OPERATING & MAINTENANCE

INSTRUCTIONS MANUAL
FOR
TURBINE

VOLUME-1

PROJECT : DVC DURGAPUR

2 X 500MW

MACHINE NO. : T-0764 TO T-0767

SERVICE : BFPDT

TYPE : K1401-2

ADDRESS FOR FIELD ENGINEERING SERVICES

COMMUNICATION Turbine & Compressors Engg.
Bharat Heavy Electricals Ltd.
Ramachandrapuram,
Hyderabad - 502 032
ANDHRA PRADESH, INDIA
 INDEX FOR VOLUMES

PROJECT: DVC DURGAPUR SERVICE : BFPDT

2 X 500MW

TYPE : K1401-2 M/C NO. : T-0764 to

T-0767

VOLUME 1 : O P E R AT I N G & M A I N T E N A N C E
INSTRUCTIONS MANUAL FOR
TURBINE

VOLUME 2 : O P E R AT I N G & M A I N T E N A N C E
I N S T R U C T I O N S M A N UA L F O R
AUXILIARIES & INSTRUMENTATION
(III parts)

BHARAT HEAVY ELECTRICALS LIMITED 1 of 1

 DVC DURGAPUR 2X500MW BFPDT

BHARAT HEAVY ELECTRICALS LIMITED 1 of 1

Bharat Heavy Electricals Limited 6
Bharat Heavy Electricals Limited 6
Bharat Heavy Electricals Limited 6
Bharat Heavy Electricals Limited 4 6
Bharat Heavy Electricals Limited 5 6
Bharat Heavy Electricals Limited 6 6
Bharat Heavy Electricals Limited 1 1
Bharat Heavy Electricals Limited 2
Bharat Heavy Electricals Limited 2 2
GENERAL
TECHNICAL DATA
GENERAL DESCRIPTION OF
STEAM TURBINE
STEAM TURBINE COMPONENTS
TURBINE CASING
BALANCE PISTON GLAND

The purpose of the labyrinth ring shown in
fig.1 is to seal the wheel chamber against the
space upstream of the gland. the effective
diameter of the packing is determined in
accordance with the requirement of balancing
the residual axial thrust.
The labyrinth ring (2) is split axially and slide on
to projecting surfaces on the turbine casing (3)
At the joints, the labyrinth ring is located by grub
screws. diameter
the turbine shaft (1) has shallow circular
grooves turned on it which mate with the
packing rings caulked into the labyrinth ring
(2). this arrangement improves the throttling
effect, as steam flow is frequently baffled.
The radial clearances between the shaft and
the packing strips have been selected with
view to ensuring a good throttling effect while
maintaining safety against rubbing.

1. Turbine shaft
2. Labyrinth ring
3. Turbine casing
4. Packing strip
5. Caulking material

Fig.1 Balance piston gland

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 TURBINE CASING

Labyrinth ring

The purpose of the labyrinth ring shown in Fig. 1 is to seal the wheel chamber against the space
upstream of the gland. The effective diameter of the packing is determined in accordance with the
requirements of balancing the residual axial thrust.

The labyrinth ring (3) is split axially and slid onto projecting surfaces on the turbine casing (1 ). At
the joints, the labyrinth ring is located by grub screws (2).

The turbine shaft (6) has shallow circular grooves, turned on it which mate with the package rings
(5) caulked into the labyrinth ring (3). This arrangement improves the throttling effect, as the steam
flow is frequently baffled.

The radial clearances between the shaft and the packing strips have been selected with a view to
ensuring a good throttling effect while maintaining safety against rubbing.

