GAPS Guidelines GAP.6.1.1.0.

A Publication of Global Asset Protection Services LLC

STEAM TURBINE LOSS PREVENTION INSPECTION

INTRODUCTION
Steam turbine loss prevention requires paying attention to how turbines, their driven objects, and
associated safety devices and systems are designed, applied, installed, operated, maintained and
repaired. Losses may result from a centrifugal rotor burst, an overpressure rupture, overspeed,
mechanical breakdown or other equipment failure.
This section suggests ways to minimize turbine losses by making periodic inspections. It focuses on
steam turbines driving generators rated at 750 kW and above and mechanical drive turbines rated at
1000 hp (750 kW) and above. The approach recommended also applies to smaller machines,
however, some features may not be necessary. Turbine fire protection is covered in GAP.17.12.1.

POSITION
Turbine Loss Prevention Management
Management commitment is the key to successful loss prevention. Loss prevention and control
programs must convey and enforce this commitment. Loss prevention inspection, one of the fourteen
interlocking management programs described in OVERVIEW, helps management evaluate the
effectiveness of all the other loss prevention programs. Every facility should formally adopt programs
similar to those in OVERVIEW.
Personnel at facilities having large turbines can perform most activities OVERVIEW recommends. If a
facility contracts out tasks, management must set up written procedures in advance to make sure the
contractors comply with all loss prevention programs.
The following management loss control programs apply to turbines:
New Construction - Submit plans to Global Asset Protection Services (GAPS) for installing new
turbines or substantially reworking existing units. Installing a large steam turbine is obviously a major
undertaking. The probable life-cost of the unit can be significantly reduced if various loss prevention
and control features are designed and built into the machine. API Standard 611, API Standard 612,
and ASME PWR - Vol. 8, Guidelines For Preparation Of Specifications For Steam-Turbine
Generators should be consulted. GAP.1.5.2 also contains recommendations.
Hazard Identification - Consider hazard analysis early when designing facility modifications and
expansions. Update the analysis periodically to incorporate operating experience and aging effects.
While turbine hazards are fairly well established, the turbine itself may be only a small part of the
exposure. Extraction steam flow to and from the turbine and driven equipment performance can
strongly influence the rest of the plant. Support system reliability influences the turbine hazards. Unit
failure probability can change significantly because of changes in operating conditions and unit aging.
Employee Training - Steam turbines and their associated equipment are large, complex and
expensive machines that are often critical to a facilitys operations. Provide an ongoing formal training
program for management, operation, maintenance and repair personnel.

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Global Asset Protection Services LLC and its affiliated organizations provide loss prevention surveys and other risk management, business continuity and facility asset
management services. Unless otherwise stated in writing, our personnel, publications, services, and surveys do not address life safety or third party liability issues. The
provision of any service is not meant to imply that every possible hazard has been identified at a facility or that no other hazards exist. Global Asset Protection Services LLC
and its affiliated organizations do not assume, and shall have no liability for the control, correction, continuation or modification of any existing conditions or operations. We
specifically disclaim any warranty or representation that compliance with any advice or recommendation in any document or other communication will make a facility or
operation safe or healthful, or put it in compliance with any law, rule or regulation. If there are any questions concerning any recommendations, or if you have alternative
solutions, please contact us.
 GAP.6.1.1.0.2

