Manual B4601

Document No.
0-2520-9302-01
Department Academy
Operating Manual Version 01
Language English
Product Code: WT9302

Product Type: B15-4.2/0.3
Edited by： 2013-01-18
Checked by： 2013-01-18
Approved by： 2013-01-18

附录：修改明细表
修改单编号修改标记修改页码修改处数时间操作人
13-8874 ① P1 1 2013.11.20. 孙青
Operating Manual 0-2520-9302-01
Contents
1. Preface
2. Technical specifications & construction

description of steam turbine
2.1 Technical specifications
2.2 Turbine sets construction and
its arrangement instruction
2.3 Steam & water system
2.4 Governing system & Control system
1-0800-01-01 Adjust valve
1-1910-20-01 Actuator
1-2110-02-01 Emergency governor
1-2222-01-01 Solenoid valve
1-2200-20-01 Emergency governor pilot valve
1-2300-01-01 ① Main stop valve
0-2522-9302-00 Manual of controls and instruments control
2.5 Oil supply system
1-4200-20-01 Main oil pump
1-5501-01-01 Lubricating oil throttle
1-5600-03-01 Unilateralism throttle
3-0320-01-01 Steam Turbine oil
3-0340-01-01 Oil washing
3-0310-01-01 Steam quality
3-0350-01-01 Blow of steam pipe
0-2521-9302-01 Assist machine system operating instruction
3. Turbine installation
3.1 Preparation before installation
3.2 Installation
2-0300-01-01 Foundation prepare work
2-0310-01-01 Second foundation
2-7600-01-01 Thermal insulating layer
4. Starting up and operation
4.1 Preparation before starting up
Hangzhou Steam Turbine Company Limited Page 1 of 15
①1 处 13-8874 孙青 2013.11.20
4.2 Starting up
4.3 Shutting down the turbine
5. Maintenance of operating and shutting down the turbine

3-2010-01-01 Operating supervision
3-3010-01-01 Abnormal vibration
3-3010-02-01 Excessive axial displacement of rotor and turbine water hammer
3-3010-03-01 Blade damage or breakage
3-3010-04-01 Oil-system fault and elimination
3-3010-05-01 Control-protection system fault and elimination
3-3010-06-01 Condensing system fault and elimination
3-3010-07-01 Load rejection
4-0100-01-01 Preface to section “maintenance”
4-0200-01-01 Checking and testing schedule
4-0300-01-01 Protection during turbine shutdown
4-0400-01-01 Oil system maintenance
4-0600-01-01 Deposition of steam-path section and cleaning
4-1000-01-01 Types of overhaul
4-1100-01-01 Inspection during overhaul
4-1200-01-01 Inspection scope and cautions during overhaul
4-1300-01-01 Overhaul example

1. Preface
The operating instruction introduce briefly our steam turbine construction and its
general characteristics to our users, help them to know the functions and construction
features of the turbine sets, thus it can be used as reference when compiling detailed
mounting and operating rules by users and mounting units.
This type is extraction condensing steam turbine; it is designed mainly for power
generation. It can drive multi-type and multi-voltage class’s steam turbine generator.
Steam turbine and power generator is direct-couplet.
The turbine set arrangements are three layers type, the elevation of working plane
is 8.0m.
When supply products, our company provide a set of easy to damage spare parts of
steam turbine, its varieties and quantities see spare parts list, users can order spare parts
from our company at any time if they have special needs.

2. Technical specifications and construction instruction
2.1 Technical specification

Type No: B15-4.2/0.3
Type: Single casing direct-couplet back-pressure turbine
Rated power: 15000kW
Rated speed of steam turbine: 3000r/min
Critical speed of steam turbine: ～4100r/min
Rated speed of power generator: 3000r/min
Turning direction: It is clockwise direction along air current
Inlet pressure：4.2+0.2
-0.3 MPa (a)
-15 ℃
Inlet temperature：440+10
Extraction pressure: 0.3 MPa（a）
Vibration:
Allowable max. vibration value (outer shell) is 0.04mm during normal running
Steam turbine body:
Rotor weight: 5.25t
Hanging weight of upper cover: 7.9t
The weight of body section: 22.9t
Contour size of turbine body (length×width×Height): 4000×3500×3500
Hanger height: 5.5m(starting from working plane)
Regulating system:
Speed unequal rate: ~4%
Synchrony range: -6~+6%
Safety system
Action speed of emergency governor gear: 3270~3330r/min
Axial Displacement clearance of safe action:
Alarm: ±0.4mm
Stop: ±0.6mm
Assistant oil-pump catenation:
Startup oil pressure: 0.65Mpa（g）
Accident oil-pump catenation:
Startup lubr-oil pressure: 0.8Mpa（g）
Bearings tile temperature:
Alarm: 90℃
Stop:100℃
Fueller：
Non-oil weight：7.5t
Oil tank volume：5.3m3
Oil-box non-oil weight: 1.9t

Dual oil cooler：
Cooling area：2×30m2
Cooling water amount：100t/h
Lube oil filter:
Oil filtering accuracy: 25μm
Flow: ~60L/min
Motoring oil pump (auxiliary pump)
Type No: 80YL-100
Voltage: (AC)400V 50Hz
Flow: 50m3/h
Lift: 100m(H2O)
Power: 37kW
Gear oil pump (accident oil pump)
Type No: 2CY-18/3.6
Flow: 18 m3/h
Power: 5.5kW
Lift: 36m
Voltage: (DC) 110V
Steam and water system

Sealing Condenser:
Cooling area：20m2
Eject steam pressure: 0.8MPa(a)
Eject steam flux: ~170kg/h
Cooling water flux: 45t/h
Running weighty: 1.15t

2.2 Turbine sets construction and its arrangement instruction
(See longitudinal section view, general arrangement drawing and relative parts
drawing of this turbine type provided by our plant)
The turbine is divided into one Curtis stage and 6 pressure stages. The casing of
turbine is chosen chrome molybdenum alloy cast steel with proof pressure and
heat-resistant material. Upper、lower half casing is connected with horizontal split bolt,
the casing affix to the front bearing pedestal with pawl structure which is fixed on the
foundation plane through front rack , the casing and rear bearing pedestal are put in the
same place, and the casing is fixed directly on the foundation through rear rack.
The steam turbine has a set of complete sliding pin system, both of the casing have
longitudinal guide plate, the casing guide plate is fixed at the inner part of the front
bearing pedestal, and the rear one is fixed on the foundation, the guiding key is installed
between the front bearing pedestal and the front rack, the casing push the front bearing
pedestal forward through pawl along the guiding key during thermal expansion.
Stop-thrust joint sphere bearing of oval radial is mounted in the front bearing pedestal,
together with main oil pump and emergency governor. The parts such as oil-relay、
emergency governor pilot valve、axial displacement transmitter、vibration transmitter as
well as speed transmitter, etc, are all placed on the front bearing pedestal case.
The rear bearing of turbine (oval radial bearing) and front bearing of generator, etc.
are mounted on the rear bearing pedestal. The front bearing of generator is oval radial
sphere bearing, its adjustable shim block is placed between sphere pedestal and bearing
pedestal. The rear bearing pedestal also has electric turning gear, turning gear can be
carried out by pulling turning handle and turn on the motor switch of turning gear . The
turning gear can automatically drop out when the speed exceeds 8r/min, and turn off
turning motor if the control system has done this connect.

2.3 Steam and water system (see drawing 0-0642-9302-00)
2.3.1 Main steam system
The fresh steam from the boiler enters into high pressure steam chamber via
isolate valve and emergency stop valve, the steam flow that enter into the turbine is
controlled by governing valve. After the steam expanded and work through one Curtis
stage and six pressure stages, the steam vent the casing to excluding-valve and
no-return-valve. The venting-pipe is equipped with a safety valve, when the
back-pressure is too high, the steam is exhausted to the air directly through the safety
valve.
Front steam gland has two gland extraction meatus. First one connected to
vent-pipe, another connected to rear gland and inducted to Seal gland condenser at last.
Steam of Seal gland condenser is from main steam or other steam pipe; when startup,
Steam of Seal gland condenser is from main steam pipe.
2.3.2 Gland system
The front and rear glands of steam turbine all use high-low tooth gland structure,
which can efficiently stem steam axial leakage. The first section leakage of the front
gland enter the vent-pipe , the second section leakage connect with Seal gland
condenser.
2.3.3 drainage system
Casing drainage, gland pipeline drainage, and T&T valve spindle drainage are all
entered into drainage or reuse. It should be noted that water or steam must not flow
backwards to steam turbine from drain pipe.

2.4 Governing and control system
2.4.1 General description of governing system (see regulating system drawing
0-0641-9302-00)
2.4.1.1 Governing system
Governing system is mainly comprised of speed transmitter (715), DEH system
(1310), I/H converter (1742), cylinder (1910) and regulating valve (0801).
This turbine governing system is autonomous control system. The DEH receives
three speed signal, which compared with fixed value. Secondary oil pressure(I/H
converter) controls adjust valve by oil cylinder.
2.4.1.2 Starting-up system
When it is time for starting-up, emergency stop assembly device (1111) is used to
open the emergency stop valve (2301).
During starting-up, spinning the handle of conversion valves (1830,1839), one of
the conversion valves (1839) builds starting-up oil [8 bar(g)], another one (1830)
connects emergency stop oil with return oil, and then loose the handle of conversion
valve (1830) to build emergency stop oil [8bar(g)]. 5 seconds later, loose the handle of
conversion valve (1839), thus the starting-up oil drop slowly, and at this moment the
emergency stop valve (2301) will open automatically. Travel switch (ZS587), which is
mounted on the emergency stop valve interlock DEH system (1310), DEH system is
allowed to starting-up steam turbine only when emergency stop valve is opened up
completely.
2.4.1.3 Steam turbine running monitoring and protection
When steam turbine overspreads, emergency governor (2110) operates, which
results in the oil leakage of emergency governor gear (2210) and the closing of
emergency stop valve as well as shutting down of turbine sets. Emergency stop oil may
be leakage and close the emergency stop valve after pressing the handle of manual
shutting down valve (2274) which mounted on the emergency stop assembly device
(1111).Solenoid valves (2225,2226) receive shutting down signal from protective
system, after received it, emergency stop circuit is cut off immediately and close
emergency stop valve.
2.4.1.4 Testing
Testing valve (1845), which is mounted on the emergency stop assembly device, is
used for on line testing whether the emergency stop valve clips, check the flexibility of
emergency stop valve. The admissible test oil pressure P1=0.1866+0.685 (P2-0.1) MPa,
in which P2 is the actual value of emergency stop oil pressure. The phenomenon of
clipping exists if the actual testing value is larger than the admissible testing value P1.

2.5 Oil supply system (see: lube oil system diagram 0-0640-9302-00)
2.5.1 Oil System synopsis
This turbine set adopts oil supply device of concentrating oil supply. The parts of
oil tank, auxiliary oil pump, accident oil pump, oil cooler, oil filter, ejection pipe of oil
suction and relevant pipeline fittings are assembled on a public chassis, and is installed
on the second floor platform with the height of 4m.
Oil supply device provides pressure oil and lube oil respectively.
Pressure oil: Normally, pressure oil is supplied by main oil pump mounted on the
main shaft. And it is supplied by auxiliary oil pump during starting-up and shutting
down.
Pressure oil primarily has the following purpose:
a. Safety: Used as power oil of emergency stop valve, governing valve and
extraction emergency stop non-return valve, it can protect the turbine set
via safety system.
b. Governing: One circuit convert into control signal of secondary oil
pressure through electro-hydraulic converter; other one enter into oil-relay,
which is used as power oil to open governing valve; still another one draw
into emergency stop assembly device to open and close emergency stop
valve.
c. Oil suction ejection pipe eject oil. The main oil pump has no self-suction
function so that oil suction ejection pipe is needed to maintain the inlet of
main oil pump a certain positive pressure. This device is a hydraulic
ejection pump installed inside of the oil tank, pressure oil flows out with
high speed from its nozzle, which at the same time suck a part of oil, they
were drawn into inlet chamber of main oil pump after their mixture.
d. Lube oil: Pressure oil form into lube oil for lubricating and cooling of
various bearings after having been throttled, cooled and filtrated.
The turbine system have oil tank above the turbine, they will safety the turbine
when it operating.

3 Installation of turbine
3.1 Preparation before mounting
3.1.1 The installation person must know the drawing, data, technical document,
drawings supplied by plant and related document of necessary equipment concerned;
Besides, they also need to know structure of turbine, characteristics and technical
requirements as well as detailed working program worked out by mounting units. The
following technical documents must be known:
(1) Operating instruction;
(2) Product qualified certificate, including various technical measurement,
project requirement and primary data record;
(3) Supplied project list, packing list, including various attached turbine tools,
spare parts, spare parts list, etc.
(4) Steam turbine longitudinal section drawing;
(5) Steam and water system drawing, governing and safety system drawing and
lube oil system drawing, etc.
(6) General arrangement drawing of steam turbine;
(7) General drawing of various important parts and necessary subsidiary
equipment, installation position, etc.
Meanwhile, you need to know before construction:
(1) The whole equipment of steam turbine machine room;
(2) Arrangement detailed drawing of various pipeline and various support hanging
drawing;
(3) Foundation drawing of different equipment, including mounting drawing of
steam turbine and power generator, etc;
3.1.2 Checking foundation
Checking whether turbine set foundation accord with the requirement, the
foundation intensity must conform to the requirement, the surface shall be flat, and
without alveolate, pockmarked surface, cracks and hollows, etc. The pre-embedded
body on the foundation should be complete, and it shall be in proper position and accord
with requirement.
Carefully check pre-remained hole on the foundation to see whether its relative
position is right, center relative distance need to keep consistency with drawing (object),
pre-remained hole shall be clean and without mess.
3.1.3 Opening cases to check and clean equipment
Open cases to check and clean all equipments before installation and construction.
All equipments and parts shall be checked to see whether they are complete and perfect,
Comparing with packing list, carefully check to know whether the equipments supplied
and parts are right, including drawing No and quantity. Every part, tool and spare part
and part must be carefully and gradually checked; major parts and special parts shall be
especially carefully checked and protected by special person.
Do no remove non-dismantled connection pieces, some oil tight pieces need to
grind flat and shovel off with wood plank and carefully rinse, Pay attention to prevent
rust.

3.2 Mounting
3.2.1 Requests for the pads arrangement
a. If the pads are needed to pre-embedded by users at the wedge, the plane is
checked by the flat plate, the contact points per area (25*25mm2) are 3~5,
total contact area shall be more than 75%, besides, the contact point shall
be uniform, and at the same time the error at the lateral direction shall be
less than 1/1000, longitudinal direction shall be less than 2/1000 for
turbine set.
b. If pads are not pre-embedded, the concrete surface at the wedge shall be
chipping. Coating the thin slurry at the force surface of concrete is not
acceptable.
c. The wedges must be matched pairs, correct the wedges, to guarantee that
the contact with the wedge shall be more than 80%, Upper and lower plane
of each of the wedges shall be parallel. When placing on the foundation,
their lateral and longitudinal gradient shall accord with requirements of a
item.
d. When adjusting level with the wedges, do not hit rough pads or let them
protrudes. Easy to raised sections shall not contact base plane of front and
rear bracket as well as remaining pads plane, so as not to influence
mounting accuracy.
e. Foundation pads shall be uniformly arranged, therefore the pads must be
set at each side of anchor bolt which loads are centralized. The upper half
of the pads must be raised beyond the edge of the bracket, after locating
the pads, the stagger section must be less than total area of 25% of pads.
f. The mounting of the pads shall ensure uniform force and without obvious
distortion of bracket, alignment is not allowed with its distortion.
g. After confirm the center, the anchor bolts shall be wrenched off and each
pair of the wedges shall be fixed with welding to avoid loosening.
3.2.2 Alignment and level requests
a. Lateral and horizontal deflection of casing (according to horizontal flange
at the hollow of front and rear casing) ≤0.15/1000.
b. Centering requirements of steam turbine and power generator coupling:
The deflection of outer circle:
Right and left: <0.03mm
Upper and lower: the height of steam turbine 0.04~0.08mm
The parallel requirements of end surface:
The upper opening: <0.03mm
The opening of right and left: <0.03mm
c. Guide key of front casing:
The sum of two sides clearance: 0.06~0.10mm
Clearance data concerned for guide key of rear casing, longitudinal key of
front bearing pedestal, longitudinal key of rear bearing pedestal see parts
drawing concerned.
d. The clearance data of steam turbine rotor and stator as well as clearance
data and requests of bearing, gland, etc. consult the product-qualified
certificate.

3.2.3 Installation
a. When install pipeline, pipeline and steam turbine shall be natural connection.
Pipeline and weight do not allowed to support on the steam turbine equipment, it
is especially need to consider for some thermal pipe to free expansion and
compensation in the pipeline arrangement. Steam turbine expansion thrust,
which is connected with pipeline, shall not more than 5000N.
b. After ended all the preparation of steam turbine installation, installation person
should finish the work one by one according to installation and construction
program of what has drawn out. The detailed and concrete construction sequence
shall according to various general equipment drawings, consult “ Power
construction and acceptance technical specification” (DL5011-92) issued by
department of energy and other provision concerned and standard.

4 Starting-up and Running
Steam turbine is a power equipment of high-speed rotation, which operates under high
temperature and high pressure, a complicated whole which is composed of a great
number of parts. Besides the quality design, manufacture and installation, it is also
important to proper starting up and running. To maintain its proper running is a
complicated and careful work. Operators must know fully the steam turbine body and
related auxiliary equipment, grasp its features and requests. Trouble and even great
accident will be caused if you do not operate properly. And therefore, operating
procedure of correct starting up, running and shutting down, etc. must be set up. Here
we provide some must be followed contents according to the characteristics of this
steam turbine. The users may consult some turbine sets operating regulations compiled
by department of irrigation works and electric power for detailed procedure and means.
4.1 Preparations before starting up
4.1.1 Before starting up, thorough and strict check must be carried out.
a. Check whether the steam and water system, oil circuit system, drainage system
are all normal;
b. Check to make sure that all instrument measurement must be proper and normal;
c. Check that all parts shall be complete, flexible in turning section and without
clip. And all fastened screws should all be tightened up. Starting turning gear to
listen carefully, check to make certain that there is no friction.
d. Check that condensing system is in the normal condition.
e. Check that regulating system is in the right position, and emergency governor
pilot valve is at the tripping condition.
4.1.2 Heating pipe and drainage
a. Open isolation valve a little, maintain that pressure inside of the pipe is among
0.25Mpa, heating the pipe, the speed of temperature rising is 5~10ºC/min;
b. Inner wall temperature of pipe reaches at 130~140ºC, and raising the pressure
of inside of pipe at the speed of 0.25MPa/min until the specified value.
When beginning pipe-heating, drainage valve should be opened up as much as
possible in order to discharge condensate in time, and then the drainage valve
should be closed gradually with the higher temperature of the pipe wall and
higher pressure of inside of pipe, to avoid the leakage of great amount of steam.
Pay attention during the pipe heating:
1) To strictly prevent that the steam leak into casing and causing rotor
deformation;
2) Difference in temperature of each part of pipes (such as flanges and bolts,
etc.) should not too large.
3) Temperature of pipe wall should not less than the saturation temperature
under the corresponding pressure.
For the new steam turbine or after overhaul, should clean the steam pipe.

4.2 Starting up
4.2.1 Starting up turning gear, keep the turning condition and pay attention the friction.
4.2.2 Closing up the emergency governor pilot valve.
4.2.3 Heating the turbine during the low speed, after complete the pipe heating drainage,
close the drainage valve, low speed heating turbine is gradually done when the vacuum
reaches the 400~500mm mercury, speed keeps at 600r/min around and maintain 20~30
minutes. Notice that lube oil temperature should be at 35~40ºC, it should not be started
up and raising speed if it is too lower.
4.2.4 Raising speed
a. After steam turbine operates normally, it can raise speed at 200r/min and it
can quicken the smooth passing when the speed approaches critical speed
(1516r/min);
b. Regulating valve is controlled by speed regulator, and raising the speed to the
rated value;
c. The first starting up turbine set of newly installation or after overhaul should
do the test of hand-pressing emergency governor pilot valve at lower speed. It
also need to do the over speed safety test when qualified. The methods: After
open fully the emergency stop valve, operates the DEH system regulator to
raise the speed of the turbine set until the emergency governor acts and
emergency stop valve closes. The emergency governor pilot valve is closed
again and regulator is used to let the speed to the rated value when the speed is
lower than 2900r/min.
d. Check to see whether the operation is normal and the vacuum is whether
reaches to the rated value.
4.2.5 With loading
a. Increasing the load speed at around 100kW/min to the full load;
b. Check to see whether the regulating system operates properly, check the
openness of secondary oil press and oil relay and to see the loads is whether
suitable to each other.
c. Check the steam turbine to see whether the sound, vibration, axial
displacement, thrust pad, bearing temperature, expansion differential, steam
and metal temperature raising speed as well as difference in temperature is
normal;
d. Adjusting in time the condenser water level, deaerator water level, pressure,
axial sealing pressure, oil outlet temperature of oil cooler, cooling water
temperature of power generator and wind inlet temperature, take notice of the
water level changes of the heater.

5 Running and shutting down maintenance
5.1 Person on duty should do the following work when turbine operates;
a. Heating-turbine protecting device, interlock-protecting device, auxiliary turbine
self-starting switch of turbine set should be on the plunging location;
b. Record the instrument reading in the daily report each hour, if the value is
abnormal, the reasons must be ascertained in time and necessary measures be
taken too;
c. Overall record timely the instrument reading in the monthly report each day,
and analyzing by combining the operating condition;
d. Touring examination is done to the turbine set each hour, if equipment fault is
found, fill in equipment fault report list in time, and accident pre-thinking should
be done for the major equipment fault;
e. Timely measure, record and analyze the various bearing vibration each day.
5.2 Shutting down and maintenance
a. If immediately starting up is needed in a short time after shutting down the
turbine, loads should be promptly fell down or remove the loads to shut down
the turbine, thus the restarting up time can be largely shortened up;
b. When shutting down and overhaul the turbine, loads should be gradually fell
down, and steadily running for a certain time at the lower loads;
c. Turning gear should be often done, starting up the turbine set when shutting
down the turbine at short time, regular turning gear should be changed into
continuous turning gear half hour before starting up. Shutting down the turbine
and overhaul the turbine set, you should first continuously turning gear and then
changed into regular turning gear. The time interval of turning gear is gradually
lengthened until completely cooled down;
d. If the turbine is shut down for a long time, necessary anti-corrosive should be
carried out.

Operating Instructions
Control Valve 1-0800-01-01
Control Valve
The control valve functions for regulating the steam flow based on the command from
the control unit to make the controlled parameters (output or speed , inlet steam pressure,
back pressure and etc.) of the turbine meet the operation requirement. Fig.1 shows the
structure of the control valve.
1. Lever 6. Valve cone 11. Bracket

2. Link 7. Bush 12. Upper guide bush
3. Cover 8. Valve seat 13. Support
4. Admission chest of casing 9. Valve spindle 14. Spring element
5. Valve beam 10. Lower guide bush 15. Oil relay
Fig. 1
The control valve consists of three main sections, the governing valve-- valve spindle,
valve beam, valve cone and valve seat, the operating mechanism-- support and lever, the
oil relay (refer to 1-1900-01-xx).
Based on the structure of the turbine casing and the requirement of the running
condition, one turbine may be equipped with 5 or 4 governing valves showed in Fig.2.

