
Slide surfaces, spherical washers.
Protect bearing pedestal against corrosion and store.
Protect hardware against corrosion and store.
Evaluation :
Slide surfaces, spherical washers.
Protect hardware against corrosion and store.
4.2 L. P. Turbine
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.
Evaluation :
Joint face, blades, seal strips, spherical washers.
Protect top-half stationary blade carrier against corrosion and store.
Evaluation :
Joint face, blades, seal strips, L-rings.
Protect top-half inner casing against corrosion and store.
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.
Evaluation :
Journal bearing.
Protect journal bearing against corrosion and stores.
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.
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.
Evaluation :
All dismantled parts, valve block, valve seats.
Clean all parts and protect against corrosion.
Procedure :
Drain all operating oil out of the oil tank (4310), suction oil tank (4320), oil cooler (4400) and oil
filter (4510).
Detach and dismantle auxiliary oil pumps (4220, 4230) and emergency oil pumps (4240).
Evaluation :
Impellers, bearing, seal faces, couplings, electric motors.
Reassemble oil pumps and reinstall in oil tank.
Procedure :
Detach and dismantle oil vapor exhauster (4340)
Evaluation :
Impeller, bearing, coupling, electric motor.
Reassemble oil vapor exhauster and reinstall on the oil tank.
Procedure :
Remove inlet strainer from oil tank (4310) and clean.
Clean interior of oil tank.
Reinstall inlet strainer and close drain valve.
Remove, inspect and clean suction-line foot valve.
Clean interior of suction oil tank (4320).
Reinstall valve and close drain valve.
Detach and dismantle lift-oil pumps (4710)
Evaluation :
Gear wheels, bearings, seal faces, couplings, electric motors.
Reassemble and reinstall oil pumps.
Procedure :
Remove, inspect and clean tube bundles in the oil coolers (4400)
Inspect and clean water channels and return boxes.
Reassemble oil cooler.
Dismantle, inspect and reinstall dual three way rotary valve.
Remove and clean filter cartridges in the duplex oil filter (4510), lifting system (4730) and fine-
filtration system (4830).
Evaluation :
Impellers, bearings, seal faces, couplings, electric motors.
Reassemble and reinstall oil pumps.
Procedure :
Fill with clean operating oil.
S# Method
Part Material Remarks
MPT DPT
1. Journal Bearing / thrust
bearing
ST52-3N/
TEGOSTAR 738
3 White Metal
5. HP Piping 14MoV63 /
GS-17CrMo511
3 Weld seams & elbows
7. HP Outer Casing
Upper part
GS-17CrMo55 3 Cross section crossings at inner surface.
6.1.1 HP Turbine
The following individual parts and areas require inspection :
6.1.1.1 Rotor
A-Wheel blading.
FROM OUTSIDE :
L-Ring grooves, main steam and overload.
Nut support face.
Cast casing.
FROM WITHIN :
Steam admission channels, main steam plus overload, upto
stationary blading.
Nozzle blades.
Stationary blades.
Seal strips between stationary blades.
Casing face between stationary blades.
Joint face.
Seal strips of gland bushing (Diaphragm / labyrinth seal).
FROM OUTSIDE :
L-Ring grooves, main steam plus overload.
Nut support face.
Parts comprising lateral palm support and lower axial guide.
Cast casing.
FROM WITHIN :
Steam admission channels, main steam plus overload, upto
stationary blading.
Nozzle blades.
Seal strips between stationary blades.
Casing face between stationary blades.
Joint face.
Seal strips of gland busing (diaphragm, labyrinth seal).
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Guide groove.
Cast casing.
Nut support face.
FROM WITHIN :
Joint face.
Stationary blades.
Seal strips.
Casing face between stationary blades.
FROM OUTSIDE :
Nut support face.
FROM WITHIN :
L-ring grooves, main steam plus overload.
Joint face.
Guide faces for stationary blade carriers, I, II and III, plus
balancing piston.
Seal strips; shaft, front; balancing piston; shaft, read.
6.1.2 LP Turbine
6.1.2.1 Rotor
Moving blades.
Seal strips between the blade rows and around the shaft seals.
Balancing weights.
