DEFECTS PROTOCOL No.

1 Sheet 1 of 8

Steam turbine K-210-130-8, Unit No.1

Equipment name
Siddhirganj TPS, Bangladesh.

This Protocol testifies that the inspection of Steam Turbine was conducted during implementation of
Overhauling works in February-March, 2020.

In result of inspection the

The technical condition of the Steam Turbine, recommendations for repair and
following was
determined: operation.

Inspection results: 1. High-pressure cylinder.

 Visual inspection of the HPC casing metal did not reveal any defects.
The casing metal was cleaned and its condition was checked
according to the scope of the overhauling works. The preparation and
condition checking of the joint studs metal were completed.
Washouts were fixed by welding and scraped, assembly tightness is
ensured. The HPC horizontal connection clearances were measured
at loose cover laying (in the steam inlet zone the horizontal
connection clearance is up to 0.45 mm at the outside and 0.40 mm at
the inside). Magnetic Particle Test and ultrasonic inspection of
welded joints, heat-affected zones and HPC radial transitions were
performed. No defects detected.
 Cleaning and ultrasonic inspection of the HPC studs have been
carried out, no defects have been revealed.
 Disassembly, cleaning and assemble of the key system completed
with taking measurements of clearances at HPC keys. No defects
were revealed.
 Visual inspection of the guide wheels blades did not reveal any
defects. It is recommended to approve for further operation.
 HPC front and rear end seals carriers, last stage carrier. Cleaning of
scale and corrosive sediments at carriers, seals and installation ribs
have been performed. The front end seals carriers have been repaired
at areas having washouts on horizontal connections. Sealing
segments replaced.
It is recommended to ensure prescribed clearances at segments of the
HPC end seals after performing the centering of these HPC flow part
elements.
 HPC diaphragms carriers Nos. 1, 2, 3. Cleaning of scale and
corrosive sediments at carriers have been performed. Washouts at
horizontal connections fixed by welding and scraped. Shroud seal at
Diaphragms No.1 canopy replaced.
 It is recommended to ensure prescribed clearance at shroud seal after
performing the centering of HPC flow part.
• HPC stages Nos. 2…12 diaphragms. Visual inspection of guiding
blades of stages Nos. 2…12 diaphragms did not reveal any damage.
Cleaning of scale and corrosive sediments at blades and diaphragms
bodies have been performed. Diaphragms shroud sealings replaced.
Segments of diaphragm seals have been dismantled, grooves have
been cleaned, new diaphragm seals have been prepared for
installation.
It is recommended to perform centering of the HPC flow part
elements and to ensure prescribed clearances at diaphragm seals and
shroud seals segments. During the Steam Turbine start and warm-up
it is required to monitor the HPR thermal expansion and not to exceed
the warm-up speeds for HPR and HPC.

2. HP Rotor (See Appendix 1).

• During visual inspection of the HPR working blades, jams were
found on the at governing stage (5 places) resulting of the hits by
foreign objects.
It is recommended to perform cutting of the damaged areas and to
fulfill non-destructive inspection tests.
• Inspection of the HPR axial channel has been carried out, no defects
have been revealed.
• Working blades of 9,10,11,12 stages have traces of stand-idle
corrosion.
It is recommended to clean the corrosive areas.
• Visual inspection of the HPR journal revealed the ring grooves up to
0.02 mm deep and grooves in the area of oil-protective rings.
It is recommended to grind and polish the HPR journal, places of oil-
protective rings installation. To clean the Turbine oil system, to
adjust the prescribed clearances at the oil-protective rings of Bearing
No.1.
• Assembly of HPR-IPR half-couplings to be carried out ensuring the
elongation of the connecting bolts on the HPR-IPR half-coupling
(0.15-0.17 mm) and the pendulum check of the HPR front end (up to
0.10-0.15mm).
3. Intermediate Pressure Cylinder.
• Visual inspection of the IPC casing metal did not reveal any defects.
The casing metal was cleaned and its condition was checked
according to the scope of the overhauling works. Magnetic Particle
Test and ultrasonic inspection of welded joints, heat-affected zones
and IPC radial transitions were performed. No defects were found.
• Cleaning and ultrasonic inspection of the IPC studs have been carried
out, no defects have been revealed.
• Disassembly, cleaning and assemble of the IPC key system
completed with taking measurements of clearances at IPC keys. No
defects were revealed.
• Visual inspection of the guide wheels blades did not reveal any
defects. It is recommended to approve for further operation.
 • IPC front and rear end seals carriers, IPC last stage carrier. Cleaning
of scale and corrosive sediments at carriers, sealings grooves and
installation ribs have been performed. While performing centering of
the flow part, warping of Diaphragms Nos. 1, 2 and of the front end
sealing last stage carrier, opening of the horizontal connection at the
left and right side of the rotor up to 4 mm have been detected.
It is recommended to perform scraping of horizontal connection
before the final closing. To replace segments of end seals with
ensuring of prescribed clearances at segments of the IPC end seals
after performing of these IPC flow part elements centering.
• IPC diaphragms carriers. Cleaning of scale and corrosive sediments
at carriers, sealings grooves and installation ribs have been
performed. The front end seals carriers have been repaired at areas
having washouts on horizontal connections.
• Diaphragms of IPC Stages Nos. 14, 15, 16, 17, 18, 19, 20, 21, 22, 23.
Visual inspection of guiding blades of stages Nos. 14…23
diaphragms did not reveal any damage. Cleaning of scale and
corrosive sediments at blades and diaphragms bodies have been
performed. Segments of diaphragm seals have been dismantled,
grooves have been cleaned, new diaphragm seals sets have been
prepared for installation. Diaphragms sealings segments are being
replaced.
It is recommended to perform centering of the IPC flow part elements
and to ensure prescribed clearances at diaphragm seals and shroud
seals segments.