In general, the fifth valve (it is fifth in the opening order and located in the middle) is an
inner by-pass governing valve. But in the turbine with the integral inner casing or 360°
nozzle chamber, the fifth valve is nozzle governing valve. The other 4 valves are nozzle
governing valves.
Fig.2 shows assembling of the governing valve schematically. The valve cone bolt (16)
is screwed in the valve cone (6) to the desired tightening moment and locked with taper
pin (17) (for the tightening moment, see the enclosed table below). The end of the pin
hole is flanged and riveted. The opening order and travel of each valve are determined
by the length S of the bush (7). h in the fig.2 means the valve idle travel. For the first
valve, h=2. The valve seat (8) is mounted in the bottom of the admission chest.
16. Valve cone bolt 17. Taper pin

Fig. 2
The admission chest showed in Fig.1 is adopted in most of the turbines. In this case, the
valve cones and the valve beam are mounted into the admission chest from its side after
they are assembled together. The valve beam is suspended in the seam chamber via two
valve spindles (9). The lower end of the valve spindle is shaped into the rabbet of
inverted-T. The rabbet is penetrated the hole in the valve beam and turned by 90 degrees,
so that the valve beam is seized. The valve cone is freely suspended in the valve beam
with the aid of the valve cone bolt. As long as the turbine remains at standstill, the valve
cone is seated upon its valve seat. When opening the valve, the valve beam is lifted by
the valve spindles and after the bush contacted to the valve cone bolt the valve cone will
thus be opened. The cover (3) is mounted at the place where the spindle penetrates
the admission chest. The guide bushes (10 and 12) are fitted at the upper and lower ends
of the cover, between them the seal ring made of flexible graphite is filled. In order to
eliminate the steam leaking around the valve spindle, tighten the press nut on the cover
to increase the tightening force on the seal ring, if necessary.
In some of the turbines the valve spindle packing showed in Fig.3 is used. The leakage

steam is led to the leakage steam piping through port K (refer to the drawing “P & I
steam and drainage” 0-0642-T.Nr-00 for details). The upper part of the cover with the
seal ring made of flexible graphite and the press nut element is same as that showed in
Fig.1. The nut thread should be protruded from the cover by about 5mm after the seal
ring assembled.
1. Sleeve
2. Bush
3. Bush
4. Seal ring made of flexible
graphite
5. Press nut element
Fig. 3
In the turbines with lower inlet steam parameter, the admission chest is slightly different
to that showed in Fig.1. In this case, the top of the admission chest is opened so as to
facilitate the mounting of the valve beam. The elliptical-shaped opening is covered with
the flat cover of the steam chamber. The valve spindle guide and sealing element are
mounted in the cover.
The support (13) is mounted on the casing top and positioned with the cylindrical pin.
The revolution axis of the support is severed as a pivot point for the lever (1). The one
end of the lever is connected with the valve spindle via the link (2), the other end is
hinged with the joint bearing at the top end of the oil relay connecting rod. When the oil
relay travels the valve beam will be lifted or lowered with the synchronization action of
two valve spindles.
The spring (14) is used against the steam force on the valve spindle and for supplying
sufficient closing force for the valve at the same time.
The bracket (11) used for supporting the oil relay (15) is mounted on the front end face
of the top casing. The oil relay is jointed to the bracket with the joint bearing and pin.
Therefore, the oil relay will swing in a narrow range around the pin during operation.
In order to eliminate the external force and moment that act on the oil relay and disturb
its normal operation, 2 or 3 groups of disk springs are fitted between the oil relay and
the bracket as required. Two groups of disk springs are adjusted according with the

following method and requirement. Loose the closing spring ( for the control valve
1-0801-, it is unnecessary), disconnect the lever and the oil relay. As the travel of the oil
relay connected with the oil piping is at 0 (upper dead point, secondary pressure P2＝
0.15Mpa), adjust the pre-tightening for the springs to make the oil cylinder vertical in X
direction. This will reduce the wear of the piston rod and prolong their service life.
The disk spring element on the side of the oil cylinder functions to buffer the swing of
the oil cylinder, making the cylinder swing smoothly. When adjusting, make
the cylinder vertical in Y direction and the pre-tightening lengths of the disk springs on
both sides of the bracket equal ( the mounting method and the number of the spring on
both sides are the same, the pre-pressed length should be maintained at factory-adjusted
valve). After the disk spring adjusted, connected the lever to the oil relay and return
the closing spring to original state.
The scale plate mounted on the side of the oil cylinder indicates the travel of the control
valve.
⎠ Caution: The piston rod of the oil relay can only be connected to the lever
when the following requirements are met for avoiding the valve
spindle pressed and bended. The piston of the oil relay should be
at position 0 (upper dead point) and the valve beam does not
contact to the valve cone with a minimum distance of 2 mm (see
Fig.2). The 0 position is indicated on the scale plate.
The first valve adopts the tapered valve cone for increasing the stability the turbine test
running and non-loaded operation of the turbo-generator (for individual turbine,
the second valve adopts the tapered cone too). The others are ball valve. In order to
improve the stress of the casing and the blades of the control stage, the second valve is
pre-opened and has a larger overlap with the first valve.
For the valve opening order , valve travel and flow of the control valve, refer to the
attached document “Characteristic line of control valve” 0-2505-T.Nr-00.
The spare part of the seal element for the valve spindle is supplied with the turbine set
(see “Spare parts list” for details). It can be changed if required.
“Mounting tool for valve beam” 2-8821-9005-xx supplied with the turbine set (only
supplied for the control valve larger than N40 or H32) is used to mount the valve beam
assembly into or dismount it from the admission chest from the casing side opening. For
the turbine with one emergency stop valve, the valve beam is mounted into or
dismounted from the opening located one side of the flange cover. For the turbine with
two emergency stop valves, when dismount the valve beam dismount one emergency
stop valve and valve seat, then take the valve beam assembly out with the mount

tool. “Guide bush” 3-2182-3190-xx and “Tamping hammer” 2-8820-9001-xx are special
tool for filling the seal element for valve spindle.
Table: Tightening moment for valve cone bolt

Valve size N25 N32 N40 N50 N63
M M20 M24 M27 M33 M39
Minimum tightening
85 140 200 350 550
moment Nm
Valve size H25 H32 H40 H50

M M20 M24 M24 M27 M27 M33 M33 M39
Minimum tightening
85 140 140 200 200 350 250 550
moment Nm
Note: the valve size is correspondence with the front sector size of the outer casing (see
0-0200-02-00 for details).

Adjusting system
Scavenging with Oil 1-1910-20-01
Adjusting system
Oil-relay
1．关节轴承 oscilating bearing
2．活塞杆 piston rod
3．活塞 piston
4．壳体 body
5．二次油 secondary oil
6．小孔 little hole
7．压力油口 pressure oil opening
8．错油门滑阀 pilot valve
9．转动肋 turning plate
10．推力球轴承 thrust ball bearing
11．弹簧 spring
12．调整螺栓 adjusting bolt
13．弯角杠杆 bend angle lever
14．滚针轴承 needle bearing
15．反馈板 feedback plate
Figure 1 oil-relay(Ⅰ)
Function
The oil-relay transfer the secondary oil signal input from govemor to the piston path,
controlling the opening of adjusting steam valve with lever, so ad to the steam flow rate into turbine
matches the needed flow rate and power.

Adjusting system
The pilot valve of oil-relay obtain the signal from secondary oil pipeline, controlling the
pressure ad power into lower and upper section of oil-relay piston.
Structure
Oil-relay consists mainly from pilot slide valve(8), body(4), piston(3) and feedback system,
oil-relay piston and valve installed commonly in the housing. On the piston rod(2) are installed the
feedback plate(1), the rotating disk(9) situated on pilot slide valve. Between rotating disk and spring
support installed thrust ball bearing(10). The acting force of spring depend on the position of
adjusting screw and bend angle lever.
Working principle
The variation of secondary oil pressure causes the up and down movement of pilot slide valve,
when the oil pressure rise, the slide valve move upwards, the pressure oil from pressure oil
opening(7) flows into piston upper section of oil-relay, and the piston lower section interlinked the
oil drainage opening, so as to move the piston downwards, and through lever system of adjusting
steam valve increase the opening of adjusting valve. At the same time, feedback plate(15) and bend
angle lever transmit the movement of piston to the adjusting screw(12), the adjusting screw
generates the reverse movement against pilot valve to enhance the feedback spring(11) force, ad the
result, the pilot slide valve return back on the middle position.
With adjusting bolt on the piston rod adjust obliquity of feedback plate to improve the ratio
between secondary oil pressure and piston rod path. The figure shows both are linear relation.
Figure 2 housing oil chamber
The role of feedback system is to be stabilized the action process, it forms feedback link with
bend angle lever, feedback plate and piston rod and pilot slide valve. The needle bearing(14) of one
nd of bend angle lever withstand against to feedback guide plate, the other end is connected th
adjusting bolt, which on acted the spring.
When the oil-relay acted, the returning oil feeds back to the oil absorbing opening of main oil
pump, the drainage oil of the oil-relay flows direct to the tank.

Adjusting system
Figure 3 oil-relay(Ⅱ)
Rotation and vibration valve piston

Pressure oil entering at the middle of slide valve, then spurt through radial and tangential hole
on rotating disk. Because the pressure oil continuous spurt along the tangential direction of rotating
disk, lead to slide valve generate rotating movement, adjusting with adjusting lever of T1 the oil spurt
mass can change rotating frequency of slide valve.
In order to enhance the flexibility if oil-relay action, at the same time of rotating valve piston
slide valve, it is being vibrated, this vibration is reached by one little hole(6) under slide valve. At
the slide valve rotates one circle, this hole will momentarily overlap with oil return chamber, at this
time some secondary oil to escape causes a small pressure drop in the secondary-oil circuit with
result that the pilot piston is moved downwards. When the drilled hole is stemmed once more
through further turning of pilot piston, the piston will be lifted again. Therefore, with rotating of
piston, piston repeat the obtain-mentioned movement, so, there are small smount pressure oil
repeatedly flow into top and upper section of oil cylinder, caused slight vibration of servo piston
spindles, thereby ensuring oil-relay response not slowly to react the impulses of the governor, the
amplitude of pilot vibration can likewise be adjusted by means of the adjusting lever(16) of T2.

Adjusting system
Figure 4 oil way of rotating disk

Emergency Governor 1-2110-02-01
Emergency Governor
The emergency governor is a mechanical protection equipment of the turbine. It will
close the emergency stop valve and control valve via the emergency trip gear when the
turbine speed rose to the set tripping speed.
1. Limit Stud 5. Eccentric bolt 9. Compression spring

2. Threaded cap 6. Counterweight pin 10. Headless screw
3. Guide bush 7. Guide bush
4. Guide ring 8. Guide ring
Usually, the emergency governor is fitted in the turbine rotor at the section located in
the front bearing housing, as showed in figure above. The guide ring (8) is fitted in
suitably machined bore in the rotor and pressed by the compression spring (9), which
presses the shoulder of the eccentric bolt (5) with other end. The supporting surface of
the eccentric bolt is against the positioning surface of the guide ring (4) that is pressed
on the positioning surface in the bore by the threaded cap (2) tightly. In the central hole
of the eccentric bolt the counterweight pin (6) is placed. The limit stud (1) is fixed in
the threaded cap to restrict the movement of the counterweight pin. The threaded cap
and the limit stud are locked with the headless screws (10). The counterweight screw (7)
is screwed in the hole of the eccentric bolt. In the guide rings the guide bushes (3 and 7)
made of Teflon are fitted, which are used for positioning and guiding the eccentric bolt.
An eccentricity exists between the centroid of the eccentric bolt with
the counterweight pin, so when the rotor rotating, the eccentric bolt will produce a
centrifugal force. Since the spring force is always larger than the centrifugal force of
the eccentric bolt within the operating speed range, the eccentric bolt remains at its
mounted position and does not move. Whenever the turbine speed is about to exceed
the set trip speed, the centrifugal force of the eccentric bolt overcomes the spring force,
diving the eccentric bolt in outward direction. The centrifugal force will increase steeply
with the increase of the eccentricity. Thereby the eccentric bolt moves out of the rotor

Emergency Governor 1-2110-02-01
(stroke H) and strikes the pawl of the emergency trip gear. This triggers the
emergency trip gear to close the emergency stop valve and the control valve.
The reset speed (the speed at which the eccentric bolt return to its mounted position) of
the emergency governor for 3-series turbine is higher than the rated speed, so
the emergency trip gear can be reset when turbine speed dropped to the rated
speed, restarting the turbine.
The setpoint of the trip speed for the emergency governor is given in the technical data
section 0-0300-T.Nr.-xx of the Operating Instructions.
The action speed of the emergency governor when testing in the workshop of
the manufacturer is recorded in the “Report of Dynamic Balance and overspeed test for
Rotor” and the “No-load Test Report” of the Product Certificate.
When examining and repairing the emergency governor, use the attached tool
“Tow-hole Nut Driver” No.2-8811-0002-xx to mount or dismount the threaded cap. To
mount or dismount the counterweight screw, turn out the screw plug, turn in
the attached tool “Adjusting Bolt” No.2-7760-0001-xx to fit its taper end tightly against
the tapered hole in the eccentric bolt. In this way, the rotation of the eccentric bolt can
be prevented when the screw turned.

Operating manual Solenoid Valve 1-2222-01-01
Solenoid Valve
Function
Two position Three way solenoid valve is mounted on the pressure oil pipe,
which is into the emergency system. It is able to cut off the pressure oil that is into
the emergency safety device, also result in the reaction of the emergency safety
device to make the trip oil discharge and make the trip valve shut down rapidly at
last.
The solenoid valve is controlled by the central control room or some protect
device (according to the actual need the solenoid valve is interlocked with the
protective physical value, which is converted into the electrical signal by the real
protect device).
Structure and Function Principle
Because the solenoid valve is the purchasing part, the detailed introduction is
referred to the relative manual provided by the solenoid valve manufacturer.

Emergency stop valve
Scavenging with Oil 1-2200--20-01
1．手柄 handle
2．定位块 positioning block
3．套筒 sleeve
4．进油口 oil inlet
5．出油口 oil oulet
6．套筒 sleeve
7．滑阀 pilot valve
8．弹簧 spring
9．活塞 piston
10．顶块 carrier block
11．壳体 body
12．回油 returing oil
图1 危急遮断油门


Function
When the turbin fails on operation and to be halted(the oerspeed released and
axial displacement of rotor is too big), the acting of emergency stop valve drainage
the emergency oil in emergency valve, at this time , the emergency valve rapidly
shut down, cut off the steam source into turbine. The emergency stop valve can only
reset with hand.
Structure
Emergency stop valve installed on bearing support, slide valve can slide up and
down in the sleeve(3,6) correspondent to the end face the position limit and oil
pipeline sealing role. When the emergency stop valve don’t work, the spring(3) push
the slide valve the contacted position against to sleeve(3) end face.
The lower end of slide valve connected with carrier block(10) by the piston(9),
the another end of carrier to sleeve(3) end face.
The lower end of slide valve connected with carrier block(10) by the piston(9),
the another end of carrier block inserted between two shoulders.
The upper end of slide valve connected with handle(1) by positioning block.
Mode of action
When turbine on operation(figure 1), the slide valve of emergency stop valve
lies on inlet opening (4) of pressure oil, throughout throttle hole plate form the
emergency stop oil into emergency stop valve. Because the acting force of emergency
oil on the slide valve is bigger than the spring force, so that the slide valve
shoulder will be hermetically pressed on the end face of sleeve(6) and cut off the
return oil(12), the emergency oil flow through the oil opening (5) out of housing,
through the starting device into emergency valve.
Emergency stop valve can act with following ways:
1. with hand, press the handle(1) downwards.
2. rotor axial displacement: carrier block is uplifted and released by the
shoulders on rotor.

3. the overspeed action of emergency stop valve causes release.
The obtain mentioned cases equally are: slide valve(7) divorced from sleeve(6).
Because of throttling function of throttle hole plate, at this time the oil
pressure in front of pilot valve is reducing rapidly, spring(8) push slide valve
to the end face of sleeve93), into emergency stop valve, the oil way is cut off ,
meanwhile emergency oil in front of sleeve(3), into emergency stop valve, the
oil way is cut off, meanwhile emergency oil in front of emergency stop valve
connected with the return oil, so as shut down emergency stop valve, halt the
turbine.

Emergency Stop Valve (N) 1-2300-01-01
Emergency Stop Valve (N)

The emergency stop valve is the fundamental shut-off organ between the live-steam line
and the turbine. Under an emergency condition, it cuts off the steam supply to the
turbine immediately, resulting in the turbine shutdown quickly. It will be in the closed
position also when the turbine is at standstill and in the fully opened position during
turbine start-up and normal operation.
The emergency stop valve is mounted horizontally on the side of the turbine steam
chamber. One turbine may be equipped with one or two emergency stop valves based on
the steam flow admitted to it.
Fig.1 shows the emergency stop valve without independent valve casing used in the
turbine of model N. Its principle parts are a seam section and a hydraulic section. It is
usually used in most of the 3-series turbines. Fig.4 shows the emergency stop valve with
an independent valve case.
1. Valve cone 10. Oil cylinder 18. Valve seat

2. Relief cone 11. Pressure gauge
3. Steam strainer Connection D Live-steam inlet
4. Guide sleeve 12. Test piston E Trip oil
5. Valve cover 13. Piston F Starting oil
6. Labyrinth bush 14. Spring H Test oil
7. Valve spindle 15. Spring cap K Leak-steam drain
8. Tension bolt 16. Piston disc T1 Oil drain
9. Nut 17. Oil catch Shield T2 Leak-oil drain
Fig. 1 Emergency stop valve
The steam section mainly consists of items 1 to 8 and item 18. The valve cover (5) is
used not only for sealing the end face of the admission chest but also as a connection of
the steam section with the hydraulic section.
Before the emergency stop valve opens, the live steam, after having passed the steam
strainer (3), arrives to the compartment before the valve cone (1). The valve cone is
pressed on the valve seat (18) under the steam force and the spring force (14), blocking
the live steam to the turbine. The relief cone (2) is provided in the valve cone, which
helps in reducing the actuating forces when the emergency stop valve is being opened,
because it tends to balance the pressure differential existing between the upstream and
downstream sides of the valve cone.
During the emergency stop valve being opened or after it closed (the isolation valve has
not been closed), a part of steam leaking out between the valve spindle (7) and the guide
sleeve (4) and labyrinth bush (6) will be drained off through connection K. As long as
the emergency stop valve is open, the valve cone contacts to the seal face of the guide
sleeve tightly, blocking the steam leaking along the valve spindle.
Most of the steam strainers used in the emergency stop valve are made of corrugated
stainless steel band through winding. But the welded steam strainer made of stainless
steel band with holes is also used in some of the turbines.
The hydraulic section mainly consists of oil cylinder (10), piston (13), spring (14),
piston disc (16) and sealing element. The oil cylinder is bolted on the valve cover (5).
On the end face of the oil cylinder three extension bolts are fitted for safety in mount
and dismount. The boltholes on the oil cylinder are fitted with thread bushes. Caution:
the bolt (8) and the nut (9) must be used in mounting and dismounting the oil
cylinder; otherwise the human injury can result.
The hydraulic section is the active element of the emergency stop valve. When opening
the emergency stop valve with the starting control (1-1840- ), the starting oil F flows to
the right of the piston (13), the oil pressure against the spring (14) force presses the
piston to the piston disc (16), making the sealing faces of the piston and the piston disc
contact each other. After that the trip oil E flows to the left of the piston disc. The
staring oil begin to drain under control with the trip oil pressure behind the piston disc is
building up. Thus, the piston disc and the piston, as an integral part, move rightwards
under the pressure difference at both sides until limited by the test piston (12). The right
end of the valve spindle is connected with the piston disc, the emergency stop valve will
opens with the movement of the piston disc.
The close of the emergency stop valve is actuated by the protection system. Once any of
the loops in the protection system acts, the trip-oil pressure will be lost. The piston will
separate from the piston disc under the action of the spring force, the trip oil at the left
of the piston disc drains through connection T1, the piston disc, together with the valve
spindle and the valve cone, is pushed to the close position.
As showed in Fig.2, a test piston (12) is equipped in the hydraulic section. It, together
with the test valve and the pressure gauge, forms a test device of the emergency stop
valve for checking the proper function of the emergency stop valve during turbine
operation.

The test valve is a manual reversal valve (or electric reversal valve) mounted in the
piping or integrated in the trip block (refer to 1-2001- ). Through operating the test
valve the pressure oil is admitted via an orifice to the right of the test piston. Since the
area of the test piston is larger than that of the oil-cylinder piston, when oil pressure P2
reached a certain value the test piston pushes, under the action of the oil pressure, the
piston together with the piston disc and valve spindle and cone to move in close
direction by a distance h, which has on effect on the normal turbine operation. So the
check may be carried out during normal turbine operation under an load up to and
including rated load. When the test valve is switched to the position as shown in the
picture, the test is disabled.
Fig.2 Test device of emergency stop valve
If the emergency stop valve functions properly, P2<P1. Here, P1 is the permissible test
pressure; P2 is the actual test pressure at which the test piston begins to move.
The permissible test pressure can be calculated with the following formula:
P1≤A＋B（P4－1）
Where:
A, B The characteristic value related with the size of the emergency stop valve,
see Technical data 0-0300-T.Nr-00
P4 Trip-oil pressure when turbine operation
If the pressure P2 observed on the pressure gauge happens to be in excess of the

permissible pressure P1, this will be indicative for deposits of salt on the valve spindle
or deposits of oil carbon on the piston. In such a case the above testing operation has to
be repeatedly a couple of times in order to recondition the emergency valve to proper
function. If this fails to reduce P2 below P1, the emergency stop valve must be
disassembled and the fault cleared as could as possible.
The emergency stop valve can be equipped with the position switcher, as required, for
sending out a corresponding signal when the valve is at full-opened or full-closed
position.

The oil catch shield fixed on the valve spindle has miscellaneous functions. It prevents
the oil from spraying to the high-temperature section and the leakage steam from
spraying to the oil cylinder and is also used as the trigger for the position switcher.
The emergency stop valve is divided into 6 sizes based on the diameter of the live-steam
inlet, they are 100, 125, 150, 200, 250 and 320. All of them have the same structure
except for 320.
The emergency stop valve 320 has a larger valve cone, in order to reduce the lifting
force in opening the valve cone and avoid valve spindle bended, the valve cone, valve
cover and valve seat shown in Fig.3 are used. The remaining parts is the same as that
showed in Fig.1.
Fig.4shows the emergency stop valve with an independent casing. Its structure and
working mode is the same as described above except for the valve casing.
1. Valve casing section on 9. Valve spindle 18. Sleeve

casing 10. Valve cover 19. Steam strainer
2. Valve seat 11. Test piston D Live-steam inlet
3. Valve cone 12. Pressure gauge connection E Trip oil
4. Relief cone 13. Piston F Starting oil
5. Nut 14. Spring H Test oil
6. Guide sleeve 15. Spring cap K Leak-steam drain
7. Labyrinth bush 16. Oil cylinder T1 Oil drain
8. Bypass hole 17. Press nut T2 Leak-oil drain
Fig. 3

1. Valve spindle 8. Steam strainer D Live-steam inlet

2. Piston disc 9. Labyrinth bush E Trip oil
3. Spring 10. Guide sleeve F Starting oil
4. Piston 11. Relief cone H Test oil
5. Test piston 12. Valve cone K Leak-steam drain
6. Pressure gauge 13. Valve Seat T1 Oil drain
Connection 14. Valve casing T2 Leak-oil drain
7. Valve cover
Fig. 4

Oil supply system
供油系统 oil supply system

油泵 oil pump
1．导向轮 guide wheel 2．密封环 sealing ring 3．导流环 antivortex baffle
4．动轮 traction wheel 5．圆环 round ring 6．密封环 sealing ring
7．转子 rotor S．吸油 absorbing oil P．压力油 pressure oil
图1 汽轮机驱动的油泵 figure 1 the turbine drived oil pump

Oil supply system
Function
The oil pump provides pressure oil to the turbine units, so as to use for
bearing’s lubrication and rotor axle diameter’s cooling and as control oil for
hydraulic regulation and safety. When the oil pump fails and turbine stop, and then
the auxiliary oil pump begin to provide oil.
Structure
The oil pump consists mainly from guide wheel(1), antivortes baffle(3), raction
wheel(4), round ring(5), sealing ring(2),(6). The traction wheel is suited on
turbine rotor and radial positioned by key, sleeve is axial positioned. Guide wheel
is one casting with radial absorb oil inlet, on antivertex is installed guide blade,
the oil of traction wheel outlet flow through guide blade of antivortex, its flow
veloctity is reducing and generates the expansion pressure function. The oil pump
is installed in the front bearing case.
Principle
The working speed of oil pump is the turbine speed, pump absorbs the needed oil
mass from tank and generates the pressure correspond to traction wheel speed and
pipeline characteristics, the pressure oil with one way lead to hydraulic, another
way through throttle, after reaching of definite pressure through oil cooler and
oil filter provide to lubrication system.

Lube-oil Throttle 1-5501-01-01
Lube-oil Throttle
The throttle is used in lube-oil line for control the oil flow. Its structure is shown in the
picture.
There are two forms of casing (4) available; one for connecting to the piping with the
welding connection (5) as showed in the picture, the other is connected to the piping
with flanges. The casing is made of carbon steel or stainless steel as required.
The oil flow to the bearing is adjusted through varying the stroke of the throttle screw
(6), keeping the temperature rise of the bearing within the permitted range during
turbine operation. To adjust, remove the cover screw (1), after loosing the cap nut (2),
turn the throttle screw counterclockwise with a screwdriver or inner-hexagon spanner to
make it move upwards. This will increase the opening of the throttle and decrease the
differential pressure before and after the throttle, resulting in oil flow increased. The
opening of the throttle is restricted by its structure. It cannot be opened fully even if the
throttle screw is at its maximum stroke, because the excessive oil will fill up the bearing
housing. Turning the throttle screw clockwise will reduce the oil flow. In order to avoid
blocking the oil due to misoperation, the minimum flow about 0.5m3/h is permitted in
its lowest position.
1. Cover screw
2. Cap nut
3. Seal ring
4. Casing
5. Welding connection
6. Throttle screw
7. Seal ring
After adjusted, the cap nut must again be firmly tightened and the cover screw must be
screwed in again.

