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Operation & Maintenance

OPERATION
STEAM PURITY OIL SPECIFICATION RELIABILITY & AVAILIBILITY OF TURBINE IS ASSURED WHEN ALL THE VITAL COMPONENTS AND MONITORING EQUIPMENT ARE IN IN THE SPECIFIED CONDITION. CONTROLLERS PROTECTIVE DEVICES SAFTEY DEVICES

STOP AND CONTROL VALVES & OTHER IMPORTANT


TURBINE VALVES MONITORING EQUIPMENT
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TESTING OF ALL COMPONENET AS PER SPECIFIED


TESTING INTERVALS WEEKLY/MONTHLY/YEARLY

START-UP OF TURBINE READINESS OF EXTERNAL SYSTEM - CIRCULATING WATER FOR CONDENSER

- COOLING WATER FOR COOLERS


- AUXILARY STEAM - DM WATER SUPPLY - CONDENSATE SYSTEM, VACUUM PUMP & EJECTORS
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READINESS OF OIL SYSTEM AND TURNING GEAR

READINESS OF CONDENSING PLANT


READINESS OF VACUUM PUMP, SEAL STEAM SUPPLY START OF BYPASS OPERATION MAIN STEAM LINE WARM UP

TURBINE WARMING UP

SPEEDING UP OF TURBINE
SYNCHRONISATION LOADING
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Why Maintenance?
To Increase To Decrease Efficiency, Availability, Reliability, Safety, Economy Forced outage, Major damage, Accident

To Assess

To Rectify / Replace

Present condition, Damage & Damage initiation, Remaining life, Subsequent inspection Deficiencies, damaged components

Criteria to increase inspection intervals


Improved Calculation methods Better Knowledge of materials More Dependable structural components Sophisticated Monitoring systems Improved Operational procedure More Service experience
However inspection intervals should not be lengthened indefinitely

Criteria to decrease inspection intervals

Ease in dismantling Thermal fatigue Bolt relaxation

Blade check
Seal wear

Turbine modules to be overhauled in 50,000 eq. hours of operation

Factors influencing turbine plant outage

Time independent (Human failure) Planning & Design


Material selection Manufacturing & Assy.

Time dependent (Component stressing) Wear & tear


Erosion & Corrosion Distortion

Erection & Commissioning


Operation & Maintenance

Deposits
Life expenditure

Failure probability

Maintenance Category

Maintenance

Routine Maintenance

Capital Maintenance
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Capital Maintenance
Operational History
Failure History Pre-overhaul survey Execute Overhauling & Compare Performance

Identify Scope of work


Identify Corrective measures Identify Spares requirement

Plan & Start Dismantling

Review identified Scope & Corrections

Checks & Findings during dismantling


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Capital Overhaul

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SEQUENCE OF OVERHAULING ACTIVITIES

Stoppage of barring gear and oil system.


Removal of HP/IP casing insulation after stoppage of oil circulation. Opening pedestal cover and upper half bearings. Measurement of bearing clearances. Measurement of catenery over the journal of the turbine rotors. De-coupling of LP/Gen rotors. Swing check measurement on HPF end of the rotor.
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Recording of CRO of the HP/IP and IP/LP coupling. Bump check of HP/IP casing. De-coupling of HP/IP/LP rotors. Horn drop check of HP/IP casing. If no loading is observed on any of the palm of the casing , then it needs correction.

Necessary corrections based on Horn Drop values to be done


by cutting / re-welding of pipelines , and not by adjusting the thickness of the packer.

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Check / Record mis-match of the HP inlet / exhaust pipe line before lifting of module for future reference.

Removal of HP module for overhaul.


Dummy shaft to be used during overhaul of HP module. In absence of dummy shaft the position of casing centering between HP inner/outer is not known. Checking of bearing contact between torus and its support and replacement of bearing , if required. Checking of pedestal level as per the centenary value and level of individual pedestal. Necessary correction in pedestal level is to be carried out , if these are sliding pedestal.

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Checking of pedestal centering with respect to piano wire. Checking of pedestal packers for their contact.

Replacement of bearing with piano wire in place of directly with rotor. Checking/correction concavity/convexity of rotor couplings. Re-finning of HP/IP rotor & casing as required. Coupling of HP/IP rotor to be done first and record swing check and CRO. Afterwards IP/LP rotor to be coupled. No change in CRO and swing check of HP/IP rotor is permitted with the coupling of IP/LP rotor.
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