TG322 - Mechanical Drive Turbine Maintenance

2 days - 1.3 Continuing Education Units Awarded

This two-day course was developed to provide the attendee with a thorough understanding of the fundamentals of maintenance of small and intermediate sized steam turbines. These STG sets are used in industrial plant powerhouses to provide process steam at various pressures and to produce electricity for plant power consumption, in utility power plants as the drive unit for boiler feed pumps, and the drive device for gas compressors.

Industrial plant powerhouse and utility power plant, supervisors, operators, engineers, and maintenance personnel who are concerned with increasing the effectiveness and reducing the cost of steam turbine maintenance outages should attend this course. Attendees will learn the differences between large utility turbine maintenance and maintenance on mechanical drive turbines.

OBJECTIVES
Upon successful completion of this course the participant should be able to:

1. Describe the major activities associated with turbine maintenance.
2. Identify and define the items of concern related to turbine maintenance activity.
3. Identify the types of defects encountered during turbine maintenance inspections.
4. Identify the relationship between operational effects and maintenance activity.
5. Describe the various inspections performed during disassembly of the turbine.
6. Describe the procedures for cleaning and inspecting the turbine components.
7. Describe the impact of the various types of defects on turbine efficiency and reliability.
8. Describe the criteria used to evaluate turbine component defects.
9. Describe the various repair methods for defective component condition.
10. Describe the details required for an effective steam path audit.
11. Describe the methods used to properly align turbine components.
12. Describe the criteria used to establish unit specific maintenance clearances.

COURSE OUTLINE

1. Introduction
   1. Introduction of Instructor
   2. Review Course Outline
   3. Discuss Text
   4. Class Participation
   5. Class Structure
   6. Course Objectives
   7. Operational Effects
   8. Feedwater Chemistry
2. Turbine Fundamentals
   1. Turbine Cycle
      1. Flow
      2. Nozzles and Expansion
      3. Turbine Blading
   2. Turbine Types
      1. Impulse Turbines
      2. Reaction Turbines
   3. Comparisons of Impulse vs. Reaction Turbines
3. Turbine Component Construction
   1. Shells
   2. Casings
   3. Cylinders
   4. Nozzles/Diaphragms
   5. Stationary Blades
   6. Turbine Seals
   7. Turbine Rotors/Spindles
   8. Blades/Buckets
   9. Standards/Pedestals
   10. Bearings
   11. Turning Gear
   12. Main/Aux. Steam Valves
       1. Trip Throttle
       2. Control/Governor
4. Turbine Maintenance
   1. Disassembly
      1. Shutdown/Cooldown
      2. Lagging
      3. Disassembly Checks
      4. Shell/Cylinder Bolting
      5. Outer/Inner Shell Cylinder Removal
      6. Rotor/Spindle Removal
      7. L/H Removal
   2. Component Cleaning
      1. Grit Blasting
      2. Solvents
      3. Scraping
      4. Stoning/Honing
      5. Strap Lapping
      6. Wire Brushing
   3. Inspection Techniques
      1. Visual
      2. Dye Penetrant
      3. Magnetic Particle
      4. Ultrasonic Testing
      5. Eddy Current Testing
   4. Component Inspections
      1. Rotor/Spindle
      2. Blade/Bucket
      3. Shell/Cylinder
      4. Diaph./Sta. Blades
      5. Steam Packing
      6. Bolting
   5. Steam Path Audits
      1. Items to Measure
      2. Procedures
      3. Economic Factors
      4. Repair Decision
      5. Computer Programs
   6. Reassembly
      1. Lubricants
      2. HP Section
      3. Bolt Tightening
5. Bearing/Coupling Maintenance
   1. Journal Bearings
   2. Thrust Bearing
   3. Couplings
6. Steam Valve Maintenance
   1. Safety Considerations
   2. Valve Disassembly
      1. Trip/ThottleValve
      2. Control Valves
   3. Cleaning/Inspection
   4. Valve Assembly
7. Alignment
   1. Provisions
   2. Alignment Checks
      1. Rotor Position
      2. Joint Opening
      3. Cpl. Align.
      4. Rotor Clearance
      5. Internal Alignment
   3. Internal Alignment Methods
      1. Tight Wire
      2. Mandrel
      3. Laser
   4. Coupling Alignment
      1. Types of Misalignment
      2. Taking Data
      3. Interpretation
      4. Realignment
      5. Making the Move
8. Course Conclusion
   1. Questions/Answers
   2. Final Exam
   3. Course Critique