Mejores Tecnicas de Mantenimiento a Turbinas a Vapor

7/26/2019 Mejores Tecnicas de Mantenimiento a Turbinas a Vapor

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IMIA WGP 42 (05)

International Association of Engineering Insurers38

thAnnual Conference Moscow 2005

Maintenance and Overhaul of Stea !ur"ines

#M$ Series Stea !ur"ine Courtes% Sieens &ower Cor'oration

(or)ing *rou'John Latcovich, The Hartford tea! "oi#er In$%ection & In$'rance

o!%an, Hartford, onnectic't (hair!an)Tho!a$ *$tro!, Poh+o#a, He#$ini

Peter -ranh'i.en, Praevenio, A!$terda!ei/o' -''$hi!a, Too Marine, Too

Han Ha!1er/, If P&, 'nd$va##tefan e##er, 3i$$ ationa#, "a$e#


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IMIA WGP 42 (05)

2

Maintenance and Overhaul of Stea !ur"ines

!a"le of Contents

Section !itle &age

Ta1#e of ontent$ 2

6ec'tive '!!ar 4

78 Introd'ction 5

28 tea! T'r1ine o!%onent haracteri$tic$, -ai#'re 9Mechani$!$, Arran/e!ent$ and A%%#ication$

A. Turbine Component Characteristics and Failure Mechanisms 9

A87 tea! T'r1ine "#adin/ 9A82 :i$c$, ;otor$, haft$, "#ade ;in/$, he##$, and :ia%hra/!$ in/#e a$in/ onC;eheat M'#ti%#e ta/e tea! T'r1ine$ 7>"8@

"870

in/#e a$in/ ;eheat M'#ti%#e ta/e o!1ined c#e tea!T'r1ine$M'#ti%#e a$in/ M'#ti%#e ta/e ;eheat tea! T'r1ine$

7>

7@


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Section

!a"le of Contents +Continued,

!itle &age

=8 Monitorin/, ?%eration$, Maintenance, andTrainin/ Infra$tr'ct're

20

A. Monitoring 20

A87 D'i%!ent Monitorin/ 20A82 Water and tea! P'rit Monitorin/ 22A8= Water Ind'ction Monitorin/ 22A84 ondition Monitorin/ 2=

B. Operations, Maintenance, and Training Infrastructure 24

"87 ?%eration$ 24"82 Maintenance Mana/e!ent 25"8= Trainin/ 25

48 tea! T'r1ine Avai#a1i#it and -ai#'re 6%erience 28 G" tandard$ =@

-8 ;i$C"a$ed Methodo#o/ie$ =@G8 ;e#ia1i#it entered or ondition "a$ed Maintenance 47(;M or "M)

8 onc#'$ion$ 49


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E-ecutive Suar%

tea! t'r1ine$ %rovide a !ean$ of convertin/ $at'rated, $'%erheated, or $'%ercritica# $tea!

fro! 1oi#er$ or heat recover $tea! /enerator$ (H;G) into rotationa# torD'e and %o3er8

on$eD'ent# $tea! t'r1ine$ are 'ti#i.ed to drive a variet of eD'i%!ent t%e$ of n'!ero'$$i.e$ and $%eed$ in +'$t a1o't ever ind'$tr $e/!ent inc#'din/ %o3er /eneration, %'#% and

%a%er, iron and $tee#, co!1ined heat and %o3er, and che!ica#, oi# and /a$ ind'$trie$8

Whi#e there are $'1$tantia# difference$ in the de$i/n, co!%#e6it, a%%#ication, $tea! condition$,

and $i.e of $tea! t'r1ine$, the a## are f'nda!enta## the $a!e8 The %erfor! the $a!e

f'nction, 'ti#i.e $i!i#ar !a+or co!%onent$ and $'%%ortin/ $$te!$, and are $'1+ected to the

$a!e fai#'re !echani$!$8 To $'%%ort re#ia1#e t'r1ine o%eration, there need$ to 1e an effective

infra$tr'ct're in %#ace for !onitorin/ the o%eratin/ condition$, 3aterB$tea! D'a#it, and hea#th of

the $tea! t'r1ine, for havin/ and '$in/ 3ritten o%eratin/B!aintenance %roced're$, for 'ti#i.in/ a

!aintenance !ana/e!ent $$te! to $ched'#eBtrac !aintenance, and for cond'ctin/ trainin/for %er$onne# on an on/oin/ 1a$i$8

There have 1een n'!ero'$ ca'$e$ of $tea! t'r1ine fai#'re$ 3or#d3ide8 The hi/he$t freD'enc

event$ have 1een #o$$ of #'1e oi# incident$ 3hi#e the hi/he$t $everit event$ have 1een

over$%eed event$8 T%ica##, hi/her freD'enc and hi/her $everit event$ have 1een

1#adeB1'cet fai#'re$, %artic'#ar# in the #o3 %re$$'re (LP) $ection of the t'r1ine 3here the

1#adin/ e6%erienced a n'!1er of fai#'re !echani$!$ ($tre$$ corro$ion cracin/ (), ero$ion,

forei/n o1+ect da!a/e (-?:)) 3hich '#ti!ate# #ed to fai#'re8

With re/ard$ to !aintenance %ractice$ in orth A!erica and 'ro%e, there are no re/'#ator!aintenance %ractice$ or interva#$ $%ecified for nonCn'c#ear $tea! t'r1ine$ re/ard#e$$ of the

ind'$tr or a%%#ication8 A$ $'ch, the freD'encie$ and ta$$ are defined 1 the t'r1ine

!an'fact'rer$, con$'#tant$, ind'$tr or/ani.ation$, %#ant %er$onne#, %#ant %roce$$

reD'ire!ent$, or in$'rer$ 1a$ed on %a$t e6%erience8 In Ja%an, ho3ever, there are re/'#ator

reD'ire!ent$ for %eriodic !aintenance8 Ho3ever, re/ard#e$$ of the area of the 3or#d, the

reco!!ended $ched'#ed !aintenance reD'ire!ent$ for $tea! t'r1ine$ are D'ite $i!i#ar8 -or

e$ta1#i$hin/ #on/er ti!e interva#$ 1et3een !a+or overha'# o'ta/e$, there are a n'!1er of

different a%%roache$ 3hich are 'ti#i.ed toda 3or#d3ide8 ;e/ard#e$$ of the a%%roach, it i$

i!%ortant that the !ethodo#o/ie$ effective# e$ta1#i$h the overha'# interva#$ 1a$ed on the

hi/he$t ri$ %ortion$ of the $tea! t'r1ine8

The techno#o/ie$ 1ein/ incor%orated into ne3 $tea! t'r1ine$ are !ore $o%hi$ticated, reD'ire

o%eration at hi/her %re$$'re$ and te!%erat're$, and /enera## have $!a##er c#earance$ to

i!%rove efficienc8 Whi#e the$e techno#o/ie$ have not ca'$ed an #ar/e #o$$e$, the inherent

ri$ e6%o$'re$ are increa$in/ and the inC$ervice e6%erience 3ith the$e techno#o/ie$ need$ to 1e

!onitored8


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In $'!!ar, !aintenance ta$$ and freD'encie$ $ho'#d 1e %rioriti.ed to3ard$ the %ortion$ of

the $tea! t'r1ine that have the hi/he$t ri$8 Thi$ '$'a## !ean$ %rotectin/ the $tea! t'r1ine

fro! over$%eed$, 3ater ind'ction, #o$$ of #'1e oi#, corro$ive $tea!, and $ticin/ va#ve$ that

co'#d ca'$e !a+or da!a/e to the t'r1ine, and cond'ctin/ interna# in$%ection$ of the t'r1ine

f#o3%ath, $he##$ and rotor$ for fai#'re !echani$! da!a/e (cree%, ero$ion, corro$ion, fati/'e,

ther!a# fati/'e, ) in order to detect the da!a/e ear# eno'/h to %revent a $'1$eD'ent!a+or fai#'re8


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./ Introduction

tea! t'r1ine$ are 'ti#i.ed in n'!ero'$ ind'$trie$ to drive 1oi#er fan$, 1oi#er feed and 3ater

%'!%$, %roce$$ and chi##er co!%re$$or$, 1#a$t f'rnace 1#o3er$, %a%er !i## #ine $haft$, $'/ar !i##/rinder$, and /enerator$ in a variet of ind'$trie$ and a%%#ication$8 on$eD'ent#, $tea!

t'r1ine$ can ran/e fro! 1ein/ $!a## and $i!%#e in de$i/nBcon$tr'ction to #ar/e, hi/h# co!%#e6

de$i/n$Barran/e!ent$ con$i$tin/ of !'#ti%#e $ection$ and !'#ti%#e $haft$8

%ecifin/ the de$ired !aintenance and overha'# interva#$ for $tea! t'r1ine$, therefore, ha$ to

tae into acco'nt the de$i/nBcon$tr'ction of the t'r1ine a$ 3e## a$ the ind'$tr and a%%#ication

'ti#i.in/ the t'r1ine8 "e$ide$ the confi/'ration and ind'$tr a$$ociated 3ith the $tea! t'r1ine,

the infra$tr'ct're for !onitorin/, o%eration$ and !aintenance inc#'din/ $%ecific %ractice$, and

$tea! D'a#it can have a !a+or effect on the re#ia1i#it of $tea! t'r1ine$ re/ard#e$$ of the

ind'$tr or a%%#ication8

In the ne6t $evera# $ection$ of thi$ %a%er, $evera# %ertinent a$%ect$ of $tea! t'r1ine$ 3i## 1e

addre$$ed8 The di$c'$$ion$ have 1een or/ani.ed in a $eD'ence 1e/innin/ 3ith $tea! t'r1ine

co!%onent characteri$tic$, fai#'re !echani$!$, arran/e!ent$ and a%%#ication$8 The$e

di$c'$$ion$ are fo##o3ed 1 3hat infra$tr'ct're$ $ho'#d 1e in %#ace to o%erate and !aintain

$tea! t'r1ine$, 3hat ha$ fai#ed 1a$ed on %a$t e6%erience, and 3hat !aintenance $ho'#d 1e

cond'cted to !ini!i.e the ri$ of fai#'re8 And #a$t#, the di$c'$$ion$ inc#'de 3hat $ho'#d 1e

taen into acco'nt for deter!inin/ #on/er !a+or overha'# interva#$ and 3hat effect$ the ne3

$tea! t'r1ine techno#o/ie$ !a have on $ched'#ed !aintenance and overha'# interva#$8


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2/ Stea !ur"ine Co'onent Characteristics 1ailureMechaniss Arrangeents and A''lications

tea! t'r1ine$ are f'nda!enta## the $a!e re/ard#e$$ of 3hether the drive a $i!%#e 500 $haft

hor$e%o3er (HP) fan or drive a 7,000 MW /enerator8 In a## ca$e$, $tea! i$ e6%anded thro'/hro3$ of $tationar and rotatin/ 1#adin/ 3hich convert the ener/ in the $tea! into !echanica#

ener/8 Whi#e the f'nction$ are the $a!e for a## $tea! t'r1ine$, the de$i/n$ are $'fficient#

different to nece$$itate 1rief di$c'$$ion$ on the i!%ortant co!%onent$, their characteri$tic$ and

fai#'re !echani$!$, and ho3 the are arran/ed or or/ani.ed a$ the$e attri1'te$ do affect $tea!

t'r1ine !aintenance ta$$ and freD'encie$8

2/A !ur"ine Co'onent Characteristics and 1ailure Mechaniss 2/A/.