One-way Throttle Valve 1-5600-03-01
One-way Throttle Valve

The one-way throttle valve is mounted in the secondary-oil line in proximity of the oil
relay. Its purpose is to prevent the transmission of possible pressure fluctuations arising
in the secondary-oil circuit, bringing about the stable operation of the pilot valve
without disturbance.
1. Adjustable sleeve
2. Spring seat
3. One-way valve
5. Retaining ring
6. Retaining ring
7. Spring
8. Valve casing
9. O-ring
The secondary oil enters into the valve casing (8) from the end B. The one-way valve (3)
is pressed against the valve seat under the action of the spring force (7) and oil pressure,
the secondary oil flows to the end A through bypass holes on the one-way valve and the
throttling passage between the valve casing and the adjustable sleeve (1). If the pressure
at end A is higher than that at the end B by 0.05 MPa, the one-way valve is opened. The
oil flows in the opposite direction without throttling, so as to unload the turbine quickly.
Turn the adjustable sleeve to change the area of the throttling passage infinitely. Turning
the sleeve clockwise (looking from B to A) will decrease the area of the passage, while
turning it in the opposite direction will increase the area. There are a scale ring on the
conical surface of the sleeve (1) in proximity of the end A and reference scale and
indicating ring on the end A of the valve casing, which indicate the working position of
the one-way throttling valve.
When adjusting, if pressure gauges are fitted at both ends of the valve, turn the sleeve
and observe the readings on the gauges. When the pressure after the valve decreases
modestly and the differential pressure between two ends reached 0 <△P<0.01MPa, turn
bake the sleeve by 1 to 2 scales. If there is no pressure gauge after the valve, it is
recommended to set the one-way throttling valve during static adjusting of the control
system before turbine start-up. In this case, turn the sleeve counterclockwise to fully
open the valve, and then change the secondary-oil pressure from the amplifier (or
electro-hydraulic converter) to bring the oil-relay stroke corresponding to the
secondary-oil pressure 0.15 to 0.45MPa in correspondence with the requirement defined
on the Characteristics Line (No.0-2500-T.Nr-00). After that, set the secondary-oil
pressure at 0.15MPa and the oil-relay stroke at 0, turn the sleeve clockwise until the
reset bar of the oil relay separates from the rolling bearing. Turn back the sleeve by 1 to

One-way Throttle Valve 1-5600-03-01
2 scales. Then recheck the oil-relay stroke corresponding to secondary oil pressure 0.45
MPa.

Turbine Oil 3-0320-01-01
Turbine Oil
Usually, turbine oil of the type L-TSA46 or L-TSA32 is selected for lubricating and
control system of the turbine, except for the electric-hydraulic control system with
fire-resistant oil.
The type of the turbine oil that is used for your turbine is specified in the Technical Data
(0-0300-T.Nr.-00).
The fresh oil quality should be in compliance with the specification given in the
standard GB11120.
The inspection items and period, the quality standard that should be reached for the oil
during turbine operation are listed in the table 2.

Table 1: Specification of turbine oil L-TSA
Quality index Test
Item
Prime class First class Qualifier method
46 46 46
Viscosity class（according to GB3141） -
32 32 32
Kinematic viscosity（at 40℃），mm2/s 28.8～35.2 41.6～50.6 GB265
Viscosity index not less than 90 GB1995
Pour point ℃ not higher than -7 GB3535
Flash point（open cup）℃
180 GB3536
not lower than
GB1884
Density ( at 20℃) kg/m3 See report
GB1885
Acid number mg koH/g
- - 0.3 GB264
not larger than
Neutralization number mg koH/g
See report See report - GB4945
not larger than
Mechanical impurities Nonexistence 1） GB511
Water content Nonexistence 2） GB260
Emulsification number（40-37-3）ml
15 GB7305
at 54℃，min not larger than
Foambility test ml/ml
450/0 450/0 600/0
at 24℃
100/0 100/0 100/0 SY2669
at 93℃
450/0 450/0 60/0
after 24℃
Oxidation stability
a. Total oxidate See report See report
Deposite See report See report GB8119
When the Acid number reached at SY2680
2.0mg koH/g after oxidized h 3000 2000 1500
not less than
Liquid-phase rust teat
Without rust GB11143
（syntheticseawater）
Copper-strip test （100℃，3h），class
1 GB5096
not larger than
Air separation（at 50℃），min 6 6
- SY2693
not larger than 5 5
1) With the method given in GB511, if the content of mechanical impurities is less than
0.005%, that is deemed to be non-existed.
2) With the method given in GB260, if the water content in the sample is less than
0.03%, that is deemed to be vestige. If there is no water existed in the receiver after
the instrument removed, the sample is deemed without water.

Table 2: Turbine-oil quality standard during operation (GB/T7596-2000)
Inspection
No. Item Quality index
method
Visual
1 Appearance Transparence
inspection
Kinematic viscosity（at 40℃），

2 Deviation from≤20％ GB/T265
mm2/s
Not less than 15 , comparing to

3 Flash point（open cup）℃ GB/T267
original value of fresh oil
Visual
4 Mechanical impurities Nonexistence
inspection
Acid number Without antirust ≤0.2 GB/T264 or

5
mg koH/g With antirust ≤0.3 GB/T7599
6 Liquid-phase rust Without rust GB/T11143
7 Emulsifiability min ≤60 GB/T7605
GB/T7600 or
8 Water content mg/L ≤200
GB/T7601
The inspection items listed in the table 2 are the routine inspection items, all of them are
required to be carried out before the newly mounted turbine put into operation or after
the turbine overhaul. After the turbine has been operated, the inspections should be
carried out at least once a time for every year. The item 1 and 4 should be made at least
once a time for every week. The period of the inspection may be prolonged properly if
the turbine runs normally. However, if the oil is found with water, the inspections
should be increased and the proper treatment should be made in time.
The item 4 “Mechanical impurities” in the table 2 is checked with eyes. If the solid
pollutant is not visible in the oil sample, it is assumed that there is no impurity
(Nonexistence) in the oil. Since the human eyes can not see the particle smaller than
40μm. The “nonexistence” only indicates that there is no solid pollutant larger than
40μm in the oil. The visual inspection is a quick and ease method but with a rough
result. The user is recommended to inspect the mechanical impurities contained in the
oil quantitatively with proper instrument.

Operation Instructions
Scavenging with Oil

Following completion of the installation and before the commissioning, the entire oil
system should be thoroughly scavenged with the oil (oil circulation) to eliminate all
solid pollutant which possibly had been introduced into the oil system during
installation.
For the inspection items and range for flush of the oil system after the turbine overhaul,
please refer to this instruction.
For the turbine using the electric-hydraulic control system with fire-resistant oil, the
flush for the fire-resistant oil system should be carried out according with the relative
procedure.
It is recommended that the oil system is flushed with the same type and performance of
oil that is employed for normal turbine operation.
1. Preparations
1.1 Oil tank
Before filling up with the scavenging oil, the strainer must be cleaned first. Clean the
inside of the oil tank with the new cloth and then clean out the residues with paste.
1.2 Oil filter: according to the arrangement.

1.2.1 For the system with a common filter for lubricating oil and control oil, dismount
the filer element. After one cycle period of flushing (see 2.4), mount in the
element again.
1.2.2 If the lubricating oil and control oil use their filters separately, dismount the
element of the lubricating-oil filter. After one cycle period of flushing, mount in
the element again.
1.3 Oil cooler

Connect a temporary pipe from the drain port of the cooler to the oil tank for avoiding
deposit of dirt in the oil cooler.
1.4 Bearings
For the turbine below size 40 (including size 40), remove the radial and thrust bearings.
the turbine rotor is supported on the gland bush temporary during oil flushing.
1.5 Emergency stop valve

Dismount the piston, spring and spring seat.
Close the cylinder end with blank flange.
1.6 Oil relay

Take out the plunger, spring and spring seat of the pilot valve.

Fit an orifice at the pressure oil inlet connection on he pilot valve temporary. The
diameter of the orifice is selected within a range of 2 to 4 mm based on the size of the
pilot valve.
Block the secondary-oil inlet connection on the pilot valve.
1.7 Speed governor

For the turbine with SRIV hydraulic governor or PG-PL mechanical-hydraulic governor,
lead the input pressure-oil of the amplifier to the return oil with a temporary pipe.
1.8 Electric-hydraulic converter

The electric-hydraulic converter does not participate in the flush with oil.
For the converter that is mounted in the piping or the on a separated support, lead its
input pressure oil to return oil with a temporary pipe.
If the converter is mounted on trip block, mount the blank plate reversedly (the face
with groove is towards the trip block)
1.9 Trip Block

Lead the input pressure oil of the trip block to return oil with a temporary pipe.
Return it to the original connection since the second cycle period of flushing.
1.10 Emergency trip gear

Remove the throttle orifice at the pressure-oil inlet.
1.11 Extraction stop valve

Lead the input pressure oil of 操纵座 or oil cylinder for the extraction stop valve to the
return oil with a temporary pipe.
1.12 Jacking-oil piping

The jacking-oil pump does not participate in the flushing.
Short-connect the inlet and outlet piping of the pump so as to flush the jacking oil
piping.
1.13 Barring-oil piping

For the turbine with a hydraulic barring gear (linear stroke), lead the input oil of the
barring-oil pump to the return oil by connecting a temporary pipe.
1.14 For the turbine with its own main oil pump, block the inlets and outlets of the main
oil pump and injector. Remove the regulating valve of the injector. connect the inlet and
outlet piping of the main oil pump to the cycle piping for flushing with oil.
1.15 Instruments
The instruments in the oil system should be blocked off, except for the instruments at
the necessary monitoring points of pressure and temperature.

1.16 Locality
Clean the surfaces of the oil piping and the equipments and surroundings.
There is no flammable substance on site and no works carried out with open fire in
surroundings.
Prepare the fire extinguisher for using at any time.
1.17 Filling oil tank

Fill the oil tank with 50 to 60% of the volume normally used for turbine operation. The
oil can not be directly filled into the tank, it should be filtered by a oil filter or strainer.
The containers for storing the oil should be clear and not confused with the containers
for other oil during transportation and storage.
2. Flushing steps and operating points

2.1 It is suggested that the flush of the oil system be carried out step by step. Flush the
lubricating-oil system first. After one cycle period, but the control-oil system in the
flushing.
2.2 During flushing, open the throttle valves at each bearing oil inlets further based on
the return oil from the bearing housing.
2.3 During flushing, run the main and auxiliary oil pumps alternatively. The Emergency
oil pump may be put in operation at the same time, making the scavenging-oil
pressure to be approximate to operating pressure of the oil system as could as
possible.
2.4 In order to increase the flushing efficiency and shorten the flushing time, besides
increasing the scavenging oil flow, alternate the oil temperature between 25 ℃ and
75℃ as showed in picture. One cycle period will last 8 hours. It should be noticed
when heating oil the temperature must not exceed 80℃ so as to avoid the oil
deteriorated. During heating
the oil, all of the piping, in temperature ℃
which the oil flows, should be
warmed up. If some of them
are still cold, find out the
reason and eliminate it. In the
course of flushing, beat the
piping, with wood or copper
hammer, especially for the
welded junctions, making the time
impurities fall off and be flushed out.
2.5 The strainer in the oil tank should be washed at least once a time for every cycle
period. After the element has been mounted in the filter, it should be cleaned
regularly. Once the differential pressure between inlet and outlet approached to the
permitted up limit, switch over and wash the filter immediately, regardless of the

specified washing time.
2.6 Flushing the control and protection system as following procedures respectively
according with the different arrangements:
2.6.1 For the turbine with hydraulic or mechanic-hydraulic governor, at the beginning
of the second cycle period, put the trip solenoid valve into the normal operation
position, place and lock the handle of the emergency trip gear at the engaged
position. After the second cycle period, return the oil inlet piping of the governor
to normal connection. From the third cycle period, operate the starting control to
switch it between two positions, the starting position and the operating position
to flush the trip-oil piping and starting-oil piping to the emergency stop valve.
Operate the test valve of the emergency stop valve regularly so that the test-oil
piping can be washed.
2.6.2 For the turbine with trip block, place and lock the emergency trip gear at the
engaged position (it is not required for the turbine without trip block) at the
beginning of the second cycle period. From the third cycle period, return the
inlet piping of pressure oil for the trip block to normal connection and place the
manual and remote controlled trip valve in the block to the normal operation
position. Regularly operate the control valves (manual and electric) for the
starting oil and trip oil, so that the starting- and trip-oil piping to the emergency
stop valve can be flushed. Place the test valve of the emergency stop valve to
test position timely for flushing the test-oil piping.
3. Evaluation of cleanliness for oil system after flushing

When cleaning the filter element after the third cycle period, check the element through
visual inspection or touching with fingers. If no evident hard granular impurities found
on the element, it is possible to begin with the cleanliness inspection for the oil system.
There are several evaluation methods due to the different implement standards and
inspection methods. Some typical methods are given below. It is suggested to use one of
them in evaluating the cleanliness for the oil system.
3.1 Weight method I:

Fit a strainer with 120-mesh at the oil inlet of each bearing. After flushed under normal
flushing oil flow for 2 hours, take out the element and wash it with gasoline in a clear
circumstance, and then filter the gasoline with a strainer of 150-mesh. The total mass of
the filtered impurities after dried should be less than 0.2 g/t, without hard granules. This
will indicate the cleanliness of the inspected oil system qualified.
3.2 Weight method II

Sampling from the oil-line downstream the filter, filter the sample oil that has been
diluted by solvent with filter or filter paper. If the mass of the filtered impurities after
dried is less than 0.05% of sample-oil mass, the cleanliness is considered to be
qualified.

3.3 Granule counting method I
Fit a cone strainer of 150-mesh at oil inlet of any bearing. After flushed under normal
flushing oil flow for 30 minutes, taken out the strainer and wash it with gasoline in a
clear circumstance, and then filter the gasoline with a strainer of 200-mesh. Collect all
of the impurities that are filtered out. Classify and count the impurities under a
magnifier with a magnifying ratio of 10 times at least and a scale. If the granule of the
impurity is conformed to the requirement given in table 1, the cleanliness of the
inspected oil system is considered to be qualified.
3.4 Granule counting method II

Fit a strainer of 100-mesh at the typical part in the oil system. Flush the oil system with
the normal flushing-oil flow at the temperature of 66 to 77℃ (or lower) for one hour
and hammer the piping, oil cooler and valves from time to time during flushing. After
that, take out the strainer for inspecting. If the maximum granule of the filtered
impurities does not exceed 0.25mm, the number of the granules that are distributed
randomly on the strainer is conformed to the limit listed in table 2 and there is no visible
impurities (oxide skin, scraps and sand) and touchable ash in the sample oils sampled
from at least two different parts of the oil system (downstream the oil filter), the oil
system is considered to be clean.
Table 1: Cleanliness requirement for oil system

Granule size of impurity（mm） Quantity （piece）
＞0.25 Without
0.13～0.25 ≤5
Table 2: Limit of granule quantity

Quantity
Pipe DN（inch） Wall of pipe（mm）
（piece）
2 ≤3.91 20
3 ≤5.49 45
4 ≤6.02 80
6 ≤7.11 180
4. Work after oil flushing

4.1 Restoring oil system
Remove the temporary piping, orifices and blank plugs for flushing, restore the piping
to normal connection.
Clean the insides of the oil cylinder of the emergency stop valve and pilot-valve housing,
wash the removed parts and components, including the bearings, restore the bearings,
turbine rotor, emergency stop valve, oil cylinder and emergency trip gear to the original
states.
For the turbine bringing its own main oil pump, connect the inlet and outlet piping of
the oil pump and mount the regulating valve of the oil injector.
For the turbine with the electric-hydraulic converter mounted on the trip block, the
attention should be taken that the blank plate between the converter and the trip block is
just used in oil flushing, is must be removed after flushing.
4.2 Replacement of oil

The flushing oil has to be thoroughly drained at the end of the flushing operation so that
absolutely no residues will be left. Clean the insides of the oil tank, bearing housing,
gearbox and oil filter, wash the filter element, and then fill up the oil tank with qualified
turbine oil to the quantity required for the turbine normal operation. The measures
should be taken during filling operation for preventing the oil from contaminating.
4.3 Checking oil quality

The quality of the oil that is going to be filling or replacing should be checked first. Two
sample oils are required, one for test and other for keeping in sealed and against light as
the control sample in oil quality checking later on. The quality requirement for new
turbine oil is given in 3-0320-xx-xx (GB11120) and only the qualified oil can be filled
into the tank.

Steam Quality 3-0310-01-01
Steam Quality
The turbine is a rotary thermal power machine with steam as its working medium, the
quality of the steam entering into the turbine will not only has an effect on economical
operation but also be related with safety operation and service lift of the turbine. The
deposits that occur in the steam path of a turbine due to impure steam can lead to a
reduced section area of the steam path, decreased turbine output and an inefficiency,
also to increased axial thrust. The deposits that occur on the blades will increase the
stress of the blade, resulting in blade breakages. Furthermore, the deposits can lead to
seizure of the spindles of the emergency stop valve and /or control valve. Therefore, in
order to operate the turbine safely and economically in a long term, the qualities of the
steam and boiler feed water should be in line with the standard listed in the tables below.
The standard value is the limit value, while the expected value is much favorable for the
safe operation of the turbine.
1. Steam quality standard

The quality of the saturated and overheated steam from the drum boiler with natural
circulation and forced circulation and concurrent boiler should be in accordance with
the valves specified in the table 1.
Table 1: Steam quality standard

Boiler Drum boiler One-through boiler
Pressure MPa 3.5～5.8 ≥5.9 ≥5.9
项目
Standard Standard Expected Standard Expected
Parkering ≤10 -
Sodium，μg/kg ≤15 ≤10 ≤5
Volatilizing ≤10 ≤5
Parkering - -
- ≤0.30
Conductivity（after Volatilizing ≤0.30
hydrion exchanged, Neutral-water
at 25℃） treatment and
- - ≤0.20 ≤0.15
μs/cm combined-water
treatment
Silicon dioxide μg/kg ≤20 ≤20 ≤20
In order to prevent the metal oxide deposited inside the turbine, the content of the
iron and copper in the steam should be in accordance with the valve given in the table 2.
Hangzhou Steam Turbine Company Page 1 of 3

Table 2: Steam quality standard
Boiler type Drum bolier
Pressure MPa ≥3.8
Item Standard Expected
Iron，μg/kg ≤20 -
Copper，μg/kg ≤5 -
2. Boiler feed-water quality standard

Table 3: Boiler feed-water quality
Overheat Conductivity （after Dissolved
hydrion exchanged, Hardness Iron Copper Sodium
steam oxygen
Boiler at 25℃）
pressure μS/cm
type
of boiler μmol/L
Standard Expected Standard Standard Standard Expected Standard Expected
MPa
Drum 3.8～5.8 - - ≤2.0 ≤15 ≤50 ≤10 - - -
boiler 5.9～12.6 - - ≤2.0 ≤7 ≤30 ≤5 - - -
One-
through ≥5.9 ≤0.30 ≤0.20 ≌0 ≤7 ≤10 ≤5 ≤3 ≤10 ≤5
boiler
Overheat Silicon dioxide
steam Mg/kg
Boiler PH Hydrazine Oil
pressure
type （25℃） mg/L mg/L
of boiler Standard Expected
MPa
3.8～5.8 The content of 8.8～9.2 - ＜1.0
Drum Silicon dioxide in
boiler 5.9～12.6 the steam should 8.8～9.3（system with ≤0.3
meet the standard copper）or 10～50 or
One- 8.8～9.5（system without 10～30（volatilzing）
through ≥5.9 ≤20 - copper） ≤0.3
boiler

3. Water quality in the boiler
Table 4: Water quality in the drum boiler
Overheat Phosphate，mg/L
Total Silicon
steam Chloridion Evaporated in PH Conductivity
Treatment salt dioxide
pressure One-step steps （25 （at 25℃）
method
of boiler evaporated Clean Salt ℃） μs/cm
mg/L
MPa step step
3.8～5.8 - - - 5～15 5～12 ≤75 9.0～11.0 -

Parkering
5.9～12.6 ≤100 ≤2.0 - 2～10 2～10 ≤50 9.0～10.5 ＜150
The quality of the make-up water and the turbine condensate should also be
controlled according to the standard “The water and steam quality for thermal generator
set and steam power equipment” GB/T12145-1999.

Purging Steam Piping 3-0350-01-01
Purging Steam Piping

The purge of the steam piping is an important measure for ensuring the turbine safety, it
should be carried out after the tightness test has been passed.
During manufacturing, welding and installing the steam piping, not only the dirt will
enter into the piping but also the oxide and welding spatter will be attached on the inner
wall of the piping. Therefore, the solid impurities with the size less than the hole of the
strainer will enter into the steam path at high speed through the strainer, colliding with
and damaging the blade and gland bush. In order to eliminate this hidden risk, the steam
inlet piping should be purged with steam prior to first commissioning after turbine
installed.
To purge the steam inlet piping with steam, the emergency stop valve must be removed
in advance, mount the “Purging tool”(2-8535-xxxx-xx) supplied with the turbine for
blocking the passage through which the steam enters into the steam path.
A temporary exhaust pipe is required for purging, the inner diameter of the exhaust pipe
should be equal to or larger than that of the purged piping with a length as short as
possible for reducing the exhaust resistance. The outlet of the exhaust pipe should be
tilted up (by approx. 30°) to the air. The exhaust pipe should be fixed by the firm
support to bearing the reaction force of the exhaust. In order to reduce the noise level
produced by exhaust, a muffler may be mounted in the temporary exhaust pipe. But the
muffler mounted will increase the exhaust resistance.
To get the efficient purging, the scouring force against the piping wall during purging
should be larger than that during normal operation. Therefore, the purging-steam
parameters is determined and controlled by a momentum coefficient K, which is the
ratio of the steam momentum m1c1 under purging condition to the steam momentum
m0v0 under rated condition, i.e.:
m ⋅v
2
mc
K = 1 1 = 12 1 K should be ≥1.2～1.5
mo c o m o ⋅ v o
Where:
m1—Purging-seam flow
m0—Steam flow under rated condition
v1—Special volume of purging-steam
v0—Special volume of steam under rated condition
Before purging, the piping should be warmed up and all of the joint bolts for flanges
should be tightened under hot state. The purging is carried out in several times, which is
based on the clean condition of the piping. Each time of purging will last for 10 minutes.
The interval time between two purges is determined by the time required for the piping
temperature to drop below 100℃. When the temperature of the piping wall dropped

Purging Steam Piping 3-0350-01-01
below 100℃, the impurities deposited on the wall will fall down and be blown off in the
next purging.
In order to examine and evaluate the purging result, a checkerboard may be fitted in the
exhaust pipe (Fig.1) or at the outlet of the exhaust pipe (Fig.2). It consists of a support
and target plate made of new aluminum plate with thickness of 1mm and width of
30mm, the length of the checkerboard is decided by the diameter of the exhaust pipe.
the target plate should be replaced and examined after each purging. On the premise that
the scouring force of the steam does not decrease, when the impacting blemishes on the
target plate in two adjacent purges has been ≤ 0.8mm and number of the blemishes is
less than 8, the purging is considered to be qualified.
Following the purging, remove the temporary exhaust pipe when the piping temperature
dropped to room temperature. Carefully clean the emergency stop valve housing and
remove the purging tool. Make sure that there is no impurity in the steam inlet
compartment and mount the emergency stop valve.

Preparation for Foundation 2-0300-01-01
Preparation for Foundation

1. Embedding packing plate
Mark the seating areas for the packing plates on the foundation according to the Layout
Drawing 0-2015-TN.r-00 ( or the attached information 0-2015-T.Nr-01 to the Layout
Drawing). An uneven foundation surface does not ensure a horizontal position of the
packing plates. Therefore, an approx. 20 mm thick layer of mortar is to be applied to the
foundation surface (the oil stain and loose layer of the tabby should be cleaned off in
advance. The packing plates are embedded into this layer (see Fig.1). The excess mortar
squeezed out at the edges is to be smoothed into a slope towards the top. The mortar
surface around the packing plate should be a little lower than the top of the packing
plate. Check the level of the top surface for the packing plate by means of a spirit level
in two axes perpendicular to each other before the mortar solidified. Beat the packing
plate slightly to make the air bubble in the level be at the middle.
1. Level
2. Packing plate
3. Layer of mortar
4. Foundation
Fig. 1 Before Turbine Installation
1. Pedestal (support plate)

2. Sizing Block
3. Packing plate
4. Layer of mortar
5. Foundation
Fig.2 After Turbine installation
The packing plates are supplied by user, for the dimension of the cross section, see
Layout Drawing. The surface roughness of the packing plate topping should be .
The deviation of the flatness should be less than 0.1.