4. Intermediate Pressure Rotor (See Appendix 2).

• During visual inspection of the IPR Stages Nos. 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23 working blades, no defects or damages were
found. At IPR Stages Nos. 18, 19, 20, 21, 22, 23 working blades
cleaning of stand-idle corrosion areas was performed, after cleaning
no defects were found.
• Visual inspection of the Bearings Nos.2,3 journals revealed the ring
grooves up to 0.05 mm deep. Grooves up to 0.50 mm deep found in
the areas of installation of oil-protective rings.
It is recommended to grind and polish the IPR journals and places of
oil-protective rings installation. To clean the Turbine oil system, to
adjust the prescribed clearances at the oil-protective rings of
Bearings Nos.2,3. To perform HPR-IPR centering at half-couplings
reaching the prescribed values, to adjust HPR-IPR misalignment
reaching the prescribed values.
• Visual inspection examination of the IPR thrust rib revealed ring
grooves up to 0.05 mm deep on both sides of the rib.
It is recommended to grind and polish of both sides of the IPR thrust
rib.
• Tearings were detected in the fit bolts holes at IPR half-coupling
from HPR side.
Holes for fit bolts installation to be polished up to acceptable surface
roughness level. Fit bolts should be made of the allowed size
 (clearance 0.02 mm).
• Tearings were detected in the fit bolts holes at IPR half-coupling
from LPR side.
Holes for fit bolts installation to be polished up to acceptable surface
roughness level. Fit bolts should be made of the allowed size
(clearance 0.02 mm).

5. Low Pressure Cylinder (see Appendix 3).

• Visual inspection of the LPC casing metal did not reveal any defects.
Cleaning of LPC horizontal connection and places for flow part
elements installation was performed. No defects were found.
• Cleaning and visual inspection of LPC fastening has been carried out.
No defects were found.
• Inspection of IPC-LPC receiver pipes has been carried out.
It is recommended to replace/repair damaged fasteners and replace
gaskets.
• LPC atmospheric dump valves have been inspected.
It is recommended to perform repacking of atmospheric valves with
replacement of gaskets, to replace/repair damaged fasteners.
• Visual inspection of end sealings carriers and LPC last stage carriers
has been performed. The leakage of horizontal connections, steaming
through seals during the turbine operation have been revealed. Radial
clearances at the sealings nibs exceed the prescribed values (up to 1.5
mm).
It is recommended to repair horizontal connections of the LPC end
sealings carriers, to replace the sealings segments and to ensure
prescribed clearances for the end sealings.
• LPC Stages Nos. 24, 25, 26, 27, 28 & 29 Diaphragms. Cleaning of
corrosive at diaphragm blades and bodies. At the lower half of the
Diaphragm No.29 the guide key (right side) and the top of the oblique
surface of the Diaphragm casing (left side) are broken off. Segments
of diaphragm seals have been dismantled, grooves have been
cleaned, new diaphragm seals sets have been prepared for
installation.
It is recommended to replace the guide key of the Diaphragm No.29,
to ensure prescribed clearances at diaphragm seals segments.