Rotor face (in the steam section and in the area of the bearing oil wiper rings).
Bearing journals.
TE and GE coupling half sections.
Couplings bolts and nuts.
FROM OUTSIDE :
Nut support face.
Casing finish.
FROM WITHIN :
Joint face.
Casing finish.
Stationary blades.
Seal strips.
FROM OUTSIDE :
Guide faces, front / rear.
Casing finish.
FROM WITHIN :
Stationary blades.
Casing finish up to diffuser outlet.
FROM OUTSIDE :
Guide faces, front / rear.
Casing finish.
FROM WITHIN :
Stationary blades.
Casing finish up to diffuser outlet.
Lateral support and axial guide.
Blading :
A-Wheel / C-Wheel blades.
Stationary / moving blades.
Blade Tip
Integrated Shrouding :
Radial rubbing ?
Axial rubbing ?
Pitting ?
Gap formation ?
Fused-on foreign particulars ?
Riveted Shrouding :
Radial rubbing ?
Axial rubbing ?
Pitting ?
Rivet-tenon damage ?
fused-on foreign particles ?
Milled Edges :
Radial rubbing ?
Axial rubbing ?
Foreign-object damage ?
Vane :
Fractures ?
Incipient cracks ?
Axial rubbing ?
Foreign-object damage ?
Deposits ?
Pitting or crevice corrosion ?
Solid-particle erosion ?
Droplet-impact erosion ?
Blade Root :
Blade fit ?
loosening?
incipient cracks ?
fracture ?
Finger-pin root connections ?
Measurements :
Static Natural Frequency.
Dimensions.
Tests / Examinations :
Magnetic Particle Test.
Liquid penetrate Test.
Seal Strips :
In shaft seals, In balancing piston, In casing between stationary blades, In rotor between
stationary blades.
Seal strip fracture ?
Deformation ?
Radial rubbing ?
Axial rubbing ?
Burring due to rubbing ?
Unacceptable abrasion ?
Scale formation ?
Seal-strip elasticity?
Bearing Journal :
Scoring ?
Rotor Faces:
Incipient cracking ?
Scoring ?
Deposits ?
Corrosion ?
L-Ring Grooves :
Scoring ?
Scale formation ?
Deformation ?
Cast Casing :
Incipient cracking ?
Deposits ?
Pitting or crevice corrosion ?
Erosion corrosion ?
Nozzle Blades :
Solid-particle erosion ?
Foreign-object damage ?
Deposits ?
Nozzle-blade fit ?
Joint faces :
Leak-tightness ?
Deformation ?
Damage ?
Deposits ?
Scoring ?
Abrasion ?
Seat mobility ?
Deformation ?
Incipient cracking ?
Fractures ?
Leak-tightness ?
Coupling bolt :
Scoring ?
Frictional oxidation ?
Balancing weights :
Fit in mounting groove ?
Droplet-impact erosion ?
Flanged connections :
Functionability impaired ?
Deformation ?
Leak-tightness ?
Damage ?
Rupture disk :
Damage ?
Bolts :
Fractures ?
Incipient cracking ?
Relaxation ?
Babbitt lining :
Visual damage to surface ?
Damage to babbit lining determined via surface crack examination according to the liquid-
penetrant method ?
Unacceptable large areas without adequate bond between the lining and the bearing body,
determined via ultrasonic testing ?
Functionability impaired due to :
Unacceptable bearing contact angle ?
Unacceptable lateral or top clearance ?
Bearing shell :
Quality of finish ?
Pedestal faces :
Corrosion ?
Damaged ?
Valve stem :
Quality of finish ?
Damage ?
Functionability impaired ?
Piston rod :
Quality of finish ?
Damage ?
Functionability impaired ?
Piston :
Quality of finish ?
Damage ?
Functionability impaired ?
Spiral springs :
Quality of finish ?
Damage ?
Functionability impaired ?
Bars :
Functionability impaired ?
Leverbar mount :
Functionability impaired ?
Valve seat ?
Quality of finish ?
Damage ?
Functionability impaired ?
How to inspect ?
Visual Inspection :
Typical accessories :
Typical accessories :
Hand-hammer (200 300 gr)
Screwdrivers (approx. 300mm long)
How to Measure ?
