500MW Turbine O&M Manual Part#3 Of3

Steam Turbine Maintenance Schedule
Maintenance FRF system
Frequency
h = hourly
Parameter
d = daily
Activity Work to be performed measured Remarks
w = weekly
No. or tested
m = monthly
y = yearly
1. Cleaning of filters ∆ p across filter
and strainers
Switch over duplex
filters; and clean fouled
filter cartridges as
prescribed in 5.1-1130
Turn plate-type filters d
through two three
revolutions
Clean plate-type filters 6m -1y during appropriate
shut-downs and
overhauls
Replace filter papers in ∆ p across filter as indicated by

fine mesh filter as criteria, max 6 m
prescribed in 5.1-1140
Replace fuller’s earth Neutralization 6m or as
filling in regenerating number indicated by
filter as prescribed in criterion
5.3-0082
Change FRF tank FRF level in as indicated by during appropriate
strainers; clean chocked strainers criteria shut-downs and
strainers overhauls
Regenerate air filters or Discoloration of 3m, or as
exchange filter filling filter filling indicated by
criterion
2. Cleaning of FRF tank after deposits in FRF 3-4y during overhauls

draining FRF tank
3. Keeping the FRF in FRF
tank at operating level.
Top up using FRF of the Level in FRF 1 d check; Top
same brand and with the tank up as indicated
same properties by criterion
4. Lubrication of motors of as specified by
pumps and fans the motor
FRF pumps manufacturer
FRF circulating pump
FRF vapour extraction
fan
BHEL Haridwar 5.3-0023-01/1

Frequency
Parameter h = hourly
Activity Work to be performed measured d = daily Remarks
No. or tested w = weekly
m = monthly
y = yearly
5. Lubrication of the bearings as specified by
of the FRF vapour fan manufacturer
extraction fan
6. Lubrication of the valve 3m
stems at the lubricating
points provided
7. Retightening of the valve 3m of if leakage
stem packing detected
8. Elimination of leaks by leakage regularly, as
retightening flanges and indicated by
unions criterion
9. Checking of damping fluid 1 -2 Y
in vibration dampers
as prescribed in 5.3-0100
10. Charging of hydraulic Filling 1m
accumulators pressure
5.3-0023-01/2
Steam Turbine Testing during Start-up
Maintenance
Introduction main trip valves in operating position, stop

valve closed etc.)
Tests demonstrate the readiness for
operation and the proper functioning of The operation sequence establishing certain
important components. They must be operating conditions is given in the form of
performed before and during start-up of the general instructions to avoid constant
turbine generator unit, irrespective of the repetition in the table of test sequences.
time of the preceding shutdown.
If all prerequisites for performance of the Test Performance
complete test program are not fulfilled, Take care to avoid any risks to people or
reduced testing to ensure the readiness of machines while performing tests.
the auxiliary, emergency and jacking oil
pumps for operation must be performed. Any simulated conditions necessary for the
tests must be cancelled after completion of
The scope of the test program for start-up of tests.
the turbine is to make sure that all tests
required to be performed before start-up Steam inlet valve may only be operated for
after a shutdown period of approx. 4 weeks test purposes if the piping systems upstream
[1, 2] have completed. of the valves are not under pressure and the
systems concerned have been expressly
cleared for testing.
Test procedures
Test performance must be recorded.
Tests, prerequisites, test activities and
criteria in table form is intended to simplify If incorrect operation of the equipment being
testing. The symbols at the head of the tested occurs, take action establishing full
columns in the tables are an aid to operational reliability of the turbine generator
understanding the concise test instructions. unit immediately. Pay attention to fault
tracing instructions.
The tables are also suited to use as
checklists. Whenever no specific test
instructions are prescribed for any test, the
sequences shown in the table must be
followed. Also refer to the following sections:
[1] 5.3-0061: Testing During Standstill
A number of tests require that certain
[2] 5.2-002..: Testing of turbine Component
components be in a definite position (e.g.

Equipment tested o Preconditions Date
o Type of test () Test Step Result
• Result Tested by
Main trip valves in
operating Position
o Stop valves closed o Starting and load limit device not in 0% position
o Test valves of stop valves in left-hand end
position (=stop valves open)
(1) Move test valve pilot into right-hand end position
using handwheel (= stop valves closed)
(2) Bring starting and load limit device into 0%
position
• Main trip valve in operating position
position
• Main trip valve in operating position and ready to
trip
• Stop valves closed
Main trip valves in o Starting and load limit devices not in 0% position
operating Position
o Test valve of stop valve in left-hand end position
o Stop valves open
position
• Main trip valve in operation position
position
• Main trip valve in operating position and ready to
trip
• Stop valves open
Auxiliary oil pumps

o Pressure-dependent o Shaft at standstill
on command from
o Oil system depressurised
subloop control before
starting turning gear o Auxiliaries and emergency oil pumps off
operation
o Subloop controls on Manual
(1) Switch auxiliary oil pump 1 subloop control to
Auto
• Auxiliary oil pump 1 on
• System oil pressure present
(2) Switch auxiliary oil pump 2 subloop control to
Auto
5.3-0030-02/2
(3) Switch auxiliary oil pump 1 subloop 1control to
Manual
(4) Switch auxiliary oil pump 1 off
• Auxiliary oil pump 2 on
D.C. Emergency oil

pump
o Pressure-dependent (1) Switch D.C. emergency oil pump subloop control
on command from on
subloop control before (2) Switch auxiliary oil pump 2 subloop control to
starting turning gear Manual
operation
(3) Switch auxiliary oil pump 2 off
• DC emergency oil pump on
• Lubricating oil pressure present
(4) Switch DC emergency oil pump subloop control
to Manual
(5) Switch DC emergency oil pump off
• Oil system depressurised
• Auxiliary and emergency oil pumps off
Auxiliary and
Emergency oil pumps
o Operational readiness o Shaft at stand still
before starting turning
o Oil system depressurised
gear operation
(testing not required if o Auxiliary and emergency oil pumps off
sobloop controls
have already been
successfully tested) (1) Switch auxiliary and emergency oil pumps in turn
to Manual on
Auxiliary and o Turning gear in operation
Emergency oil pumps
o One auxiliary oil pump operating
o Operational readiness
after starting turning (1) Switch stand-by auxiliary oil pump to Manual on
gear operational • Pressure buildup in system
(2) Switch stand-by auxiliary oil pump to Manual off
(3) Switch emergency oil pump to Manual on
• Pressure buildup in system
(4) Switch emergency oil pump to Manual off
5.3-0030-02/3
Auxiliary Oil pumps
o Speed-dependent o Turbine generator unit speed = rated speed
cutout when rated
(1) Verify cut out of auxiliary oil pump
speed is reached
Jacking oil pumps
o Speed-dependent on o Shaft at standstill
command of AC
o Jacking oil pumps off
jacking oil pump from
subloop control before o Subloop controls on Manual
starting turning
(1) Switch AC jacking oil pump subloop control to
gear operation
Auto
• AC jacking oil pump on
• Jacking oil pressure present
(2) Switch AC jacking oil pump subloop control to
Manual
(3) Switch AC jacking oil pump off
• AC jacking oil pump off
• Jacking oil system depressurised
Jacking oil pumps

o Manual on of AC o Shaft at stand still
jacking oil pump
(1) Switch AC jacking oil pump to Manual on
before starting turning
gear operation • AC jacking oil pump on
(2) Switch AC jacking oil pump to Manual off
• AC jacking oil pump off
• System depressurised
Jacking oil pumps
o Speed-dependent on o Shaft at stand still
command of DC
Jacking oil pump from
subloop control before o Subloop control on Manual
turning gear operation
(1) Switch DC jacking oil pump subloop control to
Auto
• DC jacking oil pump on
5.3-0030-02/4
(2) Switch DC jacking oil pump subloop control to
Manual
(3) Switch DC jacking oil pump off
• DC jacking oil pump off
• Jacking oil system depressurised
Jacking oil pumps
o Operational readiness o Shaft at stand still
of Jacking oil
pumps
(1) Switch jacking oil pumps in turn to Manual on
Control fluid pumps
o Pressure-dependent o Control fluid system depressurised
on command from
o Control fluid pumps off
subloop control
o Subloop control on Manual
(1) Select one control fluid pump (e.g. pump 1)
(2) Switch subloop control to Auto
• Control fluid pump 1 on
• Control fluid system pressure present
(3) Select control fluid pump 2
(4) Switch control fluid pump 1 off
• Control fluid pump 2 on
(5) Switch subloop control to Manual
(6) Switch control fluid pump 2 off
• Control fluid system depressurised
• Control fluid pumps off
Control fluid pumps
o Operational readiness o Control fluid system depressurised
(Testing not required
o Control fluid pumps off
if subloop controls
have already been o Subloop control on Manual
successfully tested)
(1) Switch control fluid pumps in turn to Manual on
5.3-0030-02/5
() Test Step Result
o Type of test
Remote trip initiation

o Push button operation o Main trip valve in operating position
o Stop valves closed
(1) Press trip push button
• Trip annunciated
Stop valves
o Leak test o Main steam pressure present upstream of stop
valves
o Stop valves closed using test valves
(1) Open control valves
• No speed increase
(2) Bring back test valves to operating position
Control valves
o Leak test o Control valves closed using motorised actuator
o Main steam pressure present upstream of turbine
(1) Open stop valves
• No abnormal speed increase
(2) Bring back motorised actuator to open position
Overspeed trip
o Oil injection test o Turbine speed < 2970rpm or
o Unit in low-load operation
(1) Release testing device for operation
(2) Press and hold down test valve for inhibiting trip
(left-hand valve)
(3) Turn handwheel of hydraulic test signal
transmitter to right until test oil circuit is
pressurised
(4) Observe oil pressures where overspeed trip
device operates
• Auxiliary trip circuit depressurised
5.3-0030-02/6
() Test Step Result
o Type of test
(5) Turn handwheel of hydraulic test signal

transmitter to left until test oil circuit is
depressurised
(6) Bring trip device of overspeed trip into operating
position using right-hand valve
• Auxiliary trip pressure built up
(7) Repeat test until overspeed trip operates at the
same test oil pressure in successive tests
5.3-0030-02/7
Steam Turbine Testing during Power Operation
Maintenance
Test that demonstrate the readiness for Test performance

operation and the proper functioning of Test performance must be recorded. If
important components, must be performed incorrect operation of the equipment tested
during power operation of the turbine occurs, take action establishing full
generator unit. The time intervals between operational reliability of the turbine generator
tests are given in a separate instruction [1]. unit immediately.
Pay attention to fault tracing instructions. [2]
Test Procedures
The table containing tests, prerequisites,
test activities and criteria is intended to
simplify testing. The tables can be used as
checklists. When no specific instructions are Also refer to the following sections:
prescribed for any test, the test sequences [1] 5.2-002.. : Testing of turbine components
shown in the table must be followed. [2] 5.2-0400 : Fault tracing

Turbine controllers
o Functional test o Control valve opening < 100%
(1) Change setpoint of effective controller
• Change in control valve-opening corresponding
to setpoint change
Bypass control
o Functional test o Load approx. 50%
(1) Open HP bypass station slowly by operating
pushbutton on control panel
• Reheat pressure increases
• Injection water pressure present
• Bypass stop valves open
• Bypass control valves begin to open
(2) Close HP bypass station
• Reheat pressure drops
• Bypass control valves close
• Bypass stop valves close
• Injection water pressure reduced

Seal steam controller
o Functional test o Seal steam controller on
(1) Seal steam controller off
(2) Induce control deviation by operating control
valves (Pushbutton on control panel)
(3) Seal steam controller on
(4) Verify correction of seal steam pressure
Oil temperature
controller
o Functional test o Oil temperature controller on
(1) Oil temperature controller off
(2) Induce control deviation by operating temperature
control valve (Pushbutton on control panel)
(3) Oil temperature controller on
(4) Verify correction of oil temperature
Auxiliary and
emergency oil pumps
o Operational readiness o Auxiliary and emergency oil pumps off
test
(1) Auxiliary pumps subloop control off
(2) Auxiliary oil pump 1 Manual on
• Pressure buildup downstream of pump
(3) Auxiliary oil pump 1 Manual off
(4) Auxiliary oil pump 2 Manual on
(5) Auxiliary oil pumps 2 Manual off
(6) Auxiliary oil pumps subloop control on
(7) Emergency oil pump Manual on
(8) Emergency oil pump Manual off
Control fluid pumps
o Operational readiness o Service control fluid pump on
test
(1) Stand-by control fluid pump Manual on
• Pressure buildup downstream of tested pump
(2) One control fluid Manual off
5.3-0035-02/2
Main trip valves
o Ease of movement o Automatic turbine tester available
test
(1) Select and start test program for one protective
device
• Main trip valves respond
• No fault annunciations on automatic turbine tester
Remote trip solenoids
o Functional test o Automatic turbine tester available
(1) Select and start Remote trip solenoids test
program
• Main trip solenoid respond
Overspeed trips
o Functional test and o Automatic turbine tester available
testing of setting
(1) Select and start Remote trip test program
• Overspeed trips respond
(2) If ATT annunciates fault repeat overspeed trip
test
Overspeed trips (1) Release hydraulic test signal transmitter
o Manual functional test (2) Depress left-hand piston of hydraulic test signal
and testing of setting transmitter to limit and hold down
(3) Increase test pressure using handwheel of
hydraulic test signal transmitter
o Overspeed trip(s) respond(s)
(4) Ascertain pressure at which trip(s) respond(s)
and record
(5) Reduce test pressure using handwheel of
hydraulic test signal transmitter
(6) Depress right-hand piston of hydraulic test signal
transmitter to limit
• Auxiliary trip pressure builds up
(7) Release right-hand piston of hydraulic test signal
transmitter
(8) Release left-hand piston of hydraulic test signal
transmitter
5.3-0035-02/3
(9) Repeat test as often necessary until trip operates

at the same test pressure as set during
commissioning
Hydraulic low-vacuum
trip
o Functional test and o Automatic turbine tester available
testing of setting
(1) Select and start Low-vacuum trip test program
• low vacuum trip operates
Differential pressure
switch in extraction
lines
o Functional test o Extraction system in operation
o Extraction swing check valve open
o Hydraulic release present
(1) Reduce differential pressure across differential
pressure switch
• Extraction swing check valve closes slightly
Stop and control valves
o Exercising o Automatic turbine tester available
(1) Apply test load
(2) Select and start test program for stop and control
valve unit to be tested
• Control valve closes
• Stop valve closes
• Stop valve opens
• Control valve opens
• No fault annunciation on automatic turbine tester
Extraction swing check
valves
o Exercising o Extraction system in operation
(1) Change load or extraction flow
• Extraction swing check units perform movements
5.3-0035-02/4
Alarms
o Functional test o Alarms generated
(1) Record alarms generated
Speed indicator (1) Compare with grid frequency
Important operating
values
o Recording (1) Record important operating values in accordance
with 5.3-0036 & 5.3-0037
Drains
o Leak test (1) Test temperature condition of drain values
5.3-0035-02/5
Steam Turbine Acquisition and Archiving
Maintenance of operating data
Procedural Instruction
Introduction Documents showing the availability

It is in the interest of both the plant operator statistics
and the supplier that the causes of faults,
severe damage and unfavourable inspection Documents from the electronic data
findings be determined, and actions taken to acquisition system
prevent a recurrence of such incidents.
Processing of analog measured values
In order to determine the cause of such
All the data specified in Table-1 should be
faults, it is essential that information be
archived in MAXSTORIAN of electronic data
available, in the form of operating
acquisition system. It should be possible to
documentation, on the operating history of
retrieve data in the form of logs or time
the turbine generator unit both in the past
curves at any time over the course of the
and immediately before and during the fault
intended archiving period. Long-term data
or damage.
archiving is to be done on magnetic tape /
This instruction contains recommendations disc.
on the acquisition and archiving of operating
Only those values for an operating
data.
parameter should be electronically archived
which, after the scanning interval has
Scope of measurement and elapsed, lie outside the scatter band given in
instrumentation Table-1, when compared to the last
The scope of measurements and also, recorded value.
therefore, the instrumentation of the turbine
generator unit are dictated by the Processing of binary signals
agreements between plant operators and
suppliers. Normally, binary signals resulting from
annunciations and switching operations are
The data are of importance for operations continuously printed out with high time
management. The scope of data resolution by the electronic data acquisition
recommended in Table-1 should therefore system, alarm and switching logs are thus
be available to permit post-event analysis. generated which form an important source
of information for operations management.
Scope of operating documentation For troubleshooting purposes, the alarm and
Operating documentation comprises the switching logs printed immediately before,
following documents: during and after the fault should be retained
and archived.
Printouts from continuous-line printer
Operating data logs or curves based on
Documents for long-term monitoring of
the data archived in the electronic data the turbine-generator unit
acquisition system
Certain operating data should be recorded
Alarm and switching logs ; such logs at long intervals in order to document the
document the histories of faults or long-term behaviour of the turbine generator
damage and should be archived unit, as well as any data relevant in terms of
Logs with handwritten entries are life expectancy considerations.
required in cases where certain data are The associated logs may be of use in
not recorded or archived analysing faults or damages if the cause can
Logs used to document the long-term be traced back to or is indicative of a
behavior of the turbine generator unit gradually developing adverse change.

