OVERHAUL REPORT

OF

BHEL – TG SET

CHENNAI PETROLUM CORPORATION LTD

CUSTOMER: M/S CHENNAI PETROLUM CORPORATION LTD

DONE BY

SWAN TURBINE SERVICES PVT. LTD.

AN ISO 9001:2008 COMPANY

Office & Works: Plot No: 168, APIIC, Pashamailaram, Medak Dist – 502
307, Hyderabad, A.P, INDIA.

Phones: Off: +91-8455-224231, 224232, Fax: +91-8455-224230

Website: www.swanturbines.com E-mail: gsk@swanturbines.com

psn@swanturbines.com
Make : BHEL

Type of Machine : Steam Turbo- Generator

Power Rating : 20 MW

Rated Speed : 300 RPM

Trip Speed : RPM

Steam Pressure : 100 kg/cm2

Steam Temperature : 520ºC

ACTIVITIES CARRIED OUT DURING OVERHAULING

 Recording of initial parameters before shutdown of TG.

Load: 20.4 MW Speed: 2983 RPM 19/04/2015 15:00 Hrs

BEARING TEMPERATURE VIBRATION MICRONS

Thrust Bearing 5 21C Turbine Front 34/48 µ
Inactive
Thrust Bearing 65⁰ C Turbine Rear 50/54 µ
Active
Turbine Bearing 86 ⁰ C Generator Front 38/43 µ
Front
Turbine Bearing 64⁰ C Generator Rear 120/105 µ
Rear
Generator 64 ⁰ C
Bearing Front
Generator 62 ⁰ C
Bearing Rear
Axial Position -0.10
Differential 0.40
Expansion
Exhaust Steam -0.75
Pressure
CoolingWater 32⁰ C
I/L Temp
Exhaust 45⁰ C
Temperature
Steam Pressure 88.60Kg/cm2
Steam 503⁰ C
Temperature
Steam Flow 177 T/Hr
JOBS CARRIED OUT

 Turbine shut down on 24/02/2015.

 Turning gear stopped on 26/02/2015.
 Locking of turbine front end at holding down bolts & rear end at LP side.
 Dismantling of all steam, Oil lines, front & rear bearing covers of turbine, servomotor
and MOP.
 Initial Alignment recorded before dismantling.
Initial Alignment Reading
TURBINE TO GENARATOR:

00 00

-0.43 L R R _-0.27 +0.02 A +0.04

-0.70 + 06
TURBINE TO MOP:

00 12.45

-0.27 R _+0.25 12.42 A 12.43

-0.03 12.43

 Checking of initial axial float = 0.29 mm.

 Dismantling of servomotor, control valve arm.
  Checking of parting plane gaps. Dismantling of turbine Parting plane bolts and lifting of
casing.

 Checking parting plane both half’s top and bottom of casing for any marking/ damage.

 Dismantling of HP, IP, and LP carriers along with BP gland, Front steam gland, Rear
Steam gland, Front & rear oil glands and lifting them.

 Recorded flow path clearances of rotor, HP, IP, LP Guide blade carriers, BP Gland, Front
& Rear steam gland, Front & Rear oil gland.

Rotor fin to Carrier Carrier fin to Rotor

S.No L R L R
3 0.80 0.80 0.85 0.75
4 0.80 0.80 0.85 0.75
Inner 5 0.80 0.80 0.80 0.75
casing 6 0.80 0.80 0.85 0.75
7 0.80 0.80 0.80 0.80
8 0.80 0.80 0.85 0.75
9 0.90 0.90 0.90 0.90
 10 0.90 0.90 0.80 0.90
11 0.90 0.90 0.80 0.85
12 0.90 0.90 0.90 0.90
13 0.90 0.90 0.85 0.90
14 0.90 0.95 0.90 0.85
GBC_1 15 0.95 0.95 0.80 0.90
16 0.95 0.90 0.90 0.85
17 0.95 0.95 0.85 0.90
18 1.00 0.95 0.85 0.90
19 1.00 0.90 0.90 0.85
20 1.00 0.90 0.85 0.90
21 1.00 0.90 0.80 0.95
22 0.90 1.00 0.50 0.90
23 0.90 1.00 0.50 0.90
GBC_2 24 1.00 0.90 0.50 0.90
25 1.00 0.90 0.60 0.90
26 1.00 1.00 0.60 0.90
27 1.00 1.00 0.55 0.80
28 1.00 0.90 0.85 0.80
29 1.00 1.00 0.85 0.85
30 1.00 1.00 0.85 0.90
GBC_3 31 1.00 0.95 0.90 0.90
32 1.00 1.00 0.90 0.90
33 1.00 0.95 0.95 1.00
34 1.00 0.95 1.00 1.00
35 1.00 1.00 1.00 1.00