Manual measuring :
How to Test ?
Manual testing :
Liquid Penetrant Test.
Magnetic Particle Test.
Ultrasonic Examination.
Electric Crack-Depth Measurements.
X-Ray Examination.
Developer.
UV lamp.
Yoke Magnet.
Coil Magnet (fluorescent or black magnetic powder carrier fluid).
Pulse-echo test instruments (transducers / sensors of various size).
Potential Probe.
Blades
Blades Tips
In order.
Radial rubbing.
Radial rubbing, scoring.
Axial rubbing.
Axial rubbing, scoring.
Radial rubbing, scoring and measurable gap.
Crevice corrosion.
Fused-on foreign particles under shrouding.
Broken rivet head.
Broken rivet shank.
Vane
Broken vane.
Cracked vane.
Axial rubbing on :
Leading edge.
Trailing edge
Foreign object damage :
Roughened - leading edge.
Dented - trailing edge
Notched - convex side.
Torn - concave side
Coatings (scale, deposit) :
where ? - convex side, concave side.
extent ? - thin, thick.
Pitting :
On the convex side.
On the concave side.
Solid particle erosion :
Leading edge, convex side.
Leading edge, concave side.
Trailing edge.
Blade Root
Ring test in order (pure, clear sound).
Ring test indicating loose fit (clanking sound).
Measurable gap formation between 2 blades.
Locking / end blade risen more than permissible (0.3 mm).
Broken blade root.
Cracked blade root.
Seal Strips
Broken off around the entire circumference above caulking groove; broken
out in part (%).
Note : Rectangular fractures indicate stress corrosion.
Curved fractures indicate vibration as the cause of cracking.
Bent due to foreign-object impact.
Wavy deformation (rippling) due to radial rubbing
Bent forward due to axial rubbing.
Bent backward due to axial rubbing.
Unacceptable abrasion due to radial rubbing.
Perceptible burring.
Residual strip height (measured).
Scale formation : in which area.?.
Scaly strips susceptible to brutal fracture.
Elastic seal strips.
Bearing Journals
In order.
Shallow scoring.
Random scoring along the journal length.
Scoring at the journal ends.
Individual gouges (depth ?).
Rotor Faces
In order.
Scaled.
Corroded.
Eroded.
Covered with deposits.
Rub marks.
Striated.
Cracked (crack depth ?)
L-ring Grooves
In order.
Scaled.
Oval deformation.
Scoring.
Cast Casing
In order.
Torn.
Covered with deposits.
Corroded.
Eroded.
Corrosion-erosion attach.
Washed-out casting pores.
Washed-out casting cavities.
Oval deformation.
Nozzle Blades
In order.
Solid particle erosion.
Scaling.
Foreign particle hammering.
Torn seal welds.
Loose nozzle-blade seat.
Joint Faces
In order.
Scaling.
Signs of steam leakage without material erosion.
Structural Elements :
Thermo-elastic Housing Guide
In order.
Unimpeded movement.
Binding movement.
Seized.
Scaled.
Torn.
Deformed.
Hammered.
Fretting corrosion.
Striated.
Abrasion.
Coupling Bolt
In order.
Fretting corrosion.
Scored from dismantling.
Unacceptable stretch.
Balancing Weights
In order.
Droplet-impact erosion.
Loose fit in mounting groove.
Flanged Connections
In order.
Concave deformation of face area.
Leaky.
Steam erosion marks without material abrasion.
Steam erosion marks with material abrasion.
Torn.
Contact face for seal grooved indented.
Rupture
In order.
Damaged
Bolts
In order.
Torn.
Broken off.
Unacceptable stretch.
Scaled thread flanks.
Galled.
Babbitt Lining
In order.
Colored oil deposits.
Full-width scoring.
Scoring at front and rear.
Scoring in the vicinity of lift-oil pressure relief hole.
Round foreign objects stuck in Babbitt metal.
Isolated wide / deep scoring.
Cavitations at front of out-let side oil groove.
Smearing.
Babbitt fretting.
Surface pores.
Crack in Babbitt lining.
Bond in order.
Unacceptably large areas without adequate bond between the Babbitt lining
and the bearing body.