The cement mortar( cement, sand and water) or epoxy mortar ( epoxy, curing agent and
quartz sand) can be used. When the cement mortar is used, the packing plate can be
loaded after the mortar solidified for at lest 24 hours. The strength of the mortar after 72
hours should be ＞ 60N/mm2. If the epoxy mortar is used, the relevant safety
measurement should be taken for the toxicity of epoxy during working. And at the same
time, the foundation and the packing plate surfaces that contacted with the mortar
should be treated according to the relevant specification. In order to prevent the epoxy
mortar aging and strength decreasing in the air, after grouting the mortar surface should
be protected with a layer of cement mortar.
2. Embedding bearing plate for trimming screw

The mounting position of the bearing plate should be corresponded with the position of
the trimming screw on the pedestal (or soleplate). The seating area on the foundation for
the bearing plate should be flattened by chiseling or scraping so that the whole bearing
plate is contacted with the seating face evenly. The bearing plate is treated by user. Its
surface should be flat and without burrs. The thickness of the bearing plate is about 30
mm (see Fig.3). The dimension of the cross section can be calculated based on the load
indicated in the Layout Drawing. The pressure intensity on the bearing face should be
≤24.5N/mm2.
1. Pedestal (soleplate)
2. Trimming screw
3. Bearing plate for trimming screw
4. Foundation
Fig.3
3. Anchor-bolt holes
The anchor-bole holes should be cleaned of sundries.
Check the contact condition between the bottom plate of the anchor bolt and the
foundation surface around the hole. Under normal condition, the pre-tightened force of
the anchor bole acts on the concrete foundation via whole bearing face of the bottom
plate. If the protruding edge-angles and stones are existed around the anchor-bolt hole,
the load on the foundation becomes unevenly distributed. This will cause part of the
foundation cracked and damaged in a short time, resulting in the tightened force of the
anchor bole lost and then endangering the normal operation of the turbine. Therefore, an
approx. 5mm thick layer of high viscosity and stagnation cement mortar is to be applied

on the bottom plate or the corresponding surface on the foundation, if necessary (see
Fig.4). Tighten the nut to press the bottom plate and it will do just for the mortar
beginning to be pressed out. This will not only benefit the turbine in long period
operation but also prevent the mortar leakage during filling the hole with the mortar.
The anchor-blot hole only can be filled after 12 hours. The strength of the filled mortar
after 72 hours should be ＞60N/mm2.
1. Asphalt tape
2. Anchor bolt
3. Anchor-bolt hole
4. Foundation
5. Filled cement
6. Bottom plate of anchor bolt
7. Nut
Fig. 4
4. Pre-treatment of anchor bolt

In order to allow the anchor bole to be in elastic strain when tightened after back
grouting, the mortar is not allowed to attach on the bolt or enter into the nut during
grouting. So the bolt should be wrapped upwards from the nut to the thread end with the
asphalt tape (see Fig.4) in the direction as the nut turning direction. When screwing in
the nut the tape will be pushed upwards and form a ball-like ferrule.
After the turbine installed, the anchor bolt should be secured by spot welding and the
exposed thread should be coated with thick grease for corrosion prevention.

Back Grouting for Foundation 2-0310-01-01
Back Grouting for Foundation

After the turbine ( including the gear box) has been installed and it is sure that the
position of the turbine set will not be moved, grout the bottom part of the pedestal
(support plate or baseplate) with specified mortar to connected it to the foundation
firmly.
The material and formulation of the mortar is independent of turbine type and size, it is
selected by user and construction company. But we recommend:
When the thickness of the grouting layer ≤60mm, either the cement mortar mixed with
cement, sand and water in a given proportion or the epoxy mortar prepared with epoxy,
curing agent and quartz sand can be used.
When the thickness of the grouting layer is 60 to 100 mm, either the concrete with
pebble in the specified granularity or the cement mortar can be used.
No matter which grouting material is used, the following requirements should be

satisfied:
1. Compression strength
≥40N/mm2, after 24 hours
≥60N/mm2, after 72 hours
≥70N/mm2, final strength
2. Volumetric change
The contraction is not allowed. The grouting material should expands slightly within 24
hours after grouting so as to ensure that there is enough cohesion between the
foundation and pedestal, but the further expansion is not allowed after 24 hours.
3. Expansion coefficient
The coefficient of the linear expansion for the mortar after solidified should be in
conform with that of the foundation.
4. No cracking on impact and vibration

Before back grouting fill the anchor-bolt holes with the cement mortar, first. The back
grouting only can be done at least after 24 hours.
Mounting or dismounting heavy component on the pedestal only can be done after back
grouting finished at least for 24 hours.
The anchor bolt only can be retightened after back grouting finished at least for 72
hours.

Back Grouting for Foundation 2-0310-01-01
when the epoxy mortar is used for back grouting, the relevant safety measurement
should be taken for the toxicity of epoxy during working.
The preparation for the foundation before grouting and the maintenance should be done
according with the construction procedure.

Heat Insulation of Turbine Casing 2-7600-01-01
Heat Insulation of Turbine Casing (Aluminum Silicate)

The heat-insulating lagging supplied with the turbine is used for heat insulation of the
turbine casing, emergency stop valve, control valve and extraction stop valve.
Preserving the turbine casing with heat-insulating lagging reduces not only the turbine
thermal lose and but also the temperature difference at the same cross-section of the
casing and consequently the heat deformation caused by the temperature difference. At
the meantime, it lowers the ambient temperature around the turbine, enhancing the
working condition for operator.
After the piping that are connected to the casing and the instruments installed, the oil
system and steam piping scavenged, the installation of the heat-insulating lagging can
be carried out.
The heat-insulting lagging is formed by irregular-shaped blanket tailored by fibergalss

cloth with aluminum-silicate filled. The shape and the thickness of the blanket are
determined by the turbine type and steam temperature. The heat-insulating lagging is
divided into inner and external layers. Each blanket has its own identification number.
The number of the first layer (inner layer) is I-xx, the second layer (outer layer) is II-xx.
The instructions, developed diagram and diagrammatic map of identification numbering

for the heat-insulating lagging can be found in the document container delivered with
the turbine. For the newly installed turbine the mounting of the lagging must be made
with great care. The blankets should adhere to the casing over their entire surface so that
no air cushions will be formed. In addition, adjacent blanket should abut tightly at the
joints without leaving any gaps. If the gaps appear due to mounting deviation, the spare
blankets can be used to fill them. For opening the turbine casing during turbine overhaul,
only the blankets at the casing-split bolts are required to be removed. After overhaul,
mount the blankets removed to the original positions. Replace old ones with spare
blankets, when necessary.
Attention: The unused blankets should be stored properly. Dragging the blanket
on the ground, standing or placing the heavy subjects on the blanket are not
allowed.
Flammable substance must not be infiltrated into the blanket. The blankets
infiltrated with turbine oil or adhered with grease must not be used.
The installation personnel should dress the tight work-clothes and rubber glove
when mounting the heat-insulating lagging.

Operating Supervision 3-2010-01-01
Operating Supervision
This section describes the monitoring requirements of the main operation parameters for
the turbine. For the instrument configuration and function (including monitoring limit)
of individual turbine, please refer to “Bill of Material” 0-2020-T.Nr-00.
Pressure and temperature of live steam

To obtain the economic and efficient operation of a turbine, the pressure and the
temperature of the admission for the turbine should be kept with the ranges (Excluding
the boiler feed pump turbine), which are given in the Technical Data 0-0300-T.Nr-00.
When the admission pressure of the turbine has exceeded the normal value and tends
toward the upper limit, the turbine operator should inform the boiler operator to reduce
the pressure at once. When necessary, turn down the isolated valve in the live steam line
for reducing the pressure; decrease the turbine load through reducing the opening of the
control valve.
When the admission pressure of the turbine has exceeded the normal value and tends
toward the lower limit, the turbine operator should reduce the turbine load and inform
the boiler operator to raise the pressure.
When the admission temperature of the turbine has exceeded the normal value and tends
toward the upper limit, the turbine operator should inform the boiler operator to reduce
the temperature. When necessary, decrease the turbine load through reducing the
opening of the control valve.
When the admission temperature of the turbine has exceeded the normal value and tends
toward the lower limit, the turbine operator should inform the boiler operator to raise
the temperature. When necessary, open the drain valve in the live steam line; decrease
the turbine load through reducing the opening of the control valve.
The continuous operation under the upper limits of both pressure and temperature for
the admission cannot exceed 15 to 20 minutes. The cumulated time in a year should not
exceed 20 hours.
The pressure and the temperature are monitored with pressure switch and thermal
coupling. When the admission pressure and/or temperature reached the reset limit, the
alarm and shutdown signal will be sent out.
Under the special conditions, such as start-up and commissioning, the admission
pressure and temperature of the turbine can differ to the normal values mentioned
above.

Wheel chamber pressure
The wheel chamber pressure is the steam pressure in the department behind the control
stage. It is used for monitoring the turbine operating condition and the working
condition of the steam-path section.
The chamber pressure has a coincidence relation with the steam flow. Under normal
condition, the chamber pressure changes with the change of the live-steam flow, please
see the attached documents No. 0-2505-T.Nr-00 “Characteristic Line of Control Valve”.
The maximum steam flow can be restricted through monitoring the chamber pressure,
so as to avoid over loading. Chamber pressure also reflects the deposition of the
steam-path section, which is related with the steam quality. The deposit on the blade
surface not only increases the blade stress, but also decreases the section area of the
steam-path, resulting in turbine output and efficiency reduced and the axial thrust
increased. If the steam-path is deposited, the chamber pressure will rise under the same
steam parameters and flow. With this characteristics, the measured relation of the
chamber pressure to the steam flow during operation can be compared with that
measured (the live-steam pressure and temperature under different operating conditions
should be kept constant) under the clean condition for the steam-path after the turbine
has been put into normal operation against “Characteristic Line of Control Valve”
0-2502-T.Nr-00. The relative increment Δ P is calculated with the formula
PR − PRO
ΔP = × 100% , here PRO is the chamber pressure corresponding to the
PRO
measured flow under clean steam-path, PR is the chamber pressure in current
operation with the same steam parameters and flow. ΔP should not exceed 10%,
otherwise the immediate flushing is required (see 4-0600-).
Exhaust pressure
The exhaust pressure deviation from the normal value for the backpressure turbine will
have effect on the turbine output and the safety as well. The excessive high exhaust
pressure is going not only against the casing strength, nut also to increase the axial
thrust, while the excessive low exhaust pressure will endanger the blade safety.
Therefore, the exhaust pressure during turbine operation is not allowed to exceed the
permitted range.
The exhaust pressure of the turbine is monitored with the pressure switch. When the
exhaust pressure reached the preset limit, the alarm or shutdown signal will be sent.
Vacuum in condenser
During condensing turbine operation, the vacuum in the condenser will drop and the
exhaust pressure rise due to excessively high temperature of the recycling water, lack of
the cooling water flow, deposit of the cooling pipe in the condenser, leakage of the
vacuum system or bad work of the air ejector.

The drop of the vacuum will lower the economical efficiency of the turbine-set
operation and affect the safety operation as well. Besides the increase of the axial thrust,
the exhaust temperature will rise with the increase of the exhaust pressure. The risen
temperature of the exhaust portion of the casing may cause the vibration increasing. For
the turbine that the bearing housing is integrated with the casing, this will also raise the
rear-bearing temperature. The rise of the working temperature of the condenser can
affect the condenser performance and safety. Therefore, when the vacuum dropped
during operation, the turbine load should be reduced. When the vacuum dropped to
–0.06Mpa, the turbine load should be reduced to zero for driving the generator, For the
turbine driving the compressor (including blower, pump and etc.), the speed should be
lower to the low governor speed or further and the output of the compressor should be
disconnected with the system. If the vacuum is kept ≥-0.06Mpa and the vibration and
bearing temperature are at normal values, the turbine can run under no-load or small
load. However, the check should be made in the shortest time to eliminate the defect. If
the vacuum continues to drop, the turbine should be stopped.
During turbine operation, the exhaust temperature under load should not exceed 70℃,
and 120℃ under no-load.
Extraction pressure
For the turbine with controlled extraction, the extraction pressure is either the exhaust
pressure of the first expansion section or the admitting steam pressure for the second
expansion section, so that it should be controlled within a permitted range.
In some of turbines, the extraction temperature is also be monitored besides the

extraction pressure.
Bearing temperature
The journal and thrust bearings used in turbine and gearbox are hydrodynamic bearings,
their normal working is lied on the oil film that can build-up loading capacity. The
viscosity of the lubricating oil, which is related with the bearing temperature, plays an
important role in influencing the loading capacity in the case that other factors have
been decided. Therefore, the bearing temperature must be strictly limited. When the
bearing temperature exceeded the specified stop value, the strength of the bearing babbit
may be reduced obviously. In order to insure the reliable operation of the bearing, the
bearing temperature should be kept within the normal range during turbine operation.
The rise of the bearing temperature during turbine operation is caused by friction power
of the bearing and the heat produced in heat exchange. When the heat the lubricating oil
takes out is equal to the heat the produce, the temperature tends to be stable. The
bearing temperature: t = t o + Δt . Here, t o is the lubricating inlet temperature, which
should be maintained within the range of 45℃（±3℃）, Δt is the permitted

temperature rise of the bearing, which is determined by the measuring method. When

using the thermal resistance or thermocouple thermometers to measure the bearing-pad
temperature, the up limit of the normal range for the bearing temperature should be
t o +45℃, while measuring the return-oil temperature of the bearing, it should be
t o +20℃.
The temperature rise of the journal bearing is related with the speed and load.
Measuring the babbit temperature with the thermal resistance or thermocouple at the
minimum oil film at the lower half of the bearing can make a quick reflection of the
temperature change for the bearing pad. Where two temperature sensors are equipped
for one journal bearing as required by user, the temperature readings on each measuring
point are bound to be different. In this case, the journal-bearing temperature monitored
should subject to the reading on the measuring point at the minimum oil film related
with the rotating direction.
When using the thermal resistance or thermocouple thermometer to measuring the

thrust-bearing temperature, two temperature sensors (up to four) are usually fitted in
each primary and secondary thrust pad. The temperature rise of the thrust bearing is
determined by the speed and axial thrust. In general, the temperature of the primary
thrust pad is higher than that of the secondary one. The load on the individual thrust pad
at the same side may be uneven, so when the bearing temperature rose, make sure
whether the temperature of one measuring-point rose or that of all measuring-points
rose. The former indicates that one of the pads is overloaded, while the later reflects the
thrust increased.
For the monitoring of the temperatures of the journal and thrust bearings, not only the
absolute value ( t o + Δt ) should be observed, but also the change of the bearing
temperature rise should be noticed. Compared with the highest temperature under same
working condition in the operation record before, if the temperature rise of the bearing
increased suddenly, it cannot be treated lightly even the bearing temperature has not
reached the alarm value yet. Should the bearing temperature rose instantaneously and
lasted for a very short period, and then it retune to the temperature in normal operation,
the partial damage of the bearing is often indicated. In this case, the continuous
operation of the turbine may cause the severe damage of the bearing.
For the alarm and stop limits of the bearing temperature, see 0-2020-T.Nr-00.
Oil pressure
For the turbine with the oil system using turbine oil as its working medium and the main
pump driven by the turbine shaft, the pressure of the pressure-oil is between 0.6～
1.3Mpa, which is related with the turbine speed. It will be ～0.8Mpa at rated speed. For
the turbine with an external oil pump, the pressure of the pressure-oil is ＞0.8Mpa. The

pressure in the lubricating header is about 0.25Mpa. For the setpoints of the alarm and
stop values for drop of the trip-oil and the lubricating-oil and excessive differential oil
pressure between the inlet and outlet of the oil filter, see 0-2020-T.Nr-00.
Where the pressure gauge is fitted in the oil inlet piping of the bearing, when adjusting
the oil flow to the bearing with the throttle valve based on the bearing temperature, the
oil pressure is only taken as the reference. The oil pressure behind the throttle valve is
not stipulated.
In general, the throttle valve is not required to readjust after adjusted in turbine
commissioning.
For the supervision of the high-pressure fire-resistant oil system, please refer to the
related instructions.
Shaft vibration
Usually, the shaft vibration of the turbine is continuously monitored with the
two-channel vibroscope.
The turbine has passed the high-speed balance and no-load test run in the workshop
before delivering. The value of the shaft vibration recorded in the Product Certificate is
the p-p value. The non-vibration deviation of the rotor resulted from the electric and
mechanical deviation in the workshop is limited within 6μm.
It is bound to produce slight vibration during turbine operates at the given speed and
within the given load range. The amplitude will increase in the process of the start of
stop, especially when turbine speed passes through the forbidden- to-stay-zone. As long
as it does not exceed the permitted range, such a vibration is still normal.
Under the good installation condition, there are many factors that will aggravate the
vibration during turbine operation, such as the uneven expansion of the turbine due to
the over-fast rate of loading or unloading, the change of the damping characteristic due
to the worsen bearing working status, the change of the original balancing state, water
hammer, compressor surging and etc. The abnormal sound is often companied with the
aggravating vibration. Therefore, listening the operation sound may be taken as the
auxiliary method for monitoring the shaft vibration.
When judging whether the vibration is normal or not, the absolute value of the
amplitude cannot be taken as the only reference. For example, the measured amplitude
is increased from 25μm to 30μm under a certain working condition, while under other
working condition it is increased from 5μm to 25μm. The former condition does not
always indicate the existence of some disturbances, while the latter may foreshow the
appearance of the fault, which must be put on alter. The cause resulting in the abnormal
vibration should be found out even it does not reach the alarm value, the corresponding

measures should be taken for preventing the operation worsen further.
Most of the turbines are equipped with key-phase sensor, as required, to measure the
frequency and phase of the shaft vibration for analyzing the vibration characteristic with
the frequency spectrograph.
At present, the larger one of two P-P values measured in two orthogonal directions is
usually taken as the estimating index for the shaft vibration. The alarm and stop values
given in 0-2020-T.Nr-00 is not unique but for suggestion. User can reset them based on
his experience in operation and the standard adopted.
We recommend assessing the mechanical vibration of a turbine-set according to the

standard ISO 7919-3.
Axial displacement
There are to kinds of axial-displacement protective devices, mechanical and electrical.
In some of turbines both of them are used, for the others, only one of them is used.
The limit value of the axial displacement for the mechanical protective device is about
±1.0mm. When the thrust bearing damaged in operation and the axial displacement of
the rotor exceeded the clearance between the tripping lever and the cam on the rotor,
which has been adjusted in installation, the emergency trip gear acts and trips the
turbine, so as to prevent the rotor from colliding with the stationary parts in axial
direction and accident from going worse.
The electric axial displacement protective device continuously monitor the axial
position of the rotor with respect to the thrust bearing through the approximant sensor
and the position detector. It can send an early warning for the thrust bearing damage to
avoid the severe damage of the turbine. For the alarm and stop limits of the axial
displacement for the rotor, see 0-2020-T.Nr-00. When adjusting the sensor in
installation, The middle value of the total clearance between the thrust collars of the
rotor and the primary, secondary thrust pads is take as the zero position.
The axial displacement of the rotor is caused by the change of the axial thrust, which is
related with the turbine working condition and statues. The axial thrust in backpressure
or condensing turbine is approximately proportional to the live steam flow. The
maximum axial thrust will appear at maximum power. For the extraction turbine, it does
not appear under the rated working condition but under a certain middle working
condition, such as zero extraction condition. During normal operation, the axial thrust
will be within the permitted range when the load is changed within the given range, so
that the thrust bearing is safety. But under abnormal condition, such as overload, worn
inner gland seal, deposit of steam path, over-low live steam temperature and water
hammer, the axial thrust will be increased additionally.

When the axial displacement is gradually increased during turbine operation, the special
attention should be paid to the monitoring of the thrust-bearing temperature. If the thrust
bearing temperature exceeds the up limit with the increased axial displacement, reduce
turbine load at once. Should the axial displacement continue to increase towards the
stop setpoint after the measures have been taken, trip the turbine immediately.
Speed
Usually, tachometers are mounted on the local instrumentation panel and in the center
control room for monitoring the turbine speed in operation. Where the electric-hydraulic
control system is adopted, the digital governor also has the monitoring function for
speed. Additionally, some of turbines are equipped with the overspeed protective system
using two-out-of –three logic. They will continuously indicate the actual speed of the
turbine in operation. When the speed exceeded the rated speed or the maximum
continuous speed rose to the reset acting value, the alarm or stop signal is sent.
For the turbine with continuous barring gear, the barring speed should not be lower than
the specified minimum barring speed.
If there is any forbidden-to-stay zone (including the forbidden-to-stay zones for turbine
and driven machine) in the process of the turbine starting and stopping, make the
turbine speed pass through this zone quickly and continuously in operating.
With the governing system the turbine runs stably within the specified speed and load.
For the turbo-generator, after load rejection of the generator, the speed will rise
instantaneously and then stabilize at the up governor speed under normal condition.
During turbine operation, If the turbine speed is out of the control and rise to the stop
value reset but the protective device has not acted yet, manually trip the turbine at once
with the manual stop valve, emergency trip gear or the stop solenoid valve that receive
the stop command from the control room.
Thermal expansion of casing

During turbine starting and operating, the sliding-key system can guarantee the casing
to expand freely but maintain the center unchanged. If it is not adjusted properly in
installation or the foreign force and moment that exceed the permissible value are acted
on the casing, the expansion of the casing in radial or axial direction is obstructed,
causing abnormal vibration of the turbine.
The thermal expansion of the casing in the axial direction is usually monitored with the
expansion indicator mounted on the front pedestal. The casing expands forwards when
heated and constricts when stopping, taking the dead point as the reference. The
expansion of the casing when heated should be continuous. The appearance of the step
change in expansion indicates the expansion obstructed. It is required, at any moment,
to check the clearances of the bolt washers on the front and rear supporting brackets of

the casing. The washers should be always in free statues.
Race time
The soundness of the turbine can be judged through measuring the race time during
normal stopping and comparing it with the race time measured in commissioning under
the same operation condition. If the race time measured currently is shorted obviously,
the rotor may be contacted with the stationary parts or bearing defect existed. While the
prolonging race time indicates that the steam leaked into the casing because of the
untight close of the emergency valve and control valve.
As the requirement in the order, the turbine may be equipped with casing-temperature
detector, absolute casing-expansion detector, differential expansion detector, rotor
eccentricity detector and etc. for monitoring the temperature deference between the top
and bottom casings, the thermal expansion of the casing in axial direction, the relative
expansion of the casing and the rotor and the flexural deformation of the rotor.

Abnormal Vibration 3-3010-01-01
Abnormal Vibration
The turbine is a rotary machine in high speed, so vibration in different amplitude and
direction will occur in its operation. Any of the vibration that is within the limited
range is permitted and has no harmful to the machine. But some times the abnormal
vibration will occur during turbine operation for various reasons, especially during
commissioning. According to the statistics of the vibration troubles, most of the
abnormal vibrations are caused by improper installation or misconduct in operation
and maintenance. Since the turbine rotor has been balanced and passed the no-load
running test before delivery, it usually is not required to rebalance, except for the rotor
that has been repaired, bended permanently or which parts have been replaced. If the
abnormal vibration occurred during turbine-set starting and operating, carry out the
test and analysis by means of the frequency spectrograph or other real-time analyzer
for finding out the reason and resolving it based on the vibration characteristics.
1. Poor quality of installation or overhaul

1.1 Due to the poor quality of the back grouting, the turbine pedestal (baseplate) did
not joint to the foundation tightly, the anchor bolts ware loosen and the foundation
sunk unevenly. If you stand near by the turbine when raising the turbine speed,
you will fell the foundation is vibrating with the turbine. The amplitude change of
the shaft vibration is not evident; the vibration signal contains the low-frequency
component. While the amplitude of the bearing housing increases obviously and is
unstable.
In this case, the best solution is to reinstall the turbine.
1.2 Piping
1.2.1 Steam piping
Due to forced connection of the mis-positioned flanges or unreasonable piping layout,
the force and torque acting on the turbine exceed the permitted values. The abnormal
vibration is marked by: the vibration is related with the turbine hot state, the
amplitude will increase obviously at a certain load (temperature), the vibration
frequency is in step with the turbine speed, the vibration signal contains the
low-frequency component. Measure the vibration of the shaft and the bearing housing
at the front and rear sections of the turbine, if the larger vibration appears at the front
section, the steam inlet piping is likely to be with the problem. If the larger vibration
is at the rear section, it is mostly caused by exhaust piping.
Measure: Reconnect the piping according to the requirement or adjust the piping
supports.
1.2.2 Inlet and outlet piping of the main oil pump

The disturbing force of the piping caused by forced connection of the mis-positioned
flanges make the turbine vibrate abnormally. With the rising speed, the vibration at
the front bearing housing will increase obviously. The vibration signal contains the
low-frequency component.