Documents on availability statistics decide on countermeasures to be
For the purpose of providing information on implemented.
the operating behaviour and the status of
the plant, it is recommended that availability Retention period for documentation
statistics is compiled which show, among
The documents described above must be
other things, the causes and duration of
archived in a magnetic tape for consultation
periods of non-availability.
for a long time after the operating data have
If the statistics show a frequent recurrence been logged in order, among other things, to
of an event which leads to plant non- analyse any correlations between
availability, in-depth investigations should be component status and operating conditions.
performed.
Documents containing operating data
which are relevant in terms of life
Processing of operating documents expectancy considerations must be
archived until the turbine generator unit is
Fault report
taken out of service.
The control room personnel should prepare
It is recommended that all other
reports on fault or damage, showing all
documents be archived until the next
relevant data on the evolution of the event
inspection and overhaul has been
leading to the fault or damage, as well as
completed.
the countermeasures implemented. Copies
of the printouts from the continuous-line
recorder or dotted-line recorder, operating Importance of documents for settling
data tables and curves generated by the guarantee claims
electronic data acquisition system, and the Without the data contained in the documents
fault and damage logs should be appended described above, the supplier of the turbine
to the fault or damage reports. generator unit is not always able to check
the legal validity of guarantee claims in the
Evaluation of the fault report and the
event of damage or a complaint regarding
operating documentation
component defects and may therefore
Faults and damage usually occur when reserve the right to reject any claims for
several adverse influences are present which the requisite documents are not
simultaneously. Because of the multiplicity available.
of conceivable faults and their possible
influencing factors, it is not possible in this
procedural instruction to present a reliable
and complete picture of all the correlations Table-1 lists the required operating data for
involved. acquisition and archiving in accordance with
the operating instruction, in order to permit
It is the duty of the operator’s or supplier’s evaluation of turbine performance. The
own experts to define the correlation requirements will have to be adapted on the
between the event and the adverse basis of the actual measuring point list.
influencing factors and to evaluate them and
Also refer to the following:

[1] BHEL-EDN document on MAX control system
5.3-0037-03/2
Table – 1
Data acquisition recommended for post event analysis
ID Code Measuring point Measuring Scatter band Retention

cycle Period
Power/Speed
MKA CE Active Power 30 s 0.002 Pnom service life
MKA CE Reactive Power 30 s 0.002 Pnom service life
MYA FS Turbine generator speed 5s 0.05 to 0.1 s-1 inspection cycle
Steam pressure
LBA CP Upstream MS stop valves 30 s 0.01 Pnom service life
MAA CP Upstream HP blading 30 s 0.01 Pnom service life
LBC/MAA CP Downstream HP blading 30 s 1 bar inspection cycle
LBB CP Upstream reheat stop valves 30 s 0.01 Pnom service life
MAB CP Upstream IP blading 30 s 0.01 Pnom service life
LBQ CP HP extractions 30 s 0.005 to 0.01 Pnom inspection cycle
LBS CP LP extractions 30 s 0.02 Pnom inspection cycle
MAG CP Condenser 30 s 0.01 bar inspection cycle
Steam temperatures
LBA CT Upstream MS-stop valves 30 s 2K service life
LBC/MAA CT Downstream HP turbine 30 s 2K inspection cycle
LBB CT Upstream reheat stop valves 30 s 2K service life
MAB CT Downstream IP turbine 30 s 2K inspection cycle
LBO CT HP extractions 30 s 2K inspection cycle
LBS CT LP extractions 30 s 1K inspection cycle
MAW CT Seal steam header 30 s 1K inspection cycle
Casing temperatures
MAA CT MS-SV/CV 100/50% 30 s 2K service life
MAA/MAB CT Turbine casing 100/90/50% 30 s 2K service life
MAA/MAB CT Turbine casing top/bottom 30 s 2K inspection cycle
MAC CT Turbine casing front/rear 30 s 1K inspection cycle
Bearing temperatures
MAD CT Turbine radial/axial bearings 5s 1K inspection cycle
MKD CT Generator/exciter bearings 5s 1K inspection cycle
Vibrations
MAD/MKD CY Turbine / generator bearing 5s 1 µm inspection cycle
casing
MAD CY Turbine shaft abs. or relative 5s 5 µm inspection cycle
MKD CY Generator / exciter shaft 5s 5 µm inspection cycle
absolute or relative
5.3-0037-03/3
Steam Turbine Remedial Actions for
Maintenance off-normal operating conditions
Turbine
Off-Normal Condition Action Classification of action
Main steam pressure > Pmax Increase turbine load or reduce In-service correction
(Long-term) steam generator output
Main/reheat steam Reduce main / reheat steam In-service correction
temperature > θmax (long- temperature
term)
Main / reheat steam Raise main / reheat steam In-service correction
temperature < θdesign temperature
Steam pressure ahead of Reduce turbine load until pressure In-service correction
turbine blading > Pmax (long- ahead of turbine blading < Pmax
term) (long-term)
HP turbine exhaust steam Take ηi measurements In-service check

temperature or extraction
If internal efficiency ηi degraded Maintenance (saturated
temperatures > normal under
flush through with saturated steam steam washing) during
otherwise comparable
short shut-down
operating conditions Clean blading
Maintenance (cleaning)
during overhaul
Seal steam pressure Check control system; if In-service check and
deviates from setpoint or necessary correct setpoint correction
fluctuates adjuster
Repair during service or
If necessary repair control valves overhaul
Replace filters at seal steam Maintenance during short
control valves shut-down
Seal steam pressure > pnormal Measure temperature in leak-off In-service check
Seal steam leak-off valve steam lines of casings, valves etc.
100%
Check functioning of Gland Steam In-service check
condenser
Check shaft seal and repair Inspection and repair
if necessary during overhaul
Temperature differential , top Check temperature sensors In-service check
and bottom casing > normal
Establish cause of temperature Actions during service or
differential as per 5.2-0423 overhaul depending on
findings
Discrepancies at TSC
- TSC test function not Check TSC and/or temperature In-service check and
correct sensors; check and repair repair
TSC or temperature sensors
- High wall temperature
differentials during steady-
state operation

Spacer plates at casing Check for casing lift In-service check

supports not free to move
Clean spacer plates and other In-service check and
fixture elements; establish maintenance (cleaning)
freedom of movement only if casing does
not lift when fixture
elements are removed;
inspection and
maintenance (cleaning) or
repair during overhaul
Check forces exerted by piping, In-service check;
check adjustment of piping correction during shut-
hangers down
Bearing or shaft vibration Perform checks as prescribed in In-service check
> normal under otherwise 5.2-0420 provided vibrations
comparable operating < trip limits
conditions
Actions as appropriate to
finding e.g.
- Rebalance rotor system In-service check
- Check alignment, bearings, In service correction
shaft seals Check during overhaul
or after turbine shut-down
Bearing metal temperatures Perform examinations and checks In-service check

> normal under otherwise as prescribed in 5.2-0421
comparable operating
If temperature changes wide with Immediate inspection and
conditions
rapid rates of change, shut down repair during forced shut-
turbine and inspect bearing down
If temperature changes small and Inspection and repair
slow, inspect and repair at earliest during overhaul
opportunity
Drain valves leaking Open drain, blow through and In-service correction
close again
Loss of integrity of stem Tighten stem seals In-service maintenance
packing of drain valves
LP turbine outlet temperature Leak in internal expansion joint In-service check
> normal under otherwise suspected if high temperature
comparable operating localised
conditions (especially
Perform inspection and if Visual inspection and
condenser vacuum)
necessary repair repairs during overhaul
or after shut-down
5.3-0040-01/2
Oil system
Oil system pressures < pnormal Perform examinations and checks Check and remedial
as prescribed in 5.2-0460 and take actions may in many
appropriate action cases be performed
during operation;
otherwise shut down
plant and perform repairs
Lubricating oil pressure Change over filter and clean In-service maintenance
downstream of filter < Pnormal
Control fluid pressure Change over filter and clean or In-service maintenance
< Pnormal replace, or clean filter by rotating
filter plates
Oil temperature downstream Perform examinations and checks In-service checks and
of oil cooler > θnormal as prescribed in 5.2-0460 check maintenance
control system, if necessary
correct setpoint or repair
Check oil cooler vents;
check that no water is
being admitted to standby oil
cooler; check oil cooler for
chocking, where necessary
change over and clean
Oil level in oil tank < normal
- Slow change Top up with oil of same make and In-service check and
type maintenance
Locate leak and take appropriate In-service check and
- Rapid change
actions, e.g. initiate fire protection remedial action
measures
Oil level in tank strainer high Change and clean strainer Maintenance during
service or shut-down
Water collecting on oil tank Drain off water; separate water In-service maintenance
bottom from oil
Establish causes and eliminate Check and repair during
overhaul
Oil escaping at oil guard Check if oil vapour exhauster In-service check and
rings of bearing pedestals fan is in operation correction
Adjust throttle valves on bearing
pedestals
Check leak-tightness of oil tank
covers and if necessary reseal
Oil properties, e.g. air Perform additional oil In-service maintenance
separation capability and examinations; consult on
antifoaming, changed appropriate actions with oil
supplier and turbine manufacturer
5.3-0040-01/3
Control Fluid System
Control fluid level in control

fluid tank < normal
- Slow change Top up with control fluid of same In-service check and
make and type maintenance
- Rapid change Locate leak and take appropriate In-service check and
actions; e.g. initiate fire protect- remedial actions
ion measures
Control fluid level in tank Change and clean strainer Maintenance during
strainer high service or shut-down
Control fluid properties, e.g. Operate regeneration plant In-service maintenance
air separation capability or continuously; shorten sampling
neutralisation value, changed intervals; replace Fuller’s
earth in filter
Control fluid temperature Check control system, where In-service checks and
downstream of control fluid necessary adjust setpoint or maintenance
cooler > normal repair
Check control fluid vents
Check that no water is being
admitted to the standby cooler;
check control fluid coolers for
chocking, if necessary change
over and clean
Charge pressures of Recharge accumulators In-service maintenance
accumulators < Pnormal
5.3-0040-01/4
Control System, Protective Devices
Change in control system Check control system, if Correction during short

setting necessary reset or correct, shut-downs or overhauls
establish cause of discrepancy
- Control valve lift sequence
and eliminate
- Control valve
synchronisation
- Control valve travel
changed
as function of secondary
pressures
Primary oil pressure Examine antifoaming performance In-service check
fluctuates or < Pnormal of turbine oil
Check oil supply to hydraulic Check during short shut-
speed transducer downs or overhauls
Open main oil pump and check Check and repair during
hydraulic speed transducer overhauls
Control valve streams not
leak-tight
- Control valve opening Replace back seat Repair during overhaul or
100% short shut-downs
- Control valve opening < Replace steam packing rings
100%
Control valve leaking Replace valve stem; rework seat Repair during overhaul
(internal steam leak)
Load shedding relay Repair load shedding relay In-service repair
defective
Faults in valves detected by
automatic turbine tester
- Running time exceeded Adjust limit switch In-service repair
during testing of stop and
control valves
Extraction swing check valve Repair position indicators In-service repair
position indicators defective
5.3-0040-01/5
Pumps and Piping
Pump and motor bearing Inspect bearing, renew or In-service maintenance

temperatures > normal replenish grease or oil charge
Pump shaft seals not leak- Tighten and if necessary In-service maintenance
tight repack shaft seals
Performance degraded Switch in standby unit In-service correction
If necessary perform overhaul Repair during overhaul
Discharge head < normal Switch in standby unit In-service correction
under otherwise comparable
Perform system check, if In-service correction
operating conditions
necessary correct system
operation
Pipes vibrating Inspect dampers In-service maintenance
Check and repair piping hangers In-service repair
and supports
Piping and/or piping
connections leaky
- Large-scale escape of Immediately shut down turbine Repair during stoppage
flammable media (initiate fire protection
measures); eliminate leak
- Small-scale escape of Establish cause of leak and Repair during stoppages
flammable media eliminate or overhauls
Valve stem seals not leak- Tighten or replace stem seals In-service maintenance,
tight repair during stoppages
and overhauls
5.3-0040-01/6
Steam Turbine Measurement of
Maintenance internal Efficiency
Test Instructions
Introduction recommendations given in Table-1 or as

specified by the operator on the basis of
This test instruction describes the procedure
practical experience with the particular plant,
used for measuring the internal efficiency of
which also includes the trend of any
turbines whose expansion line lies within the
changes in efficiency.
superheated steam region.
Principle of measurement
Recommendation for measurement Prerequisites and limitations
The economic performance of any power The steam conditions in the reference plane
plant unit depends, among other factors, on at the inlet and exhaust of the turbine,
the overall efficiency of the steam turbine whose internal efficiency is to be measured,
and thus, on the internal efficiency of each must lie within the superheated steam
cylinder. region.
Changes in the internal condition of a The internal efficiency of turbines whose

turbine (e.g. due to buildup of deposits on expansion line lies totally or partially within
blades, increased seal clearances, or the wet steam region cannot be measured,
mechanical damage) cause a marked since there is no simple way of measuring
deterioration in internal efficiency. the actual steam content of a flow of wet
steam with sufficient accuracy. This means
Consequently, the internal efficiency of a that the method described here cannot be
turbine cylinder is an important parameter used for measuring the internal efficiency of
with which the effect of the changes in LP turbines, operating under wet steam
internal condition on its performance can be condition.
assessed.
Measuring the steam conditions at the
Measurement of the internal efficiency of turbine inlet and exhaust
each turbine at regular intervals and
The steam pressures and temperatures in
comparison with values recorded previously
the reference plane at the inlet and exhaust
or when the unit was new, are
of a turbine as indicated in Figure-1 are
recommended. This will provide useful
measured, recorded and calculated during
additional information for planning the type,
normal steady-state operation under
scope and timing of maintenance work (e.g.
comparable rated design conditions.
restoring original gaps and clearances,
Carrying out test at identical load and steam
blade repairs etc.).
parameters makes the comparison / trend
The intervals between measurements more realistic.
should be either in accordance with the
Table-1: Test intervals
Type of test Boundary conditions Test interval

Measuring Steady state operation under 6-months
the internal rated design conditions
before and after inspections and overhauls
efficiency comparable with those of
previous measurements. before and after wet steam washing

P1
h1 T1
∆h
S1
∆hs P2
h2
T2
hs
Figure-1 : Steam conditions and enthalpies for calculating the internal efficiency of a
turbine cylinder
Notations:
∆h h1 - h2
Internal Efficiency in % = -------- x 100 = ----------- x 100
∆hs h1 - hs
Where,
P1 : Pressure of inlet steam before group stage section

T1 : Temperature of inlet steam before group stage section
P 2 : Pressure of exit steam after group stage section
T2 : Temperature of exit steam after group stage section
h1 : Enthalpy of inlet steam corresponding to P1 & T1
S1 : Entropy of inlet steam corresponding to P1 & T 1
h2 : Enthalpy of exit steam corresponding to P2 & T2
hs : Adiabatic steam Enthalpy corresponding to P2 & S1
Note: Values of h1, S1, h2 and hs are to be worked out from steam table.
5.3-0050-02/2
Determining the enthalpy Install precision thermocouples or use the
The enthalpies for the steam conditions operational instruments for temperature
measured in the reference plane at the measurement
turbine inlet and outlet are taken from steam Adjust the inlet steam conditions and the
table. control valve lift to the same values used
Calculating the internal efficiency for previous measurements
The internal efficiency of a turbine cylinder is Wait until turbine temperatures have
calculated with the ratio of the actual stabilized under steady-state operating
decrease in enthalpy to the isentropic conditions
decrease in enthalpy.
Measure and record the steam pressures
Trend of change in internal efficiency and temperatures
Trend of changes in internal efficiency can Use steam tables to determine the
be seen when the measurements are plotted enthalpies of the steam condition at the
versus time in a graph. turbine inlet and outlet
Calculate the efficiency
Measuring points and instruments
Compare the measured internal
When taking measurements for calculating
efficiencies with the values recorded
the internal efficiency of a turbine, the
previously or when the unit was new, and
measuring points should be in the same
evaluate
reference plane at the turbine inlet and
outlet as for the acceptance tests.
Duration of testing
The turbine is also provided with test
measuring points for installing precision For reliable measurement, arithmetic
instruments to measure pressures and averages of pressure & temperature
temperatures. measurements should be taken for at least
half an hour duration at stable load condition
Appropriate instruments can be installed in and rated steam parameters.
addition to the operational instrumentation
and used for taking necessary
Reasons for actual conditions deviating
measurements.
from reference condition
If the measurements are to be taken by Changes in internal efficiency can be due to
means of operational instrumentation one or more of the following reasons:
installed in the reference planes, the
instruments must be tested and calibrated Increased roughness of the blade
regularly in order to eliminate any surfaces due to a build-up of deposits,
inaccuracies due to problems such as drift. corrosion, or solid particle erosion
Increase in clearances in the blading flow
Measuring procedure path
The procedure for measuring the steam Increased tip clearance losses due to
pressures and temperatures and calculating seal strip wear
the internal efficiency of a turbine is as
follows: Bypass flow due to internal leaks
Install precision pressure gauges or Increase of losses in valve seats

recalibrate the operational instrument Deposits on heat transfer surfaces
Vent the pressure-sensing lines
5.3-0050-02/3
Steam Turbine Testing during Shut-down
Maintenance
Introduction Test performance