Bearing contact angle in order.
Bearing contact angle too wide.
Clearances in order.
Lateral or top clearance too small or too large.
Bearing Shell
In order.
Spherical area damaged by frictional oxidation.
Spherical area dispels evidence of hammering due to bearing vibration.
Evidence of hammering on the pedestal guide faces.
Pedestal Faces
In order.
Rusty.
Valve Stems
In order.
Scaling.
Axial scoring.
Gland corrosion.
Radial vibration marks.
Torn at cone.
Surface cracks in the hard-facing.
Torn in the spindle.
Torn at the coupling.
Unacceptable bending.
Valve Cones
In order.
Foreign objects pressed into valve seat.
Valve seat torn.
Valve broken.
Valve blow out.
Back seal blown out.
Taper shank scored.
Hard-facing torn at taper shank.
Taper shank scaled.
Pilot cone leaky.
Pilot cone seized.
Signs of hammering on the anti-rotation device.
Anti-rotation device in order.
Piston Rod
In order.
Scored.
Bent.
Torn.
Piston Plate
In order.
Damaged seal face.
Torn seal face.
Corroded.
Piston
In order.
Damaged seal face.
Corroded.
Spiral Springs
In order
Corroded.
Broken.
In order.
Torn
Noticed
Round foreign objects stuck in coiling strip.
Signs of hammering.
Broken out.
Bars
In order.
Bent.
Lever mount
In order.
Mount beater out.
Valve seat
In order.
Cracked.
Broken.
Indented by foreign objects.
Blown out.
Torn weld.
7.0 RE-ASSEMBLY :
7.1 L. P. Turbine :
Insert Rotor
Procedure :
Suspend rotor in the vicinity of the coupling flanges (Z 65) and raise slightly.
Clean rotor and protect against corrosion.
Set down rotor in the support bearing at front and bearing pedestal at rear, thereby ensuring that the
journal surface areas of both bearings are coated with viscous oil.
Install top-half journal bearing.
Unscrew spacer bolts (Z 58, 59, 60; Section F2-F2, F4-F4) on the bottom-half outer
casing.
Check for full contact between the support brackets and the base plates (Z 58, 59, 60;
Section F2-F2, F4-F4).
Check for full contact between the bearing pedestal and the base plate (Z 58, 60; Section
N4-N4).
Check alignment dimensions (Assembly data sheet EI, EII) or ascertain via rotor
displacement and record values.
Measure and record the exact values at the outer-casing circumferential profile measuring
points.
Measure and record the exact values at the rear bearing pedestal measuring points.
Record measured values and correct as necessary by way of rotor displacement.
Tighten spacer bolts (Z 58, 59, 69, Section F2-F2, F4-F4)
Remove Rotor
Procedure :
Remove top-half journal bearing.
Remove and store rotor.
Protect bottom-half journal bearing and support bearing against damage.
Set up proper clearance between the spherical washers and the outer casing; secure adjusting
elements as specified in the drawing; check and record all values.
Remove spherical washers and keep ready for further reassembly.
Measure, evaluate and record axial movement of the rotor.
Unscrew joint bolts.
Raise top-half stationary blade carrier, protect against corrosion and store.
Check and record the lateral (horizontal) radial clearance between the stationary blade carriers and
the rotor.
Measure, evaluate and record the axial clearance between the rotating and stationary blades in
positive and negative direction.
Remove top-half journal bearing.
Remove and store rotor.
Check bottom-half journal bearing and support bearing for damage.
With the aid of the adjusting elements (Z 58, 59, 60; Section A-A) vertically raise and lower the
inner casing up to stop in order to determine the overall radial clearance between the inner casing
and the rotor; evaluate; center the inter casing and record all values.
Apply lubricant to the contact faces of the top calottes (Z 58, Section A-A) and install marked
spherical washers.
Set up proper clearance between the spherical washers and the outer casing; secure adjusting
elements as specified on drawing; check and record all values.
Remove spherical washers and keep ready for further assembly.
Measure, evaluate and record the axial movement of the rotor.
Unscrew joint bolts.
Lift off top-half inner casing, protect against corrosion and store.