6. Low Pressure Rotor (see Appendix 3).

• During visual inspection of the Stages Nos. 24, 25, 26, 27, 28
working blades no defects or damages were found. Blades cleaning
of plaque and stand-idle corrosion was performed.
To perform IPR-LPR centering at half-couplings reaching the
prescribed values, to adjust IPR-LPR pairing misalignment reaching
the prescribed values.
• During visual inspection of the Stages No. 29 damages of leading
edges of blades nos. 6, 13, 29, 33, 34, 36, 40, 43, 48, 49, 52, 55, 56,
59, 61, 65, 67, 69, 71, 72, 81 & 87 were found, also some stellite
plates are missing, there are damages in the shape of ragged jams
from 3 mm to 60 mm long, from 1 mm to 10 mm deep. The leading
 edges of the blades No. 61 and No. 65 are deformed at areas of 10-
15 mm long.
It is recommended to replace the working blades of LPR Stage
No. 29.
• Tearings were detected in the fit bolts holes at LPR half-coupling
from IPR side.
Holes for fit bolts installation to be polished up to acceptable surface
roughness level. Fit bolts should be made of the allowed size
(clearance 0.02 mm).
• Tearings were detected in the fit bolts holes at LPR half-coupling
from Generator Rotor side.
Holes for fit bolts installation to be polished up to acceptable surface
roughness level. Fit bolts should be made of the allowed size
(clearance 0.02 mm).
• LPR Bearings Nos.4,5 journals. Visual inspection of LPR Bearings
Nos. 4,5 journals revealed the ring grooves up to 0.02 mm deep.
Grooves up to 0.50 mm deep found in the areas of installation of oil-
protective rings.
It is recommended to grind and polish the ДPR journals and places
of oil-protective rings installation. To clean the Turbine oil system,
to adjust the prescribed clearances at the oil-protective rings of
Bearings Nos.4,5. To perform IPR-LPR, LPR-GR centering at half-
couplings reaching the prescribed values, to adjust IPR-LPR, LPR-
GR pairings misalignment reaching the prescribed values
• No defects were found during visual inspection of the shaft-turning
gear wheel.

7. Steam turbine slide bearings.

• Front bearing. Visual inspection revealed that the rotor saddle of the
bearing bushing bottom half is smooth, of normal dimensions.
Separation of babbit filling from the bushing body has not been
revealed. At the bushing upper half there are no traces of the shaft
contact, edges of the oil channel are straight, no chippings were
found. The condition of the bushing installation pads and their seats
is satisfactory.
• Bearing No.2. Thickness of babbit filling at bearing area is 5.00 mm.
Scraping of the bushing bearing area has been performed to restore
the rotor saddle. Quality of babbit filling contact was inspected by
kerosene sample testing. Defective sections of the bearing bushing
babbit filling (2 areas – 20*10 mm and 20*20 mm) were cut out to
determine the quality of the remaining filling contact. Local babbit
refilling, scraping and contact check were performed. Checking of
contact and scraping of the bushing spherical surface against the
bearing housing (contact on paint at least 75%), as well as for
installation pads and their seats (at least 70%). Inspection of support
pads performed. Inspection of the working and installation pads of
the thrust bearing No.2 has been carried out, have been replaced with
new ones. The rotor oil run has been restored to prescribed values.
 • Bearing No.3. Visual inspection revealed no defects of the babbit
filling, rotor saddle is smooth, of normal dimensions, separation of
babbit filling from the bushing body has not been revealed. Visual
inspection of the bushing upper half showed no defects of the babbit
filling, no traces of the shaft contact, edges of the oil channel are
straight without chippings. The condition of the bushing installation
pads and their seats is satisfactory. Quality of babbit filling contact
was inspected by kerosene sample testing. The bushing babbit filling
boring to be scraped as per gage or to be processed with machine
with the removal of a minimum layer of metal. Checking and repair
of thrust pads and their seats performed (contact on paint at least
70%).
• Bearing No.4. Visual inspection revealed that at the lower half of
bushing babbit boring the rotor saddle is slightly increased (sector-
40°). Scraping and lower half babbit filling surface positioning as per
gage was performed. Separation of babbit filling from the bushing
body has not been revealed. Visual inspection of bushing upper half
revealed no defects of the babbit filling, no traces of the shaft contact,
edges of the oil channel are straight without chippings. The condition
of the bushing installation pads and their seats is satisfactory. Quality
of babbit filling contact was inspected by kerosene sample testing.
The bushing babbit filling boring to be scraped as per gage or to be
processed with machine with the removal of a minimum layer of
metal. Checking and repair of thrust pads and their seats performed
(contact on paint at least 70%).
• Bearing No.5. Visual inspection revealed that at the lower half of
bushing babbit boring the rotor saddle is slightly increased. Scraping
and lower half babbit filling surface positioning as per gage was
performed. Separation of babbit filling from the bushing body has
not been revealed. Visual inspection of bushing upper half revealed
no defects of the babbit filling, no traces of the shaft contact, edges
of the oil channel are straight without chippings. The condition of the
bushing installation pads and their seats is satisfactory. Quality of
babbit filling contact was inspected by kerosene sample testing. The
bushing babbit filling boring to be scraped as per gage or to be
processed with machine with the removal of a minimum layer of
metal. Checking and repair of thrust pads and their seats performed
(contact on paint at least 70%).
• Oil-protective rings of Bearings Nos.1-5. The clearances at oil
shields ribs Nos.1-7 of bearings housings are increased up to 0.5mm
as a result of wearing. It is recommended to replace the defective
ones, to bring clearances at oil-protective rings of Bearings Nos.1-5
to prescribed values, to inspect the fastening, to scrape the
connections.