Tests that demonstrate the proper Take care to avoid any risks to people or
functioning of important components, must machines while performing tests.
be performed during shut down of the
Any simulated condition necessary for the
turbine generator unit.
tests must be cancelled after completion of
The scope of the tests performed is listed in tests.
the Test interval instruction [1].
Steam inlet valves may only be opened for
test purposes if the piping system upstream
Test Procedures of those valves is not under pressure and
Test prerequisites, test activities and criteria the system concerned have been cleared for
in tabular form are intended to simplify testing.
testing. Test performance must be recorded.
The tables can also be used as checklists. If incorrect operation of the equipment being
When no specific instructions are given for tested occurs, take action establishing full
any test, the test sequences shown in the operational reliability of the turbine generator
table must be followed. unit immediately.
A number of tests require certain Pay attention to fault tracing instructions.
components be in a definite position (e.g.
main trip valves in operating position, stop
valves closed, etc.).
The operating sequence establishing certain
operating conditions is given in the form of Also refer to the following sections:
general instructions to avoid constant [1] 5.2-002.. : Testing of turbine components
repetition in the tables of test sequences. [2] 5.3-0061 : Testing during standstill

Main trip valves in operating
position
Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand
end position ( = stop valves open)
(1) Move test valve pilot into right-hand
end position ( = stop valves closed)
using hand wheel
(2) Bring starting and load limit device
into 0 % position
• Main trip valves in operating position
into 40 % position


and ready to trip
o Stop valves open o Starting and load limit device not in 0%

position
end position
into 0 % position
into 40 % position
and ready to trip
Overspeed trip
o Overspeed test after test interval o Generator not synchronised
or after inspections and repairs o Turbine generator unit at rated speed
(See also instruction 5.3-0030)
o Turbine at operating temperature
(1) Raise speed reference to maximum
• Speed approx. 107%
(2) Switch off Electro-hydraulic controller
(3) Run up to trip speed by pressing
mechanical push button on hydraulic
speed governor
(4) Verify operation of overspeed trip
• Trip speed
• Stop and control valves closed
Control valves and reverse power
protection relay
o Leak test valves o Generator synchronised
and o Load > 0 %
o Functional test (reverse power o Speed governor effective
relay)
(1) Lower speed set point
5.3-0060-01/2
• Secondary pressures < opening

pressure for control valves
• Control valves 0%
(2) Verify operation of reverse power
protection relay
• Reverse power protection relay
operated
• Generator breaker tripped
or
• Reverse power protection relay not
operating (see serious faults 5.2-0410)
Auxiliary oil pump

o Pressure dependent on o Stop and control valves closed
command
o Turbine speed dropping
(1) Verify startup of auxiliary oil pump on
pressure-dependent command
• Auxiliary oil pump on
Jacking oil pump

o Speed dependent on command o Stop and control valves closed
(1) Verify startup of jacking oil pump on
speed-dependent command
• Jacking oil pump on
Turning gear oil valve

o Speed-dependent open o Stop and control valves closed
command
(1) Verify opening of turning gear oil
valve on speed-dependent command
• Turning gear oil valve open
Condenser Safety devices

o Response of electrical o Turbine generator unit not operating
condenser safety device
o Condenser plant operating
5.3-0060-01/3
o Criteria for shut down of condenser

plant fulfilled
o Main trip valves in operating position
(1) Reduce condenser vacuum
(2) Verify operation of electrical condenser
safety device
• Trip initiated
(3) Restore main trip valves to normal
operating position
o Response of hydraulic low o Condenser safety device test

vacuum trip (electrical) performed
o Condenser vacuum > trip vacuum
(hydraulic)
(1) Simulated turbine speed by screwing
in locking bolt on low-vacuum trip
(3) Verify operation of electrical condenser
safety device
• Trip initiated
(4) Restore main trip valves to normal
Operating position
(5) Cancel hydraulic speed simulation
(Unscrew locking bolt on low-vacuum
trip)
(6) Move test valve into operating position
Condenser Safety devices for

bypass operation
o Response of hydraulic low o Condensate extraction pumps
vacuum trip operating
o Condenser pressure Pabs < 0.5 bar
o Criteria for shut down of condenser
plant fulfilled
5.3-0060-01/4
o Bypass operation ended

(1) Press push-button of LP bypass
governor
• Signal pressure for bypass control
valves > 1.7 bar < 2.06 bar
• Bypass stop valves
(2) Operate push-button of LP Bypass limit
controller to inhibit response due to
reduction of condenser vacuum
(4) Verify operation of low vacuum trip
• Signal pressure upstream of bypass
control valves reduced
5.3-0060-01/5
Steam Turbine Testing during Standstill
Maintenance
Introduction
Tests that demonstrate the proper Test performance
functioning of important components, must Take care to avoid any risks to people or
be performed during stand still of the turbine machines while performing tests.
generator unit.
Any simulated conditions necessary for the
The time intervals between tests are given in tests must be cancelled after completion of
a separate instruction [1]. tests.
Steam inlet valves may only be opened for
Test Procedures test purposes if the piping systems upstream
Test prerequisites, test activities and criteria of those valves are not under pressure and
in tabular form are intended to simplify the system concerned have been cleared for
testing. testing.
The tables are also suited to use as Test performance must be recorded.
checklists. Wherever no specific instructions If incorrect operation of the equipment being
are prescribed for a test, the test sequences tested occurs, take action establishing full
shown in the table are to be followed. operational reliability of the turbine generator
A number of tests require certain unit immediately. Pay attention to fault
components be in a definite position (e.g. tracing instructions.
main trip valves in operating position, stop
valves closed, etc.)
The operating sequence establishing certain
operating conditions is given in the form of Also refer to the following sections:
general instructions to avoid constant [1] 3-001x : Testing of turbine components
repetition in the tables of test sequences.

Main trip valves in operating
position
o Stop valves closed o Starting and load limit device not in 0%
position
o Test valves of stop valves in left-hand end
position ( = stop valves open)
(1) Move test valve pilot into right-hand end
position ( = stop valves closed) using hand
wheel
position
position

• Main trip valves in operating position and

ready to trip
o Stop valves open o Starting and load limit device not in 0%

position
end position
position
position
• Main trip valves in operating position and
ready to trip
Turbine control
o Testing of setting o Main trip valves in operating position
Hydraulic amplifier
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of travel of starting
and load limit device (use starting and load
limit device to change auxiliary secondary
oil pressure by 0.1 – 0.2 bar per reading).
• Travel of starting and load limit device
• Travel of governor bellows
• Auxiliary secondary pressure
• Travel of converter (mm or %)
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer
5.3-0061-02/2
o Testing of setting o Main trip valves in operating position

Electro hydraulic converter
o Control medium temperature approx. 50 ºC
(1) Read and record setting data of control
system as a function of input voltage of
turbine valve controller
• Input voltage of turbine valve controller
• Travel of converter
• Secondary pressures
• Travel of control valves
(2) Prepare curves from readings and compare
with curves of last adjustment by
manufacturer
(3) If comparison reveals major changes, have
them inspected and corrected by
manufacturer
Load rejection relay
o Functional test o Main trip valves in operating position
o Control valves open
(1) Use contactor to energize solenoid valves
operated by load rejection relay
• Control valves close for as long as solenoid
valve is energized
Bypass control
o Testing of setting o As per vendor’s recommendation
Main trip valves

o Ease of movement and trip o Main trip valves in operating position
pressure
(1) Reduce control medium pressure of
governor linkage by closing cutoff valve
• Main trip valves close
(2) Measure pressure where main trip valves
close
5.3-0061-02/3
Remote trip solenoids
o Functional test o Main trip valves in operating position
o Test valves of stop valves in closed
position
(1) Press pushbutton to start remote turbine
trip
• Trip initiated
Low vacuum trip
o Functional test and testing of o Condenser vacuum > response level
setting
or
o Test pump operating and simulated
condenser vacuum > response level
(1) Reduce condenser vacuum or increase
pump pressure
• Low vacuum trip responds
(2) Determine vacuum where trip started
Fire protection system
o Functional test o Shaft at standstill
o Normal operating conditions of oil system
established (exception : jacking oil pump
subloop control off)
(1) Operate fire protection switches 1 and 2 in
succession in the control room and at the
local control stations in the power plant
• Start of fire protection measures in
accordance with functional diagram
• No annunciation “Fire protection measures
not performed”
(2) Acknowledge fire protection measures and
re-establish normal operating conditions for
further testing
5.3-0061-02/4
Low lub oil pressure trip
o Functional test o Oil system operating
(1) Simulate pressure Transmitters (2 out of 3)
for lubricating oil trip
• Trip started
Stop valve
o Exercising o Oil system operating
o Stop valves open
(1) Actuate main trip valves (manual trip-out
from control system rack or remote trip
o Cut-off pressure o Oil system operating

o Stop valves to be tested open
(1) Reduce trip oil pressure by means of cut-off
valve upstream of control system cabinet
• Stop valve closes
(2) Measure and record trip oil pressure where
valve starts to close
Turbine control valves

o Exercising o Main trip valves in operating position
o No limitation by parallel acting controllers
(1) Open and close control valves by starting
and load limit device
Bypass Stop & Control valves
o Exercising o Bypass interlock criteria not present
or
o Release criteria simulated
(1) Open and close bypass stop and control
valves
5.3-0061-02/5
Vacuum breakers
o Functional test (1) Operate vacuum breakers
Alarms
o Functional test 4-1190
Binary signal transmitters

o Functional testing of o Remove pressure switches
pressure switches
(1) Test pressure switches with test pump
General measuring
instrumentation
o Functional and annunciation (1) Test and calibrate in accordance with
test manufacturer’s instructions
5.3-0061-02/6
Steam Turbine Testing of Safety Valves
Maintenance
Introduction The set values must be entered in the

commissioning protocol.
The set pressure of the safety valves of
turbine integral system (e.g. oil or other Bypass valves, which open in the event of
control media) are checked during excessive pressure upstream of turbine
commissioning. components may form part of the over
pressure steam removal system and must
The scope of instruction in the turbine
be likewise set and tested.
manual is, apart from certain exceptions,
strictly limited to the scope of supply of the
turbine factory. Safety valves of the steam
Testing of Safety Valves
and water systems are not normally a part of
the turbine factory’s scope of supply. Thus Regular testing of the safety valves is the
the following instructions may only be responsibility of the turbine generator unit
regarded as recommendations. operator. The testing intervals must comply
with the technical requirements and the
If the pressure in a system increases
recommendations of the valve and turbine
impermissibly from the operating pressure, it
generator unit manufacturer [2] and must be
is the function of the safety valve to reduce
observed.
this pressure to the normal value thus
protecting the system concerned from
damage. Therefore, the turbine
Performance of Testing
manufacturer must approve the valve
settings to be used [1]. Shut-down can be avoided if the testing is
carried out during operation of the turbine.
From the point of view of the turbine
Setting of the Safety Valves manufacturer, however, they can only be
performed if the turbine generator unit is not
The set values recommended by the turbine
endangered.
manufacturer are contained in the Technical
Data [1] of the turbine manual and must be Operation of the turbine with elevated
observed. reheater pressure may lead to impermissible
temperatures or the control and thrust
Setting and testing must be carried out in
characteristics of the turbine being
accordance with the technical requirements
disturbed.
and the instructions of the valve
manufacturer. Furthermore, faults in the safety valves may
cause impermissible load changes or
When the initial setting is performed during
instability of the steam generator. In this
commissioning of the turbine generator unit,
case, it is best to carry out testing when the
a representative of the turbine manufacturer
turbine is not operating.
is to witness the test or be informed of the
set values.
Also refer to the following sections:

[1] 5.1-0100 : Technical data
[2] 5.2-002... : Testing of turbine
components
BHEL Haridwar 5.3-0062-01

Steam Turbine Testing of Signaling Devices
Maintenance
Introduction Example: A water level can be raised to its

Signaling devices in their various forms are signaling limit by closing the appropriate
important aids to operational supervision. drain valve.
However, they are of value only if they are Care must be exercised with this method to
completely reliable in operation. ensure that the maximum point reached is
Therefore, the signaling devices must be not sufficient to cause an unintentional shut-
tested at regular intervals. down.
These instructions deal with the Testing during operation by varying the
fundamentals of testing and maintenance of operating condition. When shutting down
signaling devices. and starting up the turbine and its
auxiliaries. and when testing control and
protection equipment, all alarms and
Types of signaling devices condition signals must be carefully
observed and a record made of their
Alarm signaling devices give a visual and
response. It is also important to check
audible indication of operating values
that the signaling actually reflects the
reaching predetermined limits. If this results operating condition accurately.
in automatic intervention in the plant
process. e.g. triggering of the turbine trip, Examples: When shutting down the turbine
then this is also signaled. the “low oil pressure” alarm must come
before the auxiliary oil pump starts
Condition signaling indicates the state of automatically. When testing the overspeed
control devices, e.g. whether a stop valve is trips, the “Overspeed trip operated” alarm
open or closed. must come.
Finally, signaling can provide a reminder
Triggering of the sensor. In this method
that certain action needs to be taken.
the sensor is operated without there
being any change in operating value or
condition.
Basis of signaling device testing
Whenever possible, testing of the signaling Examples: The travel-controlled limit switch
devices should be carried out under a close which signals response of the thrust bearing
approximation to operating conditions. The trip is operated by hand. The pressure
test should also enclose all components of switch for the “condenser vacuum low”
the device. alarm is isolated and then vented to
atmosphere.
In addition to functional testing, the device
settings should also be checked at longer The response limit value is adjusted so
intervals, especially after inspections. that signaling response occurs. (With this
method it is possible for mistakes to be
made when returning the settings to their
Test procedures original values. Therefore the method
should only be used in exceptional
There are various ways to test the cases.)
functioning of signaling devices.
Signaling response is produced by an
Testing during operation by varying the electrical pulse. If, for some reason, none
operating values. This type of testing is of the previous methods can be used, a
most appropriate when operating values partial test of the signaling device must
can be varied by intervention in the plant be performed by means of an electrical
process. pulse.

Examples: If the level in the oil tank does condition displays, ensure that the correct
not normally fall to its minimum value during colour lamp is used.
operation, the level monitor is disconnected
and the alarm initiated by the application of
an electrical pulse. This method of testing Malfunctions
presupposes that the level sensor itself is Any malfunctioning of signaling devices
not suffering any malfunction. must be rectified Immediately upon
discovery.
Other tests If necessary, the monitored operating values
The lamps of visual signaling devices have or sensor settings must be subjected to
only a limited life. Therefore, they must be critical examination. This is particularly true
tested regularly by means of the lamp test when there is a continuous alarm although
facility to ensure that they are operative and there is no dangerous operating condition in
be replaced if they are blown. When the plant.
replacing coloured lamps in operating
5.3-0063-00/2
Steam Turbine Testing of
Maintenance Turbine Stress Controller (TSC)
Introduction measured value acquisition and evaluation

functions.
This test instruction describes the plausibility
checks to be carried out on the measured All steam and component temperatures as
values acquired by the temperature sensors well as the calculated margins are either
for turbine stress monitoring, as well as the recorded on dotted-line printers or stored by
recording of measured and calculated the computer.
values for long-term evaluation of
The plausibility of the measured data can be
temperature acquisition and of calculation
checked at a later date using the printed or
circuitry.
stored measured and calculated values. It is
Using the stress monitoring function of the however possible that, by that time, faulty
turbine stress controller (TSC), the non- turbine stress monitoring will result in
steady-state thermal stresses to which the selection of either too fast an operating
steam turbine is exposed during startup and mode, which will have an adverse effect in
shut-down and as a result of changes in terms of the degree of component fatigue, or
heat input to components during power of too slow an operating mode, which will
operation are acquired and compared with have an adverse effect in terms of
the permitted limits. economical operation.
The margins obtained from this comparison For this reason, plausibility checks should
define the stress and set the limits for be carried out on the measured values at
permitted temperature load. the intervals specified in Table-1, in order to
detect and correct any functional defects or
Evaluation of measured temperatures
faulty circuits within the temperature
recording and action of the calculated
acquisition equipment.
margins on the setpoint control for the
turbine controller allow an optimum As part of the long-term monitoring of
operating mode as regards both degree of operating parameters, all measured and
component fatigue and economical calculated TS values should be registered
operation. during steady-state operation under the
same boundary conditions. These values
should then be recorded and archived to
Test recommendations allow comparison at a later date.
A pre-requisite for the proper functioning of Measurement should be performed at the
turbine stress monitoring as described in the intervals specified in Table-1.
introduction is fault-free operation of the
Table-1 : Test Intervals
Type of check or measurement Boundary conditions Test interval

Plausibility checks on Non-steady-state and After inspections and overhauls or
measured values steady-state operation after work on the TS sensor
Recording of measured and Steady-state operation 3 months or after work on the TS
calculated values for long-term sensor or TS monitoring
monitoring purposes equipment