Check and record the lateral (horizontal) radial clearance between the inner casing and the rotor.
Measure, evaluate and record the axial clearance between the rotating and stationary blades in
positive and negative direction.
Remove top-half journal bearing.
Remove rotor and store.
Check bottom-half journal bearing and support bearing for damage.
Degrease joint faces of the top and bottom halves; apply uniform coat of sealant to one joint face.
Mount top-half stationary blade carrier and tighten joint bolts.
Clean front and rear gland bushings and protect against corrosion.
Apply lubricant to guides.
Swing in bottom-half gland bushings.
Degrease joint faces; apply uniform coat of sealant to one side of each pair of joint faces.
Mount top-half gland bushings and tighten joint bolts.
Secure all boltings with spot welds.
Remove all taper pins, jack screws and guide bolts; protect against corrosion and store.
Apply lubricant to top-half guides.
Install spherical washers in the stationary blade carrier and inner casing.
Install journal bearing for bluing imprint; lower rotor; bolt down bearing bracket; make bluing
imprint.
Remove bearing bracket; raise rotor slightly; remove journal bearing; evaluate bluing imprint;
clean bluing ink off of bearing and shaft journal.
Install journal bearing; lower rotor; thereby ensuring that the journal surface areas are coated with
viscous oil; bolt bearing bracket and install thermocouples (Z 7).
Check for full contact between the support brackets and the base plates (Z 58, 69, 60; Section F2-
F2, F4-F4).
Check measuring points on the rear bearing pedestal.
Check outer-casing circumferential profile measuring points.
Check and record clearances in the front and rear support bracket bolts (Z 58, 59, 60; Section F2-
F2, F4-F4).
Check zeroing of casing axial-position indicator (Z 58, 59, 60; Detail V4).
7.2 H. P. Turbine
Insert spherical washers of the axial casing guide and bring into contact with the guide face via the
calottes.
Apply lubricant to the threads of the hexagon head bolts; screw in and tighten hexagon head bolts
carrying tab washers (Z 37, 39; Section 03-03, Parts 115, 116).
Install bottom-half journal bearing (Z 16) and protect journal surface area against corrosion.
Insert Rotor
Procedure :
Suspend rotor in horizontal position and raise slightly.
Clean complete rotor and protect against corrosion.
Set down rotor in the bearing pedestal, thereby ensuring that both journal surface areas are coated
with viscous oil.
Mount top-half journal bearing.
Apply lubricant to the contact faces of the calottes of the front support bracket seat (Z 37, 38;
Section P1-P1); install marked spherical washers.
Suspend top-half outer casing from the lifting bosses provided and raise slightly.
Screw guide bolts into the bottom-half outer casing.
Degrease joint faces of top-half and bottom-half outer casing.
Apply uniform layer of bluing ink to the joint face of the top-half outer casing.
Mount the top-half outer casing on the bottom-half outer casing and tighten several joint bolts.
Unscrew bolts of auxiliary support brackets (Z 37, 38; Section P1-P1, Part 30).
Check for full contact of the front support brackets (Z 37, 38; Section P1-P1) and record values.
Check for full contact of the rear support brackets (Z 37, 39, Section P3-P3) on the base plates.
Evaluate recorded values and correct as necessary, either via shims between the support brackets
and base plates (Z 37, 39; Section P3-P3) or on the adjusting elements (Z 37, 38, 39).
Secure adjusting elements as per drawing (Z 37, 38, 39).
Tighten spacer bolts (Z37, 38, 39; Section 01-01, P3-P3).
Unscrew coupling nuts (Z 72).
Remove coupling bolts.
Accommodate weight of the LP rotor with the aid of the lifting fixture (Z 71).
Push coupling flange apart by turning in the jack screws.
Push rotor in the positive direction by about 1.0mm ahead of the stop.
Install support bearing; take load off of lifting fixture.
Remove Rotor
Procedure :
Remove front top-half bearing pedestal; remove bottom-half thrust bearing; remove top-half
journal bearing.
Remove rear top-half bearing pedestal; remove top-half journal bearing.
Remove and store rotor.
Protect bottom-half journal bearing against damage.
Apply lubricant to the contact faces of the upper calottes (Z 45, Section K1-K3, Part 9); install
marked spherical washers.