Measure: Reconnect the piping according to the requirement.
1.3 Improper assemble and adjustment of turbine slide-key system

The thermal expansion of the turbine is restricted during start-up and operation, so
that the alignment of the rotor with the casing and bearing housing is destroyed,
resulting in vibration, which is related with the turbine hot-state. The vibration
frequency is in step with the turbine speed. Measure the vibration at the front and rear
bearing housings for judging which guide key to be seized.
Measure: Stop for inspecting and readjust the guide element.
1.4 Poor alignment

1.4.1 Poor alignment of turbine rotor with casing
If the rotor is not aligned with the casing properly during turbine installation, the
abnormal vibration will occur during turbine test running. In the course of the turbine
starting, the moving parts will collide with the stationary parts with the increasing
speed and inside temperature so that the amplitude of the shaft vibration will increase
with a squeal of metal friction. The vibration signal contains high-frequency
component, with disturbing waveform.
Measure: Stop the turbine and recheck the alignment, repair or replace the damaged
sealing strips.
1.4.2 Poor alignment of turbine rotor with driven-machine rotor

The turbine has passed the test running, but the abnormal vibration occurs during
turbine-set test running. If the double frequency harmonics is included in the vibration
waveform, the abnormal vibration is caused by the poor alignment of the rotors.
Measure the vibration of the bearing housing; the increase in the axial amplitude
indicates that the parallelism of the end face is out of condition, while the increase in
the radial amplitude indicates that the deflection of non-axiality is excessive. The both
often exist simultaneously.
Measure: Stop the turbine and realign the rotor. If the realigning is not allowed at the
moment for some external reasons, the imbalance correction can be carried out at the
secondary balance surface of the rotor. But this is only a makeshift, the final solution
is to realign and rebalance the rotor after the turbine stopped.
1.4.3 Alignment under cold state is conformed with the requirement, but the center is
deviated during operation
In addition to the same characteristics mentioned in 1.4.2, the vibration characteristic
is related with hot state of the turbine set. For the backpressure turbine, the vibration
at its driving end will increase obviously when the load or the exhaust temperature
reached to a certain value. For the condensing turbine, the temperature of its exhaust
nozzle during operation is high than the ambient temperature when installation. If the
pre-pulling amount is too small when installing, the expansion of the exhaust nozzle
during operation will raise the center of the turbine rear bearing. Meanwhile, the
inside of the exhaust casing is under vacuum during operation, the exhaust casing

under the action of the atmospheric pressure will lower the center of the rear bearing.
Therefore, the vibration resulting from the center change of the bearing is related with
the exhaust temperature and vacuum.
Measure: For the backpressure turbine, re-measure the aligning data immediately after
the turbine stopped and correct the aligning value under cold state based on these
measured data. For the condensing turbine, maintain the vacuum as could as possible
through barring and supplying the gland steam after the turbine stopped, check the
aligning value and correct the aligning value under cold state based on these measured
data.
1.4.4 For the turbine coupled with the driven machine via a gearbox, if the offset of
the gear shaft when aligning the rotor is not conformed with the actual condition, the
vibration and noise of the turbine will increase obviously when the load reached to a
certain value. The vibration waveform contains high frequency harmonics. The high
frequency is synchronous with the working frequency.
Measure: Stop the turbine and check the aligning valve of the turbine rotor with the
gear shaft. Correct the aligning value according to the direction of the gear engaging
force.
1.5 Bearing
The carrying capacity of the multi-wedge bearing is related with the arrangement of
the oil wedge. The split of the four-wedge bearing should be angled of 45 °to the
split of bearing housing, this makes the load just be supported on the center of the
oil-wedge during operation. If the four-wedge bearing does not be turned by 45°
when installing on site, the carrying capacity of the bearing will decrease. Therefore,
during turbine operation the vibration will be increased in a sudden once the load
reached to a certain value. The vibration signal contains eddy signal at a frequency
lower than the working frequency.
Measure: Reassemble the bearing according with the requirement.
1.6 The axial positioning between the turbine and the driven machine is not
conformed to the requirement, especially for turbine that is directly coupled with the
generator. During operation, the expansion of the turbine rotor will push the generator
rotor to move axially. If the axial clearance between the moving and stationary parts
of the generator is less than the axial expansion of the turbine rotor, the moving part
will collided with the stationary one, resulting in turbine to vibrate violently with a
loud noise, finally damaging the equipment.
Measure: The turbine must be positioned correctly when installation. The amount of
the axial expansion for the turbine rotor is given in the attached document
0-0341-T.Nr-00.
2. Operation
2.1 Poor behavior of bearing
Insufficient lubricating oil, disqualified oil quality (emulsification, a lot of bubbles,

impurities and water contained in the oil), abnormally low oil temperature, excessive
bearing clearance will cause the oil film of the bearing unstable. The eddy motion of
the oil film results in discontinuous vibration with irregular waveform and abnormal
noise. The vibration frequency is not in step with the speed.
Measure: Take the corresponding measures according to the reason found out.
2.2 The water contained in the steam causes the temperature of the admitted steam to
drop suddenly, forming a water hammer. The turbine set vibrates intensively
companied by toneless roar.
Measure: Stop the turbine immediately, drain the inlet steam and exhaust piping
thoroughly, reinforce the monitoring of the boiler operation.
2.3 The deposit and corrosion of the steam path section due to the poor steam quality
will destroy the rotor dynamic balance, resulting in turbine vibration. In this case, the
vibration is increased gradually with prolong of the operation duration. Usually, it
does not occur suddenly, except for blade breakage. The vibration frequency is in step
with the speed.
Measure: The deposit content on the blade can be evaluated from the temperature of
the thrust bearing and the pressure change after the control stage. Clean the deposit in
time when necessary or during overhaul.
2.4 The drop of the vacuum for the condensing turbine will raise the exhaust
temperature and consequently change the rotor alignment under hot state, resulting in
turbine vibration. In this case, the vibration at the rear end of the turbine often
increases obviously. The vibration frequency is in step with the speed.
Measure: decrease the load and raise vacuum. Return the turbine to original operating
condition after the vibration reached to the normal value.
2.5 For the turbine that has been put into operation, most of the abnormal vibrations
occurring during starting or changing load are caused by improper operating, such as
improper barring after last stopping and insufficient warming-up during staring. If the
abnormal vibration occurs during raising speed and the noise of the metal friction at
the front and rear gland bushes can be heard, it indicates that the rotor has been
warped (where the eccentric monitor is provided, it can be used in measuring the
warping amplitude for the rotor. At this moment, the turbine speed should be lowered
and maintained at a stable value after the vibration returned to normal for warming-up
for about 15 minutes (the speed can not stay in the prohibition range), and then raise
the speed again. If the abnormal vibration still cannot be eliminated after 3 repeats,
the turbine must be stopped, check and repair the rotor.
Fast load changing also causes the vibration due to deformation of the uneven
expanded components. If the vibration occurs in loading, unload or lower the turbine
speed immediately. After stabilized, load the turbine (or raise speed) according to the
change rate given by the staring curve. If the vibration occurs in unloading, operate

the turbine in steps opposite to that mentioned above.
2.6 For the turbine driving compressor, if the abnormal vibration only appears under a
certain load, it is mostly caused by the compressor and the characteristics of the pipe
network.
Measure: When changing load to near this load, slow down the changing rate
properly.
2.7 For the turbine diving compressor, the imprudent operation when reducing the
compressor flow or the improper set of the surge-proof system will cause the turbine
set running in the surging zone, resulting in sharp fluctuation of outlet pressure of the
compressor and consequently intensive vibration of the turbine and the compressor
outlet piping companied with a loud noise.
Measure: Trip the turbine set. Operate the turbine set according with the related
operating procedure to prevent the compressor running in the surging zone.
3. Defect of equipment
3.1 Toothed coupling
The eccentric load produced by the floating parts of the coupling under the centrifugal
force due to the existed backlash will cause vibration. Under the normal condition, the
vibration of the turbine will increase with the raising speed after the turbine started,
but the amplitude is within the permitted range. Additionally, under the action of self-
centering the eccentric load will decrease with the increase of the torque the coupling
is transferring, stabilizing the operation. But the excessive backlash resulted from
machining error or wearing may cause the amplitude to exceed the up limit with the
increase of the turbine speed.
Measure: Check the coupling during overhaul, improve the lubrication and replace the
coupling when necessary.
3.2 Generator
The vibration occurs when raising the generator voltage, but it disappears after the
excitation of the generator released. This indicates that the vibration is caused by the
unbalance magnetic field, which is arose from short-circuit of the generator winding
or the uneven air gap between the generator rotor and stator.
Measure: Inquire the electric technician.

Excessive Axial Displacement of Rotor and Turbine Water Hammer 3-3010-02-01
Excessive Axial Displacement of Rotor and Turbine Water Hammer

Usually, the increase of the axial displacement for the turbine rotor is caused by the
following reasons:
Increase of the load or steam flow;
Damage of the steam path section;
Severe deposit in the steam path section;
Wear of the thrust pad;
Turbine water hammer;
Rise of the turbine exhaust pressure (for the condensing turbine, drop of the condenser
vacuum);
Play of the generator rotor in turbo-generator;
Compressor surge in the turbo-compressor;
The measures that should be taken under some of the common conditions:
Increase of load or steam flow

For the different turbine sets, the axial displacement is increased under different
working condition.
1. When a non-extraction turbine is overloaded, the axial thrust on turbine rotor is

bound to increase with the excess increase of the steam flow. If the thrust exceeds
the permitted value, the thrust bearing may be damaged, resulting in the excessive
displacement of the rotor. In order to avoid this faulty occurring, when continuing to
load the turbine near the rated power, the attention should be paid in monitoring the
temperature of the thrust bearing, axial displacement of the rotor and the pressure of
the wheel chamber. Once any of the former two approached to the alarm value,
unload the turbine immediately.
If the plant requires the turbine to operate under overload, it only can run
occasionally in a short time. When the operating condition of the plant has been
changed and the turbine cannot be suitable for this new requirement, the proper and
reasonable solution is to innovate on the turbine for increasing its output.
2. For the turbo-generator paralleled in the network, the automatic increase of the
opening for the control valve when the frequency of the network lowered may result
in the turbine overloaded. Therefore, the attention must be paid in monitoring the
operation when the frequency of the network lowered. Decrease turbine load when
necessary.
3. When the inlet steam pressure and temperature decreased or the exhaust pressure
rose, the steam flow must be increased to maintain the original power output for the
turbo-generator. The excessive steam flow may increase the axial thrust force on the
turbine rotor even the turbine is not overloaded. For the Compressor driven turbine

with the control system using a PI or PID speed governor, in this case, the opening
of the control valve will be increased automatically. The axial thrust is bound to
increase with the increase of the steam flow. Therefore, when the turbine inlet steam
parameter lowered or exhaust parameter rose, the admitted steam flow to the turbine
must be limited when necessary, besides restoring the steam parameter to normal
value immediately.
4. When loading a controlled extraction turbine under “zero” or small extraction flow
condition, the axial thrust may exceed the permitted value, although the admitted
steam flow and the output of the turbine are far from the rated values. Therefore, the
extraction turbine must be strictly operated according to the limited condition given
on the extraction flow vs. power curve (Working condition chart).
Seal strip wear of inner gland seal

The relative position of the turbine rotor with respect to the stationary parts will be
changed for some reasons during turbine starting, operating and stopping, causing the
seal strips collide each other. In especial, the damage of the seal strip for the dummy
piston and middle gland seals may result in the axial thrust increased. Usually, an
abnormal noise is generated inside the turbine and the vibration is increased when the
seal strips collided. In this case, decrease the load first. If decreasing load cannot
improve the condition and the temperature of the thrust bearing has exceeded the up
limit, stop the turbine at once and carry out the check and repair.
Deposit in steam path section

The deposit, caused by the salt and SiO2 contained in steam, reduces the steam passage
area, increasing the axial thrust and consequently the axial displacement of the rotor.
The deposit is gradually increased with the prolongation of the operation duration and
can be judged through analyzing and comparing the steam pressure in the wheel
chamber. Clean the through flushing when necessary (see 4-0600-).
Misplacing thrust pads

Misplacing the first thrust pads with the secondary ones is caused by negligence during
installation or overhaul and will be discovered during commissioning. When loading the
turbine to a certain load the turbine is tripped suddenly due to the excessive axial
displacement. Restart the turbine, the same condition occurs again. Stop the turbine and
check the bearing, the thrust pads are found damaged. The load capacity of a misplaced
pad is only 1/3 of that for a correctly mounted one. The decrease of the load capacity
causes thrust pads damaged. The attention must be paid in replacing the thrust pads; the
spare pads that have an allowance in thickness must be additionally machined to the
size given in the Product Certificate and the rotor-positioning dimension in assembling.
A set of eight pads should be machined together so as to ensure the same thickness.
Water hammer
Water hammer is one of turbine major accident. During turbine operation, if the steam

temperature drops sharply, the white steam emits or water drops splash from the gland
seal, the temperature of the thrust bearing rises or the axial displacement increases,
vibration is abnormal, these indicate the water hammer occurred. The turbine must be
tripped immediately.
Most of the water hammer occurred in the turbine are caused by improper operation, but
some of them caused by the water flowing back into the turbine from the piping due to
the check valve in the extraction piping is not tightly closed. If the boiler is overflowed
or the azeotropy of the steam and water occurs, the steam entered into the turbine will
contain water. Since the water drops flow in a low speed, they will produce a braking
action when colliding on the blade convex, making the turbine output decreased
obviously. The steam containing water will significantly increase the blade stress,
resulting in blade broken and abnormal vibration of the turbine set. It also reduces the
steam path area, causing the thrust increased rapidly and endangering the thrust bearing.
In order to avoid the water hammer occurring, the change of the steam temperature must
be noticed when paralleling boilers for preventing it to be too low. For the turbine with
different steam sources, the thorough drain must be carried out when switching steam
source. During boiler operation the attention should be noticed in keeping the steam
pressure and temperature within the specified range.
Should the drain of the steam inlet piping be not complete in turbine starting, the water
hammer will occur due to the water accumulated in the piping. The piping and the
turbine set will vibrate intensively, companied with a loud tedious noise. In this case,
the turbine must be stopped at once.

Blade Damage or Breakage 3-3010-03-01
Blade Damage or Breakage

During turbine operation the blade will be damaged by various causes, such as the
foreign hard granular impurities entered into the turbine, the bad alignment of the rotor
with the casing or friction of the blade with the seal strips. This section will mainly
demonstrate the damage of the blade caused by the corrosion due to the poor steam
quality. The corrosion damage will occur not only in an operating turbine, but also
during shutdown.
Under the normal circumstances, owing to the layer of compact and stable oxide-proof
film formed on the surface the blade made of heat-resisting stainless steel, the blade has
a good corrosion resistance. The protective film of the blade surface will be erode when
the steam contains the Co2, and So2, especially the chloridion. Furthermore, the
corrosion will develop towards the depth quickly and corrode the blade, resulting in
rapid drop of the blade strength. Take the stainless steel 2Cr13 as the example, its
endurance bending strength in the air at normal temperature is 390 N/mm2 (a
un-notched teat piece under a number of stress cycles n=5×107, the same below), it
will still be 275 to 315 N/mm2 in the clear condensate. But it rapidly reduces to 115 to
135 N/mm2 in the chloride solution containing NaCl under a content ≥1％. The
reduction denotes shorten of the blade life. The corrosion can be found when check the
blade in overhaul. Most of the blade corrosion occurs on the stages in the wet steam
zone. Usually, the corrosion begins on the blade surface under the deposit layer and then
develops to crack. If continuing to operate, the blade will break due to corrosion fatigue.
The examination and analysis of the broken blade show that the deposit on the fracture
contains chlorides.
The corrosion of the turbine blade will occur not only during operation, but also during
shutdown, it is so-called as stand-by corrosion. After the turbine shutdown, the steam
left or leaked in the casing will condensed with cooling down of the turbine to dissolve
the deposited salt on the blade, producing a corrosion action to the blade. In this case,
the corrosion damage will occur on all of the blades other than the blades working in the
wet steam zone.
In order to reduce and avoid the corrosion damage of the blade, the boiler feed water
treatment should be perfected so as to ensure the steam quality. Additionally, much
attention should be paid in shutdown maintenance (see 4-0300-xx-xx for details).
If the crack on the blade is found during overhaul, the cracked blade should be replaced.
Blade breakage seldom occurs during turbine operation, but once occurring, it can cause
the severe accident in damaging the equipment and injuring the person. The blade
breakage during turbine operation will have following phenomena:
An irregular load (speed) impact occurs suddenly;

Blade Damage or Breakage 3-3010-03-01
A suspicious noise is generated from the steam path section of the turbine (When the
last row of the blade broken for condensing turbine, the metal colliding noise will
generated in the condenser. If the broken blade damaged the cool-water piping in the
condenser, the conductivity of the condensate will be increased);
The turbine vibration increases suddenly, especially for the blade breakage on the
low-pressure stage, companied with an obvious increase in amplitude.
If the phenomena mentioned above occur during turbine operation, stop the turbine
immediately. After shutdown, open the casing for inspecting. Contact us as soon as
possible on affirmed the blade breakage for repairing. Send the rotor and damaged
component to our company for replacing the blade and rebalancing the rotor, when
necessary. The blade breakage of the middle stage will often damage the adjacent
stationary and moving blade. If the barring cannot be carried out caused by the broken
blade, the rotor should be checked whether it is bent.

Oil-system Fault and Elimination 3-3010-04-01
Oil-system Fault and Elimination

The description in this section is applicable to the normal pressure system with
turbine oil as its working medium and exclusive of high-pressure-fire-proof oil
system.
1. Oil pressure too low

1.1 Accidental leakage of pressure
1.1.1 The check valve of the auxiliary oil pump does not be closed tightly, a part of
oil discharged from the main oil pump drains into the tank through this valve.
If the oil pressure is normal before changeover from the auxiliary oil pump to
the main oil pump, but the pressure dropped after the auxiliary oil pump
stopped, it is mostly caused by the leakage of the check valve.
1.1.2 For the oil system using positive displacement oil pump, the drop of oil
pressure may be caused by excessive bleed-off flow due to improper set of the
releasing valve at the outlet of the pump.
1.1.3 For the turbine equipped with elevated oil tank, the excessive overflow
throughput of the oil tank due to improper governing of the oil inlet valve will
reduce the oil pressure.
1.1.4 For the vertical oil pump mounted in the oil tank, the leakage of the
connecting flange in the discharging piping causes a part of the oil discharged
from the oil pump to inject into the tank.
1.2 Wrong rotary direction of the electric oil pump
1.3 The level in the oil tank is too low. It will cause not only the pressure drop but
also the pressure fluctuation.
1.4 Defect in system arrangement

The oil pressure drops instantaneously when changeover between the main and
auxiliary oil pumps, or oil pressure is in normal during turbine stable operation but it
will drop when the oil-relay acts in large amplitude, even causing the emergency stop
valve closed. In order to avoid these conditions occurring, an accumulator can be
mounted in the pressure-oil or the working oil piping of the oil relay. In this case, the
nitrogen filling pressure must be in conformed to the requirement; otherwise the
accumulator will be in malfunction.
1.5 The normal oil consumption of the turbine set is larger than the rated flow of the
oil pump, causing a drop in oil pressure. The oil pressure is too low after the main
oil pump put into operation in test running. If it has been verified through

examining that the low oil pressure is not caused by the reasons mentioned above,
try to reduce the oil consumption of the system, such as the lubricating oil to the
bearings and gears as could as possible. It is not worked, the oil pump should be
replaced.
1.5.1 Changing the oil pump with a larger one;
1.5.2 Where the main oil pump is driven by the turbine shaft, raise the running
speed of the oil pump through changing the gear ratio of the driving element.
2. Trouble in changeover between main and auxiliary oil pumps

Where the main oil pump is driven by the turbine shaft, after the changeover speed
has been reached in turbine staring, the turbine cannot continue to run when the
auxiliary oil pump stopped. The main reasons are:
2.1 The oil tank position lower than the elevation specified on the layout drawing
increased the suction height of the oil pump or the inlet pressure is reduced due to
the increase in the length of the inlet piping and in the number of the elbows. This
will make the main oil pump suck with difficult and cannot work normally. In the
event that the increase in the oil flow of the oil injector cannot improve the
situation, it is better to modify the suction piping of the main oil pump.
2.2 The bottom valve of the oil injector cannot be opened to the required opening. The
increase in suction loss of the injector causes the main oil pump to suck with
difficulty. Check and repair the bottom valve. Re-filtrate the oil in the tank with a
filter, when necessary.
3. Oil leakage
3.1 Poor sealing caused by the improper assembling of the components or the
improper connection of the oil piping, or sealing surface damage will result in oil
leakage, which will be unveiled in test running. The corresponding treatment
should be carried out according to the examination for the leakage part to
eliminate the oil leakage.
3.2 The oil leakage caused by the worn sealing element during turbine operation can
be handled accordingly based on the component feature. For the devices that can
be repaired in the operation, such as the stop valve and gate valve, if the oil
leakage at the valve spindle occurs, press the seal packing properly. The further
treatment can be carried out when overhaul. When the oil leakage at the shaft seal
of the electric oil pump, which can be switched over in operation, start the spare
oil pump and stop the fault pump for repairing or replacing the damaged shaft seal.
For the component that only can be repaired after the turbine shutdown, such as
the oil relay, should be carefully inspected in regular examination. The oil
penetrating at the piston rod must be taken in account and recorded. If it is

increasing day to day, repair the piston rod or replace the seal element in time,
making the using of the turbine shutdown so as to avoid turbine forced stop due to
the leakage of the oil relay.
4. Oil-piping vibration
The oil-piping vibration that is caused by the improper connection and will result in
turbine vibration is usually eliminated through taking the corresponding measure
when test running. But the other oil-piping vibrations are ignored. For some of the
turbines, the high-frequency vibration of the secondary-oil piping will occur during
operation. For the others, the protective-oil piping vibration will occur when tripping
the turbine. The oil-piping vibration will produce a dynamic load on the piping and at
the connection and welding seam. This will probably cause the restraining force of the
connection reduced and welding seam broken, resulting in oil leakage. Therefore, the
piping vibration must be eliminated in time. The oil-piping vibration is related with
the initial stress of the piping when connected, the velocity and the state of oil flow in
the piping. It can be eliminated through installing proper piping supports in most
cases.

Control-protection System Fault and Elimination 3-3010-05-01
Control-protection system Fault and Elimination

1. Abnormal in opening emergency stop valve
1.1 For the turbine using the starting control to open the emergency stop valve,
improper operating will cause that the emergency stop valve cannot be opened
normally. In the course of the emergency stop valve opening, the starting oil will be
switched to the trip oil. If operate the handwheel of the starting control
continuously at a fast rate the decreasing rate of the starting-oil pressure will faster
than the increasing rate of the trip-oil pressure, so that the piston disk is separated
from the piston and the emergency valve cannot be opened. The proper operation
should be in such a way, observe the pressure gauge while operating the handwheel,
when the trip-oil pressure is built-up and the starting-oil pressure begins to drop,
slow down the operation of the handwheel as could as possible or stop for a few
seconds, then continue to operate until the valve in full open.
1.2 The inner leakage of the oil cylinder will cause that the emergency stop valve
cannot be opened normally. This is because the excessive radial clearance between
the oil cylinder and the piston causes leakage of the starting oil in a large quantity;
the staring-oil pressure is not able to push the piston to the piston disk. In this case,
the trip-oil pressure cannot be built-up and emergency stop valve cannot be opened.
This fault can be removed through repairing, for example, Fitting sealing element
between the oil cylinder and the piston or using a specially mated piston.
1.3 The deposit and bend of the valve spindle will also cause that the emergency stop
valve cannot be opened normally. Therefore, the functional test of the emergency
stop valve should be carried out regularly (see 1-2300- and 1-1400- for details). If
the test-oil pressure rose, the probability is that the deposit of the valve spindle or
oil cylinder or the bend of the spindle exist. In this case, the repairing should be
arranged in time for finding the reason and eliminating it.
In order to avoid the valve spindle being bended, the spare spindle should be stored in
hanging instead of in lying.
2. Oil leakage of oil cylinder for emergency stop valve (leaking out)
2.1 This is caused by the improper assembling of the seal ring. In this case, the sealing
element should be re-assembled and the seal ring pressed tightly. If the wrong size
of the seal ring is used, it must be replaced with the right size one.
2.2 The disalignment of the valve spindle with the bush of the seal element or the
contact of the valve spindle to the sleeve caused by the bended valve spindle can
rough the spindle and damage the seal ring, resulting in the leakage of the oil
cylinder. In this case, repair and replace the valve spindle or sleeve, replace the seal
ring, and reassemble them carefully.