Stea !ur"ine ladingtea! t'r1ine$ %rod'ce %o3er 1 convertin/ the ener/ in $tea! %rovided fro! a 1oi#er or heat

recover $tea! /enerator (H;G) into rotationa# ener/ a$ the $tea! %a$$e$ thro'/h a t'r1ine

$ta/e8 A t'r1ine $ta/e nor!a## con$i$t$ of a ro3 of $tationar 1#adin/ and a ro3 of rotatin/

1#adin/8 The %'r%o$e of the $tationar 1#adin/ i$ to direct the f#o3 of the %a$$in/ $tea! to the

rotatin/ 1#adin/ at the %ro%er an/#e and ve#ocit for the hi/he$t efficienc and e6traction of

%o3er8 The %'r%o$e of the rotatin/ 1#adin/ i$ to convert the directed !a$$ f#o3 and $tea!

ve#ocit into rotationa# $%eed and torD'e8 tationar 1#adin/ !a 1e referred to a$ no..#e$,

vane$, $tator$, %artition$, and $tationar 1#adin/ 3hi#e rotatin/ 1#ade$ !a 1e referred to a$

1'cet$, 1#ade$, and rotatin/ 1#adin/8 A t'r1ine !a have a $in/#e ro3 or $ta/e of $tationar

and rotatin/ 1#adin/ or !a have !'#ti%#e ro3$ or $ta/e$ of 1#adin/8

tea! t'r1ine 1#adin/ have different $ha%e$ 3hich are referred to a$ either i!%'#$e 1#adin/ or

reaction 1#adin/8 I!%'#$e 1#adin/ i$ characteri.ed 1 hi/h ve#ocit f#'id$ enterin/ the t'r1ine

1#ade, 1 a 1#ade %rofi#e that efficient# t'rn$ the direction of the f#'id 3ith #itt#e %re$$'re chan/e,

and 1 decrea$in/ the ve#ocit of the f#'id a$ it #eave$ the 1#ade to e6tract ener/8 T%ica#

i!%'#$e 1#ade$ are cre$cent or EC$ha%ed and !a not a#3a$ 1e $!!etrica#8

;eaction 1#adin/ i$ characteri.ed 1 hi/h ve#ocit f#'id$ enterin/ the t'r1ine 1#ade, 1't not a$

hi/h a$ i!%'#$e ve#ocit #eve#$, 1 a 1#ade %rofi#e that efficient# a##o3$ the f#'id to e6%and 3hi#e

%a$$in/ thro'/h the 1#ade, and 1 decrea$in/ 1oth the ve#ocit and %re$$'re of the f#'id a$ it

e6it$ fro! the 1#ade to e6tract ener/8 T%ica# reaction 1#adin/ ha$ tearCdro% $ha%ed #eadin/

ed/e$ 3ith a ta%ered thicne$$ to the trai#in/ ed/e8 The 1#ade$ !a have t3i$t to their $ha%e3hich !a ran/e fro! #o3 a!o'nt$ of t3i$t or reaction at the 1a$e of the 1#ade to hi/h t3i$t or

reaction at the ti% of the 1#ade8

I!%'#$e t%e 1#adin/ i$ t%ica## 'ti#i.ed in the hi/h %re$$'re or front $ection$ of the $tea!

t'r1ine 3hi#e reaction 1#adin/ i$ 'ti#i.ed in the #o3er %re$$'re or aft $ection$ of the t'r1ine8 Man

of todaF$ ne3 $tea! t'r1ine$, ho3ever, are 'ti#i.in/ reaction 1#adin/ in a## $ta/e$ of the t'r1ine

inc#'din/ the hi/h %re$$'re $ection$8 ;e/ard#e$$ of the 1#adin/ t%e, the 1#ade ti%$ !a 1e


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covered 3ith 1and$ %eened to their ti%$ 3hich connect $evera# 1#ade$ to/ether in /ro'%$, or the

1#ade$ !a have inte/ra# $hro'd$ 3hich are %art of the 1#ade$, or !a have no ti% cover 1and$

or $hro'd$ (free $tandin/)8 The 1#ade $hro'd$ and cover 1and$ are 'ti#i.ed to ee% the %a$$in/

$tea! fro! #eain/ over the ti% of the 1#ade$ 3hich red'ce$ efficienc and %o3er o't%'t and to

red'ce or da!%en the vi1ration characteri$tic$ of the 1#adin/8 "oth $tationar and rotatin/

1#adin/ can have $hro'd$ or cover$ de%endin/ on the t'r1ine de$i/n8 The n'!1er of 1#ade$ in


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a /ro'% that are covered 1 $hro'd$ i$ de%endent '%on the vi1ration characteri$tic$ of the

$%ecific !achine8 -or $o!e de$i/n$, thic 3ire$ (ca##ed tie 3ire$) are 1ra.ed into or 1et3een

1#ade$ to da!%en the vi1ration #eve#$ of the 1#ade$ or /ro'%$ of 1#ade$8 In other ca$e$, the tie

3ire$ are in$ta##ed in the 1#ade ti%$ %artic'#ar# in #ar/e 1#ade$ in the #a$t $ta/e$ of t'r1ine$8 And

for $o!e 1#ade de$i/n$, inter#ocin/ ti% $hro'd$ (.C$ha%ed) and !id$%an $n'11er$ (contact

$'rface$) are 'ti#i.ed to da!%en 1#ade vi1ration, %artic'#ar# for #on/ #a$t $ta/e t'r1ine 1#ade$8

tea! t'r1ine 1#adin/ can 1e $'1+ected to $evera# fai#'re !echani$!$ in $ervice8 The$e!echani$!$ are indicated in Ta1#e 7 a#on/ 3ith the re$'#tant da!a/e and t%ica# ca'$e$ offai#'re. For steam turbines to operate with high reliability and availability, the ability toregularly inspect and assess the steam blading condition is important as any of thefailure mechanisms in Table 1 can lead to failure if left undiagnosed or neglected.

!a"le . Stea !ur"ine lading 1ailure Mechaniss1ailure

Mechanis esultant 4aage Cause+s, of 1ailureorro$ion 6ten$ive %ittin/ of airfoi#$,

$hro'd$, cover$, 1#aderoot $'rface$

he!ica# attac fro! corro$ive e#e!ent$ in the $tea!%rovided to the t'r1ine

ree% Airfoi#$, $hro'd$, cover$%er!anent# defor!ed

:efor!ed %art$ $'1+ected to $tea! te!%erat're$ ine6ce$$ of de$i/n #i!it$

ro$ion Thinnin/ of airfoi#$,$hro'd$, cover$, 1#aderoot$

7) o#id %artic#e ero$ion fro! ver fine de1ri$ and$ca#e in the $tea! %rovided in the t'r1ine

2) Water dro%#et ero$ion fro! $tea! 3hich i$tran$itionin/ fro! va%or to #iD'id %ha$e in the f#o3%ath

-ati/'e rac$ in airfoi#$, $hro'd$,cover$, 1#ade root$

7) Part$ o%erated at a vi1rator nat'ra# freD'enc2) Lo$$ of %art da!%enin/ (cover, tie 3ire, etc8)=) 6ceeded %art fati/'e #ife de$i/n #i!it

4) 6cited 1 3ater ind'ction incident 3ater f#a$he$ to$tea! in the f#o3%ath-orei/nB:o!e$tic?1+ect :a!a/e(-?:B:?:)

I!%act da!a/e (dent$,din/$, etc8) to an %art ofthe 1#adin/

:a!a/e fro! #ar/e de1ri$ in $tea! $'%%#ied to thet'r1ine (forei/n) or da!a/e fro! de1ri$ /eneratedfro! an interna# t'r1ine fai#'re (do!e$tic) 3hichca'$e$ do3n$trea! i!%act da!a/e to co!%onent$

tre$$ orro$ionracin/ ()

rac$ in hi/h# $tre$$edarea$ of the 1#adin/

%ecia#i.ed t%e of cracin/ ca'$ed 1 the co!1ined%re$ence of corro$ive e#e!ent$ and hi/h $tre$$e$ inhi/h# #oaded #ocation$

Ther!a# -ati/'e rac$ in airfoi#$, $hro'd$,cover$, and 1#ade root$

Part$ $'1+ected to ra%id# chan/in/ te!%erat're/radient$ 3here thic $ection$ are $'1+ected to hi/ha#ternatin/ ten$i#e and co!%re$$ive $tre$$e$ d'rin/heatC'%$ and coo#do3n$ or 3hen a 3ater ind'ction

incident occ'r$ 3here the ind'cted coo# 3aterD'enche$ hot %art$

2/A/2 4iscs otors Shafts lade ings Shells and 4ia'hragsTo tran$!it the torD'e %rod'ced in each $ta/e of the t'r1ine, the rotatin/ 1#adin/ i$ fa$tened to

di$c$ or 3hee#$ thro'/h a $%ecia## de$i/ned attach!ent $ha%e at the 1#ade 1a$e or root8 The

root $ha%e !a 1e firCtree, TC$#ot, or $e!iCcirc'#ar firCtree $ha%ed or !a '$e !'#ti%#e %in$ to

ho#d the 1#ade$ to the di$c$8 The t'r1ine di$c$ !a 1e $hr'n fit onto a $haft 3ith an antiC

rotation e or the di$c$ !a have 1een for/ed 3ith the $haft a$ an inte/ra# a$$e!1#8 The


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o't%'t $haft fro! the $hr'n fit or inte/ra# di$c rotor i$ then connected to the driven eD'i%!ent

thro'/h a f#an/e connection or f#e6i1#e co'%#in/8


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i!i#ar#, $tationar 1#adin/ root$ !a 1e attached to $#ot$ in $he##$, ca$in/$, or 1#ade rin/$ or

3here the $tationar 1#adin/ i$ 3e#ded to $'%%ort rin/$ to create a $tationar 1#adin/ a$$e!1#

referred to a$ a dia%hra/!8 :e%endin/ on the %re$$'re and te!%erat're of the $tea! to the

t'r1ine, there !a 1e d'a# $et$ of $he##$ or ca$in/$ an inner $he## 3hich ho#d$ the $tationar

1#adin/ and an o'ter $he## 3hich act$ a$ %re$$'re 1o'ndar for the t'r1ine a$ 3e## a$

acco!!odatin/ attach!ent of 1#ade rin/$8

The !a$$ and ther!a# inertia# of $tea! t'r1ine rotor$ and $he##$ can 1e D'ite #ar/e8 A$ $'ch,

the te!%erat're /radient$ the rotor$ and $he##$ can enco'nter d'rin/ $tartin/ and tran$ient$

need to 1e contro##ed caref'## other3i$e there can 1e $erio'$ r'1$ 1et3een the rotatin/ and

$tationar %art$ andBor there can 1e e6ten$ive di$tortion of rotor$ andBor $he##$ 3hen the

/radient$ are too #ar/e or occ'r too fa$t8

Steam turbine discs, rotors, shafts, shells, blade rings, and diaphragms are subjected tothe same failure mechanisms and causes that apply to steam turbine blading. It is notuncommon to encounter permanent deformation (creep, fatigue crac!s (thermal andvibratory, and stress corrosion crac!ing in discs, rotors, shells, and diaphragms. "nli!eblading, the mechanisms may ta!e longer for the resultant damage to become detectableas these parts tend to be more robust in si#e.

2/A/3 otor 1orgings with Center oresInte/ra## for/ed $tea! t'r1ine rotor$ !an'fact'red in the %a$t t3o decade$ have not had 1ore$!achined in the center of the rotor8 The i!%rove!ent$ in $tee# refinin/ and for/in/!an'fact'rin/ have not nece$$itated the need to re!ove i!%'ritie$ and %oor# for/ed !ateria#that acc'!'#ated in the center of o#der rotor$8 The presence of the center bore results in ahigh stress in the bore that re$uires periodic ultrasonic ("T and eddy current (%Tinspection for crac!s.

"eca'$e of the D'a#it of $o!e of the ear# for/in/$, crac$ have 1een fo'nd that reD'ire

interna# !achinin/ of the 1ore to re!ove the affected !ateria#8 It ha$ not 1een 'nco!!on to

find a fe3 h'ndred tho'$and indication$ d'rin/ ET in$%ection that !a reD'ire additiona#

ana#$e$ to deter!ine if the indication$ are crac$ and if the are connected to each other,

%otentia## re$'#tin/ in a 'n$afe condition8 The i!%rove!ent$ in ET in$%ection in$tr'!entation

and techniD'e$ have a#$o re$'#ted in findin/ ne3 n'!1er$ of defect$ that 3ere not detecta1#e

3ith o#der ET techno#o/ie$8 ?n the %o$itive $ide, the %re$ence of the center 1ore doe$ a##o3 for

ET in$%ection of rotor 3hee#$ and 1#ade $#ot$ fro! 'nderneath8

2/A/ earings and 6u"rication S%stesA$ 3ith !o$t rotatin/ !achiner, 1earin/$ are 'ti#i.ed to $'%%ort the t'r1ine rotor in$ide

ho'$in/$ in$ta##ed in the t'r1ine $he##$8 :e%endin/ on the $i.e and n'!1er of $ta/e$ of the

$tea! t'r1ine, different t%e$ of 1earin/$ !a 1e 'ti#i.ed8 It i$ co!!on for $!a##er $tea!

t'r1ine$ to 'ti#i.e ro##in/ e#e!ent 1earin/$ 3hi#e #ar/er t'r1ine$ 3i## 'ti#i.e +o'rna# and !'#tiC%ad

thr'$t 1earin/$8 ;e/ard#e$$ of the t%e of t'r1ine, there need$ to 1e a co!%#ete #'1rication

$$te! that re#ia1# %rovide$ c#ean, coo# #'1e oi# to the t'r1ine 1earin/$8 -or !an #ar/e $tea!


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t'r1ine$, $haft #ift oi# $$te!$ are 'ti#i.ed to #ift the $haft in their +o'rna# 1earin/$ d'rin/ $tartin/

and to ee% the $haft #'1ricated d'rin/ coa$t do3n of the t'r1ine rotor after $tea! to the t'r1ine

i$ $h't off8 -or $o!e t'r1ine$, #'1e oi# ('$'a## !inera# oi#) i$ 'ti#i.ed to %o3er $ervo!otor$ and

act'ator$ for $to% and contro# va#ve$8 In other ca$e$, hdra'#ic f#'id$ ('$'a## %ho$%hateCe$ter


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t%e f#'id$), 3hich can o%erate at hi/her %re$$'re$ and te!%erat're$ 3itho't i/nition, are

'ti#i.ed to %rovide the reD'ired %o3er for the va#ve$8

Pro%er# de$i/ned and !aintained #'1e oi# or hdra'#ic f#'id $$te!$ are e6tre!e# i!%ortant8

Mo$t oi# $$te!$, a$ a !ini!'!, need to inc#'de an oi# re$ervoir 3ith #eve# indication, fi#ter$ and$e%arator$ (%artic'#ate and 3ater re!ova#), %'!%$ (%ri!ar and e!er/enc 1ac'% that are

inde%endent of the %ri!ar %'!% $$te!), %re$$'re $3itche$ or $en$or$ to detect #o$$ of oi#

%re$$'re, and heat e6chan/er$ to coo# the oi#8 ?f !o$t concern i$ %rotectin/ the t'r1ine fro!