Adjust clearance between spherical washers and outer casing; secure adjusting elements; check and
record all values.
Remove spherical washers and keep ready for further assembly.
Remove bottom-half thrust bearing.
Measure, evaluate and record the axial movement of the rotor.
Reinstall bottom-half thrust bearing.
Unscrew joint bolts.
Lift off top-half stationary blade carrier, protect against corrosion and store.
Check and record the lateral (horizontal) radial clearance between the stationary blade carrier and
the rotor.
Measure, evaluate and record the axial clearance between the rotating and stationary blades in
positive and negative direction.
Remove bottom-half thrust bearing.
Remove top-half journal bearing.
Remove and store rotor.
Protect bottom-half journal bearing against damage.
Insert rotor.
Install bottom-half thrust bearing.
Measure and evaluate the exact values at the outer-casing circumferential profile measuring points
and correct as necessary by adjusting the screws on the auxiliary support brackets.
Measure and evaluate the lateral (horizontal) radial clearance between the gland bushing and the
rotor and correct as necessary via the adjusting elements (Z 37, Section K-K).
Suspend top-half gland bushing in a horizontal position and raise slightly.
Clean top-half gland busing and protect against corrosion.
Degrease joint faces of top-half and bottom-half gland bushing.
Install top-half gland bushing and tighten joint bolts.
With the aid of the adjusting elements (Z 37, Section K-K), vertically raise and lower the gland
bushing up to stop in order to determine and evaluate the overall radial clearance between the
gland bushing and the rotors; center the gland bushing and record all values.
Apply lubricant to the contact faces of the upper calottes (Z 37, Section K-K, Part 289) and install
marked spherical washers.
Adjust the clearance between the spherical washers and the outer casing; secure
adjusting elements; check and record all values.
Remove the spherical washers and keep ready for further assembly.
Remove bottom-half thrust bearing.
Measure, evaluate, record the axial movement of the rotor.
Reinstall bottom-half thrust bearing.
Unscrew joint bolts.
Lift off top-half gland bushing, protect against corrosion and store.
Check and record the lateral (horizontal) radial clearance between the gland bushing and the rotor.
Remove bottom-half thrust bearing.
Remove top-half journal bearing.
Remove and store rotor.
Protect bottom-half journal bearing against damage.
Install journal bearing; lower rotor; install thrust bearing, thereby ensuring that the journals of
both bearings are coated with viscous oil.
Install thermocouples (Z 7).
Install and bolt down front top-half bearing pedestal.
Dismantle center top-half bearing pedestal; raise rotor slightly; remove journal bearing degrease
bearing and journal; check and record radial clearance of the journal bearing (Z 37, 39; Section
K3-K3).
Install journal bearing for getting a bluing imprint; lower rotor; bolt down top-half bearing
pedestal and make bluing imprint.
Dismantle center top-half bearing pedestal; raise rotor slightly; remove thrust bearing; evaluate
bluing imprint and clean bluing ink from bearing and journal.
Install journal bearings; lower rotor; thereby ensuring that the journal is coated with viscous oil.
Install thermocouples (Z 7).
Install and bolt down center top-half bearing pedestal.
Check front support bracket seat (Z 37, 38; Section P1-P1).
Check for full contact between the rear support brackets and the base plates (Z 37, 38; Section P3-
P3).
Check the front and rear bearing pedestal measuring points.
Check the outer-casing circumferential profile measuring points.
Install manual turning gear; check and record the clearance between the frame and the gear wheel
(Z 37, 39; Section U3-U3).
Unscrew cover of front top-half bearing pedestal Z1, Item 169/165); turn turbine rotor to the
proper measuring position; pull level of emergency trip gear (into operating position; Z88) and
lock in place.
Check and record the radial clearance between the ratchet lever and the overspeed trip bolt (Z 37,
38; Section S1-S1).
Check and record the axial clearance between the ratchet lever and the stopping cam (Z 37, 38;
View R1).
Return lever to its original position; reinstall cover on the front top-half bearing pedestal.
Check the maximum and minimum clearances at the front and rear support bracket bolts (Z 37, 38,
39; Section P1-P1, P3-P3).
