Chapter 5

INSTALLATION AND OPERATION

5.1 Installation of Turbines

Instructions given are for a simple, single-stage machine, but they can be
applied generally to all turbine installations.

Turbines are usually installed on a continuous cast-iron or steel base plate

which extends under the driven machine. The two shafts are connected by
a flexible coupling.

Any base plate, no matter how heavily constructed, may be sprung in

shipment. Also, it may be distorted by an uneven support on the
foundation, uneven tightening of foundation bolts, or by the pull from
improper pipe connections. After the unit is set on the foundation, it is
necessary to check alignment and make certain that the shafts of the
turbine and of the driven machine are precisely in line. No machine will
operate satisfactorily if the shafts are out of line, and serious troubles such
as bent shafts, worn bearings, and worn coupling parts may develop. The
flexible coupling will not compensate for misalignment.

The foundation may be of either concrete or structural steel. Consult the

certified dimension drawing furnished with the machine for size of base
plate and size and location of foundation bolts. When setting the unit on
the foundation, use wedges under the base plate so that there is at least
½ inch (1.27 cm) clearance between base plate and top of foundation for
grouting.

For alignment, adjust the wedges so that the base plate is level, and then
check alignment of coupling hubs. Pin-and-bushing-type couplings have
wide flanges and are easily checked. Couplings of the gear- or spring-type
have enclosing covers, and these covers must be disconnected and slid
back along the shaft before alignment can be checked.
When cold, the turbine shaft should be set low to compensate for upward
expansion when the casing becomes heated. Allow 0.001 inch (0.0025
cm) for each inch (2.54 cm) in height from turbine feet to centerline of
shaft. However, when the driven machine is also heated, such as a hot-oil
or hot-water pump, the allowance need not be so great. Therefore, it is
necessary to check alignment when cold and also after both members of
the unit have been heated to operating temperature.

After setting the unit on the foundation, check alignment by placing a

straight edge on the coupling flanges or both faces. Check at top, bottom,
and both sides. Also, insert calipers or a feeler gauge between the

5.1
coupling halves to make certain that both faces are equidistant in any
position of the shaft.
Corrections may be made by "throwing" the base or shimming under the
turbine or driven machine. Both the drive and driven shafts must run freely
with and without the coupling bolts or covers in place. Pull down the
foundation bolts, dowel turbine and driven machine to the base, and again
check for alignment; make corrections if necessary. The base may then
be grouted in.
When the turbine is mounted separately on its own foundation, with or
without soleplate, the method of installation and alignment is the same as
for units with continuous base plates.

The inlet line should be anchored at the header and must have loops or
offsets to provide flexibility so that expansion of this inlet line will not exert
undue strain on the turbine. Install a drain in the inlet line at its lowest
point between the header and the turbine. Install a throttle valve in the
steam line near the turbine. Close this valve and turn steam into the line;
when hot, check the face of pipe flange with turbine flange. Make sure
that the faces are in line and parallel and that no force is necessary to
bring them together or to match the bolt holes.

The exhaust line should have a flexible expansion joint placed close to the
turbine or should otherwise be arranged to compensate for expansion.
Provide a drain at the lowest point in this line. Exercise the same care in
lining up the pipe flange with turbine flange as described for the inlet line.
Do not depend upon the sentinel relief valve to protect the turbine casing
against excessive back pressure. It is advisable to install a large relief
valve at some point in the exhaust line. This can be large enough to
protect all equipment which may be exhausting into a common header.

Each packing box has a drain connection in the lower half. These can be
piped separately or in series, but in either case, they must exhaust to
atmosphere. For condensing turbines, there will be a tapped opening in
the upper half for admitting sealing steam under 0.14 or 0.21 bar
pressure. Each bearing has a cartridge-type, water-cooling coil. Inlet
opening is at the top and outlet at the bottom. These may be piped
separately or in series. Place a valve in the inlet line. Water pressure
should preferably be 25 to 30 pounds (1.75-2.10 bar) and must never
exceed 100 pounds (7.0 bar).

The inlet flange is tapped on the side for bleed-off line. Install valve at this
point and arrange blow-off to atmosphere. After the over speed governor
valve has closed, either due to over speeding or hand tripping, close the
throttle valve in the steam line and then open this bleed-off valve to relieve
pressure before attempting to reset the over speed trip valve. A drain
connection is provided at the lowest point of the casing. Install a valve at
this point, with or without a steam trap.