#o$$ of #'1e oi# incident$ 3hich !a invo#ve the #o$$ of oi# %re$$'re detector$ (%re$$'re $3itche$

and contro#$) or 1ac'% #'1e oi# %'!%($) andBor their $tartin/ #o/ic not 3orin/ %ro%er#8

ince oi# i$ 'ti#i.ed to #'1ricate and coo# t'r1ine 1earin/$ (and /ear1o6 /ear$ and 1earin/$, if%re$ent) and act'ate !a+or t'r1ine va#ve$, it i$ i!%ortant that the oi# 1e free of dirt, !oi$t're,foa!in/, and an conta!inant$ 3hich 3o'#d ca'$e da!a/e to 1earin/$, $ervo!otor$, and

va#ve act'ator$8 o!e conta!inant$ are re!oved 1 fi#ter$, 1't re!ova# of 3ater reD'ire$ 3ater$e%arator$, oi# %'rifier$, or centrif'/e t%e fi#ter $$te!$8 ?i# coo#er$ can a#$o 1e a $o'rce of3ater a$ #ea$ tend to f#o3 fro! hi/her %re$$'re (3ater) to the #o3er %re$$'re oi# $$te! in thecoo#er8 ?i# doe$ o6idi.e in the %re$ence of 3ater and 3i## have a #i!ited #ife8 A$ $'ch,cond'ctin/ freD'ent $a!%#in/ of #'1e oi# and hdra'#ic f#'id$ for %artic'#ate$, 3ater,conta!inant$, and re!ainin/ #ife i$ i!%ortant8 The reliability of the lube oil system isimportant as loss of lube incidents have been both fre$uent and severe events for allsi#es of turbines. &s such, periodic chec!s of loss of lube protection devices and logicneed to be conducted.

2/A/5 Stea and Oil SealsIn order to ee% the $tea! fro! /oin/ aro'nd the $tationar and rotatin/ 1#adin/, $tea! t'r1ine$

'ti#i.e $ea#$ to ee% the $tea! confined to the f#o3%ath8 :e%endin/ on the $i.e and t%e of$tea! t'r1ine, vario'$ t%e$ of $tea! $ea# de$i/n$ (car1on rin/$, #a1rinth, retracta1#e #a1rinth,

1r'$h) !a 1e 'ti#i.ed8 The$e $$te!$ are '$'a## %re$$'ri.ed 3ith $tea! to !ini!i.e the

%re$$'re differentia# acro$$ the$e $ea#$ $o that #eaa/e fro! the hi/her %re$$'re %art$ of the

t'r1ine i$ #e$$ #ie# to occ'r8 i!i#ar t%e $ea#$ are 'ti#i.ed to ee% 1earin/ oi# confined to the

1earin/ ho'$in/8 A$ $'ch, $ea# $$te!$ !a have fi#ter$, %re$$'re re/'#ator$, coo#er$, and the

#ie to !aintain a $ea# %re$$'re a$ reD'ired8 Severe rubbing of new seals after overhaul or

during transients operation, particularly starting, continues to cause steam turbine

forced outages.

2/A/7 Sto' !ri' !hrottle and Interce't 9alvesI!%ortant to an t'r1ine i$ the a1i#it to $tart and $to% the !achine 'nder nor!a# (contro##ed)

and e!er/enc condition$8 -or $tea! t'r1ine$, 1ein/ a1#e to $h't off the $tea! $'%%# D'ic#

and re#ia1# i$ reD'ired8 Thi$ i$ nor!a## acco!%#i$hed 1 either !ain $tea! (M) $to% va#ve$

or tri% and thrott#e (T&T) va#ve$ 3hich are '$'a## in$ta##ed in the in#et %i%in/ to the $tea!

t'r1ine or on the t'r1ine $he##8 The va#ve$ are de$i/ned to 1e #ea ti/ht other3i$e an $tea!

#eaa/e !a ee% the t'r1ine t'rnin/ at #o3 $%eed after $h'tdo3n or ca'$in/ an over$%eed

1eca'$e the va#ve did not c#o$e co!%#ete# after a $h'tdo3n or tri%8


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-or !o$t a%%#ication$, act'ator$ for the$e va#ve$ are %o3ered 1 hi/hC%re$$'re hdra'#ic

$$te! f#'id or #'1e $$te! oi#8 Hdra'#ic or #'1e $$te! %re$$'re %o3er$ $ervo!otor$ to o%en

the va#ve$ 3hi#e #o$$ of oi# %re$$'re re$'#t$ in $%rin/C#oad c#o$in/ of the va#ve in a fai#C$afe

condition (c#o$ed)8 -or $o!e o#d and $!a## $tea! t'r1ine$, the $to% va#ve !a 1e a !an'a#

va#ve 3ith a #ar/e hand3hee#8 The $a!e va#ve !a a#$o 1e '$ed for $tartin/ the 'nit8 In


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70

addition, there !a 1e hand o%erated va#ve$ !o'nted in the no..#e in#et for !an'a## increa$in/

$tea! to the t'r1ine8

-or reheat t%e $tea! t'r1ine$, 3hich direct $tea! 1ac to a 1oi#er $'%erheater $ection for

reheatin/ after /oin/ thro'/h the hi/h %re$$'re $ection of the t'r1ine, there are additiona#va#ve$ in$ta##ed 1et3een the hi/h %re$$'re $ection and $'1$eD'ent $ection of the t'r1ine8

;eheat $to% va#ve$ are '$ed for #ea ti/ht %rotection 1't a fa$ter active va#ve ca##ed an interce%t

va#ve i$ in$ta##ed in $erie$ or co!1ination 3ith the reheat $to% va#ve$ in order to %revent

over$%eed$8 The va#ve$ a#$o o%en 3ith oi# %re$$'re and are $%rin/C#oaded c#o$ed 3hen oi#

%re$$'re i$ red'ced to .ero 'nder tri% and over$%eed condition$8

These valves provide fundamental overspeed protection to the steam turbine and need tobe tested, inspected, and overhauled routinely as contaminants in the steam, wear ofmating valve parts, or damaged valve seats can cause stic!ing or lea!ing of these valves

in service.

2/A/: *overnor;Control 9alvesontro# va#ve$ are %rovided on the t'r1ine $he## to re/'#ate the f#o3 of $tea! to the t'r1ine for

$tartin/, increa$in/Bdecrea$in/ %o3er, and !aintainin/ $%eed contro# 3ith the t'r1ine /overnor

$$te!8 evera# different va#ve arran/e!ent$ are 'ti#i.ed8 The$e inc#'de a $in/#e in#et va#ve

3ith $e%arate act'ator, ca! #ift in#et va#ve a$$e!1#ie$, and 1ar #ift in#et va#ve a$$e!1#ie$8 The

va#ve a$$e!1#ie$ are nor!a## !o'nted onto a $tea! che$t that !a 1e inte/ra# to the $he## or

1o#ted to it8 The ca! #ift va#ve arran/e!ent 'ti#i.e$ ca!$, 1earin/$, and 1'$hin/$ 3hich are

!o'nted on ca!$haft to re/'#ate the %o$ition of each va#ve8 A hdra'#ic $ervo!otor drive$ a

rac and %inion connection to the ca!$haft to indicate the %o$ition de$ired 1 the /overnor8 In

the 1ar #ift va#ve arran/e!ent, a hdra'#ic c#inder #ift$ a## of the va#ve$ attached to the 1arto/ether, 1't the co##ar$ on each va#ve $te! are $et at different hei/ht$ and o%enin/ $eD'encin/

for ad!ittin/ $tea! d'rin/ $tartin/ and #oad chan/e$8 These valves need to be cycled

routinely to minimi#e the potential for the valves to stic!. 'hen the valves stic! open or

closed, the turbine is put into jeopardy as a result of losing the ability to control the

turbine (i.e., increase or reduce load.

2/A/8 Adission E-traction and $on


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70

e6traction$ ($in/#e, d'a#, etc8)8 tea! i$ taen fro! the t'r1ine at vario'$ $ta/e$ to !atch 3ith

the faci#itF$ %re$$'re and f#o3 reD'ire!ent$8 The e6traction$ can 1e cate/ori.ed a$ contro##ed

or 'ncontro##ed, a$ 3e## a$ a'to!atic or !an'a#8 o!e e6traction$ are 'ti#i.ed for feed3ater

heatin/8 The e6traction contro# va#ve$ t%ica## have t3o f'nction$ to re/'#ate the $tea! f#o3

e6terna## and to !aintain the e6traction $tea! %re$$'re con$tant8 The va#ve$ are hdra'#ica##

o%ened and $%rin/C#oaded $h't8 The are, ho3ever, not de$i/ned to 1e #ea ti/ht and 3i##t%ica## %a$$ 5 $tea! f#o3 in the c#o$ed %o$ition8


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77

onCret'rn va#ve$ (;) or chec va#ve$ are nor!a## in$ta##ed do3n$trea! of the contro##edand 'ncontro##ed (i8e8, no re/'#atin/ or contro# va#ve) e6traction connection$ to the t'r1ine8 Thef'nction of the va#ve$ i$ to %er!it f#o3 of e6traction $tea! in the o't/oin/ direction and %rohi1it

1ac3ard f#o3 into the t'r1ine 3hen t'r1ine e6traction %re$$'re i$ #o3er than the #ine$ it feed$8The va#ve$ are de$i/ned to 1e $%rin/C#oaded $h't 3hen there i$ no e6traction %re$$'re 1't thea#$o have an air or hdra'#ica## a$$i$ted act'ator to c#o$e the va#ve 3hen the $$te!$ are%re$$'ri.ed8 alfunctioning of e)traction *+-s is the primary cause of overspeeddamage during turbine shutdown. &s such, these valves need to be tested, inspected,and overhauled on a fre$uent basis.

2/A/= Stea 6ine Connections and 4rainsPro%er connection$ and $'%%ort of the $tea! #ine$ to the t'r1ine are i!%ortant a$ 3e## a$ the

$tea! drain$8 If the $tea! $'%%# #ine$ are %'ttin/ a #oad on the t'r1ine, it i$ #ie# to ca'$e the

t'r1ine to vi1rate and 3i## ca'$e !echanica# di$tre$$ to the attach!ent #ocation$8 i!i#ar#,

3hen $tea! t'r1ine$ are $tarted, there i$ a 3ar!C'% ti!e to heat the t'r1ine to the %ro%erte!%erat're #eve# 1efore ad!ittin/ f'## $tartin/ $tea!8 ;e!ova# of conden$ed $tea! fro! the

$to% va#ve and T&T va#ve$, the t'r1ine $he##$, and an $ea#in/ $tea! #ocation$ d'rin/ thi$

%eriod of o%eration i$ i!%ortant to %revent da!a/e to the t'r1ine8 A$ $'ch, #o3 %oint drain$,

$tea! tra%$ and drain va#ve$, vent$, and the #ie need to 1e f'nctionin/ %ro%er# and %i%in/ r'n$

orientated $o that the 3ater drain$ o't8 'hen drain systems are not operating properly, the

potential for encountering thermally distorted rotors (bowed and shells (humped will be

high.

2/A/.0 !ur"ine Overs'eed &rotection and !ri' 6ogicThe !o$t de$tr'ctive event for a $tea! t'r1ine i$ an over$%eed event a$ the $tea! t'r1ine and

it$ driven eD'i%!ent are '$'a## cata$tro%hica## da!a/ed8 The$e event$, 3hi#e infreD'ent,

contin'e to occ'r on 1oth $!a## and #ar/er $tea! t'r1ine$ re/ard#e$$ of the vinta/e, techno#o/

#eve#, a%%#ication, or t%e of contro# $$te! (di/ita#, ana#o/, hdroC!echanica#, !echanica#)

a$$ociated 3ith the $tea! t'r1ine8

A $tea! t'r1ine !a 'ti#i.e a !echanica# over$%eed %rotection $$te!, e#ectronic over$%eed

%rotection $$te!, or co!1ination of $$te!$ to !a6i!i.e %rotection8 The !echanica#

over$%eed device con$i$t$ of a $%rin/C#oaded %i$ton !o'nted in the t'r1ine $haft at the front of

the t'r1ine8 When t'r1ine $%eed reache$ an over$%eed condition (i8e8, 70 a1ove r'nnin/

$%eed), the %i$ton %o%$ o't and hit$ an oi# d'!% va#ve #ever 3hich ca'$e$ de%re$$'ri.ation of

the oi# $'%%# to the $to%, tri% and thrott#e, and interce%t va#ve$8 Thi$ re$'#t$ in a## $to% andinterce%t va#ve$ i!!ediate# c#o$in/8 Man !echanica# $$te!$ a#$o 'ti#i.e a f#3hee# 1a##

/overnor driven 1 the t'r1ine $haft8 An chan/e in /overnor %o$ition i$ converted to a chan/e

in oi# %re$$'re to the t'r1ine contro# va#ve $ervo!otor or act'ator8 Ender over$%eed condition$,

the f#3hee# /overnor 3i## hit the oi# d'!% va#ve #ever to c#o$e the $tea! $to% va#ve8

With e#ectronic $$te!$, n'!ero'$ !a/netic $%eed %ic'%$ are in$ta##ed on the t'r1ine $haft8