6 5 4

1. Turbine Casing
2. Grub screw
3. Labyrinth ring
4. Caulking material
5. Packing rings
6. Turbine shaft

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STEAM TURBINES
Description
BLADING
General
The blading converts the thermal energy of the
steam into mechanical energy. The efficiency
and reliability of the machine are therefore very
dependent on the blading. Consequently,
exceptional)y high standards must be set in the
design and manufacture of the blades.
There are two different types of moving blades:
The reaction blade for the drum blading and the
tapered and twisted blade for the low-pressure
stages of condensing turbines.
The main features of the reaction blading are as
follows:
The rings of fixed blades are made of drawn
profile material with loose, machined spacers at
the root to give the required pitch. There is
normally riveted shrouding.
Fig. 1
Drum blading – moving blades with shrouding
The rings of moving blades are as assembled
from individual blades; and blade is machined
from one piece of metal, i.e., root, blade
proper and shroud, all from same piece.
The fixed and moving blades have the same
profile and the same angle of incidence. All
the blades are made of rust-resistant steels.
Moving blades
The moving blades for the drum blading
always have an inverted- T root and an
integral shroud. The inverted-T roots are
inserted into grooves in the turbine rotor and
caulked with brass profile strip. The blade
roots are designed to produce the required
passages between the blades in the ring
without the need for spacer pieces. A gate
blade closes off the point where the blades
are inserted into the groove. This blade,
which is secured to the rotor with grub
screws, ensures that there is no gap or
sudden change in pitch in the ring of blades.
Fixed blades are made of drawn bar. They
have a pronged root and are held at the
required pitch in the grooves of the guide
blade carrier by machined spacers. At the
joint face of the guide blade carrier the
spacers are screwed and also brazed.
The shrouding is riveted to the fixed blades in
lengths, joining several blades together to
form segments.
Low-pressure stages
The last three stages of the turbine form a
standard stage group.
The substantial difference between the
circumferential velocity at the hub and at the
blade tip is allowed for by using a suitable
profile and stagger
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profile and stagger angle. This gives the low-
pressure blades their twisted form. The
thickness of the blade also decreases from the
hub to the tip because of the high centrifugal
force.
Again the moving blades have inverted- T roots
which means that the method of fixing is no
different from the remainder of the drum
blading. The final-row blade are with curved fir-
tree roots. They are inserted into axial grooves
in the rotor and secured with caulking pieces.
Fig.2 Moving blade with inverted – T
root and integral shroud
The moving blades are fitted with loose
damping pins. The final-row blades have
integrally forged thickness around the hole for
the damping pin so that the remainder of the
blade cross section is not over- stressed.
The fixed blades of the I.p. stage groups have
thin trailing edges in order to prevent the
formation of water droplets. The axial distance
before the final row of moving blades is made
large in order to facilitate the acceleration and
atomization of any water droplets which detach
from the trailing edges of the Ked blades.
This reduces the force with which the droplets
impinge on the leading edges of the blades.
he leading edges of the blades are hardened
if circumferential velocity. high steam wetness
and low condenser. pressure are
encountered together .
The LP guide blades of the last two stages
are of hollow type and manufactured from
alloy steel plates which have high erosion
resistance.
Fig. 3 LP Guide blade
Blade tip sealing
There is a radial clearance of several
millimeters at the tip of all fixed and moving
blades fitted with shrouding. This eliminates
any possibility of contact between the
stationary and moving parts of the machine
due to distortion of the rotor or casing. This
relatively large radial clearance is sealed with
sealing strips in order to restrict the loss in
power due to the tip loss to an absolute
minimum.
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The sealing strips for fixed blades are caulked
into the rotor and those for the moving blades
into the guide blade carrier. The sealing strips
are very thin and leave only a few tenths of a
millimeter between the shrouding and the rotor
or guide blade carrier.
Fig. 4
Blade tip sealing
The sealing strips are also made of rust-
resistant steel. They are sufficiently strong to
withstand the maximum pressure differences
which can occur. Should rubbing occur, the
amount of heat generated by them is
insufficient to cause any dangerous distortion
of the rotor or guide blade carrier.
The sealing strips are easy to replace;
therefore it is a simple matter to remove any
damaged strips and fit new ones to give the
proper clearances during overhaul at site.
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 Fig. 1
Front bearing pedestal
1. Thermometer connections for journal
2. Aperture for emergency tripping device
3. Thermometer connections for thrust
4. Supporting web of thrust bearing
5. flange for main oil pump connection
6. Oil inlet to journal bearing
7. Keyway for sliding key of base plate
8. Oil drain
9. Elongated hole for bearing-pedestal mounting screw
10. Oil inlet to thrust bearing
11. Tapped hole for turbine-casing fastening screw
12. Supporting web of journal bearing
13. Flange for emergency speed governor adjustment.