Maintenance - Maintenance is the most important aspect of successful turbine operation. A properly
designed and protected turbine that undergoes continued quality maintenance may require fewer
overhauls. Maintenance programs are discussed in GAP.1.3.0.
Insurance Company Recommendations Provide a procedure for documenting and reporting
evaluation of, and compliance with, insurance company recommendations. Insurance company
surveys examine the effectiveness of loss control programs. Loss experience of turbines in many
industries supports such recommendations.
Pre-Emergency Planning - Provide a pre-emergency plan for each facility. Steam turbines are
usually vital to facility production. A turbine loss can severely upset the facility energy balance. A
large turbine rotor can require a year to replace; a complete machine can possibly require longer.
Spare rotating elements are one part of pre-emergency planning for turbines. This subject is
discussed in GAP.6.0.1.0. Explore alternate means of production and ways to make temporary
repairs.
Proper Housekeeping - Housekeeping and maintenance are strongly related. Sloppy plants seldom
have good maintenance; plants with good maintenance are seldom sloppy. Turbines require
cleanliness, corrosion control and minimal clutter.
Loss Prevention Inspection - Monitor loss prevention programs. Although properly trained
equipment operators continuously inspect equipment, a trained inspector who periodically monitors
the actual performance of the various loss prevention programs on the ground provides a more
direct line to management. GAP Guidelines is designed to help a technically oriented person perform
meaningful loss prevention inspections. When a turbine needs inspection, a larger facility might
consider a specialty inspector; a smaller facility might consider a contract service.
Turbine Loss Prevention Inspection
A loss prevention inspector performing a turbine inspection reviews, records and witnesses selected
operations and tests to determine that a turbine has been properly designed, constructed and
installed and that it is being properly operated, maintained and repaired. A facilitys loss prevention
inspector may be an employee, a corporate staff member or a consultant under contract. GAPS
clients may contact the GAPS Area Office to help set up an inspection program or audit an existing
program.
Inspection Guidelines
Turbines need several kinds of inspections. Each should be performed under a program that
produces suitable reports to management. The types of inspections are:
Routine inspections by operators.
In service inspections.
At rest inspections.
Dismantled inspections.
Specialized inspections, such as accident investigations, are not discussed in this section.
The following recommendations apply to any inspection:
Provide the loss prevention inspector with access to a master maintenance data file for each piece
of equipment. Even if the necessary information is not in one place, it should be readily accessible.
GAP.6.1.1.0.2.A lists data that should be available. Any needed information which does not exist
should be generated over a reasonable period of time. Additional maintenance systems which are
needed should be recommended.
Observe and report on housekeeping. This is a good indicator of facility personnel and
management attitude toward the equipment.
Review operating logs and records from the last inspection through the current date. There should
always be a properly maintained written system. This may be supplemented where appropriate by

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electronic data systems. The condition and contents of the operating logs or records tell much
about the attitude toward loss prevention.
Audit the written operating procedures. Operators should have written procedures covering normal
and emergency conditions. Normal operations include:
Startup and normal shutdown.

Transition between hot standby and other operating modes.

Steady state and transient operation at full and part load.

The emergency conditions to be covered are site-specific, however, cover at least the following at
all facilities:
Loss of the normal electric power or lubrication source.

Load rejection.

Overspeed or other loss of control.

Abnormal noise or vibration.

Activation of other installed alarms and protective devices.

Weather emergencies, including above- or below-normal temperatures (where applicable).

Verify the condition of major spare parts. If parts are not on the premises (pool spares, those held
by the manufacturer or in contract storage, etc.), confirm the arrangements.
Review vibration monitoring and analysis programs; where applicable, audit data. Look for adverse
trends that might have been missed.
Audit the following additional items on an as-needed basis, periodically or as suggested by history.
Lubricating oil system reliability during any upset or utility outage. See GAP.6.1.1.0.5.

Trip valve, extraction valve and reheat intercept valve exercising and overspeed trip testing.
See GAP.6.1.1.0.3.
Compliance with the ASME standard practice on water/cool vapor induction protection. See
GAP.6.1.1.0.4.
Life extension analysis or activity for:

Major equipment more than 15 years old.

Reheat piping over 10 years old.

Other piping over 25 years old.