The t'r1ine contro# $$te! and $oft3are #o/ic 3i## e#ectronica## o%en the oi# d'!% va#ve to

de%re$$'ri.e the oi# $$te! and c#o$e a## $to% and interce%t va#ve$8 There are vario'$ ver$ion$


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72

of e#ectronic over$%eed $$te!$ in $ervice8 o!e inc#'de 1oth %ri!ar and 1ac'%

(e!er/enc) $$te!$ that o%erate inde%endent#8 o!e inc#'de te$t $3itche$ to te$t the

%ri!ar $$te! for %ro%er o%eration 3itho't act'a## tri%%in/ the t'r1ine8 -or !o$t t'r1ine$ the

over$%eed %rotection $$te! 3i## a#$o ca'$e or co!!and the t'r1ine contro# va#ve$ to c#o$e a$

3e##8 "eca'$e the contro# va#ve$ are not #ea ti/ht 1 de$i/n and their c#o$'re rate i$ !'ch


19/76

$#o3er than $to% and interce%t va#ve$, the are not con$idered to %rovide an over$%eed

%rotection8

In addition to the t%e of over$%eed %rotection %rovided, the tri% #o/ic 'ti#i.ed 1 the contro#

$$te! to o%en the circ'it 1reaer a$$ociated 3ith the $tea! t'r1ineF$ /enerator doe$ have$o!e effect on the %erfor!ance of the %rotection8 T%ica##, t3o tri% $che!e$ are 'ti#i.ed

$eD'entia# tri%%in/ and $i!'#taneo'$ tri%%in/8 eD'entia# tri%%in/ i$ 3hen the $tea! t'r1ine i$

a#3a$ tri%%ed fir$t and the /enerator circ'it 1reaer o%en$ 3hen the t'r1ine $%eed and

decain/ %o3er ha$ decrea$ed $'fficient# to ca'$e the /enerator rever$e %o3er re#a to o%en

the 1reaer8 The !ethod i$ t%ica## 'ti#i.ed 3ith #ar/e $tea! t'r1ine$ o%eratin/ at hi/h $tea!

in#et %re$$'re$ and te!%erat're$ 3here it i$ de$ired to di$$i%ate the ener/ in the t'r1ine 1efore

o%enin/ the 1reaer to !ini!i.e the over$%eed #eve# on $h'tdo3n8

i!'#taneo'$ tri%%in/ i$ 'ti#i.ed 3hen 1oth the t'r1ine $to% or tri% and thrott#e va#ve and the

/enerator circ'it 1reaer are o%ened at the $a!e ti!e, re/ard#e$$ of 3hether the t'r1ine or/enerator %rotection $$te! initiated the tri%8 Thi$ t%e $$te! i$ 'ti#i.ed $'cce$$f'## on $!a##to !edi'! $i.e $tea! t'r1ine$ 3here the $tea! %re$$'re$ and te!%erat're$ are #o3 and therei$ #itt#e $tea! vo#'!e in the t'r1ine to ca'$e an increa$e in $%eed on $h'tdo3n8 +egardless ofthe type of overspeed and trip protection systems provided, the system needs to beregularly tested by simulation and by actual testing of the complete system.

2/ Stea !ur"ine Arrangeents and A''lications 2//.

!%'e of SteaThe $tea! 'ti#i.ed in $tea! t'r1ine$ can 1e in three different $tate$ $at'rated, $'%erheated,

and $'%ercritica#8 at'rated $tea! i$ %rod'ced 3hen o' heat 3ater to the 1oi#in/ %oint or

va%ori.ation te!%erat're for a /iven %re$$'re8 Ender tho$e condition$, o' have ver hot 3aterand a $tea! va%or that i$ /iven off at the 3ater interface, $i!i#ar to 3hat ha%%en$ in a tea %ot8

Ho3ever, for $tea! t'r1ine$, the 1oi#in/ occ'r$ in the 1oi#er $tea! dr'! 3here the $tea! i$

$e%arated fro! the #iD'id 3ater that it ca!e fro!8 :e%endin/ on the %re$$'re and te!%erat're

of the 3ater 1ein/ heated, the $tea! !a $ti## contain a %ortion of entrained 3ater 'n#e$$ it i$

heated f'rther to va%ori.e the re!ainin/ 3ater content8 tea! t'r1ine$ do not #ie 3ater in their

$tea! $o the $tea! i$ heated 'nti# a## of the re!ainin/ 3ater ha$ va%ori.ed8

at'rated $tea! !a 1e heated to a hi/her te!%erat're at the $a!e %re$$'re in other 1oi#er

$ection$ referred to a$ $'%erheater$ or reheater$8 at'rated $tea! heated to the$e hi/her

te!%erat're$ i$ then referred to a$ $'%erheated $tea!8 tea! t'r1ine$ 3hich 'ti#i.e$'%erheated and $at'rated $tea! are often referred to a$ $'1critica# $tea! t'r1ine$8

If the %re$$'re of the $'%erheated $tea! i$ increa$ed f'rther 'nti# the ther!odna!ic critica#

%oint of 3ater i$ reached (227 1arB=,205 %$i), then the $tea! i$ referred to a$ $'%ercritica#

$tea!8 Thi$ $tea! ha$ the characteri$tic of %a$$in/ fro! a #iD'id (3ater) to a va%or ($tea!)

$tate 3itho't /oin/ thro'/h an inter!ediate #iD'id and va%or %ha$e8 Thi$ !ean$ a 1oi#er dr'!

i$ not needed a$ the heated 3ater direct# convert$ to va%or 3ith no !oi$t're to $e%arate or


20/76

reheat8 T'r1ine$ 'ti#i.in/ thi$ t%e of $tea! are referred to a$ $'%ercritica# t'r1ine$8 If the

%re$$'re of the $tea! i$ increa$ed to =


21/76

$tea! t'r1ine$ 'ti#i.e $at'rated $tea!8 Mo$t ind'$tria# and %o3er %#ant a%%#ication$ '$e

$'%erheated $tea!, and !o$t advanced %o3er %#ant$ are !ovin/ to3ard$ $'%ercritica# $tea!8

The $'%ercritica# 'nit$ have hi/her efficiencie$, %rod'ce #e$$ e!i$$ion$, need #e$$ f'e#, 1't tend

to reD'ire !ore advanced and thicer !ateria#$ to dea# 3ith 1oth the hi/her %re$$'re$ (=- (250C=


22/76


23/76

2//3 *rou'ing and $u"er of !ur"ine StagesT'r1ine$ are often de$cri1ed 1 the n'!1er of $ta/e$8 -or e6a!%#e, $in/#e $ta/e t'r1ine$ are

'$'a## $!a## 'nit$ that drive %'!%$, fan$, and other /enera# %'r%o$e eD'i%!ent in a faci#it8

-or !edi'! $i.e $tea! t'r1ine$ that drive air conditionin/ chi##er$ or /enerator$, 4 to 70 $ta/e$

!a 1e 'ti#i.ed8 In #ar/e $i.e 'nit$, there !a 1e 72 to 40 $ta/e$ drivin/ /enerator$ or othereD'i%!ent8 The$e $ta/e$ !a 1e /ro'%ed into different $ection$ of the t'r1ine8 The $ection

3ith the hi/he$t %re$$'re #eve#$ i$ ca##ed the hi/h %re$$'re (HP) $ection8 The inter!ediate

%re$$'re (IP) $ection ha$ the !idC#eve# %re$$'re #eve#$8 The #o3 %re$$'re (LP) $ection ha$ the

#o3e$t %re$$'re #eve#$ and di$char/e$ to the conden$er or 1ac%re$$'re $$te!8 The t'r1ine

$ection$ can 1e %aca/ed into $e%arate $ection$ in a $in/#e t'r1ine ca$in/, into $e%arate

ca$in/$ for each $ection, or in co!1ination (HPBIP t'r1ine$ in one ca$in/ and LP t'r1ine in

another)8 In addition, in !an LP t'r1ine$ and $o!e HP and IP t'r1ine$, there are t3o t'r1ine$

connected to/ether in the $a!e ca$in/ 1't in o%%o$in/ direction$ to 1a#ance the thr'$t #oad$8

-#o3 to the$e t'r1ine$ i$ thro'/h the center of the ca$in/ and e6it$ fro! each end of the t'r1ine8

The$e are referred to a$ t'r1ine$ 3ith do'1#e f#o3$ (i8e8, o%%o$in/ f#o3%ath$ on $a!e $haft)8

The MW ratin/ of the $tea! t'r1ine, ho3ever, !a not 1e indicative of the n'!1er of $ection$

or ca$in/$ 3hich !ae '% the t'r1ine8 Thi$ i$ e6e!%#ified in -i/'re 2 3here a


24/76

on$i$tent 3ith the variation in the n'!1er of t'r1ine ca$in/$, the #a$t $ta/e 1#ade$ in the LP

$ection, 3hich i$ the #ar/e$t 1#ade in the t'r1ine, !a ran/e in $i.e and !ateria#$ over a 1road

ran/e8 -i/'re = $ho3$ a t%ica# $'ite of 1#ade $i.e$ that a !an'fact'rer !a 'ti#i.e in their

$tea! t'r1ine$8 evera# !an'fact'rer$ are no3 'ti#i.in/ titani'! !ateria# for the #a$t $ta/e


25/76

1#ade$ 1eca'$e of the #i/hter 3ei/ht and i!%roved corro$ion re$i$tance a$ co!%ared to $tee#

1#ade$8 Enfort'nate#, 3hether !ade fro! titani'! or $tee#, the$e #ar/e 1#ade$ are '$'a## the

!o$t e6%en$ive in the t'r1ine and the !o$t #ie# to fai# 3ith ti!e8

1igure 3 !%'ical 6& !ur"ine 6ast Stage lade Si>es +Courtes% Mitsu"ishi #eav% Industries,

630 mm 750 mm 970 mm 1010 mm 1140 mm 1040 mm 1179 mm 1370 mm(25 inch) (29.5 inch) (33 inch) (40 inch) (45 inch Ti) (41 inch) (46 inch) (54 inch)

2// !ur"ine ArrangeentIn !o$t ca$e$, $tea! t'r1ine$ and the /enerator$ the drive are #aid o't in $eD'ence, !eanin/

that the ca$in/$ and $haft$ of a## of the t'r1ine $ection$ and /enerator are in a $in/#e #ine8 Thi$

i$ referred to a$ a tande! co!%o'nd #ao't or arran/e!ent8 In $o!e ca$e$, the ca$in/$ and

$haftin/ are #aid o't 3ith t3o %ara##e# $haftin/ arran/e!ent$8 The$e are referred to a$ cro$$

co!%o'nd arran/e!ent8 The$e 'nit$ are characteri.ed 1 the HP and IP t'r1ine$ drivin/ one

/enerator and the LP t'r1ine drivin/ another /enerator8 The $tea! for the LP t'r1ine co!e$

fro! a cro$$ connection fro! the IP t'r1ine e6ha'$t8 Thi$ i$ e6e!%#ified in -i/'re 4 3here the

HP and IP t'r1ine$ and their /enerator !ae '% the #eft drive train 3hi#e the 2 LP t'r1ine$ and

their /enerator !ae '% the ri/ht drive train8 ;e/ard#e$$ of the t3o %ara##e# $haftin/

arran/e!ent, the 'nit ha$ to r'n a$ if the $$te!$ 3ere a## direct# connected to/ether8

1igure .050 M( Cross Co'ound Stea !ur"ine *enerator+Courtes% Mitsu"ishi #eav% Industries,


26/76


27/76

-or $o!e $tea! t'r1ine de$i/n$, the t'r1ine $ection$ are !o'nted on o%%o$ite $ide$ of the

/enerator8 An e6a!%#e of a ta# A !od'#ar $tea! t'r1ine /enerator de$i/n i$ $ho3n in

-i/'re 58 In thi$ t'r1ine de$i/n, the HP t'r1ine $ection i$ on the #eft of the /enerator and the LP

t'r1ine i$ !o'nted on the other $ide of the /enerator8 A red'ction /ear1o6 i$ %rovided to

red'ce HP t'r1ine $%eed to the /enerator8 ta# a#$o de$i/ned radia# t'r1ine$ 3here there are

no $tationar 1#adin/ 1't rather co'nter rotatin/ 1#adin/ that connect to t3o $e%arate

/enerator$8

1igure 5 Stal 9A? Modular Stea !ur"ine +Courtes% Alsto &ower,

Whi#e the e6ha'$t arran/e!ent, $tea! in#et condition$, and t'r1ine $ta/e$ andBor 1#ade $i.e

can characteri.e a t'r1ine, $o can the o%eratin/ $%eed8 Mo$t #ar/er $tea! t'r1ine$ and o#der

t'r1ine$ r'n at =,000 (50 H.) or =,900 (90 H.) ;PM8 The LP t'r1ine$ and /enerator$ 3ith cro$$

co!%o'nd 'nit$ t%ica## r'n at ha#f $%eed 7,500 (50H.) and 7,>00 (90 H.) ;PM8 A## of the$e

t'r1ine$ connect direct# to the /enerator for o%eration at thi$ $%eed8 !a##, !edi'! and #o3erC

end #ar/e t'r1ine$ r'n at hi/her $%eed$ (5,000 to 72,000 ;PM)8 Thi$ nece$$itate$ the '$e of a$%eed red'ction /ear1o6 to !atch the /enerator de$i/n $%eed$8 In nonC/enerator drive

a%%#ication$, the $tea! t'r1ine$ !a 1e r'n at hi/her $%eed$ 3ith or 3itho't a /ear1o6 to !atch

the driven $%eed of co!%re$$or$, %'!%$, fan$, #ine $haft$, and other eD'i%!ent8

2//5 Single Stage Sall Stea !ur"inesA t%ica# $in/#e $ta/e t'r1ine i$ $ho3n in the #eft $ide of -i/'re 98 The$e 'nit$ t%ica## con$i$t

of a do'1#e ro3 of $tationar and rotatin/ 1#adin/, 3hee#$ eed and $hr'n onto $haft, antiC

friction thr'$t and radia# +o'rna# 1earin/$, car1on $haft $ea#$, over$%eed tri% 1o#t, !echanica#

