Q1

In Mazoon Electricity Company, from maintenance department:

The structure:

Objective: The prime objective of maintenance is to keep the equipment in good

condition to maximize lifetime productively.

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Responsibilities:

a. Supervisor:

1. Anticipates all work hazards and ensures that all safeguards are
utilized.
2. Ensures that all employees are properly trained and instructed in the
safe operation of electrical equipment and aware of all hazards
associated with the use of these electrical devices.
3. Initiates any necessary administrative action required to enforce
safety practices.
4. Requests assistance from Health, Safety and Environment Section
on equipment and devices, which require unique safety practice
instructions.

b. Employee:

1. Follows MZEC HSE policy, related procedures and instructions of

responsible supervisor and/or Health and Safety Staff.
2. Brings to the attention of the supervisor and/or Health and Safety
Staff potential hazardous situations such as discrepancies between
instruction, procedures, policies and manual, faulty equipment,
misapplication of device, etc.
3. Electrical equipment known to be malfunctioning must be repaired or
replaced before use. The repair must be initiated as soon as
possible after the malfunction is noted.

c. The following practices are to be followed by all employees:

1. The user (MZEC and contactor staff) is responsible for obtaining

necessary tools and safety equipment from the designated storage
area, checking it for discrepancies, returning it to storage area in
good condition and reporting any faulty equipment to his/her
supervisor. It shall be the supervisor's immediate responsibility to
replace any faulty safety equipment and notify the Health and Safety
Section.
2. Eye protection is required during any electrical hardware repair,
installation and/or during electrical operation.
3. Electrical safety shoes, shirts, pants and proper gloves will be worn
when operating or testing electrical equipment.
4. Protective apron will be worn over polyester or other highly
flammable clothing during soldering operations.
5. Jewelry such as rings and metal watches should not be worn while
performing electrical repairs.

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Q2

a) What are the various types of maintenance strategies that can be adopted for a process industry?

There are many maintenance strategies can be adopted by the maintenance department in process
industry, each maintenance strategy has its advantages as well as the disadvantages.

The six types of maintenance strategies going to be listed below can all be used in the process industries
and some of them can be used together.

1) Beak down maintenance. - where the maintenance is started only after the device fails to finish
a certain job-

In this type of maintenance the industry won’t have to recruit lots of maintenance employees and
will not stop working unless the device stops the job finishing, at the same time it sometimes costs
the company the price of the whole device, and might stop the production for many hours that the
industry can’t handle.

2) Planned maintenance. – the maintenance will be starting depending on the structure from the
manufacture usually depending on the working hours of the machine-

In this type of maintenance since the manufacture provides the planning of maintenance of the machine
and that how you make sure that the machine will work in a very high performance percentage for a
very long time, at the same time you might change some parts and components and sometimes even
the lubrication even if it can work for one more month, so this how you are going to pay and change for
something doesn’t needs to be changed.

3) Preventive maintenance. – to avoid failure making the maintenance before the failure time-

In this case the machine will perform well in a very high rate, but at the same time it might fail before
the maintenance time due to any reasons that may happen, at the same time you might change the
parts before the time they need to be changed (spending more money).

4) Scheduled maintenance. – putting a time table for each device maintenance time depending on
the history and experience of the machine-

In this case the machine will be well performed, but it needs lots of man power at the same time, the
industry will loss many of working hours on the due to the maintenance schedule which will cost lots of
money.

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 5) Corrective maintenance. – to avoid repeated maintenance of equipment redesigning some of
the components and modifying the machine-.

In this type of maintenance the industry won’t have to stop much for maintenance especially for regular
cases of failure due to component shape errors, but it will cost the company much to spend on the
development and research of the maintenance and design.

6) Condition based monitoring. – maintenance done based on condition of machine-

The machine will be loaded with lots of sensors that are operated by operators, which gives the
operator the whole information of the device and component conditions, where the industry won’t have
to stop unless something is really going on, at the same time they won’t change any part before the
actual changing time, at the same time it will cost the company a very big amount of many to establish
this type of maintenance, that’s why it is only recommended for high capital industries.

b) What is work order? In Al-Quram desalination plant, Muscat, feed pump is creating noise, design a
suitable work order form to above problem. With whole details planner, crew, supervisors … etc.

