Steam Turbine Maintenance Inspections or Repairs: Turbine Restart After Major

Steam Turbine Turbine Restart after Major
Maintenance Inspections or Repairs
Introduction
The operational reliability and availability of Pre-service Inspections
a steam turbine unit are determined by,
The functioning and the setting of all of the
among other factors, the care with which the
major equipment of the turbine must be
unit was initially started up. The same rule
checked. This applies both to mechanical /
also applies to restarts after large scale
hydraulic components and to
maintenance and repair work, e.g. in the
instrumentation and control devices. The
course of major inspections.
scope of inspection and testing of defined in
instruction 3-001x, and covers:
Information Required for Restart All closed-loop controls
In restarting a turbine it is useful to possess All protective devices
the following data:
All sub loop controls and automatic
The performance of the turbine unit and changeover controls
its components prior to inspection
The characteristics of all electro-hydraulic
The scope of the inspection controllers must be recorded. The test
programs appear in maintenance
Findings and checks made during the
instructions 4-1110 and 4-1190.
inspection
Alarm system and monitoring equipment
Repairs carried out on the basis of the
must like wise be overhauled and tested.
findings
If the result of operating parameters and
Retrofitting and upgrading measures
setting checks reveal changes from earlier
taken
results, new records must be prepared.
Checks planned for the restart period
The information required may be found in
In-Service Inspections
the following documents:
The tests, which could not be carried out in
Reports on turbine performance prior to
the pre-service phase because the boundary
inspection
conditions had not been fulfilled, must be
Operating parameters and setting performed during the service phase
records for the unit when new or at the subsequent to the pre-service inspections.
last restart The essential step-by-step test schedules
appear in maintenance instruction 4-1160.
Reports on inspections, findings and
repairs
Protective devices
Documents on retrofitting and
modifications Service phase testing applies mainly to
those devices which protect the turbine
The following are also required: against over speed. The test programs of
Diagrams showing current control system the automatic turbine tester may also be
setting (in the case of special settings the executed if required.
most recent records are binding) Controllers
Documents from the turbine manual, The performance of the controllers must
such as controller circuit diagrams and be observed throughout the restart
descriptions. phase.
BHEL Haridwar 4-1330-04/1

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
4-1330-04/2
Pre-service inspection and testing of Report on the scope of the inspection
major C&I hardware Report on the findings and checks made
- Controllers and protective devices Report on repairs and other actions
- Turbine stress controller Report on the replacement and spare
- Automatic testers parts used or required
- Automatic functional group controls If these special reports are not available,
brief details must be given on these subjects
Pre-service inspection and testing of under the above headings.
controls, interlocks and alarms by owner
/ operator’s personnel.
The main section of the reports must cover:
The scope and nature of pre-service
Summary of results from major inspections
inspections and repairs
Findings from the pre-service inspections
Full documentation of the history of a turbine
unit includes, among other elements, The scope and nature of in-service
reporting on turbine restart following major testing
inspections or repairs. Evaluation of turbine performance
The report on restart should make reference Findings from in-service testing
to certain preceding reports, namely:
Matters remaining open (actions,
Report on the performance of the turbine replacement parts, implementation
unit prior to the major inspection deadline, etc.)
4-1330-04/3

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Steam Turbine Turbine Restart after Major

Maintenance Inspections or Repairs

BHEL Haridwar 4-1330-04/1

- Control system characteristics Where necessary, spare parts must be

- Steam pressure and temperatures These measures may include further

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