Plausibility checks on measured values The steam temperatures upstream of
the turbine must be higher than the
When performing plausibility checks on the component temperatures.
measured TS values, the steam and
component temperatures must be compared The differences that exist between the
with each other, taking certain criteria into main steam temperature and the
consideration. During non-steady-state temperature at the heated surface in
operation, it is also important to evaluate the the main steam valve bodies or the
trend of the measured values over time. steam admission area are only very
slight
If the actual values do not conform to (< 5 K).
expected values, this may be due to
incorrect assignment of measuring points or During steady-state operation,
to a polarity fault, e.g. at the transducers. temperature differences of
approximately 15 K maximum develop
As regards the criteria to be considered, a between the measuring points on the
distinction must be made between heated surfaces and at the mid-wall of
plausibility checks performed during non- valve bodies or the steam admission
steady-state and steady-state steam turbine area.
operation.
The closer the turbine operating mode
comes to the conditions for purely
Criteria for plausibility checks during constant-pressure operation, the
non-steady-state operation stronger will be the Influence of turbine
output on the differences between main
The temperature at the heated surface of a steam temperatures and the
component must respond faster than that at temperatures at the heated surfaces of
the mid-wall of the component. the turbine casing and the shaft.
The temperature at the heated surface The temperatures at the heated
of a component is higher during warm- surfaces of the casing and the shaft
up and lower during cooling-down, as cannot be higher than those at the
compared to the temperature at the heated surface of the valve body or the
mid-wall of the component. steam admission area.
During linear changes, the temperature For the shafts, the differences between
difference ∆θ (in K) arising in the the temperatures at the heated
component is directly proportional to surfaces and the mean integral shaft
the rate of change dθ/dt (in K/min) temperatures are always approximately
0.
During a cold start or startup after an
extended shut-down, the HP turbine For the barrel-type casing of the HP
warms up rapidly, even while still turbine, differences of upto
operating below rated speed. In the approximately 10 K between
case of the IP turbine however, warm- temperatures at the heated surfaces
up of the shaft takes place to a certain and those at the mid-wall are normal
extent as a sudden step change and during steady state operation.
occurs only just before rated speed is
reached, and then to a greater extent For the IP turbine, the surface
temperature of the IP turbine shaft is
during subsequent loading.
not measured directly but only at the
heated surface of the inner casing.
Depending on the design-related
Criteria for plausibility checks during
location of the measuring point,
steady-state operation
differences of 10 to 40 K between the
The same absolute temperatures and reheat steam temperature and the
temperature margins must exist for the surface temperatures of the shaft can
same steady-state operating conditions. occur during steady-state operation.
5.3-0064-01/2
Long-term monitoring through recording the turbine stress monitoring equipment.
of all measured and calculated values These must be adapted to plant-specific
requirements.
By registering and recording all measured
and calculated values at the intervals
specified in Table-1 during steady-state Actions to be taken when actual
turbine operation, the thermal behavior of conditions deviate from reference
the turbine and the function of the turbine conditions
stress monitoring equipment can be
monitored on a long-term basis. If actual conditions deviate from reference
conditions, the measured value acquisition
Long-term monitoring can be used to detect function must be carefully checked and any
and rectify any gradually developing faults corrected.
changes.
If the deviations in measured and calculated
If the check on the measured values reveals values are particularly large, it must be
that the margins have changed due to the assumed that the behavior of the turbine
measured absolute temperatures and the plant will be adversely affected. In this case,
differences arising between them, this can action of the TS monitoring equipment on
probably be traced to a fault in the the setpoint control for the turbine controller
calculation circuitry. The cause of the fault must be temporarily deactivated.
must be determined, e.g. by checking the
specified limit curves in accordance with the As long as action of the TS monitoring
procedure described in the manual for the equipment on the set point control for the
TS monitoring equipment. turbine controller is deactivated, the TS limit
curves must be used for evaluation of the
Table-2 contains all measured and thermal stresses imposed on the turbine
calculated values which may be required for components.
5.3-0064-01/3
Table-2 : Measured and calculated values for long-term monitoring
Measured and calculated values Terms Unit

Effective power and reactive power
effective power peff MW
reactive power preact MVA
Main steam upstream of HP turbine
mass flow mms kg/s
pressure pms bar
temperature θms ºC
Exhaust steam downstream of HP turbine
pressure pHPexh bar
temperature θHPexh ºC
HP expansion section
differential temperature θms - θexh ∆θ K
Reheat steam upstream of IP turbine
pressure pRS bar
temperature θRS °C
Exhaust steam downstream of IP turbine
pressure pIPexh bar
temperature θIPexh °C
Wall temperatures, MS admission area
surface θi-adm °C
mid metal θm-adm °C
Wall temperatures, HP casing
surface θi-HPC °C
mid metal θm-HPC °C
Temperatures, HP shaft
surface θi-HPS °C
simulated, shaft center θm-HPS °C
Temperatures, IP shaft
surface θi-IPS °C
simulated, shaft center θm-IPS °C
Upper TS margins
steam admission area ∆ ∆ θ adm-u K
HP casing ∆ ∆ θHPC-u K
HP shaft ∆ ∆ θHPS-u K
IP shaft ∆ ∆ θIPS-u K
Lower TS margins
Steam admission area ∆ ∆ θadm-l K
HP casing ∆ ∆ θHPC-l K
HP shaft ∆ ∆ θHPS-l K
IP shaft ∆ ∆ θIPS-l K
5.3-0064-01/4
Steam Turbine Steam Washing of Turbine
Maintenance
Introduction own time of the turbine. Special measures

should be taken to accelerate cooling [3].
During operation, deposits occur on the
turbine blading to a greater or lesser degree For maximum success, steam washing
depending on the steam purity [1] and the should not be started until the casing
pressures and temperatures of the operating temperatures have dropped to < 100°C.
steam. These deposits cause a reduction of
When Steam Washing the turbine stages,
the turbine generator unit’s efficiency due to:
the initial saturated steam temperatures
Changes in the flow profiles must be as low as possible. Steam Washing
with a constant steam condition is not very
Thicker boundary layers in the steam
effective. After a certain time the turbine
flow as a result of rough surfaces.
blading reaches the temperature of the
In extreme cases the flow area of turbine washing steam and the condensation that
may get reduced with consequent reduction brings about the effect is lost. To get
in the maximum possible steam flow through maximum success in the shortest possible
the turbine, and corresponding output. time, it is necessary to increase the steam
temperature in stages by increasing the
Choking of blade flow path can be detected pressure. As the temperature is raised the
on the basis of internal efficiency (ηi) turbine speed will generally increase (take
measurements [2]. care to avoid critical speed ranges).
If deposit leads to an increase in stage Increased speed will also promote cleaning.
pressures, the maximum stage pressures The steam entering the condenser must be
shown in the Technical Data should not be condensed during the entire process i.e. one
exceeded. If necessary, the output must be circulating water pump must be in operation.
reduced. If possible, the turbine generator unit should
Complex, i.e. water-insoluble, silicate be started up and loaded after steam
deposits occur in a temperature range washing. Any dissolved salt residue
between 500°C and 350°C. Alkali silicates remaining on the blading will be blown out
and silicic acid are deposited between due to the high velocity of the steam under
350°C and 60°C. Salt deposits occur at load conditions.
temperatures ranging from 480°C to the Steam washing with saturated steam will
blading stages where condensation begins. only have the desired success if the steam
Salt deposits are water-soluble and can be has adequate moisture content upstream of
removed by steam washing with saturated the blading.
steam. Depending on their composition,
silicate deposits are either water-soluble The saturated steam is introduced into the
(e.g. alkali silicates) or occur as a hard HP turbine via the connection flanges
Water-insoluble coating. In latter case the provided between the stop and control
deposits can only be removed mechanically valves.
during overhauls. The steam is introduced into the IP turbine
between the control valves and the turbine.
General Instructions Appropriate blind flanges are provided.
The effort required for saturated steam The steam line must be blown-out before
washing is considerably lesser than that saturated steam washing commences.
required for opening the turbine. If efficiency
reduction occurs, saturated steam washing It may be ensured that no external
should be performed first. In that case, the condensate can enter the condenser during
major part of the turbine generator unit steam washing.
downtime is accounted for by the cooling

Fig. 1 : Flow diagram for saturated steam washing
Steam Washing of IP Turbine After the saturated steam line (Fig.1, item 2)
has been joined up at the connection points
All stop and control valves and all valves in
(3), the washing steam can be routed into
the extraction lines remain closed during
the IP turbine, from there via the cross-
steam washing of the IP turbine. Any
around lines to the IP turbine and then to the
isolating valves present upstream of the
condenser.
feedwater heaters must also be closed.
There are two possible ways of discharging
The drains from the IP turbine between the
the condensate condensing in the
reheat control valves and the IP outlet, the
condenser to the atmosphere. These are:
extraction valves or the swing check valves
in the extraction lines must be vented during By opening the blind flanges (4) on the
steam washing only to the extent required to condenser. The condenser must be
allow the condensate arising to drain off under atmospheric pressure. With this
whilst preventing excessive loss of steam. method of steam washing samples for
All other drains from the turbine generator finding out the saIt content may also be
must be full open. taken at this point.
5.3-0070-02/2
With the vacuum pump \ ejector Steam Washing of HP Turbine
switched on and the blind flange (4) The main control valves must be open
closed, i.e. with the condenser at sub during steam washing of the HP turbine.
atmospheric pressure, via the
All drains (7, 8) from the HP turbine situated
condensate discharge line of an
between the main stop valves and the HP
operation condensate pump. In this
outlet may be vented during steam washing
case, make sure that the condensate is
only to the extent required to allow the
discharged to the atmosphere
condensate arising to drain off while
downstream of the pump. Samples for
preventing excessive loss of steam.
finding out the salt content are also
taken at this point. All other drains particularly those in the cold
reheat line, must be fully open. Local
The first method of steam washing with the
drainage may also be provided so that no
condenser under atmospheric pressure
steam can enter the Reheater of the Boiler,
guarantees a slight overpressure at the
if at all possible.
drains so that it is possible to perform
additional sampling at these points. For this After the steam line (6) has been joined up
purpose, the appropriate drains may be cut at the connection points (3), the stream can
off at the sludge traps, or the steam inserts be routed into the HP turbine. The steam
of the drain valves may be removed. leaving the HP turbine is exhausted to the
condenser via the drains (9).
It is suggested to record the salt content at
the sampling point continuously throughout The condensate is discharged and samples
the washing Process. Also, water samples are taken to determine the salt content as
should be taken every half an hour for described in steam washing of IP turbine,
deposit analysis. the completion criteria remaining same.
Steam washing may be stopped when the
purity of steam entering the turbine (as Restoring the Turbine to Operating
determined by sampling) is approximately Condition
the same as that of the condensate or steam On completion of steam washing, all
extracted at the discharge sampling point. temporary fittings must be dismantled and
The steam washing may be stopped when the flanges closed off. Any drain lines cut off
the salt content in condensate remains must be rewelded. Controllers and control
constant at a very low level. valves must be returned to normal position.
The temporary lines are to be preserved for
future use.

[1] 5.1-0120 : Steam purity
[2] 5.3-0050 : Measurement of internal
efficiency
[3] 5.2-0350 : Fast cooling down of the
turbine
5.3-0070-02/3
Steam Turbine Turbine Oil Care
Maintenance Maintenance Instructions
Introduction The Turbine Oil Specification [1] contains

Function of the turbine oil is to lubricate and standards and selection criteria for turbine
cool the bearings of the turbine generator oil as well as the requirements in terms of
and to actuate governing system physical and chemical properties.
components. Turbine oil is subjected to high The following oil properties are particularly
physical loads, should have a long service important for turbine oil care:
life and must not have any adverse effect on
the proper functioning of the bearings and Total-acid number
other turbine oil consumers Water contents and water separability
The physical and chemical properties of new efficiency
turbine oil must comply with the Solid contaminant quantities, purity
requirements of the Turbine Oil Specification
[1]. The aim of turbine oil care is to maintain Air release properties
the properties and the useful service life of Foaming characteristics
the turbine oil for as long as possible.
Turbine oil properties and the values which
This general maintenance instruction can change those properties are discussed
discusses the necessity for, and the briefly below.
procedures involved in turbine oil care.
Further information can be found in the
The program for the care of turbine oil standards cited in the Turbine Oil
includes regular inspection and analysis of Specification [1] as well as technical
turbine oil samples. In this way changes in literature, including those issued by turbine
turbine oil properties can be determined and oil manufacturers.
the necessary actions can be taken to
remedy the situation. Actions to be taken to rectify typical changes
in turbine oil properties are listed in Table-1.
The filters and strainers in the operating oil
systems retain solid contaminants which can
cause damage and/or impair functioning if Total-acid number of the turbine oil
they ingress into turbine oil consumers. The total-acid number is an easily
By centrifuge (i.e. oil conditioning station) determined reference value for turbine oil
which is independent of the oil operating aging.
systems, contaminants and aging and Catalysts and thermal loading of the turbine
corrosion products which are not soluble in oil can trigger an oxidation process in which
oil are removed from the turbine oil. oleic acids are formed, raising the total-acid
Thorough cleaning of the oil system during number of the turbine oil. The oil ages.
initial startup and after inspections and The oleic acids attack oil system component
overhauls is one of the prerequisites for materials and corrosion products are formed
successful turbine oil care. In addition, the which can, in turn, catalytically accelerate
ingress of contaminants into the oil system the oxidation process.
must be prevented.
Under certain circumstances, contaminants
which ingress into the oil system from
Turbine oil properties outside can promote the oxidation process.
As a rule, turbine oils are paraffin-based
New turbine oil contains additives which,
mineral oils which contain additives to
provided that oil is properly cared for, give
improve their resistance to corrosion and
sufficient protection against agin
their oxidation stability.

The additives become depleted over time. High water contents of the turbine oil can
Under unfavorable conditions, e.g. where also be the result of low water separability of
there is improper or negligent oil care, this the turbine oil. In this case, it is particularly
depletion process can result in premature important that the ingress of water in to the
aging of the turbine oil. oil system be prevented.
In this case, the turbine manufacturer and Solid-contaminant quantities and purity
the turbine oil supplier should be consulted of turbine oil
in order that measures for restoring the Whereas the material property value for
turbine oil can be implemented. solid-contaminant quantity defines the
overall content by weight of solid-
The turbine oil cannot be used if the function
contaminant quantities in a turbine oil
of sensitive turbine generator components is
sample, when defining turbine oil purity only
impaired through corrosion and/or aging
the proportion of solid-contaminants of a
products and if the aging process, i.e., the
specified size is determined. Turbine oil
change in the total-acid number, cannot be
purity is the more reliable criterion.
reversed by treating the turbine oil.
Solid-contaminants can ingress into the
From this highly simplified description of the
turbine oil from outside, or as a result of the
turbine oil aging process, it can be seen that
aging process or corrosion. They contribute,
aging is affected not only by physical loading
along with other factors, to the turbine-oil
of the turbine oil but also by catalysts and
aging process and impair the condition and
aging products, e.g., oleic acids. Treatment
function of the turbine components.
of the turbine oil in the oil conditioning
station removes products of aging and Among the principal areas which can be
corrosion which are not soluble in oil, affected are turbine and generator bearings.
thereby slowing down the aging process. Their load capacity can be reduced due to
scoring caused by solid-contaminants in the
turbine oil. In addition, changes of state and
Water content and water separability of
impaired functioning in control and
the turbine oil
protection equipment can be expected.
With healthy gland sealing & oil vapor
extraction system during normal operation The oil system is thoroughly cleaned during
the moisture content in turbine oil is not initial startup of the turbine generator set.
expected to be more then 100 ppm as in the Flushing of the entire system is included in
turbine oil specification (1). In case the the cleaning process.
moisture content found more then 300 ppm The filters and strainers of the operating oil
during sample testing, the reason is to be systems are used to retain contaminants
investigated. With moisture content value with a particle size larger than the filter mesh
more then 1000 ppm machine should be size, before the turbine oil reaches the oil
tripped and source of water entry is to be consumers. The dwell time of the oil in the
eliminated. filters and strainers will depend on the purity
Water which ingresses into the oil system of the turbine oil.
from an oil cooler, in the form of shaft seal Purity in accordance with the Turbine Oil
steam or leakage water, results in the Specification [1] is achieved through
corrosion in ferrous materials and can continuous filtration or separation of turbine
adversely affect the aging process and oil in the oil centrifuge.
foaming characteristics of the turbine oil.
During inspections and overhauls the turbine
Corrosion causes changes in the surfaces must be drained and the main oil tank, the
and shape of the sensitive turbine generator oil coolers and the bearing pedestals must
components. The corrosion products behave be thoroughly cleaned. It is recommended
in the same as solid contaminants, and lead that the turbine oil be either filtered or
to impaired component functioning. treated in a separator during drainage an
The cause of any increase in turbine-oil refilling.
water contents must be determined and The ingress of solid contaminants into the
remedied. turbine oil must be prevented.
5.3-0080-03/2
Air release properties of the turbine oil with the foam, resulting in a drop in the oil
level in the main oil tank. This change in the
The air release property represents the time
level can cause activation of the level
taken for a specific volume of air to be
monitoring equipment for the main oil tank.
released from the turbine oil sample under
the boundary conditions stipulated in the Increased turbine oil foaming tendency
testing standard of the Turbine Oil occasionally occurs due to high water
Specification [1]. content or increased dust contamination of
the turbine oil.
The turbine oil circulates inside the oil
system and becomes aerated. This air is Silicone-based foam inhibiting additives
-1
released during the dwell time tv = 60n (in have an adverse effect on air release
min) of the turbine oil in the main oil tank, n properties. There is no generally binding
corresponds to the number of passes per evidence regarding any further correlation
hour made by the turbine oil. between foaming tendency and air release
properties, although such a correlation may
If the time required for air release by the exist in individual cases and should be
turbine oil is longer than the dwell time in the investigated.
main oil tank, an oil-and-air mixture will
develop, which will not have as favourable a
density and compressibility as non aerated
Turbine oil care program
turbine oil. This can lead to faults in the
operating oil pumps, fluctuations in oil Owing to correlation between the turbine oil
pressure and impaired functioning of any properties and the factors influencing turbine
control and protection equipment which is oil during operation, the following care
supplied with turbine oil. program for turbine oil must be implemented
during and after initial startup of the turbine
Only in rare cases it is possible to improve
generator set:
the Air release properties of turbine oil with
economically viable treatment methods. For Regular inspection of turbine oil samples
this reason, any factors which might lead to
Continuous treatment of the turbine oil
deterioration of the air release properties of
the turbine oil, must be avoided. Protection of the turbine oil system from
the effects of contaminants
It has been proven that the air release
properties of turbine oil are adversely Drainage of the turbine oil and cleaning
affected by materials containing silicone, of the oil system and the turbine oil
e.g., seal materials or foam inhibiting during inspections and overhauls.
additives.
Inspection of turbine oil samples