/overnor, and ho'$in/$8 "eca'$e the$e t'r1ine$ r'n #o3 %re$$'re and te!%erat're $tea!, the

are '$'a## con$tr'cted of #e$$ $o%hi$ticated and #o3er co$t !ateria#$8 The$e t%e$ of 'nit$ are'ti#i.ed to drive 1oi#er fan$, 3ater %'!%$, 1oi#er feed %'!%$, and /enerator$ in a variet of

ind'$trie$8

2//7 Multistage Mediu Si>e Stea !ur"inesThe t%ica# con$tr'ction of a !'#ti$ta/e 'nit 3ith nine $ta/e$ i$ $ho3n in the ri/ht $ide of -i/'re

98The$e t%e of 'nit$ con$i$t of an initia# i!%'#$e $ta/e fo##o3ed 1 $evera# reaction $ta/e$, 3hee#$$hr'n onto a $haft, ti#tin/ %ad thr'$t and radia# +o'rna# 1earin/$, #a1rinth $haft $ea#$,over$%eed tri% device, and ca$in/8 The$e !a 1e '$ed for drivin/ #ine $haft$ in %a%er !i##$,


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chi##er co!%re$$or$ for 1'i#din/ air conditionin/, $!a## centrif'/a# and reci%rocatin/co!%re$$or$ in the oi# and /a$ ind'$tr, and /enerator$ in a## ind'$trie$8


29/76

1igure 7 Single and Multistage Stea !ur"ines +Courtes% Elliott Co'an%,

2//: Single Casing Adission;E-traction Multistage Stea !ur"inesThe t%ica# con$tr'ction of a =5 MW ad!i$$ionBe6traction $tea! t'r1ine i$ indicated in -i/'re


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2//8 Single Casing $on


31/76


32/76

2//.0 Multi'le Casing Multi'le Stage eheat Stea !ur"inesA !odern five ca$in/ reheat $tea! t'r1ine in $ho3n in -i/'re 708 A$ %revio'$# di$c'$$ed, the

n'!1er of ca$in/$ 3i## 1e a tradeoff 1et3een co$t, t'r1ine efficienc, and #a$t $ta/e 1#ade ri$8

A$ 3ith the co!1ined cc#e $tea! t'r1ine$, there have 1een de$i/n chan/e$ !ade to $to%,

contro#, and interce%t va#ve$ to inte/rate the! to/ether a$ co!1ined a$$e!1#ie$8 The$e arec#ear# $ho3n to the ri/ht and #eft of the HP and IP t'r1ine$ ca$in/$ in -i/'re 708 In /enera#, the

n'!1er of ca$in/$ do %re$ent an overha'# cha##en/e a$ 5 $e%arate t'r1ine$ have to 1e a#i/ned

to each other and to the /enerator a$ $ho3n in -i/'re 778 A$ $'ch, it i$ not 'nco!!on for

$ectiona# overha'#$ to 1e cond'cted, i8e8, the HP and IP t'r1ine$ !a 1e cond'cted a$ one

overha'# and the LP t'r1ine$ and /enerator cond'cted a$ a $e%arate overha'#8

1igure .0 Multi'le Casing eheat Stea !ur"ine +Courtes% Sieens &ower Cor'oration,

1igure .. Multi'le Casing eheat Stea !ur"ine +Courtes% #itachi,


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20

3/ Monitoring O'erationsMaintenance and !rainingInfrastructure

;e/ard#e$$ of the $i.e, n'!1er of ca$in/$, $tea! condition$, and arran/e!ent$, it i$ e$$entia#that $tea! t'r1ine$ have effective !onitorin/, o%eratin/ and !aintenance %roced're$B%ractice$,

and trainin/ for %er$onne#8 The$e to%ic$ are di$c'$$ed in the ne6t $ection$8

3/A Monitoring

3/A/. E@ui'ent MonitoringTo effective# !ana/e the hea#th and %erfor!ance of $tea! t'r1ine$, there are a n'!1er of

t'r1ine %ara!eter$ 3hich $ho'#d 1e !ea$'red, !onitored andBor di$%#aed on a contin'o'$

1a$i$8 Ho3 !'ch infor!ation i$ !onitored i$ a f'nction of the $tea! t'r1ine de$i/n and

a%%#ication, 1't 3ith todaF$ !odern $tea! t'r1ine$, the fo##o3in/ %ara!eter$ $ho'#d 1e!onitored

%eed (;PM) and #oad (WBMW, or $haft hor$e%o3er (HP)) tea! t'r1ine in#et %re$$'re and te!%erat're tea! t'r1ine 7

$t$ta/e %re$$'re and te!%erat're (the$e are the condition$ do3n$trea! of the

fir$tB#ar/e i!%'#$e $ta/e 1efore re!ainin/ HP $ection 1#adin/, a$ a%%#ica1#e) HP t'r1ine o't#et (or co#d reheat), IP t'r1ine in#et (or hot reheat), and IP t'r1ine o't#etBLP

t'r1ine in#et (or cro$$over) %re$$'re$ and te!%erat're$ for reheat and !'#ti%#e $he## t'r1ine$on#

tea! t'r1ine rotorB$he## differentia# e6%an$ion$ (a$ a%%#ica1#e for #ar/e t'r1ine$) tea! t'r1ine $he## and $tea! che$t te!%erat're$Bdifferentia#$ (#o3er and '%%er ha#f

ther!oco'%#e$ in$ta##ed in HP and IP t'r1ine $ection$ for #ar/e t'r1ine$) Ad!i$$ion and e6traction %re$$'re$ and te!%erat're$ (a$ a%%#ica1#e) 6traction #ine ther!oco'%#e$ to detect 3ater ind'ction (a$ a%%#ica1#e) Water and $tea! %'rit at the !ain $tea! in#et and conden$ate %'!% di$char/e ea#in/ $tea! and e6ha'$ter %re$$'re$ (a$ a%%#ica1#e) tea! t'r1ine e6ha'$t %re$$'re and te!%erat're L'1e oi# and hdra'#ic f#'id $'%%# %re$$'re$ and te!%erat're$ oo#in/ 3ater $'%%# %re$$'re$ and te!%erat're$ for the #'1e oi# and hdra'#ic f#'id $$te!$ Jo'rna# 1earin/ and thr'$t 1earin/ !eta# te!%erat're$ (or drain te!%erat're$, if a%%#ica1#e) for

the t'r1ine and /ear1o6 (a$ a%%#ica1#e) "earin/ vi1ration $ei$!ic, $haft rider, or $haft 6CandC %ro6i!it %ro1e$ !ea$'re!ent$ for a##

t'r1ine and /ear1o6 (%inion) 1earin/ #ocation$ (a$ a%%#ica1#e)

Monitorin/ of the$e and other %ara!eter$ i$ t%ica## done in con+'nction 3ith todaF$ !odern

t'r1ine di/ita# contro#$ and %#ant contro# roo! $$te!$8 The$e $$te!$ 3i## a#$o hand#e the

$tartin/ $eD'ence, $nchroni.in/, #oadin/, $%eed /overnin/, a#ar!$, and tri% #o/ic for the

t'r1ine, /ear1o6 (if %re$ent), /enerator, and an $'%%ortin/ $$te!$8 The$e $$te!$ a#$o

%rovide the e#ectronic %ortion of the %rotection (i8e8, t'r1ine over$%eed) for critica# t'r1ine and

/enerator %ara!eter$8 -or o#der 'nit$ there !a 1e an ana#o/ contro# $$te! 3hich %rovide$

#i!ited %rotection a#on/ 3ith !echanica#Be#ectrica# device$ on the 'nit8 There '$'a## i$ a #i!ited

di$%#a of !onitorin/ %ara!eter$8 -or even o#der 'nit$, a## o%eration 3i## 1e !an'a# 3ith on# a


34/76

20

/a/e %ane# to !onitor a fe3 t'r1ine %ara!eter$8 i1ration !onitorin/ i$ done %eriodica## '$in/

handChe#d in$tr'!entation8 The$e o#der 'nit$ are de%endent $o#e# on the no3#ed/e of the

o%eratin/ $taff, the %re$ence and '$e of 3ritten o%eratin/ %roced're$, and the

!echanica#Be#ectrica# device$ on the 'nit for %rotection8 A## of the$e i$$'e$ are i!%ortant for

ever 'nit 1't the con$eD'ence i$ hi/her 3ith o#der, o'tdated 'nit$8


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27

"eca'$e the a!o'nt of eD'i%!ent !onitorin/ !a de%end on the co!%#e6it of the $tea!

t'r1ine, the minimum acceptable t'r1ine %ara!eter$ that $ho'#d 1e !onitored 1 t'r1ine

t%eB$i.e are indicated in Ta1#e 2

!a"le 2 < ecoended Stea !ur"ine Monitoring &araeters "% !ur"ine Si>e;!%'e

Stea !ur"ine &araetersto "e Monitored Continuousl%

SallSingleStagenits0/5e

Multi

indicate 3hat i$ con$idered to 1e the iniu recoended 'ractice for achievin/ hi/h#eve#$ of re#ia1i#it and avai#a1i#it, 1a$ed on the di$c'$$ion$ in ection$ 2C4 and 1a$ed on

atte!%tin/ to !iti/ate the ri$ of hi/h %ro1a1i#it and hi/h con$eD'ence t%e fai#'re$8

!a"le 7 Euro'ean Annual Stea !ur"ine Maintenance 1re@uencies and !as)s1re@uenc% Maintenance !as)

/aily or 0ess 78 ond'ct vi$'a# in$%ection of the 'nit for #ea$ (oi# and $tea!), 'n'$'a#noi$eBvi1ration, %#'//ed fi#ter$ or a1nor!a# o%eration28 c#e nonCret'rn va#ve$

'ee!ly or 0ess 78 Trend 'nit %erfor!ance and hea#th8 HandChe#d vi1ration readin/$ $ho'#d 1etaen fro! the $tea! t'r1ine and /ear1o6 if %er!anent vi1ration !onitorin/ $$te!i$ not in$ta##ed

28 Te$t e!er/enc 1ac'% and a'6i#iar #'1e oi# %'!%$ for %ro%er o%eration=8 Te$t the !ain #'1e oi# tan and oi# #o3 %re$$'re a#ar!$48 Te$t the $i!'#ated over$%eed tri% if %re$ent58 c#e the !ain $tea! $to% or thrott#e va#ve98 c#e contro# va#ve$ if $tea! #oad$ are 'nchan/in/


52/76

48 Te$t the !echanica# over$%eed for %ro%er o%eration ann'a## 'n#e$$ the %ri!ar$$te! i$ e#ectronic and ha$ an ? te$t $3itch8 -or that $$te!, e#ectronicover$%eed $i!'#ation$ $ho'#d 1e cond'cted 3ee# 3hi#e !echanica# ande#ectrica# over$%eed te$t$ $ho'#d 1e cond'cted ever = ear$8 -or e#ectronic$$te!$ 3itho't an ? te$t $3itch, an over$%eed te$t $ho'#d 1e cond'cted


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ann'a##8

58 ond'ct vi$'a# in$%ection of /ear1o6 (if in$ta##ed) teeth for 'n'$'a# 3ear orda!a/e, and /ear1o6 $ea#$ and 1earin/$ for da!a/e8

98 Interna## in$%ect nonCret'rn va#ve act'ator$ for 3ear

Pa$t ?M reco!!endation$ for one !an'fact'rer for their !edi'!C$i.ed and #ar/e $tea!

t'r1ine $et$ are $ho3n 1e#o3 in Ta1#e


54/76

o!%#ete e6a!ination of the co'%#in/$, inc#'din/ a6ia# r'nCo't te$t :i$!ant#in/ and e6a!ination of the /enerator rotor


55/76

#n$%ection$ of the entire $tator 3indin/ (end 3indin/ $'%%ort, $#ot 3ed/in/, 1andin/, 1'$ 1ar$,ter!ina#$)

6a!ination of the entire $tator core for $tren/th and da!a/e :i$a$$e!1# and in$%ection of the e6citation eD'i%!ent (e6citer, 1r'$h /ear and $#i% rin/

1r'$he$) Additiona# chec$ accordin/ to the %artic'#aritie$ of the 'nit and individ'a#o%erationa# o1$ervation$

