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Technical Specification

for the
Major Overhaul
of the
Steam Turbine Generator
system T20
in
2014

Final ]
Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

Contents

1 Objective

2 Qualification and quality management

3 Present condition of the system


3.1 Operational and maintenance history

3.2 Known conditional shortcomings

4 Scope
4.1 Turbines, gear and auxiliary systems
4.2 Generator

4.3 Deliveries and scope by others

5 Applicable standards and contractor requirements

6 Performance and operational requirements after the


overhaul

7 Enclosures

8 Authorization

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
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1. Objective:
Inspection and repair of the steam turbine generator system T20 so that it is suitable for
efficient, reliable, and safe operation for the next 20 years defined by:
a) A time availability >= 98 %, excluding scheduled maintenance according:
The VGB R-115 M- Richtlinie (2-1993) Empfehlungen fr die
Revision von Dampfturbinen code for the turbine with auxiliariess.
The VGB R 167 e: Guidelines for the overhaul of Turbo Generators

b) API 612: 5 years of continuous operation, and design life of 20 years.


c) Compliance with the performance and operational requirements mentioned in
chapter 6 of this document

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
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2. Qualification and Quality management


The inspection and repair of the HP rotor must be executed in compliance with API 687
The maintenance policy and the scheduled overhauls is bases upon the instruction
manuals and the codes:
Turbine and auxiliaries:
VGB-R 115 M Revision 2 1993: Empfehlungen fr die Revision von
Dampfturbinen. A description of this overhaul is described in this code as
Groe Revision
Generator:
The VGB R 167 e: Guidelines for the overhaul of Turbo Generators. A
description of this overhaul is described in this code as Main Inspection

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
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3 Present condition of the system

3.1 Operational and maintenance history.


The turbine generator T 20 has been in almost continuously in operation at high to full
load after commissioning in 1992 without major overhaul.
The HP turbine casing has never been opened.
For the LP turbine an exchange of the HP guide carrier and the rotor took place
in in 2002. For the history of the exchange of the LP rotors and the First guide
vane carrier of the LP turbine between T 10 and T 20 see enclosure E
The generator had a major overhaul in 2002
In March 2013 an inspection stop of the turbine and the generator was made
without opening the turbine casings or removal of the generator rotor.

So in 2014 the operational time is 22 years or 195.000 hours including the effect of
starts and stops according VGB-R 115.M

3.2 Known conditional shortcomings


HP turbine
The HP turbine has never been opened before, and operates without notable vibration
issues or performance shortcomings .

It has considerable steam leakage at the seals of the balancing cylinder. For the
analysis of this experience see enclosure F.

The inspection of March 2013 concluded the following shortcomings and recommended
actions:
The control valve stems and nuts showed considerable wear. They must be
replaced
The control servomotor main piston and cylinder showed unacceptable wear.
They must be repaired or replaced
Leakage test of trip valve not executed, to be executed during this overhaul
Control range of the spare E/H to be calibrated.

LP turbine
The LP turbine operates without notable vibration issues or performance shortcomings.

The inspection of March 2013 concluded the following shortcomings:

The LP blades were inspected by means of endoscopy in 2013. There are


considerable signs of water droplet erosion in the last stage. Therefore the LP
rotor must be replaced by the spare rotor.
The first guide vane carrier showed unacceptable wear (washing out) during the
endoscopic inspection in 2013. It must be replaced. The HP gland of the LP
turbine will likely have the same defect in that case it must be replaced.