Foaming characteristics of the turbine oil
By regularly sampling and inspecting turbine
The material property values for foaming
oil and by evaluating the results, it is
tendency and foam stability of turbine oil
possible to adapt oil care measures
should comply with Turbine Oil Specification
optimally to the particular properties of the
[1].
turbine oil being used.
A certain amount of foaming on the surface
Turbine oil samples are taken
of the oil in the main oil tank can be
simultaneously upstream and downstream
expected as a result of air release. If the
of the oil centrifuge and the inspection
turbine oil shows an increased foaming
results thus permit an evaluation of the
tendency and high foam stability, the space
efficiency of the relevant oil care measures.
above the oil level in the main oil tank
becomes partially or completely filled with The scope and the intervals for turbine oil
foam which can, under certain inspections are listed in the turbine oil
circumstances, result in foam being released maintenance instruction.
from the oil system. Turbine oil is entrained
5.3-0080-03/3
If the turbine oil inspections reveal that or wear to parts such as oil pump seal
alarm levels for certain properties have been ring, etc.
reached or exceeded, it is advisable to
request inspection and evaluation of the Treatment of the turbine oil in the oil
turbine oil by the turbine oil supplier. All data centrifuge
relevant to turbine oil inspection should be
The oil centrifuge can be continuously
sent in together with the turbine oil sample
operated independent of the operating oil
When taking turbine oil samples, care must systems. A small volume of turbine oil is fed
be taken to ensure that sampling bottles are through oil centrifuge with a high separation
clean. efficiency. This achieves a high degree of
purity for the treated turbine oil.
In case of deviation in properties, actions to
be taken as per table 1. As regards the treatment of turbine oil in the
centrifuge, oil filter, dynamic or static
separators, and multipurpose oil purification
Treatment of the turbine oil in the oil
units can be used either independently or in
filters or strainers of the operating oil
combination. In addition, many power plants
systems
have centralised oil purification equipment,
Switchable oil filters either permanently installed or mobile.
The switchable oil filters of the operating The function of the most commonly used oil
oil systems are used to protect purification equipment is described below:
downstream consumers. Contaminants
which, because of their size or
consistency, can cause damage and/or Fine-mesh filter
impair functioning are retained in the oil The turbine oil can be conditioned in an
filters. Because of their relatively large oil filter with filter elements made of fine-
mesh size, the operating oil filters are pored cloth or filter paper. Since the fine-
not suitable for complete removal of mesh filter has a high separation
contaminants from the turbine oil. The efficiency, a high degree of turbine oil
differential pressure across the oil filters purity can be achieved. Contaminants
is monitored. insoluble in oil which ingress into the oil
system from outside, as well as products
If the differential pressure across an oil
of system-internal aging and corrosion
filter increases, this filter should be
mechanisms are almost completely
isolated from the system and cleaned.
removed from turbine oil.
Fine-mesh filters with cloth or paper
Oil Strainers of the main oil tank
elements can also retain small amounts
The oil strainers of the main oil tank of water. If the turbine oil has a high
have a relatively large mesh size and water content, a dynamic or static
are used to retain contaminants in the separator must be used to reduce the
returning turbine oil and to protect the oil water content in the turbine oil to the
pumps from contaminant damage. value stipulated in the Turbine Oil
If the strainer mesh becomes clogged Specification [1].
during the course of operation, this can
lead to a drop in the level in the suction Dynamic separator
space of the main oil tank as a result of
The dynamic separator uses centrifugal
an increase in the level in the riser
force to remove either solid or liquid
space.
contaminants as required from the
For this reason, the oil strainers of the turbine oil. The dynamic separator must
main oil tank must be regularly cleaned, be set to operate in either solid
if possible while the oil pumps are shut contaminant or water separation mode
down. Metal particles in the oil strainers in accordance with the manufacturer’s
can be an indication of bearing damage instructions.
5.3-0080-03/4
Static separator different additive packages. For this
reason, when topping up, turbine oil
A static separator is used to remove
which has the same product designation
water from the turbine oil. Since the
and which is supplied by the same
efficiency of the filter elements
manufacturer as was originally filled,
deteriorates due to deposits of solid
should be used.
contaminants, and in view of the
expense of filter elements, it is
recommended that the static separator Hydraulic oil
be used in conjunction with an upstream Hydraulic oil or control fluid containing
fine mesh filter. phosphoric esters, if in use, must not be
allowed to ingress into the oil system.
Multipurpose oil purification unit
The multipurpose oil purification unit is Main oil tank
used to remove solid and liquid Openings in the main oil tank must
contaminants from the turbine oil. always be closed and sealed in such a
Operation and maintenance instructions of way that there can be no ingress of
the oil purification unit manufacturer must be contaminants into the main oil tank. The
complied with. cover plates of the main oil tank must be
tightly bolted. There must be no bolts
The maintenance interval for oil filters missing from the plates.
depends on the differential pressure across
the oil filters. For this reason, the differential
pressure instrumentation must be regularly Oil coolers
checked and corresponding annunciations If the water content of the turbine oil
noted. increases, the leak tightness of the
operating oil cooler must be checked.
Cleaning of the oil system during
inspections and overhauls Oil return lines
Over the course of time, solid contaminants Inspection holes in oil return lines must
settle in areas of the oil system not be sealed to prevent the ingress of
subjected to high flow velocities, e.g. the contaminants into the oil system.
main oil tank. For this reason, the turbine oil
must be drained via filters during inspections
Oil vapor extraction system
and overhauls, and the main oil tank, the oil
coolers and the bearing pedestals must be The throttle check valves in the oil vapor
thoroughly cleaned. The drained turbine oil extraction system must be set so that
must either be refilled into the main oil tank the pressure in the bearing pedestals
via fine-mesh filters or treated in a and the main oil tank is slightly sub
centralised oil purification unit before atmospheric. This ensures that no
refilling. leakage steam, or airborne water and/or
dust is drawn into the oil system in the
event of turbine oil or oil vapor being
Measures to protect the oil system from released to the atmosphere.
contaminant ingress
Just as important as turbine oil care are
Dirty fluid
measures designed to protect the oil system
from contaminant ingress: Fluid from the dirty-fluid tank must not
be refilled into the main oil tank without
thorough inspection and treatment.
Turbine oil Small amounts of turbine oil which
Problems can arise as a result of the accumulate in the dirty-fluid tank are to
incompatibility of turbine oils from be disposed properly.
different manufacturers and containing
5.3-0080-03/5
Material
The compatibility of materials with the
turbine oil has been taken into account
by the turbine manufacturer during
materials selection. During inspections
and overhauls, care must be taken to
ensure that no incompatible materials
are used. This applies particularly to
gaskets and silicone-based seal
materials.
Leakage steam system

The butterfly valves of the leakage
steam system must be set to prevent
leakage steam from escaping via the
turbine shaft seals since this could result
in water ingress into the oil system.
Disposal of Turbine Oil

For disposal Turbine oil may be send
back to oil company (OEM) for its
recycle.

[1] 2-0400 : Oil Specification
5.3-0080-03/6
Table1 : Actions to be taken when actual conditions deviate from reference conditions
Fault Cause Actions

Boundary conditions
The Turbine oil properties
do not comply with the
Turbine Oil Specification
Total-acid number Turbine oil aging Inspect turbine oil samples for:
> mg KOH/g
- Solid contaminant content
- Purity
- Water content
- Air release properties
- Foaming
- Other physical and chemical
properties
Send further oil samples to
turbine oil supplier for inspection
and evaluation. Check operating
performance and condition of
components supplied with
turbine oil, in order to determine
the effect of the change in total-
acid number. Check oil
purification system and intensify
turbine oil maintenance in
accordance with the
recommendations of the turbine
oil supplier and the turbine
manufacturer:
- Keep oil centrifuge in
continuous operation
- Adjust operation of oil
centrifuge to contaminant
content of turbine oil (solid
contaminants or water)
- If necessary install additional
oil purification equipment
- Take turbine oil samples
upstream and downstream
of oil centrifuge and check
separation efficiency (solid
contaminants and/or water)
5.3-0080-03/7
Fault Cause Actions
Boundary conditions
- Reduce intervals for turbine
oil inspections and monitor
evaluation of total-acid
number
Investigate the origin of
contaminants and prevent
contaminant ingress into oil
system.
The solid contaminant The oil centrifuge is not in Put oil centrifuge into operation.
content or the purity of the operation
turbine oil does not comply
The contaminant separation Take turbine oil samples
with the Specification
efficiency of the oil centrifuge upstream and downstream of
does not comply with the the oil centrifuge and determine
requirements the separation efficiency.
Implement measures in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements, replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.
Solid contaminants ingress Check whether and at what

into the oil system point it is possible for air borne
contaminants to ingress into the
oil system.
Check atmospheric pressure in
the main oil tank, the bearing
pedestals and the oil return lines
and, if necessary, correct using
the check valves in the oil vapor
extraction lines.
If necessary, close or reseal the
maintenance covers of the main
oil tank.
High air borne dust content in Reduce airborne dust content in

area around turbine generator area around turbine generator
set set
5.3-0080-03/8
Fault Cause Actions
Boundary conditions
The water content of the There is no permanently Install a dynamic or static
turbine oil does not comply installed dynamic or static separator for removing water
with the specification separator for removing water form the turbine oil. Take turbine
from the turbine oil oil samples upstream and
downstream of the separator
and check water separation
efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
The permanently installed Put dynamic separator of the

dynamic separator of the oil centrifuge into the operation.
conditioning system is not in
Note that the required
operation
separation temperature must be
complied with in accordance
with the operating instructions of
the separator manufacturer, and
that the separator must be
protected from the effects of
solid contaminants.
Take turbine oil samples
upstream and downstream of
the separator and check water
separation efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
Water is ingressing into the oil Check whether leakage steam is

system ingressing into the oil system.
If necessary, prevent the escape
of leakage steam from the
steam seals by the correcting
the seal steam pressure or by
adjusting the butterfly valves in
the seal steam lines.
Check the leak tightness of the
operating oil cooler.
5.3-0080-03/9
Fault Cause Actions
Boundary conditions
The air release properties In many cases, there is no Check whether the deterioration
of the oil do not comply specific cause for a in air release properties has an
with the Specification deterioration in air release adverse affect on the operating
properties performance of the systems of
components supplied with
turbine oil.
Involve oil supplier and turbine
manufacturer in inspection
program. If effects are
particularly unfavorable,
consider replacing the turbine
oil.
As a precautionary measure,
care should always be taken to
prevent the ingress into the
turbine oil of materials which
could adversely affect the air
release properties (e.g. silicone-
based materials)
Turbine oil foaming The foam inhibiting additives in Consult oil supplier and top up
characteristics do not the turbine oil have been turbine oil with foam inhibiting
comply with the depleted over time additives.
Specification
As a rule, foam inhibiting
additives have an adverse effect
on the air release properties and
for this reason, the air release
properties must be closely
monitored when topping up with
such additives.
The turbine oil contains Determine the water content of

materials which adversely the turbine oil and, if necessary,
affect the foaming take appropriate measures to
characteristics reduce this. In certain
circumstances it may be
advisable to skim off the foam
from the surface of the turbine
oil.
5.3-0080-03/10
Fault Cause Actions
Boundary conditions
The oil centrifuge is
defective or the operating
conditions for the oil do not
comply with the
requirements
Oil filters
The differential pressure Isolate duplex oil filter and clean
across one oil filter is high filter cartridge
Take oil centrifuge filters out of
operation and replace filter
elements
One oil filter is not sufficiently Open valve in oil filter venting
vented line and adjust
Unit-specific or additional The mode of operation of the Adapt the mode of operation of
dynamic separator dynamic separator does not the separator (solid-contaminant
correspond to the content of separation or water separation)
solid or liquid contaminants in according to the content of solid
the turbine oil contaminants or water in the
turbine oil
Unit-specific or additional The efficiency of the static Replace filter elements.

static separator separator is reduced due to
Implement measures to prevent
clogged filter elements
filter element clogging. e.g.
install an upstream fine-mesh
filter.
Turbine oil temperature If necessary, put heating system

upstream of static separator of oil centrifuge into operation
too low
Oil circulating pump (if The oil circulating pump of the If necessary, put oil circulating
installed) oil centrifuge is not in pump into operation
operation
5.3-0080-03/11
Steam Turbine Grease and Oil Lubrication
Maintenance
Introduction from the manufacturer’s specification in the

maintenance instructions, it must be clarified
To ensure satisfactory functioning and to beforehand whether this will be universally
limit wear, a small number of components suitable.
on the turbine must be lubricated at regular
intervals.
Application of Lubricants
Scope Before re-lubricating components which are

exposed to the collection of dirt {e.g. shut-off
The following are the individual components, valve stems) they must first be carefully
which require regular lubrication. cleaned.
Control device in accordance with the Over-greasing or overfilling must be
lubrication Chart [1] avoided.
Actuators for remote-controlled Grease guns, which cause no damage to
governing, control and similar devices greasing nipples, etc. should only be used.
Spindles of hand-operated shut-off
devices Lubrication Intervals
Pumps and similar machines The lubrication intervals are stated by the
Drive motors manufacturers in the maintenance
instructions. It is essential for them to be
maintained, especially in the case of motors,
Lubricants pumps and similar equipment.
Only the lubricants stated by the respective It is advisable to prepare lists of items
manufacturers in the maintenance requiring lubrication, noting when the
instructions may be used. various items are to be re-lubricated. This
If for reasons of stocking or for simplifying will ensure that lubrication is carried out at
regular maintenance, it is desired to use the regular, prescribed intervals.
only one particular type of lubricant deviating

[1] 5.1- 0690 : Lubrication Chart

Steam Turbine Care of Control Fluid
Maintenance
Introduction control fluid for flushing or service. Check for

dust and dirt by first wiping with white filter
The use of fire resistant control fluid for
paper. All traces of detergent must be
turbine control and protection systems
removed.
reduces the risk of fire. This is due to the
higher ignition temperature (compared to Although the control fluid manufacturer must
mineral oil) in case of leaks. ensure that there are no solid or liquid
impurities in the control fluid supplied for the
Phosphoric esters with a low water and
initial filling, the tank must be filled through
chlorine content (HS-D series) are used and
the Fuller’s earth and fine-mesh filter
must be carefully maintained to preserve
equipment.
their properties.
Baseline reference samples for later
This instruction contains the following:
comparison must be taken before filling with
Guidelines for handling control fluid and control fluid for flushing the system and after
for treatment of control fluid systems. regeneration of the fluid used for flushing.
Data on the compatibility of the control
fluid with other materials. Refilling with Control Fluid
Procedures to preserve the control fluid The system must be refilled from lead-
properties. sealed barrels; precautions must be taken to
prevent filling with a control fluid that is not
Data on sampling points in the cycle. identical to the one specified for use or with
Sampling and analysis programs. mineral oil from similar casks.
Maintenance procedures to be followed Changing Control Fluid

if the property characteristics of the fluid
reach the permissible limits. The entire system must be drained when
changing the fluid. New filter elements must
be installed or those present thoroughly
Guidelines for Handling Control fluid and cleaned.
for the Treatment of Control Fluid System
If unavoidable, old control fluid residue (up
Initial filling of system to 3%) may be tolerated.
The control fluid system must be cleaned The system must be refilled and samples
after assembly. The same control fluid may taken for comparison with the initial filling.
be used as service filling as well as for The amount of residue of control fluid within
flushing the system. However, when the the system and the neutralisation number
control fluid has been regenerated by the must be checked by analysing and
manufacturer, especially after filtering comparing the samples taken before filling
through 5 µm fine mesh filters, the property and after the system has been put into
characteristics of the control fluid must operation. If this shows an increase in the
comply with the requirements of the neutralisation number, it must be reduced by
specification [1]. passing the control fluid through the bypass
regenerating system.
All moisture must be carefully eliminated
from the system (e.g. by drying and/or
evacuation) otherwise the control fluid forms Treatment of waste control fluid
acid components when in contact with Biological decomposition of control fluid is
water. The control fluid tank must be difficult; control fluid is heavier than water
thoroughly cleaned before it is filled with and affects it adversely and therefore must