8. Steam distribution units.

• Stop valves (HPC automatic shutter valves). The working surfaces
of the valves and the seats have been cleaned. Steam boxes of valves
are cleaned for metal inspection according to works scope, defects
 have not been identified. Disassembly and repair completed with
replacement of worn and damaged parts. The valves are fitted to the
seats (contact 100%). The steam strainers are cleaned. Measurements
of lift and clearances completed according to regulations.
• HPC automatic shutter valves servomotors. The oil chambers
cleaned of sludge and coking oil. Piston drive stem of right Stop
Valve repaired – replacement of the upper thread part. Internal
spring of servodrive, two piston rings, shock absorbers spring
washers of both valves have been replaced. Measurements of lift and
clearances completed according to regulations.
• HPC Governing valves. The working surfaces of the valves and the
seats have been cleaned. Steam boxes of valves are cleaned, metal
inspection completed as per works scope. The valves are fitted to the
seats (contact 100%). The steam strainers are cleaned. Measurements
of lift and clearances completed according to regulations.
• HPC Governing valves Nos.1-4 carriers. The working surfaces of the
carriers and valve frames have been cleaned of scale. Repair
completed.
• HPC Cam distribution device, valves racks and rods. The jammed
pin was dismantled with replacement of the pin and needle bearings.
The geometry of the rack work surfaces has been restored by welding
followed by a paint fit. The gear wheel pitch is eliminated by key
welding and following fitting. Cam shafts with valve cams replaced
with new ones.
• Safety valves (IPC automatic shutter valves). The working surfaces
of the valves and the seats have been cleaned. Steam boxes of valves
are cleaned, metal inspection completed as per works scope. The
valves are fitted to the seats (contact 100%). The steam strainers are
cleaned. Measurements of lift and clearances completed according to
regulations.
• IPC Governing valves Nos.1-4. The working surfaces of the valves
and the seats have been cleaned of scale and sediments. Steam boxes
of valves are cleaned, metal inspection completed as per works
scope. Inspection of cover flanges working connections and
replacement of worn fasteners completed. The valves are fitted to the
seats (contact 100%). The steam strainers are cleaned. Measurements
of lift and clearances completed according to regulations.
• IPC Governing valves Nos.1-4 carriers. The working surfaces of the
carriers and valve frames have been cleaned of scale. Repair
completed.
• IPC Cam distribution device, valves racks and rods. The jammed pin
was dismantled with replacement of the pin and needle bearings. The
geometry of the rack work surfaces has been restored by welding
followed by a paint fit. The gear wheel pitch is eliminated by key
welding and following fitting. Defective bearings replaced. Cam
shafts with valve cams replaced with new ones.
• Servomotor (main) of HPC, IPC Governing valves. Standard repair,
cleaning completed. Casing and flanges gaskets replaced. Slide valve
 HPR Inspection.

Bearing No.1 Journal.

HPR Governing stage
Oil-protection rings installation position from Bearing No.2 side
Stand-idle corrosion of working blades of HPR Stages Nos. 9,10,11,12
Intermediate Pressure Rotor.

Bearing No.2 Journal surface.

Bearing No.3 Journal surface.
Thrust rib from Governing side.
Thrust rib from Generator side.
 Low Pressure Rotor.

29th Stage working blades.

 LPR Journals.

Bearing No.4 Journal.

Bearing No.5 Journal.
LPC 29th Stage Diaphragm.