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
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The main oil pump was completely overhauled in 2010. In 2013 the driving gear
set showed considerable wear patterns. Replacement is of the gear is necessary
The bearing on the gear side showed a clearance increase of 0.41 mm. The
bearing must be inspected , the cause must be estimated and repair or
replacement to be executed.
Generator

The inspection of March 2013 concluded the following shortcomings:

By means of endoscopy and electrical testing ( partial discharge, insulation value


and tang delta)there are no noticeable shortcomings.
It is recommended that the rotor is inspected, the rotor retaining rings must be
removed and tested for cracks.
High speed balancing is necessary
Replacement of the ceramic star point insulators by resinous material .
4 Scope:
Execution of all recommend actions mentioned in 3.2

4.1 Turbines, gear and auxiliary systems

Scope Major overhaul Turbine-Generator T 20 with auxiliaries on basis of VGB R 115 m


Last inspection

2014 inspection
Inspection
Function

Location

Code
Part

Function Last 2014


Function Part Location Inspection Inspection Code
Couplings Coupling HP turb/ VGB R 115 M 2013 VGB R 115 M yes
between (Gear type) gear of Alignment 2013 Manual yes
shafts oil pump

Coupling HP turb/ VGB R 115 M 2013 VGB R 115 M yes


(Gear type) gearbox Alignment no Manual yes

Coupling Gear box/ VGB R 115 M no VGB R 115 M yes


(Gear type) generator Alignment no Manual yes

Coupling HP turb/ VGB R 115 M no VGB R 115 M yes


(Stiff) LP turb Alignment no Manual yes

Coupling Lp turb/ VGB R 115 M no VGB R 115 M yes

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(Stiff) Generator Alignment no Manual yes

Coupling Generator/ VGB R 115 M no VGB R 115 M yes


(Stiff) Excitor Alignment Manual yes

Alignment Sliding system HP turbine Manual no Manual yes


of bearing- with keys Front bearing
pedestals pedestal with
with casings turbine casing

HP turbine Manual no Manual yes


rear bearing
pedestal with
turbine casing

LP turbine Manual no Manual yes


front bearing
pedestal with
turbine casing

LP turbine Manual no Manual yes


rear bearing
pedestal with
turbine casing

Generator Manual 2002 Manual yes


front bearing
pedestal with
stator

Generator Manual 2002 Manual yes


rear bearing
pedestal with
stator

3 Rotor support Journal bearing HP turbine VGB R 115 M 2013 Manual yes
(Bearings) front side

Thrust bearing HP turbine VGB R 115 M 2013 Manual yes


front side

Journal bearing HP turbine VGB R 115 M 2013 Manual yes


rear side

Journal bearing gear box VGB R 115 M 2013 Manual yes


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pinion
driving side

Thrust bearing gear box VGB R 115 M 2013 Manual yes


pinion

Journal bearing gear box VGB R 115 M 2013 Manual yes


pinion
n.d. side

Journal bearing gear box VGB R 115 M 2013 Manual yes


wheel
n.d. side

Thrust bearing gear box VGB R 115 M 2013 Manual yes


wheel

Journal bearing gear box VGB R 115 M 2013 Manual yes


wheel
driving side

Journal bearings Generator VGB R 115 M 2013 Manuals yes


Casing support Turbine casings Keys and bolts Manuals no Manuals yes
and alignment T. Bearing pedestals Keys and bolts Manuals no Manuals yes
Gear casing Keys and bolts Manuals no Manuals yes
Generator stator Keys and bolts Manuals no Manuals yes
Generator pedestals Keys and bolts Manuals no Manuals yes
Connection to Turbine casings Sliding plates VGB R 115 M no Manual yes
concrete Bearing casings Sliding plates VGB R 115 M no Manual yes
Gear casing Sliding plates VGB R 115 M no Manual yes
Generator stator Sliding plates VGB R 115 M no Manual yes

Bearing casing Turbines (HP and LP) All related parts Manual no Manual yes
sliding and Generator All related parts Manual no Manual yes
guidance
system

Connection of Turbines (HP and LP) All related parts Manual no Manual yes
bearing casings
with turbine
casing

Anchoring to Turbines Anchor bolts Manual no Manual yes


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concrete Gear box Anchor bolts Manual no Manual yes


Genarator Anchor bolts Manual no Manual yes

Safeguarding Trip valves All parts Manuals no Manuals yes


steam system Non return valves All parts Manuals no Manuals yes
Bypass valves All parts Manuals no Manuals yes

Steam filtration Steam strainers All parts Manuals 2013 Manuals no

Steam blocking All extraction lines Valves VGB R 115 M no VGB R 115 M yes
system

Condensate All drains Condensomates VGB R 115 M yes VGB R 115 M yes
drain system and valves