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TURBINE
Thrust Bearing (-2)

Function :
thrust bearing and transmitted to the front
The residual axial thrust of the turbine rotor,
bearing pedestal. The magnitude of the
in so far as it has not been compensated by
axial force thus acting on the thrust bearing
the balancing piston in the labyrinth
is chiefly determined by the turbine load.
section, is taken up by the

1. Upper bearing shell 6. Dowel pin

2. Cylindrical pin 7. Bearing pad
3. Bearing pad 8. Liner ring
4. Lower bearing shell 9. Arresting plug
5. Socket-head cap screw 10. Thermometer well

Fig.1
Thrust bearing

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Design :
The thrust bearing is accommodated in the
front bearing pedestal. Its principal parts are
the upper bearing shell (1), the lower bearing
shell (4), and the segmental bearing pads
(7). Dimensionally the design has been
made so as to prevent axial displacement of
the turbine rotor except for the part which is
caused by thermal expansion (sf. 1-12 10
00).
The thrust bearing is secured in its position
by the front bearing pedestal and the binder
which is bolted to it.
2. Cylindrical pin
3. Bearing pad
11. Seating face of segmental pad
12. Running face of segmental pad
13. Collar of rotor shaft
Fig. 2.
Arrangement of a segmental bearing pad
For this purpose, the pedestal and the binder
are both provided with an integrally cast rib
which in the assembled state engages with
a corresponding annular groove machined in
the middle of the bearing shell periphery.
Rotation of the radial bearing is prevented
by an arresting plug (9). It is screwed into the
rib of the binder and engages into a hole
drilled into the upper bearing shell.
The two bearing shells are held together by
two socket-head cap screws. The relative
position of the two shells with respect to
each other is fixed by two dowel pins.
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Hydraulic Jacking devices

A further oil pocket (6), machined in the middle of the bottom bearing shell, is connected
via a drilled passage (5) with a special oil line of the hydraulic pressure jacking system.
When the turbine is being started by means of the turbine gear, high-pressure oil from
the jacking system will be admitted through this line to the pockets underneath the rotor
journals of the turbine. This has the effect of relieving the bearing from load, because
the break-away torque will be reduced and dry friction is avoided. An additional
advantage is that the starting torque, which has to be supplied by the turning gear, will
be considerably reduced.

• Extra equipment

1. Bearing shell, upper shell 6. Oil pocket for jacking oil

2. Oil pocket for bearing oil 7. Fillister head screw
3. topper pin 8. Drilled passage for bearing oil
4. bearing shell lower half 9. Annular oil channel
5. drilled passage for jacking oil 10. Connection for jacking oil

Fig. 1: Radial bearing cross section

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Function
The rear support elements - Exhaust Hood, support Paws of the exhaust part and the
alignment elements - serve to support the turbine casing and the turbine rotor and for
their alignment relative to each other.

Design
The exhaust hood (1) with its support paws (2) is directly connected to the turbine
foundations, whereby the two support paws each rest on a bed plate (7). The bed
plates are rigidly anchored to the turbine foundations Base frame. The support paws
and bed plates are connected by bolts. However, the bolts are designed such that in
case of thermal expansion the support brackets can expand laterally. Freedom of
movement can be checked by spacers which must always be easily movable.

Fig. 1 Exhaust part with rear support

1. Exhaust Hood
2. Support Paws
3. Forked prong
4. Adjusting element
5. Mating part
6. Steeped Key
7. Bed Plate

Bharat Heavy Electricals Limited 1-0750-03

Page 1 / 2
 The rear fixed point of the turbine casing, relative to which the turbine
expands towards the front end, is formed by one stepped key (6) per supporting
paw inserted transverse to the turbine axis. A forked prong (3) is bolted on
beneath the bearing housing as a center guide. A forked prong (3) which is
integral to the lower part of the exhaust hood prevents the lateral movements of
the turbine casing with the help of the mating part (5) fixed to the foundations /
Base frames.

The exhaust hood is split horizontally. It houses the rear journal bearing
supporting the turbine rotor in the lower part and bearing cover for the upper part.
In between the exhaust portion and rear journal bearing sealing is done by rear oil
gland and rear labyrinth gland. The bearing cover designed to accommodate a
manual or electro hydraulic shaft turning gear which can be supplied on request.

Bharat Heavy Electricals Limited 1-0750-03

Page 2 / 2
 Bearing seal ring (Oil Gland)
Purpose
The bearing seal ring serves for sealing off the bearing pedestal against the turbine casing at the
point where the rotor shaft penetrates from the casing. The scraper rings in the bore of the seal ring
prevent bearing oil from flowing along 1he shaft into the turbine casing. Radially drilled holes starting
from the interstitial spaces between the individual scraper rings form passages for draining the
scraped-off oil into the oil-return pipes connected to the bearing pedestal.