After reachin/ 700,000 ?H the ?MF$ t%ica## reco!!end %erfor!ance of an a$$e$$!ent of

the re!ainin/ #ifeti!e for $o!e critica# co!%onent$ a$ e8/8 rotor, $o!e hi/h# $tre$$ed re/ion$

of the HP ca$in/, HP in#et va#ve$, etc8 The$e reco!!endation$ corre#ate 3e## 3ith the G"

reco!!endation$ $ho3n in Ta1#e > 1e#o38

!a"le 8 9* Multi'le


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Periodic Maintenance (!aintenance !andated 1 /overn!ent a'thoritie$ 1a$ed on re/'#ator

#a3$), and the ;e/'#ator Periodic Maintenance interva# 3a$ #en/thened to t3ice the %revio'$#


57/76

reD'ired %eriod8 Thi$ i$ d'e to the 1ac/ro'nd of recent advance$ in techno#o/ increa$in/ the

re#ia1i#it of the eD'i%!ent and an increa$e in $afet #eve#$8 -'rther, accordin/ to directive$ for

the La3, ther!a# %o3er %#ant o3ner$ have a d't to $trict# !ana/e their dai# o%eration$ and to

f'## o%ti!i.e their inde%endent $afet !ea$'re$ and attain the 't!o$t $tandard of $afet8

Periodic e#f Maintenance !'$t 1e co!!enced 3ithin 4 ear$ fro! the !o$t recent ;e/'#ator

%eriodic !aintenance or the %eriodic $e#f !aintenance, and it$ record$ !'$t 1e e%t for 5 ear$8

The record$ 3i## 1e in$%ected d'rin/ the $'1$eD'ent ;e/'#ator Periodic Maintenance8

In Ta1#e @ the /'ide#ine$ for the ite!$ for %eriodic $e#f !aintenance are indicated8 The$e are

near# $i!i#ar to the re/'#ator %eriodic !aintenance8 The detai#ed !aintenance ite!$ and the

$ched'#e$ of %o3er %#ant$F adherence to the /'ide#ine$ cannot 1e re%orted $ince the$e are not

di$c#o$ed to the %'1#ic8

!a"le = Fa'anese &eriodic Self


58/76

48 :ai# in$%ection$ are carried o't accordin/ to the :irective$ of the La3858 o a1nor!a#itie$ 3ere detected at the %revio'$ in$%ection or that a1nor!a#itie$ or

di$order$ 3ere re%aired andB or %revention !ea$'re$ a%%ro%riate# taen8


59/76

98 After the %revio'$ in$%ection, if an accident or di$order occ'rred, the da!a/ed ite! 3a$%er!anent# re%aired and !ea$'re$ taen to %revent an rec'rrence$, and the $a!e%revention !ea$'re$ taen to an $i!i#ar ite!$ of the %#ant8

1) -or %#ant eD'i%!ent 3ith #o3 o%eratin/ ho'r$

-or %#ant$ 3ith #o3 o%eratin/ ho'r$ $'1$eD'ent to the #a$t Periodic e#f Maintenance or

;e/'#ator Periodic Maintenance, an a%%#ication for a chan/e in in$%ection interva# can

1e $'1!itted 3ith a !a6i!'! of the fo##o3in/, 3hichever co!e$ ear#ier

78 ?%eratin/ ho'r$ >,000 ho'r$28 '!1er of $tart'%$ 240 ti!e$ (4>0 ti!e$ for 'nit$ that have co!%#eted %revention

!ea$'re$ for #o3 cc#e fati/'e)

Ho3ever, the !a6i!'! in$%ection interva# a##o3a1#e at an one a%%#ication i$ 4 ear$8


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7/ A''roaches;Methodologies;Criteria forEsta"lishing 6onger !ie Intervals "etween MaGorOverhauls

With the hi/h# co!%etitive nat're of todaF$ !aret$ 3or#d3ide re/ard#e$$ of ind'$tr $e/!ent,co!%anie$ cannot afford to do !a+or $tea! t'r1ine /enerator o'ta/e$ too freD'ent#8 The

o'ta/e$ are e6%en$ive to e6ec'te 3hi#e inc'rrin/ additiona# e6%en$e$ andBor #o$t reven'e 3hi#e

the 'nit i$ offC#ine for the o'ta/e8 ?f co'r$e, 3aitin/ too #on/ to %erfor! an o'ta/e !a re$'#t in

!ore da!a/e to re%air, or 3or$e, havin/ to 'ndertae a forced o'ta/e to re%air di$a1#in/

da!a/e8 Ho3ever, over the %a$t $evera# ear$, it ha$ 1een de!on$trated that $tea! t'r1ine$

and /enerator$ can $'cce$$f'## r'n #on/er than 5 to 9 ear$ 1et3een o'ta/e$ that had

traditiona## 1een an ind'$tr $tandard in !an %art$ of the 3or#d8 Thi$ ha$ 1een %artic'#ar#

tr'e for 'nit$ 3here the a!o'nt of interna# 3earBda!a/e fo'nd d'rin/ overha'#$ 3a$ neither

$i/nificant nor ref#ected a hi/h %ro1a1i#it of a near ter! fai#'re (i8e8, fe3 ear$)8

o ho3 doe$ an o3ner, o%erator, or in$'rer of $tea! t'r1ine$ decide 3hat i$ the ri/ht interva# to

acco!%#i$h !a+or o'ta/e$ and ho3 do o' en$'re that the #on/er o'ta/e interva# i$ re#ia1# and

$afe# achievedR There have 1een a n'!1er of a%%roache$ 'ti#i.ed in the %a$t and there are

different !ethodo#o/ie$ 'ti#i.ed in vario'$ ind'$trie$ toda8 The 1a$ic %rinci%#e, 1enefit$, and

effectivene$$ of the a%%roache$ and !ethodo#o/ie$ are di$c'$$ed in the ne6t $ection$8

7/A Manageent 4irected Interval

The $i!%#e$t a%%roach '$ed 1 !an co!%anie$ 3a$ the !ana/e!ent directed interva#, i8e8,

there 3a$ no !one to do !a+or o'ta/e$ !ore freD'ent# than the ti!e interva# $%ecified 1 thefinancia# !ana/e!ent of the faci#it8 Enfort'nate#, !an of the$e deci$ion$ 3ere 'ni#atera##

!ade 3itho't an technica# in%'t or rea# a$$e$$!ent of the ri$ of fai#'re of the co!%anF$

t'r1ine$8 #ear#, t'r1ine$ 3hich did not have a %riorBc'rrent hi$tor of %ro1#e!$ and on# had

#i!ited 3earBda!a/e d'rin/ %a$t o'ta/e$ 3ere #o3er ri$ candidate$ for #on/er o'ta/e interva#$8

Ho3ever, '$in/ the $a!e interva# for a## t'r1ine$, re/ard#e$$ of their %a$tBc'rrent e6%erience,

re$'#ted in !an forced o'ta/e$ for tho$e that cho$e thi$ a%%roach8

The %ro1#e! 3ith the !ana/e!ent directed interva# 3a$ not in $%ecifin/ the interva# 1't rather

en$'rin/ that $'1$eD'ent $tea! t'r1ine overha'# 3or$co%e$ too a #on/er ti!e %eriod vie3 of

3hat 3or needed to 1e done8 i!%# $tated, t'r1ine overha'# and re%air effort$ needed toaddre$$ a## area$ of the t'r1ine 3hich 3ere !o$t #ie# to have !a+or da!a/e or fai# in the

#on/er $%ecified interva#8 If that a%%roach i$ 'ti#i.ed for e6ec'tin/ overha'#$, then !eetin/ a

directed interva# can 1e re#ia1# achieved if a## reD'ired 3or i$ acco!%#i$hed8 If o' have a

f#eet of t'r1ine$, ho3ever, it 3i## tae $evera# ear$ to 1rin/ the condition of a## the t'r1ine$ to a

#eve# that the are a## ca%a1#e of #on/er interva#$8

7/ &rocess and Criticalit% 4riven Intervals


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In !an ind'$trie$ the $tea! t'r1ine i$ 'ti#i.ed a$ %art of a #ar/er !an'fact'rin/ %roce$$8 -or

e6a!%#e, $tea! t'r1ine$ in the che!ica#, oi# and /a$ ind'$trie$ !a drive centrif'/a# and

reci%rocatin/ co!%re$$or$ that are %art of a co!%#e6 $erie$ of che!ica# %roce$$e$8 In the$e

a%%#ication$, $tea! t'r1ine overha'# interva#$ and the a##otted ti!e for the overha'# are driven

1 the reD'ire!ent$ of the %roce$$8 A$ $'ch, the overha'#ed t'r1ine$ need to achieve the

$%ecified %roce$$ interva# 3itho't forced o'ta/e$ a$ #o$$ of the $tea! t'r1ine 3i## ca'$e$h'tdo3n of the %roce$$ and #o$t reven'e a$ hi/h a$ S7M %er da8 -or the$e a%%#ication$ the


62/76

ti!e interva# 1et3een !a+or o'ta/e$ ha$ 1een $%ecified at 9 ear$ and, fort'nate#, !o$t

faci#itie$ have !a+or $%are$ to !ini!i.e the #o$t ti!e $ho'#d a $i/nificant fai#'re occ'r8

In the $tee#, %a%er, and %har!ace'tica# ind'$trie$, !an $tea! t'r1ine$ are inte/rated into the

$tea! or %re$$'ri.ed air %ortion of the !an'fact'rin/ %roce$$e$8 The$e t'r1ine$ !a drivet'r1o1#o3er$ fro! avai#a1#e %#ant $tea! or !a red'ce the %re$$'re of avai#a1#e %#ant $tea! for

interna# !an'fact'rin/ %roce$$e$ 3hi#e conc'rrent# !ain/ e#ectricit8 In the$e ca$e$, the ti!e

interva# for overha'#$ !a re!ain in the 5C9 ear ti!e fra!e 1eca'$e of the critica# nat're of the

%rod'ct and to en$'re that the t'r1ine$ !aintain a hi/h #eve# of re#ia1i#it8 Thi$ $a!e %hi#o$o%h

a%%#ie$ to critica# co!1ined heat and %o3er (HP)Bco/eneration a%%#ication$ 3here hi/h

re#ia1i#it i$ !ore i!%ortant than the co$t $avin/$ %o$$i1#e fro! e6tendin/ o'ta/e interva#$8

7/C !ur"ine Manufacturers Intervals

:e%endin/ on the $i.e of the $tea! t'r1ine and the !an'fact'rer, overha'# interva#$ !a 1e$%ecified in ear$ of o%eration, eD'iva#ent o%eratin/ ho'r$ (?H), or 1a$ed on condition8

Man'fact'rer$ of $!a##er $tea! t'r1ine$ tend to $%ecif interva#$ in the =C5 ear ti!e fra!e

3hi#e !o$t %o3er /eneration ind'$tr !an'fact'rer$ 'ti#i.e a 'niD'e for!'#a for ?H 3hich

!a tae into acco'nt the n'!1er of r'nnin/ ho'r$, co#d $tart$, 3ar! $tart$, hot $tart$, tri%$

fro! a1ove or 1e#o3 $%ecified #oad #eve#$, rate of #oadin/B'n#oadin/, and over$%eed$8

Enfort'nate#, the for!'#a$ are different for each !an'fact'rer and !an %#ant$ do not active#

co##ect the a%%#ica1#e data to ca#c'#ate ?H8 A$ $'ch, interva#$ !a 1e $%ecified 1 the

!an'fact'rer 1a$ed on a e6terna# condition a$$e$$!ent (i8e8, %erfor!ance, vi1ration, no3n

%ro1#e!$, %a$t hi$tor) 3hich !a 1e !ore 1ia$ed to3ard !ore freD'ent overha'#$8 -or

e6a!%#e, Genera# #ectric adverti$e$ that their $tea! t'r1ine$ are de$i/ned for 72 ear$1et3een !a+or o'ta/e$ 1't their officia# $ervice /'ide#ine$ $%ecif 5 ear$ 1et3een o'ta/e$8

7/4 Electric &ower esearch Institute +E&I,

In the !idCto #atter 7@@0F$ P;I 'ndertoo an ind'$tr effort to deve#o% a !ean$ of deter!inin/

the ti!e 1et3een !a+or o'ta/e interva#$8 The initia# 3or 3a$ 1a$ed on '$in/ deci$ion ana#$i$

!ethodo#o/ co'%#ed 3ith %ro1a1i#itBcon$eD'ence infor!ation $%ecified 1 the '$er to %ro+ect

3hat the net %re$ent va#'e (P) of the t'r1ine 3i## 1e 3ith ti!e 'nder vario'$ overha'#

$ched'#e$ and fai#'re $cenario$8 A t'r1ine overha'# 3a$ then reD'ired in the ear 3hen the

ca#c'#ated P of the t'r1ine t'rned ne/ative8 The ca#c'#ation !ethodo#o/ 3a$ the e$$ence oftheir T'r1oC %ro/ra!8

That a%%roach ha$ $'1$eD'ent# 1een a1andoned in favor of a condition a$$e$$!ent a%%roach8

$$entia##, P;I $%ecifie$ that overha'#$ $ho'#d 1e cond'cted ever >0,000 ?H accordin/ to

an ?H for!'#a the have deve#o%ed8 In a addition to the ?H #eve#, a condition a$$e$$!ent i$

cond'cted that i$ e$$entia## a co#orCcodin/ (1#'e, e##o3, red, or /reen) of the #eve# of

de/radation ($o!e, $i/nificant, $evere, or /ood condition) of !a+or $tea! t'r1ine co!%onent$


