TG301 - Steam Turbine-Generator Maintenance

4½ days - 2.9 Continuing Education Units Awarded

Planning, scheduling, and implementing a steam turbine-generator outage can be one of the most demanding tasks you perform.  Especially, when problems are found that were not anticipated (and there are always these kinds of problems).  In the class we will learn to better plan the work (from a technical perspective).  Once the work is planned, as we know, the next task is to work the plan.  Here is where the surprises can occur.  Some component will not disassemble according to procedure – what are your options?  Some component does not meet OEM specifications – what are your options?  Some component doesn’t go back together according to procedure – again, what are your options?  These options usually involve repair / replace / reuse decision making.  Effective decision making is a function of your knowledge of the importance of this component, your understanding of recommended tolerances, your understanding of how different options can impact the schedule and/or cost of this outage.  Complicating this issue is a strong need to make outages shorter in length, AND longer in frequencies between outage.  It’s simple:  You need to more with less time and money available.  This course is intended to help you (or your staff) make better steam turbine-generator maintenance decisions.

Topical Outline includes: Planning, Scheduling and Decision Making; Maintenance of Shells, Casings & Rotors; Journal and Thrust Bearings; Couplings, SteamValves; Generator Maintenance; Steam Path Alignment; and Job Wrap Up.

HPC Technical Services' course on Steam Turbine Generator Maintenance is, perhaps, one of the most popular courses we offer.  The course targets those individuals who have a need to better understand the maintenance process.  This includes engineers (who have not yet received formal training on this topic), experienced-mechanics, mechanical maintenance foremen, planners and management.  

Over the past couple years the most commonly received comment is, "I wish I had taken this course 10-years ago."  Well, the truth is, 10-years ago our course wasn't as near as good as it is now.  About 5-years ago, when we reorganized our instructor staff, this course underwent a long overdue revision.  This revision was significant, and you can benefit!

Listen to what our clients are saying (in courses presented in just the past year):

• The instructor did an excellent job on the class!  His knowledge and hands-on experience were invaluable.  I would highly recommend this class to others. - CF Industries
• Excellent class. Instructor varied discussions per the level of class knowledge. - Golden Valley Electric Association
• Everything was great!  I enjoyed every minute.  Thank you. - American Electric Power
• The instructors' knowledge and experience on the subject is outstanding.  I would recommend this course to others. - Sherwin Alumina
• Should have had this course 14 years ago. - EPCOR
• This course was invaluable in developing an appreciation of the turbine-generator maintenance issues. - EPCOR Generation Technical Service
• This was a great introduction to steam turbine maintenance. - ATCO Electric

OBJECTIVES:

1. List steam turbine-generator operational and safety issues that typically cause the scheduling of a maintenance outage.
2. List the considerations that must be included when developing an outage plan or schedule.
3. Describe the major considerations when making a replace/reuse/repair decision.
4. Describe the procedures necessary for the safe and effective disassembly and reassembly of steam turbine generator components.
5. Describe the purpose and operation of the major steam valves.
6. Describe the disassembly and reassembly of the major steam valves.
7. List the five (5) most common causes of steam path damage and their possible affects upon future operation.
8. Describe three (3) common causes steam path defects and their impact upon turbine efficiency and reliability.
9. Describe the type and purpose of clearance and alignment measurements commonly taken during the disassembly and reassembly of a steam turbine generator.
10. Describe the measuring instruments used to determine steam turbine generator component clearances.
11. List and describe the various non-destructive examinations performed during disassembly of the steam turbine generator.
12. Describe the common procedures for cleaning and inspecting steam turbine generator components
13. Describe the criteria used to evaluate steam turbine generator defects.
14. Describe the common repair methods for repair of steam turbine components.
15. Describe the purpose of conducting a steam path audit, and how that audit would be accomplished.
16. Describe the common types and operation of journal and thrust bearings.
17. Describe the common causes of bearing damage.
18. Describe the measurements required to determine oil clearances.
19. Describe common bearing inspection and repair procedures.
20. Describe the considerations to be taken into account when evaluating alignment of steam turbine generator components.
21. Describe the methods used to properly align steam turbine generator components.
22. Demonstrate the ability to perform the necessary calculations to align steam turbine generator components.
23. List and briefly describe the electrical tests often performed on generator components.
24. State the purpose of each electrical test listed.
25. Describe the proper disassembly, inspection and reassembly of a generator hydrogen seal.

COURSE SYNOPSIS
Monday
Planning, Scheduling and Decision Making:  This presentation is intended to provide participants with an understanding of those major items that must be considered PRIOR to commencing a scheduled turbine-generator outage.  Discussion will also include those items we need to consider when making repair/replace/reuse decisions.

Turbine Shells, Casings & Rotors:  Two hours into the course and we're into the meat!  This lecture is intended to prepare the participant to safely and efficiently disassemble/reassemble major turbine components, as well as to improve inspection/repair techniques, communications on equipment, and make better replace/repair/reuse decisions.  Presentations include specific discussions on the different types of distress typically found on these components.

Tuesday
Turbine Shells, Casings & Rotors continues for ½ day.

Journal & Thrust Bearings:  Learn the different types of bearings and their applications, disassembly/reassembly procedures, inspection techniques, and typical types of distress as well as causes.

Couplings:  Learn what types of couplings are used on T-G sets, how torque is transferred, how to properly disassemble/reassemble, how to inspect, what measurements to take, and what they mean.