Design:
The bearing seal ring is axially split. It fits into appropriate turned grooves in the bearing pedestal.
The upper half of the ring is fixed to the pedestal bearing cap by grup screws.

Heat transfer
The transfer of heat from the turbine casing to the bearing pedestal is effectively reduced by a
screw-mounted annular heat shield.

1. Heat shield
2. Top half of bearing seal ring
3. Oil scraper ring
4. Botlom half of bearing seal ring

Fig 1
Bearing seal ring

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GOVERNING SYSTEM
GOVERNING PROCEDURES
GOVERNING SYSTEM
Device for remote operation of emergency Solenoid valve (1051) and an
trip gear from the control room automatically opening control switch
(1052) with interlocking mechanism (011)
Purpose: which will block the switch in the open
position.
Starting a turbine from the control room
requires, in addition to the distant operation Mode of operation:
of the starting device, remote control of the After the sailing device (1840)has
emergency trip gear. Such control will be been brought into the starting position,
achieved with the help .of the following the solenoid valve (1051) will be moved
apparatus. through the action of the control switch
(1052) in to the position represented by
"b". This will allow pressure

011 Pressure switch

1051 Solenoid valve
1052 Control switch
221 0 Emergency trip gear
2242 Auxiliary slide waive
2242.1 Pilot valve
2242.2 Slide valve piston
2300 Emergency stop valve
2611 Emergency speed governor testing device

Fig. 1
Schematic circuit diagram for remote operation of emergency trip gear from the control room

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GOVERNING SYSTEM
COMPONENTS
00800 Control Valves,HP 5621(2) Damping devices
080 (2) Control Valves, LP ST Speed transmitter
12320 Wood ward controller C Second oil
1680 I/H Converter D Steam
1681 I/H Converter E Trip Oil
1900 Control valve actuater, HP P Pressure oil
190 (2) Control valve actuater, LP T Drain oil
5620 Damping devices

Fig. 1:
Speed governing System using the digital Wood Ward controller

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STEAM TURBINES

Description

Control valve Actuator

(Device No. 1910,1911)

Purpose: receives its control pulses from the secondary

The actuator transmits the secondary oil
positioning pulses for the control valves to the
valve-operating levers. The lever system raises
or lowers the control valves so that the steam
flow always corresponds to the preset or
required turbine output. The actuator pilot valve
b
oil circuit. However, the actual servo power
for positioning the control valves is derived
from the pressure of the oil which flows either
to the space above or below the actuator
piston.

Fig. 1 Actuator

1 Eyebolt joint head

2 Reset bar
3 Piston rod
4 Servo cylinder
5 Servo piston
6 Connection piece
7 Pilot sleeve
8 Pilot piston
9 Pilot valve
10 Lever
11 Adjusting screw
12 Bell-crank follower
13 Pressure rooler

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Design :
The principal parts of the actuator are the pilot
valve (9) with pilot piston (8), the connection
piece (6) and the feedback system. The piston
(5) and piston rod (3) are located in the actuator
housing. The piston rod carries the feedback
bar (2) and the eyebolt joint head (1) for
connecting the actuator with the lever system of
the control valves.
A thrust ball bearing (15) is shrunk on to the
pivot pin arranged on the top face of the
impeller (16). A cup shaped spring is pressed
against the thrust bearing. Preloading of the
compression spring is determined by the
setscrew (11) and the position of the lever
(10).
Mode of operation :

Any change in secondary oil pressure brings

Several sleeves (7), in which the pilot piston (8)
slides, are fitted tightly into the pilot-valve
housing. The pilot valve has on its periphery
grooves which coincide with corresponding oil
pockets in the bore of the sleeves. The top end
of the pilot piston carries an impeller (16) with
evenly spaced passages drilled in radial and
tangential direction.
about a corresponding displacement of the
pilot piston. The grooves and oil pockets in
the pilot valve and sleeves are arranged such
that, with increasing secondary-oil pressure,
the pilot piston is moved upwards, thus
enabling pressure oil p to flow into the space
above the actuator piston. The piston moves
down and opens the control valves through
the lever system. If the secondary oil
pressure drops, the movement is reversed.