Turbine casings High pressure All related parts VGB R 115 M no VGB R 115 M yes
Low pressure All related parts VGB R 115 M no VGB R 115 M yes

Steam inlet Hp turbine control All related parts VGB R 115 M no VGB R 115 M yes
valve chest

Alignment inner HP turbine All related parts VGB R 115 M no VGB R 115 M yes
casings LP turbine All related parts VGB R 115 M no VGB R 115 M yes

Bolt relaxation All bolting > 300 C HP turbine VGB R 115 M no Manual yes

Steam seals Rotors and casing HP turbine VGB R 115 M no Manual yes
LP turbine VGB R 115 M 2002 Manual yes

Turbine rotor Rotor HP turbine API 687 no API 687 yes


Rotor with blades LP turbine To be replaced 2002 Manual yes

Moving blades All blades HP turbine API 687 no API 687 yes

Erosion Stationary Blades LP turbine VGB R 115 M 2002 VGB R 115 M yes
Support bars inner
casings and drain
LP Casing holes VGB R 115 M no VGB R 115 M yes
Wear of stage Tip of moving blades HP turbine API 687 no API 687 yes
shrouds

Grounding Brushes HP turbine VGB R 115 M 2013 Manual yes


LP turbine VGB R 115 M 2013 Manual yes
Generator VGB R 115 M 2013 Manual yes

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Oil supply Main oil pump HP turbine VGB R 115 M 2010 Manual yes
Driving gear pump HP turbine 2013 Manual yes
Yes
Control Flow control HP turbine VGB R 115 M 2013 Manual Yes
Stems and
bushings VGB R 115 M 2013 Renewed in Yes
2013
To be
Valves and seats VGB R 115 M 2013 renewed Yes

Control servo Several parts to


To be renewed Yes
Monitoring HP turbine Manual 2013 Manual Yes
systems Mechanical, electric LP turbine Calibration
hydraulic, and Generator Functional
pneumatic testing

By
Condenser Pipes Filthiness no Manual others
Pipe plates
Water chambers
Support plates
Flash tank
Damage
Tightness

Vacuum system Ejector (nozzles) Complete Inspection no Manual yes


heat exchangers vacuum and
Control valves gland steam
Gland condenser system
Control valves
Steam piping In turbine HP turbine Cracks no Manual yes
LP turbine Cracks no
( Incl. 6 Bellows)

Steam piping To and from turbine HP turbine Cracks no Manual yes


bellows LP turbine Cracks
Cross over (incl. 4
bellows) Cracks
Piping support All piping Steam oil and Condition no Manual yes
water

Water injection Complete systems Bypasses Condition ? Manual yes


seal steam
export steam

Oil tank Oil and tank Oil console Removal of oil no Manual yes
Reconditioning
or
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renewal
Clean tank and
strainers
Suction non return
valves Inspection no Manual yes
Oil filters Lube and control Oil console Filter Elements 2013 Manual yes
filters inspection

Coolers Lube oil coolers Oil console Inspection on no VGB R 115 M yes
water and oil
Side.
Water box
repair or
replacement

Oil piping Lube and control Complete system Visual on no VGB R 115 M yes
leakage

Oil vapor Ventilator and Oil console Inspection no Manual yes


removal separator cleaning

Gear box and Gear box Complete train Visual 2013 Manual no
turning gear Couplings
Turning gear no yes

In addition to the above mentioned standard scope the following actions


and supplies are in the scope:
Commissioning and decommissioning
Inspections and certificates according VGB R 115 M (Anlage 2), see enclosure
H

HP turbine:

The overhaul supplier is invited to quote improved HP gland designs and power
limitation solutions

Inspection and repair of the HP rotor according API 687 including high speed
balancing
Replacement of the steam seals in the casings
Replacement of the HP control valve stems bushings and nuts (Supplied by AEB)
Repair of the main oil pump driving gear
Overhaul of the HP control servomotor, replacement or repair of power piston,
power piston bushing and actuator, no spares available at AEB