not be passed into the sewage system. The Only the following may be used for cleaning:
competent Regional Water Authority is Nonfelting textile and paper clothes,
responsible for determining the maximum benzene, white spirit and hydrochloric acid
concentration limit in ppm for sewage water. based cleaning agents approved for general
use.
All containers for storing new or used control
Caution: Observe all safety regulations
fluid must be clearly and permanently
when using cleaning agents to clean the
marked. A record of the quantity of used
tank’s interior.
control fluid and of fluid lost due to
maintenance, leakage and damage must be
kept. Precautions to Ensure Compatibility of
the Control Fluid with other Materials
For disposal, control fluid may be send back
to oil company (OEM) for its recycle. All components of the control fluid system
are selected by the turbine manufacturer in
regards to their material to ensure they are
When control fluid is burned, carbon dioxide compatible with control fluid and that no
(CO2) and phosphorus pentaoxide (P4O10) interactions are to be anticipated between
are produced, the latter in such small the control fluid and materials used.
quantities, making it harmless. To avoid confusion, all spare parts and
Disposal must be done by companies materials used in the control fluid system
authorised and licensed by legislation for the must be stored separate from other
collection, storage and disposal of waste materials and clearly marked.
materials. Caution: Not all components that are
Control fluid leaks must be absorbed by compatible with control fluid are also
using sawdust or oil binding granules and compatible with oil.
removed immediately. Where possible, components and materials
Control fluid has the same effect on for use in the control fluid system should be
concrete as mineral oil. Floors or obtained from the turbine manufacturer. This
foundations made of asphalt are not will make sure compatibility with control fluid
compatible with control fluid. by prescribing specifications to be used by
subcontractors and by using suitable
materials. If parts must be obtained from
Preservative Agents in Control Fluid
other sources, the chapter referring to the
System
compatibility of the control fluid must be
Spare parts are maintained in serviceable observed.
condition by using anti-corrosion agents Whenever an order is placed with the-
and/or suitable packing (enclosing in plastic turbine manufacturer or with third parties for
foil and use of desiccants); storage in dry parts or materials, it must be expressly
area is recommended. stated that these will be used for the control
When removing anti-corrosion agents, or fluid system.
cleaning spare parts, take care to ensure the
parts are dry and, above all, that all traces of Health care measures
solvents containing chlorine have been
No special safeguards are required to
removed. Then apply an intermediate
protect against toxic properties of the control
protective coating immediately to protect the
fluid. Follow manufacturers instructions
freshly cleaned surface against corrosive
and/or other legal provisions. Here are some
attacks by the control fluid used. recommendations:
Note: Chlorine presence in the control fluid All containers for control fluid must be
causes erosion-corrosion at the control
kept tightly sealed and permanently
edges of the control components.
marked with the Health Hazard danger
sign.
5.3-0082-02/2
Do not eat, smoke or drink when working copper does not apply since the surface
with control fluid or parts in contact with area exposed to control fluid is small.
control fluid. Only austenitic steel may be used for filter
Keep control fluid away from foodstuffs. meshes; brass is unsuitable.
Keep control fluid away from skin, eyes

and clothes. Materials for pumps and electric motors
If control fluid gets into eyes, sponge Bearing and shaft seals and the nonmetallic
carefully and rinse with water. Obtain parts of couplings on pumps and their drive
medical attention if irritation persists. motors most be compatible with control fluid.
Since aerosols of the fluid may reach the
After handing control fluid, wash hands motors windings through the motor
immediately. ventilation system, the windings must be
Wear protective clothes, gloves and designed to be compatible with control fluid.
goggles.
Change any article of clothing that comes Materials for tools
into contact with control fluid. If skin Nonmetallic parts of tools (handles) must be
contact occurs, flush areas with water. made of material compatible with control
Obtain medical attention if irritation fluid or covered with suitable surface
persists. protection (See plastics). Remember this
when ordering new tools.
If control fluid is swallowed, give large
amounts of warm salty water to cause Plastics
vomiting; if unsuccessful tickle inside the
patients throat with a finger. Obtain Plastic materials are susceptible to swelling,
medical attention if stomach discomfort shrinking and surface deterioration.
persists. Plastic incompatible with control fluid may
Avoid inhaling spray clouds (aerosols) or impair the control fluid properties. Following
decomposition products (e.g. use clothes plastics are compatible with control fluid:
to protect respiratory tract). Fluorcarbon elastomers FKM Viton
Wear gas mask if thick clouds of control Butyl rubber IIR Butyl IIR-40
fluid are present. Polytetrafluorethylene PTFE Teflon
Polyethylene PE Hostalene
Polyamide PA Nylon
Compatibility with other materials
Following Plastics are incompatible with
Control fluid’s foaming, air release capability control fluid: PVC plastic, Polycarbonate-
and its resistance to aging are impaired by Makrolon, normal plexiglass.
contact with materials incompatible with
control fluid. Also materials, which are Only glass or Plexidur T may be used for
incompatible with control fluid, can be sight glasses. Protective caps on switches,
attacked. plungers and valves must be of metal or
plastic material compatible with control fluid.
Metallic materials
Sealing material, hose, cable insulation
Phosphoric esters have a negligible effect
and accumulator bladders
on steel, copper alloys, zinc, tin and
aluminum alloys provided the neutralisation Following sealing materials are compatible
number is within the admissible limits. The with phosphoric esters:
solid outer oxide layer of aluminum alloys For o-rings, packing rings, collars and
must not be destroyed due to friction. diaphragms: viton, teflon, butyl rubber
Pure copper cannot be used due to its and composite material such as cotton-
catalytic effect on the decomposition of the viton, teflon-white asbestos, viton
phosphoric ester. Sealing material made of asbestos.
5.3-0082-02/3
For flat gaskets: viton, teflon, butyl - Stability
rubber and compressed asbestos. Acid and aging products may cause a loss
For hoses and cable insulation: viton, of stability; the speed of aging increase in
teflon and nylon coatings. the manner of a chain reaction, drastically
reducing the service life of the control fluid
For accumulator bladders: butyl IIR-40 (resulting from chemical reactions of the
(up to 80 ºC), viton control fluid with water, air and other
Liquid sealing materials: Hylomar impurities).
SQ32L, Loctite 270, ciba-geigy CY246.
+ Removal of acids and aging products
Caution: Butyl rubber IIR is not compatible The presence of acids and aging products
with oil. Silicon rubber must not be used raises the neutralisation number; the
since it severely impairs the properties of the permissible limit is 0.5 mg KOH/g.
control fluid (reduces its air release
capability). Acid and aging product must be eliminated
from the control fluid by continuous bypass
filtration through a Fuller’s earth filter.
Paints
Only two-component, desmodur / Regeneration through a Fuller’s earth filter is
desmophene (DD) base and epoxy resin based on an ion exchange reaction.
base lacquers may be used. When painting The Fuller’s earth used must be dry (1 % by
the inner surface of containers, make sure weight expellable water at 105 ºC). We
the coating is applied properly. If the paint recommended drying the Fuller’s earth
flakes off, it may cause considerable before filling. The design of the Fuller’s earth
damage. and filter regenerating equipment conforms
to the control fluid manufacturer’s
Caution: Paints compatible with control fluid requirements.
(epoxy resin and desmodur /desmophene
base) give off toxic vapour when exposed to Design and functioning of the filters are
heat. (e.g. during welding or grinding). explained in the Description Section. The
Repair procedures must specify the flow diagram of the regenerating plant is
presence of such paints. Signs on parts, also given in the relevant chapter.
containers with these paints must not be The grain size of the fuller’s earth should be
removed. US screen number 16/30 to 30/60 mesh.
The dust portion must not be used.
Control Fluid properties
When filling the filter, ram down and/or
Requirements shake the earth into the filter elements to
Requirements for control fluid are listed in prevent formation of gaps or channels that
the specifications for control fluid (1). would reduce the efficiency of the Fuller’s
earth.
Special care must be taken during
commissioning and operation to preserve Unnoticed exhaustion of the Fuller’s earth is
control fluid properties. prevented by changing the earth filling at
six- month periods, unless this interval does
Keeping a daily service log is not have to be reduced for other reasons.
recommended; all values from analysis and
details of important events (filter changes Since the control edges of electrohydraulic
and exchange of filter mass, refilling) must servo valves are subjected to erosion-
be entered. All changes and their cause corrosion if the control fluid is not suitably
should be readily detectable on the basis of treated, regular regeneration of the Fuller’s
these records. earth is always necessary, even if there is
no increase in neutralisation number.
Preservation of Properties
5.3-0082-02/4
Regeneration should be started about 48 element being cut out as soon as the limit is
hours before commissioning of the servo reached.
valves. Temperatures above 75°C are admissible
The control element of control circuits for a short period only during flushing
actuated by servo valves must be filled with procedures.
new control fluid through the regeneration
equipment even when the fluid supplied by
the manufacturer has the specified Note: If the temperature rises from 60°C to
neutralisation number. This applied both for 70°C, the speed of oxidation doubles.
initial and refills.
A fine-mesh mechanical filter (polishing + Prevention of influence due to foreign
filter) downstream of the Fuller’s earth filter matter
traps Fuller’s earth particles and other
foreign matter that would act as a catalyst in Measures must be taken to stop the entry of
the control fluid. The fine-mesh filter has the solid or liquid foreign matter or other
added function of establishing the required impurities with a view to maintaining the
purity of the control fluid in the overall stability of the system. All possible
system. measures must be taken to protect the
system from rust.
The fine-mesh filter must be cleaned in the
same way as other fitters in the system. The system is vented and deaerated via a
When changing the filter elements, do not defined opening to stop degeneration of the
remove the protective covers from the new control fluid due to moisture and
elements until just before they are installed. contamination. The opening is sealed by
absorbers or filters to prevent the entry of
Strainers must be cleaned using the moisture and contamination when venting
cleaning agents recommended by the filter and to ensure adequate deaeration.
and control fluid manufacturer; make sure
that dirt does not get onto the clean side. Silica gel absorbers are used to indicate the
buildup of absorbed moisture by changing
Immerse filters in the cleansing fluid only up colour. Evaporating moisture is necessary in
to their upper edge. Filters must always be the absorbers during deaeration. Refill Silica
blown-out from the clean side towards the gel if a permanent change in colour is
dirty side. Use only dry air for blowing-out noticed.
(relative humidity 60% at 20 ºC).
A large absorber or filter is used when the
Confirm absence of oil and dust by using system is vented or deaerated via exhaust
filter paper test. fans to ensure that the control fluid is
Use a magnifying glass to check the separated from the air downstream of the
completeness of the cleansing process. fan.
When deaerating using fans, the system
+ Prevention of thermal influences must not be under a substantial vacuum.
If deaerating valves are used that open
The control system requires a service
when a slight internal over pressure has built
medium viscosity that complies with the
specification at a control fluid service up, make sure the moist air is unable to
temperature of 55±5 ºC. enter into the system.
Accumulated water is annunciated by using
No adverse effects on the stability of the
electrodes. The cause of water
control fluid due to thermal influences are to
accumulation must be located immediately
be expected at this service temperature.
and corrected. Water accumulating on the
A maximum temperature of 90°C is surface of the control fluid tank due to its low
admissible locally, for example, at heating density, must be removed by siphoning or
element / protective pipes with heat pumped off. Condensate occurring in small
conducting oil fillings. Compliance with this amounts evaporates at service temperature.
limit temperature is monitored the heating Increase monitoring the neutralisation
5.3-0082-02/5
number if and after the accumulation of the About 3-4 % mineral oil will dissolve in,
water is detected. control fluid between room temperature and
50°C. If oil enters the control fluid circuit, the
control fluid manufacturer must examine the
- Fire resistance effect this has on the fluid’s fire resistance
Following are the causes of impairing the properties. It is impossible to separate oil
fire resistance properties of the control fluid: from the control fluid since the mixture is a
Mixing of mineral oil by mistake; this can genuine solution. Only when the oil content
be prevented if filling guidelines are exceeds 3-4% does a two-phase liquid
followed. result.
Penetration of mineral oil from the
lubricating oil circuit. - Air release capability
Design measures have been taken to The air release capability of the fluid
prevent oil and control fluid from intermixing. depends on the presence of foreign matter.
Contact points between the lubrication oil The chapters on the subject of stability and
control systems are separated by interface prevention of the influences of foreign matter
made of metal bellows between which there must be observed to ensure the air release
is a drain line to the leakage tanks; the tank capability complies with the requirements.
has a device to annunciate the accumulation
of control fluid due to leaks.
- Purity
The bellows are arranged if one ruptures,
the second takes over its shielding function. SAE guidelines (Table-1) govern the purity
Penetration of one media into the other is requirements for media used in hydraulic
only possible if both dividing elements have systems.
leak.
Magnitude Particles / 100 ml

0 1 2 3 4 5 6
5 – 10 µm 2700 4600 9700 24000 32000 87000 128000
10 – 25 µm 670 1340 2680 5360 10700 21400 42000
25 – 50 µm 93 210 380 780 2510 3130 6500
50 – 100 µm 16 28 56 110 225 430 1000
> 100 µm 1 3 5 11 21 41 92
Table-1: SAE permissible degrees of contamination for hydraulic systems
SAE Class classification applicable for Samples must be taken at sampling points
maintaining the service reliability for from the flowing liquid into clean laboratory
protection and control systems are as bottles. Take care to avoid any secondary
follows: contamination. The sampling bottles must
be permanently marked with these data:
Class-6: Protection and Control systems
facility, sampling point, fluid manufacturer
without servo valves
and type, date, sampler.
Class-3: Protection and Control systems
They must then be sent to a laboratory
with servo valves
(turbine manufacturer, control fluid supplier
or operator) for examination.
Sampling and analysis It is possible to filter the samples at the site
by using the field monitoring method so only
Samples must be taken and examined to be
the diaphragm filter has to be sent for
able to ensure the control fluid meets the
analysis to a laboratory outside the power
purity requirements.
plant.
5.3-0082-02/6
Performing routine analysis of the same fluid mesh filter, before it enters control system
filling involves relating the degree of colour sections susceptible to contamination, and
change of the test filter (relative measuring at the same time to check the function of the
method) to the quantitative degree of fine-mesh filters.
contamination as determined by counting
the contamination particles. Sampling point - Return (PNR)
The precondition for application of the field The PNR is provided in the return line.
monitoring method using diaphragm filters or Analysis of the samples from this point
of the relative measuring method is the makes it possible to determine the degree of
availability of reliable sampling and analysis purity of the fluid in the overall system
equipment at the plant site. without the direct influence of the service
filters.
Sampling and analysis programme
The sampling and analysis program Sampling point - Fluid Tank (PNB)
according to Table-2 makes it possible to The PNB is provided at the tank.
perform the essential assessment of the
control fluid properties and purity at all Sampling points downstream of the
stages of commissioning and during circulation pump (PNU), downstream of
continuous service. Fuller’s earth filter (PNFB) and downstream
of the fine-mesh mechanical filter (PNMF)
Besides, it allows assessing the flushing are provided.
procedures and the condition, efficiency and
regeneration of the filter equipment. Samples from the sampling points (PNU,
PNBF and PNMF are used to determine the
When required, it is possible to compare the efficiency of the regeneration and filtration
results of the routine analysis with the processes.
analysis of the baseline reference samples
taken before filling and completion of The sampling program applies both to the
commissioning. initial filling and to all fillings thereafter.
The samples taken before filling the control

fluid system must be representative of each Maintenance measures to be carried out
consignment delivered; the samples must be to ensure Fluid property characteristics
taken from a collecting container where a Table-3 contains maintenance measures to
certain amount of control fluid mixture from be taken if analysis values obtained for the
each individual container has been retained. samples approach the limits prescribed in
The first control fluid container opened is to the specification [1].
be used as the collecting container to
prevent contamination due to use of a Examination of system components
vessel that was not a part of the control fluid During inspections and major overhauls,
consignment. carefully examine the system components
Table-2 gives the sampling program for SAE for formation of deposits or scale and for
purity grade class-6, which is applicable for erosion-corrosion at the control edges of
this turbine. sensitivity control equipment.
Sampling points are marked as follows: If any deposits are found, they must be
analysed in consultation with the control fluid
manufacturer.
Sampling point - Supply (PNV)
Then checks must be carried out to find out
The PNV is provided within the supply unit. if rust or other forms of corrosion have
Analysis of the samples from this point developed within the system.
makes it possible to ensure the degree of
purity of the fluid downstream of the fine
5.3-0082-02/7
Time of Sampling Degree of purity NZ ASC Water Density Kinem. Anti-
3
Discol Particle KOH min content g/cm Visco corro.
mg/g % by 2 Props.
oration count V mm /s
test vol. (2)
Before filling FRF
Lab sample x x x
x x x
Control sample
Two weeks after filling
FRF, if flushing not yet x x x
started
Before commencing PNB
flushing for record of
as-delivered condition
Continuous sampling PNR
during flushing
Towards end of refilling x x x x
via superfine filter
(3)
Continuous monitoring PNB
during superfine PNU
filtering
PNBF
PNMF
Before commencing
hot operation (Last x x x
sample taken more
than 2 weeks earlier)
24h after
commencing hot x x x x x
operation
One month after
commencing of x x x
operation: weekly
One month after
x x x x x
commencing hot
(1)
operation : monthly
Before handing over PNR x x x x x
with final log
Table-2: Sampling program for SAE purity grade class 6
Entire program applies for refills also.
(1) Continuous monitoring programme after handing over

(2) Anti-corrosion properties to DIN 51585, ASTM D 665-60
(3) Test intervals according to filter capacity
PNB = Tank PNU = downstream of recirculating pump

PNV = supply line PNBF = downstream of fuller’s earth filter
PNR = return line PNMF = downstream of mechanical filter
5.3-0082-02/8
Parameter and Inspection Permissible Inspection Measures to be taken if
dimensions method limit interval limits exceeded
Water content No free water weekly Evaporate, suction-extract,
% by vol. visible to ladle-off, centrifuge using
naked eye special device
Neutralisation DIN 51 558-1 0.5 Monthly, Check regeneration plant,
number ASTM D974 weekly if Replace fuller’s earth, Check
NZ (mg KOH/g) negative effects by frequent
trend measurement of NZ
Kinematic DIN 51562-1 26-50 monthly Replace filling
viscosity at ASTM D445
2
40°C (mm /s)
Solid impurities Particle count SAE purity monthly Check filters for proper
and grade class 6 functioning. If necessary,
discolouration replace filter elements.
test Examine deposits on filter
elements
th
Air separation DIN 51381 Proper every 4 Check fluid for contamination
capability functioning of month (chemical and mechanical,
(min. at 50°C) system must entrained oil)
be assured
th
Density at 15°C DIN 51757 every 4 Check points in system
3
(g/cm ) ASTM D1298 month where oil can enter FRF
system. Examine fluid for
entrained oil, air or water
Fire resistance DIN/ISO 14935 ≤ 5 sec after Replace FRF filling
test determining
oil content
th
Anti-corrosion DIN 51585 no corrosion every 4 Have anti-corrosion additive
properties ASTM D665-60 permissible month analysed by fluid
manufacturer. Replace FRF
filling if necessary.
Oil content nuclear 3% max. see note Replace FRF filling. Perform
% by vol. resonance test, fire resistance test.
density
Table-3: Maintenance Measures
Note : If examination of the points in the system where the oil and FRF loops are structurally
separated reveal that oil has entered the FRF system as a result of structural failure, the
oil content in the FRF must be determined.