Front Steam Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.45 0.50 0.45 0.35
BP Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.80 0.80 0.80 0.80
Intermediate Gland 1

Rotor fin to Gland Gland fin to Rotor

L R L R
0.90 0.70 0.85 0.70
Intermediate Gland 2

Rotor fin to Gland Gland fin to Rotor

L R L R
0.90 0.70 0.85 0.70

Rear Steam Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.60 0.65 0.40 0.45

 Initial Centering Reading

00 FOG +0.07

00 FSG -0.05

+0.20
 +0.05

FOG – Front Oil Gland

FSG - Front Steam Gland

FBH - Front Bearing Housing

ROG

00 00

-0.30 RSG

00 -0.12

+0.01 00 REC +0.71

+0.65

ROG -Rear Oil Gland

RSG - Rear Steam Gland

REC – Rear End Coupling

OBSERVATIONS ON 2O MW BHEL TG-2,

During dismantling/overhauling of TG, following are the observations carried out and further
recommendations:
 OBSERVATIONS ON TURBINE ROTOR
 Observed Heavy Scaling on all the stages of the rotor.

 Inspection of turbine Bearings by DP and UT test and checking of bearing

clearances carried out.
TURBINE BEARING FINAL CLEARENCES & INTERFERENCES

BEARING BEARING SHAFT CLEARANCE INTERFERENCE

ID JOURNAL OD
Turbine front Ø220.02 Ø219.66mm 0.36mm 0.03
Bearing
Turbine rear Ø250mm Ø249.60mm 0.40mm 0.04
Bearing

TURBINE THRUST BEARING PAD THICKNESS:

S NO ACTIVE NON ACTIVE

1 38.18 37.84
2 38.17 37.85
3 38.17 37.85
4 38.17 37.84
5 38.18 37.85
6 38.16 37.85
7 38.18 37.85
8 38.18 37.85

Front & Rear Steam Gland on Rotor

 Inspection of front & rear steam glands Observed worn out of sealing fins & fin clearances
observed on higher side.
 BP Gland

 Observed damage & worn out of sealing fins on BP Gland.

 Observed worn out of sealing fins of all stage of rotor and gudie blade carriars.
  Observed HP carriar 1st stationary blade are in damaged condition

Nozzle Chamber

 inspection of nozzle chamber Observed blades are in damaged condition.

 Inspection of rotor observed crities wheel blades are in damaged conditons.

Yoke Assembly

 Inspection of yoke assembly observed one number of valve cone is in damaged condition
replaced with new valve cone.
 Steam Chamber

 Observed one number of valve seats/Diffuser is in damaged.

 Dismanataled the 4 th no diffuser with liquied nitrozen and replaced with new diffsuer.

Control Valve Stems

 Observed rubbing of 2no. of control valve stems and to replace with new stems.
 Dismantling of HP control valve assembly Observed 2 no. of nut in control valve assembly
tight & damage of threading and replace with new one.

 Dismantling of IP,LP control valves assembly Observed control valve spindle idle lift higher
side.

 Dismantling of IP,LP control valve stems by machining replaced with new stems, bush,
washer, loc nut.
RECOMMENDATIONS

Turbine Rotor

 Grit Blasting of rotor to be carried out.

 Replacement of all the inter-stage sealing fins on the rotor as the flow path clearances are
observed to be on higher side than the protocol readings.
 Low Speed Balancing of Rotor to be carried out as per ISO 1940 G 2.5.
 High Speed Balancing to be carried out as per API 612.
 Polishing & Burnishing of Front & Rear journals.
 Polishing of Active & Inactive thrust collar faces.

Guide Blade Carriers

 Grit Blasting of HP, IP & LP Guide Blade Carriers.

 Replacement of all the inter-stage sealing fins as the sealing fin clearances are
observed to be on higher side than protocol readings.