LP turbine:
Replacement of the rotor by the spare rotor (Supplied by AEB)
Repair of the steam seals in the casing
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Replacement of the guide vane carrier by the spare guide vane carrier (Supplied
by AEB)
Replacement of the HP gland casing by a spare casing (Supplied by AEB)
Replacement of 2 block valves to the LP heater 1 (Supplied by AEB)
Replacement of 3 compensators in the LP turbine. (Compensators supplied by
AEB)

Couplings

Coupling between LP turbine and generator: alignment check and eventual


correction, reaming of new coupling bolts (Oversize bolts to be supplied by the
contractor)

4.2 Generator
The requested scope and type of inspection are a Main Inspection (MI) or so called Major
Inspection according to code VGB R 167e Overhaul Recommendations for Turbo Generators.

The following inspection Schedules are to be applied :

Schedule Taking out of Service


Schedule Disassembly and Reassembly
Schedule Rotor
Schedule Commissioning

All measured data as found and as installed, should be reported.

Regarding visual inspections a digital photo record is requested for each inspected subject.
The rotor must be removed and inspected, the rotor retaining rings must be removed
and tested for cracks.
High speed balancing is necessary

The rotor must be high speed balanced according to EN 11324 (balancing of flexible rotors)
class Q2,5 or equivalent.

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4.3 Deliveries / Scope by others

The following items are supplied by AEB

Set of driving gears of the main oil ump


Overhauled LP-rotor
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First guide vane carrier of the LP turbine


Control valves, nuts, bushes and seats.
Addition of a redundant electronic over speed trip system
Cleaning of oil console and supply of new oil
Three (3) compensators (Supplied by AEB), to be mounted in the LP turbine by
the contractor

The following works are carried out under the responsibility of AEB

Removal of insulation HP-turbine


Removal of insulation steam piping
Dismantling and storage of steam piping
Dismantling and storage of control & shut-off valves
Re-installation of piping and valves
Removal and installation of the insulation of the HP and LP turbine
Cleaning of condenser, inspection of pipes, pipe plates, pipe support plates water
cambers, flash tank
Correction of the cross over piping and bellow alignment
Replacement of the star point insulators

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5 Applicable standards and contractor requirements


General

In general the requirements as mentioned in this document and in this section in


particular apply fully. In case Contractor does not meet the requirements or does not
comply with rules as mentioned, any costs occurred by this non-compliance shall be for
Contractors account and cannot be claimed by AEB.

Applicable standards

The following standards apply to the described Works in this document:

VGB r 115 M Empfehlungen fr die Revision von Dampfturbinen


VGB R 167 (5/2010) Powertech
Richtlinie: Revisionsempfehlungen fr Turbogeneratoren
NEN-ISO 1940-1:2005 en Mechanical vibration - Balance quality
requirements for rotors in a constant (rigid) state - Part 1: Specification and
verification of balance tolerances
ISO 7919-2 Land based steam turbines and generators in excess of
50MW with normal operating speed of 3000 rpm.
ISO 10816-2:2009 Mechanical vibration - Evaluation of machine vibration
by measurements on non-rotating parts - Part 2: Land-based steam
turbines and generators in excess of 50 MW with normal operating speeds
of 1 500 r/min, 1 800 r/min, 3 000 r/min and 3 600 r/min
ISO 1940 Balancing, ISO 11324
ISO 4386-1 Ultrasonic bearing assessment
ISO 4386-3 Dye penetrant bearing assessment
EN 60034-1 For testing of electrical windings

HSE Requirements

Contractor shall provide a project specific Health and Safety Plan (Dutch : VGWM-plan
) for the work scopes at the site of AEB, according to an example plan available at AEB.
The Contractors Health and Safety plan must be sent to the project leaders of AEB at
least 1 month before work starts at AEB site. The Health and Safety plan will be judged
by the Safety department and project leaders of AEB. In case of missing information or
questions, the contractor should make improvements to the Health and Safety Plan.
Contractor shall not start the works prior to approval of the HSE-plan. It is Contractors
responsibility to obtain an approved HSE-plan.