5.2
5.2 Turbine Automatic Standby power

Pumps, fans, blowers, and other plant auxiliaries normally driven by

constant-speed motors can be equipped with double extended shaft for
connecting a turbine opposite the motor. If this is impossible, the motor
shaft can be extended and the turbine coupled behind the motor so that it
can drive the auxiliary through the motor shaft. On dual-driven units, the
standard speed governor can be easily adjusted so that the turbine will
automatically pick up the load in case of electric power failure. With the
unit in operation (driven by the electric motor), the adjusting screw at the
lower end of the turbine governor lever is tightened, closing the governor
valve and shutting off steam-flow. The screw is then locked in that
position, and the governor valve will remain closed as long as normal
electric-motor speed is maintained. Upon motor power failure, the unit
immediately slows down, fly balls close in, governor valve opens, and
steam is admitted to the nozzles. The load is automatically picked up by
the turbine at a speed 3% to 5% below normal, with full-speed operation
possible by loosening the adjusting screw to open the governor valve. No
other automatic controls are required.

5.3 TURBINE OPERATION

Before attempting to start the turbine, clean off any dirt which might have
accumulated during installation, flush out bearing cavities, and fill with new
oil. Then, work the governor and trip valves by hand to make certain that
they are free.

when starting for the first time, check alignment after the turbine has
become heated. Coupling halves must be in line within 0.004 inch (0.010
cm). If found to be out of line, disconnect the inlet and exhaust flanges
and realign. Be sure that the flanges of these lines are parallel with the
turbine flanges before reconnecting them.

To start the turbine, proceed as follows:

1. Check the oil level in the bearings.

2. Open the drain from the turbine casing.

3. Open drains in the inlet and exhaust lines.

4. Open the exhaust valve.

5. Crack the throttle valve.

6. Close the drain valves after condensation ceases to flow and the

5.3
 turbine has become heated.

7. Open the throttle valve sufficiently to start the turbine.

8. Examine the oil rings, make sure they are turning.

9. Open the throttle valve gradually until the machine comes up to speed
and the governor has taken control.

10. Open the throttle valve wide.

When the operator becomes familiar with the turbine, it may be brought up
to full speed within 30 to 60 seconds.

5.4 Over speed Test

Test the over speed trip governor by actually over speeding the machine.
If not advisable to over speed the driven machine, disconnect the flexible
coupling.
To over-speed the turbine, push on the top governor lever. This opens
governor valve, increases the supply of steam to the nozzle, and speeds
up the turbine. The over speed governor should trip at a speed of 10 to
15% above the designed speed shown on the name plate.

5.5 Turbine Shut Down

To shut down the turbine, proceed as follows:

1. Trip the over speed governor valve by disengaging the trip latch. This
will test the valve mechanism.

2. Close the throttle valve in the steam line.

3. Reset the over speed governor.

4. Open all turbine drains.

5.6 Required Service During Turbine Operation

During operation, observe the following:

1. Watch the oil level in the bearings.

2. Examine the oil at least once every week to make sure that it is in good
condition. Evidences of deterioration are an increase in viscosity,
development of acidity, and the deposit of sludge or sediment.

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3. Clean out and flush the oil reservoirs at least every two or three
months. Refill with new oil.

4. Keep the valve stems clean and properly packed.

5. Trip the over speed governor occasionally to see that it is in proper

condition.

6. Watch for endwise movement in the shaft of the driven machine. Make
sure that this movement is not transmitted to the turbine shaft.

7. Inspect the bearings frequently. On sleeve bearing turbines the

governor end bearing is set for 0.008 inch (0.020 cm) total clearance
between thrust faces. See that this clearance is maintained. Keep the
bearings in good condition and the turbine will operate indefinitely.

5.7 Preparation and Precautions before Starting Up

For preparations and precautions before starting up, the following must be
checked:

1) Steam supply system is established and steam traps are working.

2) Exhaust steam (low pressure) system is properly controlled in pressure

without any blockage.

3) Exhaust pressure relief valve is fixed in position and its block valve is
locked open.