Check and record the clearances at the casing guides (Z 37, 38, 39; Section W1-W1, W3-W3).
Check and record the clearances at the lower bearing pedestal guides (Z 37, 38, 39; Section M1-
M1, M3-M3).
Check and record the clearances on the longitudinal guides of the front bearing pedestal (Z 37, 38;
Detail T1).
Check and record the clearance between the brackets and spacer bolts on the front bearing pedestal
(Z 37, 38; Section 01-01).
Check the zeroing of the shaft position indicator (Z 37, 38; View V1) on the front bearing
pedestal.
Procedure :
Steam End :
Clean valve seat (Part 10); coat mating surfaces with lubricants; install and secure valve seat.
Install valve stem with valve cone (Part 30). Do not lubricate the valve stem for installation.
Prepare valve cone for bluing imprint; run valve stem to open position.
Install steam-end components in the body (without the steam strainer); hand-tighten nuts;
make bluing imprint.
Remove nuts.
Remove steam-end components with stem; evaluate bluing imprint; clean bluing ink from
valve cone and valve seat.
Clean steam strainer and mount on steam end, thereby threading in the anti-rotation
device.
Install steam end with steam strainer in the body and bolt down; the gland steam and leakage
oil bores must point downwards.
Oil End :
Push piston plate (Part 12) onto valve stem and connect bolted joint.
Install actuation piston (Part 14) in the body; coat sealing surfaces with sealant, and install
cover.
Arrange oil end with opening showing upwards and install piston (Part 13).
Check valve strokes (valve cone, pilot cone, piston.)
Install spring with spring retaining plate; coat seal face with sealant; mount oil end on steam
end as per drawing and tighten nuts onto the spring-loaded tie rods.
Apply uniform torque to the tie rod nuts in order to generate evenly distributed tension in the
springs; screw nuts onto the other bolts and tighten all nuts.
Attach the valve-lift monitor.
Bolt on and pin the drive rod (Chapter III 2.1.2, Part 19); adjust and secure set screw (Chapter III
2.1.2, Part 31) as specified in the setting sheet.
Install compression springs (Chapter III 2.1.2, Part 36) with spring retaining plates; screw on nuts
(Chapter III 2.1.2, Part 40) and pre-stress the compression springs.
Attach lever (Chapter III 2.1.2, Part 46).
Remount control cylinder (Z 87).
Install valve lift monitor (Z 80)
Procedure :
Prepare lift-oil pumps ready for operation.
HP / LP Turbine
Procedure :
Dismantle center top-half bearing pedestal (Z 15). Caution ! first remove the manual turning gear.
Position the lifting fixture (Z 21).
Connect LP and HP rotors with at least 4 coupling bolts (Z 72); pull coupling flange halves
together to within 3 mm; install all coupling bolts, thereby heeding the identification markings,
and hand-tighten the coupling nuts.
Take load off of lifting fixture (Z 21)
Remove support bearing shims, protect against corrosion and store.
Remount center top-half bearing pedestal (Z 15) and bolt down tight.
Check, evaluate and record alignment between HP and LP turbines (coupling inspection).
Pull coupling flange together; tighten coupling bolts as specified; secure coupling nuts.
Remove lifting fixture (Z 21), protect against corrosion and store.
Measure, evaluate and record turbine runout (runout check).
Check, evaluate and record the alignment between the main oil pump (Z 8) and the HP turbine (Z
8) (= coupling inspection).
Assemble coupling sleeve (Z 10, Part 100).
Check and record axial clearance of the coupling sleeve.
Check and record radial clearance in the toothing.
HP Turbine :
Dismantle front top-half bearing pedestal (Z 1).
Check and record the alignment dimensions (Assembly data sheet, EI, EIII, EIV).
Remove thrust bearing; check and record minimum axial movement of rotor; reinstall thrust
bearing, incl. thermocouples (Z 7).
Measure and record dimension L (Assembly data sheet) on the front support bracket seats.
Mount and bolt down front top-half bearing pedestal.
Check and record the exact values at the front and rear bearing pedestals.
Check and record the exact values at the outer casing circumferential profile measuring points.
Dismantle front and center top-half bearing pedestals.