Contractor shall hold required toolboxes at a minimum of once a week with all assigned
personnel. The signed toolbox form shall be handed over to AEB HSE department.
AEB HSE department an d project leader may attend these toolbox meetings.

Hoisting qualification for staff on site, for use and operation of gantry cranes for lifting
works in the turbine hall.

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Quality and reporting requirements

Contractor should have ISO 9001 : 2000 for the following activities :
Repair, overhaul, re-engineering of steam turbines
Repair, overhaul, re-engineering of high-voltage power generators (10 KV,
50MVA)

The Quality Department of AEB plans to verify the conduction of works in workshops
and on site versus the contractor ISO 9001 documents applicable for these work
scopes.

Contractor shall provide a project specific:


A commissioning and decommissioning plan
Inspection & test plan for the whole works. The inspection and test plan
shall indicate hold, witness, review points related to the work.

Preliminary (eventually hand written) inspection reports Must be made on site, in


suppliers workshops or sub suppliers workshops on daily basis, Copies of these
preliminary inspection results must be made available to the owner immediately after
the execution of each inspection

Some work scopes contain witness points. In case of witness points AEB want to be
invited to inspect / discuss finding resulting from inspections, measurements which can
lead to more / less work. In case AEB does not respond to invitation, contractor should
continue with the work.

Some work scopes contain holding points. In case of holding points the contractor
should wait for consent of AEB to proceed with further works.

Prior to start of works Contractor shall send the inspection and test plan for review.
Contractor shall incorporate comments given by AEB . Contractor shall not start the
works prior to approval of the inspection and test plan. It is Contractors responsibility to
obtain an approved inspection and test plan.

Prior to start of works, a pre-inspection meeting shall be held. The following attendees
from AEB shall be present:
AEB project leader
AEB Quality engineer
AEB Rotating equipment specialist

Documentation requirements

All components supplied by the contractor (bolts, nuts, parts etc,) must be accompanied
by material certificates according EN 10204.

All re-engineered drawings created during this project are property of AEB and must
be supplied to AEB on paper and digital as DWG (AutoCAD) file.
Reports must be supplied to AEB on paper and digital as MS WORD or MS Excel file.

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Contractor requirements

Contractor fabrication / shop requirements turbine scope

Contractor demands regarding competencies for the work scope

In-company dedicated workshop and suited machinery for repair,


overhaul and re-engineering of turbine parts.
Experienced project leader on site for the duration of the work, with
ability to fluently communicate in Dutch, English or German. Project
leaders should demonstrate a project list of major overhauls which were
performed under their leadership.

Contractor fabrication / shop requirements Generator scope

Contractor demands regarding competencies for the work scope of the Generator :

In company dedicated workshop and suited machinery for repair,


overhaul and re-engineering of generator rotors and generator stators
with a power of 50 MVA and larger.
In company high speed balancing facility for generator-rotors of 50
MVA and larger.
Experienced project leader on site, with ability to fluently communicate
in Dutch , English or German. Project leaders should demonstrate a
project list of major overhauls which were performed under his leadership.

Contractor shall provide the following:

Reference list with comparable projects, containing the names of the


customers, year of the project and size (Power in MW) of the machinery
for overhaul of Overhaul of HP- and LP turbines
Reference list with comparable projects, containing the names of the
customers, year of the project and size (Power) of the machinery for
overhaul of high voltage generators of 50 MVA and larger

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Project requirements

General

Contractor shall provide a project plan for the complete project, work scopes,
containing at least the next information:

Health & Safety (VGWM) Plan


Risk Assessment for critical or dangerous handlings for this project
Work scopes
Overall planning
Day-to-day planning
Quality documents relating to the work scopes
List of names and telephone numbers of responsible persons

Contractor shall provide, as minimum:


Project manager, primary contact and overall responsible
24 hours per day on site supervision during execution of works
Quality inspectors for in view of Contractors works
All other required personnel to meet safety and quality requirements

Contractor shall participate in AEB overall work preparation in view of this project. As
such Contractor shall attend all requested:
Planning meetings
Clarification meetings
Alignment meetings
Kick-off meetings

During execution of the works daily coordination meetings shall be held to monitor:
Safety
Progress of works
Quality

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Project planning
To reduce downtime to a minimum during turbine generator shutdown works shall be carried
around the clock in either 2 or 3 shifts, as per contractors preference.