4) Cooling water to bearings or lube oil coolers is flowing well.

5) Lube oil circulation, if oil system is provided, is established properly

and its protection devices work correctly.

6) Driven equipment is ready to start and coupled to the turbine.

7) For a condensing turbine, the following should be checked:

A. The water level in the surface condenser is normal.

B. Vacuum breaker is closed, if provided.
C. The condensate piping, level controller, control valve and
condensate pump are ready for operation.

5.5
5.8 Starting Up of Single Stage Back Pressure Turbine

Piping layout around a single stage turbine is shown in Figure 5.1.

1) The first thing to do is to warm up the turbine rotor and casing by the
following procedure:

2) Open the exhaust valve while other valves are closed except the block
valves 4 and 6 for steam traps.

3) Open the drain valves 5, 8, 7.

3) Slightly open the inlet steam by-pass valve 3.

4) If it is a normal start-up, allow the turbine to warm itself for approx. 30

minutes.

5) Then open the steam inlet valve 2 slowly to about 1/3 to 1/2 open and

A. If speed comes up, continue to open very slowly until the

valve is fully
open.
B. If turbine does not start, help the governor lever to slightly
open the
governor valve.

The difference between A, and B is due to the type of governors

and the detailed procedure for your turbine and governor must
be referred to the relevant instruction book.

6) When the turbine speed reaches the rated speed, try to trip the turbine
by the hand trip lever to check that the emergency trip valve works
well.

7) Close valves 2 and 3.

8) Follow the steps from steps 3 to 5.

9) When the turbine speed reaches the rated speed again, necessary
action must be taken to connect the driven equipment to the process
system.

10) Close valve 3.

11) When the inlet steam temperature rises to 20°C - 30°C above its
saturated temperature, close drain valves 5, 7,8.

12) Confirm that valves 4 and 6 are open and steam traps are working
correctly.

5.6
Fig. 5.1: Piping layout around a single stage turbine.

5.9 Operation of a Multistage Back Pressure Turbine

Operating procedure of a multistage back pressure turbine is basically

the same as the procedure for a single stage turbine. However, a
multistage turbine is usually provided with a bearing lubrication system
and control oil system for the emergency trip valve and governor valve,
and a gland sealing vacuum device. The instructions for these systems
must be referred to before handling multistage back pressure turbines.

5.10 Operation of a Condensing Turbine

A condensing steam turbine consists of a further conplicated system

including the surface condenser, vacuun devices, condensate pumps and
drivers, etc. Also, the arrangement of the system varies depending on
the manufacturers standard.
Figure 5.2 shows a typical piping arrangement around a condensing
turbine. Therefore, the instruction manuals of each turbine must be
referred to for the operating procedures of the condensing steam turbine.

5.7
5.11 Precautions During Operation

During turbine operation, the following must be periodically checked or

monitored:

1) Vibration

Vibration on the bearing housings must be checked by touching with hand

very often to confirm there is no serious or unusual vibration.

In the case of a multistage steam turbine, vibration monitors are provided

at each bearing like centrifugal compressors. Vibration amplitudes must
be checked and recorded to grasp the trend of turbine vibration.

2) Steam Temperature

Inlet steam temperature must be at least 20 deg C higher than its

saturated temperature unless the turbine is specially designed for such
conditions.

If steam is not superheated enough, a part of the steam condenses in the

piping and turbine, and droplets will attack the turbine blades.
Impingement of water droplets will cause erosion on the blades and
vibration of the rotor.

3) Steam Leakage from Stuffing Boxes

The stuffing box with carbon packing allows only a small amount of steam
leakage through it. Also, labyrinth packing with a vacuum device does not
allow steam leakage in normal conditions.
Leakage of steam from the stuffing boxes will contaminate the lube oil in
the bearing housing and will lead to bearing failure.

4) Critical speeds

A multistage turbine usually is to run above its critical speed like

centrifugal compressors. For the turbine rotor to stay in the speed range
plus or minus 10 percent of the critical speed is dangerous. Only passing
through this range in operation is permitted. The turbine manufacturers
instruction book or turbine data sheet must be referred to for the critical
speed.

5.8
Fig. 5.2: Piping arrangement around a condensing steam turbine.

5.9