Front, Rear intermediate Steam Glands

 Replacement of sealing fins of Front & Rear Steam Gland as the fins are in worn
out condition and clearances are observed to be on higher side.

BP Gland

 Replacement of sealing fins as the fin clearances are observed to be on higher

side.

Front & Rear Oil Glands/Seals

 Front & Rear oil glands, refining of glands to be performed.

Nozzle Assembly

 Replacements of nozzle segment blades because of old blades are in damage.

Control Valve/Steam Chamber Assembly

  Replacement of 1 No of Valve Cones & Diffusers because of the damage of the
valve cones with reference to the valve seat..

Considering the above recommendations it was decided by CPCL for reconditioning the
Turbine Rotor along with the above mentioned accessories to M/s Swan Turbine
Services Pvt. Ltd
 All the reports related to Reconditioning & High speed balancing of rotor, Guide blade
carriers have been attached.

Assembling of bottom halves of HP, IP, LP Guide blade carriers, placing of rotor and
recorded final clearances

 Final Centering Reading

FBH

00 -0.04

00 F0G 00

-0.02

+0.08 00 FSG -0.08

+0.01

FBH - Front Bearing Housing

FOG – Front Oil Gland

FSG - Front Steam Gland

 RSG

00 -0.06

-0.06 R0G

00 -0.08

- 0.08 00 REC -0.05

-0.03

ROG -Rear Oil Gland

RSG - Rear Steam Gland

REC – Rear End Coupling

OUTER CENTERING READING

FRONT REAR
FINAL FLOW PATH CLERANCES

RADIAL :

Rotor fin to Carrier Carrier fin to Rotor

S.No L R L R
3 0.35 0.35 0.40 0.40
4 0.35 0.30 0.40 0.40
Inner 5 0.35 0.35 0.45 0.40
casing 6 0.35 0.30 0.40 0.40
7 0.35 0.35 0.45 0.40
8 0.35 0.35 0.40 0.40
9 0.45 0.50 0.45 0.55
10 0.45 0.55 0.45 0.55
11 0.40 0.50 0.40 0.50
12 0.45 0.50 0.45 0.55
13 0.45 0.55 0.45 0.55
14 0.40 0.50 0.40 0.55
GBC_1 15 0.45 0.50 0.45 0.50
16 0.45 0.55 0.45 0.55
17 0.40 0.50 0.45 0.55
18 0.45 0.55 0.45 0.55
19 0.40 0.50 0.40 0.55
20 0.55 0.50 0.55 0.50
21 0.55 0.55 0.50 0.55
22 0.55 0.55 0.50 0.55
23 0.50 0.50 0.50 0.50
GBC_2 24 0.55 0.55 0.50 0.55
25 0.55 0.55 0.50 0.55
26 0.55 0.50 0.55 0.50
27 0.50 0.55 0.55 0.55
28 0.60 0.55 0.60 0.55
29 0.60 0.55 0.60 0.55
30 0.60 0.55 0.60 0.55
GBC_3 31 0.60 0.55 0.60 0.55
32 0.60 0.55 0.60 0.55
33 0.60 0.55 0.60 0.55
34 0.60 0.55 0.60 0.55
35 0.80 0.85 0.85 0.85
Front Steam Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.20 0.25 0.25 0.25

BP Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.50 0.55 0.75 0.75

Intermediate Steam Gland 1

Rotor to Gland
L R
0.55 0.55

Intermediate Steam Gland 1

Rotor to Gland
L R
0.60 0.50

Rear Steam Gland

Rotor fin to Gland Gland fin to Rotor

L R L R
0.35 0.40 0.30 0.35
FINAL AXIAL CLEARANCES:

