TG401 - Steam Turbine Advanced Maintenance Topics

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4.5 days - 2.9 Continuing Education Units Awarded


Course Dates Download Brochure PDF
USD 2,995.00


HPC’s standard Steam Turbine Generator Maintenance Seminar offering (TG301) deals with the routine aspects of a steam turbine generator outage.  This Seminar goes above and beyond.  In this ‘advanced’ Seminar HPC deals with the need to understand what goes on in a steam path audit, why it might be important, and how to proceed.  Furthermore, we have found that too often maintenance personnel aren’t prepared to deal with some relevant operations and controls issues.  So in this Seminar we present basic materials on steam turbine controls and the conditions under which thermal stress exists.  Sometimes steam path alignment is not so routine.  This Seminar deals with abnormalities associated with steam path alignment, specifically distortion and how to measure the level of distortion as well as possible corrective (or compensating) actions.  Balancing steam turbines is somewhat of an “art” and a “science”, in this Seminar we will take one-day and fully explain the “science” so the maintenance engineer is more capable to deal with vibration issues as they occur.  Finally, decision making is often based upon the financial implication of the situation, so this Seminar will better prepare the engineering staff to equate the mechanical difficulties to $$ and cents, through a brief overview of engineering economics.

Are these issues important? If yes, this may be an opportunity to answer all these questions and more, in one setting.
  • Steam Turbine Performance
  • Steam Turbine Controls
  • Thermal Stress
  • Steam Path Alignment
  • Steam Turbine Vibration Analysis & Balancing
  • Decision Making Based Upon Financial Implications
  • Report Writing
Note: An engineering degree is not a prerequisite to attendance, but experience is suggested. This Seminar should be considered as a natural extension to our popular Steam Turbine Generator Maintenance Seminar, TG301, or our Steam Turbine Overhauls Seminar, TG316.

Objectives:
  1. Describe the design and operation of a turbine stage using thermodynamic principles.
  2. Describe how stage performance can deteriorate and how this deterioration is detected and corrected.
  3. Describe packing designs that provide variable clearances from start up to full load operations.
  4. Describe two methods to determine leakage flow on opposed flow steam turbines.
  5. Demonstrate a fundamental understanding of the erosion mechanisms in the steam path.
  6. Describe thermal stress, how it is derived and what is the impact upon steam turbine components.
  7. Describe how one can minimize the negative impact of thermal stress while minimizing start up times.
  8. Describe the importance of Fracture Appearance Transition Temperature.
  9. Demonstrate the ability to interpret the OEM starting and loading instructions.
  10. Describe shell distortion and how it affects centerline alignment issues.
  11. Describe two methods used to compensate for shell distortion during centerline component alignment.
  12. Describe fundamental terms and concepts important to vibration analysis.
  13. Demonstrate the ability to relate the use of vibration measuring instruments to your applications.
  14. Describe normal conventions used during balancing and how they relate to your equipment.
  15. Demonstrate the ability to calculate a “first-shot” using the “one-shot method” for calculating balance weight locations.
  16. Demonstrate the ability to calculate a “second-shot” using the “measured effect method” for calculating balance weight locations.
  17. Demonstrate the ability to translate calculated weight information to the actual installation of weights on any given rotor.
  18. Demonstrate the ability to conduct a “low-speed balancing” program on a bowed rotor.
  19. List those major components that have a direct bearing on the operations and/or reliability of steam turbine controls.
  20. Describe how steam turbine governors function off-line.
  21. Describe how steam turbine governors function on-line.
  22. Describe how steam turbine governors function on-line and being responsive to grid conditions.
  23. Describe how steam turbine governors function on-line when programmed to not be responsive to grid conditions.
  24. Describe steam turbine governor response to overspeed conditions.
  25. Describe operation of typical servomechanisms such as the Abex and Moog Servovalves.
  26. Describe the relationships between steam flow and valve positioning.
  27. Describe how to perform economic evaluations of the available repair/replace options in order to determine which will optimize maintenance expenditures and maximize return on investment.
  28. Describe those elements important to the writing of an outage report.
Presentation Schedule:

Monday
Thermodynamic Review: Propoerties of a fluid, Cycles, Sankey Diagram, Heat Balance Diagrams, Turbine Stage, Acceleration of Steam, Losses, LSB Designs, N2 Packing, Positive Pressure Variation Packing.
Steam Path Analysis, Audit and Evaluation: Causes of Loss of Efficiency, Evaluating Performance Loss, Restoring Thermal Performance, Diagnostics, Example Steam Path Audit.

Tuesday
Thermal Stress: Definitions, Starting & Loading Instructions, Decision Making re Starting/Shutdown Procedures.
Advanced Alignment Topics: Deviation from Standard Practices, Joint Measurements, Data Collection as an Analysis for Distortion.

Wednesday
Turbine Generator Vibration Analysis & Balancing: Definitions, Conventions, Data Collection, High Spot Rotation, Analysis of HS Rotation, Static / Couple Components, Balancing Decision Making, 1st Shot Calculation, Measured Effect Balancing, Shot Resolution
Types of Turbine Vibrations, Symptoms, Causes & Solutions: Rubbing, Coupling, Alignment, Oil Whip, Thermal Sensitivity, Non-Synchronous Frequencies
Low Speed Balancing: Bowed Rotors, Detection, Analysis, Equipment Setup, Avoiding Mistakes, Centerspan Calculation

Thursday
Steam Turbine Control Concepts: Turbine Control Components, 3-Laws of Steam Turbine Controls, Speed Control Concepts, Load Control Concepts, Pressure Control Concepts, Overspeed Protection Concepts, Need for Incremental Regulation, Upgrade Considerations
Friday
Engineering Economics: Basic Concepts of the Evaluation of Money, Fixed Outage Charges, Payback Analysis re Replace/Repair/Reuse Decisions, Outage Cost Considerations, Recoverable versus Non-Recoverable Outage Costs.
Report Writing: A reminder of the value and costs of a valuable outage report.

TurboCareThis course is scheduled at TurboCare's facilities in 2010.