3. Fault of slide valve in pilot valve
The slide valve is formed by the rotating disc and the valve body through sticking (see
1-1910- for details). In some of turbines, the rotating disc can be separated from the
valve bode due to the additional resistant moment of the rotating slide valve or the
decreased strength of the adhesive. The delay rate of the control system will be
increased obviously because the valve body is no longer rotated. When changing the
setpoint of the governor, the oil relay will have no reaction or overshoot in large
amplitude. Meanwhile, the oil overflows from the ventilator. If touch the inlet and outlet
oil piping of the pilot valve with hand, there is no vibration can be filled.
Measure: Stop the turbine in time and replace the slide valve. The replaced slide valve
can be stuck again user himself. Before sticking, clean the solidified adhesive on the
jointing surface with knife and sand cloth. The single-component anaerobic adhesive
with shear strength higher than 14.7 Mpa at room temperature can be chosen as the
adhesive. The sticking operation should be carried out according to the requirement for
the adhesive.
4. High-frequency oscillation of secondary-oil pressure

For the turbine using the hydraulic amplifier, in some times the pointer of the gauge for
the secondary-oil pressure swings, the secondary-oil piping vibrates, the turbine load or
speed fluctuates quickly and without attenuating under a certain operating condition
because of the secondary-oil pressure oscillation. In this case, turn down the one-way
throttle valve in the secondary-oil line or adjust the adjusting valve of the pilot valve to
reduce the rotation frequency of the slide valve for decreasing the amplitude of the slide
valve and eliminating the oscillation of the secondary-oil pressure. The pipe clips can be
mounted additionally for the secondary-oil piping when necessary.
4.1 Turbine cannot be started normally

When starting the turbine with hydraulic or mechanical-hydraulic governor, the control
valve closed suddenly during raising speed, causing the turbine cannot be started
normally. This is mostly caused by the improper setting of the “cut-off point” of the
amplifier. See 1-1830- for details.
4.2 Load (speed) fluctuation

For the turbine using hydraulic or mechanical-hydraulic governor, the un-attenuating
load (speed) fluctuation may occur in some of them during operation. There are many
reasons that can cause the control system unstabilized. Here we enumerate two of them”
4.2.1 The play of the fork of the amplifier caused by the excessive axial clearance at
the joint of the fork and comparison lever can disturb the normal work of the
following-up piston, resulting in ripple of the secondary-oil pressure and
consequently the fluctuation of the load or speed.
Measure: Make-up the washer again in overhaul. The axial clearance at the joint
should be within 0.02 to 0.03 mm, making the fork swing flexibly without play

in axial direction.
4.2.2 For the turbine using PG-PL governor, the unsuitable opening of the
compensating needle valve in the governor to the turbine performance can cause
the control system unstabilized. The needle valve can be adjusted during turbine
operation. The low fluctuating velocity indicates the opening of the needle valve
is too small, turn the needle valve counterclockwise to increase its opening.
While the fluctuating period is very short, the valve should be turn down. The
needle valve should be adjusted slowly and the turbine operation should be
observed when adjusting until the system stabilized. The adjustment of the
needle valve is considered to be in conformed to the requirement, when
changing the setpoint of the governor, the system can react immediately and
after a trifle overshoot it will return to the stable state. Usually, once the needle
valve adjusted, readjusting is not required.
4.3 Electric-hydraulic converter

For the turbine with the electric-hydraulic converter, the output oil pressure of the
converter will drop at the same electric signal comparing to the data measured in
commissioning after turbine has been operated for a period. This is probably that the
inlet oil strainer of the converter is blocked due to the poor cleanness of the oil system.
Measure: After the normal stopping, clean the oil strainer and verify the relationship
between the electric signal and the oil pressure. If the relationship returns normal, it can
be put in operation. And meanwhile, the maintenance of the oil system should be
strengthened for improving the cleanness. If it is still abnormal, try to reset the initial
valve and range of the converter.
When the electric-hydraulic converter fault caused by inner reason occurred during
operation, it is better to stop the turbine and replace the converter with spare one.
Contact to the converter supplier for repairing.

Condensing System Fault and Elimination 3-3010-06-01
Condensing System Fault and Elimination

During the condensing turbine operating, the vacuum drop of the condensing system
often occurs. There are many causes that have influence on the condensing system
vacuum. When the vacuum drop is discovered, find out the reason based on the features
and take the corresponding measures. Some of the main reasons are list below:
1. Interruption of cooling water

If the vacuum inside the condenser becomes zero, meanwhile the exhaust temperature
rises sharply and inlet pressure of the cycling water for the condenser is lost during
turbine operation, it is sure that the cooling water has been interrupted. At this moment,
trip the turbine immediately and close the inlet valve of the cycling water. The
condenser can be supplied with the cycling water only after the condenser temperature
dropped below 50℃.
2. Shortage of cooling water

Under a certain load, the shortage of cooling water will cause an increase in the
differential temperature between the inlet and outlet of the cycling water and a slow
drop in the vacuum of the condenser. This is especially in summer, the required vacuum
cannot be kept even if the cooling-water flow is increased for some of turbines because
of the increased temperature of the inlet cycling water. In this case, the turbine load
should be limited for reducing the exhaust flow and returning the vacuum to the normal
value.
The shortage of the cooling-water flow is usually resulted from the block of a part of the
cooling pipe in the condenser or abnormal operation of the cycling-water pump. If it is
caused by the former, an increase in differential pressure between the inlet and outlet of
the cycling water must be companied with.
3. Water level in condenser too high

When the condensate level in the condenser is beyond the up limit of hot-well nilometer
and a part of the cooling pipes is flooded by the condensate, the vacuum will drop
slowly because of the decrease of the cooling area at the steam side of the condenser.
Under the worse condition, the condensate will enter into the air-bleeding pipe so that
the vacuum drops quickly and the water is injected from the exhaust piping of the air
ejector. The another endanger caused by overtopping water level is to increase the
condensate depression. The overtopping level is mainly caused by:
3.1 Condensate pump fault: Pump or motor fault causes that the condensate cannot be
drawn out. Whether the pump fault or the motor fault can be judged from the change
of the pump discharge pressure of the motor current.
3.2 The cycling water leaks into the steam side of the condenser, caused by the broken
cooling-water pipe or the loose joint of the pipe to the pipe plate. This can be judged

through chemical analysis of the condensate.
3.3 Excessive opening of the recycling valve in the condensate line.
3.4 The check valve at the output of the spare condensate pump is not closed tightly,
resulting in the condensate flowing back to the condenser.
4. Improper adjustment of gland steam

Since the gland steam pressure is too low, a lot of air is inhaled from the rear gland seal
of the turbine, causing the vacuum to drop rapidly.
5. Leakage of vacuum system

The leakage of the vacuum system will cause an increase in the amount of air leaked
into the air side of the condenser, resulting in the vacuum drop due to the overloading
operation of the air ejector. When the vacuum dropped, close the air valve of the ejector
for a short time (less than 1 minutes), if the vacuum of the ejector rises but that of the
condenser continue to drop, indicating that the drop of the vacuum is caused by the
increase of the air leaked into.
If the vacuum drops when the load decreased, while it returns to normal when the load
increased, the drop of the vacuum is usually caused by the leakage at the joint of the
connecting piping for the low-pressure casing.
The leakage of the vacuum system may occur at the following parts: the flange between
the exhaust casing and the exhaust nozzle, the welded junction, the exhaust relief valve,
the drainer, the valve and the joint. To find the leakage requires not only being familiar
with the vacuum system but also being careful and patient. Once the leakage is detected,
handle it immediately.
6. Abnormal operation of air ejector

The abnormal operation of the air ejector in bound to cause the vacuum drop of the
condensing system. When the vacuum dropped during operation, close the air valve of
the ejector for a short time (less than one minute), if there is no obvious change in the
vacuum of the main ejector, the ejector fault is indicated. The abnormal operation of the
air ejector may be mainly caused by:
6.1 The working steam parameter of the air ejector is deviated from the normal value
significantly, decreasing the ejector efficiency.
6.2 The shortage of the cooling-water flow to the cooler caused that the steam in the
drawn mixture of steam and air cannot be condensed completely and a good deal of
steam emerged from the exhaust pipe of the air ejector.
6.3 The cooler was full with water due to the obstructed draining or broken water pipe.

If the second stage cooler is full with water, the mixture of steam and water drains
from the exhaust pipe.
6.4 The drainer fault or loose close of the drain valve caused the air to leak into the air
ejector.
6.5 The improper distance between the ejector nozzle and the diffuser decreased the
capacity of air bleeding. Usually, this will be found and eliminated in test running.
6.6 The steam strainer or nozzle of the air ejector was blocked. It is because that the
steam inlet piping of the air ejector does not blown thoroughly, the impurities enters
into the ejector with the steam to block or even damage the steam strainer, making
the nozzle blocked. This will occur during test running and normal operation as
well.
When the strainer or nozzle blocked, the vacuum of the air ejector drops and the cooler
temperature decreases obviously and the ejector operates with an abnormal sound (the
steam jetting sound lowers and even disappears. When the second stage air ejector is
blocked, a sniffing sound can be heard in the exhaust pipe).
Should the vacuum drop during operation, start the spare air ejector when necessary. If
it is caused by the abnormal operation of the main ejector and cannot be eliminated
under operation, stop the faulty ejector for repairing.

Load Rejection 3-3010-07-01
Load Rejection
The electric load may drop to zero suddenly during the turbo-generator operating, this
is called as load rejection. The load rejection of the turbo-generator should be handled
according to the feature and reason.
1. Load rejection caused by electrical accident

When the generator load rejected and decoupled from the network, the reading in the
wattmeter drops to zero. The turbine speed rises instantaneously and tends to stabilize
after fluctuated for a short time. The control valve closes to the opening of no-load
automatically.
In this case, set the speed setpoint of the governor to the rated speed and adjust the
gland steam, immediately. Cut off the extraction for the extraction turbine and adjust
the recycling flow of the condensate for the condensing turbine. Should the
turbo-generator operate normally, it can be incorporated in power network and loaded
again after the electric fault eliminated.
2. Load rejection caused by electrical accident, turbo-generator stopped due to

control system defect of turbine
wattmeter drops to zero. Turbine overspeed makes the overspeed protection system
acted, the emergency stop valve and the control valve closed, resulting in shutdown of
the turbo-generator.
In this case, in addition to take the measures mentioned in item 1, check whether the
oil supply system operates normally. If there is no other fault, reset the overspeed
protection system and the emergency trip gear. After the control system adjusted,
restart the turbine, raise turbine speed, synchronize and load on.
3. Load rejection caused by electrical accident, turbo-generator stopped due to

protection system defect of turbine
wattmeter drops to zero. After a slight increase the speed dropped with the close of the
emergency stop valve and the control valve, resulting in shutdown of the
turbo-generator.
For the extraction turbine using hydraulic control system, the hydraulic
reference-value relay (see 1-1114-01-xx for details) will act when load rejection. The
improper adjustment of the hydraulic reference-value relay will cause the momentary
oil flow of the working oil to the oil relay too large. Thus the trip-oil pressure is
dropped, making the emergency stop valve and the control valve closed.
In this case, the measure mentioned in item 2 may be taken. At the same time, the

Load Rejection 3-3010-07-01
acting stoke of the lower piston in the hydraulic reference-value relay should be
reduced properly. Where the accumulator is fitted in the working oil line of the oil
relay, check whether the nitrogen filling pressure of the accumulator is conformance
with the requirement. If the accumulator is not provided, mount an accumulator when
overhaul.
4. Load rejection caused by false action of turbine protection system

The generator load is rejected due to the close of the emergency stop valve and the
control valve. The reading in the wattmeter drops to zero, but the current reading is
not zero. The turbo-generator speed keeps unchanged, this indicates the generator is
not decoupled from the electric network. This accident is often caused by the false
action of the emergency trip gear or trip valve (manual or remote).
In This case, the turbo-generator runs in motor mode must not exceed 3 minutes. The
fault should be eliminated immediately, then reopen the emergency stop valve and the
control valve and load the turbo-generator again. If the fault cannot be eliminated in 3
minutes, inform the control room for decoupling and stop the turbine. After the fault
eliminated, restart the turbine.

Preface to section “maintenance” 4-0100-01-01
Preface to section “maintenance”

The section “maintenance” in this Operating Instructions deals chiefly with the
demonstrations and suggestions for turbine maintenance, inspection and repair.
The maintenance of the turbine includes the maintenance when operation and the
protection during shutdown.
The operation maintenance is a regular job for the operator. He should strive for the
turbine operating under optimal state through proper operating with the help of the
monitoring instruments during turbine starting, operating and stopping. In case the
abnormal condition occurs, the operator should make a judgment for fault trend calmly
and rapidly. For the defect that does not endanger safety but can not be eliminated
temporarily, adjust or limit the operating condition of the turbine-set in time and make a
record in details and truth at the same time, which will be taken as the basis for
determining the repairing time and program. For the serious fault under which the
turbine must be stopped immediately, stop the turbine decidedly to avoid the fault
expanding further. In general, the reason causing fault can be divided into two kinds.
One is not influenced by the operation duration, such as the construction quality, the
design and manufacture level, the improper assembling and adjusting in installation and
overhaul, the false operation and etc. The other is related with the operation duration,
such as the normal wear, corrosion, deformation, material ageing, the expiring of the
service life, the deposition and consequent damages, the abnormal disturbance in
operation and etc. Most of problems caused by the first kind of reason (except for the
false operation) will come in light in the test running after installation and overhaul.
Typically, this kind of problems can be handled through “defect eliminating”. From the
second kind of reason and practical experience, it is known that the proper operation and
the careful maintenance will not only enhance the turbine usability, but also prolong the
service life within the expected lifetime. To ensure economic and reliable operation of
the turbine, must pay sufficient regards to the canonical operation during starting and
stopping, the avoidance of the intensive change of the steam parameter deviated from
the normal value, the limitation of the load change-rate, the monitor of the steam quality
and maintenance of the oiliness, scheduled overhaul and etc.
The turbine maintenance also includes the test carried out during operation. Before
testing, the operator must know fairly well about which parameters will change in the
process of the test, so as to avoid mishandling.
Protective care is required during turbine shutdown, so the necessity of protection and
the related measures that may be taken during shutdown are explained here.
Overhaul is to examine and repair the turbine (including the auxiliaries) during
shutdown. A reasonable overhaul schedule is based on the operation supervision and the
fault diagnosis. The operation statue of the turbine-set can be improved and the turbine

Preface to section “maintenance” 4-0100-01-01
efficiency can be enhanced through overhauling purposefully in time and eliminating
the defect founded, replacing the worn parts and leaning the deposit. Also, with such
overhaul, the factors and hidden troubles, which will cause the fault, can be found out
and removed to reduce or avoid stopping. Meanwhile the collected data is useful for
estimating the turbine statue completely. When necessary, amend the operation
procedure accordingly. It has been proved in practice that the careful overhaul is the
absolutely necessarily important measure for insuring the optimum and safety operation
of the turbine.
The necessity and essentiality of the preventative examination in the process of the
overhaul is cognized now days. The examining items and methods during overhaul will
be explained in the following sections to aid to the examinations.
Of cause, to overhaul the turbine-set must be shutdown and the production of the plant
must be stopped. Therefore, the examining items and the schedule should be made out
based on the operation state of the turbine-set and the production schedule in
consideration of the spare-parts reserve, the personnel and the cost, carrying out the
overhaul duly.
After the overhaul, the result should be estimated and the necessary preparation for next
overhaul should be made. When necessary, amend the operation procedure according to
the overhaul result. The overhaul effect must be verified through re-commissioning after
the turbine overhauled.

Checking and Test Schedule 4-0200-01-01
Checking and Testing Schedule

It is an integral part of the turbine maintenance to check and test the protective, safety
and monitoring equipments of the turbine at regular intervals. The table below shows
designation and the period (interval) of the main checking and testing item and the
turbine state when carrying out the checking and testing. Here, the period and state are
represented with following codes:
h: Hourly
d: Daily
w: Weekly
m: Monthly
y: Yearly
The combination of the digit and letter is used, such as 3m, that means every 3 months.
State codes:
A: On start up
B: On shutdown
R: In normal operation
S: After stopped or overhauled
The items listed in the table are not the unique, user can add or omit some items
according to the requirement on his turbine. The condition and the result of the checking
and the testing should be recorded.

Item or Period State Remarks
component name
Leakage of front and d R Under the approximately similar operating condition, the
real gland seals increase of the steam leakage from the gland seal usually
indicates the increase of the radial clearance of the gland
seal. The clearance of the inner gland seal (including the
gland seal of the dummy piston) will change with the
change of the clearance of the outer one. The clearance
increase of the gland seal will increase not only the loss of
the steam leakage but the axial thrust as well. Therefore, the
checking and handling should be made.
Temperature of h R The bearing temperature is continuously recorded or
journal and thrust observed regularly by operator based on the configuration of
bearings the monitoring instrument. If the temperature rises, pay
attention to its change. When the it has approached or
reached to the alarm value, the load must be reduced. When
it reached the stop value, stop the turbine at once and find
out the cause.
Control valve
1.Check freedom of w A/R Change the valve opening through controlling a step change
movement of the actuating command of the oil relay and observe
whether the control valve reacts quickly. For the non-electric
system, briefly operate the accelerator lever on the speed
governor to carry out the test. Any deposit on the valve stem
will be cleaned at the same time.
2.Check tightness B Judge the valve tightness based on the race time.
3.Vlave-stem leakage R If the leakage at the position where the valve stem
penetrates through the valve bonnet, retighten the seal nut of
the valve stem. This should be done under the condition that
the admitted steam pressure has been reduced. The
replacement of the seal ring, if necessary, only can be done
after shutdown and cooled down.

component name
4.Check setpoint and ≥3m S For the turbine operated above 3 months, check the relation
sluggishness between the actuating command (secondary-oil pressure for
non-high-pressure-fire-resistant-oil system) of and the oil
relay travel, the control valve lift after shutdown. Determine
the sluggishness and readjust when necessary.
d R During operation, Check whether the valve opening, the
power (speed), steam flow and the wheel-chamber pressure
change smoothly with the change of the secondary-oil
pressure.
Hydraulic governor S The following examinations should be made after the
governor repaired or turbine overhauled:
1.Check static Check the static characteristic of the control system against
characteristic 0-2500-T.Nr-00, following the method described in 1-1840-.
2.Check the speed Connect the coupling to the driven machine, check the up
regulating range and and low limits of the speed regulating range, and reset them
droop when necessary. Determine the speed droop when the
condition is permitted.
3.Check stability Produce a step disturbance with the accelerator lever and
observe the transition. Under normal condition, the speed
will swing instantaneously and stabilize at the value before
disturbed.
Mechanical-hydraulic s The following examinations should be made after the
governor governor repaired or turbine overhauled:
1.Check static Check the static characteristic of the control system against
characteristic 0-2500-T.Nr-00, following the method described in 1-1840-.
2.Check the speed Connect the coupling to the driven machine, check the up
regulating range and and low limits of the speed regulating range, and reset them
droop when necessary. Determine the speed droop when the
condition is permitted.
3.Check stability Produce a step disturbance with the accelerator lever and
observe the transition. Under normal condition, the speed
will swing instantaneously and stabilize at the value before
disturbed.

component name
Speed transmitter Y R/S The filter of the breather should be cleaned at least once
every year.
Digital governor According to the Instructions of the governor.
Electric-hydraulic Y S Clean the filter after shutdown, as required.
converter Determine the characteristic once every year, mainly for the
relation between the electric signal and the secondary-oil
pressure.
Adjust the initial value and the range of the secondary-oil
pressure, when necessary. In case of fault, it is better to
replace it with the spare one, and then contact with the
supplier of the converter for repairing.
Oil relay D R Check for leakage.
Breather of pilot valve 6m R/S Clean the filter of breather.
Test valve of 3m R The test must be done periodically, no matter where the test
emergency stop valve valve is mounted, in the trip block or the piping. Compare
the measured test pressure P2 (see 1-2300-) with that
recorded in commissioning, if P2 increases, the
corresponding handling should be made during overhaul.
Teat valve of 3m A/R During start-up or operation, check for proper functioning
emergency governor of the emergency governor using the test valve (see
1-2810-).
Functional test for trip S/A/B Before turbine start or during starting or stopping, check for
components proper functioning of the trip action through operating the
trip device manually (such as manual stop valve,
remote-controlled stop solenoid valve, emergency trip gear
and etc.).
Extraction stop valve S After shutdown, check whether the open and close of the
controlled and non-controlled extraction stop valves are in
normal when the oil system is still running. Before testing,
it must be ensured that the isolated valve in the live steam
line has been closed.

component name
Speed measuring 3m R Check the speed measuring instruments for monitoring in

instruments operation, including the speed indicators on the instrument
panel, digital governor and speed monitor, with manual
speed measuring instrument.
Pressure measuring 6 S For the turbine operated above 6 months, verify all of the
instruments pressure gauges and switches after shutdown.
Exhaust safety valve Y B Check whether the action of the safety valve is conform to
the requirement through raising the exhaust pressure in the
process of stopping, at least once every year.
Casing expansion d A/R/B Check the axial expansion of the casing during starting and
stopping and load changing. The casing can move freely
and smoothly with respect to the pedestal. The bolt washer
of the casing-bracket must always be easily movable. There
is a clearance between the washer and the bolt head should
amount to 0.10 mm.
The casing temperature (average temperature) can be
calculated approximately form the axial expansion of the
casing
Vibration monitor The shaft vibration must be monitored when starting or
1. Monitoring shaft D A/R/B stopping the turbine. The change of the vibration should be
vibration recorded with a recorder.
During long-term operation, provided that there is no
change or very small change in vibration under the same
operating condition, the turbine operation can be considered
in a good state.
To judge whether the vibration is in normal or not, pay
attention firstly to the deviation from the normal value, then
the actual amplitude.
2. Calibration 6m S For the turbine operated above 6 months, calibrated the
sensor with portable calibrator.

component name
Monitor and verify of d A/R/B The continuous monitoring of the rotor axial position may
monitor for rotor axial indicate:
position The thrust direction of the turbine rotor;
The displacement caused by the worn thrust bearing;
The elastic deformation of the thrust bearing and the
pedestal.
Under normal condition, the rotor position should be the
same under same operating condition.
The axial displacement monitor can be calibrated with the
same calibrator at the time when the vibration sensor
calibrated.
Oil system See 4-0400-
Grounding brush d R Check for the wear of the brush through view window,
replace it following the instructions in 1-7650, when
required.

component name
Overspeed trip test of 3m* B/S The reliability of the overspeed trip for the emergency
emergency governor governor is dependant on the flexibility of the eccentric bolt,
(For turbine without which may be locked by following causes:
test valve) Scraped sliding surface of the eccentric bolt;
The oil contains water or other causticity substance;
The oil contains foreign impurities;
The part is damaged by the shaft current caused by invalid
brush or without mounting the brush;
Improper operation in supplementing oil, the oil mud
separated out the oil is deposited in the emergency governor.
To ensure the reliability of the emergency governor, the trip
test of the emergency governor should be made under
following conditions:
After turbine overhaul;
After the emergency governor dismounted and adjusted;
Restarting after shutdown for a month;
* After the turbine operated for 3 months.
* After the turbo-generator operated for 3 months, the
overspeed trip test should be made when the turbine-set is
connected from the net.
For the turbine driving compressor or pump, when it
operated continuously above 3 months, disconnect the
coupling between the turbine and the driven machine and
carry out the overspeed trip test of the emergency governor
after shutdown.
For the test method and requirement, see 3-1400-.
The turbine-set cannot be put into operation when the
emergency is abnormal.