LEFT RIGHT
S.No + - + -
3 4.30 2.80 4.30 2.85
4 4.30 3.00 4.30 3.00
Inner 5 4.30 3.25 4.35 3.20
casing 6 4.50 3.10 4.50 3.20
7 4.50 3.15 4.55 3.15
8 4.30 4.00 4.35 4.20
9 4.75 4.10 4.75 4.20
10 4.40 4.10 4.40 4.10
11 4.30 4.45 4.30 4.45
12 5.60 4.30 5.70 4.50
13 5.20 4.00 5.20 4.00
14 6.45 4.35 6.50 4.40
GBC_1 15 6.40 5.00 6.40 5.00
16 6.10 4.20 6.15 4.30
17 5.90 4.80 5.90 4.80
18 5.90 5.00 5.90 5.00
19 5.95 5.50 5.95 5.50
20 6.25 5.75 6.25 5.75
21 6.55 5.70 6.55 5.70
22 7.30 6.70 7.30 6.70
23 8.10 6.90 8.10 6.90
GBC_2 24 7.85 7.00 7.85 7.10
25 7.80 7.40 7.85 7.45
26 7.75 7.70 7.75 7.70
27 7.80 7.90 7.80 7.90
28 9.85 9.70 9.85 9.70
29 10.10 9.60 10.10 9.60
30 10.10 8.70 10.20 8.90
GBC_3 31 10.40 9.00 10.45 9.00
32 10.50 9.10 10.55 9.20
33 10.50 9.00 10.60 9.10
34 11.00 9.10 11.00 9.20
35 13.00 9.00 13.20 9.10
CARRIER THERMAL GAPS

L R
GBC 1 2.45 3.00
GBC 2 2.40 2.60
GBC 3 4.50 4.60
INNER CASING 3.75 4.50

CARRIERS PARTING PLANE LEVEL:

L R
GBC 1 +0.18 +0.25
GBC 2 +0.20 +0.32
GBC 3 +0.80 +0.73

CARRIERS VERTICAL FLOT:

TOP BOTTOM
GBC 1 0.40 0.40
GBC 2 0.50 0.55
GBC 3 0.70 0.75

HP CONTROL VALVE IDLE LIFT

S NO VALVE LIFT
1 4.50
2 15.10
3 20.10
4 29.00
5 44.14

 Assembled of hp control valve assembly new stems ,with new graphed gland packing
 Assembled of ESV with new valve steam, cone and locking bush.
 Assembled of both IP control valves with new steams, bush, washer and lock nut.
 Assembled of both LP control valves with new steams, bush, washer and lock nut.
 final Alignment recorded.
Final Alignment Reading
TURBINE TO GENARATOR:

00 00

-0.02 R _+0.08 00 A +01

+0.05 00
TURBINE TO MOP:

00 10.04

+0.03 R _ +0.03 10.02 A 10.01

+0.05 10.03
  TG 2 rolled on turning gear on 14/06/2015.
 TG 2 synchronized on 15/06/2015 at 4 MW load.
Parameters recorded at various load are as below.

Load: 4 MW Speed: 2990RPM 15/06/2015

BEARING TEMPERATURE VIBRATION MICRONS

Thrust Bearing 47.1/47.5⁰ C Turbine Front 36/46 µ
Inactive
Thrust Bearing 48.4/50.8⁰ C Turbine Rear 20/18 µ
Active
Turbine Bearing 61⁰ C Generator Front 28/20µ
Front
Turbine Bearing 53 ⁰ C Generator Rear 74/86µ
Rear
Generator 57⁰ C
Bearing Front
Generator 63⁰ C
Bearing Rear
Axial Position -0.18 mm
Differential -3.15 mm
Expansion
Exhaust Steam -0.80/-0.83
Pressure
Exhaust 55⁰ C
Temperature
CoolingWater 30.1⁰ C
I/L Temp
Steam Pressure 101 Kg/cm2
Steam 514 ⁰ C
Temperature
Steam Flow 98.7 T/Hr

 Comparing the parameters before & after overhauling, there has been considerable
improvement in the efficiency of the machine.

Recommendations

 perform Minor Overhauling for every 2 years/No. of Working hours as applicable

& Major Overhauling for every 4 years/No. of working hours.

Spares Required for next Major Overhaul/In case of Emergency

 1 no of new Turbine front & Rear Journal Bearing.
 1 no of Generator Front & Rear Journal Bearing.
 5 no of Valve seats/Diffusers.
 5 no of Valve Cones.
 4 no of L Section Rings.
 1 no of ESV Stems.
 1 no of ESV Cone.
 2 no of HP Control Valve Stems.
 2 no of IP Control Valve Stems with bush, washer, lock nut.
 2 no of LP Control Valve Stems with bush, washer, lock nut.

 As mentioned, it is mandatory to make the above spares readily available for next
overhaul or in case of any emergency.