63/76

and $$te!$8 Enfort'nate#, there are no defined $tandard$ for deter!inin/ 3hich #eve# of

codin/ $ho'#d a%%# or 3hat incre!ent$ or decre!ent$ to the ?H #eve# $ho'#d 1e !ade8

on$eD'ent#, the #eve#$ are e$ta1#i$hed 1 3hoever i$ doin/ the a$$e$$!ent8


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7/E 9* Standards

The G" ;eco!!endation$ for the In$%ection and ?verha'# of tea! T'r1ine$ (2nd dition,

7@@5)N define$ $evera# criteria for e$ta1#i$hin/ overha'# interva#$8 G" indicate$ that the fir$t

overha'# !a 1e cond'cted after 700,000 ?H 1a$ed on an ?H for!'#a that on# '$e$ then'!1er of o%eratin/ ho'r$ and tota# n'!1er of $tart$8 If no !a+or i$$'e$ or %ro1#e!$ are fo'nd

d'rin/ that overha'#, $'1$eD'ent overha'#$ !a 1e cond'cted at the 700,000 ?H interva# 'nti#

$'ch ti!e that re!ainin/ #ife a$$e$$!ent$ or other avai#a1#e o%eratin/ e6%erience fro!

co!%ara1#e t'r1ine$ indicate the need for $horter interva#$8 The 700,000 ?H interva#$ are

1a$ed on $evera# criteria inc#'din/

T%e of t'r1ine (conden$in/ 3ith hi/h $tea! 3etne$$, t'r1ine $ection$ 3ith a'$tenitic $tee#,/eared t'r1ine$, etc8)

Mode of o%eration (contin'o'$ d't, offC#oad o%eration, $tartin/B#oadin/ !ode, $#idin/Bfi6%re$$'re o%eration, etc8)

?1$ervation$ d'rin/ o%eration (vi1ration, $tea! and oi# te!%erat're$ and%re$$'re$, #eaa/e$, a#i/n!ent$, chan/e$ in $ervice f#'id$, etc8)

%ecia# !ea$'re!ent$ (interna# efficienc, vi1ration ana#$i$, heat rate, fo'ndation di$tortion) -'nctiona# te$t$ (%rotective and contro# eD'i%!ent) Life a$$e$$!ent ca#c'#ation$ T'r1ine #ife e6%endit're In$%ection interva# of other 'nit co!%onent$ ($tea! /enerator and /enerator) Man'fact'rer and in$'rer reco!!endation$ 6chan/e of infor!ation 3ith other 'ti#itie$ (3eane$$e$ and 1reado3n$) Inf#'ence of do3nti!e

"et3een !a+or overha'#$, !inor or inter!ediate overha'#$ !a 1e $ched'#ed ever 25,000

?H for vario'$ co!%onent$ or %ortion$ of the t'r1ine a$ %revio'$# di$c'$$ed in ection 58

7/1 is)


65/76

!an'fact'rin/, %roce$$ (refiner, %etroche!ica#, che!ica# %rod'ct$), en/ineerin/ con$'#tin/,

and re%air ind'$trie$8 The co!1ined e6%erience of the tea! !e!1er$ 3a$ #evera/ed to

e$ta1#i$h 3hat attri1'te$ are i!%ortant and nece$$ar for a 'nit to achieve a #on/er ti!e

1et3een !a+or o'ta/e$ and corre$%ondin/ #o3er ri$ #eve#$8 The$e attri1'te$ 3ere converted


66/76

40

into ri$ !odifin/ factor$ to vie3 t'r1ine and /enerator ri$$ on a ho#i$tic 1a$i$ de$i/n and

con$tr'ction, hi$tor, d't cc#e, o%eration, !aintenance, !onitorin/, and condition at %a$t

o'ta/e$8 The factor$ 3ere ca#i1rated 3ith ana#$e$ of 'nit$ of a## ind$8 The !ode#$ and

a$$ociated ri$ #eve#$ 3ere then /ro'nded 3ith 'nit$ that have r'n #on/er interva#$ to corre#ate

ri$ #eve# 3ith ti!e 1et3een !a+or o'ta/e interva#$ !ea$'red in either ?H 1 the T??P

%ro/ra! or da$ of #o$t %rod'ction 1 the T;AP %ro/ra!8

The ri$ !ode#$ 3ere deve#o%ed 1a$ed on AMF$ ;i$ "a$ed In$%ection G'ide#ine

!ethodo#o/ie$8 Ana#$e$ have 1een co!%#eted for over @0 T??PC$i.e $tea! t'r1ine$, 7=0

T;APC$i.e $tea! t'r1ine$ and 700 /enerator$8 The$e re$'#t$ ref#ect 77 t'r1ine and @

/enerator ?MF$, $i.e ran/e$ fro! 5@0 HP to >@0 MW, o%eratin/ ho'r$ fro! 72,000 to

=40,000, or ear$ of o%eration fro! ne3 to 5< ear$8 Ti!e$ 1et3een !a+or o'ta/e$ have

ran/ed fro! 5 ear$ to 72 ear$ 1a$ed on the a$$ociated ri$ #eve#8 A$ a $ide %rod'ct of the

ca#c'#ation$, individ'a# t'r1ine$ can 1e ri$ raned 3ith other co!%an t'r1ine$ or 3ith

!an'fact'rerF$ 'nit$ in the a$$ociated data1a$e8 An e6a!%#e of the T??P %ro/ra! ca#c'#atedri$ #eve#$ for HP t'r1ine$ in the data1a$e i$ indicated in -i/'re 758 The HP t'r1ine ri$ #eve# i$

%#otted on the Ca6i$ in de$cendin/ order for the individ'a# t'r1ine$ #i$ted on the Ca6i$8 A

corre#ation 3a$ e$ta1#i$hed 1et3een ri$ #eve#$ and ?H 1et3een o'ta/e$ $'ch that 'nit$ 3ith

#o3 ca#c'#ated ri$$ had #on/er ti!e$ 1et3een o'ta/e$ than tho$e 3ith hi/her ri$ #eve#$8

1igure .5 !OO& Calculated #& !ur"ine is) #istogra +#S 1iles,

HP!ur"ineCalculatedis)6evel

Individual !ur"ine nits

The !ethodo#o/ i$ D'ite effective in e$ti!atin/ o'ta/e interva#$ and definin/ ri$C1a$ed!aintenance action$ 3hich $ho'#d 1e taen 1et3een !a+or overha'#$ to achieve the #on/erinterva#8 The %roce$$, ho3ever, doe$ reD'ire a detai#ed revie3 of %#ant doc'!entation and%ractice$, '$'a## in e6ce$$ of that acco!%#i$hed d'rin/ nor!a# in$'rance in$%ection$ of $tea!t'r1ine$8 Interestingly, the longer outage intervals have not resulted in any notableincrease in the amount of damage, cost or time to complete major overhauls.

Fa'anese E-'erience


67/76

40

Enti# the a!end!ent of Ja%anU$ #ectricit "'$ine$$ La3 in 7@@5, e#ectricit %rod'cer$F

individ'a# !aintenance %roced're$ 3ere not con$idered a va#id for! of !aintenance8 Ho3ever,


68/76

47

d'e to the recent dere/'#ation of the e#ectricit !aret, the %rod'cer$F inde%endent %eriodic

!aintenance ha$ 1een reco/ni.ed and !achiner !an'fact'rer$ and e#ectricit %rod'cer$ have

raced to ado%t the ri$ 1a$ed !aintenance (;"M) a%%roach and to c't tota# co$t 3hi#e

!aintainin/ the re#ia1i#it of the %#ant eD'i%!ent8 The rea$on for thi$ trend #ie$ in the fact that

>0 of the $tea! t'r1ine$ in Ja%an are a/ed faci#itie$ 3ith over 700,000 ho'r$ of o%eratin/

ti!e, and the %art$ have reached the %eriod of acce#erated 3earin/8 -'rther, the e!er/ence of

inde%endent %o3er %rod'cer$ enterin/ the e#ectricit !aret i$ a#$o one rea$on for the trend8

The ;"M a%%roach a$$e$$e$ and ca#c'#ate$ the da!a/ea1i#it and freD'enc of !achiner

fai#'re there1 D'antifin/ ri$ and f'rther add$ econo!ic factor$ in con$tr'ctin/ a !aintenance

%#an for the %#ant !achiner8

The ;"M a%%roach 3a$ initia## deve#o%ed 1 the A!erican ociet of Mechanica# n/ineer$

(AM) enter for ;e$earch and :eve#o%!ent 3ith ind'$tr and in$'rer %artici%ation at the

reD'e$t of the 'c#ear ;e/'#ator o!!i$$ion (;) a$ ri$ 1a$ed /'ide#ine$ for in$%ection8The co!%#ete $et of /'ide#ine$ 3a$ created in 7@@7 thro'/h 7@@48 In Ja%an the introd'ction of

thi$ a%%roach 1e/an in the #ate 7@@0F$ for %etro#e'! %#ant$8

In order to a%%# thi$ a%%roach to the ther!a# %o3er %#ant$, data of %#ant !achiner and %a$t

o%eration$ !'$t 1e o1tained fro! o%erator$ and !an'fact'rer$ and ana#.ed 'ti#i.in/

%ro1a1i#it theorie$, and thi$ a%%arent# ha$ on# 1een e6%eri!enta## introd'ced the$e %a$t fe3

ear$8 Ho3ever, in order to $'$tain the re#ia1i#it of the %#ant !achiner and achieve co$t

red'ction$ at the $a!e ti!e, thi$ a%%roach i$ indi$%en$a1#e, and a !a+orit of o%erator$ are

a%%arent# cond'ctin/ ana#$e$ and a$$e$$!ent$ and deve#o%in/ !aintenance %#an$ for their

re$%ective $tea! t'r1ine /enerator$8 ;e/retta1#, thi$ infor!ation i$ not di$c#o$ed in Ja%an $othere i$ no avai#a1#e infor!ation on the act'a# !aintenance %roced're$ and their ana#$e$8

7/* elia"ilit% Centered or Condition ased Maintenance +CM or CM,

In the %a$t the freD'enc of overha'#$ 3a$ !o$t# 1a$ed on the e6%ected $ervice #ifeti!e of the

!o$t critica# co!%onent$8 ?verha'#$ 3ere $ched'#ed and done re/ard#e$$ of the act'a#

condition of the$e co!%onent$ at the ti!e8 "a$ed on the need of their c'$to!er$ for

o%ti!i.ation of %#ant re#ia1i#it and avai#a1i#it and at the $a!e ti!e c'ttin/ !aintenance co$t$,

a## ?MF$ have deve#o%ed %#ant data !ana/e!ent $$te!$ 3hich e!%ha$i.e the co##ection of

onC#ine o%eration and condition data, ana#$i$ of thi$ data 1 e6%ert $$te!$ andBor e6%erienceden/ineer$ and /ivin/ feed1ac to c'$to!er$ 'ti#i.in/ the$e $$te!$8 A## thi$ i$ done in order to

$'%%ort and a$$i$t their c'$to!er$ 3ith their dai# o%erationa# %ro1#e!$ and /enera#

!aintenance $ched'#in/ a$ 3e## a$ /ivin/ advice and $'%%ort d'rin/ o'ta/e$ and $'1$eD'ent

reco!!i$$ionin/ of the %#ant$8

'ch $$te!$ can co!%ri$e %#ant !onitorin/ and dia/no$tic !od'#e$ and inc#'de tran$ient data

%roce$$in/, ear# 3arnin/ $$te!$ ai!ed at the detection of hidden and deve#o%in/ %ro1#e!$ or

fai#'re$, !onitorin/ and dia/no$tic re%ort$, %#ant a$$e$$!ent re%ort$ and other o%erationa# and


69/76

42

!aintenance re#ated $ervice$ 3hich he#% o%erator$ in deve#o%in/ $%otCon !aintenance

%ro/ra!$ for their individ'a# %#ant$ and avoidin/ 'nnece$$ar o'ta/e$ and 'n$ched'#ed

$h'tdo3n$8 A## thi$ #ead$ to condition oriented !aintenance %ro/ra!$ 3hich a##o3 $ervice

interva#$ to 1e e6tended if the 'nit$ are o%erated in /ent#e o%eration !ode$ and at the $a!e

ti!e a##o3ed to 'ti#i.e the act'a# #ife ti!e of the critica# co!%onent$ 1efore havin/ to $ched'#e

overha'#$ if 'nit$ are r'n in $trin/ent !ode$8


70/76

In $'!!ar, there are different a%%roache$ 3hich !a 1e taen for e$ta1#i$hin/ #on/er ti!e

interva#$ 1et3een !a+or overha'# o'ta/e$8 ;e/ard#e$$ of the a%%roach, !ethodo#o/, or

criteria 'ti#i.ed, 3hat i$ i!%ortant to in$'rer$ i$ that the !aintenance ta$$ and freD'encie$

1et3een !a+or overha'#$ are %rioriti.ed to3ard$ the %ortion$ of the $tea! t'r1ine that have the

hi/he$t ri$8 Thi$ !ean$ %rotectin/ the $tea! t'r1ine fro! over$%eed$, 3ater ind'ction, #o$$ of