- Work order is a form in which written instructions are detailed for work to be carried out. The purpose
of work order is to enable the following:

1) To make the request in writing the work to be carried by maintenance.

2) Ascertaining the work requested by operation.

3) Assigning the best method and the best qualified workers for the job.

4) Reducing the cost through the most effective utilization of resources.

5) Maintaining and controlling the maintenance work.

6) To improve the planning and scheduling of maintenance activities.

7) To collect data of the work carried and the feed back to improve future work procedure.

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Hassan Al-Najjar POM 07724
Steam turbine

Steam turbines are is used in many industries to impel process and chiller compressors, boiler fans,
boiler feed and water pumps, sugar mill grinder, paper mill line shafts and generators in different of
industries and applications especially in power plants. Accordingly, steam turbines can be
designed/constructed simple and small to large and complex designed/constructed.

To specify the desired maintenance and overhaul times for steam turbines, the design/construction of
the steam turbines as well as the industry and application using the turbine for must be taking under
consider.

Fig.1 210MW Steam Turbine

TECHNICAL SPECIFICATION OF 210 MW STEAM TURBINE

Serial No. Description Parameter
1 RATED CAPACITY 210 MW
2 PRESSURE AT STOP VALVE 150 KG/CM2
3 TEMPERATURE AT STOP VALVE 535 C
4 MAX. STEAM FLOW AT S.V 641 TONNES /HR
5 REHEAT/NON REHEAT REHEAT
6 TYPE OF GOVERNING THROTLLE CONTROL
7 TURBINE SPEED 3000 RPM
8 EXHAUST PRESSURE 76 MM HG.ABS
9 NUMBER OF CYLINDERS H.P-1,DOUBLE FLOW IP-
1,DOUBLE FLOW LP-1
10 NUMBER OF STAGES HP-25, IP-20 +20,LP-8+8
11 HEIGHT OF LAST STAGE BLADE 676 MM
12 LAST STEAGE MEAN DIA 2132 MM
13 SPECIAL FEATURE -DOUBLE SHELL HP WITH BARREL
TYPE OUTER SHELL – DOUBLE
SHELL DOUBLE FLOW IP –
HYDRAULIC BARRING –

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 ELECTRO-HYDRAULIC
GOVERNING
14 WEIGHT OF TURBINE 425 TONNES
15 LENGTH OF TURBINE 14.1 METERS
16 TYPE OF TURBINE REACTION
17 COLLABORATOR SIEMENS, GERMANY
Table.1 Specification of 210MW steam turbine

The type of maintenance was applied in this industry is condition based monitoring, since the amount of
equipment depends on the complexity of the steam turbine, the minimum acceptable turbine
parameters that should be monitored by turbine size/type are shown below:

Small Medium Admission/ Large

Single Size Extraction Combined Reheat
Steam Turbine
Stage Multistage and Non- Cycle Subcritical
Parameters to be
Units Units Reheat Reheat and
Monitored Continuously
0.5-2 1.5-10 Units Units Supercritical
MW MW 100 MW Units
Speed (RPM) X X X X X
Power (MW or SHP) X X X X X
Steam Turbine Inlet
X X X X X
Pressure
Steam Turbine Inlet
X X X X X
Temperature
Steam Turbine 1st Stage
X X X X
Pressure
HP Turbine Outlet, IP
Turbine Inlet, IP
Turbine Outlet/LP Turbine
X X
Inlet
Pressures and
Temperatures
Admission Steam Inlet
Pressure and
X X
Temperature (As
applicable)
Extraction Steam Outlet
Pressure and
X
Temperature (As
applicable)
Turbine Exhaust Steam
X X X X X
Pressure
Turbine Exhaust Steam
X X X
Temperature
Sealing Steam Pressures X X X X X
Sealing Seal Exhauster
X X X X
Vacuum
HP and IP Turbine
Shell/Steam Chest
X X X
Temperatures/Differential
s