Fig. 2 Pilot Valve

14 Compression spring
15 Axial thrust bearing
16 Wheel disk
17 Slide piston
18 Drain hole
19 Set screw for vibration
20 Small drilled hole
21 Set screw for rotation
22 Drilled radial hole
23 Aluminum insert
24 Drilled radial passage

C Secondary oil
T Oil drain
P Pressure oil

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By means of a feedback bar (2), the piston
stroke is fed back to the lever (10) via a bell
crank follower (12). The action of that lever on
the compression spring opposes the pilot piston
movement. The pilot piston reacts to the spring
force and returns to its neutral position. The
feed back system thus stabilizes the
movements.
The functional relationship between secondary
oil pressure and piston movement can be
changed by adjusting the inclination of the
feedback bar to the desired position with the
help of a setscrew. Such adjustments will affect
only the amount of proportional gain, while the
secondary oil pressure/piston displacement
relationship remains linear with the design of
the feedback bar shown here. However, non-
linear control characteristics can also be
provided through an appropriately shaped cam
profile of the feedback bar.
Rotation and vibration of pilot piston :
Pressure oil p passes through drilled passages
in the pilot valve housing to the upper part of
the pilot piston. From there, it flows through four
radial holes (22) into the cavity of the hollow
pilot piston, from where it passes to the drilled
radial and tangential passages (24) of impeller
(16) from which it escapes.
Fig. 3
Oil flow through wheel disc
The permanent flow of oil leaving the impeller
(16) from which it escapes. The permanent
flow of oil leaving the impeller tangentially
imparts a continuous rotational motion to the
pilot piston. The setscrew (21) allows
adjustment of the speed by adjusting the oil
flow volume. The speed can be measured in
the aluminum insert (23).
The secondary oil pressure acting on its
underside imparts a constant axial motion to
the pilot valve. This is achieved by a small
hole drilled into the lower part of the pilot
piston. During every complete revolution of
the piston, this hole momentarily over- laps a
drain hole (18) in the housing. The quantity of
secondary oil which is thus allowed to escape
causes a small pressure drop in the
secondary oil circuit causing the pilot piston to
move downwards by a small amount. When
the hole is covered again the piston is lifted
until the next overlap. During each of the
movements by the pilot piston, a minute
volume of pressure oil flows to the actuator
piston. This causes slight vibration of the
spindles of the control valves, thereby
ensuring immediate response of these
components to the control pulses of the
governor. The vibration stroke of the pilot
piston can likewise be adjusted by means of a
setscrew ( 19).
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TURBINE PROTECTIVE DEVICES
SPEED MONITORING Design and mode of operation:

(With electronic pick-up of the type
manufactured by Messrs. "Jaquet" , "
Bently" , or similar)
Function:
Convenience of operation or local site
conditions of a turbine plant sometimes
warrant the accurate measuring or remote
reading of the turbine speed. To this effect,
the speed will be measured by an
electromagnetic pick-up which does not
require mechanical contact with rotating
parts. This signal may also be used as
input for supplementary governor and
control equipment.
A steel disk is bolted onto a pinion shaft
driven by the turbine rotor or onto the
turbine rotor itself at the head end. Near its
periphery, the disk carries a number of
equally spaced axial holes. The pick-up is
screwed into the cover in front of the
rotating disk.
When the perforated disk rotates in front of
the pick up this produces a frequency
proportional to the speed of the turbine
rotor. The pick-up frequency is converted
into a speed-proportional current in a
following converter and measured on an
indicating instrument.