Wednesday
Steam Valve Maintenance:  Learn the purpose of the various steam turbine valves, how to properly disassemble/reassemble, how to inspect, what are the typical types of distress, what measurements to take, and what they mean.

Generator Maintenance:  Learn how a large AC generator is constructed, how to disassemble major components, what are the typical types of distress, how to clean, routine repair, and why generator inspection/testing is so important.  This presentation also includes an introduction to the various electrical test techniques.

Thursday
Alignment: Learn how to properly take clearance/alignment and how to evaluate. Discussions include how to calculate and make moves for stationary equipment such as diaphragms and inner shells. Discussions also include how to take coupling rim/face readings, how to calculate moves to correct for coupling misalignment, and how to calculate and make moves to bearings to accomplish alignment objectives.

Friday
Job Wrap-Up:  Learn what kind of data should be recorded following the outage, and what checks to make as we prepare to return the equipment to service.

Steam Turbine Field Engineer / Mechanic Certification Examination

What you will receive:

1. 1 copy of HPC's textbook, Steam Turbine Generator Maintenance, a $295 value, as written by Harold Parker, with technical support by Robert Doughty, Turbine Services Incorporated, and Doug Lemmo.  (This valuable text is available for purchase if you cannot attend).
2. A "Certificate of Completion" with 2.9 CEUs

For those who voluteer to be member of HPC's Steam Turbine Field Engineering Certification program, they will receive one comprehensive examination that is to be completed and returned to HPC under specific guidelines for the program. THat participant will receive further accommodation ofr his/her accomplishment. This examination is at no additional cost.

Satisfied Clients: A/C Power, AEC, Alabama Power, Alberta Power Limited, Alstom Power, Ameran CIPS, Ameran UE, American Electric Power, American Crystal Sugar, Amoco Oil, Arkansas Nuclear One, Arizona Public Service, Associated Electric Cooperative, ATCO, Austin Electric Department, Baltimore Gas & Electric, Basin Electric Power Cooperative, Bechtel Corporation, Bismarck State College, Boralax-Stratton Energy, Calpine Corporation, Cajun Electric Cooperative, Cardinal Company of Canada, Cargill Fertilizer, Carolina Power & Light, Central California Power Agency, Central Hudson Gas & Electric, Central Illinois Lighting, CF Industries, Champion International, Chevron Geothermal (Indonesia), Commonwealth Edison, Conectiv, Consolidated Edison, Consumers Energy, Covanta Energy, Crawsfordsville Electric, Light & Power, Dairyland Power Cooperative, Daishowa-Marubeni International LTD, Dartmouth College, Dayton Power & Light, Delmarva Power & Light, Detroit Edison, Dominion Energy,  Dragon Sandblasting (Canada), Duke Energy, Eastern Power Developers, Edison Mission Energy, El Paso Electric, Edmonton Power, Electric Energy Inc., Energea Cogeneracion y Termico SL (Spain), Entergy Louisiana, Entergy Operations, EPCOR, Equistar Chemicals, Erving Paper Mills, Exelon Corp, First Energy Corporation,  Fort James Marathon LTD, General Chemical, General Physics Corporation, Georgia Power, Golden Valley Electric Assosciation, Grand Island (NE) City Utilities, Holland (MI) Board of Water & Light, Iberdrola Ingeneria y Conclutoria, Inberinco (Spain), Illinois Power, Indianapolis Power & Light,  Industrial Risk Insurers, Intermountain Power Service, Irving Pulp & Paper, Kennecott Copper, Keyspan Energy, Korea East-West Power, Korea Midland Power, Korea Nuclear & Hydro, Korea Plant Services & Engineering, Korea Western Power, LGE Power Services, Lakeland Department Electric & Water, Lower Colorado River Authority, Massachusetts Municipal Wholesale Electric Cooperative, Mead Paper Company, MidAmerican Energy, Miller Brewery Company,  Minnesota Power, Minnkota Power, Montenay Power,  Nebraska Public Power District, New Brunswick Power, New York Power Authority, New York State Electric & Gas, Niagara Mohawk, Northern Atlantic Energy Services, Northern Indiana Public Service, Nova Scotia Power, Ocean States Power, Ogden Martin, Ohio Electric Power Cooperative, Oklahoma Gas & Electric, Omaha Public Power District, Ontario Hydro, Ontario Power Generation, Orlando Utilities Commission, Otter Tail Power, OxyChem, PacifiCorp, Pacific Gas & Electric, Pennsylvania Power & Light, Pinetree Power Fitchburg, Port Townsend Paper, Power Resources, PPL Inc., Progress Energy, Public Service Colorado, Public Service New Mexico, Puerto Rico Electric Power Authority, Reliant Energy, Ryegate Associates, Salt River Project, Santee Cooper, SaskFerco, SaskPower, Sherwin-Alumina, Sierra Pacific Power, SITCA, Southern California Edison, Southern Company, Southern Indiana Gas & Electric, Southern Nuclear, Southwestern Public Service, Springfield City Utilities, Suncor, Syncrude, Tampa Electric, Tata Steel (India), Tennessee Valley Authority, Texas Utilities, TPS Generacione of Guatamala, TransAlta Utilities, Turbine Generator Maintenance, United Power Associates, US Air Force, US Generating, US Sugar, Valero Aruba Refinery, Vattenfall (Denmark),  Virginia Electric Power, Waste-Management Energy, WE Energies, Weldwood of Canada, Western Resources, West Plains Energy, Westmoreland LG&E, Wheelabrator Energy Systems, Willamette Industries, Wisconsin Public Service, Xcel Energy