Estimated time frame is 4 weeks . Contractor is challenged to reduce overall downtime as much
as possible without consequences to safety, quality and overall performance.

Project execution

As soon as main components like the generator , HP turbine, LP-turbine, regulator valve
and lubrication oil pump are dismantled, contractor should deliver as soon as possible
an engine condition status report to AEB, giving information about the engine
technical condition and expected more / less work to be conducted, and time needed
for execution of the more works.

Contractor shall not conduct any additional works other than described in this document
prior to AEB approval. In such case AEB shall not be held accountable for the occurred
costs by Contractor.

Extra work forms should include the naming and description of the extra works, the sum
of the extra work made up of unit rates x (man) hours and costs of extra materials used.

During the scheduled overhaul, contractor must have available immediately sufficient
capability of facilities and qualified human resources, to execute adequate corrective
actions that must be made as a result of the inspections executed.

Contractor should give AEB the number of expected staff on site for the project. AEB
uses this number to organise sufficient clothing and sanitary facilities for the contractors
at its site. Before start of the project, contractor should inform the project leaders of AEB
with the names of all staff working on site.

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6 Performance and operational requirements after the


overhaul.
After commissioning the turbine generator must have or give:

a) The same or better specific steam consumption, flow capacity, feed water
temperature and generator power as it had before the execution of the overhaul
in compliance with the complete operational range as described in the operation
manual

b) Vibratory behavior:

a. Absolute vibration according ISO 10816 for new turbines

b. Shaft vibration according API 612 rev 5: 25 micron peak-peak

c) Control stability in compliance with DIN 45635

d) All supervisory instrumentation ( Bearing temperatures, shaft position etc.)


indicating values below the original lowest alarm settings

e) Startup times and load fluctuation capabilities in compliance with the original
indications of the manual

f) Noise that is not higher than the values before the overhaul

g) Absence of steam, water, oil and other fluid leakages inside and outside the
machinery. Internal steam leakage is only allowed to the magnitude related with
the clearances as indicated by Traupel.

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7 Enclosures:

A Technical specifications of the installed equipment

B General arrangement

C Cross sectional drawings

C1 HP turbine

C2 Gear box

C3 LP turbine

C4 Generator

D P&I diagrams

D1 Steam

D2 Lube oil

D3 Machine system

E History of the exchange of the LP rotors and the First guide vane carrier of the LP
turbine between T 10 and T 20.

F Steam leakage and power limitation of the first reaction part of the HP turbine

G Generator inspection report 2013

H Specification of the scope turbine inspections and certificates

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8 Authorization

Revesion number:0

Name Signature Date

Author J.Schrieken 2013

Checked P.Lensen 2013

Authorised M.Krikke 2013

Document revision

Revision number Name Signature Date

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Enclosure A

Technical specifications installed equipment

Low Pressure (LP) Turbine


Serial number : 452336
Manufacturer : MAN Turbo (Blohm + Voss), Hamburg, Germany
Type : KR 120/310-2
Year of manufacturing : 1991
Year of commissioning : June 1992
Speed : 3000 rpm
Over speed trip speed : 3300 rpm
Year of manufacturing : 1991
Year of commissioning : June 1992
Inlet Steam Pressure : 4,24 / 4,8 bar (norm / max)
Inlet Steam Temperature : 168 / 189 C (norm / max)
Working pressure : P abs = 0,05 /0,06 bar (norm / max)
Power : 19400 kW / 19810 kW (norm / max)