1. Indicating instrument
2. Converter: frequency/current
3. Pulse pick-up
4. Perforated disk
5. Drilled hole

Fig. 1 Speed monitoring arrangement

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MEASUREMENT OF AXIAL ROTOR
POSITION
(With "Reutlinger, Bentley Nevada and the
like")
Function:
The thrust bearing forms the fixed point of
the turbine rotor. An axial displacement of the
turbine beyond the given limits (bearing
clearances) can have serious consequences.
Frequent checks permit early recognition of
rotor displacement. If such displacement has
occurred it has been shown by experience
that immediate tripping will allow the turbine
to coast to standstill without causing any
secondary damage.
Construction and mode of operation:
The measuring point is located in the front
bearing housing in the immediate vicinity of
the thrust bearing. The measuring units
(converters) operate on the eddy-current
principle. They consist essentiality of a
proximate, a transducer and the associated
2 1
1. Transducer
2. Extension Cable 3 5
3. Protective casing
4. Extension Cable
5. Proximitor
6. Console
Fig. 1: Electrical measurement of
Axial rotor position 4
extension cable. The transducer is
arranged perpendicularly to a collar on the
turbine rotor.
The measuring medium is a high-frequency
signal (HF signal) which is generated in the
proximitor by means of an auxiliary voltage
and fed to a coil in the transducer. The coil
transmits the energy to the surrounding
atmosphere as a magnetic field. When an
electrically conductive material cuts this
field eddy currents are produced, the
amplitudes of which become larger the
closer the turbine rotor comes to the coil in
the transducer. The resulting energy loss in
the measuring unit reduces the amplitude
of the HF signal between the transducer
and the proximitor . The amplitude of the
HF signal is a function of the gap, i.e. the
closer the turbine rotor comes to the
transducer the greater the energy loss but
the lower the HF voltage. The proximitor
measures the amplitude of the HF signal
from zero to the negative peak and
produces a proportional output voltage
which can be used for display (analogue,
digital or recorder).
6
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LUBE OIL SYSTEM
TURBINE ACCESSORIES
STEAM TURBINES
Operation
Purpose
If the rotor of a turbine, which has been
disconnected from the steam supply, is not
being rotated any ore, it very likely will suffer
from considerable warping during a
characteristic interval of the cooling-down
period. Any attempt to re-start the turbine in
this condition would therefore produce
rubbing con-.tact between the moving and
stationary blading with resulting deterioration
of the blade-lip sealing. In order to permit
safe re-starting of the turbine during that
Interval, a hydraulic turning gear has been
provided which by Imparting a rotational
motion ensures distortion-free cooling of the
turbine rotor an thus effectively prevents Its
warping.
Design and mode of operation
The hydraulic turning gear is incorporated in
the rear bearing housing. It is designed as a
1 Turbine shaft,
2 Blade wheel
3 Segment-shaped nozzle housing
Fig 1: Hydraulic turning gear
hydraulic turbine with a single row of blades
which is powered by pressure oil and
consists of a segment-shaped nozzle
housing (3) and a blade wheel (2). -The
blade wheel is shrunk- fitted on the turbine
shaft.
During the turning operation, the turbine rotor
(1) is rotated by the impact of the pressure
oil on the wheel blading. The pressure oil will
be supplied by an auxiliary oil pump and
after having passed a shut- off valve, is
admitted to the nozzle segment which directs
the oil jet upon the wheel blades.
After leaving the running blading, the oil jet
will flow into the bearing housing and from
there into the drain line. With fully opened
shut-off valve, the hydraulic turning gear will
normally revolve at speeds between 80 and
120 rpm.
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SHAFT - RIDING BRUSHES
(Shore Principle: General Description,
installation and operation) Due to the large number electrical potential
General Information: differences between shaft and stator, there
Shaft brushes permit measurement of shaft are no brushes which can protect a machine
voltage and current and balances potential against all possible combinations of such
differences. currents.
Thus, they protect bearings, couplings, gears
etc; to a great extent against damage from
excessive current transfer. This applies
particularly to electrostatic currents.

1 2 3 4 5 6 7 8 9

13

12

11

10

7. Brush arm
8. Brush
9. Bearing housing
1. Terminal assembly
10. Brush ground switch
2. Set screws and pins
11. Bearing pedestal
3. Head bolts
12. Current conductor
4. Raising screw
13. Head Assembly
5. Indicator
6. Pivot assembly