[1] 5.1-0140 Fire Resistant Fluid
[21 5.1-1110 Control Fluid Pump
[3] 5.1-1120 Plate Type Filter
[4] 5.1-1130 Duplex Filter
[5] 5.1-1140 Regenerating Plant
[6] 5.3-0083 Analysis of Fire Resistant Fluid
5.3-0082-02/9
Steam Turbine Fire Resistant Fluid
Maintenance Determination of Fluid Purity
Introduction For this reason, the ground glass flasks and

Erlenmeyer flasks must be flushed three
A fire-resistant control fluid (FRF) is used in
times with extra-purified n-heptane.
control and governing systems. The purity of
the fire-resistant fluid is of vital importance to
the reliable operation of the plant and must
Sampling
be monitored continuously.
Always perform sampling at the same
location directly from the system.
Brief Description of the Procedure
Recirculate the fire-resistant fluid long
To determine its purity, a defined quantity of enough prior to sampling to avoid settling
the fire-resistant fluid is dissolved in and give a homogeneous sample.
n-heptane and filtered through a diaphragm
Always perform sampling while the FRF
of pore size 0.45 µm. Size and quantity of
system is in operation.
the separable foreign matter particles are
then determined. A comparison shows Flush the sampling point prior to
whether the fire-resistant fluid lies within the sampling by draining about 10 litres of
purity requirements established in the fire-resistant fluid into a clean receptacle;
specification [1]. return this into the system after sampling.
Allow about 10 litres of fire-resistant fluid
to pass through the sampling point
Equipment and Chemicals Required
before performing sampling by filling the
Membrane filters, 50 mm dia., 0.1µm and fire-resistant fluid directly into the
0.45 µm pore size cleaned ground-glass flask.
Filtering device and aspirator Do not use aids such as syringes or
beakers.
n-heptane, p.a., purified by filtration
Always identification-mark the specimens
Filter the quantity of n-heptane p.a. that
uniquely and durably.
is required for dissolving and washing of
the fire-resistant-fluid specimen through Complete the sampling records and send
a membrane filter of pore size 0.1 µm to the analysing laboratory together with
four times to exclude even the most the FRF sample.
minute impurities.
100 ml ground glass flasks
Determination Procedure
100 ml Erlenmeyer flasks with ground
Measure 20 ml (about 23 g) of fire-
glass stoppers
resistant fluid into an Erlenmeyer flask
Vacuum pump, e.g. water jet pump previously cleaned with purified
n-heptane, p.a., and dissolve in 80 ml of
Microscope slides
purified n-heptane, p.a.
Adhesive tape
Use a clean hair brush to remove any
dust from the membrane filter and clamp
the filter into the filtering device.
Preparation of Sampling Vessels
Connect up the water jet pump to the
Note: Flasks cleaned by a normal cleaning
aspirator and filter the fire-resistant fluid /
procedure still contain far too many minute
n-heptane mixture through the
impurities which can give a false impression
membrane filter.
of purity.

Then flush the Erlenmeyer flask five After drying the filter, place it between
times with about 50 ml each purified two cleaned microscope slides and seal
n-heptane. p.a. and also pass the the edges with adhesive tape.
n-heptane used for flushing through the Determine the sizes and quantities of the
filter. separable foreign matter particles.

[1] 5.1-0140 : Fire Resistant Fluid
[2] 5.3-0082 : Care of Control Fluid
5.3-0083-01/2
Steam Turbine Vibration Dampers
Maintenance
Introduction with foreign matter. Another point to watch

are the attachments of the dampers to the
If the piping of the lubricating and control
piping and to any thermal installation plates
fluid system is excited to vibration, the
installed between them, as these
deflections involved could cause
connections may work loose. For these
inadmissible stressing of the piping material.
reasons, regular inspections are necessary
Dampers are used to attenuate piping to ensure that the vibration dampers are in
vibration. These consist essentially of a good condition and functioning properly.
cylindrical casing enclosing a plunger
embedded in a viscous bitumen mass that
performs the actual damping function. The Inspection Intervals, scope of Inspection
upper part of the damper is sealed by a Table-1 gives all important criteria to be
fabric-base plastic guard sleeve. reviewed during vibration damper
This damper design is not subject to wear, inspections. The intervals between
but the damping medium properties may be inspections are given in “y” (years).
impaired by temperature influences or, if the The inspections may also be performed
guard sleeve is damaged, by contamination during plant operation.
Table-1 : Inspection Intervals, Scope of inspections and Criteria
Inspection Scope of Inspection

Intervals - Criteria
1y Damper Attachment
- firm seating of damper components on pipe and support sides (and at
thermal insulation plates, if applicable)
Motion reserve
- cold condition: position of plunger as in support drawing
Guard sleeve
- correct and firm seating
- tension of the clamps
- damage (cracking or perforations)*
External influences
- effects of water, oil or similar *
5y As for 1 y
Condition of the damper medium
- surface appearance
- elasticity
* If found, perform 5-year inspection immediately

Points to Note If cracking, crumbling or loss of elasticity is
If welding work is to be performed close to discovered on the surface of the damper
the piping dampers, take care to protect the medium, or if the plunger has worked itself
dampers (and particularly the guard sleeves) out of the medium, this indicates that
from weld spatter and other potential ambient temperatures in excess of design
damage. have caused deterioration in the damper
medium properties.
To preclude any deterioration due to ingress
of foreign matter such as water, oil, etc., Consult the damper manufacturer if the
replace guard sleeves as soon as any damper medium is unserviceable and has to
damage is discovered. In that event, also be replaced. Damper medium can be
check the condition of the damper medium removed from the casings without leaving
immediately. residue if heated to about 80°C.
5.3-0100-00/2
Steam Turbine Instructions for Overhaul
Maintenance
In this chapter scope and schedule of Detailed knowledge of the next major
overhaul has been described. overhaul can be gained from the medium
overhaul.
Types of Overhaul The following criteria form the basis for
deciding whether or not to open a casing:
Minor Overhaul (inspection, servicing)
conclusions drawn from long-term
A minor overhaul should be carried out as observation, operating experience and
required simultaneously with shutdowns of manufacturer’s recommendations.
other plant components or during standstill
of the turbine-generator unit due to faults.
Major Overhaul (inspection, servicing,
The purpose of the minor inspection is to repair)
avoid reduction in availability due to forced
A “major overhaul” is a planned shutdown. It
outages by inspection and servicing and, if
permits detailed inspection and the
necessary, by preventive maintenance,
determination of the condition of all
The casings are not opened. components. All casings are opened.
Detailed knowledge of importance for Schedule inspection interval: after 50,000
intermediate overhaul or major overhaul is equivalent operating hours.
gained during minor overhaul.
The term equivalent operation hours is
Scheduled interval: after about 17,000 defined by the following equation:
equivalent hours of operation.
Te = To + ns x 25
Medium Overhaul (Inspection, Where,

servicing, repair) Te = equivalent operating hours
A Medium Overhaul is a planned shutdown,
if possible, simultaneously with other plant To = actual operating hours
components during which a casing may be
ns = the number of starts, without
opened. It covers all work which has a
bearing on the availability of the turbine- differentiation between cold, warm and hot
generator unit. starts.

TURBINE OVERHAUL
Equivalent Operating hours Variant-1 Variant-2
Minor
Major Overhaul Medium Overhaul
Overhaul
Turbine bearings
Turbine bearings
Turbine bearings
Operating years
Coupling check
Coupling check
Coupling check
Turbine valves
Turbine valves
Turbine valves
HP turbine
HP turbine
LP turbine
LP turbine
IP turbine
IP turbine
8600 01
02
* *
25800 03
04

43000 05
06

60200 07
08
77400 09

10
94600 11
12

111800 13
14
129000 15

16
146200 17
18

-Mandatory, -Optional, *Mandatory for turbines with spring mounted TG deck
5.3-0200-05/2
Medium Overhaul
Minor Overhaul
Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul
For units with spring mounted TG deck, check reference readings of deck * *
spring units, carryout alignment and catenary check and readjust spring
units after first year of operation.
Check guides of inner casing for freedom of movement and wear. Overhaul.
Measure permanent elongation of bolts in high temperature zone and check
them for embrittlement, check all bolts for cracks.
Check shaft seals and labyrinth glands for abrasion and scaling. Check
springs of spring-mounted ring segments. Replace springs of high
temperature zone.
Check shaft for cracks. Perform run out check, eliminate score-marks in
shaft journals. Inspect coupling.
Visually examine last stage blades of LP turbine (check for cracks if
necessary).
Clean rotors and casings and examine for damage. Pay particular attention
to blades and seal strips.
After every 50,000 equivalent hours of operation, remove LP free standing
blades from fir-tree grooves, clean root & groove, check complete blade
with specific attention to blade root for crack by MPI and carry out NFT.
Check earthling brush contact surface of shaft.
Open main oil pump, check bearings, seal rings, shaft, impeller etc.
Open auxiliary, emergency and jacking oil pumps.
Check control and protective devices. Pay particular attention to parts
subject to wear or deposits, replace these if necessary.
Perform mechanical, electrical and/or hydraulic functional tests on
monitoring instrumentation; if necessary, overhaul and re-calibrate.
Disconnect couplings, measure elongation of coupling bolts, check axial *
and radial alignment, perform run out check, clearance check.
Disassemble bearings, check babbitt surface, measure clearances, check
seating of bearing in bearing pedestal.
Check, overhaul and, if necessary, replace seal rings of bearing pedestals.
Check casing guides for deposit, if guides are jammed, remove, clean and
overhaul keys. Ensure design key clearances.
Check stop valves, control valves, bypass valves; if necessary, replace
worn parts on the hydraulic and steam sides.
- If necessary, if applicable, - Mandatory, * for turbines with spring mounted TG deck
5.3-0200-05/3
Medium Overhaul
Minor Overhaul
Major Overhaul
List of’ Activities to be performed during Minor, Medium and Major Overhaul
Remove and check steam strainers for deposits and damage, clean/replace
if necessary.
Check drains for foreign material, open and clean sludge traps.
Measure casing distortion, check casing joints for erosion, check for cracks.
Replace springs of sealing segments in high temperature zone
Drain main oil / control fluid tank, separate impurities, change oil / control
fluid if necessary. Inspect tank. Clean strainers.
Check oil / control fluid filters for leaks, remove and clean the inserts, pay
attention to damage.
Examine oil / control fluid lines for damage, eliminate leaks. Retighten
flange joints. Change gaskets, if applicable.
Examine steam turbine integral piping for cracks, deformation and
ballooning. Special attention is to be given to balance piston leak-off line of
HPT.
Check pipe supports and hangers and readjust if necessary. Check casing
horn drop and eliminate pipe pull by adjusting hangers & supports
Replace TSE/TSC thermocouples fitted in IP inner casing whenever IP
turbine is overhauled.
= If necessary, if applicable, = Mandatory, * for turbines with spring mounted TG deck
5.3-0200-05/4
MINOR OVERHAUL If couplings are disengaged it is advisable to
perform a roll check, especially if the
Casings are not opened. Bearing check,
couplings need to be realigned. At the same
coupling check if necessary, mandatory for
time measure the axial displacement of the
spring mounted TG deck after first year of
rotors relative to the casing. If
operation, checks of controls, safety and
disengagement of the couplings is not
protective equipment on steam and oil sides.
performed, coupled run out checks are to be
performed in the vicinity of the bearing as a
Components to be inspected minimum requirement. For accurate runout
− TG deck springs (if applicable) after 1
st
measurement, rotor system temperature
year of operation, alignment & catenary should be close to ambient.
− Casing roll check (if rotors realigned)
− Bearings Bearings
− Oil guard rings of bearing pedestals Dismantle bearings. It is necessary to check
the babbitt metal lining for damage and
− Sliding pieces in casing guides and looseness by UT. Check seating of bearing
supports in bearing pedestal. Measure clearances of
− Control valves, bypass valves bearings.
− Emergency stop valves and extraction
− non-return valves Oil guard rings of bearing pedestals
− Control and safety equipment Remove contaminants and abraded
particles on the seal edges to prevent oil
− Piping supports and hangers
leakage. Replace oil guard ring in case of
− Steam strainers excessive clearance.
− Drains
− Oil lines Sliding pieces in casing guides and
supports
− Pumps (main oil pump, jacking-oil pump,
auxiliary oil pumps and emergency oil Inspect keys and sliding pieces for any
pumps, if necessary) abnormality. If there are indications of
− Oil / control fluid tanks jamming, dismantle and overhaul. Check
and ensure thermal clearances as per
− Oil / control fluid filters design.
− Last stage of LP Turbine
− Monitoring equipment Control valves, bypass valves
Activities should generally be concerned
Scope of activities with checking of parts subject to wear.
TG deck springs (where applicable) Decisions on further activities and valves to
be covered are to be taken according to the
For units with spring mounted TG deck, the
circumstances on the basis of performance
deck springs are to be inspected and
in the preceding period of operation. Spindle
reference dimensions compared and
seals consisting of packing material are to
adjusted after first year of operation. This
be replaced in all cases. Clearances
will also call for alignment, catenary and roll
between moving and stationary parts should
check.
be checked and corrected.
Couplings Emergency stop valves
If couplings are to be opened, carry out Emergency stop valves should always be
swing check & coupled runout measurement inspected completely (steam and oil side).
before loosening the coupling bolts, This includes spindle, cone, seat, bush,
measure the pretension of the coupling bolts actuator. With mechanical drives (lever
while loosing and tightening. Check the linkage) in particular, attention is to be give
alignment radially and axially. If deviations to compliance with plays and travel
exceed the permissible tolerance, reserves.
realignment is required.
5.3-0200-05/5
Piping supports and hangers − Inlet and outlet connections
Check and measure alignment dimensions − Casings
in the cold conditions and adjust, if − Inner casing guides
necessary. Verify adjustment by casing horn − Blading
drop test. Check pipes for visible changes. − Glands
− Rotors
Steam strainers − Fasteners
Dismantle and check for foreign bodies and
damage. Replace gasket. Scope of activities
Inlet and outlet connections
Drains Inspect for scale and freedom of movement
The scope of activities depends on at I-and L-seal rings. Inspect U-seal rings
performance during the preceding period of and measure precompression.
operation and susceptibility to malfunctions.
The sludge traps should be opened in all Casing
cases. Measure for deformation, crack examination.
Rework according to findings. Inspect casing
Oil lines joint plane for erosion
Remove leaked oil, inspect pipes and
mounting for fretting point and strengthen Inner casing guides
accordingly. Check for freedom of movement and wear.
Pumps Blading
The main oil pump is to be opened in order Clean entire blading with casing open and
to inspect bearings, sealing rings, shaft, inspect for damage and incipient cracks,
impeller and coupling. Check other pumps in Check shrouds for scale according to
redundancy configuration only as necessary. temperature. Check for blade looseness and
lock blade lift.
Oil / Control fluid tanks
The fir-tree root free standing blades of LP
Clean strainers rotor need special attention. After every
50,000 hours of operation, take out the
Oil / Control fluid filters blades from groove, clean root and groove,
Remove elements and clean. Check for carry out crack detection of the entire blade
damage. including root, check natural frequency in
position with technological pieces.
Last stages of LP turbine
Visual inspection of condition. Crack Glands and labyrinths
examination where necessary. Check for abrasion and scale (dependent on
temperature). Check condition of springs.
Monitoring equipment
Check that mechanical, electrical and Rotor
hydraulic monitoring equipment function Check for cracks in fillets. Perform run out
properly and repair or recalibrate as check. Eliminate scoring on the journals.
necessary. Check coupling.
MEDIUM OVERHAUL TSC thermocouples