Install bearing oil wiper rings (Z 2, 17, 24); check and record the radial and axial clearances (Z 37,
38, 39; Details H1. H3).
Check and record the radial and axial clearances between the blade disk and bearing pedestal of the
hydraulic turning gear (Z 37, 38, 39; Detail L3).
Mount and bolt down the front and center top-half bearing pedestals.
LP Turbine :
Check and record the alignment dimensions (Assembly data sheet EI, EII).
Check and record the exact values at the rear bearing pedestal (Z 22).
Check and record the exact values at the outer casing circumferential profile measuring points.
Install bearing oil wiper rings; check and record radial clearances (Z 58, 59, 60; Details H4, R4).
Mount and bolt down rear top-half bearing pedestal.
Evaluation :
Follower piston, sleeve, transducer, other parts.
Clean all parts and protect against corrosion.
Disassemble EHC :
Disconnect all electric leads (pull plugs).
Dismantle piping.
Evaluation :
Pilot valve, control sleeve, governor pedestal, power piston, piston rod seal, follower piston, other
parts.
Disassemble Operator :
Remove feedback lever (Z 87, Parts 30, 32, 42).
Remove servo valve cover.
Remove pin, spring retaining plate, spring and thrust bearing.
Extract pilot valve.
Detach stem head piece (Z 87, Part 7) over the control cylinder (Z 87, Part 1).
Open control cylinder and remove piston and piston rod.
Evaluation :
Pilot valve, control sleeve, piston rod seal, other parts.
Clean all parts and protect against corrosion.
Reassemble Operator :
Install piston and piston rod.
Close Control Cylinder.
Check for free movement of piston.
Reinstall stem head piece.
Lubricate and install pilot valve and check for freedom of movement.
Install thrust bearing, spring retaining plate and pin.
Install and secure cover of servo valve.
Install feedback lever.
Evaluation :
Pilot valve, control sleeve, rotary piston, bearings, other parts.
Clean all parts and protect against corrosion.
Evaluation :
Valve disk, housing, bearing.
Replace stem seal.
Evaluation :
Follower piston, other parts.
Clean all parts and protect against corrosion.
Evaluation :
Seal plate, bearing, housing, other parts.
Reassemble check valve, check for free movement of seal plate and shaft.
Reassemble control cylinder and mount on check valve.
Evaluation :
Seal plate, bearing, housing.
Reassemble check valve; check for free movement of seal plate.
Evaluation :
Valve, lever, other parts.
Reinstall valve; check for free movement of valve and lever; reinstall emergency trip gear.
Evaluation :
Slide valve, lever, diaphragms, other parts.
Reassemble steam pressure monitor and check for free movement of slide valve, lever and bars.
Check function of associated equipment while resetting the control set points.
Cut in high-pressure pump no. 2 of the lift-oil system, thereby taking note of the
direction of rotation.
Cut out high pressure pump no. 1.
Heat the operating oil up to about 70OC (if possible), hold at that temperature for approximately 4
hours and allow to cool to about 30OC.
Switch oil cooler and lube-oil filter over to the other chamber.
The above procedure must be repeated a number of times.
Oil flushing must be continued until no appreciable amount of soil collects in the strainers.
Extract and clean the filter cartridges of the double oil filter (4510), lift-oil system (4730) and
fine-filtration system (4830).
Drain remaining oil out of filter shell.
Clean shell.
Reinstall filter cartridges.
Remove fine-mesh screens upstream of the bearing pedestals.
Set lube-oil throttles to the values stated in the assembly data sheet and record the settings.
Dismantle the special auxiliary line leading from the lube-oil/oil drain line and reconnect both lines
to the main oil pump (ready for operation).
Remove front, center and rear top-half bearing pedestals and clean the interior of the pedestals.
Remove bottom-half thrust and journal bearings, clean, protect against corrosion and reinstall.
Install top-half thrust and journals bearings ready for operation.
Reassemble lift-oil piping ready for operation.
Tighten thermocouples ready for operation.
Apply sealant to the mating surfaces of the top-half bearing pedestals and bolt down ready for
operation.
Remove, clean and reinstall the oil tank inlet strainer (4310).