High Pressure (HP) Turbine


Serial Number : 452336
Manufacturer : MAN Turbo (Blohm + Voss), Hamburg, Germany
Type : GR 36/70
Year of manufacturing : 1991
Year of commissioning : June 1992
Speed : 6293 rpm
Over speed trip speed : 6930 rpm
Inlet Steam Conditions : 40 Bar abs, temp 415 C (norm) / 430 C (max)
Outlet Steam Conditions : 4.24 Bar abs (nom) / 4.8 Bar abs (max)
Power max : 19550 kW at 415 C
Power max : 19970 kW at 430 C

Generator
Serial number : 412911
Manufacturer : Alstom, Belfort, France
Type : T190-240, Three Phase Star configuration of windings
Year of manufacturing : 1991
Year of commissioning : June 1992
Operation mode and speed : Continuous, 3000 rpm, 50 Hz
Power : S =49725 KVA, U = 10500 V, I = 2734 A, cos = 0.8,
Erection : 281V, 580 A, Norm IEC, IP 54
Bearings : (2x) type EGXYQ 28-280, 44430401
Manufacturer Bearings : Renk, Hanover, Germany

Erector
Serial number : 412943
Manufacturer : Alstom, Belfort, France
Type : TKJ70-10
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Power : S = 163 kW, U = 281 V, I = 580 A, 3000 rpm


Type : Multi Phase (5 phase), Frequency = variable
Power assistant erector : 42 V, 67 A, Class F
Operation mode : continuos, code IEC, IP54

Gearbox
Commission Number : 724728
Manufacturer : Renk, Rheine, Germany
Type : TNA 500-1
Year of manufacturing : 1991
Year of commissioning : June 1992
Transmission ratio : 2,098
Power : 23470 kW
Speed : 6293 / 3000 rpm
Oil viscosity class : VG46
Oil quantity : 430 l/min / 1,9 bar

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Enclosure B
General arrangement

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Enclosure C1:
High pressure turbine

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Enclosure c 2:
Gear box

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Enclosure C3:
Low pressure turbine

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Enclosure C 4

Generator

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Enclosure D 1
P&I diagram, Steam

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Enclosure D 2

P&I diagram, Lube oil

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Enclosure D 3

P&I diagram, Machine System

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2014

Enclosure E

History of the exchange of the LP rotors and the first guide vane carriers of the
LP turbine between T 10 and T 20.

Low pressure turbines rotors and guide vane carriers (g.v.c.)

T10 T 20
GGG40 g.v.c., rotor A no stellite ` GGG40 g.v.c., rotor B no stellite

1993 Start of operation Start of operation

2000 Installed new 13 % Cr g.v.c.


Installed new rotor AB, 2 rows stellite
2002 GGG 40 g.v.c. emergency repaired by (Elbar)
T 10 rotor A stellited 3 rows by Elbar
2010 Rotor B stellited 3 rows by Sulzer
Rotor AB becomes spare rotor

2013 The present spare rotor is AB was 10 years in operation with 2 rows stellited
Rotor B is in T 10 is in 2013 8+3=11 years in operation, the stellite is 3 years in
operation
Rotor A is in T 20 is in 2013 7+11=18 years in operation, the stellite is 11 years in
operation
The guide vane carrier is emergency repaired in operation for 11 years

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

Enclosure F

Steam leakage and power limitation of the first reaction part of HP


turbine
420C

Enclosure G
?C
T 20 Generator inspection report March 2013

?C

ca 295C

400 T 10 317C
C T 20 343 C

The Hp gland leakage is at design


T10 /T20 clearance of 0,6 mm: 2.245 t/h
Leak flow kg/h 1000/2000 The flow to A 1 is 1.045 t/h
Real power kW 9800/10300 T 10
This is confirmed by tests of T 10 this
Measured kW 7980/6082 year
Limit kW kW 8800 T 20
Has a tested leakage of 2 t/h. This is
caused by an increased clearance to
about 1,2 mm
Recommended is to repair the seal of T
20 in order to avoid operational
problems ( Thrust bearing overload,
blowing gland)
Modern reaction turbines have for the
balance piston brush seals.

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

Enclosure G

Generator inspection report

849000~1.PDF

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

Enclosure H

Specification of the scope turbine inspections and certificates

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

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Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014

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