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 Rotor/Shell Differential
X X X
Expansions
Rotor Eccentricity X X X
HP and IP Stress X
Extraction Line and Drain
Line X X X
Thermocouples
Lube Oil Supply Pressure X X X X X
Lube Oil Supply
X X X X
Temperature
Lube Oil Sump Level X X X
Bearing Metal or Drain
X X X X
Temperatures
Thrust Bearing
X X X X
Wear/Temperatures
Thrust Bearing
X X X X
Wear/Temperatures
Hydraulic Fluid Pressures
and X X X X
Temperatures
Cooling Water Supply
Pressures and
Temperatures for Lube Oil
X X X X X
and
Hydraulic Fluid Heat
Exchangers
Water and Steam Purity
X X X X
Monitoring
Control Valve Position (%)
X X X X
Indication
Admission and Extraction
Valve X X
Position (%) Indication
Table.2 Parameters should be monitored in steam turbine based on the size and type

Fig.2 online Steam Turbine monitoring

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The history of the steam turbine maintenance will be shown and discussed below:

Fig. 3 history of failure causes for the steam turbine lost availability in MW-Hrs per year from 1998-2002

The loss of lube oil incidents had the highest frequency of failure. These have happened in sizes ranging
from 10MW to 400 MW for the variety of the reasons shown in Table.3. From the history we can
understand that many of the failures due to these problems have resulted in turbine rubs in addition to
damage to applicable bearings. Over speed events had the highest severity failure. While some of the
failure causes due to improper checkout during commissioning or losing control during testing of steam
turbine with uncoupled boiler feed pump, the others are due to component failures. Most of the blade
failures have been in the low pressure (LP) section of the turbine, where the blades have experienced
stress corrosion cracking or excessive erosion and FOD.

Failure
Component Cause(s) Frequency Rank Severity Rank
Mechanism
1. Pressure
switches did not
work.
2. Backup lube oil
pump did not work.
Turbine Rotor and
Loss of lube oil 3. Duplex filter 1 3
Bearings
switching problem
4. Oil supply valve
leaked
5. Ruptured
bearing oil line
Bucket or Bucket Fatigue, 1. Blade and/or 2 2
Cover Failure corrosion, cover cracked,
erosion, pitted,
rubbing, and thinned or eroded
SCC and finally broke.
2. Corrosive
chemicals in the
steam
3. High
backpressure for
last turbine

Hassan Al-Najjar POM 07724

 stage.
4. Water induction
5. Resonance
sensitive bucket
design
6. Bowed rotor
and/or humped
shell
1. NRV stuck open
during shutdown.
2. Mechanical OS
device did not
work.
Overspeed (OS) 3. Main Steam
Turbine Rotor with or without Stop/T&T valve 3 1
Water induction stuck
partly open.
4. Lost control of
test
5. Controls – OS
did not work
1. NRV stuck open
during shutdown.
2. Mechanical OS
device did not
work.
3. Main Steam
Major rubbing,
Turbine Rotor Stop/T&T valve 2 2
high vibration
stuck
partly open.
4. Lost control of
test
5. Controls – OS
did not work.
1. Exfoliation –
boiler inlet piping.
Nozzle and
Solid particle 2. Main Steam
Buckets, HP and 3 4
erosion Stop/T&T valve
IP Stages
inlet
strainer broke.
1. Saturated steam
Nozzle and
in the LP turbine.
Buckets, LP Droplet erosion 3 4
2. Poor turbine
Stages
design.
1. Debris in inlet
line to turbine.
2. Main Steam
Stop/T&T valve
Foreign or
Nozzles and inlet
Domestic Object
Buckets, All strainer broke. 4 3
Damage
Stages 3. Parts adrift
(FOD/DOD)
inside turbine, or
broken nozzle
partitions or bucket
shrouds.

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 Table.3 Steam Turbine Failure – Mechanisms and Causes (1=highest, 4=Lowest)

Fig.3 operation of a steam turbine generator system

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