Protection during Turbine Shutdown 4-0300-01-01
Protection during Turbine shutdown

The turbines are constantly being taken out of service for shutdown of varying duration
due to various reasons. After shutdown the turbine will suffer the damage caused by the
corrosion under the action of the internal and external factors. Therefore, some
necessary provision must be made for internal corrosion protection during turbine
shutdown.
The corrosion of turbine interior can occur in a few days after the turbine has cooled.
For example, the blade can be corroded because of the presence of salt deposit in
conjunction with moisture. Such shutdown corrosion will not only produce chemical
corrosion on the scatheless blade but also cause secondary corrosive damage of the
corroded parts, resulting in an obvious decrease in the endurance limit of the blade.
Therefore, the protective measure must be taken even for short shutdown.
For the condensing turbine that will not be restart immediately after shutdown, make the
turbine interior as dry as possible through proper operation in stopping. This is one of
the protective measures in common use.
For long-term shutdown (for turbine overhaul or seasonal shutdown), one of the
necessary protective measures, without opening the casing, is to block the steam inlet
and outlet of the turbine for separating the turbine from the steam and condensing
system and avoiding the steam and vapor entering into the turbine. However, This can
not remove the possibility of the corrosion inside the turbine, because the temperature
of the parts inside the turbine will change with the ambient temperature in the workshop
(see Fig 1). The volume of the air contained inside the casing will change with the
change of the temperature. The interchange will occur between the airs inside the casing
and the exterior through shaft gland and other openings. Fig.1shows that the casing
(including the rotor) temperature is always lower than the temperature of the external air
entering into the casing within a larger range. It will transfer the heat to the turbine parts,
so that the air temperature will drop below the dew point forming water drops under
corresponding relative humidity, which supplies a prerequisite for corrosion. The test
also indicates: when the relative humidity is less than 60%, the corrosion rate for steel
decreases rapidly (see Fig.2). When the relative humidity is less than 35%, the corrosion
rate becomes zero soon. The polished surface of steel will not be rusted for a long time
at a relative humidity less than 35%. Therefore, to avoid corrosion of the turbine interior
during shutdown, the air inside the casing must be kept at a relative humidity less than
50%.

Fig. 1 Temperature change inside workshop and turbine in three days
Fig. 2 Corrosion rate for steel versus relative humidity
Hot air method

This is easy and efficient method for reducing the air humidity inside the casing. The
hot air is injected into the turbine to reduce the air humidity and dry the parts inside the

casing. At the time when the hot air absorbs the moisture inside the turbine the inner
parts is heated by it and remain at a temperature higher than the ambient temperature.
The hot air should be injected from the lowest point (e.g. connection of the gland steam)
of the turbine as could as possible and is discharge via the shaft gland and opened drain
ports. To ensure that the air discharged at the remotest point is 8 to 10 ℃ above the
ambient temperature, the flow and temperature of the air injected should be regulated as
required.
Nitrogen method
Fill the casing with inert gas, such as nitrogen, for protecting corrosion..
Before filling nitrogen, dry the turbine interior first and then close the steam and drain
connections tightly and seal off the lead-throughs of the shaft gland and valve stem with
airproof tape carefully. The nitrogen may be injected into the casing from the exhaust
casing or a drain port. The nitrogen pressure inside the casing should be kept at 0.5 to 1
Mbar.
Before restarting the turbine protected with nitrogen, the nitrogen inside the casing must
be vented thoroughly.
The nitrogen content in the air under normal condition is 78%. When it is higher than
84%, it will be harmful to human. So the measure must be taken in using the nitrogen
method for preventing accident
Protective coatings
For the turbine stopped not for overhaul, the application of the protective coatings only
can be used if the casings are opened.
Coat the surfaces of the parts inside the casing with antirust oil according to the
instructions for antirust oil.
Should the rotor coated with antirust oil still rest on the bearings, the oil film at the
journals will break or be squeezed out under the action of the rotor weight and outside
force (e.g. the foundation vibration), resulting in journal rusted. So it is better to lift out
the rotor from the casing and rest it on the special pedestal after coated with antirust oil.
The protection effect can be inspected regularly, because of the opened casings.
Protection of other components

For the turbine that its oil system can still run after shutdown, run the oil system for 1 to
2 hours every two weeks, making the part surface contacted with the oil be covered with
a layer of oil film having the protective function.
For the turbine that its oil system cannot run after shutdown, when the expected

shutdown duration exceeds 1 month, dismount the bearings and clean them with
cleaning liquid, such as gasoline, dry and coat them with antirust oil, then mount them
again. Should the shutdown duration exceed 3 months, the coating protection should be
taken for components of controlling and protective system (governor, oil relay, oil
cylinder of emergency stop valve, emergency trip gear and etc) and the gearbox of
driving element, especially for the turbine located in south and rainy region.
If the shutdown duration is less than 3 days, the cycling water for the cooler, such as
condenser, oil cooler and etc, may not be interrupted, otherwise, it should be cut off.
Drain away the water in the water chamber, make the walls of the water chamber and
piping as dry as possible. The accumulated water inside the equipments and piping must
be drained away to avoid the damage of equipment caused by freezing during shutdown
in winter.

Maintenance of Oil System 4-0400-01-01
Maintenance of Oil System

During turbine-set operation, the check should be made for operating state of the devices and
the oil quality in oil system following the operation procedure.
1. Oil level in oil tank

The oil level in the oil tank not merely indicates the amount of the filled oil but from which
change the troubles appeared in oil system can be found. A drop of oil level will indicate a
leak-out is existed in the oil system, e.g. opening of the drain valve by mishandling, break of
the cooling piping in the oil cooler and etc (Usually, the pressure at oil side in the oil cooler is
higher than that at the water side, so that the oil will be found in the outlet water of the oil
cooler when the cooling piping broken or the expansion joint loosen). An insufficiently high
oil level is likely to cause irregular operation of the oil pump due to increased bubbles in the
oil with the decreased circulating ratio and consequently disturb the normal operation of the
bearings and control system. Therefore, the reason should be found out when the oil level
dropped and the same brand of turbine oil should be filled up when required. When the water
entered into the oil and the air separation capacity of the oil decreased the oil level will be
rose. With too high an oil level, the return-oil port of the oil tank is flooded partially, the
ventilation spaces of the oil tank and bearing house is reduced, resulting in oil returning
difficult and oil leaking at the seal ring of the bearing housing. At the same time, part of the
turn-oil will flow over the partition wall entering directly into the oil tank without filtered,
increasing the impurities in the oil. When the oil level rose, the cause must be found out and
the corresponding measures must be taken.
2. Oil temperature and oil cooler

The rise in outlet oil temperature of the oil cooler is bound to increase the temperatures of the
inlet oil to each bearing and whole oil system. It is required to increase the opening of the
water inlet valve for increasing the cooling water flow to the cooler water when the outlet oil
temperature of the oil cooler rose, maintaining it within the normal range. If the oil
temperature does not lower obviously after the opening of the inlet valve has been increased,
it is likely caused by insufficient water supply or severe deposit in the oil cooler. Usually, the
drop of inlet water pressure or the increase of the temperature difference between the cooling
water inlet and outlet will indicate the insufficient water. If the deposit appears at the oil or
water side of the piping in the oil cooler, the heat transfer coefficient will be reduced, causing
the effect of the heat transferring worse. This will be bound to increase the temperature
difference between the inlet water temperature and the outlet oil temperature. For the rise of
the oil temperature caused by the former, the reason should be found out to insure the required
water flow. If it cannot be solved in time, the turbine must be operated under reduced load.
Should it be caused by the latter, switch the oil cooler and clean the deposited one.
Where the temperature of the cooling water changes with the change of the ambient
temperature, the cooling water flow to the oil cooler is small, at a slow velocity of flow in the
cooling piping. In order to avoid and reduce the settlement of the feculence in the piping,
further open the inlet valve at least once a time every day for about 10 minutes to flush out the

deposits that may be settled in the piping with the cooling water at high velocity.
3. Check for leakage of the system during regular inspection
4. Check for operation of the oil pump during regular inspection. Start the auxiliary and
emergency oil pumps periodically for functional examination.
5. Check the filling pressure of the nitrogen in the accumulator periodically.
6. For the system with the ventilator, check the vacuum in the oil tank periodically. The
vacuum in the oil tank and the return-oil header should be kept at 5 to 10 mm WS. A too
high vacuum will cause a large amount of dust and water vapor to be imbibed into the oil
system.
7. Oil quality
The reliable operation of the turbine is closely related with the usability of the oil system,
which is mainly affected by the oil quality.
The reasons that will cause the oil quality dropped and deteriorated are: gaseous, solid, and
liquid pollutions.
Gaseous pollution:
The main and frequent gaseous pollution is the oxidizing action. During using, the turbine oil
will contact with the air ceaselessly and make oxidizing reaction continuously. The water or
the metal particulates, if there is any contained in the oil, will has a catalysis on the oxidizing
reaction. The oxidizing action will translate the hydrocarbon molecule into acid, raising the
acid number of the oil, which will increase the corrosion action. The oxide will form jelly or
solid leavings to increase the viscidity, to block the oil passage, baffling the normal operation
of the hydraulic elements. Along with the increase in the oxidizing degree, the oil color will
become dark and turbid, the transparence of the oil drops. In addition, for the turbine driving
the compressor, the leakage of the process gas (such as ammonia, sulfureted hydrogen and
etc.) of the compressor under failure also will pollute the oil and deteriorate the oil quality.
In order to improve the antioxygenic property of the turbine oil, antioxidant, such as butylated
hydroxytoluene (T501) is added in the oil, which will restrain the oxidizing action, reducing
the oxidizing rate of the oil and prolong the oil service life. The T501 content in the new or
regenerated oil should not be lower than 0.3 ~ 0.5% (mass ratio), while the T501 content in
the operating oil should not be lower than 0.15%. When it is lower than 0.15%, the oil with a
PH number above 5.0 should be supplemented.
Solid pollution:
The solid impurities in the oil will speed the ware and make the oil thick, blocking the filter
and oil passage. Furthermore, the solid contaminations will reduce the air separation ability of
the oil, resulting in the oil being oxidized easily.

Flushing of the oil system must be carried out after installation or overhaul (see 3-0340-xx-xx
for details). The solid contaminations, such as scrap, foundry sand, welding spatter, metallic
oxide, paint film, fabric fibre, in the oil can be cleaned off through oil circulation. However,
the flushing of the oil system may be not thorough, resulting in the solid contaminations still
remaining in some components and piping, which will interfuse into the oil under the action
of the vibration, change of the oil temperature and flow rate after the turbine put into the
operation. Additionally, abrasive dust produced by wearing parts of the gear and bearing and
the dust inhaled from the air will also worsen the oil cleanliness and consequently the oil
quality.
During operation, the solid contaminations are mainly cleaned off with the oil filter. Under
normal condition, the filter element must be cleaned in time when the oil pressure difference
between the inlet and outlet of the oil filter approached its up limit. For the newly installed
turbine, it is better to clean the filter once a week at least in the initial stage of operation.
Liquid pollution:
The moisture pollution is a main liquid pollution. The moisture makes the acid out of the oil
and become chemical soap that has strongly corrosive action. In this case, the oil is emulsified
to greasy stain, blocking the oil passage. In addition, the mixture of the other brand of oil in
the turbine oil will also worsen the oil quality.
Usually, the water will enter into the oil mainly under the following condition: the leaking
steam from the turbine shaft gland enters into the oil system through the bearing house; for
the oil system with a higher pressure at the water side than that at the oil side in the oil cooler,
the cooling water will enter into the oil system through the oil cooler when the water piping
broken of the expansion joint loosen; for the turbine using filling air structure at the seal ring
of the bearing house, the water will enter into the oil system when the filling air without
depurating contains water; the water vapor is inhaled into the oil system with the air.
Under normal condition, the water entered into the oil will be separated soon and settled at the
bottom. Find out from whence the water comes through assaying the water drained from the
oil tank and take the measure based the assaying result.
For the turbine with oil containing water, the antirust additive T746 may be added in the
turbine oil with an amount of 0.02 ~0.03% of the oil amount (mass ratio).
The oil quality will be changed during turbine operation, so that examination of the oil must
be made periodically. For standard on turbine oil quality, see 3-0320-xx-xx. When necessary,
purify and regenerate the oil. If it cannot reach the requirement after that, the oil should be
changed.
The main cause to affect the oil service life is oxidizing action. The oil should be changed
every 2 or 3 years at an operation temperature about 50℃. The period of oil change should be
shortened at a higher temperature.

8. Requirement of supplement oil
For the turbine having been put into operation, when the oil level in the oil tank lowered, it is
required to supplement the same supply and brand of oil with the same additive as the
working oil. The property indexes of the supplement oil (new or treated used oil) should not
be lower than that of the working oil. Should the amount of the supplement oil exceed 5% of
the working oil quantity, the mixing test with the sample in pro rate should be made before
supplementing oil to the oil tank. The oil supplement only can be carried out if it is sure that
no deposit produced, so as to avoid the oil sludge being separated out after oil supplemented.

Deposition of Steam-path Section and Cleaning 4-0600-01-01
Deposition of Steam-path Section and Cleaning

The steam admitted into the turbine always carries, more or less, some impurities,
which will adhere to and settle on the blade surface to form a deposit during flowing
with the steam. The layer of the deposit will greaten surface roughness of the blade,
alter the blade profile, narrow the steam path and consequently decrease the turbine
output due to reduced steam flow and efficiency. Besides an increase in the axial thrust,
the deposit on the blade not only increases the flexure and centrifugal stresses of the
blade but also corrode the blade resulting in blade service life shortened. Meanwhile,
the deposit on the valve stem spindle is likely to cause the emergency stop valve and
control valve stuck. A great deal of turbines operating experience has shown that the
deposition of the steam-path section impairs not only the economical operation but also
the safety and reliability of the turbine. Therefore, it must pay enough attention to the
control of steam quality. The steam quality will be affected by various factors. It is
mainly related with the treatment of the boiler water and feed water and the operation of
the boiler with the given boiler type and inner devices. The steam quality can be
enhanced through perfectly treating the water and properly operating the boiler. Of
course, the perfect treatment of the feed water requires a certain cost, especially for the
turbine that needs a large amount of the supplement water. However, if only the turbine
output is sought for but the control of the steam quality omitted, the result should be not
worth the candle.
The increase of the steam quality may prolong the efficient operation duration of the
turbine. However, the in the turbine is unavoidable. The extent of deposition of the
steam-path section can be judged though monitoring the chamber pressure (see 3-2010-
for details). When the chamber pressure exceeds the permitted value, the cleaning
should be carried out in time.
Based on the deposit components, which are related with the feed water quality and
treatment equipment and technics, various methods may be adopted in leaning the
steam-path section. In the most cases, the deposition includes salt and silicon deposits.
The salt deposit mainly contains NaCl, Na2So4, silicate and etc, which are soluble in
water, while the silicate deposit contains insoluble SiO2，SiO2 with different crystal
structures and very strong depositing potency. Its deposited layer is very hard.
Usually, the method of manual cleaning, flushing with wet steam or chemical flushing is
used in cleaning the deposition.
When the manual cleaning method is used during turbine overhaul, lift out the rotor and
place it on the supports prepared. Firstly, flush the rotor with high-pressure water or
solvent, and then remove the deposit manually with scraper and sand paper. It should be
careful so as not to damage the blade when doing so.
Flushing with wet steam is one of the common cleaning methods. The saturated steam

produced by the cleaning device (temperature-decreased pressure reducer) is led in the
turbine under operation state for flushing the deposits. The salt deposit will be removed
by the condensate in the wet steam. For the deposit formed by the compound of salt and
SiO2, after the soluble compound has been flushed off, the layer of insoluble SiO2
deposit will be consequently disintegrated and removed.
In some cases when the flushing with wet steam cannot clean the silicon deposit
efficiently, the chemical flushing should be used. With this method, the chemical, such
as NaOH solution, is added in the flushing steam. Owing to the generation of Na2Si2O5
resulted from the reaction of the NaOH and SiO2, the silicon deposit can be removed.
Since the chemical will corrodes the turbine components, the concentration of the
additive and flushing temperature should be strictly controlled. Furthermore, the turbine
should be flushed with pure wet steam again after chemical flushing to avoid the
residual additive corroding the blade.
In order to prevent the deformation of the casing, the casing temperature should be
reduced to the temperature of the flushing steam before flushing. If the operation
condition permitted, reduced the inlet steam parameters gradually in the process of
unloading and stopping to decrease the casing temperature. This may shorten the
cooling time of the casing before flushing.
In order to reach the good effect n flushing, the saturated steam admitted into the turbine
should not be throttled, namely the nozzle controlling valves should be fully opened
(the valves 1st to 4th are nozzle controlling valves for most of the turbines).
The turbine speed when flushing is decided based on the actual condition. It may be any
speed between the rated and governor lower limit speeds.
During flushing, regularly sample the condensate for chemist analysis, sampling at the
drain port of the exhaust piping for backpressure turbine and the discharge of the
condensate pump for condensing turbine.
In order to keep the validity of the flushing, it is required to adjust the parameter of the
flushing steam continually. This is because when the temperature in the steam-path
section reached the temperature of the saturated steam, the steam cannot be condensed
to generate the condensate on the blade surface so that the flushing action is weakened.
Therefore the temperature and pressure of the flushing steam should be adjusted in time
during flushing based on the analysis result of the condensate.
The draining in the process of flushing must be thorough, closely monitor the turbine
speed, listen in the sound from the turbine, preventing water hammer.
After flushing, the turbine interior should be kept dry and start the turbine as early as
possible to prevent the corrosion during shutdown.

After the turbine has been put into operation again, assess the flushing effect based on
the chamber pressure.
The flushing under load for the turbine driving the generator may be carried out
according to the “turbine operation procedure” prepared by ministry of electric power.
For the turbine driving the machine, it is recommended to flush the turbine after the
driven machine is separated from the process.
For the user lacking of the experience in turbine flushing, especially for the chemical
cleaning, it is better to flush the turbine together with the professional cleaning
company.

Types of Overhaul 4-1000-01-01
Types of Overhaul
Based on the range and work amount of inspection and maintenance involved in the
overhaul, the turbine overhaul can be divided into four types, i.e. minor overhaul,
intermediate overhaul, major overhaul and componenet overhaul. However, the
overhaul mentioned in this Operation Instructions does not including the repair after the
event (the overhaul after the forced outage).
Minor overhaul
The minor overhaul is an overhaul method, which will spend shorter time with smaller
amount of inspection and repair. It is not required to open the turbine case. The minor
overhaul is basically restricted to the inspection and repair of the individual item
external casing and determined in advance, such as the inspection of the bearing and
coupling, measurement of the alignment, the visual r examination of the gear, the reset
of the controlling and protective systems, the checkout of the operating instrument and
etc. It mainly involves the examination and treatment aimed to the defect that is
discovered in operation and does not require forced outage. The forced stop of the
turbine can be avoided through such minor overhaul.
Usually, the minor overhaul is carried out on schedule as necessary. In some cases, it
might be possible to make use of a shutdown caused by other device of the plant..
The inspection and test data and experience got in the minor overhaul can be used as the
reference for the intermediate and major overhauls.
Intermediate overhaul
The intermediate overhaul is carried out during a planned shutdown of the turbine. The
work is approximately the same as for the minor overhaul but the percentage of
involved item is greater, e.g. radial runout checks, axial displacement check with thrust
bearing removed, check and measurement of rotor alignment to casing without opening
the casing.
Usually, the casings are not opened this overhaul. However, should the intermediate
overhaul be combined with a componenet overhaul, opening of the casing may be
required.
The inspection and test data will provide detailed information for the next overhaul.
Major overhaul
The major overhaul requires a planned shutdown of the turbine. The duration of the
shutdown will depend on the size of the turbine, the amount of labor available and the
diathesis of the service personnel, the overhaul schedule, the local conditions and the
availability of spares.

Types of Overhaul 4-1000-01-01
This overhaul involves the dismount of most components and detailed inspection and
repair of all components and all auxiliaries of the turbine (e.g. casings, rotor, bearings,
piping and etc.). it enables an assessment to be made of the condition of the equipment.
The damaged or worn the parts can be replaced by spares.
Should the turbine be renovated during major overhaul, the overhaul only can be carried
out when the substitutions has been got, so as to carry out the overhaul on schedule.
Modular overhaul
The modular overhaul is mainly to check and repair the turbine components, such as
main oil pump, governor, controlling valve, emergency stop valve, steam chest,
guide-blade carrier, seal gland and etc.
The modular overhaul may be carried out together with the intermediate overhaul.
The modular overhaul may be considered as the staged overhaul. It is very useful for the
turbine that cannot be stopped long time for overhaul due to the production.
During overhaul, the casings may be opened or not as required.
The detailed inspection in the process of overhaul, please refer to 4-1100- and 4-1200-.

Inspection during Overhaul 4-1100-01-01
Inspection during Overhaul

During an overhaul the precautionary inspections for the defects should be performed so
as to discover and eliminate the hidden troubles as soon as possible for preventing fault.
The following are the principal methods for the inspection and testing of the turbine
parts (including the auxiliary components). Being convenient for illuminating, they are
identified by the various codes.
A. Function test
This is an inspection and testing method for the components such as governor,
emergency stop valve, pump control system and etc, in order to ascertain what checks
and adjustments are necessary.
B: Visual inspection
-- Appearance inspection by eye or optical device with good illumination.
-- Inspection with a microscope for determining the nature of damage.
-- Inspection with endoscope, together with the camera or vidicon, especially for
inaccessible part surface, such as control valve seat, inner wall of the piping in cooler.
-- Inspection of the surface roughness of the part.
C: Surface crack testing

-- Chalk test
-- Magnaflux test
-- Ultrasonic test
-- Eddy-current test
D: Ultrasonic testing
E: X-ray testing
H: Sounding testing
Excitation by a blow from a tool and judgment of the defect from the sound produced.
I: Measurement of wall thickness
K: Measurement of dimension and shape

-- Measurement of length, for checking relaxation, ovality and etc.
-- Measurement of runout, for checking the distortion of the rotor.
-- Gauging of components for actual shape, for checking bending angle, parallelism of
the flanges and etc.
L: Other nondestructive testing

-- Examination of grain structure of the part surface with “print” method.

-- Hardness testing.
-- Spark test for material identification.
O: Static and dynamic balances
P: Pressure testing
Pressure or leak testing with water or working medium for checking tightness.
R: Testing of insulation and earthing of shafting system by measuring resistance
T: Sampling analyzing test.
The followings are required to consider in determining the method and range of
the testing.
1. Lift time of the equipment
2. Operation mode (stable or frequently changed operating condition)
3. The experience from a comparable machine
4. The data from the fault
5. Structure and type of the turbine
6. Operating parameters (steam, output and etc.)
7. The abnormal conditions occurred in operation by accident (quick drop of
temperature, overspeed and etc.)
The following table lists the item and method of testing for main components of the
turbine. Here, the testing item means the defect to be found out. The overhaul type is
identified with code:
1—Minor overhaul; 2—Intermediate overhaul;
2—Major overhaul; 4—Modular overhaul.