Fig. 1 Brush Installation

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 3
1. Oscilloscope
2. Non – inductive resistance
3. Brush ground switch
Fig. 2
Arrangementr to measure flashing currents
(as per P. Nippes)
- Open brush ground switch ;
- raise brush by turning brush-raising
screw (4) all the way in, but do not exert
force;
- disconnect earthing wire from terminal (1);
- remove four head screws (3);
- pull brush catridge out
- cover opening;
- replace brush by removing flat-head
screws. Ensure that the rake of the new
brush is in the direction of rotation.
Note : It is not necessary to disassemble the
catridge for brush replacement. However, if it is
desired to disassemble the catridge components,
this can be done by removing the two set screws
and pin (2).
- carefully insert brush catridge into casing
- replace four screws and lock washers;
- reconnect terminal
- lower brush on to shaft. Note position of
indicator in window;
- check contact resistance;
- close brush ground switch.
Starting and operation :
Before the unit is started, the brushes should
be checked with the brush ground switch open,
for:
- Resistance to casing with brush raised.
This should be infinite;
- resistance from the terminal to shaft with
brush down. This should be Zero.
In addition :
- Check for proper operating of the brush
ground switch in the closed position;
- Check for possible difference of
electrical potential between rotor, casing and
earth, using a millivolt meter.
Start-up:
- The turbine can be started up with the
brush raised and the brush ground switch
open;
- at the required speed and with the brush
ground switch still open, lower the brush, or
only one if here are several. Using in
oscilloscope, measure the voltage across
the brush ground switch. This is the shaft
voltage being generated.
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 It will usually show up as a Series of
near-vertical spikes across the
screen of the scope, often giving
indications, of running-frequency or
multiples thereof;
Measure current, as shown in
Fig.2, using a non- indicative
resistance of approx. 1 ohm from
the brush to earth, and measuring
voltage-drop across this resistance
using the oscilloscope. This voltage
drop can then be converted into
current, using the formula: I (A) =
Voltage drop/Ohm resistance.
The resulting current is the current
discharged by the voltage spikes from the
rotor to earth. If voltage and current are within
the limits given below and no signs of distress
are noted, the brush ground switch can be
closed. However, if the current is over 0.5 A p-
p, shutdown and demagnetization should be
scheduled, because the brushes may
deteriorate very rapidly. If readings are much
over 1.0 A, immediate shut should be
considered;
if several brushes are used, observe
effect of each brush upon the
voltage and current of all other
brushes. It is recommended that
detailed at periodic intervals are kept;
records of the readings made at start-up and
¾ excessive heat is a sign of strong
currents; the vicinity of the brush
must therefore be checked for
excessive heat. In the event of doubt,
pull the brush and check for heat;
¾ when the brush is in operation, .the
raising screw (9) must be secured
with two lock nuts.
Brush checkout:
If voltage and current hold steady over
periods of weeks the brush(es) is (are) very
probably in good condition. Readings of zero
should be investigated.
Ohmmeter readings
¾ Although an ohmmeter is not a
suitable instrument to check brush
contact resistance, it can be used,
however, to get a fair .idea of brush
effectiveness. This can be done as
follows (see Fig.3);
¾ Open brush ground switches of the
two brushes on a rotor,
¾ Connect ohmmeter across the
terminal of the brushes.

1. Coupling
2. Brush
3. Brush ground switch
4. Ohm-meter
5. To ground
6. Generator or compressor

Fig. 3
Checkout schematic for brush contact
resistance

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 1. Brush
2. Brush ground twitch
3. Battery
4. D.C. Voltmeter
5. To ground
6. Generator or compressor

Fig.4
Checkout schematic for
voltage check

The meter will probably fluctuate. If the average
reading is below 100 ohm, the brushes are
operating properly. Reverse the meter leads.
Probably one reading is quite high, because a
semi-conductor effect seems to exist across
the brush interface. The lower reading should
be used for judging brush conditions;
raise each brush briefly and make sure
that the resistance goes to infinity,
indicating there is no short to earth.
Observe the reading after the brush
has been lowered again.
Note: If the brush is raised to its extreme
position, the brush arm may contact
the brush casing, giving a zero
reading. For this checkout, the brush
need only be raised slightly off the
shaft.
Voltage check
shown in Fig. 4. Repeat this test with the
leads reversed. If the measured voltage is
greater than 10 V (voltage drop across the
rotor is 2 to 3 V), both brushes are in good
condition.
Caution: Do not connect the above
battery circuit or the
ohmmeter to the brush
terminal for any longer than
necessary, because even a
small battery current can
generate rather substantial
eddy currents in the shaft
underneath the brush, with
consequent shaft heating and
brush contact-surface deterio-
ration. Never test the brush by
lighting a light bulb with the
battery circuit, because then
the eddy currents will be
very significant, and heat and
surface deterioration can be quite
rapid in a few minutes.

Using an electronic DC voltmeter or, Brush condition and wear should be checked
preferably, an oscilloscope, check the hourly It first, later at weekly intervals once
voltage of a 1 2 V battery with the satisfactory operation has been established.
rotor in series with the
instrumentation , as

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STEAM AND DRAIN SYSTEM
OPERATION OF STEAM TURBINE
PROTOCOLS FOR
BOLT TIGHTENING
MAINTENANCE, OVERHAULING &
TROUBLESHOOTING
MAINTENANCE
OVERHAULING
TROUBLESHOOTING