At least one casing is to be opened and the Replace TSC thermocouples fitted in IP
rotor lifted out. Otherwise as for minor inner casing, whenever IP Turbine in
overhaul. opened for overhaul. Take advance action
for procurement of the TSC thermocouples
Components to be inspected and associated fittings.
As for minor overhaul but augmented by the
following:
5.3-0200-05/6
5.3-0200-05/7
Fasteners in high temperature zone Depending on the results of the inspection
Replace all fasteners of size upto M64 in the examined components are to be:
high temperature zone after 100,000 Left in the as-inspected condition,
equivalent hours of operation. Carry out because no faults have been found.
destructive test on sample fastener of higher
sizes to determine usability of the lot. Left in the as-inspected conditions
although damage (e.g. crack formation)
has been found. Continued operation,
MAJOR OVERHAUL either in an unaltered or altered mode, is
All casings are to be opened and the rotors to be justified. The propagation of the
lifted out. Otherwise as for medium damage is to be kept under observation;
overhaul, but instruction if necessary is spare parts, often requiring lengthy
inapplicable. delivery periods, are to be ordered.
Replaced with spare parts (in general
Components to be inspected
small parts subject to wear are normally
As for medium overhaul but instruction “if kept in stock e.g. spindles, fasteners)
necessary” is inapplicable, and augmented
by the following: Repaired by reworking at site or in the
− Oil / Control fluid tanks works of the supplier
− Steam lines It is necessary to increase the scope of the
− Casing center guides inspection as soon as the units have clocked
more than 100,000 equivalent hours of
Scope of Activities operation. Component integrity assessment
and/or residual life assessment studies are
Oil / Control fluid tanks to be initiated at this stage. Inspection
Drain and clean tank. Purify oil / Control planning must allow for the additional time
fluid, change if necessary. and costs consumed by the inspections.
Apart from this, the intervals between major
Steam lines overhauls necessitate the coverage of
considerably more components by the
Check steam lines exposed to main or
inspection as has been customary hitherto.
reheat steam for expansion, deformation
and crack. When stipulating the scope of the
inspection, the experience gained from
Casing centre guide comparable units should be taken into
account in the plans and/or the
Disassemble and overhaul. Ensure design
manufacturer is to state at which highly
clearances
stressed points the various components are
to be inspected. It is advisable to get the
SUGGESTED INSPECTION & TESTING special checks and tests conducted by the
PROCEDURES specialists from turbine plant.
During inspection of steam turbine generator
units, certain components are required to be
INTEGRITY ASSESSMENT
inspected in-depth to achieve more accurate
evaluation of their condition. The findings During integrity assessment, following
are to be documented (descriptions, check examination / inspection / testing of steam
calculations, drawings and photographs). turbine parts may be done.
Visual Inspection
− With the naked eye and good Surface crack examination
illumination e.g. 500 Watt − Dye penetration test (DPT)
photographic lamp, mirror
− Magnifying glass − Magnetic particle inspection (cannot
be used on austenitic materials)
− Borescope
5.3-0200-05/7
− Eddy-current examination − Contact print (Replica) procedure
after etching material surface
− Crack depth determination as far as
possible with capacitance probe or
ultrasound Hardness test
Ultrasonic examination Material verification test

− Manual spectroscope
X-Ray examination
Material testing
Detection of permanent deformations − Tensile test to determine yield
strength, tensile strength, elongation
− Out-of-roundness (ovality), angle of
after fracture and necking down.
bend (in pipe elbows), warp
− Notched bar impact test
− Wall thickness measurement
− Chemical composition
− Expansion measurements
(measurement of diameter, length, − Metallographic microstructure
circumference). evaluation
Surface micro-structure examination Testing of electrical insulation

− Microscopic examination at site against shaft currents
5.3-0200-05/8
Steam Turbine Turbine Restart
Maintenance After Boiler Repairs
Introduction operation, all solid particles remaining in the

Following extensive boiler repairs, measures system are blown down into the condenser,
must be taken to protect the turbine against which prevents them from causing particle
erosion by solid particles. erosion on the turbine blades Particles
blown down into the condenser must be
removed from the hot well before
Bypass Operation commencement of process operation. The
When extensive repairs have been carried bypass steam mass flow rate must comply
out on the boiler, it is not possible to prevent with the limits (mass flow rate and duration
solid particles remaining in the system in of operation) defined in the specifications.
spite of chemical cleaning. For this reason,
The bypass stop and control valves may
provision must be made for a lengthy period
suffer slight damage to their seats and discs
of bypass operation with the highest
as a result of steam dumping and must,
possible bypass steam mass flow rate at the
where necessary, be checked by sampling.
time of unit restart. During this bypass

Steam Turbine Turbine Restart after Major
Maintenance Inspections or Repairs
Introduction Pre-service Inspections

The operational reliability and availability of The functioning and the setting of all of the
a steam turbine unit are determined by, major equipment of the turbine must be
among other factors, the care with which the checked. This applies both to mechanical /
unit was initially started up. The same rule hydraulic components and to
also applies to restarts after large scale instrumentation and control devices. The
maintenance and repair work, e.g. in the scope of inspection and testing of defined in
course of major inspections. instruction 5.2-002x, and covers:
All closed-loop controls
Information Required for Restart All protective devices
In restarting a turbine it is useful to possess All sub loop controls and automatic
the following data: changeover controls
The performance of the turbine unit and The characteristics of all electro-hydraulic
its components prior to inspection controllers must be recorded. The test
programs appear in maintenance
The scope of the inspection
instructions 5.3-0030 and 5.3-0061.
Findings and checks made during the
Alarm system and monitoring equipment
inspection
must like wise be overhauled and tested.
Repairs carried out on the basis of the
If the result of operating parameters and
findings
setting checks reveal changes from earlier
Retrofitting and upgrading measures results, new records must be prepared.
taken
Checks planned for the restart period
In-Service Inspections
The information required may be found in
The tests, which could not be carried out in
the following documents:
the pre-service phase because the boundary
Reports on turbine performance prior to conditions had not been fulfilled, must be
inspection performed during the service phase
subsequent to the pre-service inspections.
Operating parameters and setting The essential step-by-step test schedules
records for the unit when new or at the appear in maintenance instruction 5.3-0060.
last restart
Reports on inspections, findings and
repairs Protective devices
Documents on retrofitting and Service phase testing applies mainly to
modifications those devices which protect the turbine
against over speed. The test programs of
The following are also required: the automatic turbine tester may also be
Diagrams showing current control system executed if required.
setting (in the case of special settings the Controllers
most recent records are binding)
The performance of the controllers must
Documents from the turbine manual, be observed throughout the restart
such as controller circuit diagrams and phase.
descriptions.

The control range of the hydraulic which are subjected to large-scale changes
controller must be checked and, if in this phase must be recorded.
necessary, corrected during no-load The operating parameters of the turbine
operation. stress controller must be subjected to critical
Automatic functional group controls analysis, because the start-up time, and
hence the cost-efficient operation of the
The turbine systems and the turbine turbine unit, is largely determined by the
generator unit should be started up with limits set by the TSC.
the aid of the automatic functional group
controls, and checks carried out to
establish whether all criteria for the Evaluation of Tests and Operating
execution of the step programs are Parameter Records
fulfilled.
The test results and the operating parameter
Operating parameters records provide vital information on the
The values of all operating parameters compliance of the turbine and its
must be recorded during steady-state components with the performance
operation when they have remained specifications.
constant for an adequate length of time, Malfunctions and other major discrepancies
and then compared either with the set must be eliminated as far as possible,
point or with previous recorded values. especially when they constitute a hazard to
- Output the operational reliability of the turbine unit.
- Control system characteristics Where necessary, spare parts must be

ordered and/or measures to facilitate future
- Steam mass flow rates elimination of the off-norn1al conditions
- Feed water / condensate mass flow rates detected must be defined.
- Steam pressure and temperatures These measures may include further

measurement of off-normal conditions,
+ Main steam rebalancing and other similar actions.
+ Extraction steam
+ Exhaust steam Re-Commissioning of the set
- Casing temperatures Most of the activities which have to be
- Expansions performed in the course of turbine restarts
go beyond the scope of normal maintenance
- Vibrations work. They call for special knowledge which
- Oil pressure and temperatures is too detailed to be described in full in the
turbine manual, especially where fault
- Bearing metal temperatures elimination is involved.
- Control fluid pressures and temperatures It is therefore expedient to assign
commissioning personnel to assist in
- Circulating water temperatures
restarting the turbine.
+ Condenser
The following is one conceivable allocation
+ Coolers of functions:
- Condensate temperatures Pre-service inspection and in-service
testing of the unit by one specialist
- Condenser leak tightness (leak test)
engineer each for turbine and generator
During non-steady-state operation, e.g. from the supplier company.
during a cold start, all operating parameters
5.3-0220-00/2
Pre-service inspection and testing of Report on the findings and checks made
major C&I hardware Report on repairs and other actions
- Controllers and protective devices Report on the replacement and spare
- Turbine stress controller parts used or required
- Automatic testers If these special reports are not available,

brief details must be given on these subjects
- Automatic functional group controls under the above headings.
Pre-service inspection and testing of
controls, interlocks and alarms by owner
/ operator’s personnel. The main section of the reports must cover:
The scope and nature of pre-service
inspections
Summary of results from major
inspections and repairs Findings from the pre-service inspections
Full documentation of the history of a turbine The scope and nature of in-service
unit includes, among other elements, testing
reporting on turbine restart following major Evaluation of turbine performance
inspections or repairs.
Findings from in-service testing
The report on restart should make reference
to certain preceding reports, namely: Matters remaining open (actions,
replacement parts, implementation
Report on the performance of the turbine deadline, etc.)
unit prior to the major inspection
Report on the scope of the inspection
5.3-0220-00/3
Steam Turbine Environmental protection
Maintenance
It is the social and moral obligation of all Oil leakage does not only pollute the
concerned to ensure adequate protection of environment but is also a potential fire
the environment in every wake of operation. hazard. Oil leakage from any source is to be
quickly attended. In the viscinity of high
During maintenance inspection and capital temperature equipment & pipes, any oil
overhauls, it is of paramount importance to leakage has to be immediately attended,
ensure safety of work force by adhering to even if it calls for unit shutdown.
the applicable safety codes. In addition,
while handling and disposing hazardous Steam leakage from any source is
materials, necessary precautions, as associated with thermal & noise pollution of
published from time to time, are to be the environment. Depending on the source
adhered. & parameters of the leakage steam, it can
be injurious to the associated equipment
Some material, through harmless in normal and also to any individual coming in contact.
regime, may become quite hazardous under Any such leakage is to be quickly attended.
different circumstances. Gaskets made of
Fluorelastomers (viz. Viton), when exposed Proper upkeep & periodic lubrication of all
0
to temperatures in the region of 400 C or rotating equipment as per the
higher due to fire or any other reason, get manufacturer’s instructions goes a long way
decomposed. One of the products of such in ensuring their smooth and noise-free
decomposition is Hydrofluoric acid, which is operation.
highly corrosive and any skin contact with it
must be prevented. To promote environment friendly aesthetic
appearance, the external surface of all the
To protect the natural environment and to equipment should be painted once in two
control pollution from disposed hazardous or years. General upkeep and cleanliness
non-bio-degradable material, a proper standard should be maintained all around,
system of disposal is to be evolved and especially around the turbine floor to
compliance ensured. promote a pleasing look.

[1] 5.3-0251 : Fluorelastomer products
safety notice
[2] 5.3-0252 : Safe disposal of Turbine Oil

Steam Turbine Fluorelastomer Products
Maintenance Safety Notice
Precautions to be taken during handling equipment should be denied to unauthorised

of Viton synthetic rubber and other or unprotected personnel and warning
Fluorelastomer products after they have notices posted.
been exposed to very high temperatures The affected areas must be decontaminated
Fluorelastomers are synthetic rubber like before either inspection or maintenance is
materials commonly used for making resumed. Do not touch anything in the
gaskets and seals of various kinds. vicinity of the decomposed material until it
has been decontaminated.
‘Viton’ is used extensively in control fluid
(FRF) system due to its compatibility with
phosphate ester fluids. It is also compatible Decontamination procedures for
with mineral oil and can appear in ‘O’ ring decomposed Fluorelastomer products
form in the lubricating oil, jacking oil and
power oil systems. In normal use, fluid Decontamination of equipment exposed
temperature excursions beyond 100 °C are to decomposed Fluorelastomer products
rare and therefore the use of ‘Viton’ seals If decomposed fluorelastomer products are
does not constitute a hazard to safety. suspected, great care must be taken when
However, extreme care should be taken removing the residues from equipment.
when dismantling equipment which may Protective equipment and clothing must be
have been subject to fire damage. used and worn, including heavy duty rubber
When exposed to temperatures in the region gloves and full face protection, to prevent
of 400 °C or higher, fluorelastomers do not accidental skin contact with the Hydrofluoric
burn but decompose into a number of acid (H-F).
materials, one of which is hydrofluoric acid. The residues should be disposed of with
This is corrosive and almost impossible to great care, such as very high temperature
remove once it contaminates the skin. incineration. All containers or bags used to
Personnel who could come into contact with transport the residues must be clearly
degraded ‘Viton’ (or any other marked to ensure careful handling to the
fluorelastomer) should be made aware of its point of disposal.
hazardous nature. Equipment which has H-F residues may be washed away using
been exposed to a very high temperature sufficient quantities of water to dilute them to
(e.g. equipment which has been involved in harmless concentrations.
a fire), and which may contain
fluorelastomer components, should not,
under any circumstances, be touched until it Decontamination of personnel exposed
has been visually inspected for gaskets or to decomposed Fluorelastomer products
seals which have suffered decomposition. If
decomposition has occurred, the component H-F residues should not be handled without
will appear as a charred or black sticky adequate protection. If accidental exposure
mass. occurs, wash well with water and apply an
H-F Antidote Gel as directed. Medical
Supervisory staff should be informed attention should be obtained immediately. A
immediately and inquires made to confirm Calcium Gluconate injection is the normal
whether fluorelastomer components are treatment for Hydrofluoric Acid Burn.
involved. Meanwhile, access to the

Steam Turbine Safe disposal of
Maintenance Turbine Oil
Oil of viscosity class ISO VG 46, commonly procedure for safe disposal of used turbine
known as turbine oil, is used for lubrication oil is as follows:
of turbine bearings as well as for hydraulic
turning gear. To send the discarded oil to
registered refiners who have facilities to
The oil should comply with the requirements reclaim the oil by physico-chemical
given in Operation and Maintenance Manual treatment for further use in non-critical
[1]. It is recommended that the condition of applications.
oil in use, be periodically monitored to
ascertain the quality and properties of To send the used oil to the parties
turbine oil [2]. All major oil manufacturers who are licensed to handle and dispose
have facility for complete checking of oil used lubricating oil.
properties.
To burn-off the discarded oil in
Turbine oil has to be changed if its boiler furnace by mixing with fuel oil.
properties have crossed discard limits. The

[1] 5.1-0130 : Oil specification
[2] 5.3-0080 : Turbine Oil care

Steam Turbine Ordering of Spares
Maintenance
While ordering for spares, complete the functioning. For ordering spares, only the
identification details of the required project specific drawings supplied separately
component should be furnished. The details should be referred and following details may
of components described in various chapters be furnished:
of this manual are given only to understand
Enquiry for Steam Turbine O&M Spares

Name of the project :
Capacity :
Unit No. :
Previous enquiry / offer / order reference :
A] BHEL Supplied Spares

Sl.No. Assembly Item No. Qty. Description Part Drg.No. / Application
Drawing Code No. /
No. KKS tag No.
1.
2.
3.
4.
5.
B] Purchase resold items

1. Name of the supplier :
2. Model :
3. Year of manufacturing / supply :
4. Equipment Serial / Fabrication No. :
5. KKS Tag No. :
6. Other details noted from name plate :
7. Supplier’s catalogue reference No.
8. Supplier’s Sketch / Drg. No.
9. Application / location where installed :
10. Details of spares
Sl.No. Description as above Installed Quantity Required Quantity

1.
2.
3.

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Steam Turbine Maintenance Schedule

Maintenance FRF system

Replace filter papers in ∆ p across filter as indicated by

2. Cleaning of FRF tank after deposits in FRF 3-4y during overhauls

BHEL Haridwar 5.3-0023-01/1

Introduction main trip valves in operating position, stop

BHEL Haridwar 5.3-0030-02/1

Auxiliary oil pumps

D.C. Emergency oil

Jacking oil pumps

Remote trip initiation

(5) Turn handwheel of hydraulic test signal

Test that demonstrate the readiness for Test performance

Equipment tested o Preconditions Date

BHEL Haridwar 5.3-0035-02/1

(9) Repeat test as often necessary until trip operates

Introduction Documents showing the availability

BHEL Haridwar 5.3-0037-03/1

Also refer to the following:

Data acquisition recommended for post event analysis

ID Code Measuring point Measuring Scatter band Retention

Off-Normal Condition Action Classification of action

HP turbine exhaust steam Take ηi measurements In-service check

BHEL Haridwar 5.3-0040-01/1

Spacer plates at casing Check for casing lift In-service check

Bearing metal temperatures Perform examinations and checks In-service check

Off-Normal Condition Action Classification of action

Off-Normal Condition Action Classification of action

Control fluid level in control

Off-Normal Condition Action Classification of action

Change in control system Check control system, if Correction during short

Off-Normal Condition Action Classification of action

Pump and motor bearing Inspect bearing, renew or In-service maintenance

Introduction recommendations given in Table-1 or as

Changes in the internal condition of a The internal efficiency of turbines whose

Table-1: Test intervals

Type of test Boundary conditions Test interval

BHEL Haridwar 5.3-0050-02/1

P1 : Pressure of inlet steam before group stage section

hs : Adiabatic steam Enthalpy corresponding to P2 & S1

Install precision pressure gauges or Increase of losses in valve seats

Introduction Test performance

Equipment tested o Preconditions Date

BHEL Haridwar 5.3-0060-01/1

• Main trip valves in operating position

o Stop valves open o Starting and load limit device not in 0%

• Secondary pressures < opening

Auxiliary oil pump

Jacking oil pump

Turning gear oil valve

Condenser Safety devices

o Criteria for shut down of condenser

o Response of hydraulic low o Condenser safety device test

Condenser Safety devices for

o Bypass operation ended

Equipment tested o Preconditions Date

BHEL Haridwar 5.3-0061-02/1