Component Testing item Testing Overhaul Remarks
method type
Outer casing Intern. And ext. cracks, B,C,E,K 3 Inspection of
(including admission distortion, erosion, corrosion, mating and
chest and emergency leaks sliding surfaces
stop valve shell)
Seal ring of L-shaped Abrasion B,K 3
cross section
Inner casing
Intern. And ext. crack, B,C,K 3
distortion, erosion, corrosion,
Steam chest (Nozzle leaks
box) Distortion, abrasion B,C,K 3
Inner gland bush
Outer gland bush Distortion, abrasion B,K 3
Distortion, abrasion B,K 3
Valve seat Deposits, corrosion, erosion, B 3, 4 Functional
mechanical damage testing before
Valve cone Deposit, corrosion, erosion, B 3, 4 and after
mechanical damage overhaul
Valve stem Mechanical damage, permanent B, C, K 3, 4
distortion, cracks
Valve gland Mechanical damage, corrosion B 3, 4
Steam strainer Mechanical damage, deposit, B, K 3, 4
distortion
Oil cylinder Abrasion, deposit, leak B, K 3, 4
Valve bonnet Damage on sealing faces, crack B, C 3,4

method type
Control valve (EB1)
Valve seat Deposit, corrosion, erosion, B 3, 4 Functional
Deposit, corrosion, erosion, testing before
Valve cone mechanical damage, abrasion B 3, 4 and after
Valve stem mechanical damage, deposit, B, C, K 3, 4 overhaul
crack, distortion
Valve beam Abrasion B 3, 4
Valve bonnet and Sealing faces, leak B 3, 4
sealing element
Joint Abrasion, rust B 2, 3, 4
Oil cylinder Abrasion, mechanical damage, B, K 2, 3, 4
leak
Split bolt Distortion, crack, mechanical B,C,D,K 3
damage
Nozzle Deposit, erosion B,T 3, 4
Guide blade Deposit, radial displacement, B, K, T 3, 4
erosion, scrape
Rotor (shaft) Scuffing B 3, 4 Attention to
Crack B, C 3, 4 checks of
Flexural distortion B, K 3, 4 shoulders and
Abrasion and electron erosion B,C,K,R 1,2,3,4 relief grooves on
of journal and thrust collar the shaft
Corrosion B 3, 4
Dynamic balancing D 3, 4
Radial and end-face runouts at K 2, 3, 4
rotor ends
Changes of alignment and axial K 2, 3, 4
displacement

method type
Ratchet, gear or Loose B, D, H 3, 4
impeller of barring Mechanical damage B, K 3, 4
gear Crack B, C 3, 4
Moving blade Deposit B, T 3, 4 Including the
Corrosion, crack B, C checks of blade,
Displacement B, K shrouding, tie
Scrape B, C, K wire, taper pin
of root, blocking
screw of last
blade and etc.
Coupling Loose B, D, H 3, 4 Rigid, gear or
Crack B, C 3, 4 flexible coupling
Backlash K 2, 3, 4
Radial and end-face runouts B, K 2, 3, 4
Distortion and damage of bolt B, K 3, 4
and bolt hole
Bearing Mechanical damage, abrasion B,K 1,2,3,4
Electron erosion B.R 1,2,3,4

Cavitation B.D 1,2,3,4
Corrosion
B.C 1,2,3,4
Bond
B 1,2,3,4
Crack
B,C 2,3,4
Babbit separation
B,D,H 1,2,3,4
Deposit
B 1,2,3,4

method type
Gearing Tooth flank bedding pattern B, K 1,2,3,4
Change in clearance B, K 2,3,4

Abrasion or bond B 1,2,3,4
Pit corrosion and crack
B, C 2,3,4
Electron corrosion
B, C, R 1,2,3,4
Plastic distortion
B, K 1,2,3,4
Turbine exterior and Surface crack B,C,I,L 3, 4 Including checks
steam piping of turbine Permanent distortion B, K 3, 4 for piping,
body Change in support position B, K 2, 3, 4 connection,
Non-straightway draining drain port,

B 1, 2, 3, 4
Pre-stress, tightness exhaust nozzle,
B, K, P 2, 3, 4
especially for
supporter and
hanger, welding
seam and flange
Oil piping Leak B, P 1,2,3,4 Including checks
Crack B, C 3, 4 for piping,
Corrosion, deposit B 3 valve, fitting and
Tube.
Attention to
fireproofing
requirement

method type
Heat exchanger Flow A,B 1,2,3,4
Condenser Leak B,P 1,2,3,4
Oil cooler Corrosion B 3,4
Deposit B 3,4
Loose and crack of expansion B,C 3,4
joint
Damage of protection film on B 3,4
piping wall
Pump Functional disturbance A 2,3,4
Mechanical damage B 3,4
Cavitation B, C 3,4
Abrasion B, K 3,4
Corrosion B, C 3,4
Loose impeller B, K 3,4

Inspection Scope and Cautions during Overhaul 4-1200-01-01
Inspection scope and cautions during overhaul

Final readings of all operating data at various loads should be taken prior to shutting
down the turbine. After the coastdown time and the characteristic of cooling process
have been measured it is essential to measure the alignment between the turbine and
driven machine. Check the following before dismantling the machine:
Coupling assembly and clearances
Deposit in the half-coupling
Axial relative position of the coupling sleeve
Alignment of the rotor to the bearing housings and outer casing
Relative position of the pedestal to the casing
Axial positioning dimension of the rotor in relation to the casing
Axial movement of the rotor with the thrust bearing removed
Generally, the control-oil and lubricating oil piping are not required to dismantle so as
to avoid readjustment of the throttle valve, entering of the dirt into the system and
leakage when restarting up after the overhaul.
When lifting the top half of the casing it is essential to check that all of the split bolts
have been removed and that the guide bolts have been fitted. During dismantling, all
important components should be marked or documented (including sketches or
photographs) so that a subsequent reassembling in every details in always possible.
When opening up the machine take particular notice of any wear and deposit. If there
is any visible sign of leak on sealing surface found, it is necessary to check the
flatness and opening of the mating surfaces by means of blueing, taking leads or using
feeler gauges.
Very accurate records must be taken of any deposit on the blade and its position in the
turbine. Sample should be taken and analyzed to determine under which state
(running or shutdown) and with which method (steam flushing or chemical cleaning)
in cleaning deposit.
For the damage caused by solid foreign matter, it is necessary to specify the
cleanliness of the steam system besides checking of the steam strainer and etc.
Bearings, journals and oil seal rings should be inspected visually for damage.
A close check for the grooves in the gland bush or the shrouding can provide
important clues to the running state of the rotor during startup and operation. It also
indicates the presence of any distortion of the rotor and casing. The required clearance
and alignment can be gained through analyzing.
Worn or corroded sealing strips will indicate the maloperation during stopping and

startup, e.g. starting up while the rotor is still distorted after a brief shutdown, the
leakage of wet steam into the turbine when shutdown, the action piping force or
moment, the movement of the pedestals.
The admission section, beginning with the steam strainer, must be inspected very
carefully for damage. The working reliability of the emergency stop valve and the
operating performance of the control valves must also be checked closely.
The moving and fixed blades should be examined thoroughly, cleaning the deposit on
the blade surface if there is any. The cleaning process is also an essential preparation
for crack testing (magnetic or dye-penetration testing).
The adjusting elements of the guide-blade carriers should be inspected closely. From
the measurements of the relative position of the supporting surface and casing split to
the guide-blade carrier the clearance and adjusting value can be obtained. The guide
elements of the bearing housings, casing and carrier should also be checked. An
assessment of their condition can be made through clearance measuring.
The checks described above provide the findings from which the decisions on the
repairs, modifications and spares required can be taken.
After all the checks and necessary corrective work have been carried out, the
reassembly can begin. Special care must be taken with the lifting or the rotor, the
measurement of the clearances and the reassembly of the bearings.
Another important aspect of the work is the measurement of the relative position
between the individual sections of the plant:
Turbine to turbine
or turbine to gearbox
or turbine to driven machine
or gearbox to driven machine
In calculating the alignment valve and correcting, the relative movement between the
sections of the plant during operation must be considered. Checking firstly the radial
and axial runouts is an important method for correct adjustment.
In the process of reassembly, measure the actual values against the reference values,
which are given in the Product Certificate, steam-path drawing and initial installation
record, and log the measured results.
The next work is to mount and connect the supervisory system. Thorough check and
testing of all instruments, protection and safety systems are essential.
The oil supply system should also be checked. The cleaning of the oil system, the

check and readjustment of all valves are required if the lubricating oil and control oil
piping have been reconnected after dismounted in overhaul.
Reset the control system and check all of the steam piping.
The code in the table means as following:

1—Minor overhaul
2—Intermediate overhaul
3—Major overhaul
4—Modular overhaul
*-- When needed
**--Recommended
***-- Essential
NO.
Scope of overhaul 1 2 3+4
1 Inspect setting of control system * ** ***
2 Inspect alignment between individual section of turbine ** *** ***
Inspect gearing (We recommend inspecting gearbox within the first

3 *** *** ***
8000 operating hours)
Check earthing insulation shafting system of the bearing at the side of

4 *** *** ***
exciter
Dismantle coupling (gear-type), measure gear backlash and check free

5 * *** ***
axial movement and play of sleeve.
6 Check alignment of casings to bearing housings * ** ***
Dismantle bearings, check bearing pads, journal and thrust collars,
7 measure bearing clearance. Check thrust bearing bracket and adjusting *** *** ***
ring (A type pedestal)
Check adjusting washers (or plate) of casing supporting brackets and

8 * ** ***
bearing housings
Check seal rings of bearing housing, repair or replace them as

9 ** *** ***
necessary
Check casing and bearing-housing guides for dirt and jamming, dismantle,
10 ** *** ***
repair and readjust them when necessary

NO.
Check emergency stop valve, control valve and etc, replace any worn part at
11 - ** ***
both hydraulic and steam sides
Dismantle steam strainer, check for foreign bodies or damage, replace it

12 * ** ***
when necessary
13 Check shutoff devices in extraction lines ** ** ***
Open up casings, check and measure casing splits, supporting surfaces

14 - * ***
and split bolts. Check casing for deflection, distortion and corrosion
15 Check sliding surfaces of casing and bearing housing - ** ***
16 Check drains for foreign matter and dirt * ** ***
Check connections and joint bolts of initial steam and extraction steam
17 - * ***
lines
18 Examine internal components of casing for rust, deposit and wear - * ***
Check movement and wearing conditions of the supporting surface of
19 inner casing (steam chest) and guide-blade carries, replace when - * ***
necessary
Test bolts in high temperature zone for looseness and crack, check
20 - * ***
thread
Inspect seal ring of L-shaped cross section, measure clearance and

21 - * ***
dimension, replace when necessary
Measure openings between splits of two-half inner casings and
22 guide-blade carries with feeler gauge or taking leads under bolts loosen - * ***
and tighten. Check split bolts for distortion
Check shaft glands and labyrinth seals for wearing, corrosion, warping
23 - * ***
and breakage, replace when necessary
Check radial runout and axial play of rotor, mounting position of
coupling, re-measure dimension of steam path and determine whether

24 - * ***
dimension deflection exist comparing with Product Certificate and
initial installation recoord

NO.
Check the fixed and moving blades for deposit and corrosion, cleaning
as necessary, examine for crack, sign of rubbing and damage caused by

25 - + ***
foreign impurity, inspect for gaping of shrouding and displacement of
blades
26 Dynamic balancing of rotor - - ***
27 Check the earthing brush and clean up the contact surface ** ** ***
28 Inspect the main and auxiliary oil pumps (including coupling) ** *** ***
Dismantle the oil pump for checking bearings, seal rings, shaft,
29 * ** ***
impeller and etc.
Check the easily worn locations in the control, monitoring and
30 protection devices, replacing as necessary. The disabled parts must be ** ** ***
replaced
Inspect the level gauge and drain the oil tank, examine and purify the
31 - * ***
oil, check the tank and clean the strainer
Check the oil filter, remove the elements, clean and examine, test for
32 * ** ***
leaks
33 Check the oil cooler, withdraw the tubes, clean and examine * ** ***
Examine the pressure oil and return oil piping, eliminate any leak,
34 replace the fittings as necessary. If the oil piping is disconnected in - * ***
subsection, cleaning and examining should be made
Inspect the steam piping of the turbine body for crack, distortion and
35 - - ***
rust
36 Check the pipe supports and hangers, record positioning data *** *** ***
Inspect tubes and waterbox of condenser for deposit, damage and leaks,
37 * *** ***
check the air ejector
Inspect the proper functioning of the monitoring devices and automatic

38 *** *** ***
gear (electric and hydraulic), reset as necessary

Overhaul Example 4-1300-01-01
Overhaul Example
This section, taking a condensing turbine as the example, introduces the steps of the
check and repair for turbine body in overhaul.
When establishing the overhaul schedule, the user should draw up the complete
overhaul items and timetable based on the turbine structure, operation condition and
local condition (field, staff, equipment and etc.).
1. Preparation
1.1 Preparation and check of the necessary tools and equipments for overhaul.
1.2 Vibration measurements with frequency analysis (shaft vibration, bearing housing,
foundation).
1.3 Final operating data logging, including the records of various operating condition
stopping and coastdown time, the barring gear put into operation until to turbine
cooled.
1.4 Check of spare parts.
1.5 Functional test of oil cylinder.
1.6 Leak check by sight and touch.
1.7 Test of shafting system earthing.
2. Dismantling turbine
2.1 Removal of encloser.
2.2 Removal of lagging.
2.3 Disconnection of initial-steam and extraction-steam piping, blanking off the
openings.
2.4 Removal of control-oil and lubricating-oil piping.
2.5 Disconnect of the couplings between the turbine and driven machine, turbine and
main oil pump.
2.6 Opening of the bearing housings, checking of differential expansion indicator and
lifting of bearing upper halves.
2.7 Measurement positioning dimension of rotor relative to casing and bearing housings,
inspection of alignment value.
2.8 Measurement of radial and axial runout of the rotor at coupling end.
2.9 Removal of casing split bolts and supporting bracket bolts.
2.10 Raising of casing top half with jacking bolts after fitting the guide bars, lift-off of
top half.
2.11 Release of the jointing blots of inner casing (two-half inner casing), guide blade
carriers and shaft glands, lift-off of top halves.
2.12 Radial runout check along full length of rotor, measurements of static and dynamic
clearances of each stage.
2.13 Lift-out of rotor.
2.14 Removal of bottom halves of inner casing, guide blade carriers and shaft glands.
2.15 Dismantling of emergency stop valve, control valves and main oil pump (see, 3.9,

3.10, 3.11 and 3.12)
2.16 Inspection of all parts, deciding on overhaul measures required, use of spares,
cleaning method and further examination needed.
2.17 Writing of dismantling note.
3. Inspection and overhaul

Look round the initial condition and record before inspecting and repairing the
following components (outer casing, rotor and etc.).
3.1 Outer casing

3.1.1 Clean split measuring and mating faces, checking according to the inspection
items decided.
3.1.2 Examine the clearance and gaping between top and bottom casings with blots
loosen and tighten respectively and correct as necessary.
3.1.3 Inspect the bolts and nuts, especially for that located in the high temperature area
(the front section before the first flange for H-type turbine), for loosen, crack.
Check bolt holes in casing split.
3.1.4 Check guide elements interior the casing, repair when necessary.
3.1.5 Check supporting faces of the inner casing, guide blade carriers, correct when
necessary.
3.1.6 Check and correct the supporting faces of the casing.
3.2 Inner casing

3.2.1 Clean split measuring and mating faces, checking according to the inspection
items decided.
3.2.2 Examine the clearance and gaping between top and bottom casings with blots
loosen and tighten respectively and correct as necessary.
3.2.3 Inspect the bolts and nuts, especially for that located in the high temperature area
(≥450℃), for loosen, crack. Check bolt holes in casing split.
3.2.4 Inspect the guide blading, shrouding and gland strips.
3.2.5 Check the nozzles for damage caused by foreign impurities.
3.2.6 check the seal ring of L-shaped cross section, measure the clearance and
dimension, repair or replace conditionally.
3.2.7 Check the supporting and guide faces, repair when necessary to make them flat
and smooth.
3.3 Guide blade carriers

3.3.1 Dismantle the adjusting element for cleaning and checking, replace spherical
washers when necessary.
3.3.2 Smooth guide faces of the guide blade carriers and guide stem (radial and axial).
3.3.3 clean and examine the split and positioning faces, correct when necessary.
3.3.4 Inspect guide blading, shrouding and gland strips.
3.3.5 Check positioning pin and hole, make up again when necessary.
3.3.6 Check bolts and nuts.

3.4 Dummy piston labyrinth ring
3.4.1 Clean, check and correct the split and mating faces.
3.4.2 Check gland strips, repair and replace conditionally.
3.4.3 Measure the roundness of inner and outer circles.
3.5 Outer gland seal

3.5.1 Clean mating and split faces, check connectors.
3.5.2 Replace gland strips.
3.6 Rotor
3.6.1 Remove and inspect emergency governor.
3.6.2 Check journals and thrust faces, smooth when necessary.
3.6.3 Smooth bearing seal ring section.
3.6.4 Smooth earthing brusher section.
3.6.5 Check gland strips, repair or replace conditionally.
3.6.6 Check moving blades (straight blade), shrouding, twist blades and tie wire, inspect
the blades for deposit, corrosion and crack.
3.6.7 Crack-test shaft.
3.6.8 Clean and finish half coupling.
3.6.9 Reassemble emergency governor, overspeed-test before test running again.
3.6.10 Rebalancing of rotor.
3.7 Front pedestal

3.7.1 Clean bearing housing and check seal face, refit when necessary.
3.7.2 Dismantle emergency trip gear, clean, inspect and reassemble.
3.7.3 Clean and inspect bearing seal rings, replace seal strips when necessary, making
up the inner circle according to the shaft dimension.
3.7.4 Clean and refit radial bearing, replace if the damage is severe or the bearing
clearance is excessive.
3.7.5 Clean and refit thrust bearing. Should the pads be replaced, the attention must be
paid that the set of pads should be supplemental-machined together.
3.7.6 Loosen distant screws of bearing housing, check adjusting and guide elements of
the bearing housing, smooth or replace as required.
3.7.7 Readjust bearing housing.
3.7.8 Check pedestal, foundation and anchor bolts.
3.7.9 Check spherical washers (plate) of casing supporting bracket, refit or replace
conditionally.
3.7.10 Check casing guide, refit guide face when necessary.
3.8 Rear pedestal

3.8.1 Clean bearing housing and refit split.
3.8.2 Overhaul barring gear.
3.8.3 Clean and inspect bearing seal rings, replace seal strips when necessary, making
up the inner circle according to the shaft dimension.

3.8.4 Clean and refit radial bearing, replace if the damage is severe or the bearing
clearance is excessive.
3.8.5 Check adjusting, guide and positioning elements of bearing housing, smooth or
replace as required.
3.8.6 Readjust bearing housing.
3.8.7 Check pedestal, foundation and anchor bolts.
3.8.8 Check positioning and guide elements of casing.
3.9 Emergency stop valve

3.9.1 Release bolts connecting valve cover and admission chest, dismantle emergency
valve, steam strainer and valve seat.
3.9.2 Dismantle oil cylinder, when dismantling the attention must be paid that it only
can be done by means of the special bolts at valve cover side (see 2-2300- for
details). Loosen nuts, the nuts at the oil cylinder cover end can be loosened only
after the spring fully released.
3.9.3 Disconnect piston disc from valve stem.
3.9.4 Clean oil cylinder, check oil cylinder, piston, piston disc, test piston, refit as
required.
3.9.5 Check valve stem and sealing elements, replace sealing elements and repair valve
stem when necessary.
3.9.6 Inspect valve cone, valve seat, refit if contacting surfaces are damage.
3.9.7 Check guide bush, sealing sleeve, clean deposit. Repair and replace if mechanical
damage is found.
3.9.8 Inspect sealing face of valve cover.
3.9.9 Reassemble emergency stop valve (after control valve has bee overhauled).
Functional test after turbine overhauled.
3.10 Control valve (first expansion section)

3.10.1 Measure connection dimensions of oil relay, lever, and control valve and
assembly dimension of closing spring and disk spring in damper.
3.10.2 Release the close spring, disconnect the oil relay from the lever and bracket,
remove the oil relay.
3.10.3 Disconnect the lever from valve stem, remove the lever.
3.10.4 Remove the parts on the upper section of the valve stem, disconnect the valve
from valve beam through turning the valve stem by 90°, remove the valve
cover and stem.
3.10.5 Remove the valve beam, together with the valve cones out of the admission chest
with installing tool of valve stem.
3.10.6 Check, clean and refit the valve cone and seat, replace if it is damaged severely.
Inspect the valve-cone stroke. Usually, the sleeve is required to replace if the
stroke is changed.
3.10.7 Check, clean and refit the valve stem, replace when necessary. Check the guide
bush, refit or replace conditionally. Replace the sealing stuff..
3.10.8 Check driving parts, such as pin, bush, knuckle bearing.

3.10.9 Dismantle and clean the oil cylinder, replace piston ring and sealing elements
when necessary.
3.10.10 Dismantle the pilot valve, clean the valve shell. Check the slide valve and
sleeve, replace when necessary.
3.10.11 Assemble the components and control valve, reset before test running.
3.11 Control valve (second expansion section)

3.11.1 Measure connection dimensions of oil relay, lever, and control valve and
assembly dimension of closing spring and disk spring in damper.
3.11.2 Release the close spring, disconnect the oil relay from the lever and bracket,
remove the oil relay.
3.11.3 Disconnect the lever from valve stem, remove the lever.
3.11.4 Remove the parts on the upper section of the valve stem, disconnect the valve
from valve beam through turning the valve stem by 90°, remove the valve
cover and stem.
3.11.5 Check, clean and refit the valve cone and seat, replace if it is damaged severely.
Inspect the valve-cone stroke. Usually, the sleeve is required to replace if the
stroke is changed.
3.11.6 Check, clean and refit the valve stem, replace when necessary. Check the guide
bush, refit or replace conditionally. Replace the sealing stuff..
3.11.7 Check driving parts, such as pin, bush, knuckle bearing.
3.11.8 Dismantle and clean the oil cylinder, replace piston ring and sealing elements
when necessary.
3.11.9 Dismantle the pilot valve, clean the valve shell. Check the slide valve and sleeve,
replace when necessary.
3.11.10 Assemble the components and control valve, reset before test running.
3.12 Main oil pump

3.12.1 Dismantle valve housing (or volute casing, end cover), check impeller and seal
ring, refit or replace conditionally.
3.12.2 Realign and make up positioning pin when necessary.
4. Others
4.1 Check and maintenance of the digital controller and electro hydraulic converter
should be carried out according to the relevant product manuals.
4.2 Check and verify of the operation supervision instruments.
4.3 Check and overhaul of the oil system (e.g. oil tank, auxiliary oil pump, oil cooler, oil
filter, accumulator and etc.), condensing system (e.g. condenser, condensate pump,
level controller, air ejector, gland steam pressure controller, exhaust safety valve and
etc.), steam line (piping, supports and hangers, extraction stop valve and actuator,
safety valve, exhaust nozzle and etc.), oil line (piping, expansion joint, tube, fittings
and etc.) should be carried out according to the overhaul schedule and procedure.
5. Reassembly of turbine

For assembly, adjustment program and requirement of each component after turbine
overhaul, see installation section of Operating Instructions.
6. Functional testing of component

6.1 Clean oil system through oil cycle when necessary.
6.2 Functional testing of jacking system.
6.3 Functional testing of barring system.
6.4 Functional testing of emergency stop valve.
6.5 Setting of control valve.
6.6 Functional inspection of governor.
6.7 Performance inspection of air ejector.
7. Overhaul report
The overhaul items, personnel, schedule, problems discovered and measures taken,
measurement records of reassembly, the results of the functional testing for components
should be reported in written, the chart and photos can attached when necessary (see
4-1400- for details).

Manual B4601

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Copyright:

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Manual B4601

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Document No.

Product Code: WT9302

Edited by： 2013-01-18

Checked by： 2013-01-18

Approved by： 2013-01-18

修改单编号 修改标记 修改页码 修改处数 时间 操作人

2. Technical specifications & construction

4. Starting up and operation

4.1 Preparation before starting up

Hangzhou Steam Turbine Company Limited Page 1 of 15

4.3 Shutting down the turbine

5. Maintenance of operating and shutting down the turbine

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Hangzhou Steam Turbine Company Limited Page 3 of 15

2.1 Technical specification

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Steam and water system

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Hangzhou Steam Turbine Company Limited Page 9 of 15

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1. Lever 6. Valve cone 11. Bracket

Hangzhou Steam Turbine Company Limited Page 1 of 5

16. Valve cone bolt 17. Taper pin

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Hangzhou Steam Turbine Company Limited Page 4 of 5

Table: Tightening moment for valve cone bolt

Valve size H25 H32 H40 H50

Hangzhou Steam Turbine Company Limited Page 5 of 5

1． 关节轴承 oscilating bearing

2． 活塞杆 piston rod

5． 二次油 secondary oil

7． 压力油口 pressure oil opening

8． 错油门滑阀 pilot valve

9． 转动肋 turning plate

10． 推力球轴承 thrust ball bearing

12． 调整螺栓 adjusting bolt

13． 弯角杠杆 bend angle lever

14． 滚针轴承 needle bearing

15． 反馈板 feedback plate

Hangzhou Steam Turbine Company Limited Page 1 of 4

Figure 2 housing oil chamber

Hangzhou Steam Turbine Company Limited Page 2 of 4

Rotation and vibration valve piston

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Figure 4 oil way of rotating disk

Hangzhou Steam Turbine Company Limited Page 4 of 4

1. Limit Stud 5. Eccentric bolt 9. Compression spring

Hangzhou Steam Turbine Company Limited Page 1 of 2

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Structure and Function Principle

修改单编号修改标记修改页码修改处数时间操作人

1．关节轴承 oscilating bearing

2．活塞杆 piston rod

5．二次油 secondary oil

7．压力油口 pressure oil opening

8．错油门滑阀 pilot valve

9．转动肋 turning plate

10．推力球轴承 thrust ball bearing

12．调整螺栓 adjusting bolt

13．弯角杠杆 bend angle lever

14．滚针轴承 needle bearing

15．反馈板 feedback plate

2．定位块 positioning block

4．进油口 oil inlet

5．出油口 oil oulet

10．顶块 carrier block

12．回油 returing oil

4．动轮 traction wheel 5．圆环 round ring 6．密封环 sealing ring

7．转子 rotor S．吸油 absorbing oil P．压力油 pressure oil