#'1e oi#, corro$ive $tea!, $ticin/ va#ve$, and an other ri$ of fai#'re or #ife i$$'e$ that co'#d

ca'$e !a+or t'r1ine da!a/e and forced o'ta/e$8


71/76

:/ Issues with $ew Stea !ur"ine !echnologies andA''lications

Mo$t of the %revio'$# di$c'$$ed !aintenance ta$$ and freD'encie$ have 1een a$$ociated 3ith

$tea! t'r1ine and techno#o/ #eve#$ that have 1een %roven 1 !an ear$ or decade$ in$ervice8 'ch i$ not the ca$e 3ith ne3 $tea! t'r1ine techno#o/ie$8 The advance!ent$ !ade

in aerodna!ic$, $ea# de$i/n, and !ateria#$ are chan/in/ the characteri$tic$ of ne3 techno#o/

t'r1ine$8

In /enera#, HP and IP t'r1ine$, for e6a!%#e, are !ovin/ to3ard$ '$in/ !ore reaction t%e

1#adin/ than the ori/ina# i!%'#$e t%e 1#adin/ in the$e t'r1ine$8 That i$ e6e!%#ified in -i/'re 79

!ovin/ chrono#o/ica## fro! #eft to ri/ht8 Mo$t o#der /eneration $tea! t'r1ine$ have %ri!ari#

i!%'#$e 1#adin/8 In the !idCtoC#ate 7@@0F$, $o!e of the$e $ta/e$ 3ere re%#aced 3ith !ore

$ta/e$ of reaction 1#adin/ a#on/ 3ith $!a##er radia# and a6ia# c#earance$8 The techno#o/ #eve#

toda i$ no3 !ovin/ to3ard$ even !ore reaction content re$'#tin/ in a f'rther increa$e in then'!1er of $ta/e$ and ti/hter a6ia# and radia# c#earance$8 In $o!e ca$e$, the t'r1ine$ are

incor%oratin/ aero /a$ t'r1ine techno#o/ #eve#$ to red'ce $ea# #eaa/e and i!%rove efficienc8

Whi#e it i$ diffic'#t to o1+ect to techno#o/ i!%rove!ent$, the ear# e6%erience of $o!e of the

ne3 de$i/n$ ha$ 1een !i6ed8 The ne3 techno#o/ !achine$, not $'r%ri$in/#, have 1een !ore

$'$ce%ti1#e to radia# and a6ia# r'1$ d'rin/ $tartin/ and tran$ient$8 -'rther!ore, the do not

a%%ear to 1e a$ to#erant of -?: de1ri$ in the inco!in/ $tea! and tend to $ho3 increa$ed 3ear

and r'11in/ at 1#ade ti%$8

1igure .7 $ew Stea !ur"ine !rends !owards eaction lading and Saller Clearances

+Courtes% *eneral Electric,

I'ulse Stages Increased eaction Su"stantiall% Increased eaction1ewer ows Content;More ows Content;Even More ows

(ide Clearances educed Clearances 1urther educed Clearances

The $it'ation 3ith LP t'r1ine$ i$ $i!i#ar e6ce%t that the /enera# trend i$ to3ard$ '$in/ fe3er

$ta/e$ 1't #ar/er $i.e 1#adin/ to red'ce the co$t of ne3 !achine$8 on$eD'ent#, 1#adin/

aerodna!ic and attach!ent #oadin/$ (dia%hra/!$ and rotor di$c$) 3i## 1e hi/her than that of

%rior /eneration of t'r1ine$, 3hen co!%ared on an eD'iva#ent 1a$i$8 E$e of titani'! !ateria#$

in $o!e a%%#ication$ i$ an a1$o#'te nece$$it to achieve an adeD'ate $ervice #ife8 In addition,

there have 1een $o!e nat'ra# re$onance %ro1#e!$ 3ith LP #a$t $ta/e 1#adin/ for $o!e de$i/n$8


72/76

Additiona# t'r1ine re$earch and deve#o%!ent i$ 1ein/ directed to3ard$ hi/h $tea! te!%erat're$

(


73/76

1igure .: E-a'le of Cooling I& !ur"ine sing #& E-haust Stea+Courtes% Mitsu"ishi #eav% Industries,

In Ja%an there i$ a $tron/ de!and to3ard$ decrea$in/ ?2 e!i$$ion$, and increa$in/ the

efficienc of ther!a# %o3er %#ant$ i$ an i!%ortant i$$'e8 In %artic'#ar, increa$ed efficienc of

$tea! t'r1ine$ contri1'te$ /reat# to the efficienc of ther!a# %#ant$, and i$ therefore a cr'cia#

factor8

A%%roache$ to increa$ed efficienc of $tea! t'r1ine$ can 1e #ar/e# cate/ori.ed a$ (7) 1etter

$tea! condition$ and efficienc of heat cc#e$ (2) interna# efficienc of the $tea! t'r1ine it$e#f8To !eet the$e o1+ective$, !a+or Ja%ane$e t'r1ine !an'fact'rer$ $'ch a$ To$hi1a, -'+i #ectric,

Hitachi and Mit$'1i$hi Heav Ind'$trie$ (MHI) are deve#o%in/ techno#o/ie$ inde%endent# and

have incor%orated !an of their achieve!ent$ into their co!!ercia# t'r1ine$8

78 "etter $tea! condition$ and efficienc of heat cc#e$

tea! condition$ are !ovin/ to3ard$ hi/her te!%erat're$ and hi/her %re$$'re$8 Thi$

reD'ire$ chan/e$ in the t'r1ine $tr'ct're and i!%rove!ent of t'r1ine !ateria#8 With

the$e techno#o/ica# advance$, in contra$t to conventiona# $tea! condition$ (247 1arB

=,4@5 %$i, 5=>B7,000-), a 5 %ercent increa$e in efficienc can 1e e6%ected for 900(7772-) c#a$$ t'r1ine$ and an > %ercent increa$e can 1e e6%ected for 950 (7,272 -)

t'r1ine$8 900 (7,772-) t'r1ine$ are a#read in co!!ercia# '$e, and deve#o%!ent for

950 (7,272-) c#a$$ t'r1ine$ are the !ain foc'$ at %re$ent8 e3 e#e!ent$ (W, o,

and ") have 1een added to 72 r $tee# a$ !ateria# for rotor 1#ade$ to increa$e $tren/th

a/ain$t cree%8

28 Interna# efficienc of the $tea! t'r1ine it$e#f


74/76

The i!%rove!ent of interna# efficienc of $tea! t'r1ine$ de%end$ on ho3 to !ini!i.e

the vario'$ #o$$e$ occ'rrin/ 3ithin the t'r1ine it$e#f8 The$e #o$$e$ can 1e c#a$$ified into

$evera# ite!$ and the ne3e$t %revention !ea$'re$ are incor%orated at the de$i/n $ta/e


75/76

to i!%rove each ite!8 Man of the! can 1e ana#.ed fair# ea$i# d'e to the advance$ in

aerodna!ic n'!erica# ana#$i$8 6a!%#e$ are i!%rove!ent$ in reaction 1#ade$, fir$t

$ta/e 1#ade$ and #o3 %re$$'re 1#ade$8

The$e ne3 techno#o/ie$ and the de$i/n and !ateria# chan/e$ incor%orated into a $tea! t'r1inehave not 1een the ca'$e of an heav #o$$e$, 1't the inherent ri$ e6%o$'re$ are definite#

increa$in/8 At %re$ent, the radi'$ of the rotor 1#ade$ i$ /ettin/ #ar/er, and the 1#ade ti%F$

revo#vin/ $%eed reache$ hi/h $%eed$ of 9>0 !eter$ %er $econd (2,244 feet %er $econd)8

-'rther!ore, the 1a$e of a 727@ !! (4> inch) rotor 1#ade 1ear$ a centrif'/a# force of 5@0 ton$8

The de$i/n$ of each co!%an are a## co!%#e6 and 'niD'e, and the techno#o/ica# deve#o%!ent

and %'r$'it of increa$ed efficienc 3i## contin'e8 e3 techno#o/ica# deve#o%!ent$ entai# ne3

ri$$ to in$'rer$8 Thi$ i$ a rea#it 3hich ha$ not chan/ed fro! the %a$t8

In $'!!ar, there need$ to 1e vi/i#ance 3ith re/ard$ to !onitorin/ the re#ia1i#it and avai#a1i#it

of ne3 techno#o/ $tea! t'r1ine$ a$ the are not et %roven to 1e a$ ro1'$t a$ their%redece$$or$8 Therefore, $ched'#ed !aintenance and overha'# interva#$ $ho'#d 1e

con$ervative# defined 'nti# the ne3 de$i/n$ have $'fficient, $ati$factor o%eratin/ e6%erience8


76/76

8/ Conclusions

-ro! the %revio'$ di$c'$$ion$, $evera# conc#'$ion$ a1o't the !aintenance and overha'# of

$tea! t'r1ine$ can 1e !ade

78 Whi#e there are $'1$tantia# difference$ in the de$i/n, co!%#e6it, a%%#ication, $tea! condition$, and$i.e of $tea! t'r1ine$, the a## are f'nda!enta## the $a!e8 The %erfor! the $a!e f'nction, 'ti#i.e$i!i#ar !a+or co!%onent$ and $'%%ortin/ $$te!$, and are $'1+ected to the $a!e fai#'re!echani$!$8 on$eD'ent#, the e6%ected !aintenance and overha'# effort$ for the !a+orco!%onent$ to achieve hi/h #eve#$ of re#ia1i#it and avai#a1i#it 3o'#d 1e e6%ected to 1e $i!i#ar,a#tho'/h the effort$ do need to 1e tai#ored to the $%ecific t%e of 'nit and a%%#ication8

28 To $'%%ort re#ia1#e t'r1ine o%eration, there need$ to 1e an effective infra$tr'ct're in %#ace for!onitorin/ the o%eratin/ condition$, 3aterB$tea! D'a#it, and hea#th of the $tea! t'r1ine, for havin/and '$in/ 3ritten o%eratin/B!aintenance %roced're$, for 'ti#i.in/ a !aintenance !ana/e!ent$$te! to $ched'#eBtrac !aintenance, and for cond'ctin/ trainin/ for %er$onne# on an on/oin/ 1a$i$8The #ac of an effective infra$tr'ct're can #ead to #o3er #eve#$ of re#ia1i#it and avai#a1i#it8

=8 There have 1een n'!ero'$ ca'$e$ of $tea! t'r1ine fai#'re$ 3or#d3ide8 T%ica##, the hi/he$tfreD'enc event$ have 1een #o$$ of #'1e oi# incident$, the hi/he$t $everit event$ have 1eenover$%eed event$, and the hi/her freD'enc and hi/her $everit event$ have 1een 1#adeB1'cetfai#'re$, %artic'#ar# in the LP $ection of the t'r1ine 3here the e6%erienced a n'!1er of fai#'re!echani$!$ (, ero$ion, -?:) 3hich '#ti!ate# #ed to fai#'re8 A$ $'ch, $tea! t'r1ine!aintenance and overha'# effort$ $ho'#d 1e directed to3ard dia/no$in/ and !iti/atin/ the$e t%e$ ofevent$8

48 With re/ard$ to !aintenance %ractice$ in orth A!erica and 'ro%e, there are no re/'#ator!aintenance %ractice$ or interva#$ $%ecified for nonCn'c#ear $tea! t'r1ine$ re/ard#e$$ of the ind'$tror a%%#ication8 A$ $'ch, the freD'encie$ and ta$$ are defined 1 the t'r1ine !an'fact'rer$,con$'#tant$, ind'$tr or/ani.ation$ (P;I, G"), %#ant %er$onne#, %#ant %roce$$ reD'ire!ent$, orin$'rer$ 1a$ed on %a$t e6%erience8 In Ja%an, ho3ever, there are re/'#ator reD'ire!ent$ for%eriodic !aintenance8 Ho3ever, re/ard#e$$ of the area of the 3or#d, the reco!!ended $ched'#ed!aintenance reD'ire!ent$ for $tea! t'r1ine$ are D'ite $i!i#ar8

58 There are a n'!1er of different a%%roache$ 3hich are 'ti#i.ed toda for e$ta1#i$hin/ #on/er ti!einterva#$ 1et3een !a+or overha'# o'ta/e$8 The$e inc#'de %roce$$Bcritica#it driven interva#$, t'r1ine!an'fact'rerF$ reco!!endation$, ind'$tr /ro'% $tandard$ (P;I, G"), ri$ 1a$ed!ethodo#o/ie$, re#ia1i#it centered and condition 1a$ed !ethodo#o/ie$8 ;e/ard#e$$ of the a%%roach,it i$ i!%ortant that the !ethodo#o/ie$ effective# e$ta1#i$h the overha'# interva#$ 1a$ed on thehi/he$t ri$ %ortion$ of the $tea! t'r1ine8

98 The techno#o/ie$ 1ein/ incor%orated into ne3 $tea! t'r1ine$ are !ore $o%hi$ticated, reD'ireo%eration at hi/her %re$$'re$ and te!%erat're$, and /enera## have $!a##er c#earance$ to i!%roveefficienc8 Whi#e the techno#o/ie$ have not ca'$ed an #ar/e #o$$e$, the inherent ri$ e6%o$'re$ areincrea$in/ and there need$ to 1e contin'ed vi/i#ance 3ith re/ard$ to !onitorin/ the re#ia1i#it andavai#a1i#it of the$e ne3 'nit$ and to ad+'$t their !aintenance interva#$ accordin/#8

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