Provide the loss prevention inspector with a checklist or a report guideline for each inspection tour.
GAP.6.1.1.0.2.B suggests items to consider for in service or at rest inspections and
GAP.6.1.1.0.2.C suggests items for dismantled inspections.
Routine Inspections by Operators
Routine inspections include most operator actions needed to monitor and control the machine.
Document all important activities and periodic observations in a log. Promptly and formally report
abnormal conditions to management. Operating specifics are outside the scope of this section,
however, the following operator and support staff activities are recommended:
Measure unit steam consumption. Changes in steam consumption under constant load usually
indicate deteriorating conditions. A slow increase may indicate accumulated deposits or erosion
damage. A sudden increase may indicate blade failure or foreign object damage. If possible,
measure steam consumption for the unit and for each casing, because problems in one casing
may be compensated by altered conditions in other casings.
Calculate unit efficiency. If steam flow measurement is not practical, calculate unit and casing
efficiencies using inlet and outlet temperatures and pressures.
Measure stage pressures. Changing stage pressures also indicate changes in the blading
condition.

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Conduct casing temperature scans. Casing temperature changes may indicate internal leaks,
which may be caused by damaged seals or distorted casings.
Measure and analyze unit vibration. Vibration analysis can reveal more about machine condition
than any other on-line technique. Operators must report any change in the nature or amount of
machine vibration. Management must promptly respond to reported changes by providing
analytical support.
Measure shaft and casing differential movement. Carefully tracking the differential expansion
between shafts and casings may reveal flexibility loss that may cause casing distortions and rubs.
Flexibility loss may be caused by seized expansion joints or sliding feet.
Inspect foundation bolts. Loose foundation bolts may indicate serious problems which will
adversely affect the machine alignment. Promptly investigate any foundation looseness or
insecurity.
Closely monitor bearings. Constant attention to bearing temperatures and lubrication temperature
differentials is needed to detect deteriorating bearings. Subtle changes in the lubrication system
pressure balance may indicate bearing deterioration before bearing temperature increases occur.
Wear particle analysis may signal deterioration before any other symptoms appear.
Perform the following inspections during jacking gear operation:
Listen for clanking or scraping noises, particularly near shaft penetrations. These noises may
indicate misalignment or shaft or casing distortion.
Check the power required by the jacking gear and compare it to the power required during
previous jacking gear operation. An increase in power consumption may reveal binding or
rubbing in the unit. Readings may need to be adjusted for different unit temperatures or other
factors.
Perform the following inspections during shutdown:
Check rotor axial and radial position and shaft runout. This is most effective on machines that
have borescope ports at suitable measuring points. Some measurements can be taken at
coupling flanges by using a dial indicator.
Inspect the internals through borescope ports, drain connections and other casing
penetrations. Modern instruments can provide a reasonably thorough internal inspection
without the casing having to be lifted. Examining internal parts such as nozzles and blading
provides information that is critical to overhaul decisions. Therefore, machines which require
long intervals between overhauls should have borescope ports retrofitted to allow the most
complete internal inspection possible. Consult the turbine manufacturer concerning the size
and location of borescope openings.
Take bearing measurements. Depending on the bearing design, bearing inspections may
also be possible if necessary.
In Service, At Rest and Dismantled Inspections
Turbines should be periodically inspected and their operating and maintenance records reviewed by a
trained person from outside the operating department. All turbines should have a monthly in-service
or at-rest inspection.
Turbine overhaul frequencies depend upon their size, age, service and history. It is recommended
that turbines be overhauled:
Every two years for turbines under 1000 hp (750 kW).
Every three years for turbines 1000 hp (750 kW) to 10,000 hp (7,500 kW). If units are monitored as
described below, and they have no known adverse conditions, the interval for machines in
continuous service may be increased to five years.
Every 50,000 equivalent operating hours ( Te ) for turbines over 10,000 hp (7,500 kW). Te is
determined by the following formula:

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Te = Ta + 25ns

Where: Te = equivalent operating hours

Ta = actual operating hours
ns = number of starts, including cold and hot starts
If full monitoring is performed and there are no known or suspected adverse conditions, the
interval for machines in continuous service may be increased to seven years. The overhaul
interval should never exceed seven years. Full monitoring includes:
Installed vibration monitoring equipment including alarms and automatic shutdown for high
vibration and rotor axial position out of limit.
All recommended protective devices in service.

Wear particle analysis performed.

Inspections conducted at least annually after three years of operation through borescope
openings that permit all nozzles, blading and throttle valves to be inspected.

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